Mercedes Benz GLK 200 / 220 / 250 CDI (X204)

Transcription

1 Water Heater Feel the drive Thermo Top Evo 5+ Parking Heater e Installation documentation Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Diesel from model year 009 Left-hand drive vehicle Automatic air-conditioning Blue Efficiency 4 Matic WARNING! Hazard warning: Incorrect installation or repair of Webasto heating systems may cause a fire or result in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as a result. Specialist company training, technical documentation, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heater accessories from Webasto. NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. ALWAYS follow all Webasto installation and repair instructions and observe all warnings. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 668F_EN Fee Euro 0.00 Webasto AG

2 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Table of Contents Validity Heater/Installation Kit Foreword General instructions Special tools Explanatory notes on document 4 Preliminary work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 7 Fan control 9 Mount push button Telestart Preparing installation location 4 Preparing heater 5 Coolant circuit 9 heater 5 Fuel 7 Underride protection Final Work Validity Manufacturer Model Type EG-BE-No. / ABE Daimler AG GLK Class X04 e * 00 / 6 * 0480 *... Type Engine model Output in kw Displacement in cm³ GLK 00 CDI Diesel / R GLK 0 CDI Diesel / R4 5 4 GLK 50 CDI Diesel / R Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. 668F_EN

3 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Heater/Installation Kit Quantity Description Order No.: Delivery scope Thermo Top Evo 5+ Mercedes Benz 667B GLK 00 / 0 / 50 CDI (X04) Diesel with Telestart T9 black (sw) Optional heater control to be ordered according to choice: Quantity Description Order No.: Digital timer See price list Telestart T00 HTM black (sw) See price list The installation location of the digital timer/push button should be confirmed with the end customer before installation. When installing a parking heater, we recommend the use of the next larger vehicle battery. Foreword This installation document applies to the Mercedes Benz GLK 00 / 0 / 50 CDI (X04) vehicles - for validity, see page - from model year 009 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. However, where this is the case, the stipulations of this "installation documentation", the "operating instructions" and the "installation instructions" of the Thermo Top Evo should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. General instructions 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. 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 00K, Order No. 9). While installing an IPCU, the corresponding settings are to be checked or adjusted before the installation. Special tools - Torque wrench for.0-0 Nm - Hose clamping pliers 668F_EN

4 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Explanatory notes on 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. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. Reference to these, the general installation instructions of the Webasto operating elements and to vehicle-specific documents of the manufacturer Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of 5x heater bolts = 8Nm! Tightening torque of 5x5 bolt of water connection piece retaining plate = 7Nm! 668F_EN 4

5 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Preliminary work WARNING! - Open the fuel tank cap, ventilate the tank. - Close the fuel tank cap again. - Depressurise the cooling system. - Copy the factory number from the original type label to the duplicate type label. - Remove years that do not apply from the duplicate label. - Attach the duplicate label (type label) in the appropriate place. - Remove the battery with the carrier fully. - Remove the battery cover in the engine compartment on the right. - Remove the trim of the passenger compartment fan air inlet. - Remove the lower engine cover. - Drain off the engine coolant according to the manufacturer instructions. - Remove the lower left vehicle trim. - Detach the wheel well trim of the left front wheel. - Remove the seat bench of the rear bench seat. - Open the tank-fitting service lid on the right and on the left. - Detach the fuel-tank sending unit on the right as described in the manufacturer's instructions. - Remove the A/C control panel. - Lift the shift lever cover. - Remove the ashtray or storage compartment with the socket outlet below 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 lower left instrument panel trim. - Remove the front right floor trim. - Loosen the right footrest. Heater installation location Heater (hidden) Installation location 668F_EN 5

6 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Preparing electrical system Detach 6mm dia. cable lug. Preparing wiring harness of fan control IPCU view on contact side. The pre-programmed settings of both function controls in the vehicle are to be checked and adjusted if necessary. A E IPCU E A Duty cycle: 56-6% Frequency: 400Hz Voltage:.0V Function: High-side IPCU view X Discard section X. a b 0 mm dia. corrugated tube a = mm dia. corrugated tube b = 0 Cutting corrugated tube to length Slit 0mm dia. 500mm long corrugated tube longitudinally and slide on wiring harness of heater. Preparing wiring harness of heater 668F_EN 6

7 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Electrical system Earth wire Connect earth wire to the original vehicle earth support point with 6mm dia. cable lug. Wiring harness pass through of passenger compartment Drilling of 6mm dia. hole at centre of protective rubber plug. Wiring harness of passenger compartment fuse holder 4 5 For routing wiring harness of heater and wiring harness of metering pump, see following page Do not route wiring harness of metering pump until later together with fuel line on underbody Wiring harness routing installation diagram Fuse holder of engine compartment Replace F with A fuse. 5mm dia. hole, M5x6 bolt, washers, retaining plate of fuse holder, washer, nut F+ fuses mounted 6 Positive wire Manufacturer installs different positive support points. Connect power supply of heater to positive terminal (battery or starter cable of positive support point) F_EN 7

