Water Heater Installation documentation Mercedes Benz C Class

Transcription

Water Heater
Feel the drive
e1
Thermo Top Evo5+ Parking Heater
00 0258
Installation documentation
Mercedes Benz C Class S204, W204 / from model 2007
GLK Class X204 / from model 2008
Gasoline and Diesel
Left-hand drive vehicle
Automatic air-conditioning
Blue Efficiency / Blue Tec
Sport package AMG 950
Not at C 63 AMG
Not for GLK 250 CDI
WARNING!
Hazard warning:
Incorrect installation or repair of Webasto heating systems may cause a fire or result in the
emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as
a result.
Specialist company training, technical documentation, specialised tools and equipment are
required to install and repair Webasto heating and cooling
systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heater accessories from Webasto.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not
successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools
and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all warnings.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff.
Ident. No.: 1315959C_EN
Fee Euro 10.00
© Webasto AG
Mercedes Benz C Class S204, W204 / GLK Class X204
Table of contents
Heater/Installation Kit
Foreword
General instructions
Special tools
Validity
Explanatory Notes on Document
Preliminary Work
Heater installation location
Preparing electrical system
Electrical system
Fan controller
Push button installation
Telestart
2
2
2
2
3
5
6
6
7
8
9
12
13
Preparing installation location
Installing heater
Exhaust gas
Fuel
Metering pump of 60l fuel tank
Gasoline fuel stand pipe
Diesel fuel standpipe
Connecting metering pump
Coolant circuit
Combustion air
Exhaust end section
Final Work
14
16
17
19
21
22
22
26
27
29
35
37
38
Heater/Installation Kit
Quantity
1
or
1
Description
Order No.:
1315954A
Delivery scopeThermo Top Evo Mercedes Benz C Class
S204, W204 / GLK Class X204 Gasoline with Telestart T91
black (sw)
Delivery scopeThermo Top Evo Mercedes Benz C Class
1315955A
S204, W204 / GLK Class X204 Gasoline with Telestart T91
black (sw)
Option heater controls to be ordered according to choice:
Quantity
1
1
Description
Digital timer
Telestart T100 HTM black (sw)
Order No.:
See price list
See price list
The installation location of the digital timer/push button should be confirmed with the end customer before installation.
When installing a parking heater, we recommend the use of the next larger vehicle battery.
Foreword
This installation documentation applies to the Mercedes Benz C-Class S204, W204 vehicles - for validity, see page 3 - from model year 2007 and later, also GLK Class X204 Gasoline and Diesel from
model year 2008, assuming technical modifications to the vehicle do not affect installation, any liability
claims excluded. Depending on the vehicle version and equipment, modifications may be necessary
during installation with respect to this installation documentation.
However, where this is the case, the stipulations of this "installation documentation", the "operating instructions" and the "installation instructions" of theThermo Top Evo should be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
Note:
Due to the lack of available space, the replacement of the bulb of the right front fog light/cornering light
is more complicated after the parking heater is installed. The time required for replacement will be increased. Please inform your customers accordingly!
General instructions
Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties.
Sharp edges should be fitted with edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
While installing an IPCU, the corresponding settings are to be checked or adjusted before the installation.
Special tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
1315959C_EN
2
Validity
Manufacturer
Daimler AG
Daimler AG
Daimler AG
Model
C Class
C Class
GLK Class
Type
W204
S204
X204
EG-BE No./ABE
e1 * 2001/116 * 0431 * ...
e1 * 2001/116 * 0431 * ...
e1 * 2001/116 * 0480 * ...
