Mercedes - A 200 CDI - Wiring Diagram - 2012 - 2012

Water Heater Thermo Top Evo Parking Heater E1 00 0258 Installation Documentation Mercedes Benz A-class (W176) and B-class (W246) Validity Manufacturer Mercedes Benz Model A-Class Type W176 Motorisation Fuel Transmission type Output in kW A 180 A 200 A 180 CDI A 200 CDI Petrol Petrol Diesel Diesel SG SG SG SG Manufacturer Mercedes Benz Model B-Class EG-BE No. / ABE e1 * 2007 / 46 * 0928 * ... 90 115 80 100 Displacement in cm³ 1595 1595 1796 1796 Type W246 EG-BE No. / ABE e1 * 2007 / 46 * 0751 * ... Motorisation Fuel Transmission type Output in kW B 180 B 200 B 180 CDI B 200 CDI Petrol Petrol Diesel Diesel SG SG SG SG 90 115 80 100 Displacement in cm³ 1595 1595 1796 1796 Engine code M 270 M 270 OM 651 OM 651 Engine code M 270 M 270 OM 651 OM 651 SG = Manual transmission From Model Year 2012 Left-hand drive vehicle Verified equipment variants: Thermatic / Thermotronic Headlight washer system Daytime running lights Not verified: Passenger compartment monitoring Front fog light Total installation time: approx. 8 hours Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE Mercedes Benz A-class (W176) and B-class (W246) Table of Contents Validity 1 Necessary Components 2 Installation Overview 2 Information on Total Installation Time 2 Information on Operating and Installation Instructions 3 Information on Validity 4 Technical Information 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Electrical System 6 Fan Control 7 Digital Timer 10 Remote Option (Telestart) 10 Preparing Installation Location Preparing Heater Installing Heater Coolant Circuit for Petrol Vehicles Coolant Circuit for Diesel Vehicles Fuel Final Work Installation Instructions for Thermatik Installation Instructions for Thermotronik 11 11 15 17 21 25 31 32 33 Necessary Components • Basic delivery scope Thermo Top Evo in accordance with price list • Installation kit for Mercedes Benz A-/B-class 2012 Petrol and diesel: 1318146A • Heater control 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 • Additionally required: Contact adhesive to glue standpipe (for example Loctite 406) • Additionally required: CAN-bus-module H2-W246 Order via: Henni GmbH, 73249 Wernau, Asemweg 2 Tel: +49(0)7153/37953, Fax: +49(0)7153/37959 Homepage: www.hennigmbh.de, Mail: [email protected] Installation Overview Legend: 1 5 3 7 1. Heater 2. Engine compartment fuse holder 3. Fan module 4. CAN-node 5. Circulating pump 6. Digital timer 7. Metering pump 6 2 4 Information on Total Installation Time 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.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 2 Mercedes Benz A-class (W176) and B-class (W246) Information on Operating and Installation Instructions 1 Important Information (not complete) Beginning of excerpt. 1.1 Installation and Repair ANNEX VII The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death. 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 according to the requirements of this Annex. Only use genuine Webasto parts. See the Webasto air and water heaters accessories catalogue for this purpose. 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply with the requirements of this Annex. 1.2 2.2. Positioning of heater 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. 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. Do not operate the heater in closed rooms due to the danger of poisoning and suffocation. 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 installation ensures an adequate distance to all parts and suitable ventilation, 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. To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appropriate 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 Webasto 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. Operation Always switch off the heater before refuelling. The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or petrol (DIN EN 227). The heater may not be cleaned with a high-pressure cleaner. 