8 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) 5 8mm hole at position in plastic trim 5. Slit open plastic trim 5 at position 4 from bottom up to 8mm dia. hole. Cut out protective rubber plug up to centre at position. Route wiring harness of heater and wiring harness of metering pump through 8mm hole in the engine compartment. Insert protective rubber plug in plastic trim 5. Routing wiring harness of heater 4 8 Detach retaining clip [x]. Route wiring harness of heater and wiring harness of metering pump behind the insulation protection mat on left vehicle side and further to the underbody. Routing wiring harness of heater 9 Route wiring harness of heater and wiring harness of metering pump to underbody. Degrease adhesive surface for adhesive base. Paste adhesive base at position. Fasten wiring harness of heater in corrugated tube with cable tie at position. Routing wiring harness of heater 0 668F_EN 8

9 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Fan control Webasto HG X 5 X F Mercedes 0 5 Wiring diagram F F rt 0,5² rt/ge rt/ge ws GE M 7 rt 4² rt/sw 0,5² br 8 0,5² ge 0,5² gn/ws 0,75² 6 A sw 0,5² ws Kl. 4 X0 5 St 4 4 KB sw St 4 br a K 4 A IPCU bl 4² bl 4² rt rt LIN-Bus 9 rt br a K B M M M M br br 0,5² Webasto components Vehicle components Colours and symbols HG TT-Evo heater GE Fan unit rt red X 6-pin heater connector KB A/C control panel ws white X -pin heater connector A Socket outlet/lighter sw black X0 4-pin connector B Flap positioning module bl blue Heater control F fuse ge yellow K Fan relay ST 4 Connector, 4-pin, KB br brown K Additional relay gn green F Fuse, 0A F 0A fuse replaced with A. IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 56% Frequency: 400Hz Voltage:.0V X Cutting point Function: High-side Wiring colours may vary. Legend 668F_EN 9

10 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Prepare wiring harness of engine compartment fuse holder in the passenger compartment. Connect red (rt) 4² wire and red/black (rt/sw) 0.5² wire soldering connector. Produce connections as shown in wiring diagram. Preparing wiring harness of engine compartment fuse holder Route wiring harness of engine compartment fuse holder 5 in the footwell on the front passenger side, and secure with cable tie. Produce connections as shown in wiring diagram. original vehicle stud bolt, original vehicle earth wires Angle bracket M5x6 bolt, washer, flanged nut 4 IPCU socket 6 Relay socket relay socket and IPCU socket Install green/white (gn/ws) wire in the IPCU/86 socket. Produce connections as shown in wiring diagram. Brown (br) wire of wiring harness of engine compartment fuse holder Brown (br) wire of fan control wiring harness Connecting wiring harnesses Route wiring harness of fan control to centre console and secure with cable tie. K and K relay mounted IPCU mounted relay [x] and IPCU 4 668F_EN 0

11 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Connection to 4-pin connector 4 from A/C control panel. Produce connections as shown in wiring diagram. White (ws) wire of fan unit Black (sw) wire K/0 White (ws) wire of 4-pin KB connector Connecting A/C control panel 4 5 Connection to 4-pin connector from A/C control panel. Produce connections as shown in wiring diagram. 5 Blue (bl) wire K/0 Red (rt) wire of flap positioning module 4 Red (rt) wire of 4-pin KB connector 5 Blue (bl) wire K/87 Connecting A/C control panel 4 6 Connection to plug-in connector of socket outlet/lighter. Produce connections as shown in wiring diagram. 4 Red (rt) wire K/86 Pink/yellow (ro/ge) wire 4 Pink/yellow (ro/ge) wire Connection to socket outlet/lighter 7 668F_EN

12 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Mount 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 installation is done according to Figure 4. Removing cover Cover 8 Mount union nut of push button, align in centre and drill 6mm dia. hole in the cover (stepped drill bit). Hole in cover 9 Install push button, align and secure it with union nut. push button 0 When drilling, watch components located behind. mm dia. hole Hole for wiring harness 668F_EN

13 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Cover cover Alternative installation location Only in connection with Telestart. Use wiring harness extension. 6mm dia. hole, push button push button Telestart Receiver, adhesive tape receiver 4 Antenna antenna 5 668F_EN