W 204 Sedan
Type
Engine model
Output in kW
C 180 K
C 180 CGI
C 200 K
C 200 CGI
C230
C 250 CGI
C280
C 280 4Matic
C 300
C 300 4Matic
C 350
C 350 4Matic
C 350 CGI
C 200 CDI
C 220 CDI
C 250 CDI
C 250 CDI 4Matic
C 320 CDI
C 320 CDI 4Matic
C 350 CDI
C 350 CDI 4Matic
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / V6
Gasoline / V6
Gasoline / V6
Gasoline / V6
Gasoline / V6
Gasoline / V6
Gasoline / V6
Diesel / R4
Diesel / R4
Diesel / R4
Diesel / R4
Diesel / V6
Diesel / V6
Diesel / V6
Diesel / V6
115
115
135
135
150
150
170
170
170
170
200
200
215
100
125 / 150
150
150
165
165 / 170
165 / 170
165
Type
Engine model
Output in kW
C 180 K
C 180 CGI
C 200 K
C 200 CGI
C 230
C 250 CGI
C 280
C 280 4Matic
C 300
C 350
C 350 4Matic
C 200 CDI
C 220 CDI
C 250 CDI
C 250 CDI 4Matic
C 320 CDI
C 320 CDI 4Matic
C 350 CDI
C 350 CDI 4Matic
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / R4
Gasoline / V6
Gasoline / V6
Gasoline / V6
Gasoline / V6
Gasoline / V6
Diesel / R4
Diesel / R4
Diesel / R4
Diesel / R4
Diesel / V6
Diesel / V6
Diesel / V6
Diesel / V6
115
115
135
135
150
150
170
170
170
200
200
100
125
150
150
165
165
165 / 170
165 / 170
Displacement in
cm³
1796
1796
1796
1796
2496
1796
2996
2996
2996
2996
3498
3498
3498
2143
2143
2143
2143
2987
2987
2987
2987
S 204 Station wagon
1315959C_EN
Displacement in
cm³
1796
1796
1796
1796
2496
1796
2996
2996
2996
3498
3498
2148
2148
2143
2143
2987
2987
2987
2987
3
X 204 GLK
Type
GLK 280 4Matic
GLK 350 4Matic
GLK 320 CDI 4Matic
GLK 350 CDI 4Matic
1315959C_EN
Engine model
Gasoline / V6
Gasoline / V6
Diesel / V6
Diesel / V6
Output in kW
170
200
165 / 170
165 /170
Displacement in cm³
2996
3498
2987
2987
4
Explanatory Notes on Document
To provide you with a quick overview of the individual working steps, you will find an identification mark
on the outside top right corner of the page in question.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Special features are highlighted using the following symbols:
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Reference to these, the general installation instructions
of the Webasto operating elements and to
vehicle-specific documents of the manufacturer
Reference to a special technical feature.
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
All dimensions are in mm!
Tightening torque of 5x13 heater bolts = 8Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
1315959C_EN
5
Preliminary Work
WARNING!
-
Open the fuel tank cap, ventilate the tank.
Close the tank cap again.
Depressurize the cooling system.
Copy the factory number from the original type label to the duplicate type label.
Remove years that do not apply from the duplicate label.
Attach the duplicate label (type label) in the appropriate place.
Remove the windshield wipers.
Remove the coolant reservoir cap.
Remove the dome strut on the left.
Remove entire windshield wiper linkage with engine.
Remove battery with carrier fully (if installed at the right)
Remove engine control device (if installed on the right))
Remove the battery cover in the engine compartment on the right.
Remove the trim of the passenger compartment fan air inlet
Detach the coolant expansion tank.
Take off the cover off the positive distributor in the engine compartment.
Remove the air intake pipe on the right (V6 only).
Remove the lower engine cover.
Discharge engine coolant according to manufacturer specification
Remove the lower right vehicle trim.
Remove the right-hand wheel.
Remove the right-hand wheel well trim.
Remove the seat bench of the rear bench seat.
Open the right-hand fuel sender service lid.
Detach the fuel-tank sending unit on the right as described in the manufacturer's instructions.
Remove the A/C control panel.
Lift the shift lever cover.
Remove the ashtray or storage compartment with the socket outlet below the A/C control panel.
Remove the A-pillar trim in the footwell on the right.
Remove the front right door sill cover.
Remove the lower right instrument panel trim.
Remove the lower left instrument panel trim.
Remove the front right floor trim.
Loosen right footrest
Heater installation location
1 Heater
Installation location
1
1315959C_EN
1
6
Preparing electrical system
1
Detach 6mm dia 1 cable shoe
Preparing
wiring harness of fan
control
2
IPCU view on contact side!
The pre-programmed settings of both function controls in the vehicle are to be checked
and adjusted if necessary.
A
86
IPCU
15
85
A
E
86
1315959C_EN
E
Duty cycle:
Frequency:
Voltage:
Function:
56-62%
400Hz
3.0V
High-side
IPCU view
85
7
Electrical system
Ground wire
Wiring harness pass through
Connect ground wire 1 to the original vehicle
ground support point 2 with 6mm dia cable shoe.
