Mercedes - C 180 - Workshop Manual - 2002 - 2002

Water Heater Unit Thermo Top C Auxiliary Heating e1 00 0002 Installation Instructions Mercedes Benz W203 (C Class) Gasoline and diesel 1 2 From model year 02 3 4 For left-hand drive vehicles only Not for AMG look 1 Legend for figure 1: 1 Thermo Top C Heater Unit 2 Metering pump 3 Antenna Option 4 Receiver Option 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. Ident. No.: 9015593A €10 fee © Webasto AG Mercedes Benz W 203 Table of Contents Validity 2 Heater Unit / Foreword / Special Tools 3 Explanatory Notes on the Document 4 Preliminary Work / Installation Location 5 Electrical Diagram 6 Remote Start and Thermo Call 7 Heater Unit Assembly 8 Pre-assembling and Assembling the Metering Pump 9 Fuel Take-off / Fuel Lines 10 Fuel Lines / Connecting to the Heater Unit 11 Water diagram 12 230 Compressor Hose System 13 220CDI/320 CDI Hose System 14 Final Work 15 Operating Instructions for the End Customer 16 Validity Manufacturer Model Type EG-BE No. / ABE Daimler Chrysler Mercedes Benz C Class W 203 e1*98 / 14*0139 to * 0159 Engine type Engine Power in kW Engine capacity in cm³ C 180 Gasoline 95 1998 C 180 K Gasoline 105 1796 C 200 Gasoline 120 1998 C 200 K Gasoline 120 1796 C 230 K Gasoline 145 2295 C 240 Gasoline 125 2597 C 320 Gasoline 160 3199 C 350 Gasoline 200 3498 C 200 CDI Diesel 85 2148 C 220 CDI Diesel 105 2148 C 270 CDI Diesel 125 2685 C 320 CDI Diesel 165 2487 Vehicle types, engine types and equipmentvariants, which are not listed in these installation instructions, have not been tested. Installation according to these installation instructions may, however, be possible. 2 Mercedes Benz W 203 Heater Unit / Scope of Delivery Quantity Name Order No. Scope of Delivery Water heater unit Thermo Top C-B W 203 sedan/station wagon up to model year 03 1 9011466A 1 Scope of Delivery Water Heater Unit Thermo Top C-D W 203 sedan/station wagon up to model year 03 9011465A 1 Scope of Delivery Water heater unit Thermo Top C-B W203 Sport coupé to model year 03 9011468A 1 Scope of Delivery Water Heater Unit Thermo Top C-D W203 Sport coupé to model year 03 9011467A 1 Scope of Delivery Water heater unit Thermo Top C-B W 203 sedan/station wagon up to model year 03 9010977A 1 Scope of Delivery Water Heater Unit Thermo Top C-D W 203 sedan/station wagon up to model year 03 9010976A 1 Scope of Delivery Water heater unit Thermo Top C-B W203 Sport coupé from model year 04 9011508A 1 Scope of Delivery Water Heater Unit Thermo Top C-D W203 Sport coupé from model year 04 9011509A Optional: Remote start: 9011461A Thermo Call: 9001132B (only in connection with the Y adapter ID no. 9010325B and remote start ID no. 9011461A) Along with the remote start and thermo call options, the basic scope of delivery can also be equipped with a direct start button in the center console. The required parts, press switch, center console, and UBF – OBF cable harness, can be ordered directly from DaimlerChrysler for the vehicle and are to be assembled according to the manufacturer’s requirements. Foreword These installation instructions apply in respect of Mercedes W203 vehicles with gasoline/diesel engines – re. validity, see page 2 - as from model year 2002 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Special Tools - Torque spanner for 2.0 - 10 Nm - Vise-grip wrench 3 Mercedes Benz W 203 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. Mechanical work Electrical connection Water connection Fuel connection Exhaust system 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. i ( Reference to general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle 4 Mercedes Benz W 203 Warning! Pre- Remove the passenger compartment filter in the engine compartment liminary - Disconnect the