Webasto Thermo Top Evo 5+ Installation Documentation

Brand: Webasto

Model: Thermo Top Evo 5+

Type: Installation Documentation

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE

Water Heater

Installation Documentation

Mercedes Benz C-Class S204, W204 /

from model year 2007

Mercedes Benz C-Class C204 / from model year 2011

GLK-Class X204 / from model year 2008

Validity

Coupe (C204):

Saloon (W204):

Manufacturer Model Type EG-BE No. / ABE

Daimler AG C Class S204 e1 * 2001 / 116 * 0431 * ...

Daimler AG C Class W204 e1 * 2001 / 116 * 0457 * ...

Daimler AG C Class Coupe C204 e1 * 2001 / 116 * 0431 * ...

Daimler AG GLK Class X204 e1 * 2001 / 116 * 0480 * ...

Motorisation Fuel

Transmission type

Output in kW

Displacement in cm³

Engine code

C 180 CGI Petrol / R4 AT / SG 115 1796 271.820

C 200 CGI Petrol / R4 AT / SG 135 1796 271.820

C 250 CGI Petrol / R4 AT 150 1796 271.860

C 350 Petrol / V6 AT 225 3498 276.957

C 220 CDI Diesel / R4 AT / SG 125 2143 651.911

C 250 CDI Diesel / R4 AT / SG 150 2143 651.911/ .912

Motorisation Fuel

Transmission type

Output in kW

Displacement in cm³

Engine code

C 180 K Petrol / R4 AT / SG 115 1796 271.952/ .910

C 180 CGI Petrol / R4 AT / SG 115 1796 271.820

C 200 K Petrol / R4 AT / SG 135 1796 271.950

C 200 CGI Petrol / R4 AT / SG 135 1796 271.820/ .911

C 230 Petrol / R4 AT / SG 150 2496 272.911/ .921

C 250 CGI Petrol / R4 AT 150 1796 271.860/ .948

C 280 Petrol / V6 AT 170 2996 272.947/ .948

C 300 Petrol / V6 AT 170 2996 272.947/276957

C 350 Petrol / V6 AT 200/225 3498 272.961

C 350 CGI Petrol / V6 AT 215 3498 272.982

C 180 CDI Diesel / R4 AT / SG 88 2143 646.811/ .812

C 200 CDI Diesel / R4 AT / SG 100 2143 651.913/ .811

C 220 CDI Diesel / R4 AT / SG 125/150 2143 651.911/ .811

C 250 CDI Diesel / R4 AT 150 2143 642.832

C 300 CDI Diesel / V6 AT 170 2987 651.911/ .912

C 320 CDI Diesel / V6 AT 165 2987 642.960/ .961

C 350 CDI Diesel / V6 AT 165

170

195

2987 642.960/ .961

642.832/ .830

642.834

Thermo Top Evo 5+ Parking Heater

00 0258

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 2

Estate Car (S204):

GLK (X204):

Motorisation Fuel

Transmission type

Output in kW

Displacement in cm³

Engine code

C 180 K Petrol / R4 AT / SG 115 1796 271.952/ .910

C 180 CGI Petrol / R4 AT / SG 115 1796 271.820

C 200 K Petrol / R4 AT 135 1796 271.950

C 200 CGI Petrol / R4 AT / SG 135 1796 271.820

C 230 Petrol / R4 AT 150 2496 272.921

C 250 CGI Petrol / R4 AT 150 1796 271.860

C 280 Petrol / V6 AT 170 2996 272.947

C 300 Petrol / V6 AT 170 2996 272.947

C 350 CGI Petrol / V6 AT 200

225 3498 272.961

276.957

C 180 CDI Diesel / R4 AT / SG 88 2143 651.913

C 200 CDI Diesel / R4 AT / SG 100 2143 646.811

C 220 CDI Diesel / R4 AT / SG 125 2143 651.911/646811

C 250 CDI Diesel / R4 AT / SG 150 2143 651.911/ .912

C 300 CDI Diesel / R4 AT 170 2987 642.832/ .830

C 320 CDI Diesel / V6 AT 165 2987 642.960/ .961

C 350 CDI Diesel / V6 AT 165

170

195

2987 642.960/ .961

642.832/ .830

642.834

Motorisation Fuel

Transmission type

Output in kW

Displacement in cm³

Engine code

GLK 280 Petrol / V6 AT 170 2996 272.948

GLK 350 Petrol / V6 AT 200

225 3498 272.971/ .991

276.957

GLK 320 CDI Diesel / V6 AT 165 2987 642.961

GLK 350 CDI Diesel / V6 AT 165

170

195

2987 642.961

642.832

642.835

AT = 7G - Tronic

SG = Manual transmission

From Model Year 2007

Left-hand drive vehicle

Verified equipment variants:

Automatic air-conditioning

Blue Efficiency / Blue Tec / 4 Matic

Headlight washer system

Not verified: AMG 950 Sports Package

AMG Optical package

Exclusion: C 63 AMG

GLK 200/220/250 CDI

Total installation time: approx. 8 hours

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

The total installation time includes the time needed for mounting and demounting of the vehicle-specific components,

the heater specific installation time and all other times required for the system integration and initial start-up of the

heater.

The total installation time may vary for vehicle equipment other than provided.

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 3

Table of Contents

Necessary Components

Installation Overview

Information on Total Installation Time

Legend:

1. Heater

2. Engine compartment fuse

holder

3. Push button

4. Metering pump

Validity 1

Necessary Components 3

Installation Overview 3

Information on Total Installation Time 3

Information on Operating and Installation Instructions 4

Information on Validity 5

Technical Information 5

Explanatory Notes on Document 5

Preliminary Work 6

Heater Installation Location 6

Preparing Electrical System 7

Electrical System 8

Fan Control 9

Mounting Push Button 12

Telestart 13

Preparing Installation Location 14

Mounting Heater 16

Exhaust Gas 17

Fuel 19

60L Fuel Tank Metering Pump 21

80L Fuel Tank Metering Pump 22

Petrol Fuel Standpipe 23

Diesel Fuel Standpipe 26

Connecting Metering Pump 28

Coolant Circuit 29

Combustion Air 35

Exhaust End Section 37

Final Work 38

• Basic delivery scope of Thermo Top Evo Mercedes Benz

C-Class C204, S204, W204 / GLK-Class X204 petrol (incl. T91) : 1315954B

• Basic delivery scope of Thermo Top Evo Mercedes Benz

C-Class C204, S204, W204 / GLK-Class X204 diesel (incl. T91) : 1315955B

• Optional heater controls in accordance with price list and upon consultation with end customer

• In case of Telestart, indicator lamp in accordance with price list and in consultation with end

customer

Note:

When installing a parking heater, we recommend the use of the next larger vehicle battery.

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 4

1 Important Information (not complete)

1.1 Installation and Repair

The improper installation or repair of Webasto heating and cooling sys-

tems can cause fire or the leakage of deadly carbon monoxide, leading

to serious injury or death.

To install and repair Webasto heating and cooling systems you need to

have completed a special company training course and have the appro-

priate technical documentation, special tools and special equipment.

Installation and repair may ONLY be carried out by persons trained and

certified in a Webasto training course. NEVER try to install or repair We-

basto heating or cooling systems if you have not completed a Webasto

training course, you do not have the necessary technical skills and you

do not have the technical documentation, tools and equipment available

to ensure that you can complete the installation and repair work properly.

Only use genuine Webasto parts. See the Webasto air and water heat-

ers accessories catalogue for this purpose.

1.2 Operation

To ensure safe operation, we recommend having the heater checked every two

years by an authorised Webasto dealer, especially when used over a long period

and/or under extreme environmental conditions.

Do not operate the heater in closed rooms due to the danger of poisoning and suf-

focation.

Always switch off the heater before refuelling.

The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or pet-

rol (DIN EN 227).

The heater may not be cleaned with a high-pressure cleaner.

1.3 Please note

ALWAYS follow all Webasto installation and operating instructions and observe all

warnings.

To become familiar with and understand all functions and properties of the heater,

the operating instructions must be read carefully and observed at all times.

For proper, safe installation and repair work, the installation instructions with all

warnings and safety information must be carefully read and observed at all times.

Please always contact a workshop authorised by Webasto for all installation and

repair work.

Important

Webasto shall assume no liability for defects, damage and injuries resulting

from a failure to observe the installation, repair and operating instructions

of the information contained in them.

This liability exclusion particularly applies to improper installations and re-

pairs, installations and repairs by untrained persons or in the case of a fail-

ure to use genuine spare parts.

The liability due to culpable disregard to life, limb or health and due to dam-

age or injuries caused by a wilful or reckless breach of duty remain unaf-

fected, as does the obligatory product liability.

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.

Insulate loose wire ends and tie back.

Sharp edges should be fitted with rub protection (split-open fuel hose)!

