Installation Documentation for water heater Thermo Top Evo ‘Inline’ coolant circuit with engine preheating Mercedes Benz Sprinter Leftchand drive vehicle (Jebasto lequipment variants [Manufacturer Model [Type [Model JEG-BE-No. / ABE lyear [Mercedes Benz [Sprinter lw207 lfm 2078 [e1* 2007/46" 0301" Mercedes Genz _|Sprinter |woo7 [from 2078 [et 200171 16 0354" [Mercedes Benz [Sprinter |wat0 [from 2078 [et* 2007/46" 1761 [Motorisation __]Fuel [Emission standard [Transmission output [Displace- Engine code ltype lkwi ment fem?) 214 cor Diesel Eure 66 se 105 2143 foment [514 cor Diesel Eure 6 sc 105 as fomest 516 cor Diesel Euro 6e Isc 20 a1as___fomest 17 cor Diesel Furo 6 wiTe, PL. [5G 25 i350 [om asa [519 cr Diesel Euro VID) las 140 2987 [om ez [valiaity [Equipment variants ‘Model Sprinter \veriied HTEMPMATIC x [THERMOTRONIC Rear-wheel dive Front wheel drive [Unverified lequipment variants [Alarm system [Total installation time INote la.5 hoursContents 1 2 24 22 23 24 3 3A 32 33 34 4 5 5.1 52 6 7 mM 72 a at a2 83 a4 9 9.1 9.2 93 94 95 96 10 List of abbreviations Installation notes Information on Validity Components used Notes on installation, in coordination with ‘the end customer Information on Total Installation Time About this document Purpose of the document Warranty and lability Safety Using this document Technical Information Preparations Vehicle preparation Heater preparation Installation overview Electrical system Preparation of passenger compartment Connection in engine compartment Mechanical system Preparing installation location - vehicle with rear-wheel drive Preparing installation location - vehicle with front-wheel drive Preparing heater - all vehicles Heater mounting Fuel Mounting fuel pump - vehicle with rear- wheel drive Mounting fuel pump - vehicle with front= wheel drive Fuel pump connection - all vehicles Fuel extraction for vehicles with manufac: ‘turer code KB7 and with a 93! tank with tank fitting ID.: A8074702400 Fuel extraction for vehicles with manufac- turer code KB8 and a 921 tank with tank fit- ting ID.: 48104701900 Fuel extraction for vehicles other than those with manufacturer code KB7 with a 931 tank or with code KB8 with a 921 tank Coolant - vehicles with 2.0D and en- gine code: OM654 vows 10 10 " 2 2 3B 7 18 19 2 25 27 27 28 29 29 29 32 10.4 10.2 " 2 124 12.2 3 13.41 13.2 13.2.1 13.22 14 5 154 152 153 16 16.1 16.1.1 16.1.2 16.1.3 16.1.4 16.15 16.1.6 162 162.1 16.2.2 16.23 7 Hose routing diagram - vehicles with 2,00 and engine code: OM654 Coolant circuit installation - vehicles with 2.0 and engine cade; OM654 Coolant - vehicles with 2.2D and en- gine code: OM651 Hose routing diagram - vehicles with 2.20 and engine code: OM651 Coolant circuit installation - vehicles with 2,2D and engine code: OM651 Coolant - vehicles with 3.0D and en- gine code: OM642 Hose routing diagram - vehicles with 3.00 and engine code: OM642 Coolant circuit installation - vehicles with 3,0D and engine code: OM642 Exhaust - vehicles with rear-wheel drive Exhaust silencer installation Mounting exhaust pipe Mounting exhaust pipe - version 1 Mounting exhaust pipe - version 2 Exhaust - vehicles with front-wheel drive Final work in engine compartment Vehicles with rear-wheel drive Vehicles with front-wheel drive All vehicles Electrical system of passenger com- partment Electrics - cold start system Electrical system preparation Wiring diagram Connection in passenger compartment Connection in engine compartment - vehicles with 2.00 and engine code: omes4 Connection in engine compartment - vehicles with 2.20 and engine code: oss Connection in engine compartment - vehicles with 3,00 and engine code: omsa2 Electrics -fan controller Electrical system preparation Wiring diagram Fan controller Electrical system of control element 32 33 36 36 37 a a1 42 46 46 48, 49 51 55 60 60 61 62 6a 6a 66 6 70 R 74 76 76 22 2a 87174 17.2 18 19 20 20.1 20.2 21 2a 212 Multicontrol option, Telestart option Final work in passenger compartment Final Work ‘TEMPMATIC operating instructions ANC control panel settings Installation location of fuses ‘THERMOTRONIC operating instruc- tions ANC control panel settings Installation location of fuses a7 87 88 89 91 31 92 93 3 94AG cur pp HG K2 uN cc RSH RID 86 sie up Veh. t of abbreviations ‘Automatic transmission Cold start module Fuel pump Heater Additional relay LIN Gateway MultiControl (control element) Relay and fuse holder of passenger compartment Temperature sensor Manual transmission Engine compartment fuse holder for FI/F2 Coolant pump Vehicle2 2.41 Installation notes Information on Validity This installation documentation applies to vehicles listed on page 1, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to this instalation documentation. Vehicle and engine types, equip- ment variants and other specifications not listed in this installation documentation have not been tested. 2.2 Components used Designation [order number Basic delivery scope of Thermo Top Evo In accordance with price| ist installation Kit (nel. cold start system and Webasto Standard’ AIC contro Hor Mercedes Benz Sprinter diesel 2018 Standard 13284728 In case of Telestart, control element, as well as indicator lamp in consultation with end cus- ltomer In accordance with price| ist ‘The additional ‘Tank extraction kit for Mercedes Benz Sprinter TT-Evo diesel’ is required for some vehicles. Please check in advance in the vehicle or in the vehicle documentation provided by the manufacturer, which tank was installed in the vehicle (View of product sticker on tank (for example a 651 lank): [651 tank: no additional kit needed 1711 tank: no additional kit needed 1921 tank: additional tank extraction kit needed (see below) l931 tank: additional tank extraction kit needed (see below) [Additional tank extraction kit [order number [Additional tank extraction kit for Mercedes Benz Sprinter TT-Evo diesel, only for 1327808_ Veh. with manufacturer code KB7 (931 tank lwith tank fitting 1D.: A9074702400) mse 1 = sto zane cuune so Veh. with