battery and remove it! - Remove the battery base plate. - Let off pressure in 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. - Open the tank cap, ventilate the tank. - Close the tank cap again. - Remove the right front wheel. - Remove front right headlight. - Remove the cover strip for the towing hook on the front right bumper. - Remove the underride protection on the right side of the vehicle. - Remove the rocker panel strip on the front passenger side and the front and back of the driver’s side. - Remove the A-pillar panel in the driver’s side and passenger side footwell. - Remove the lower dashboard panel on the passenger side, loosen on the driver’s side - Remove the cover of the fuse box on the driver’s side of the dash board. - Remove the gas pedal. - Remove the floor carpet on the driver and passenger side - Remove the air channels for the rear seat heating in the driver’s side and passenger side footwell. - Remove the floor mat in the trunk. - Remove the cover plate for the cable duct behind the rear seat bench. - Remove the side trunk panelling on the driver’s side. - Loosen the fuse and relay box (SAM) in the trunk. - Remove the antenna cable from the cable harness (is not required). 1 (1) Heater unit Heater Unit Installation Location 2 5 Mercedes Benz W 203 Installation should be carried out according to the general, standard rules of technology. Unless Conspecified otherwise, you should fasten to original vehicle lines and cable harnesses using cable clips. nection Sharp edges should be fitted with edge protectors! Electrics Grounding point in front Cable harness duct in front (1) Grounding point (2) Grounding cable (1) Cable harness to the heater unit (2) Cable feed-through Connection to the SAM controller unit On the rear fuse and relay box ( (1) Fuse/relay module (2) Connector on the SAM controller (blue) 1 1 2 2 2 1 3 4 5 i CAN nodes to model year 04 Electrics diagram CAN nodes from model year 04 1 3 2 1 1 2 ( 2 3 6 7 8 Fuse holder CAN bus connection Left grounding point (1) Fuse holder (on yellow connector) (2) Fuse holder (3) Dashboard (1) CAN plug connector (2) CAN cable harness (3) Rocker panel cable conduit (1) Rocker panel cable conduit (3) Grounding point 6 Mercedes Benz W 203 1 Remote start option 2 Slide the remote control receiver on the bracket tracks on the fuse and relay box. 3 (1) Remote start receiver (2) Fuse and relay box (3) Remote start cable harness (4) Antenna cable ( Remote start T90 4 9 (1) Adhesive antenna remote start (2) Trunk ledge 1 Assembling the adhesive antenna 2 10 Thermo Call option 13 2 Connect the ThermoCall cable harness with the Y-adapter and the remote start cable harness and insert in the remote start receiver. 1 (1) Thermo Call cable harness (2) Thermo Call housing ( Thermo Call TC 1.1 11 (1) Thermo Call adhesive antenna (2) Trunk ledge 1 i Assembling the adhesive antenna 2 12 7 Mercedes Benz W 203 Fasten the heater unit bracket with edged bolts to the front frame. 2 ( (1) M6x16 edge bolts [2x] (2) Front screen Assembling the Heater Unit 1 13 2 Fasten the heater unit bracket with two edged bolts. 3 (1) M6x16 edge bolts with body washer (2) M6x16 edge bolts (3) Heater unit bracket ( Assembling the Heater Unit 1 14 8 Mercedes Benz W 203 CAUTION! Open the vehicle's tank-cap lock, ventilate the tank and then re-close the tank lock. Fuel connection Catch any fuel running off with an appropriate container. Install the fuel line so that it is protected from impact by rocks! Fit the fuel line with edge protectors around sharp edges. 