Route wiring harness to heater in corrugated
tube of 10mm dia 3.
Drilling of 6mm dia 2 hole at centre of rubber plug 1!
3 Cable harnesses of engine compartment fuse
holder and heater control
1
1
2
2
3
3
4
3
Do not route wiring harness of
metering pump until later together with fuel line on underbody
1
2
Wiring harness installation
diagram
1
5
1
6
Fuse holder of engine compartment
Plus wire
Replace F2 with 1 A fuse.
Manufacturer to install different positive support
points. Connect power supply of heater 1 to positive terminal (battery or starter cable of positive
support point)!
1 5mm dia. hole, M5x16 bolt, washers [2x], retention plate of fuse holder, nut
2 F1+2 fuses mounted
1315959C_EN
8
Fan controller
Mercedes
Webasto
30
15
HG
X2
1
2
2
5
Wiring diagram
F
X1
rt/ge
ws
F2
F1
rt
0,5²
rt/ge
7
rt
ge
gn/ws
4²
0,5²
0,75²
GE
M
4
sw
0,5²
0,5²
8
0,5²
Kl.31
ws
X10
St 4
4
St 4
3
5
86
87
A
87a
85
rt
86
bl
4²
rt
4
rt
LIN-Bus
4²
IPCU
30
br
2
bl
K1
85
1
KB
sw
86
87
85
30
87a
1
K2
9
1
A
6
rt/sw
br
2
br
B
M
M
M
M
2
3
br
br
0,5²
Webasto components
HG
TT-Evo heater
X1
6-pin heater connector
X2
2-pin heater connector
X10
4-pin connector
Heater control
K1
Fan relay
K2
Additional relay
F1
Fuse, 20A
F2
30A fuse replaced with
1A
IPCU Pulse width modulator
IPCU adjustment values:
Duty cycle: 56%
Frequency: 400Hz
Voltage:
3.0V
Function:
High-side
1315959C_EN
31
Vehicle components
GE
Fan unit
KB
A/C control element
A
Socket outlet/lighter
B
Flap positioning module
F
Fuse
ST 4 Connector, 4-pin, KB
Colours and symbols
rt
red
ws
white
sw
black
bl
blue
ge
yellow
br
brown
gn
green
Legend
X
Cutting point
Wiring colours may vary.
9
1
3
1
Prepare wiring harness of engine compartment fuse holder 2 in the passenger compartment. Connect red (rt) wire 4² 1 and red/black
(rt/sw) 0.5² wire 3 soldering connector. Produce connections as shown in wiring diagram.
2
Preparing
wiring harness of engine
compartment fuse
holder
7
2
3
6
4
Route wiring harness of engine compartment
fuse holder 5 in the foot well on the front passenger side, and secure with cable tie. Produce connections as shown in wiring
diagram.
1 Original vehicle stud bolt, original vehicle
ground wires
2 Angle bracket
3 M5x16 bolt, washer, flanged nut
4 Base of IPCU
6 Relay base
Installing
relay base
and IPCU
base
5
8
Install green/white (gn/ws) wire 6 1 in the
IPCU/86 base. Produce connections as
shown in wiring diagram.
1
2 Brown (br) wire 3 of wiring harness of engine compartment fuse holder
3 Brown (br) wire 9 of fan controller wiring
harness
Connecting wiring
harnesses
2
9
3
1
Route wiring harness of fan control 3 to centre console and secure with cable tie.
2
1 Mount K1 and K2 relay
2 Plug IPCU
Mounting
relay [2x]
and IPCU
3
10
1315959C_EN
10
Connection to 4-pin connector 4 from A/C
control element. Produce connections as
shown in wiring diagram.
1
2
4
1
1 White (ws) wire of fan unit
2 Black (sw) wire 4 K1/30
3 White (ws) wire of 4-pin KB connector
Connecting A/C
control
panel
11
3
Connection to 4-pin connector 3 from A/C
control element.
Produce connections as shown in wiring diagram.
2
1
2
4
5
Blue (bl) wire 2 K2/30
Red (rt) wire of flap positioning module
Red (rt) wire of 4-pin KB connector
Blue (bl) wire 1 K2/87
Connecting A/C
control
panel
5
4
12
3
Connection to plug-in connector 3 of socket
outlet/lighter. Produce connections as shown
in wiring diagram.
