Webasto Mercedes-Benz E-Class CLS BR 219 User manual

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
e1
00 0002

22
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

33
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

44
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.
i
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.

5
Mercedes-Benz E-Class BR 211 / CLS BR 219
Heater Unit Installation Location
1Heater unit
Installation
location
1
1
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.

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.
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
2
2
1
3
1
3
2
3

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
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
3
4
2
1
5
3
1
2
1
6
2
1 2
7

8
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
8
1
2
9
1
10
1
2
11
3
1
6
5
2
4

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 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
12
1
2C
13
1
2
14
1
3
2
15
2
1
3

10
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
1
2
16
2
17
3
1
18
2
1
1
19

11
Mercedes-Benz E-Class BR 211 / CLS BR 219
Route the wiring harness for
the fuel pump
Routetheconnectorforthewiringharnessfor
thefuelpumpthroughthecableconduittothe
rear seat bench.
Route behind the back cover next to the arm
rest to the plug connector.
1Cable conduit cover
2Rocker panel cable conduit
Place
in cable
conduit
Remove the red gasket piece from the free
slot in the terminal strip (no longer needed).
Insert the connector for the fuel pump wiring
harness in the slot.
1Connector for the fuel pump wiring harness
2Wheel case terminal strip Connector
for fuel
pump in
passenger
compart-
ment
Plug the connector on the short wiring
harness to the fuel pump from the
wheelhouse to the corresponding slot.
1Plug Fuel
pump
connector
in wheel
house
Open the fastening lugs for the wiring
harness guide.
Route the wiring harness down through the
guide to the fuel pump and fasten.
1Wiring harness guide fastening lug Wiring
harness
guide in
the wheel
house
20
1
2
21
1
2
22
1
23
1

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!
The connection is based on the following diagram:
All vehicles
Water
installation
diagram
All undesignated clamps are Ø 25mm spring band clamps!
All undesignated coolant hose couplers are Ø 15x18.
Motor
Ø 23
Ø 22
Ø 22
A
B
C
Wärme-
tauscher
Ø 18/18
Heat
exchanger

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.
1Fastening clips [2x]
2Fuel line Fuel line
installation
Water Connection
Disconnect both coolant hoses to the original
vehicle electric water pump with pliers and
remove.
Pull the plug off.
1Water pump connector
2Water pump
Water
pump
preparat-
ion
Turn the water pump in the bracket about
180°.
Check that the hose supports move easily to
the lines in the ABS unit.
Replace the connectors.
1Hose supports
2Water pump connector
Turningthe
water
pump
Shortentheenclosedbraidedhoseprotection
by 380 mm.
From this 380 mm long piece, cut off
two 100 mm long pieces.
Place one 100 mm long piece on the hose
to the mechanical water pump.
Insert the coolant hose coupler and fasten
with a clamp.
1Coolant hose coupler 18x18
2Spring band clamp Ø25 mm
3Braided hose protection 1=100 mm
4Hose to the mechanical water pump
Coolant
hose
preparat-
ion
24
1
2
2 1 25
26
1 2
27
1 2 3 4

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.
1Water pump
2Coolant hose Assembl-
ing the
coolant
hoses
Put the braided hose protection on the end of
the moulded hose.
Pre-assemble two clamps.
1Braided hose protection 1=100 mm
2Spring band clamps Ø25 mm [2x]
AMoulded hose Coolant
hose
pre-
assembly
Before connecting, fill the coolant hoses with
coolant. Connect the preassembled coolant
hose to the solenoid valve. Connect the other
end of the hose to the mechanical water
pump.
Fasten moulded hose to the original vehicle
stay bolts with the tube clamp.
Fasten the preassembled hose from the
heater unit coolant inlet to the free supports
on the water pump.
1Hose for heater unit coolant inlet
2Rubberised tube clamp Ø25, nut M6
AMoulded hose
Assem-
bling the
coolant
hoses
1Hose for heater unit coolant inlet
2Hose to the mechanical
water pump connected with
moulded hose A
Assem-
bling the
coolant
hoses
28
1
2
29
A2
1
30
2
1
A
31
1
2

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].
Remove the rubber sleeve.
Remove the valve.
1Protective rubber sleeve
2Engine outlet hose
Removing
switch
valve
Before connecting, fill the coolant hoses
with coolant!
Install new switch valve
(5 connections).
Replace protective rubber sleeves.
Check that the connections are
completely locked.
Reinstall the series coolant hose.
Fasten the additional moulded coolant
hose with clamps and move to the
right.
BMoulded hose, spring band clamp Ø23 mm
1Series coolant hose
2Switch valve, 5 connections
Switch
valve
assembly
Create coolant connections
Route moulded coolant hose along rear
bulkhead.
Position coolant hose as low as possible.
1Switch valve, 5 connections
BMoulded hose
Routing
thecoolant
hose
Route the moulded coolant hose under the
guide in the bleed hose from the coolant
reservoir.
1Bleed hose guide
BMoulded hose Routing
the
Coolant
hose
32
1
2
2
1
33
B
34
1
B
35
B
1