manufacturer code KBB (921 tank lwith tank fitting ID.: A9104701900) & as on yet E 1020.05 towne 08 toons 42.3. Notes on installation, in coordination with the end customer k only about % full > Arrange for the vehicle to be delivered with the > The installation location of the following elements should be chosen in coordination with the end customer: ~ the push button in case of the Telestart and/or ThermoCall and/or ThermoConnect options ~ the MultiControl CAR option 2.4 _ Information on Total Installation Time ‘The total installation time includes the time needed for mounting and demounting 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.3 About this document 3.1 Purpose of the document ‘This instalation documentation i prt ofthe product and contain ll ‘the information requied to ensure profesional vehicle specific instali= tion f the: [Thermo Top Evo heater 32 \weoasto shall assume no lablty for defects, damage and injuries ras ting fom a failure o observe the installation, repair and operating in structions of the information contained in thar Warranty and liability This labilty exclusion partculaly applies to improper installations and repais by untrained persons oF nthe case of fale to use genuine spare pats, ‘The labilty due to culpable disregard to fe, mb or health and due to damage o injuries caused by a wll or reckless breach of duty remain unaffected, as does the obligatory product labilty. Installton should be cared out according tothe general, standard ‘les of technology. Unless spectied otherwise, fasten hoses, lines and ‘ring hamesses to erga veice Ines and witng harasses using cable tes, Insulate loose wire ends and te back. Connectors on ec tronke components must audlbly snap int place during assembly Spray unfinished body areas, cll holes, with anincorroson wax ‘ecty 1006 (Observe the instructions and guidelines of the respective vehicle manu- facture for emounting and mounting vencl specific components The inital star-up ito be executed withthe Webasto Thermo Test Di gnosis When installing 2 programmable contol module (eg. 2 PWM Gate ay the corresponding settings must be checked or adjusted 3.2.1. Statutory regulations governing installation The Thermo Top Evo heater has been type-ested and approved in ac cordance with ECER 10,EMC) and ECE- 122 eater). The regulations ‘ofthese guidelines are binding inthe scope of the Directive 7/15/EEC andlor 2007/46/EC (or new vehicle models from 29/04/2009) nd ‘should also be observed in countries in which there are no spec regu ition. “Tre heater is licensed in accordance with paragraph 19, section 3, No 2b ofthe StVZ0 (German Road Traffic Licensing Autmorty) 3.3 Safety Qualifications of installation personnel ‘The instalation personnel must have the follwing qualifications: = successful completion of Webasto taining — Coresponding qualification for working on technical systems Regulations and legal requirements “Te regulations ttm the heats ganeal installation and operating in structions must be observed 3.3.1 Safety information on installation Danger posed by live parts > Prior to installation, disconnect the vec ‘rom the voltage supply. ake sue the electcal system is earthed correctly > always comply with egal requirements > coacerve data on type label. Danger of fire and leaking toxic gases due to improper installation > Vehicle pats inthe vicinity of the eater must be protected against excessive heating by *he following measures: Maintain minimum safery distances, © Ensure adequate venlaton Use fre-resstant materiale or hast hls Danger due to sharp edges = short circu due to electical wire damage > Fit protectors on sharp edges.3.4 Using this document Before insaling and operating the heater, red this instalation docu mentation, te instalation meuctions ofthe heater, the operating in ns and supplementary shets provided, 3.4.1 Explanatory Notes on the Document There san Wentficaton mark near the respective work step to allow You to auckyallocace the other applicable documents tothe Webasto components tobe installed [Generally vale Webasto documentation [Veiclespecti installation documentation Type and source of the risk Consequences Fallte to follow the instructions can ead to material damage, > Actions to protect yourself agains risks Reference ta the vehicle manufacturer's spate docue CEP Note on a special technical feature 3.4.3. Work step identification marks 3.4.2 Use of symbols DANGER ‘Type and source of the risk Consequences: Fallure to follow the instructions can result in death, > ctions to protect yourself against risks. WARNING ‘Type and source of the risk Consequences Faure to folow the instructions can ead to serious or even fatainjures. > Actions to protect yourself against risks CAUTION ‘Type and source of the risk CConseauences: Faure to follow the instructions can ead ‘to minor ines. > actions to protect yourself against rks. [Vehicle-specific installation documentation of the cold start| Le age: ki Mechanical [Electrical sys-|High-voltage] Coolant Iwebasto Comfort A/C control Le system tem Tank evading dence fog Fuel) Le oT (S) = || ee | ee Le = Bw 2 = ey LA WS] }) MO] | | BB fo! [he arow indicates the postion on the vehicle and the wewing angle 3.4.5 Use of highlighting [Highlight [Explanation iv acon > Necessary action > ec {orth image deseiptons| a7aa/e@ Posivon numbers forthe image deseripons or elecvcal wires and components a well ss coolan: hose sections4 Technical Information [Dimension specifications = All dimensions specified in mm — Perforated brackets and mounting angles are shown to scale = Observe data regarding scale on the templates [Tightening torque specifications = Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm — Tightening torque values of 5x15 retaining plate of water connection piece bolts = 7Nm Nm — 5x12 bolt tightening torque of 2-part heater bracket = Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the art-technology [Temperature specification for heat shrink plastic tubings = Fabric heat shrink tubing: shrink temperature max. 230°C = Standard heat shrink plastic tubing: shrink temperature max. 300°C Necessary special tools = Hose clamp pliers for auto-tightening hose clamps for Clic hose clamps of type W = Hose clamping pliers = Hose clamp pl = Hose cutter = Automatic wire stripper 0.2 - 6 mm? — Crimping plier for cable lugs 0.5 ~ 10 mm® = Crimping pliers for male connector 0.14 ~ 6 mm? = Crimping pliers for connector 0.25 ~ 6 mm? = Torque wrench for 2.0- 10 Nm = Deep-hole marker = Metric thread-setter kit = Webasto Thermo Test Diagnosis with current software5 Preparations 5.1 Vehicle preparation [ Further information can be found in the vehicle manufacturer's technical documentation, [Vehicle [Components to be removed [other ap- larea plicable [documents [General [> Open the fuel tank cap LS > Ventilate the fuel tank > close the fuel tank cap again > Depressurise the cooling system [Engine > Battery Ls omar J> pir fier box nd > Air fiter box bracket lbody —_|» Ventilation box for passenger compartment fan > Engine underride protection (if present) [Passenger [> Upper cover for entry on driver's side and front passenger's side Fompar I» carpet on cv’ side and front passenger’ side > Side instrument panel trim on the driver's side > Side trim of the centre console on the driver's side > centre console sce trim, shift lever with cup holder > Acpilar trim on driver's side (only in case of Telestart) > Side instrument panel trim on front passengers side > Lower trim of Acpillar on front passenger's side > Fuse and relay box of passenger compartment 5.2 Heater preparation JEngine > Remove years that do not apply from the type and duplicate label jel fompar J» artach the duplicate label (ype label in the appropiate place in the engine compart ment6 Installation overview Se] a @ SB IC [| Fig. 1 Legend to installation overview [Abbreviation] Component we [Adapter connector fcuk [erR module DP Fuel pump HG Heater kz [Additional relay Lin LIN Gateway Mec altiControl CAR (control element) RSH Relay and fuse holder of passenger compartment RTD [Temperature sensor [su Fuse holder for FO st Frngine compartment fuse holder UP [Coolant pump Heater installation location (EP Figure shows a vehicle with rear-wheel drive 1 Heater7 Electrical system 7.1 Preparation of passenger compartment Preparing positive extension wiring harness with fuse FO Fuse Fo: 308 Fig. 3 Mounting retaining plate, fuse holder SH1 (> Figure shows a vehicle with rear-wheel drive > Drill a 4.5 hole in the battery box, at a suitable location ‘and in accordance with the installation conditions. Ensure sufficient wire length to reach the following positive con nection point. T 5.5x13 bolt, retaining plate SH1, drilled hole T SHI with fuse FO O_ Red (rt) wire from fuse FO of positive extension wir ing harness @P Red (rt) wire from fuse FO of positive extension wir- ing harness7.2 Connection in engine compartment Protective rubber plug for pass through Protective rubber plug > Replace 30A passenger compartment main fuse F2 [3] with BA fuse © Fuse Ft: 208 Fig. 7 Premounting fuse holder SH2 -T. MSx16 bolt, large diameter washer, retaining plate ‘of SH2, angle bracket, large diameter washer, nut Fig. 8Mounting SH2 OT Fuse F1: 204 and F2: 34 Z Loosely mount original vehicle stud bolt, original vehicle nut > Route red (rt) wire @ from fuse FO of positive extension wiring hamess in the engine compartment TT Red (rt) wire from positive supply of heater wiring harness Z Crimp and shrink butt connector (EP To prevent water seeping into the passenger com- partment, the wiring harness must be routed up- wards to the protective rubber plug and this plug must then be sealed with a suitable sealing com- pound. AD. Cable pass through for control element, fan control ler and positive extension Z sw 3 Route heater wiring harness on original vehicle wir- ing harness Fig. 11Earth wire installation - vehicle with rear-wheel drive DANGER Fig. 12 Positive wire installation - all vehicles Fig. 13 Observe tightening torque Earth wire Z Original vehicle earth support point Earth wire installation - vehicle with front-wheel drive DANGER ‘Observe tightening torque Original vehicle earth support point 2 Earth wire DANGER ‘Observe tightening torque {>The Fig. shows the installation situation. the bat- tery is connected during the final work phase. {E> Shown on a vehicle with rear-wheel drive, Version 1 1 Original vehicle positive support point, MB flanged nut Fig. 14 Red (rt) wire from fuse FO of positive extension wir- ing harness Red (rt) wire from fuse FO of positive extension wir ing harnessDANGER © Observe tightening torque ‘The Fig. shows the installation situation. The bat- tery is connected during the final work phase. > shown on a vehicle with rear-whee! dive. Version 2 Original vehicle positive terminal, M8 flanged nut Red (rt) wire from fuse FO of positive extension wir- ing harness Fig. 158 Mechanical system 8.1 Preparing installation location - vehicle with rear-wheel drive Removing insulation > Cut cable clip holder from the wiring hares and dis- card > Remove insulation mats [2] and discard. Drilling hole ia ib JX, Paro of dame conronais e E A : 3 3 2 z i = 7™ > Drill a hole in the centre between pos. a] and pos. 7B} fd Z oshole Inserting rivet nut T M6 rivet nut Fig. 18Copy hole pattern > Position bracket 1Jon the stud bolt [3] and fix with a Méx20 bolt and Spring lockwasher at pos, 4. > Copy hole pattern at pos [2] Fig. 19 Ay. Panger of damage to components max.5 mm ——— T a9 hole, Mé rivet nut Fig. 20 8.2 Preparing installation location - vehicle with front-wheel drive Detaching insulation > Remove retaining clip 1 of original vehicle wiring harness. > Remove retaining clip 3 of lateral insulation mat [21> Cut off bottom insulation mat [1] as shown and discard with lateral insulation mat 2] Danger of damage to components max.5 mm —— > Position bracket on the top left at the edge of the emiboss- ing, on the right at original vehicle stud bolt [2Jand on the lower side at the edge of the body as shown. > Copy hole pattern at pos. T. Remove bracket again. 