1.3 Please note 2.2.4. ALWAYS follow all Webasto installation and operating instructions and observe all warnings. 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. 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. 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 labelled. 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. 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. This liability exclusion particularly applies to improper installations and repairs, installations and repairs by untrained persons or in the case of a failure to use genuine spare parts. 2.4. Exhaust system 2.4.1. The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators, heated air inlets or opening windows. 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. 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 The liability due to culpable disregard to life, limb or health and due to damage or injuries caused by a wilful or reckless breach of duty remain unaffected, 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). 2.6. Heating air inlet 2.6.1. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. 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. When installing an IPCU, the corresponding settings must be checked or adjusted before the installation. 2.7. Heating air outlet 2.7.1. Any ducting used to route the hot air through the vehicle must be so positioned 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. Observe the instructions and guidelines of the respective vehicle manufacturer for demounting and mounting vehicle specific components! 2 Statutory regulations governing installation Guidelines Thermo Top Evo Heating Directive ECE R122 EMC Directive ECE R10 E1 00 0258 E1 03 5627 NOTE End of excerpt. In multilingual versions the German language is binding. 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 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 3 Mercedes Benz A-class (W176) and B-class (W246) Information on Validity This installation document applies to Mercedes Benz A-class (W176) and B-class (W246) Petrol and diesel vehicles - for validity, see page 2 - from model year 2012 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be 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 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 • 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-theart-technology. Explanatory Notes on Document 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. Special features are highlighted using the following symbols: Mechanical system Specific risk of injury or fatal accidents Electrical system Specific risk of damage to components Coolant circuit Specific risk of fire or explosion. Combustion air Reference to general installation instructions of the Webasto components or to the manufacturer's vehicle-specific documents. Fuel Exhaust gas Reference to a special technical feature The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle Software Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 4 Mercedes Benz A-class (W176) and B-class (W246) Preliminary Work Vehicle • • • • • • • • • • • • • • • • • Open the fuel tank cap. Ventilate the tank. Close the fuel tank cap again. Remove the engine cover. Depressurise the cooling system. Disconnect the battery and remove it with the battery trim. Completely remove the air filter. Remove the right front wheel. Remove the right-hand wheel well trim. Remove the coolant expansion tank. Remove the right and left underride protection. Remove the lower engine trim. Remove the heat shield plate of the fuel tank. Remove the fuel-tank in accordance with the manufacturer's instructions. Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. Remove the glove compartment. Remove instrument panel in accordance with manufacturer's instructions (CAN-node). 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 1 Heater Installation location 1 Ident. No.: 1318147E_EN 1 Status: 21.11.2012 © Webasto Thermo & Comfort SE 5 Mercedes Benz A-class (W176) and B-class (W246) Electrical System Fuse holder of engine compartment Wiring harness pass through Ensure sufficient distance to intake manifold at position 1. 1 Protective rubber plug 2 Wiring harness of heater / heater control 2 M5x16 bolt, washer, retaining plate of fuse holder, 6mm dia. hole, washer, nut 3 Battery box 4 Fuses F1-2 1 1 3 2 4 2 3 2 Wiring harness routing diagram Do not route the metering pump wiring harness until later together with fuel line along the original vehicle fuel lines on the underbody 1 1 4 Positive wire Earth wire 1 Positive wire on positive terminal of battery Ident. No.: 1318147E_EN 5 1 Earth wire at original vehicle earth support point Status: 21.11.2012 © Webasto Thermo & Comfort SE 6 Mercedes Benz A-class (W176) and B-class (W246) Fan Control Webasto Mercedes-Benz 30 15 HG F2 F1 X2 1 Wiring diagram CAN 2 2 5 X1 St B St A ge CAN 0,5² br rt/sw 0,5² 0,5² rt gn/ws 4² 0,75² rt/ge 0,75² X10 ws 0,75² br br 0,5² 0,75² CAN-Modul 31 Webasto components Vehicle components HG TT-Evo heater ST A CAN-node X1 6-pin heater connector X2 2-pin heater connector X10 4-pin connector Heater control F1 Fuse, 20A F2 Replace 30A fuse with 1A fuse. ST B Connector of CAN-busmodule Colours and symbols rt red sw black ge yellow gn green or orange ws white br brown Legend Cable colours may vary. 1 Route wire of CAN-bus to the left side of the vehicle 2 Fasten CAN-module with adhesive tape 1 2 Installing CAN-module 6 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 7 Mercedes Benz A-class (W176) and B-class (W246) 1 Connect wires with solder wire terminator 1 according to wiring diagram. 2 2 Red/yellow (rt/ge) positive (plus) wire of CAN-module 3 Red/black (rt/sw) wire of connector X10 4 Red (rt) wire of fuse F2 Connecting wires 4 3 7 Connect wires with connector according to wiring diagram. 1 2 1 White (ws) wire of CAN-Module 2 Brown (br) earth wire of CAN-Module 3 Brown (br) earth wire of heater wiring harness 4 Green/white (gn/ws) wire of connector X1, Pin 5 Connecting wires 3 4 8 Remove instrument panel in accordance with manufacturer's instructions to facilitate installation of the CAN-connector. Remove window frame, loosen bolts [2x] at position 1 and remove instrument panel. Removing instrument panel 1 1 9 Image shows A-class. 1 2 Unclip CAN-node plug connector Unclipping plug connector of CAN-node 10 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 8 Mercedes Benz A-class (W176) and B-class (W246) Image shows B-class. Insert connector of CAN-module into free socket. 1 1 CAN-node 2 Connector of CAN-module (St B) 2 Connection of CAN-bus 11 All vehicles. Image shows B-class. Re-insert plug connector of CAN-node. Reinstall instrument panel. 1 Completing instrument panel 12 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 9 Mercedes Benz A-class (W176) and B-class (W246) Digital Timer 1 1 Digital timer Mounting digital timer 13 Remote Option (Telestart) 1 1 Receiver 2 Bracket 3 Original vehicle bolt Mounting receiver 2 14 3 All vehicles 1 1 Antenna Mounting antenna 15 Temperature sensor T100 HTM 1 Image shows B-class. Fasten temperature sensor 1 with adhesive tape. Installing temperature sensor 16 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 10 Mercedes Benz A-class (W176) and B-class (W246) Preparing Installation Location 1 Rivet nut, existing hole Installing rivet nut 17 1 1 Unscrew original vehicle bolt by approx. 5mm 2 Remove original vehicle bolt, will be reused Preparing installation location 1 18 2 Preparing Heater 1 1 Water connection pieces, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of water connection pieces 2 Mounting water connection pieces 19 1 1 Hose section, 10 mm dia. clamp [2x] 2 Fuel line Premounting fuel line 2 Ident. No.: 1318147E_EN 1 20 Status: 21.11.2012 © Webasto Thermo & Comfort SE 11 Mercedes Benz A-class (W176) and B-class (W246) 1 2 Insert M6x25 bolt 3 into hole prior to installation. 2 1 Section 1 of bracket 2 5x13 self-tapping bolt [3x] Installing section 1 of bracket 3 21 2 1 1 Section 2 of bracket 2 Attach rubber bearing 3 5x13 self-tapping bolt [2x] 2 Installing section 2 of bracket 3 22 3 Discard section X. 1 1 Combustion air pipe a = 40 Cutting combustion air pipe to length a X 1 2 3 4 Combustion air pipe 51 mm dia. clamp Combustion air silencer M5x16 bolt, flanged nut 1 Premounting combustion air silencer 2 4 Ident. No.: 1318147E_EN 3 23 Status: 21.11.2012 © Webasto Thermo & Comfort SE 12 Mercedes Benz A-class (W176) and B-class (W246) 1 Discard section X. 2 1 Exhaust pipe a = 150 2 Exhaust end section b = 140 a Preparing exhaust pipe b X 1 2 3 4 Hose clamp [3x] Exhaust manifold Exhaust-gas insulation Silencer Premounting exhaust system 1 4 1 2 3 1 2 24 1 2 1 2 3 4 Exhaust end section Hose clamp Twist protection M6x16 bolt, spring lockwasher Premounting exhaust system 3 1 4 2 25 A B C D A B C Ident. No.: 1318147E_EN = = = = 950 70 90 1090 Preparing hoses D Status: 21.11.2012 © Webasto Thermo & Comfort SE 13 Mercedes Benz A-class (W176) and B-class (W246) 1 Slide braided protection hoses onto hoses A and D and cut to length. Cut heat shrink plastic tubing to size. 1 A 1 Heat shrink plastic tubing, length 25 [4x] 2 Slide on black (sw) rubber isolator Preparing hoses D 1 2 1 1 Ensure proper seating of rubber gasket. 1 1 Torx screw [4x] 2 Cover of circulating pump, twisted by 90° Twisting cover of circulating pump 2 1 1 1 26 1 2 3 4 2 4 Circulating pump Mounting of circulating pump Large diameter washer, flanged nut Wiring harness of circulating pump Mounting circulating pump 3 27 All spring clips = 25 mm dia. B 1 Connection piece on heater inlet Installing hoses B and C C 1 Ident. No.: 1318147E_EN 28 Status: 21.11.2012 © Webasto Thermo & Comfort SE 14 Mercedes Benz A-class (W176) and B-class (W246) Spring clip = 25 mm dia. 1 Connection piece on heater outlet Premounting hose D D 29 1 Installing Heater 1 Insert bracket section 2 with rubber bearing 2 into original vehicle mounting 1. Mounting heater 30 2 1 Exhaust end section 2 Original vehicle bolt [2x] Mounting heater 2 2 1 31 1 M6x20 bolt, spring lock washer, large diameter washer Mounting heater 1 Ident. No.: 1318147E_EN 32 Status: 21.11.2012 © Webasto Thermo & Comfort SE 15 Mercedes Benz A-class (W176) and B-class (W246) 1 Wiring harness of heater [2x] 1 Attaching wiring harness of heater 33 1 1 Centrally align exhaust end section 1 with hole and flush with underride protection 2. 2 Aligning exhaust end section 34 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 16 Mercedes Benz A-class (W176) and B-class (W246) Coolant Circuit for Petrol Vehicles WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram D A 1 B C All spring clips without a specific designation = 25 mm dia. 1 = Black (sw) rubber isolator . All connecting pipes and = 18x18 mm dia. Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 17 Mercedes Benz A-class (W176) and B-class (W246) 1 1 Drill out hole to 8 mm dia. 2 Perforated bracket 2 Preparing perforated bracket 82 90° 1 Countersink hole with 10mm dia. drill Preparing perforated bracket 1 35 1 Install hose bracket 1 Preparing perforated bracket 36 1 M6x20 bolt, spring lockwasher, original vehicle threaded hole 1 Preparing routing 37 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 18 Mercedes Benz A-class (W176) and B-class (W246) Loosen strut 1 to facilitate installation. 1 2 M6x25 bolt, original vehicle hole, pin lock Preparing routing 2 38 1 Cut hose of engine outlet / heat exchanger inlet at marking 1 [2x]. 2 2 Hose section on heat exchanger inlet 3 Hose section of engine outlet 4 Discard hose section 4 1 Cutting point 39 3 1 Circulating pump A Connection of hose A 40 1 1 2 1 Wiring harness of heater 2 38 mm dia. rubber-coated p-clamp 3 10mm spacer, flanged nut D Routing in engine compartment 3 Ident. No.: 1318147E_EN A 41 Status: 21.11.2012 © Webasto Thermo & Comfort SE 19 Mercedes Benz A-class (W176) and B-class (W246) 1 2 1 Position black (sw) rubber isolator 2 Hose bracket A Routing in engine compartment D D 42 Ensure sufficient distance from neighbouring components. 1 1 Hose of heat exchanger inlet Connecting heat exchanger inlet 43 1 Hose on engine outlet D Connecting engine outlet A 1 44 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 20 Mercedes Benz A-class (W176) and B-class (W246) Coolant Circuit for Diesel Vehicles WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram D A 1 B C All spring clips without a specific designation = 25 mm dia. 1 = Black (sw) rubber isolator . All connecting pipes and = 18x18 mm dia. Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 21 Mercedes Benz A-class (W176) and B-class (W246) 1 1 Drill out hole to 8 mm dia. 2 Perforated bracket 2 Preparing perforated bracket 82 90° 1 Countersink hole with 10mm dia. drill Preparing perforated bracket 1 45 1 Install hose bracket 1 Preparing perforated bracket 46 1 2 3 4 1 Original vehicle bolt Wiring harness of heater Perforated bracket with hose bracket Cable tie Preparing routing 2 4 Ident. No.: 1318147E_EN 3 47 Status: 21.11.2012 © Webasto Thermo & Comfort SE 22 Mercedes Benz A-class (W176) and B-class (W246) Loosen strut 1 to facilitate installation. 1 2 M6x25 bolt, original vehicle hole, pin lock Preparing routing 2 48 1 Cut hose of engine outlet / heat exchanger inlet at marking 1 [2x]. 2 2 Hose section on heat exchanger inlet 3 Hose section of engine outlet 4 Discard hose section Cutting point 4 1 49 3 1 Circulating pump A Connection of hose A 50 1 1 2 1 Wiring harness of heater 2 38 mm dia. rubber-coated p-clamp 3 10mm shim, flanged nut D Routing in engine compartment 3 Ident. No.: 1318147E_EN A 51 Status: 21.11.2012 © Webasto Thermo & Comfort SE 23 Mercedes Benz A-class (W176) and B-class (W246) A 1 Hose bracket 2 Position black (sw) rubber isolator 1 Routing in engine compartment 2 D D 52 Ensure sufficient distance from neighbouring components. 1 1 Hose of heat exchanger inlet Connecting heat exchanger inlet 53 A 1 Hose on engine outlet 1 Connecting engine outlet 54 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 24 Mercedes Benz A-class (W176) and B-class (W246) 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. Unless 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 routing diagram. 1 2 3 Complete connector of metering pump after routing. Pin assignment is not relevant. 4 5 1 2 3 4 5 Connector housing Lock Blue/brown (bl/br) wires Coding Timer lock Dismantling connector 5 55 Cut standpipe 2 at position 1 in the centre of the bead as shown. 2 2 Cut standpipe to length Petrol a = 210 Diesel Preparing standpipe 220 a 1 56 1 2 1 Perforated bracket 2 Drill out hole to 9 mm dia. Preparing perforated bracket 78 90° Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 25 Mercedes Benz A-class (W176) and B-class (W246) 1 2 a 3 b Cut 10mm dia. corrugated tube to length. 4 1 Corrugated tube 1 a = 300 2 Corrugated tube 2 b = 330 3 Corrugated tube 3 c = 200 4 Corrugated tube 4 d = 300 d c Petrol 2 1 Preparing corrugated tube Cut off top of blind plug at position 2 and countersink it slightly. 1 Fuel-tank sending unit Fuel extraction 57 Insert standpipe 1 and glue in place using suitable contact adhesive (for example Loctite 406). 1 2 Insert clamp Inserting standpipe 2 2 58 Affix standpipe 2 from below at position 1 using suitable contact adhesive (for example Loctite 406). 1 Affixing standpipe 2 Ident. No.: 1318147E_EN 59 Status: 21.11.2012 © Webasto Thermo & Comfort SE 26 Mercedes Benz A-class (W176) and B-class (W246) 2 1 Mount tank 2 in accordance with manufacturer's instructions after installation. 3 1 Moulded hose, 10 mm dia. clamp 3 Fuel line Connecting fuel line 60 1 Diesel 1 Bend barbs 1 [2x] by approx. 1-2 mm in direction of arrow. 3 2 Clamp 3 Bend up tab [2x] 3 Preparing clamp 2 61 1 1 Cut off top of blind plug at position 2 and countersink it slightly. 2 1 Fuel-tank sending unit Fuel extraction 62 Insert standpipe 1 and glue in place using suitable contact adhesive (for example Loctite 406). 