1
1 Red (rt) wire 5 K1/86
2 Pink/yellow (ro/ge) wire
4 Pink/yellow (ro/ge) wire
4
2
3
1315959C_EN
Connection to
socket outlet/lighter
13
11
Push button installation
1
Only in connection with Telestart. Use wiring
harness extension!
WARNING:
If the push button cannot be installed in the
trim piece due to parts lying behind it, the installation is undertaken according to Figure 19.
Removing
cover
1 Cover
14
Mount cap nut 1 of push button, align in centre and drill 16mm dia hole 2 in the cover
(step drill)!
1
Hole in
cover
2
15
Install push button 1, align and secure it with
cap nut!
Installing
push button
16
1
When drilling, watch components located behind.
1
1 12mm dia hole
Hole for
wiring harness
17
1315959C_EN
12
1 Cover
1
Mounting
cover
18
Alternative installation location
1
Only in connection with Telestart. Use wiring
harness extension!
1 12mm dia hole, push button
Installing
push button
19
Telestart
1
1 Receiver, adhesive tape
Installing
receiver
20
1 Antenna
1
Installing
antenna
21
1315959C_EN
13
Preparing installation location
1
2
5
4
3
Figure shows W204 with daytime running
light!
Loosen original vehicle bolt at position 2, 3
and 5 . Insert large diameter washer at position 5 between bracket 4 and bumper. Tighten
bolts at position 3 and 5.
Bend twist protection at position 1 toward
rear. Turn cylinder of the headlight cleaning
system and fix with cable tie (observe distance between connector of fog light, if available, and bracket of heater).
Detaching
bracket
22
1
Remove joint sealer in the area of the holes 1
or 2 on the inner side of the frame side member!
2
S204 and W204
1 7 mm dia. hole
10
10
X204
35
Hole in
frame side
member
2 7 mm dia. hole
23
light!
Mount heater bracket 3 with oblong hole between detached bracket 2 and bumper at position 1.
3
1
1 Original vehicle bolt
Mounting
heater
2
24
S204 and W204
1
When drilling, watch components located behind.
1 M6x20 bolt, flanged nut
Loosely
mounting
heater
25
1315959C_EN
14
X204
1
Insert 8 mm shim between bracket of heater
and frame side member.
1 M6x25 bolt, 8 mm shim, flanged nut
Loosely
mounting
heater
26
S204, W204 and X204 with daytime running light
1
1 Copy 7 mm dia. hole pattern
2
Copying
hole pattern
3
1
27
S204 and W204 with fog light
1
5
2
Ensure proper spacing between connector of
front fog light 3 and bracket of heater 1 (at
least 5mm!
3
3
1
Copying
hole pattern
28
X204 with fog light
1
Copying
hole pattern
29
1315959C_EN
15
light!
Remove heater. For vehicles with fog light, it
must be removed for the hole.
1
1 7 mm dia. hole [2x]
Hole in
bumper
1
30
1
2
light!
Install horn 3 with original vehicle bolt 1.
2 M6x25 bolt,pin lock
Installing
bolt
31
3
Installing heater
1
2
3
4
6
5
light!
Mount bracket of heater 1 on bolt 3 between
detached bracket and bumper. Align heater
and fasten at position 4 and 6.
Tighten original vehicle bolt at position 5.
Tighten bolt 4 on retaining strut.
Installing
heater
2 Flanged nut
32
1
2
3
Figure shows X204 with fog light.
Mount bracket of heater 1 on bolt 3 between
detached bracket and bumper. Insert 8 mm
shim between bracket of heater and frame
side member at position 4. Align heater and
fasten at position 4 and 3. Tighten bolt on retaining strut.
Installing
heater
4
2 Flanged nut
4 M6x20 bolt, 8 mm shim, flanged nut
33
1315959C_EN
16
Exhaust gas
1
1 Shape exhaust pipe
2 Hose clamp
3 Push on pipe insulation
Preassembling exhaust pipe
3
34
2
Mount exhaust muffler 3 on exhaust pipe 1
and align relative to hole 4. Mount wiring harness 5 on heater.