9 ET]and insert M6 rivet nut. > Drill 09 hole at po: 83 Preparing heater - all vehicles Mounting, aligning and fastening with 7 Nm water connection piece with sealing ring and retaining plate Fig. 24Mounting bracket oT Heater bracket Z 5x13 selttapping bolt Fig. 25 T_Mox25 bolt with serrated flange, heater bracket, Smm spacer, lock washer Z_Méx25 bolt with serrated flange, heater bracket, ‘8mm spacer, lock washerx Preparing hoses Vehicles with | Vehicles with | Vehicles with 2.00 and 2.2D and 3.0D and engine code: | engine code: | engine code: omes4 omest omea2 l@ [740 [720 760 [@ [a0 moulded 90° moulded 80" moulded hose hose hose [© [oor moulded B80" moulded [80° moulded &R KR & hose hose hose (®) [90° moulded 90° moulded | 90° moulded ® ® hose hose hose (© |re0 [760 i770 Fig. 28 [® [so iso [eo Mounting coolant pump EP Allspring dips 225 > Mount hose © between heater inlet and coolant pump outlet F Coolant pump Z Stud bolt, coolant pump mount, flanged nut Fig. 29 Mounting combustion air intake pipe ‘Observe the installation instructions of the combus- tion air intake silencer. T Combustion air intake line Fig. 30Mounting fuel line “Z_ 90° moulded hose, 10 clamp [2x} % Fuel lne Combustion air intake silencer Z MS5x16 bolt, 251 clamp, angle bracket, flanged nut & Foam Fig. 32 8.4 Heater mounting CZ The next assembly steps are shown on a vehicle with rear-wheel drive but apply similarly to all vehicles Mounting heater TL Mount M6x20 bolt, spring lockwasher, bracket, rivet nut looselyMounting combustion air intake silencer on combustion air intake pipe . > Position original vehicle wiring hamess as shown, L_ Combustion air intake silencer, premounted 2 Combustion air intake line Fig. 34 Mounting heater and combustion air intake silencer (> > Tighten alle bolts L Prepared bolt on bracket, rivet nut © Prepared bolt on bracket, combustion air intake sk lencer bracket angle bracket, rivet nut Fig. 35 Mounting connectors for wiring harnesses 3 Heater wiring harness connector Z Coolant pump wiring hamess connector Fig. 36Mount coolant pump wiring harness connector . 1. Coolant pump wiring harness connector Fig. 379 Fuel DANGER Risk of fire and explosion due to leaking fuel and escaping fuel vapours. ‘The incorrect installation of the fuel extractor can cause damage and fire > Avoid electrostatic discharges and open fire > When working on the fuel system, ensure sufficient ventilation and bleeding > Open the fuel tank cap of the vehicle > Ventilate the fuel tank > Re-close the tank lock > catch any fuel running off with an appropriate container Danger of damage to components > Install fuel line and fuel pump wiring harness so that they are protected against stone impact. > Provide rub protection for fuel line and wiring harness in areas where there are sharp edges. Dismantling fuel pump connector X7 Fig. 38 > Draw fuel line and fuel pump wiring harness into corrugated tube [I] and route them behind insulation [2}to the driver's side, > Attach all the routed lines with cable tes. Fig. 39Fuel line and fuel pump wiring harness in cortuge ated tube Fig. 40 > Route fuel line and fuel pump wiring hamess in corrugated tube [along original vehicle AVC line to the underbody. > Route fuel ine and fuel pump wiring harness in corrugated tube [T]on underbody to fuel pump installation location,Premounting fuel pump Mounting fuel pump Fig. 3 Inserting rivet nut {EP The alignment of the fuel pump and fuel hoses wil be carried out afterwards, during the installation. 4. Fuel pump mount Z 180° moulded hose, G10 clamp Fuel pump E 80° moulded hose, B10 clamp 9.1 Mounting fuel pump - vehicle with rear-wheel drive M6x25 bolt, support angle bracket, fuel pump mount, original vehicle hole, flanged nut F Premounted fuel pump 9.2 Mounting fuel pump - vehicle with front-wheel drive > Drill 29 hole “Las shown and insert rivet nut 2}Mounting fuel pump T Premounted fuel pump Z Méx25 bolt, support angle bracket, fuel pump mount, premounted rivet nut ~ Fig. 45 9.3. Fuel pump connection - all vehicles ‘Assembling fuel pump connector X7 Fig. 7 EE The nest assembly steps are shown ona vehicle with rear-wheel rive but apply similarly to al veces. Connecting fuel pump haa 1 2 1 210 clamp Z Heater fuel line 3. Fuel pump wiring harness, connector X7 mounted Fig. 48(al 9.4 — Fuel extraction for vehicles with manufacturer code KB7 and with a 931 tank with tank fitting ID.: A9074702400 View of tank fitting > For these vehicles, carry out work for the fuel extraction in accordance with the separate installation documentation from the additional tank extraction kit for the Mercedes Sprinter (see ‘Components used”): W4 Installation documentation for FuelFix tank extrac- sso 3: ka 2800 tion in case of vehicles with manufacturer code KB7 and with a 931 tank with tank fitting ID. bee! ‘89074702400 for Mercedes Sprinter gorgzoe00s E Onr2 1 Fig. 49 9.5 Fuel extraction for vehicles with manufacturer code KB8 and a 921 tank with tank fitting ID.; A9104701900 View of tank fitting > For these vehicles, carry out work for the fuel extraction in accordance with the separate installation documentation from the additional tank extraction kit for the Mercedes Sprinter (see ‘Components used’) Installation documentation for FuelFix tank extrac- & pao an 80) tion in case of vehicles with manufacturer code B8 and with a 921 tank with tank fitting I. ea ‘49104701900 for Mercedes Sprinter aovie 27008 omaes 1 Fig. 50 9.6 Fuel extraction for vehicles other than those with manufacturer code KB7 with a 931 tank or with code KB8. a 921 tank Connecting fuel line to fuel pump T Fuel ine for tank extraction Z 010 clampRouting fuel line > Route fuel line [1] of fuel pump along the original vehicle fuel line. Fig. 52 Cutting off original vehicle return line (EP Only for vehicles with rear-wheel drive original vehicle return fine with blue quick-release coupling Z Cutting point [E> only for vehicles with front-nheel drve Original