14 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Preparing installation location Remove threaded insert and discard. Detaching bracket 6 Insert M6x0 bolt and large diameter washer d a = 7.4mm from wheel trim side in existing hole and secure with pin lock. Detach original vehicle bolt Inserting bolt 7 WARNING! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. When opening the clamps and pulling out the fuel supply line, collect the leaking fuel in a suitable container. Remove original vehicle fuel supply line, slide on 8 mm dia. rubber isolator and remount opposite. rubber isolator 8 0 WARNING! When opening the clamps and pulling out the fuel return line, collect the discharged fuel in a suitable container. Remove original vehicle fuel return line. Discard section Slide on 5mm dia. black (sw) rubber isolator rubber isolator 9 668F_EN 4

15 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Position black (sw) rubber isolator fuel return line 0 Remove original vehicle nut at position, will be reused. Mount strut and earth wire loosely Original vehicle stud bolt, original vehicle nut Reinstall original vehicle fuel return line opposite. Premounting strut Preparing heater Discard section X. a Combustion air pipe a = 50 Cutting combustion air pipe to length X Bracket Silencer 5 mm dia. clamp 4 M5x6 bolt, flanged nut 5 M6x bolt, pin lock silencer F_EN 5

16 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Water connection pieces, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water connection pieces water connection pieces 5x self-tapping bolt [x] heater 4 Combustion air pipe mm dia. spring clip combustion air pipe X 5 Discard section X. a b 6x protective hose a = 00 6x protective hose b = 0 Cutting fabric protective hose to length 668F_EN 6

17 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Slide on 6x, 0mm long fabric protective hose on to fuel line. 90 moulded hose, 0 mm dia. clamp [x] Premounting fuel line 6 Discard section X. Exhaust pipe a = 80 Exhaust end section b = 0 Preparing exhaust pipe a b X Replace bolt at position with M6x40 bolt. Hose clamp Preparing hose clamp 7 Silencer Hose clamp Shape exhaust pipe Premounting exhaust system 8 668F_EN 7

18 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Angle bracket Flanged nut angle bracket 9 5 Silencer M6x6 bolt, spring lockwasher Twist protection 4 Hose clamp [x] 5 Shape exhaust end section exhaust system F_EN 8

19 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Coolant circuit WARNING! Drain off the coolant and collect it in a suitable 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 C A Ø 7 Ø 8x8 B All spring clips without a specific designation = 5 mm dia. = Black (sw) rubber isolator. Non-designated connecting pipe = 8x0 dia. 668F_EN 9

20 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) C D X Discard section X. Hose A = 8x0mm moulded hose Hose B = 90, 8mm dia. moulded hose Hose C/D = 8mm dia. hose 5 B = 95 C = 890 D = 50 Cutting hoses to length X X B A D Slide on braided protective hose on hoses B, C and D. Cut heat shrink plastic tubing into 6 equal pieces, slide on and shrink. C Preparing hoses B A Slide black (sw) rubber isolator onto hose B. Mark the direction of flow on hoses C and D. C B Preparing hoses D 4 Drain off coolant. Cut the original vehicle hose on engine outlet / heat exchanger inlet at the marking. Remove hose section of engine outlet and spring clip and discard. Cutting point 4 668F_EN 0

21 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Remove strut Removing strut 4 Perforated bracket Angling down perforated bracket Cable tie Perforated bracket 50mm edge protection Preparing perforated bracket 44 M6x40 bolt, flanged nut 0 mm shim Perforated bracket 4 Original vehicle bolt perforated bracket F_EN

22 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Perforated bracket M6x0 bolt, pin lock Preparing perforated bracket 46 Perforated bracket Original vehicle stud bolt, plastic nut 00mm edge protection perforated bracket 47 Perforated bracket 75 Angling down perforated bracket 90 Circulating pump of circulating pump M6x5 bolt, flanged nut 4 Perforated bracket Premounting circulating pump F_EN

23 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Circulating pump Original vehicle bolt circulating pump A 49 Mount hose A with the shortened end on the connection piece of the engine outlet. Connecting engine outlet 50 B A hose B 5 Route hose C to the connecting point. C hose C 5 668F_EN

24 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Hose of heat exchanger inlet Close cable tie D Connecting heat exchanger inlet 5 4 D Fasten hose D with cable tie to black (sw) rubber isolator 4. Attach wiring harness of circulating pump. Route hose C, D and wiring harness of circulating pump through 8 mm dia. rubber-coated p-clamp. Routing in engine compartment B 54 D Flanged nut 8 mm dia. rubber-coated p-clamp C Routing in engine compartment 55 D 4 80 Route hose C and D so that 80mm is available for connection with the heater. Route hose C, D and wiring harness of circulating pump through 8mm dia. rubberised p- clamp 4. Cable tie Original vehicle stud bolt, plastic nut Routing in engine compartment C F_EN 4