1
2 Hose clamp
5
Preassembling muffler
2
3
35
4
Cut tab 1 off exhaust end section 3.
1
2 Cutting point
2
Preparing
exhaust
end section
3
36
Vehicles with daytime running light
1
1 M6x12 bolt, spring lockwasher
2 Hose clamp
3 Exhaust end section
2
3
1315959C_EN
Installing
muffler and
end section
37
17
Ensure sufficient distance to neighbouring
components, align bracket if necessary. Minimum distance between bracket of daytime
running light and muffler at Position 1 must be
observed
1
Aligning
muffler
min. 15mm
38
Vehicles with fog light
1
Ensure sufficient distance to neighbouring
components, correct if necessary.
S204 and W204
Slide incomplete exhaust end section 3 onto
exhaust muffler (5 mm distance between end
section 3 and muffler), align and fasten.
2
3
1315959C_EN
39
Installing
muffler and
end section
X204
Slide complete exhaust end section 3 onto
exhaust muffler.
1 M6x12 bolt, spring lockwasher
2 Hose clamp
18
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with an appropriate container.
Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties.
Mount the fuel line and wiring harness with rub protection on sharp edges.
WARNING!
The fuel line and wiring harness are routed to the metering pump in as shown in the wiring harness
routing diagram.
1
3
2
Pin out connector housing of metering-pump
wiring harness before pulling into corrugated
tube.
4
1 9 mm dia. corrugated tube, wiring harness
of metering pump
2 Cable tie
3 Fuel line, 10 mm dia. clamp
4 Moulded hose of heater
Connection to
heater
40
1
Degrease adhesive surface for adhesive
base 1.
2
1 Adhesive base, cable tie
2 Corrugated tube
Installing
lines
41
base 1.
1
2 Corrugated tube
Installing
lines
2
1315959C_EN
42
19
1
base 1.
2
1 Adhesive base [2x], cable tie [2x]
2 Corrugated tube
3 Cable tie, existing hole
Installing
lines
3
1
43
1
base 1.
2
1 Adhesive base [2x], cable tie [2x]
2 Fuel line, wiring harness of metering pump
1
Installing
lines
44
1
2
1
2
Distribute retaining clips 1 [10x] evenly along
vehicle underbody and insert fuel line 2 and
wiring harness of metering pump.
1
Installing
lines
45
1
1
2
3
4
2
Fuel line, wiring harness of metering pump
Hose section 8x12 dia
Cable tie
Original vehicle retaining strap
Installing
lines
3
4
1315959C_EN
46
20
20
S204 and W204
Drill 9.1 mm dia. hole 1, mount M6 rivet nut.
Rivet nut
for metering pump
20
47
1
base 4.
1
2
3
1 M6x25 bolt
2 Wiring harness of dosing pump, connector
mounted
3 90° F moulded hose, 10 mm dia. clamp
[2x], fuel line
5 Mounting of metering pump
6 Metering pump
Installing
metering
pump
4
6
48
5
X204
Drill 9.1 mm dia. hole 1, mount M6 rivet nut.
15
Rivet nut
for metering pump
15
49
1
1
2
3
base 4.
4
1 M6x25 bolt
mounted
3 90° F moulded hose, 10 mm dia. clamp
[2x], fuel line
5 Mounting of metering pump
6 Metering pump
6
1315959C_EN
5
Installing
metering
pump
50
21
1
2
Angle down perforated bracket 1 and drill
hole at Position 2 to 8.5mm dia.
Preparing
perforated
bracket
75
90°
1
2
1
2
3
4
5
6
3
M6x25 bolt, flanged nut
Mounting of metering pump
Metering pump
Cable tie
Perforated bracket
180° moulded hose, 10 mm dia. clamp
6
5
Premounting metering pump
51
4
1
2
Install perforated bracket on original vehicle
bolt of fuel tank fastening. Paste insulation
strip 4.
3
mounted
2 90° Moulded hose, 10 mm dia. clamp [2x]
3 Fuel line
4
Installing
metering
pump
52
Gasoline fuel stand pipe
1
Version 1
Remove fuel-tank sending unit 1 in accordance with manufacturer's specifications.
Watch drilling chips while drilling!
Mount large diameter washer 2 da = 17.6mm
dia, copy 6mm dia hole pattern
Removing
fuel
3
3 6 mm dia. hole
2
1315959C_EN
53
22
Cut standpipe 1 obliquely!