vehicle return line with blue quick-release coupling 2 Cutting point Fig. 54Installing fuel extractor Cs B The assembly step is shown on a vehicle with rear- wheel drive but it also applies similarly to vehicles with front-wheel drive TF 910 screw clamp 8xSx8 Tpiece uel line for tank extraction 4 Hose section, 810 lamp [2x]10 Coolant - vehicles with 2.0D and engine code: OM654 10.1 Hose routing diagram - vehicles with 2.0D and engine code: OM654 Fig. 56 All spring clips [==1= 025 All connecting pipe 0-1) or "B= oraxte [Optional in case of an additional coolant pump at the engine outlet10.2 Coolant circuit installation - vehicles with 2.0D and engine code: OM654 Preparing hoses T 18x18mm connecting pipe ZL 18x18 / 90° connecting pipe Fig. 58 Removal instructions for air filter box bracket ig, 59 [7] Remove original vehicle fastening bolts of air fil [2] Air filter box bracket removed ter box bracket (covered) [Z]_ View of orginal vehicle thread in bracket of air 2] Air filter box bracket filter boxCutting point Remove and discard heat exchanger inlet hose sec- tion Z Engine outlet hase section Cutting point > Remove original vehicle clamp [Band align engine outlet hose section '2] as shown, T @iexra, 90° connecting pipe Engine outlet hose section Z Coolant pump inletHeater outlet connection Hose bracket between hose (E) and hose (A) Hose bracket between hose () and original vehicle heat exchanger outlet hose section Original vehicle heat exchanger outlet hose section11 Coolant - vehicles with 2.2D and engine code: OM651 11.1 Hose routing diagram - vehicles with 2.2D and engine code: OM651 Fig. 65 All spring clips [=]= 025 All connecting pipe 0-1) or "B= o1axte [Optional in case of an adeitional coolant pump at the engine outlet11.2. Coolant circuit installation - vehicles with 2.2D and engine code: OM651 Preparing hoses T 18x18mm connecting pipe 18x18 / 90° connecting pipe Cutting point (SP Vehicles with rear-wheel drive AE Remove and discard heat exchanger inlet hose sec- tion Engine outlet hose section F Cutting point Fig, 68CSP Vehicles with front-wheel drive A. Remove and discard heat exchanger inlet hose sec tion Z Engine outlet hose section 3 Culting point [= The nox assembly steps are shown on a vehicle with rear-wheel drive but apply similarly to all vehicles Heat exchanger inlet connection T 225 spring clip T_Engine outlet hose section Fig. 71Coolant pump T Heater/OUT connection piece 41g. 74Fastening hoses “4. Hose bracket between hose (and hose (A) © Hose bracket between hose ) and original vehicle heat exchanger outlet hose section Original vehicle heat exchanger outlet hose section12 Coolant - vehicles with 3.0D and engine code: OM642 12.1 Hose routing diagram - vehicles with 3.0D and engine code: OM642 Fig. 76 Al spring clips == 025 All connecting pipe 1-9 or "S = o1ax18 [H optional in case of an additional coolant pump at the engine outlet3 12.2 Coolant circuit installation - vehicles with 3.0D and engine code: OM642 Preparing hoses T 18x18mm connecting pipe A. 18x18 / 90° connecting pipe Cutting point 1. Remove and discard heat exchanger inlet hose sec tion Z Engine outlet hose section Cutting pointFitting edge protection T_ 70 long edge protection on air filter box bracket T Heat exchanger inlet connection piece Engine outlet hose sectionL Coolant pump inlet connection piece T Heater/OUT connection pieceFastening hoses ==] “A. Hose bracket between hose © and hose Z Hose bracket between hose () and original vehicle heat exchanger outlet hose section Original vehicle heat exchanger outlet hose sectionAl 13 Exhaust - vehicles with rear-wheel drive 13.1 Exhaust silencer installation Preparing perforated bracket aR favo Fig. 87 Preparing exhaust silencer Exhaust silencer 2.9x9.5 self-tapping screw in existing hole Iv I Fig. 88 _ Méx16 bolt, spring lock washer, perforated bracket, exhaust silencerMounting exhaust silencer riginal vehicle hole Z Exhaust silencer z M6x20 bolt, perforated bracket, original vehicle hole, flanged nut, Preparing exhaust pipe Edge clip cable te for fastening the original vehicle wiring harness able te for fastening the original vehicle wiing hamess [aT 200mm BZ 760mm Fig. 92Mounting exhaust pipe [aT] Hose clamp Fig. 93 13.2 Mounting exhaust pipe Preparing exhaust pipe [22] Spacer bracket Fig. 94 Overview - exhaust pipe '@Z installation location variants Installation location for variant 1 Installation location for variant 2 Vehicle without vacuum valve at position [7] Vehicle with vacuum valve at position T13.2.1 Mounting exhaust pipe - version 1 Mounting angle bracket T M6x20 bolt, large diameter washer, original vehicle hole, angle bracket, flanged nut Z Original vehicle stud bolt, angle bracket, original vehicle nut Hose clamp Méx16 bolt, 25mm dia. pipe clamp, angle bracket, flanged nut 1. M6x50 bolt, 225 pipe clamp, spacer (30), angle bracket, flanged nut Fig. 98Preparing perforated bracket 7 A. Drill out hole to 98.5. 20 Fig. 98 T Max20 bolt, perforated bracket, original vehicle hole, flanged nut T Méxao bolt, spacer (20), perforated bracket, 025 pipe clamp, flanged nut13.2.2 Mounting exhaust pipe - version 2 Preparing perforated bracket 1 Fig. 702 Preparing perforated bracket sections 2 and 3 Fig. 103 T Dill out hole to 28.5 Perforated bracket section 2 2 Perforated bracket section 3> Remove bracket for original vehicle vacuum pump and control unit[4] from frame side member. Mounting and fastening exhaust pipe Fig. 104 Z Stud bolt of vacuum pump bracket, perforated bracket section 2, original vehicle nut (covered) Stud bolt of vacuum pump bracket, perforated bracket section 3, original vehicle nut (covered) ‘F Méx20 bolt, original vehicle hole, perforated bracket section 2, flanged nut E Méxdo bolt, original vehicle hole, perforated bracket section 3, spacer (20), angle bracket, flanged nut [| Hose clamp > Route exhaust pipe [a as shown Fig. 105 T Hose clamp F Méx20 bok, p-clamp, premounted angle bracket, flanged nut » Postion spacer bracket ]at the edge of frame side member [2] as shownFastening exhaust pipe 'a2] M6x50 bolt, 024-26 p-clamp, spacer (30), angle bracket, flanged nut Z Original vehicle stud bol, angle bracket, original vehicle flanged nut T_ MBx20 bolt, perforated bracket 1, original vehicle hole, flanged nut T Méxt6 bolt, 224-26 p-clamp, perforated bracket 1, flanged nut Fig. 108Checking distance Fig. 109 > Align spacer bracket [T] with original vehicle ines as shown, Ensure sufficient distance between spacer bracket 2 and original vehicle lines, correct if neces~ sary. eaAN AN 14 Exhaust - vehicles with front-wheel drive Preparing perforated bracket 1 Preparing perforated bracket 2 T Méxt6 bolt, spring lockwasher, perforated bracket 4, exhaust silencerCopying hole pattern > Position premounted perforated bracket [1] in embossing as shown and copy hole pattern [21 T 29 hole, rivet nut T_ M6x20 bolt, spring lock washer, premounted per- forated bracket, rivet nutPreparing exhaust pipe far 150 [az 850 T Hose clamp 1 Exhaust silencer Original vehicle stud bok, angle bracket, original vehicle nutMounting and routing exhaust pipe [a2_ Danger of damage to components > Ensure sufficient distance between exhaust pipe ‘aZ] and neighbouring components, correct if ne- cessary. ey > align spacer bracket [T] with original vehicle wiring harness below. Z Hose clamp °F M6x25 bolt, 224-26 p-clamp, premounted angle bracket, flanged nut 7 27 hole in original vehicle cross-memberMounting exhaust pipe [a2 1. M6x20 bolt, perforated bracket 2 (short side), driled hole, flanged nut Z Méx20 bolt, 224-26 p-clamp, perforated bracket 2 (long sie), flanged nut Ensure sufficient distance between exhaust pioe \, a2 and pulley|1] correct if necessary. FY15 Final work in engine compartment 15.1 Vehicles with rear-wheel drive Preparing engine underride protection > Cut insulation [1] of engine underride protection Z)as shown and discard. Fig. 124 Hole in engine underride protection > Drill 260 hole [7] in engine underride protection as shown. Fig. 125 Aligning exhaust pipe [a2] > Mount engine underride protection 1] > Align exhaust pipe AZ] with centre of dried hole as shown15.2 Vehicles with front-wheel drive Preparing engine underride protection > Cut insulation of engine underride protection [1] parallel to marked welding spots 2].as shown. Fig. 127 Hole in engine undertide protection > Drill 860 hole [Tin engine underride protection as shown, Aligning exhaust pipe [a2 7 > Mount engine underride protection T. » Align exhaust pipe [a2] with centre of drilled hole as shown. 22] Fig. 12915.3 All vehicles Drilling hole in air duct A Danger of damage to insulation material Air duct 28 hole, only through the top plastic layer IM Ia) Fig. 130 > Clip hose bracket [T]into the drilled hole. spring clip (3) correct if necessary. I+] A. Ensure sufficient distance from original vehicle Tighten screw fitting SH2 Z Lock hose bracket @ Airduct & Cable tieA Cable tie16 Electrical system of passenger compartment 16.1 Electrics - cold start system 16.1.1 Electrical system preparation Assigning wires oO On a 1000 Fig. 134 > Insert red (rt) wite GD in provided protective sleeving. 2B Red (rt) wire of cold start wiring harness 5 Black (sw) wie of cold start wiring hamessPreparing CLR module > Detach black (sw) wire from terminal A and insulate. > Mount wires 24 and 25) > Connect wire SD with wire 2D. Fig. 13516.1.2 Wiring diagram Webasto Mercedes Benz Fig. 136Legend to wiring diagram {BP The vehicle connector and component designations are freely chosen by Webasto, Wiring colours may vary. Vehicle components Note [Abbrevi- [Component [Graphic [Besignation ase Frain contra unit a Engin code: 2.20 OME: b6-pn MSG connector for engine codes 220 OMS and | [F* [Engine code: 2.00 OMGA2 6 00 ose ba-pn MSG connector for engine code 2.00 0m654 | [F¥ __ [Engine code: 2.00 OMEBA oa [onsoard- dlagnons Webasto components Symbols JAbbrevi- [Component [Graphic [Designation la Mate pug for CLR module wing harness ik esting point fe Female plug for CLR module wing harness exiting elecical connection fe vale plug for adapter wiing harness ew elect connection b Female plug for adapter wing hares [ring harness section or protecve sieving E [Male plug for PagBPlay wring hares FF Female lig for gay wing harness nsuate and ve back wire FEcLGW [were Gateway CAN CAN LN facGW [ico 5 CAN Wau (Gateway CAN LIN) [The connection scared out a described in the heater lar [CAN UN Re eo art mole) nstatation documentation br Piode oe Piode group Wire colours Fo [Adaivonal fase for pawersupaly JAbbrevi [Colour ation Ft Heater main fase lbs beige 2 Passenger comparment fan convaler main fuse br bve is control element hse be brown ia Fan controler foe lar [eakbce Fs [adaivonal foe ea iG Heater To lae___retow etay Kt on sreen tay 2 ae rey reay or fight ue ta Power adapter ron [isnt areen ew [un caeway la aren a Soenoidvave or ange PAM GW [LN Gateway” PHIM ipa width modulation Pe ine ish Relay and fuse holder of pasienge compartment le Pink Rt fenperature senor In lea iki Female pa for contol element lw [eck G fice fas foie16.1.3 Connection in passenger compartment Mounting CLR module on the socket T CLR module socket 2 CUR module > Route wires 22 and QB) as well as temperature sensor RTD to the engine compartment cable grommet. > Route wires $9, 26) and QP) to the OBD socket outlet TT Fasten CLR module using double-sided adhesive tapeConnecting connectors and sockets Fig. 133 Connection to OBD socket outlet Fig. 140 { Further information can be found in the vehicle manufacturer's technical documentation, > Remove OBD socket outlet from bracket. > Crimp and shrink butt connector “T) Z Grey/white (gr/ws) wire of OBD socket outlet/ pin 6 3 Grey (g1) wire of OBD socket outlevpin 14 26 White (ws) wire of CLR module/ H cold start wiring hamess ® Orange (or) wire of CLR module’ L cold start wiring harness16.1.4 Connection in engine compartment - vehicles with 2.0D and engine code: OM654 J) Panger of damage to components > The next work steps are only necessary for vehicles