Table of Contents
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Water Heater
Thermo Top Evo 5+ Parking Heater
Installation Documentation
Mercedes Benz C-Class S204, W204 /
Mercedes Benz C-Class C204 /
GLK-Class X204 /
Validity
Manufacturer
Daimler AG
Daimler AG
Daimler AG
Daimler AG
Coupe (C204):
Motorisation
Fuel
C 180 CGI
Petrol / R4
C 200 CGI
Petrol / R4
C 250 CGI
Petrol / R4
C 350
Petrol / V6
C 220 CDI
Diesel / R4
C 250 CDI
Diesel / R4
Saloon (W204):
Motorisation
Fuel
C 180 K
Petrol / R4
C 180 CGI
Petrol / R4
C 200 K
Petrol / R4
C 200 CGI
Petrol / R4
C 230
Petrol / R4
C 250 CGI
Petrol / R4
C 280
Petrol / V6
C 300
Petrol / V6
C 350
Petrol / V6
C 350 CGI
Petrol / V6
C 180 CDI
Diesel / R4
C 200 CDI
Diesel / R4
C 220 CDI
Diesel / R4
C 250 CDI
Diesel / R4
C 300 CDI
Diesel / V6
C 320 CDI
Diesel / V6
C 350 CDI
Diesel / V6
Ident. No.: 1315959G_EN
E
00 0258
from model year 2008
Model
C Class
C Class
C Class Coupe
GLK Class
Transmission type Output in kW
AT / SG
AT / SG
AT
AT
AT / SG
AT / SG
Transmission type Output in kW
AT / SG
AT / SG
AT / SG
AT / SG
AT / SG
AT
AT
AT
AT
AT
AT / SG
AT / SG
AT / SG
AT
AT
AT
AT
Status: 31.01.2013
1
from model year 2007
from model year 2011
Type
EG-BE No. / ABE
S204
e1 * 2001 / 116 * 0431 * ...
W204
e1 * 2001 / 116 * 0457 * ...
C204
e1 * 2001 / 116 * 0431 * ...
X204
e1 * 2001 / 116 * 0480 * ...
Displacement in cm³ Engine code
115
1796
135
1796
150
1796
225
3498
125
2143
150
2143
Displacement in cm³ Engine code
115
1796
115
1796
135
1796
135
1796
150
2496
150
1796
170
2996
170
2996
200/225
3498
215
3498
88
2143
100
2143
125/150
2143
150
2143
170
2987
165
2987
165
2987
170
195
© Webasto Thermo & Comfort SE
271.820
271.820
271.860
276.957
651.911
651.911/ .912
271.952/ .910
271.820
271.950
271.820/ .911
272.911/ .921
271.860/ .948
272.947/ .948
272.947/276957
272.961
272.982
646.811/ .812
651.913/ .811
651.911/ .811
642.832
651.911/ .912
642.960/ .961
642.960/ .961
642.832/ .830
642.834
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Table of Contents
Related Manuals for Webasto Thermo Top Evo 5+
Summary of Contents for Webasto Thermo Top Evo 5+
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Page 1: Validity
C 300 CDI Diesel / V6 2987 651.911/ .912 C 320 CDI Diesel / V6 2987 642.960/ .961 C 350 CDI Diesel / V6 2987 642.960/ .961 642.832/ .830 642.834 Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 2 Blue Efficiency / Blue Tec / 4 Matic Headlight washer system Not verified: AMG 950 Sports Package AMG Optical package Exclusion: C 63 AMG GLK 200/220/250 CDI Total installation time: approx. 8 hours Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 3: Table Of Contents
The total installation time may vary for vehicle equipment other than provided. Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 4: Information On Operating And Installation Instructions
Installation and repair may ONLY be carried out by persons trained and VEHICLE INSTALLATION REQUIREMENTS certified in a Webasto training course. NEVER try to install or repair We- 2.1. Scope basto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you 2.1.1. -
Page 5: Information On Validity
• Torque wrench for 2.0 - 10 Nm • Hose clamping pliers • Metric thread-setter kit • Stepped drill bit • Webasto Thermo Test diagnosis with current software Dimensions • All dimensions are in mm. Tightening torque values • Tightening torque values of 5x13 heater bolts = 8Nm. -
Page 6: Preliminary Work
• Remove years that do not apply from the type and duplicate label. • Attach the duplicate label (type label) in the appropriate place in the engine compartment. Heater Installation Location 1 Heater Installation location Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 7: Preparing Electrical System
IPCU view on contact side. The pre-programmed settings are to be checked during function control and adjusted if necessary. Duty cycle: 56-62% IPCU view IPCU Frequency: 400Hz Voltage: 3.0V Function: High-side Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 8: Electrical System
1 5mm dia. hole, M5x16 bolt, washers [2x], re- itive terminal (battery or starter cable of positive taining plate of fuse holder, nut support point). 2 F1+2 fuses mounted Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 9: Fan Control
Fuse, 20A 30A fuse replaced with IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 56-62% Frequency: 400Hz Voltage: 3.0V Cutting point Function: High-side Wiring colours may vary. Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 10 Route wiring harness of fan control 3 to cen- tre console and secure with cable tie. 1 Mount K1 and K2 relay 2 Plug IPCU Mounting relay [2x] and IPCU Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
- Page 11 Connection to plug-in connector 3 of socket outlet/lighter. Produce connections as shown in wiring diagram. 1 Red (rt) wire K1/86 2 Pink/yellow (ro/ge) wire Connec- 4 Pink/yellow (ro/ge) wire tion to socket out- let/lighter Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 12: Mounting Push Button
Install push button 1 , align and secure it with union nut. Mounting push but- When drilling, watch components located be- hind. 1 12mm dia. hole Hole for wiring har- ness Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 13: Telestart
Only in connection with Telestart. Use wiring harness extension. 1 12mm dia. hole, push button Mounting push but- Telestart 1 Receiver, adhesive tape Mounting receiver 1 Antenna Mounting antenna Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 14: Preparing Installation Location