1 2 Insert clamp Inserting standpipe 2 2 63 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 27 Mercedes Benz A-class (W176) and B-class (W246) Affix standpipe 2 from below at position 1 using suitable contact adhesive (for example Loctite 406). 1 Affixing standpipe 64 2 1 2 Mount the tank in accordance with manufacturer's instructions after installation. 3 1 Tank 2 Moulded hose, 10 mm dia. clamp 3 Fuel line Connecting fuel line 65 1 2 1 Line holder 2 Corrugated tube 1 3 Fuel line and wiring harness of metering pump 3 Routing lines 66 1 2 Route fuel line and wiring harness of metering pump at position 3 in elbow for later installation of wheel-well inner panel. 3 1 Line holder 2 Fuel line and wiring harness of metering pump 2 Ident. No.: 1318147E_EN Routing lines 67 Status: 21.11.2012 © Webasto Thermo & Comfort SE 28 Mercedes Benz A-class (W176) and B-class (W246) Route fuel line and wiring harness of metering pump at position 1 in elbow to keep it from coming into contact with wheel-well inner panel. 1 2 Corrugated tube 2 3 Line holder 3 Routing lines 2 68 1 Line holder Routing lines 1 69 1 1 1 Line holder [3x] 1 Routing lines 70 1 1 Line holder [2x] 1 Routing lines 71 Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 29 Mercedes Benz A-class (W176) and B-class (W246) Discard plastic plug at position 1 prior to installation. 1 1 M8x20 bolt, spring lockwasher, original vehicle threaded hole 2 Perforated bracket 3 Plug through M6x25 bolt 3 72 2 1 Perforated bracket 2 Support angle, flanged nut 3 Mounting of metering pump 1 2 2 Check the position of the components; adjust if necessary. Check that they have freedom of movement. 3 4 7 6 Ident. No.: 1318147E_EN Mounting metering pump 73 3 1 Installing perforated bracket 5 1 90° moulded hose, 10 mm dia. clamp [2x] 2 Wiring harness of metering pump, conConnectnector mounted ing meter3 Hose, 10 mm dia. clamp [2x] ing pump 4 Corrugated tube 4 5 Fuel line fuel standpipe 6 Corrugated tube 3 7 Fuel line of heater 74 Status: 21.11.2012 © Webasto Thermo & Comfort SE 30 Mercedes Benz A-class (W176) and B-class (W246) Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate all loose wires and tie back. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). • • • • • Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. Adjust digital timer, teach Telestart transmitter. Mount signboard "Switch off parking heater before refueling" in area of filler neck. For initial startup and function check, please see installation instructions. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1318147E_EN Status: 21.11.2012 © Webasto Thermo & Comfort SE 31 Mercedes Benz A-class (W176) and B-class (W246) Installation Instructions for Thermatik Please remove page in case of manual air-conditioning and add it to the vehicle operating instructions. Note: 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. Passenger compartment monitoring , if installed, must be deactivated in addition to the vehicle settings for the heating cycle. Instructions for the deactivation can be taken from the operating instructions manual of the vehicle. The following settings are to be selected prior to turning off the vehicle to improve the heat input inside the vehicle: 1 Temperature on "max." 1 A/C control panel 75 1 1 20A heater fuse F1 2 1A fuse F2 of heater control 2 Fuses of engine compartment 76 Mercedes Benz A-class (W176) and B-class (W246) Installation Instructions for Thermotronik Please remove page in case of manual air-conditioning and add it to the vehicle operating instructions. Note: 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. Passenger compartment monitoring , if installed, must be deactivated in addition to the vehicle settings for the heating cycle. Instructions for the deactivation can be taken from the operating instructions manual of the vehicle. The following settings are to be selected prior to turning off the vehicle to improve the heat input: 1 1 Temperature to "HI" on both sides 1 A/C control panel 77 1 1 20A heater fuse F1 2 1A fuse F2 of heater control 2 Fuses of engine compartment 78