with 2.0D and engine code OM654. There is a risk of confusion when selecting the wire to be used, [E> To prevent water seeping nto the passenger com- partment, the wiring harness must be routed up- ‘ards to the protective rubber plug and this plug must then be sealed with a suitable sealing com- pound > Route wires 24 and QB) as well as temperature sensor RTD through cable grommet 7 into the engine compartment, to engine control unit [3] AL Remove 5: n connector G of engine control unit Fig. 142 View of engine control unit connector G, contact side Engine control unit connector G, pin 40 Fig. 143View of engine control unit connector G, wiring side > Remove the Obere Abdeckung upper cover from connector G and detach part of the wiring har- ness wrapping, Insulate and reinstall after com- pletion 1 Yellow/white (ge/ws) wire of engine control unit connector G, pin 40 > Crimp and shrink the butt connector. T Yellow/white (ge/ws) wire of S4-pin engine control unit connector G/ pin 40 2 Yellowswhite (gerws) wire 2 Red (rt) wire of CLR moduleMW from cold start wir- ing harness 5) Black (sw) wire of CLR module/A from cold start wiring hamess16.1.5 Connection in engine compartment - vehicles with 2.2D and engine code: OM651 Danger of damage to components Z's, > the next work steps are only necessary for vehicles with 2.20 and engine code OM651. There i ask of confusion when selecting the wire tobe used Fastening temperature sensor ®TD: SS D Fig. 147 (E> To prevent water seeping into the passenger com- partment, the wiring harness must be routed up- wards to the protective rubber plug and this plug must then be sealed with a suitable sealing com- pound. > Route wires 2@ and 28) as well as temperature sensor TD through cable grommet 7 into the engine compartment, to engine control unit 3] > attach temperature sensor (ETB to witing harness [Z] with cable ties, 1. Remove 96-pin connector G of engine control unit View of engine control unit connector G, contact side Fig. 148 Engine control unit connector G, pin 57View of engine control unit connector G, wiring side > Remove the Obere Abdeckung upper cover from connector G and detach part of the wiring har- ness wrapping, Insulate and reinstall after com- pletion 1 Green/ted (gnitt) wire of engine control unit con- nector G, pin 57 Fig. 149 Connection to engine control unit > Crimp and shrink the butt connector. T Greenired (gnitt) wire of 96-pin connector 6 of en- gine control unitipin 57 2. Greenvred (gnvt) wire 2 Red (rt) wire of CLR moduleAW from cold start wir- ing harness 5) Black (sw) wire of CLR module/A from cold start wiring hamess16.1.6 Connection in engine compartment - vehicles with 3.0D and engine code: OM642 J Panger of damage to components Ze Wipe ett work steps arelonly necessary for venicles withs OD end engine code OMe42 There isa risk of confusion when selecting the wire to be used. Fastening temperature sensor RTD. [E> To prevent water seeping nto the passenger com- partment, the wiring harness must be routed up- wards to the protective rubber plug and this plug must then be sealed wth a suitable sealing com- pound > Route wires 24 and 2B) as well as temperature sensor TD through cable grommet 7 into the engine compartment, to engine control unit [3] cable ties. 1. Remove 96-pin connector G of engine control unitView of engine control unit connector G, wiring side > Remove the Obere Abdeckung upper cover from connector G and detach part of the wiring har- ness wrapping, Insulate and reinstall after com- pletion 1 Green/ted (gnitt) wire of engine control unit con- nector G, pin 87, > Crimp and shrink the butt connector. L Greenired (gnitt) wire Z Greenvred (grit) wire of 96-pin connector 6 of en- gine control unitipin 87 BB Red (rt) wire of CLR module/W from cold start wir- ing harness 2B) Black (sw) wire of CLR module/A from cold start wiring harness16.2 Electrics - fan controller 16.2.1 Electrical system preparation Preparing and assigning wires Oe Ory Fig. 156 View of LIN GW Fig. 157 (> Wire sections retain their numbering inthe entire document. TL 48 female connector ). Green (gn) wire from wiring harness of LIN control @ Greenvblack (gn/sw) wire from wiring harness of LIN control B White (ws) wire of additional relay wiring harness 9) Black/white (swiws) wire of additional relay wiring hamess > Check the LIN GW settings when starting up the heater. If necessary, a modification of the fan capacity is possible by adjusting the voltage in increments of + 0.1V and monitor- ing at the same time the total power consumption. Parameter Setting [Duty cycle not relevant Frequency not relevant IVolage 53V [Function LinDisconnecting and discarding red (rt) wire from RSH, connecting green (gn) and green/black (gn/ sw) wires Fig. 158Premounting relay K2 Fig. 153‘Assembling / preparing RSH and socket relay K2 br rt. tis Janis los |e fos: [os RSH oF nisw Os Fig 160 > Connect wires > Connecting connectors and sockets Preparing perforated bracket Fig. 161Installing perforated bracket Fig. 162 Mounting relay K2 and LIN GW Installing perforated bracket Fig. 164 _M5x16 bolt, large diameter washer, RSH, perfor- ated bracket, large diameter washer, nut TL M5x16 bolt, large diameter washer, RSH, perfor ated bracket, large diameter washer, nutMounting relay K2 and LIN IM Relay K216.2.2 Wiring diagram Webasto ! Mercedes Benz + 1 30 1 15 40 I it | acm {iro 1 ¥ \ ® | Es eis it I" ! gnipk ¢ \ a hs _ | HG i ji i DIA reir \ —* | Bevo Jor Hi rt ! ~ «, fusw ft lors Ef Ee Foal +4 oe | be, Juow fa Joris \ fe i ' | \ ‘sw (ot) 34 Fig. 166Legend to wiring diagram {The vehicle connector and component designations are freely chosen by Webasto. Wiring colours may vary. Vehicle components Symbols [Abbreviation [Component [Abbreviation [Explanation be [cenit tect a euting oi ret ruse 5a le spn ZF connector cae Fan contoter le [cp Gar connector ksi ap postoning motor acon Body conrohunt e Tein adapter Webasto components Cable colours [Abbreviation [Component [Abbreviation [Colour lA ale plug for CLA