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Water Heater Unit
Thermo Top C Auxiliary
Heating
Installation Instructions
Mercedes-Benz E-Class BR 211 / CLS BR 219
Gasoline and diesel
from the 2003 model
For left-hand drive vehicles only
Not for AMG or AMG look
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, specialized tools and
equipment are required to install and repair Webasto heating and cooling systems.
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
warning instructions.
Webasto does not accept any liability for defects and damage that are attributable to
an installation by untrained staff.
Doc. No.: 5001169A
e1
00 0002
Kit No.: 5001168A
Feel the drive
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Related Manuals for Webasto Mercedes-Benz E-Class BR 211
Summary of Contents for Webasto Mercedes-Benz E-Class BR 211
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Page 1: Installation Instructions
Specialist company training, technical documentation, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. 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. - Page 2 Mercedes-Benz E-Class BR 211 / CLS BR 219 Table of Contents Validity Connecting the Heater Unit to the Water Heater Unit / Installation Kit Pump Foreword Replacing the Switch Valve / General Instructions Installing the Coolant hoses 15 - 17...
- Page 3 9014164 A Foreword These installation instructions apply to vehicles Mercedes-Benz E-Class BR 211 / CLS BR 219 with Gasoline and dieselengines, for validity, see page 2 - as from model year 2003 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded.
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Page 4: Water Connection
Mercedes-Benz E-Class BR 211 / CLS BR 219 Explanatory Notes on the 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. - Page 5 Mercedes-Benz E-Class BR 211 / CLS BR 219 Preliminary Work - Slide the passenger seat backwards as far as possible. - Remove the vehicle keys from the ignition. - Disconnect the battery. (in the trunk) - Remove the side cover of the fuse box on the driver’s side of the dash board.
- Page 6 Mercedes-Benz E-Class BR 211 / CLS BR 219 Loosen the bumper on the side facing the wheel well: Loosen the screws, move the clamping bar to the front and remove it. 1 Clamping bar 2 Bolt Tips and 3 Coolant hose to the heater unit (will be...
- Page 7 Mercedes-Benz E-Class BR 211 / CLS BR 219 Preparing the Heater Unit Place the solenoid valve and bracket on the stay bolts in the heater unit and fasten with the flanged nuts. Fasten the preassembled coolant hose with Connect- the spring band clamp to the solenoid valve.
- Page 8 Mercedes-Benz E-Class BR 211 / CLS BR 219 Electrical Connections CAN junction Ground connection 1 Heater wiring harness 1 Grounding point in passenger foot area 2 CAN plug connector Wiring harness installation diagram Dashboard fuse box T90 and SPAL remote control...
- Page 9 Mercedes-Benz E-Class BR 211 / CLS BR 219 Installing the wiring harness Unclip the harness conduit cover on the right suspension strut mount, remove the harness grommet from the guide. Cut the side of the grommet and insert the Webasto Wiring wiring harness.
- Page 10 Mercedes-Benz E-Class BR 211 / CLS BR 219 T90 Remote Receiver Attach Velcro strips to the receiver. 1 Receiver 2 Velcro strips Remote pre- paration SPAL Remote Receiver 1 Receiver antenna 2 SPAL remote receiver 3 Remote harness from Y-adapter harness...
- Page 11 Mercedes-Benz E-Class BR 211 / CLS BR 219 Route the wiring harness for the fuel pump Route the connector for the wiring harness for the fuel pump through the cable conduit to the rear seat bench. Place Route behind the back cover next to the arm in cable rest to the plug connector.
- Page 12 Mercedes-Benz E-Class BR 211 / CLS BR 219 Water Connection Attention: 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 spring band clamps so that no other hose can be damaged!
- Page 13 Mercedes-Benz E-Class BR 211 / CLS BR 219 Route the fuel line under the air intake silencer to the wheel house cross member. Fasten to cross member with it two fastening clips and route to the wheel house. 1 Fastening clips [2x]...
- Page 14 Mercedes-Benz E-Class BR 211 / CLS BR 219 Connect the disassembled coolant hose back on the electric water pump as shown in Figure 28. 1 Water pump 2 Coolant hose Assembl- ing the coolant hoses Put the braided hose protection on the end of the moulded hose.
- Page 15 Mercedes-Benz E-Class BR 211 / CLS BR 219 Replacing the Switch Valve Loosen the hose on the top of the switch valve on the rear bulkhead and loosen the plug. Loosen the hose connections by pulling out the spring wires [3x].
- Page 16 Mercedes-Benz E-Class BR 211 / CLS BR 219 Place the moulded coolant hose in the gap in the windshield fluid container and then along the wiring harnesses under the container shackle. 1 Windshield fluid container shackle B Moulded coolant hose...
- Page 17 Mercedes-Benz E-Class BR 211 / CLS BR 219 Route the coolant hose on the side over the bracket and down into the fender. (Figure shows CLS, always check for access to the headlight!) Routing the coolant hose Connect the coolant hose to the preassembled hose on the solenoid valve.
- Page 18 Mercedes-Benz E-Class BR 211 / CLS BR 219 Fuel Connection Remove the vehicle's fuel tank cap, ventilate the fuel tank and reinstall fuel tank cap. CAUTION! Catch any fuel running off with an appropriate container. Install the fuel line so that they are protected from impact by rocks! Unless specified otherwise, always fasten using cable ties.
- Page 19 Mercedes-Benz E-Class BR 211 / CLS BR 219 Assembling the fuel pump 1 Fuel line coupler 90° 2 Fuel pump 3 Rubber bracket 4 Universal clamp Ø10 mm, Fuel pump (white color identification) [4x] pre- 5 Fuel line coupler [2x]...
- Page 20 Mercedes-Benz E-Class BR 211 / CLS BR 219 Insert a screw driver in the fuel pump mounting bracket hole and bend the strap to align it for free access to the fuel pump from the adjacent components. 1 Suction side of the fuel line...
- Page 21 The Mercedes E Class comes factory equipped with a HVAC controller that can be programmed to control the Webasto heater On / Off times. STAR Diagnostics must be used to program this feature for the heater. Only a certified Mercedes dealership has the necessary diagnostic tool and information to properly set up these heater functions.
- Page 22 Mercedes-Benz E-Class BR 211 / CLS BR 219 NOTES:...
- Page 23 Mercedes-Benz E-Class BR 211 / CLS BR 219 Documentation Feedback Form Detailed user feedback is extremely valuable to us in producing accurate, comprehensive, and useful documentation Please complete the relevant parts of the form below; your comments and suggestions will help us improve our documentation.
- Page 24 F e e l t h e d r iv e Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us www.techwebasto.com Org.07/2006 Rev. N/A P/N 5001169A...
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