2 Section, discard
145
Cutting
standpipe
to size
2
1
7
54
1
6
Observe tightening torque 5 Nm of flanged
nut 6 on fuel standpipe 7.
Mount 3.5 mm dia. moulded hose 4 on fuel
standpipe 7.
1
2
3
5
5
4
Fuel-tank sending unit
Standpipe
10 mm dia. clamp
8 mm dia. clamp
Installing
fuel standpipe
3
2
55
1
Install fuel-tank sending unit 4 in accordance
with manufacturer's specifications.
Mount 3.5 mm dia. hose 1 on fuel standpipe
3.
2
7
3
6
4
2
5
6
7
8 mm dia. clamp
6x11 hose (rattle protection)
Fuel line
10 mm dia. clamp
Installing
line
5
56
Version 2
1
Remove fuel-tank sending unit in accordance
with manufacturer's instructions.
Remove upper section 1 from lower section 2
in accordance with manufacturer's instructions.
2
Removing
fuel
57
1315959C_EN
23
Cut off connection piece 2 flush on underside 1.
Drill 6 mm dia. hole in centre.
1
Removing
fuel
58
2
Insert fuel standpipe 1 in upper section of
fuel-tank sending unit 2.
Removing
fuel
1
2
59
Removing
fuel
1
2
60
1
2 Section, discard
Cutting
standpipe
to size
160
2
1315959C_EN
61
24
Mount standpipe 1 in 4.5 mm dia. moulded
hose 3.
2 10 mm dia. clamp
Premounting standpipe
3
2
1
1
62
Premount standpipe 3 on fuel standpipe 1
and secure with 8 mm dia. clamp 2.
2
4 Fuel-tank sending unit
4
Installing
standpipe
63
3
Insert line holder 3 for guiding standpipe 2 in
lower section of fuel-tank sending unit 4.
1
Installing
standpipe
2
3
4
64
1
standpipe 2.
2
3
4
5
3
5
6
7
8 mm dia. clamp
10 mm dia. clamp
Fuel line
Installing
line
6
7
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65
25
Diesel fuel standpipe
1
Remove fuel-tank sending unit 1 in accordance with manufacturer's specifications.
Watch drilling chips while drilling!
2 6 mm dia. hole
Removing
fuel
2
66
Insert fuel standpipe 2 into fuel-tank sending
unit 1.
1
Removing
fuel
2
67
1
2 Fuel-tank sending unit
2
Removing
fuel
3
68
2 Discard section
155
Cutting
standpipe
to size
2
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1
69
26
standpipe 6.
6
5
1
4
1
2
3
5
Fuel-tank sending unit
Standpipe
10 mm dia. clamp
8 mm dia. clamp
Installing
standpipe
3
2
70
1
2
Mount 90° moulded hose 2 with 3.5mm dia on
fuel standpipe 5.
3
7
6
4
1
4
6
7
10 mm dia. clamp
8 mm dia. clamp
Fuel line
Installing
fuel line
71
5
1
S204 and W204
6
base 6.
5
1
2
3
4
5
6
4
3
Metering pump
10 mm dia. clamp
90° moulded hose
10 mm dia. clamp
Fuel line
Cable tie, adhesive base
72
2
X204
base 2.
1 90° moulded hose, 10 mm dia. clamp
2 Cable tie, adhesive base
3 Fuel line
3
2
1
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73
27
1
80l fuel tank
2
1 10 mm dia. clamp
2 Fuel line
3 180° moulded hose
3
74
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28
Coolant circuit
WARNING!
Any coolant running off should be collected using an appropriate container! Install hoses so that they
are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no
other hose can be damaged! When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Hose routing diagram
1
1
A
2
B
Ø 27
2
All spring clips without a specific designation
2 = Black (sw) rubber isolator
[2x]!
1315959C_EN
= 25 mm dia. 1 = Original vehicle spring clip
29
Discard section X.
Hose A = 18mm dia hose
Hose B = 180°, 18x18 moulded hose
B
A
A =
B =
X
1250
1540
Cutting
hoses to
length
X
Slide braided protection hoses on to hoses A
and B and cut to length.
Cut heat shrink plastic tubing to size.