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.
1Windshield fluid container shackle
BMoulded coolant hose Routing
thecoolant
hose
Slide the long remnant of the braided hose
protection on hose C l=800 mm.
On one side, slide on the red rubber insulator.
On both sides, insert the coolant hose
couplers and fasten with clamps.
1Spring band clamps Ø25 mm [2x]
2Braided hose protection
3Rubber insulator, red
4Coolant hose coupler 15x18 [2x]
Coolant
hose
preassem-
bly
Connect the preassembled coolant hose to
the moulded hose and fasten with
clamp.
Remove the filling from the conduit.
Move the coolant hose to the front through
the guide.
Clip on the conduit cover.
1Conduit cover
BMoulded hose
2Spring band clamp Ø22 mm
CCoolant hose
Place
coolant
hose in
guide
Route coolant hose under the cross rail
according to Figure 39.
(Figure shows the CLS, always check
for access to the headlight!)
1Coolant hose C Installing
coolant
hose
36
B
1
37
1 432
38
C
B
1
2
39
1

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
thecoolant
hose
Connect the coolant hose to the
preassembled hose on the solenoid valve.
CCoolant hose
2Spring band clamp Ø22 mm
3Preassembled hose on solenoid Coolant
hose
connection
40
41
C
2
3

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.
Fit the fuel line and wiring harness with edge protectors around sharp edges.
Attention:
The wiring harness to the fuel pump should be installed based on the wiring harness installation
diagram.
Installing the fuel line
Removetheroundprotectiverubbersleevein
the side of the frame side rail and the long
protective rubber sleeve on the underside of
the frame side rail and punch a Ø 5mm hole.
Pull the round sleeve over the fuel line and
insert the fuel line into the frame side rail
through the round opening.
Slide on two rubber sliders on the fuel line
to protect from wear.
1Round protective rubber sleeve
2Fuel line
3Rubber sliders [2x]
Insert the
fuel line
in the
frame
side rail
Route the fuel line out of the long opening
in the frame side rail.
Slide of grommet and insert in opening.
1Fuel line
2Long grommet Routing
the
fuel line
Replace the four single line clips with
double line clips.
Clip in the brake line and fuel line.
Route the fuel line back to the installation
location for the fuel pump.
1Double line clips [4x]
2Fuel line Fastening
the
fuel line
42
2 31
43
2
1
44
1
2

19
Mercedes-Benz E-Class BR 211 / CLS BR 219
Assembling the fuel pump
1Fuel line coupler 90°
2Fuel pump
3Rubber bracket
4Universal clamp Ø10 mm,
(white color identification) [4x]
5Fuel line coupler [2x]
6Mecanyl fuel line 1=130 mm
Fuel pump
pre-
assembly
Install the fuel pump mounting bracket (with
M6x25 collar screw) on the original vehicle
bolts with plastic nuts.
1M6x25 collar screw
2Plastic nuts [2x]
3Fuel pump mounting bracket Installing
the fuel
pump
mounting
bracket
Note the installation position of the metering
pump, see the "Installation Instructions".
Secure the fuel pump bracket to the M6x25
collar bolt with nut provided.
1Flanged nut M6
2Bracket with fuel pump Assembl-
ing the fuel
pump
Remove the cap and pull the end of the fuel
nipple out of the fuel tank.
Cut the end of the fuel nipple off with a sharp
knife. Immediately connect the fuel line
between the fuel tank nipple and the suction
side of the fuel pump and tighten clamp.
1Fuel nipple on the tank Cutting off
the end of
the fuel
nipple
45
21 3 4
6
5
46
2
3
1
47
1
2
48
1

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.
1Suction side of the fuel line
2Fuel pump mounting bracket Align the
fuel pump
bracket
Cut the fuel line on the fuel pump into
sections and connect to the fuel pump outlet
(side with connector) with fuel line coupler
and clamps.
Route the connector for the fuel pump
to the fuel pump and connect.
1Universal clamps Ø10 mm,
(white color identification) [2x]
2Fuel pump connector
Assembl-
ing the fuel
pump
connector
Install the fuel line along the original vehicle
lines.
Where the hose sections (wear protection)
are already located,fasten with cable ties.
Use split fuel hose as an additional wear
protection if necessary.
1Cut open end piece
2Cable ties
3Protection from wear (present)
Fuel line
installation
49
1
2
50
2
1
51
1 2 3