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Retrofit stationary heater - AZ83.70-P-0008MCC

MODEL 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 

except CODE 494 (US version) 

except CODE P02 (car2go) 

Shown on MODEL 451.4 

Fig 1: Identifying Digital Timer - Shown On Model 451.4
G10979279Courtesy of MERCEDES-BENZ USA
Fig 2: Identifying Heater Unit And Fuel Metering Pump
G10979280Courtesy of MERCEDES-BENZ USA

Shown on MODEL 451.4 with ENGINE 132.9 

Fig 3: Identifying Air Duct Segment, Fuel Tank And Fuel Pump With Fuel Level Sensor - Shown On Model 451.4 With Engine 132.9
G10979281DANGERDANGERDANGERNOTESIMPORTANTREMOVINGREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRINSTALLINGSPECIAL TOOLSPECIAL TOOLSPECIAL TOOLIMPORTANTSPECIAL TOOLREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRNOTESREMOVINGREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRINSTALLINGTORQUE SPECIFICATIONSPECIAL TOOLREFER TO TESTING & REPAIRIMPORTANTIMPORTANTSPECIAL TOOLTORQUE SPECIFICATIONTORQUE SPECIFICATIONSPECIAL TOOLREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRSPECIAL TOOLSPECIAL TOOLREFER TO TESTING & REPAIRREFER TO TESTING & REPAIRIMPORTANTDANGERNOTESREFER TO TESTING & REPAIRREFER TO SELF-DIAGNOSTIC SYSTEMSREFER TO TESTING & REPAIRDANGERREFER TO MAINTENANCEREFER TO TESTING & REPAIRCourtesy of MERCEDES-BENZ USA
DANGER Risk of death  caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. AS00.00-Z-0010-01A
DANGER Risk of injury  to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning  from swallowing coolant. Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.		 AS20.00-Z-0001-01A
DANGER Risk of explosion  caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.		 AS47.00-Z-0001-01A
NOTES Notes on coolant   AH20.00-N-2080-01A
IMPORTANT Notes on stripping   AH00.19-P-1000-12SM
REMOVING Remove     
1 Disconnect ground line to battery    
REFER TO TESTING & REPAIR     AR54.10-P-0003MCC
2 Remove vertical strut paneling    
REFER TO TESTING & REPAIR     AR68.00-P-1500MCC
3 Remove front roof frame paneling    
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)		 AR68.30-P-4450MCC
REFER TO TESTING & REPAIR   Model 451.4## (except 451.401/480/490/491) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)		 AR68.30-P-4450MCO
4 Remove right paneling from A-pillar    
REFER TO TESTING & REPAIR     AR68.30-P-4050MCC
INSTALLING Install     
5 Prepare stationary heater wiring harness for installation   AZ83.70-P-0008-06MCC
    SPECIAL TOOL Wiring harness repair kit Fig 6
6 Install stationary heater wiring harness   AZ83.70-P-5302-01MCC
    SPECIAL TOOL Hot air blower Fig 5
    SPECIAL TOOL Wiring harness repair kit Fig 6
7 Install digital timer (1) IMPORTANT Before installing the digital timer (1), agree on the installation location with the customer. AZ83.70-P-0002-05MCC
    SPECIAL TOOL Twist drill bit set Fig 4
8 Install front roof frame paneling    
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)		 AR68.30-P-4450MCC
REFER TO TESTING & REPAIR   Model 451.4## (except 451.401/480/490/491) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)
NOTES
Make sure that the digital timer branch-off line (1) is not damaged by kinking, crushing or chafing during installation.
Otherwise failure of the stationary heater may occur.		 AR68.30-P-4450MCO
REMOVING Remove     
9 Remove engine compartment cover    
REFER TO TESTING & REPAIR     AR88.40-P-1100-03MCC
10 Drain coolant    
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)		 AR20.00-P-1142MCC
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 660.9
except code 494 (US version)
except code P02 (car2go)		 AR20.00-P-1142MCD
11 Remove diagonal struts    
REFER TO TESTING & REPAIR   Model 451.4## (except 451.401/480/490/491) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)		 AR61.10-P-5138MCC
12 Remove air duct segment (4)    
13.1 Remove fuel pump with fuel level sensor (M3/3) Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)		  
REFER TO TESTING & REPAIR     AR47.20-P-7000MCC
13.2 Remove right fender liner in rear fender Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 660.9
except code 494 (US version)
except code P02 (car2go)		  
REFER TO TESTING & REPAIR     AR88.10-P-1400MCC
INSTALLING Install     
14 Install fuel tank remover Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)		 AZ83.70-P-0020-02MCC
    TORQUE SPECIFICATION Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)Nut, tank remover to fuel pump with fuel level sensor		 *BA83.70-P-1001-01G 
    SPECIAL TOOL Twist drill bit set Fig 4
15 Install fuel pump with fuel level sensor (M3/3) in fuel tank (5) and screw fuel tank (5) to vehicle floor    
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)