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax

(Tectyl 100K, Order No. 111329).

Observe the instructions and guidelines of the respective vehicle manufac-

turer for demounting and mounting vehicle specific components!

The initial startup is to be executed with the Webasto Thermo Test Diagno-

sis.

When installing an IPCU, the corresponding settings must be checked or

adjusted before the installation.

2 Statutory regulations governing installation

Note

The regulations of these guidelines are binding in the scope of the Directive

70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and

should also be observed in countries in which there are no special regulations.

Important

Failure to follow the installation instructions will result in the invalidation of the type

approval for the heater and therefore invalidation of the general homologation of

the vehicle.Note

For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4

of Annex VIII b to the Road Traffic Act is required.

2.1 Excerpt from the directive 2001/56/EC Appendix VII for the

installation of the heater

Beginning of excerpt. ANNEX VII

REQUIREMENTS FOR COMBUSTION HEATERS

AND THEIR INSTALLATION

1. GENERAL REQUIREMENTS

1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when

the combustion heater is switched on or off.

2. VEHICLE INSTALLATION REQUIREMENTS

2.1. Scope

2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed ac-

cording to the requirements of this Annex.

2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply

with the requirements of this Annex.

2.2. Positioning of heater

2.2.1. Body sections and any other components in the vicinity of the heater

must be protected from excessive heat and the possibility of fuel or oil

contamination.

2.2.2. The combustion heater shall not constitute a risk of fire, even in the case

of overheating. This requirement shall be deemed to be fulfilled if the in-

stallation ensures an adequate distance to all parts and suitable ventila-

tion, by the use of fire resistant materials or by the use of heat shields.

2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in

the passenger compartment. However, an installation in an effectively

sealed envelope which also complies with the conditions in paragraph

2.2.2 may be used.

2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned

so that it can be easily read when the heater is installed in the vehicle.

2.2.5. Every reasonable precaution should be taken in positioning the heater

to minimise the risk of injury and damage to personal property.

2.3. Fuel supply

2.3.1. The fuel filler must not be situated in the passenger compartment and

must be provided with an effective cap to prevent fuel spillage.

2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the

vehicle is provided, the type of fuel and its filler point must be clearly la-

belled.

2.3.3. A notice, indicating that the heater must be shut down before refuelling,

must be affixed to the fuelling point. In addition a suitable instruction

must be included in the manufacturer's operating manual.

2.4. Exhaust system

2.4.1. The exhaust outlet must be located so as to prevent emissions from en-

tering the vehicle through ventilators, heated air inlets or opening win-

dows.

2.5. Combustion air inlet

2.5.1. The air for the combustion chamber of the heater must not be drawn

from the passenger compartment of the vehicle.

2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish

or luggage is unlikely.

2.6. Heating air inlet

2.6.1. The heating air supply may be fresh or recirculated air and must be

drawn from a clean area not likely to be contaminated by exhaust fumes

emitted either by the propulsion engine, the combustion heater or any

other vehicle source.

2.6.2. The inlet duct must be protected by mesh or other suitable means.

2.7. Heating air outlet

2.7.1. Any ducting used to route the hot air through the vehicle must be so po-

sitioned or protected that no injury or damage could be caused if it were

to be touched.

2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish

or luggage is unlikely.

End of excerpt.

In multilingual versions the German language is binding.

Guidelines Thermo Top Evo

Heating Directive ECE R122 E1 00 0258

EMC Directive ECE R10 E1 03 5627

Information on Operating and Installation Instructions

Special features are highlighted using the following symbols:You will find an identification mark on the outside

top right corner of the page in question to provide

you with a quick overview of the individual working

steps.

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Mechanical system

Electrical system

Coolant circuit

Combustion air

Fuel

Exhaust gas

Software

Specific risk of injury or

fatal accidents

Specific risk of damage to

components

Specific risk of fire and explosion

Reference to general installation instructions

of the 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

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 5

Information on Validity

This installation documentation applies to the vehicles Mercedes Benz C-Class C204, S204, W204 For validity see

page 1/2 - from model year 2007 and later, as well as GLK-Class X204 Petrol and diesel from model year 2008 - for

validity see page 2 - , assuming technical modifications to the vehicle do not affect the installation, any liability claims

excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with

respect to this installation documentation.

Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation

have not been tested. However, installation according to this installation documentation may be possible.