1 2 3 4 5 (1) Mecanyl fuel pipe to the heater unit (pressure side) (2) Universal clip [4x] (3) Straight hose section (4) Connection to metering pump cable harness (5) Metering pump (6) 90° moulded hose (7) Mecanyl fuel pipe to the tank (suction side) shortened to 900 mm. 6 ( Preassembling the metering pump 7 15 1 2 (1) Angle bracket (2) M6x30 bolt (3) Metering pump bracket (4) Flanged nut M6 (5) Metering pump cable harness ( 3 Preassembling the metering pump 5 4 16 1 ( 2 3 4 Installation location to the left above the rear axle. Screw on two brackets for the fuel line on the original vehicle stay bolts behind the rear axle mounting to the left and right of the differential housing. Assemble the bracket on the original vehicle Preparing stay bolts. the Remove the original vehicle grommet. metering pump (1) Line clips [2x] installation (2) Angle bracket location (3) Plastic nuts [2x] (4) Bore grommet 17 9 Mercedes Benz W 203 Note the installation position of the metering pump, see the "installation instructions" Fasten the pre-assembled metering pump to the angled bracket with bolt M6x25 and flanged nut. 3 2 1 4 (1) Metering pump bracket (2) Metering pump (3) Angle bracket (4) M6x20 bolt i Assembling the metering pump 18 1 2 3 4 19 Cut off the nipple on the fuel take-off for the fuel container with a knife. Place the hose section on the fuel take-off and fasten with universal clips. Insert the preassembled fuel line to the metering pump intake in the hose section for the tank extracting device and fasten with universal clips. Clip the Mecanyl fuel line into the preassembled line bracket. (1) Fuel pipe to the heater unit (2) Shortened Mecanyl line to the metering pump (3) Universal clips [2x] (4) Hose section Run the Mecanyl fuel pipe along the tank belt and fasten with cable clips. (1) Mecanyl fuel pipe to the heater unit (2) Tank fastening belt ( Fuel takeoff ( Running the lines 1 2 20 Screw the bracket for fuel lines onto the existing stay bolts. Clip the Mecanyl fuel line into the bracket and run to the front in the opening for the frame side rail. 1 2 3 (1) Bracket for fuel lines [4x] (2) Mecanyl fuel pipe (3) Frame side rail opening ( Run the fuel line along the underbody panel and fasten 21 10 Mercedes Benz W 203 1 2 Remove both oval protective rubber sleeves in the frame side rail, run the Mecanyl fuel line through the rear opening and pull through. Then lead this back into the rear opening, push out to the front and lead through the front grommet opening. 3 (1) Rear grommet opening (2) Mecanyl fuel pipe (3) Front grommet opening ( Running lines 22 Reinsert the rear grommet, drill d= 5 mm in the front grommet, place on the Mecanyl fuel line and insert again. Screw the hose bracket onto the existing stay bolts. Clip the Mecanyl fuel line into the hose bracket. 2 1 (1) Front grommet opening in frame side rail (2) Hose bracket [2x] (3) Hose bracket (4) Mecanyl fuel pipe 3 4 1 2 3 4 Installing the fuel line 23 Shorten the Mecanyl fuel pipe on the heater unit and connect. Add the wear protection hose and fasten with cable clips. 5 (1) Wear protection hose (2) Mecanyl fuel pipe (3) Universal clip [2x] (4) Hose section (5) Heater unit ( Fuel on heater unit 24 11 Mercedes Benz W 203 WARNING! Tighten all hose clamps with 2.0 + 0.5 Nm. Any cold water running off should be collected using an appropriate container! Install hoses so that they are kink-free and to prevent wear. Position hose clamps so that no other hose can be damaged! The connection should be "inline" based on the following diagram: ( WT O 25 18/20 O 27 Water diagram (shown on 230K hose system) without residual heat pump M A O 27 20/20 O 27 O 27 C O 27 20/18 O 25 B 25 On vehicles with a residual heat pump, the hose placement in the engine area may vary slightly. ( 12 Mercedes Benz W 203 A a = 210 mm b = 70 mm c = 90° bend (remaining) B Dispose of section 8 (230K without residual heat pump) 8 a ( Cutting water hoses into sections b C 26 Separate the original vehicle