25 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) heater Wiring harness of circulating pump Wiring harness of heater [x] Attaching wiring harness to heater 57 Mount M6x0 bolt, flanged nut, existing hole loosely Mount flanged nut loosely Loosely mounting heater D 58 Observe direction of flow. Connect hose D to heater outlet and hose C to heater inlet. Connecting heater C 59 Original vehicle nut Angle bracket heater F_EN 5

26 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Tighten original vehicle nut at premounted strut to 5Nm! Strut Flanged nut Fastening strut 6 Tighten screw joints at position and heater 6 668F_EN 6

27 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) 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. 4 Complete connector of metering pump after routing. Pin assignment is not relevant. 5 5 Connector housing Lock Blue/brown (bl/br) wires 4 Coding 5 Timer lock Dismantling connector 6 Slide on 0mm dia., 0mm long corrugated tube onto fuel line. Grease adhesive surfaces Adhesive base, cable tie [x each] 4 Metering pump wiring harness Routing lines 4 64 Insert retaining clips [6x] Fuel line Metering pump wiring harness Routing lines F_EN 7

28 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) X Discard section X. 0 mm dia. corrugated tube c = 800 c Cutting corrugated tube to length 4 Slide on 8x fabric protective hose [x] on fuel line and wiring harness of metering pump. Slide on 0mm dia., 800mm long corrugated tube 4 onto fuel line and wiring harness of metering pump. Cable tie Routing lines 66 Route fuel line and wiring harness of metering pump in corrugated tube to the installation location of the metering pump. Routing lines 67 Angle down perforated bracket and drill hole at position to mm dia. 75 Preparing perforated bracket F_EN 8

29 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) 5 M6x5 bolt, flanged nut Perforated bracket Metering pump 4 of metering pump 5 Cable tie Premounting metering pump 4 68 Mount perforated bracket on original vehicle bolt of fuel tank fastening. Fuel line of heater, hose section, 0mm dia. clamp [x] Original vehicle flanged nut Wiring harness of metering pump, connector mounted metering pump 69 Remove fuel-tank sending unit on right according to manufacturer's instructions. Watch drilling chips while drilling. 6 mm dia. hole Fuel extraction 70 Insert fuel standpipe into fuel-tank sending unit. Fuel extraction 7 668F_EN 9

30 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Observe tightening torque 5 Nm of flanged nut on fuel standpipe. Fuel-tank sending unit Fuel extraction 7 Cut standpipe at an angle. 55 Discard section Cutting standpipe to size Mount.5 mm dia. moulded hose 4 on fuel standpipe 6. Fuel-tank sending unit Standpipe 0 mm dia. clamp 5 8 mm dia. clamp standpipe 74 7 Install right fuel-tank sending unit in accordance with manufacturer's instructions. Mount.5mm dia. hose section 6 on fuel standpipe 4. Slide on 6x, 00mm long fabric protective hose on to fuel line. 7 0 mm dia. clamp 5 8 mm dia. clamp fuel line F_EN 0

31 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Route fuel line with fabric protective hose to left of fuel-tank sending unit. Routing fuel line 76 Route fuel line with fabric protective hose to installation location of metering pump. Routing fuel line 77 Hose section, 0mm dia. clamp [x] Fuel line fuel standpipe Connecting metering pump F_EN

32 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Underride protection Cut out heat protection film along the hatched lines and fold upward and downward. Remove the chamber profiles in the area of the marking (hatching). Processing underride protection mm dia. hole Hole in underride protection 80 Remove heat protection film and fix with suitable temperature-resistant adhesive. Processing underride protection 8 Copy 60mm hole pattern at position on heat protection film and cut out. Processing underride protection 8 668F_EN

33 Mercedes Benz GLK 00 / 0 / 50 CDI (X04) Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Teach Telestart according to "Installation instructions T9 / T00 HTM", adjust digital timer if necessary - Activate push button according to "Installation instructions T9 / T00 HTM" ( Repositioning of switch input) - Define settings of A/C control panel according to the "operating and maintenance instructions of TT-Evo" - Mount signboard "Switch off parking heater before refueling" in area of filler neck. - For initial startup and function check, please see installation instructions WARNING: After conducting an operating test of the parking heater, carry out an "input short test" with the "Diagnosis assistance system" of the manufacturer on the vehicle. Reprogram the positioning motors in the KLA air conditioner. Large diameter washer d a =.5mm; flanged nut Underride protection Installing underride protection 8 Align exhaust end section at the centre of the hole and justified to the underride protection. Aligning exhaust end section 84 Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: technikcenter@webasto.com 668F_EN Printed in Germany 06/0 Printing: Steffen