Technical Information

Explanatory Notes on Document

Special Tools

• Hose clamp pliers for self-clamping hose clamps

• Hose clamp pliers for Clic hose clamps of type W

• Automatic wire stripper 0.2 - 6mm²

• Crimping pliers for cable lug / tab connector 0.5 - 6mm²

• Torque wrench for 2.0 - 10 Nm

• Hose clamping pliers

• Metric thread-setter kit

• Stepped drill bit

• Webasto Thermo Test diagnosis with current software

Dimensions

• All dimensions are in mm.

Tightening torque values

• Tightening torque values of 5x13 heater bolts = 8Nm.

• Tightening torque value of 5x15 retaining plate of water connection piece bolt = 7Nm.

• Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with

state-of-the-art-technology.

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 6

Preliminary Work

Vehicle

• Open the fuel tank cap.

• Ventilate the tank.

• Close the fuel tank cap again.

• Depressurise the cooling system.

• Disconnect the battery earth connection.

• Remove the trim of the passenger compartment fan air intake.

• Remove the windscreen wipers.

• Remove the coolant reservoir cap.

• Remove the dome strut on the left.

• Remove entire windscreen wiper linkage with engine.

• Remove battery with carrier fully (if installed at the right).

• Remove engine control unit (if installed on the right).

• Remove the battery cover in the engine compartment on the right.

• Remove the trim of the passenger compartment fan air inlet.

• Detach the coolant expansion tank.

• Take off the cover off the positive distributor in the engine compartment.

• Remove the air intake pipe on the right (V6 only).

• Remove the lower engine cover.

• Drain off the engine coolant according to the manufacturer’s instructions.

• Remove the lower right vehicle trim.

• Remove the front right-hand wheel.

• Remove the front right-hand wheel well trim.

• Remove right underbody trim.

• Remove seat of rear bench seat (detach screw fitting 1x in cup holder, C coupe only).

• Open the right-hand tank-fitting service lid.

• Detach the fuel-tank sending unit on the right as described in the manufacturer's instructions.

• Lift the shift lever cover.

• Remove the ashtray or storage compartment with the socket outlet below the A/C control panel.

• Remove decorative screen of centre console with air outlet above the radio (from MY 2011).

• Remove radio (from MY 2011).

• Remove the A/C control panel.

• Remove the A-pillar trim in the footwell on the right.

• Remove the front right door sill cover.

• Remove the lower right instrument panel trim.

• Remove the front right floor trim.

• Loosen the right footrest.

Heater

• Remove years that do not apply from the type and duplicate label.

• Attach the duplicate label (type label) in the appropriate place in the engine compartment.

Heater Installation Location

1Heater

Installation

location

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 7

Preparing Electrical System

Detach 6mm dia. cable lug 1.

Preparing

wiring har-

ness of fan

control

IPCU view on contact side.

The pre-programmed settings are to be

checked during function control and adjusted

if necessary.

Duty cycle: 56-62%

Frequency: 400Hz

Voltage: 3.0V

Function: High-side

IPCU view

86 85

IPCU

86 85

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 8

Electrical System

Earth wire

Connect earth wire 1 to the original vehicle earth

support point 2 with 8 mm dia. cable lug. Route

wiring harness to heater in 10mm dia. corrugated

tube 3.

Wiring harness pass through

Drill 6 mm dia. hole

at centre of protective rubber

plug

if original vehicle wiring harness is not available.

Wiring harnesses of heater and heater control

Wiring har-

ness rout-

ing

diagram

Fuse holder of engine compartment

Replace F2 with 1 A fuse.

15mm dia. hole, M5x16 bolt, washers [2x], re-

taining plate of fuse holder, nut

2F1+2 fuses mounted

Positive wire

Manufacturer installs different positive support

points. Connect power supply of heater 1 to pos-

itive terminal (battery or starter cable of positive

support point).

Do not route wiring harness of

metering pump until later togeth-

er with fuel line on underbody

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 9

Fan Control

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG TT-Evo heater GE Fan unit rt red

X1 6-pin heater connector KB A/C control panel ws white

X2 2-pin heater connector A Socket outlet/lighter sw black

X10 4-pin connector

Heater control B Flap positioning module bl blue

F fuse ge yellow

K1 Fan relay ST 4 Connector, 4-pin, KB br brown

K2 Additional relay gn green

F1 Fuse, 20A

F2 30A fuse replaced with

1A.

IPCU Pulse width modulator

IPCU adjustment values:

Duty cycle: 56-62%

Frequency: 400Hz

Voltage: 3.0V XCutting point

Function: High-side Wiring colours may vary.