2 and bumper at po- sition 1 . Installing 1 Original vehicle bolt heater C204, S204 and W204 When drilling, watch components located be- hind. 1 M6x20 bolt, flanged nut Loosely mounting heater Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 15 5mm ). Copying 2 Copy 7 mm dia. hole pattern hole pat- tern X204 with front fog light 1 Copy 7 mm dia. hole pattern Copying hole pat- tern Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 16: Mounting Heater
4 . Align heater and fasten at position 4 and 3 . Tighten bolt on re- Mounting taining strut. heater 2 Flanged nut 4 M6x20 bolt, 8 mm shim, flanged nut Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 17: Exhaust Gas
2 Cutting point Preparing exhaust end section Vehicles with daytime running light 1 M6x12 bolt, spring lockwasher 2 Hose clamp 3 Exhaust end section Mounting silencer and end section Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 18 3 and silencer), align and fasten. section X204 Slide complete exhaust end section 3 onto exhaust silencer. 1 M6x12 bolt, spring lockwasher 2 Hose clamp Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 19: Fuel
3 Fuel line, 10 mm dia. clamp 4 Moulded hose of heater Connec- tion to heater Degrease adhesive surface for adhesive base 1 . 1 Adhesive base, cable tie 2 Corrugated tube Routing lines Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 20 2 Fuel line, wiring harness of metering pump Routing lines Distribute retaining clamps 1 [10x] evenly along vehicle underbody and insert fuel line 2 and wiring harness of metering pump. Routing lines Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 21: 60L Fuel Tank Metering Pump
4 Adhesive base, cable tie 5 Mounting of metering pump 6 Metering pump X204 Drill 9.1 mm dia. hole 1 , mount M6 rivet nut. Rivet nut for meter- ing pump Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 22: Fuel Tank Metering Pump
Paste insulation strip 4 . 1 Wiring harness of metering pump, con- nector mounted Mounting 2 90° Moulded hose, 10 mm dia. clamp metering [2x] pump 3 Fuel line Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 23: Petrol Fuel Standpipe
Mount 3.5 mm dia. hose 1 on fuel standpipe 3. 2 8 mm dia. clamp 5 6x11 hose (rattle protection) Mounting 6 Fuel line wire 7 10 mm dia. clamp Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 24 Insert fuel standpipe 1 in upper section of fuel-tank sending unit 2 . Fuel ex- traction Observe tightening torque 5 Nm of flanged nut 2 on fuel standpipe 1 . Fuel ex- traction Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
- Page 25 Mount fuel-tank sending unit 1 in accordance with manufacturer's instructions. Insert line holder 3 for guiding standpipe 2 in lower section of fuel-tank sending unit 4 . Mounting standpipe Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 26: Diesel Fuel Standpipe
Insert fuel standpipe 2 into fuel-tank sending unit 1 . Fuel ex- traction Observe tightening torque 5 Nm of flanged nut 1 on fuel standpipe 3 . 2 Fuel-tank sending unit Fuel ex- traction Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 27 Mount 90° moulded hose 2 with 3.5mm dia. on fuel standpipe 5 . 1 10 mm dia. clamp Mounting 4 8 mm dia. clamp fuel line 6 6x11 hose (rattle protection) 7 Fuel line Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 28: Connecting Metering Pump
2 Cable tie, adhesive base ing meter- 3 Fuel line ing pump 80l fuel tank 1 10 mm dia. clamp 2 Fuel line 3 180° moulded hose Connect- ing meter- ing pump Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 29: Coolant Circuit
The connection should be "inline" based on the following diagram: Hose rout- ing dia- gram Ø 27 Non-designated spring clips = 25 mm dia. 1 = Original vehicle spring clip [2x]. 2 = Black (sw) rubber isolator [2x]. Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 30 1 Heat shrink plastic tubing, length 50 [4x] Preparing hoses Detach pass through 1 at the marking and re- move. Removing pass through Turn original vehicle spring clip 1 [2x] as shown. Aligning clamps Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
- Page 31 1 Battery carrier 2 200mm edge protection Mounting edge pro- tection 1 8 mm dia. hole Hole in guard plate 1 Hose bracket 2-fold, can be locked Inserting hose bracket Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
- Page 32 Routing in engine compart- ment Insert hose bracket 1 between hose A and the coolant pipe of the heat exchanger outlet lying under it. Routing in engine compart- ment Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
- Page 33 Route hose B into hose bracket 1 and route forward through pass through. Close lock. Routing in engine compart- ment 1 Battery carrier mounted Routing in engine compart- ment Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
- Page 34 Slide black (sw) rubber isolator 1 onto hose B. Routing in engine compart- ment 1 Connection piece on heater outlet 2 Align black (sw) rubber isolator Connec- tion of heater out- Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 35: Combustion Air
1 Perforated bracket Angling down per- forated bracket 90° 1 Original vehicle bolt 2 Angle bracket Mounting angle bracket 1 Combustion air pipe Mounting combus- tion air pipe Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... - Page 36 Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204 1 Combustion air pipe 2 Cable tie Routing combus- tion air pipe 1 51 mm dia. p-clamp 2 Silencer 3 M5x20 bolt, flanged nut Mounting silencer Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...
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Page 37: Exhaust End Section
1 and aligned flush with Aligning the trim 2 ; realign exhaust end section 3 if exhaust necessary. end sec- tion 3 Exhaust end section 1 Exhaust end section Aligning exhaust end section Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE... -
Page 38: Final Work
Reprogram the positioning motors in the KLA air conditioner. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE...