Webasto Thermo Top C User manual

Ident. No.: 9015593A €10 fee © Webasto AG
e1
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
2
13 4
1

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.
2
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

3
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

4
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.

i
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

5
(1) Heater unit
Heater Unit
Installation
Location
2
1
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

6
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
2
13
6 7
2
3
1 1 2
8
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)
1
2
3 4
2
1
5
2
1
Electrics
diagram
CAN nodes
to model year 04
CAN nodes from
model year 04
(
(
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i
Mercedes Benz W 203

7
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
3
4
1
9
2(
(1) Adhesive antenna remote start
(2) Trunk ledge
Assem-
bling the
adhesive
antenna
1
2
10
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
2
1
11
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i
(
Mercedes Benz W 203
(1) Thermo Call adhesive antenna
(2) Trunk ledge
Assem-
bling the
adhesive
antenna
2
1
12

8
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
2
1
13
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
23
1
14
(
Mercedes Benz W 203
(

9
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
3
4
17
(
(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
5
1
15
3
24
7
6(
(1) Angle bracket
(2) M6x30 bolt
(3) Metering pump bracket
(4) Flanged nut M6
(5) Metering pump cable harness
Preassem-
bling the
metering
pump
1
2
5
416
3
(
Mercedes Benz W 203

10
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
3
4
1
2
18
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i
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
4
2
19
3
1(
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
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) Bracket for fuel lines [4x]
(2) Mecanyl fuel pipe
(3) Frame side rail opening
Run the
fuel line
along the
underbody
panel and
fasten
1
2
21
3
(
Mercedes Benz W 203

11
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.
(1) Rear grommet opening
(2) Mecanyl fuel pipe
(3) Front grommet opening
Running
lines
1 2 3
22
(
Shorten the Mecanyl fuel pipe on the heater
unit and connect.
Add the wear protection hose and fasten with
cable clips.
(1) Wear protection hose
(2) Mecanyl fuel pipe
(3) Universal clip [2x]
(4) Hose section
(5) Heater unit
Fuel on
heater unit
4
23
24
1 5 (
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.
(1) Front grommet opening in frame side rail
(2) Hose bracket [2x]
(3) Hose bracket
(4) Mecanyl fuel pipe
Installing
the fuel
line
3
4
2
1
23
Mercedes Benz W 203

12
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
M
A
18/20
20/20
20/18
O25
O27
O27
O27
O27
O27 O25
B
C
Water
diagram
(shown on
230K hose
system)
without
residual
heat pump
25
(
Mercedes Benz W 203
On vehicles with a residual heat pump, the hose placement in the engine area
may vary slightly. (

13
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.
Fasten the hoses with spacers (clips).
(1) Rubber ring (wear protection)
(2) Clips d=25 [2x]
(3) Clips d=27 [6x]
(4) Hose spacers [2x]
(5) Hose from header unit outlet to engine
inlet
(6) Hose from heat exchanger outlet to heater
unit inlet
Connect
hoses
(230K
without
residual
heat pump)
29
14
5
6
23
a = 210 mm
b = 70 mm
c = 90° bend (remaining)
Dispose of section 8
Cutting
water
hoses into
sections
(230K
without
residual
heat pump)
26
a
B
A
b
C
8
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]
Connec-
ting pipe
(230K
without
residual
heat pump)
1
28
2
3
4
(
(
Mercedes Benz W 203
Separate the original vehicle engine hose on
the marking.
(1) Original vehicle hose
Splitting
point.
(230K
without
residual
heat pump)
1
27

14
a = 360 mm
b = 170 mm
c = 20 mm
Dispose of section 8
Cutting
water
hoses into
sections
(220 CDI
without
residual
heat pump)
30
a
B
A
b
C
8
c
8
8
Only 220 CDI/320 CDI
Cut the braided protective hoses to 220 mm
and slide onto hose A.
(1) Connecting pipe 18-20
(2) Braided protective hose
(3) Clips d=27 [3x]
(4) Connecting pipe 20-20
Pre-
assem-
bling the
hoses
(220 CDI
without
residual
heat pump)
2
1A
31
C
B
34
(1) Original vehicle hose for the engine inlet
Splitting
point
(220 CDI
without
residual
heat pump)
1
32
(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)
2
33
4
3
1
5
6
Mercedes Benz W 203

15
WARNING!
Reassemble disassembled components in reverse order.
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:
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
F
i
nal
work

i
Mercedes Benz W 203

16
(Please remove page and insert with vehicle operating instructions.)
Before parking the vehicle, make the following settings:
O
perat
i
ng
instruc-
tions for
the end
customer
Mercedes Benz W 203
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.

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