Webasto

Mercedes

X2 1 2 X1

F2 F1

gn/ws

0,75²

0,5²

rt/sw

0,5²

4²

0,5²

X10

85 30

87a87

4²

IPCU

85 86

85 30

87a87

4²

0,5²

rt/ge

0,5²

rt/ge

St 4 4 1

St 4 3 2

2 1

GE M

LIN-Bus

Kl.31

MMMM

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 10

Prepare wiring harness of heater

in the pas-

senger compartment. Connect red (rt) 4² wire

and red/black (rt/sw) 0.5² wire

to soldering

connector. Produce connections as shown in

wiring diagram.

Preparing

wiring har-

ness of

heater

Route wiring harness of heater 5 in the foot-

well on the front passenger's side, and secure

with cable ties. Produce connections as

shown in wiring diagram.

1Original vehicle stud bolt, original vehicle

earth wires

2Angle bracket

3M5x16 bolt, washer, flanged nut

4IPCU socket

6Relay socket

Mounting

relay sock-

et and IPCU

socket

Install green/white (gn/ws) wire  1 in the

IPCU/86 socket. Produce connections as

shown in wiring diagram.

2Brown (br) wire  of heater wiring har-

ness

3Brown (br) wire  of fan control wiring

harness

Connect-

ing wiring

harnesses

Route wiring harness of fan control 3 to cen-

tre console and secure with cable tie.

1Mount K1 and K2 relay

2Plug IPCU Mounting

relay [2x]

and IPCU

1 2

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 11

Connection to 4-pin connector 4 from A/C

control panel. Produce connections as shown

in wiring diagram.

1White (ws) wire of fan unit

2Black (sw) wire  K1/30

3White (ws) wire of 4-pin KB connector Connect-

ing A/C

control

panel

Connection to 4-pin connector 3 from A/C

control panel.

Produce connections as shown in wiring dia-

gram.

1Blue (bl) wire  K2/30

2Red (rt) wire of flap positioning module

4Red (rt) wire of 4-pin KB connector

5Blue (bl) wire  K2/87

Connect-

ing A/C

control

panel

Connection to plug-in connector 3 of socket

outlet/lighter. Produce connections as shown

in wiring diagram.

1Red (rt) wire  K1/86

2Pink/yellow (ro/ge) wire

4Pink/yellow (ro/ge) wire Connec-

tion to

socket out-

let/lighter

4 3

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ident. No.: 1315959G_EN Status: 31.01.2013 © Webasto Thermo & Comfort SE 12

Mounting Push Button

Only in connection with Telestart. Use wiring

harness extension.

WARNING:

If the push button cannot be installed in the

trim piece due to parts lying behind it, the in-

stallation is done according to image 19.

1Cover

Removing

cover

Mount union nut 1 of push button, align in

centre and drill 16mm dia. hole 2 in the cover

(stepped drill bit).

Hole in cov-

Install push button 1, align and secure it with

union nut.

Mounting

push but-

ton

When drilling, watch components located be-

hind.

112mm dia. hole

Hole for

wiring har-

ness

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

1Cover

Removing

cover

Alternative installation location

Only in connection with Telestart. Use wiring

harness extension.

112mm dia. hole, push button Mounting

push but-

ton

Telestart

1Receiver, adhesive tape

Mounting

receiver

1Antenna

Mounting

antenna

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Preparing Installation Location

Figure shows W204 with daytime running

light.

Loosen original vehicle bolt at position 2, 3

and 5. Insert large diameter washer at posi-

tion 5 between bracket 4 and bumper. Tighten

bolts at position 3 and 5.

Bend twist protection at position 1 toward

rear. Twist cylinder of the headlight washer

system and fix with cable tie (observe dis-

tance between connector of front fog light, if

available, and bracket of heater).

Detaching

bracket

Remove joint sealer in the area of the holes 1

or 2 on the inner side of the frame side mem-

ber.

C204, S204 and W204

17 mm dia. hole

X204

27 mm dia. hole

Hole in

frame side

member

Figure shows W204 with daytime running

light.

Mount heating bracket 3 with oblong hole be-

tween detached bracket 2 and bumper at po-

sition 1.

1Original vehicle bolt Installing

heater

C204, S204 and W204

When drilling, watch components located be-

hind.

1M6x20 bolt, flanged nut Loosely

mounting

heater

10 35

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

X204

Insert 8 mm shim between bracket of heater

and frame side member.

1M6x25 bolt, 8 mm shim, flanged nut Loosely

mounting

heater

S204, W204 and X204 with daytime run-

ning light

1Copy 7 mm dia. hole pattern

Copying

hole pat-

tern

S204 and W204 with front fog light

Ensure proper spacing between connector of

front fog light 3 and bracket of heater 1 (at

least 5mm).

2Copy 7 mm dia. hole pattern Copying

hole pat-

tern

X204 with front fog light

1Copy 7 mm dia. hole pattern

Copying

hole pat-

tern

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Figure shows W204 with daytime running

light.

Remove heater. If vehicles have front fog

light, this must be removed for the hole.

17 mm dia. hole Hole in

bumper

Figure shows W204 with daytime running

light.

Install horn 3 with original vehicle bolt 1.

2M6x20 bolt,pin lock Mounting

bolt

Mounting Heater

Figure shows W204 with daytime running

light.

Mount bracket of heater 1 on bolt 3, insert be-

tween detached bracket and bumper. Align

heater and fasten at position 4 and 6.

Tighten original vehicle bolt at position 5.

Tighten bolt 4 on retaining strut.

2Flanged nut

6M6x20 bolt, flanged nut

Mounting

heater

Figure shows X204 with front fog light.

Mount bracket of heater 1 on bolt 3 between

detached bracket and bumper. Insert 8 mm

shim between bracket of heater and frame

side member at position 4. Align heater and

fasten at position 4 and 3. Tighten bolt on re-

taining strut.

2Flanged nut

4M6x20 bolt, 8 mm shim, flanged nut

Mounting

heater

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Exhaust Gas

1Shape exhaust pipe

2Hose clamp

3Push on pipe insulation Premount-

ing exhaust

pipe

Mount exhaust silencer 3 on exhaust pipe 1

and align relative to hole 4. Mount wiring har-

ness 5 on heater.

2Hose clamp Premount-

ing silencer

Cut tab 1 off exhaust end section 3.

2Cutting point

Preparing

exhaust

end section

Vehicles with daytime running light

1M6x12 bolt, spring lockwasher

2Hose clamp

3Exhaust end section Mounting

silencer

and end

section

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Ensure sufficient distance from neighbouring

components, align bracket if necessary. Mini-

mum distance between bracket of daytime

running light and silencer at position 1 must

be observed Aligning si-

lencer

Vehicles with front fog light

Ensure sufficient distance from neighbouring

components, correct if necessary.

C204, S204 and W204

Slide incomplete exhaust end section 3 onto

exhaust silencer (5 mm distance between

end section 3 and silencer), align and fasten.

X204

Slide complete exhaust end section 3 onto

exhaust silencer.

1M6x12 bolt, spring lockwasher

2Hose clamp

Mounting

silencer

and end

section

min. 15mm

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Fuel

CAUTION!

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

Catch any fuel running off in an appropriate container.

Install fuel line and metering pump wiring harness so that they are protected against stone impact. Un-

less specified otherwise, always fasten using cable ties.

Mount the fuel line and wiring harness with rub protection on sharp edges.

WARNING!

The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness rout-

ing diagram.

Complete connector of metering pump after

routing. Pin assignment is not relevant.

1Connector housing

2Lock

3Blue/brown (bl/br) wires

4Coding

5Timer lock

Disman-

tling con-

nector

19 mm dia. corrugated tube, wiring har-

ness of metering pump

2Cable tie

3Fuel line, 10 mm dia. clamp

4Moulded hose of heater Connec-

tion to

heater

Degrease adhesive surface for adhesive

base 1.

1Adhesive base, cable tie

2Corrugated tube Routing

lines

1 43

1 3 4

1 2

Mercedes Benz C-Class S204, W204, C204 / GLK-Class X204

Degrease adhesive surface for adhesive

base 1.

1Adhesive base, cable tie

2Corrugated tube Routing

lines

Degrease adhesive surface for adhesive

base 1.

1Adhesive base [2x], cable tie [2x]

2Corrugated tube

3Cable tie, existing hole Routing

lines

Degrease adhesive surface for adhesive

base 1.

1Adhesive base [2x], cable tie [2x]

2Fuel line, wiring harness of metering

pump Routing

lines

Distribute retaining clamps 1 [10x] evenly

along vehicle underbody and insert fuel line 2

and wiring harness of metering pump.

Routing

lines

1 2

111

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Webasto Thermo Top Evo 5+ Installation Documentation

Webasto Thermo Top Evo 5+ Installation Documentation

Webasto Thermo Top Evo 5+ Installation Documentation

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