Webasto Thermo Top C Installation Instructions Manual

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Manual is about: Typ BW50 (Benzin/Petrol/Bensin) Typ DW50 (Diesel)

Summary of Thermo Top C

  • Page 1

    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. Seri...

  • Page 2: Mercedes Benz W 203

    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...

  • Page 3: 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 scop...

  • Page 4: Mechanical Work

    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 ...

  • Page 5: 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 l...

  • Page 6: 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...

  • Page 7: 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-...

  • Page 8: Mercedes Benz W 203

    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- blin...

  • Page 9: 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 ...

  • Page 10: 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 pum...

  • Page 11: 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 (...

  • Page 12: 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 th...

  • Page 13: Mercedes Benz W 203

    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 ) hos...

  • Page 14: Mercedes Benz W 203

    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 ) ...

  • Page 15: 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)....

  • Page 16: Mercedes Benz W 203

    16 (please remove page and insert with vehicle operating instructions.) before parking the vehicle, make the following settings: operating 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 whe...

  • Page 17

    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.