engine hose on the marking. (1) Original vehicle hose 1 ( Splitting point. (230K without residual heat pump) 27 1 2 3 Insert the connecting pipe in the hose ends and fasten with clips. Slide the rubber ring onto the hose to the engine. (1) Vise-grip wrench (2) rubber ring (3) Clips d=25 [2x] (4) Connecting pipe 18-20 [2x] Connecting pipe (230K without residual heat pump) 4 28 2 1 3 4 5 6 29 Connect the water hoses with the connecting pipe and clips according to the figure and diagram. Position the rubber ring on the frame side rail. Connect Fasten the hoses with spacers (clips). hoses (1) Rubber ring (wear protection) (230K (2) Clips d=25 [2x] without (3) Clips d=27 [6x] residual (4) Hose spacers [2x] heat pump) (5) Hose from header unit outlet to engine inlet (6) Hose from heat exchanger outlet to heater unit inlet 13 Mercedes Benz W 203 A C a = 360 mm b = 170 mm c = 20 mm B Dispose of section 8 (220 CDI without residual heat pump) 8 a c b 8 1 8 A Cutting water hoses into sections 30 Only 220 CDI/320 CDI Cut the braided protective hoses to 220 mm and slide onto hose A. 2 (1) Connecting pipe 18-20 (2) Braided protective hose (3) Clips d=27 [3x] (4) Connecting pipe 20-20 (220 CDI without residual heat pump) B C 4 3 Preassembling the hoses 31 (1) Original vehicle hose for the engine inlet 1 Splitting point (220 CDI without residual heat pump) 32 3 4 5 2 1 6 (1) Spacer bracket [2x] (2) Braided protective hose (3) Rubber ring (4) Original vehicle hose to the engine inlet (5) Clips d=25 [2x] (6) Clips d=27 [6x] Connect hoses (220 CDI without residual heat pump) 33 14 Mercedes Benz W 203 WARNING! Reassemble disassembled components in reverse order. Final work Check that all hose lines, hose and universal clips, and all electrical connections are securely fastened. Secure all loose lines using cable clip. Spray heating unit components with anti-corrosion wax (Tectyl 100K, Order No. 111 329). - Connect battery. - Start engine, bleed water circuit according to the vehicle manufacturer's specifications, top up with cold water, check that the cooling system is sealed according to the manufacturer’s recommendations. Release the auxiliary heater function: i After assembly, follow the manufacturer’s instructions for star diagnosis to code the auxiliary heater. - Set the vehicle heating with automatic air conditioning or without automatic air conditioning according to the "operating instructions for the end customer". - Check that the auxiliary heating operates properly, see operating instructions / installation 15 Mercedes Benz W 203 (Please remove page and insert with vehicle operating instructions.) Operating instructions for the end customer Before parking the vehicle, make the following settings: Set the heater times with the steering wheel buttons when the key is in position 1 or 2 (ignition) or when the engine is running. - Press the up or down steering wheel menu buttons until the “Settings” menu appears. - Move the arrow buttons up or down until the “Auxiliary Heating” menu appears. - Press +/- to set the start times 1 to 3. - Use the arrow button to select the time setting - Press +/- to set the start time for the auxiliary heat. - Exit the menu, the start time is saved. Options: - The optional "Auxiliary heat/vent" button in the center console is for immediate heating and ventilation (see also the vehicles operating manual). - Use the optional remote start to directly start the auxiliary heat. (see also the vehicle operating instructions). - Use the optional Thermo Call to start the auxiliary heat over the telephone. 16 Webasto Thermosysteme International GmbH Postfach 80 - 82132 Stockdorf - Hotline 0 18 05 / 93 22 78 Hotfax (0395) 55 92-353 - http://www.webasto.de Printed in Germany 04/06 Printed by: Steffen