module wiring harness ba beige fe errae plug for CLR module wiring haress bt ie e vale pag Yor eater wig harness lb brown b Female plug fr adopter wring harness aor ear blue E ale pug for Pug Play wring hanes lean eark green F Ferma plug for PugéPay wiring hares oe freon eclaw vito Gateway CAN CAN LIN on lareen cow vicroSP5 CAN / Wus (Gateway CAN LIN lo lsrey jar [CaN UN Re fold star mode har ane bue bi biode han ight green b2 biode group la Fanon Fe [Adational fuse for power sappy oe orange i eater main fase Pe nk ia Passenger compartment fan convl man fuse le Pine Fa [contra lent fase le es Fa Fan contol use bw e is [adaional fe i [ice ine Heater Teve ws tite Reiki Relay etay ts rower adapter av Solenoid vabe Pa cw LN Gateway PWM (pulse width moduler ast Relay and fuse holder of passenger compartment RT [remperatore sensor kro Female plug fr contol element16.2.3 Fan controller Mounting RSH T Premounted RSH 2. Original vehicle stud bolt, original vehicle nut Fig. 167 Connecting same colour wires of wiring harnesses a Fig. 168 T Connector D, 18-pin Z Groenypink (an/pk) wire Fig. 169LIN connection Connector D, 18-pin Z Greervpink (gn/pk) wire of connector €/ pin 4 EF Greenvpink (gn/pk) wire of connector D/ pin 10 @ Green (gn) wire from wiring harness of LIN control ® Greenilack (gn/sw) wire from wiring hamess of LIN control ig. 170 Overview of BCM []and connector A position [2] (both depend on the equipment) Version 1 Version 2 Fig. 171 Connecting relay K2

Lift 26 1 and detach connector C 2 > Detach 26 [1] [2] Original vehicle bott Connecting wires = T Connector ¢, removed Blackiorown (swibt) wire of connector € / pin 3 5O Red (rt) wire of K2/86 ED Red (11) wire extension of red/white (rtws) wire from 2 CLR/15 > Mount Ze [7] Check that the original vehicle fuses > Mount connector € [Z]on 7¢ [Hl Bare fitted correctly 3 Original vehicle bott17 Electrical system of control element 17.1 MultiControl option Installing MultiControl ‘Observe the MultiControl CAR installation docu mentation, Installation frame 17.2 Telestart option Mounting receiver a] Observe the Telestart installation documentation. > Fasten receiver [T] using double-sided adhesive tape. Fig. 177 T Aerial18 Final work in passenger compartment Connection to positive battery terminal Fig. 179 Fig. 180 DANGER > Observe tightening torque [Z shown on a vehicle with rear-wheel drive. Version 1 Original vehicle positive support point, M flanged nut 4D Red (rt) wire from fuse FO of postive extension wir ing harness DANGER Observe tightening torque > Shown on a vehicle with rear-wheel drive. Version 2 Original vehicle positive terminal, M8 flanged nut Red (rt) wire from fuse FO of positive extension wir- ing harness Edge protection Battery coverx22 ‘This is a translation from the original German installation instructions. ‘To request ths Installation Documentation in another language, please locate and contact your local Webasto dealer. g ‘You can find your nearest dealer at: https1/dealerlocator.webasto.conven-t. . © Copyright 2022 - The contents of this document, incliding but not Imited to text, photographs and graphics, are protected by copyright All rights, incliding reproduction, publication, editing and translation in any way, shape or form, are reserved by Webasto. 24738_EN + 03722 + Webasto Thermo & Comfort SE Postfach 1410 22199 Gilehing Germany Company address: Friedrichshafener Str. 9 22205 Gilehing Germany Technical Extranet: htpsidealers sebasto.com C € WWW.WEBASTO.COM20 Coe LB = « 20.1 (Aebasto Feel the Drive TEMPMATIC operating instructions Information regarding the heating time We recommend matching the heating time to the driving time (heating time = driving time) Example: for a driving time of approx. 20 min. (in one direction), we recommend nat exceeding a switch- ‘on time of 20 min. Vehicles with passenger compartment monitoring Further information can be found in the vehicle operating instructions. > Deactivate passenger compartment monitoring for the heating operation. Notes about the active parking heating mode ‘The vehicle fan is deactivated when the vehicle is opened and is available again once the ignition is switched on. After the vehicle is closed again, it can take several minutes for it to be active again, Note for parking heater function Your vehicle is equipped with a passenger compartment and engine preheating unit. AJC control panel settings AIC control panel EP Before parking the vehicle, make the following set- tings: > Setting the fan speed is not required, it will automatically be set to approx. 1/3. Set temperature to HI’ with rocker switch 2 Press defrost push button Fig. 182Installation location of fuses 20.2 F1-20A heater main fuse F2- 3A main fuse of passenger compartment T 2 T. F3- 1A control element fuse A. FO-30A main fuse(Aebasto Feel the Drive 21 THERMOTRONIC operating instructions {<=> Information regarding the heating time We recommend matching the heating time to the driving time (heating time = driving time) Example: for a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch- ‘on time of 20 min. { Vehicles with passenger compartment monitoring Further information can be found in the vehicle operating instructions. > Deactivate passenger compartment monitoring for the heating operation. (SF Notes about the active parking heating mode ‘The vehicle fan is deactivated when the vehicle is opened and is available again once the ignition is switched on. After the vehicle is closed again, it can take several minutes for it to be active again, [> Note for parking heater function Your vehicle is equipped with a passenger compartment and engine preheating unit. 21.1 A/C control panel settings AIC control panel Setting the fan speed is not required, it will automatically be set to approx. 1/3. Set temperature to HI’ with rocker switch 2 Press defrost push button Fig. 186Installation location of fuses 21.2 F1-20A heater main fuse F2- 3A main fuse of passenger compartment T 2 T. F3~ 1A control element fuse AL. FO-30A main fuse