Webasto Thermo Top C Manuale utente

Ident. No.: 9015593A €10 fee © Webasto AG

00 0002

Water Heater Unit

Thermo Top C Auxiliary Heating

Installation Instructions

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.

Mercedes Benz W203

(C Class)

Gasoline and diesel

From model year 02

For left-hand drive vehicles only

Not for AMG look

Legend for figure 1:

1 Thermo Top C Heater Unit

2 Metering pump

3 Antenna Option

4 Receiver Option

13 4

Table of Contents

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.

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

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

Mercedes Benz W 203

Heater Unit / Scope of Delivery

Quantity Name Order No.

1 Scope of Delivery Water heater unit Thermo Top C-B 9011466A

W 203 sedan/station wagon up to model year 03

1 Scope of Delivery Water Heater Unit Thermo Top C-D 9011465A

W 203 sedan/station wagon up to model year 03

1 Scope of Delivery Water heater unit Thermo Top C-B 9011468A

W203 Sport coupé to model year 03

1 Scope of Delivery Water Heater Unit Thermo Top C-D 9011467A

W203 Sport coupé to model year 03

1 Scope of Delivery Water heater unit Thermo Top C-B 9010977A

W 203 sedan/station wagon up to model year 03

1 Scope of Delivery Water Heater Unit Thermo Top C-D 9010976A

W 203 sedan/station wagon up to model year 03

1 Scope of Delivery Water heater unit Thermo Top C-B 9011508A

W203 Sport coupé from model year 04

1 Scope of Delivery Water Heater Unit Thermo Top C-D 9011509A

W203 Sport coupé from model year 04

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

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.

Special features are highlighted using the following symbols:

Mechanical work

Electrical connection

Water connection

Fuel connection

Exhaust system

Combustion air

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

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

Mercedes Benz W 203

(1) Heater unit

Heater Unit

Installation

Location

Warning!

- Remove the passenger compartment filter in the engine compartment

- 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).

Pre-

liminary

Mercedes Benz W 203

Installation should be carried out according to the general, standard rules of technology. Unless

specified otherwise, you should fasten to original vehicle lines and cable harnesses using cable clips.

Sharp edges should be fitted with edge protectors!

Con-

nection

Electrics

Fuse holder

(1) Fuse holder (on yellow

connector)

(2) Fuse holder

(3) Dashboard

CAN bus connection

(1) CAN plug connector

(2) CAN cable harness

(3) Rocker panel cable conduit

Left grounding point

(1) Rocker panel cable conduit

(3) Grounding point

6 7

1 1 2

Grounding point in front

(1) Grounding point

(2) Grounding cable

Cable harness duct in front

(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)

3 4

Electrics

diagram

CAN nodes

to model year 04

CAN nodes from

model year 04

(



Mercedes Benz W 203

Remote start option

Slide the remote control receiver on the

bracket tracks on the fuse and relay box.

(1) Remote start receiver

(2) Fuse and relay box

(3) Remote start cable harness

(4) Antenna cable

Remote

start T90

(1) Adhesive antenna remote start

(2) Trunk ledge

Assem-

bling the

adhesive

antenna

Thermo Call option 13

Connect the ThermoCall cable harness

with the Y-adapter and the remote start

cable harness and insert in the remote

start receiver.

(1) Thermo Call cable harness

(2) Thermo Call housing Thermo

Call TC 1.1



(

Mercedes Benz W 203

(1) Thermo Call adhesive antenna

(2) Trunk ledge

Assem-

bling the

adhesive

antenna

Fasten the heater unit bracket with edged

bolts to the

front frame.

(1) M6x16 edge bolts [2x]

(2) Front screen

Assem-

bling the

Heater Unit

Fasten the heater unit bracket with two

edged bolts.

(1) M6x16 edge bolts with body washer

(2) M6x16 edge bolts

(3) Heater unit bracket Assem-

bling the

Heater Unit

(

Mercedes Benz W 203

(

CAUTION!

Open the vehicle's tank-cap lock, ventilate the tank and then re-close the tank lock.

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.

Fuel

connec-

tion

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

stay bolts.

Remove the original vehicle grommet.

(1) Line clips [2x]

(2) Angle bracket

(3) Plastic nuts [2x]

(4) Bore grommet

Preparing

the

metering

pump

installation

location

1 2

(

(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.

Pre-

assem-

bling the

metering

pump

(1) Angle bracket

(2) M6x30 bolt

(3) Metering pump bracket

(4) Flanged nut M6

(5) Metering pump cable harness

Preassem-

bling the

metering

pump

416

(

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.

(1) Metering pump bracket

(2) Metering pump

(3) Angle bracket

(4) M6x20 bolt

Assem-

bling the

metering

pump



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 pre-

assembled line bracket.

(1) Fuel pipe to the heater unit

(2) Shortened Mecanyl line to the

metering pump

(3) Universal clips [2x]

(4) Hose section

Fuel take-

off

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

Running

the lines

(

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) Bracket for fuel lines [4x]

(2) Mecanyl fuel pipe

(3) Frame side rail opening

Run the

fuel line

along the

underbody

panel and

fasten

(

Mercedes Benz W 203

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