Webasto Mercedes-Benz E-Class CLS BR 219 Manual de usuario

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.

Feel the drive

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

Doc. No.: 5001169A Kit No.: 5001168A

Water Heater Unit

Thermo Top C Auxiliary

Heating

Installation Instructions

00 0002

Mercedes-Benz E-Class BR 211 / CLS BR 219

Validity

Vehicle and engine types as well as equipment variants, which are not listed in these installation

instructions, have not been tested. Installation according to these installation instructions may,

however, be possible.

Manufacturer Model Type EG-BE No. / ABE

Daimler-Chrysler E Class 211 e1 * 2001 / 116* 0213

Daimler-Chrysler CLS Class 219 e1 * 2001 / 116* 0295

Engine type Engine Power in kW Engine capacity in cm³

200 CDI Diesel / R4 90 2148

220 CDI Diesel / R4 110 2148

270 CDI Diesel / R5 130 2685

280 CDI Diesel / V6 140 2987

280 CDI 4MATIC Diesel / V6 140 2987

320 CDI Diesel / V6 165 2987

320 CDI 4MATIC Diesel / V6 165 2987

400 CDI Diesel / V8 191 3996

420 CDI Diesel / V8 231 3996

200 NGT Gasoline / R4 120 1796

200 K Gasoline / R4 120 1796

240 Gasoline / V6 130 2597

240 4MATIC Gasoline / V6 130 2597

280 Gasoline / V6 170 2996

280 4MATIC Gasoline / V6 170 2996

320 Gasoline / V6 165 3199

320 4MATIC Gasoline / V6 165 3199

350 Gasoline / V6 200 3498

350 4MATIC Gasoline / V6 200 3498

500 Gasoline / V8 225 4966

500 4MATIC Gasoline / V8 225 4966

Validity 2

Heater Unit / Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on the Document 4

Preliminary Work 5

Tips and Tricks / Preparing the Electrical 6

Preparing the Heater Unit / Installing the

Heater Unit 7

Electric diagram 8

Installing the Wiring harness /

Electrical Connection 9

T90 remote receiver /SPAL remote receiver 10

Routing the Fuel Pump Wiring Harness 11

Water diagram 12

Turning the Water Pump 13

Connecting the Heater Unit to the Water

Pump 14

Replacing the Switch Valve /

Installing the Coolant hoses 15 - 17

Installing the Fuel Line 18

Assembling Fuel Pump 19 - 20

Final Work 21

Table of Contents

Mercedes-Benz E-Class BR 211 / CLS BR 219

Heater Unit / Installation Kit

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. Depending on the vehicle version and equipment, modifications may be

with respect to these “Installation Instructions”.

However, thestipulationsinthe "installationinstructions"and"operating andmaintenanceinstructions"

for the Thermo Top C/P/E are to be observed in any event.

The corresponding rules of technology and any information from the vehicle manufacturer should be

observed during the installation work.

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, such as for example bore holes, with anti-corrosion wax (Tectyl 100K,

Order No. 111329)!

After installation, release the auxiliary heater function using the DC Star diagnosis (coding).

Special Tools

- Torque spanner for 2.0 - 10 Nm

- Vise-grip wrench

Amount Description Order No.:

1 Scope of delivery TT-C Diesel W211 / W219 9014163 A

1 Scope of delivery TT-C Gasoline W211 / W219 9014164 A

Special features are highlighted using the following symbols:

Mechanics

Electrics

Water connection

Fuel connection

Exhaust system

Combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the

viewing

angle.

Mercedes-Benz E-Class BR 211 / CLS BR 219

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.

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.

Mercedes-Benz E-Class BR 211 / CLS BR 219

Heater Unit Installation Location

1Heater unit

Installation

location

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.

- Remove the footwell panel under the dashboard on the passenger side.

- Remove the A-pillar panel in the passenger side.

- Remove the floor cover in the passenger footwell area.

- Loosen the footrest plate located behind this.

- Remove the cover from middle console around the gear shift stick (optional).

- Remove the A-pillar panel in the passenger side.

- Loosen the cable conduit cover next to the fond armrest.

- Open the hood.

- 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 fuel tank cap, ventilate the tank.

- Close the fuel tank cap again.

- Remove the right front and rear wheels

- Remove the front part of the right wheel house panel.

- Loosen the front section of the wheel house panel and lift it to the back.

- Remove the lower right section of the engine enclosure under the rocker panel (2 sections).

- (CLS only) loosen the front grill

- Loosen the bumper on the right side of the vehicle.

- Remove right headlight (CLS: 2 screws on the top, 1 screw from the wheel house).

- Remove the engine design cover (pull off).

- Remove the covers in the left and right engine area (turn locks 90°).