1
1
B
1 Heat shrink plastic tubing, length 50 [4x]
Preparing
hoses
A
1
1
Detach pass through 1 at the marking and remove!
1
Removing
pass
through
75
Turn original vehicle spring clamp 1 [2x] according to figure
1
Aligning
clamps
1
76
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30
Cut out corrugated tube 1 according to length
and slide onto brake line!
1
Installing
corrugated tube
1
77
1 Battery carrier
2 Edge protection 200
1
Mounting
edge protection
2
78
1 8 mm dia. hole
Hole in
shield
plate
1
79
1 Hose bracket 2-fold, can be locked
Installing
hose
bracket
1
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80
31
Remove original vehicle hose 1 and discard.
Original vehicle spring clips will be reused.
Cutting
point
81
1
A
1 Original vehicle spring clip
2 Connection piece on engine outlet
1
Connecting engine
outlet
2
82
A
Route hose A into hose bracket 1 and route
forward through pass-through!
1
Routing in
engine
compartment
83
Insert hose bracket 1 between hose A and
the coolant pipe of the heat exchanger outlet
lying under it.
Routing in
engine
compartment
1
A
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84
32
1 Connecting piece of circulating pump
Connecting heater
inlet
85
1
A
1 Connection piece on heat exchanger inlet
2 Original vehicle spring clip
B
Connecting heat
exchanger
inlet
2
B
1
86
Route hose B into hose bracket 1 and route
forward through pass-through! Close lock!
1
Routing in
engine
compartment
A
87
1 Battery carrier mounted
B
Routing in
engine
compartment
1
A
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88
33
Slide black (sw) rubber isolator 1 onto hose B.
B
A
Routing in
engine
compartment
1
89
1 Connection piece on engine outlet
2 Align black (sw) rubber isolator
1
Connecting heater
outlet
2
B
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90
34
Combustion air
1
Discard section X.
1 Combustion air pipe
a = 480
Cutting
combustion air
pipe to
length
a
X
1 Perforated bracket
1
Angling
down perforated
bracket
80
90°
1 Original vehicle bolt
2 Angle bracket
1
Installing
angle
bracket
91
2
2 25 mm dia. spring clip
1
Installing
combustion air
pipe
2
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92
35
1
2 Cable tie
2
Routing
fuel line
1
93
1
1 51 mm dia. pipe clamp
2 Muffler
2
Installing
muffler
3
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94
36
Exhaust end section
1
S204 and W204
Cut out wheel well inner panel 1 at the markings.
2 Discard section
Cut out
wheel well
inner panel
95
2
Installing wheel well inner panel. The exhaust
end section 1, must be centered relative to
the hole 1 and aligned flush with the wheel
well inner panel 2; realign exhaust end section 1 if necessary.
1
Aligning
exhaust
end section
96
X204
1
Drill 45 mm dia. hole 1 in trim 2.
The exhaust end section 3, must be centered
relative to the hole 1 and aligned flush with
the trim 2; realign exhaust end section 3 if
necessary.
3
2
Aligning
exhaust
end section
97
Aligning
exhaust
end section
1
98
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37
Final Work
WARNING!
Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical
connections for firm seating. Secure all loose cables using cable ties.
Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl
100K, Order No. 111329).
- Connectbattery
- Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.
- Teach Telestart according to "Installation documentation T91 / T100 HTM", adjust digital
timer if necessary
- Activate push button according to "Installation documentation T91 / T100 HTM" ( Repositioning of switch input)
- Define settings of air conditioning control panel according to the "operating and maintenance instructions of TT-Evo"
- Mount information label "Switch off parking heater before refueling" in area of filler neck.
- For initial startup and function check, please see installation instructions
WARNING:
After conducting an operating test of the parking heater, carry out an "input short test" with the "Diagnosis assistance system" of the manufacturer on the vehicle.
Reprogram the positioning motors in the KLA air conditioner.
Feel the drive
Webasto AG
Postfach 80
D-82132 Stockdorf / Germany
National Hotline: 01805 93 22 78
(14 Cent aus dem deutschen Festnetz)
Hotfax: 0395 5592 353
Hotmail: hotline@webasto.de
http://www.webasto.de
1315959C_EN
Printed in Germany
01/2011
Printing: Steffen
38

Water Heater Installation documentation Mercedes Benz C Class

Transcription

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