- Remove the combination filter housing (1 plastic nut, left and right snaps).

- Remove the windshield wipers.

- Pull off the gasket that runs across the water reservoir cover.

- Remove the water reservoir cover, remove the drain hose.

- Remove the windshield wiper arm and motor.

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.

1Clamping bar

2Bolt

3Coolant hose to the heater unit (will be

added Later, not yet present during

disassembly)

Tips and

Tricks

To route wiring harnesses and wires through

grommets, cable ducts or tight areas, we

recommend using the mecanyl fuel line. This,

for example, is pushed through a cable duct

until the desired point is reached, the wiring

harness is fastened with insulation tape and

pulled behind. Tips and

Tricks

Preparing the wiring harness

Remove the wiring harness twine between

the connection of the fuel pump plug and the

unwrapped section.

1Beginning of the wrapped section

2Disconnecting the fuel pump connector

3Fuel pump connector (blue)

Removing

the

wiring

harness

twine

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

the spring band clamp to the solenoid valve.

Replace the connector on the solenoid valve.

1Solenoid valve connector

2Preassembled coolant hose with clamp

3M6 flanged nuts [3x]

Connect-

ing the

solenoid

valve

Connect the mecanyl fuel line to the heater

fuel line nipple with the

hose section and clamp.

1Fuel line

2Universal clamp

(white color identification) [2x]

3Hose section Connect-

ing

the fuel

line

Installing the heater unit

Loosely pre-assemble the solenoid valve

bracket on the wheel well

with two screws.

1M6x12 collar screws [2x]

2Solenoid valve bracket

Installing

the

solenoid

valve

Loosely pre-assemble the heater unit

bracket on the bumper cross member with

two screws.

Tighten all fastening bolts.

Plug the wiring harness connector into the

heater.

Route the wiring harness to the right

suspension strut mount.

1M6x12 collar screws [2x]

2Heater unit bracket

Assembl-

ing the

heater unit

1 2

Mercedes-Benz E-Class BR 211 / CLS BR 219

Electrical Connections

CAN junction

1Heater wiring harness

2CAN plug connector

Ground connection

1Grounding point in passenger foot area

Wiring

harness

installation

diagram

Dashboard fuse box

1Fasten the heater unit fuse holder on the free

slot in the left row, fifth from the top

(position 25)

2Dashboard fuse box left

T90 and SPAL remote control

elements

(schematically pre-assembled)

1Heater harness 4Remote harness

2Remote antenna 5 T90 remote receiver

3SPAL receiver 6Y-adapter harness

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 harness. Seal the grommet with

adhesive sealant and reinstall in guide.

1Webasto wiring harness

2Cut open grommet

The figure shows coolant hose C covered

with braided hose protection.

Wiring

harness

routing

Route the wiring harness under the

hoses to the rear bulkhead.

Cut open the rubber sleeve.

Route wiring harness to passenger

compartment.

Seal the protective rubber sleeve with

sealant.

1Protective rubber sleeve

2Wiring harness

Wiring

harness

routing

Make electrical connection

Place wiring harness in passenger

compartment: Insert CAN plug in the plug

connector. Secure the ground cable to

existing ground point, route the fuse holder

behind the dash board to the fuse box, route

the fuel pump connector to the cable conduit

in the rocker panel, leave the wiring harness

for the T90 remote receiver in the foot area,

separate the six-pin plug from the wiring

harness.

1Footrest plate

2CAN plug connector

3Grounding point

Distribut-

ion of

wiring

harnesses

Connect the red and brown wires from the Y

adapter to the wires of the same color in the

remote wiring harness.

Connect the yellow wire from theY adapter to

the gray-blue wire in the remote wiring

harness.

Crimp and shrink the connectors.

1Connector for SPAL receiver wiring

harness

2T90 remote connector (Y adapter)

3Crimp shrink connectors [3x]

Y- adapter

connection

Mercedes-Benz E-Class BR 211 / CLS BR 219

T90 Remote Receiver

Attach Velcro strips to the receiver.

1Receiver

2Velcro strips T90

Remote

pre-

paration

SPAL Remote Receiver

1Receiver antenna

2SPAL remote receiver

3Remote harness from Y-adapter harness SPAL

Remote

pre-

paration

Note:

Note the chapter “Final work“on

page 22“

Fasten the T90 remote receiver on the rear

side of the glove compartment.

Fasten the SPAL remote receiver next to the

T90 remote receiver using nylon wire ties.

1Glove compartment housing

2T90 remote receiver

T90 / SPAL

remote

receiver

assembly

Glue the SPAL remote receiver antenna to

the black area on the windshield.

1Windshield antenna

Antenna

installation

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