IMPORTANT During installation, fuel line of stationary heater must be routed from tank bleeder to activated charcoal canister and fastened to existing fuel line using a cable tie.
Do not screw in bolts of fuel tank (5) in marked areas (arrow).
IMPORTANT Model 451.4## (except 451.401/480/490/491) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)
The diagonal struts and the bulkhead are installed later.		 AR47.20-P-7000MCC
16 Drill mounting holes on vehicle floor   AZ83.70-P-0008-07MCC
    SPECIAL TOOL Twist drill bit set Fig 4
17 Lower vehicle with vehicle lift Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 660.9
except code 494 (US version)
except code P02 (car2go)		  
18 Install fuel line Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 660.9
except code 494 (US version)
except code P02 (car2go)		 AZ83.70-P-0008-01MCC
19 Install fuel metering pump (3)   AZ83.70-P-0011-03MCC
    TORQUE SPECIFICATION Bolt, fuel tank to body *BA47.10-P-1001-01F 
20 Lower vehicle with vehicle lift    
21 Install relay holder of stationary heater in vicinity of battery box   AZ83.70-P-0008-08MCC
22 Install heater (2)   AZ83.70-P-0002-02MCC
    TORQUE SPECIFICATION Bolt, fuel tank to body *BA47.10-P-1001-01F 
23 Connect heater (2) to fuel system   AZ83.70-P-0001-06MCC
24 Connect fuel metering pump (3)   AZ83.70-P-0011-01MCC
    SPECIAL TOOL Wiring harness repair kit Fig 6
25 Install coolant lines   AZ83.70-P-0008-03MCC
26 Prepare and install air intake pipe for combustion air   AZ83.70-P-6256-01MCC
27 Install bulkhead in rear    
REFER TO TESTING & REPAIR   Model 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)		 AR61.25-P-6600MCC
28 Install diagonal struts    
REFER TO TESTING & REPAIR   Model 451.4## (except 451.401/480/490/491) 1# up to 8/30/10
except code 494 (US version)
except code P02 (car2go)		 AR61.10-P-5138MCC
29 Attach cutout to air duct segment (4)   AZ83.70-P-0008-10MCC
30 Install air duct segment (4)    
31 Make opening for exhaust pipe in underfloor paneling   AZ83.70-P-0008-09MCC
    SPECIAL TOOL Graduated drill Fig 7
32 Install circulation pump wiring harness   AZ83.70-P-0001-17MCC
    Adhesive parts kit (with isopropanol cleaner) *BR00.45-Z-1141-02A 
    SPECIAL TOOL Hot air blower Fig 5
33 Lower vehicle with vehicle lift    
34 Pour in coolant    
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)		 AR20.00-P-1142MCC
REFER TO TESTING & REPAIR   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 660.9
except code 494 (US version)
except code P02 (car2go)
IMPORTANT The underfloor paneling will be installed at a later point in time.		 AR20.00-P-1142MCD
35 Fill in fuel Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9
except code 494 (US version)
except code P02 (car2go)		  
DANGER Risk of explosion  from explosive gas. Risk of poisoning and caustic burns  from swallowing battery electrolyte. Risk of injury  through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A
36 Start up stationary heater   AZ83.70-P-0008-04MCC
NOTES Notes on battery   AH54.10-P-0001-01A
37 Install foot support at front passenger side    
REFER TO TESTING & REPAIR     AR68.30-P-1340MCC
38 Read out fault memory with diagnostic system    
REFER TO SELF-DIAGNOSTIC SYSTEMS     AD00.00-P-2000-04MCC
39 Retrofit stationary heater duplicate plate   AZ83.70-P-0008-05MCC
40 Install vertical strut paneling    
REFER TO TESTING & REPAIR     AR68.00-P-1500MCC
DANGER Risk of accident  from vehicle starting off by itself when engine running. Risk of injury  (bruises and burns) resulting from working on the engine while it is being started or when it is running. Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A
41 Carry out an engine test run    
42 Check fuel system and coolant circuit for leaks    
43 Check coolant level    
REFER TO MAINTENANCE   Model 451.3## (except 451.301/334/380/390/391) 1# up to 8/30/10, 451.4## (except 451.401/480/490/491) 1# up to 8/30/10 with engine 132.9, 660.9
except code 494 (US version)
except code P02 (car2go)		 AP20.00-P-2010MCC
44 Raise vehicle with vehicle lift    
45 Spray heater (2) with protective wax Teroson multi-wax spray, art. no. 119.48M *BR00.45-Z-1009-05A 
46 Install underfloor paneling    
47 Lower vehicle with vehicle lift    
48 Install engine compartment cover    
REFER TO TESTING & REPAIR     AR88.40-P-1100-03MCC
49 Fill in the warranty certificate    
50 Place EU type approval into vehicle    
51 Enter CODE 11Z (Stationary heater) in online vehicle data card via vehicle documentation system (VeDoc)    
52 Attach note "Stationary heater retrofitted as per AZ83.70-P-0008MCC " under field organization texts in VeDoc to design group 83    
FUEL TANK

Number Designation Model 451.3/4
BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13
STATIONARY HEATER UNIT

Number Designation Model 451.3/4 with engine 132.9
BA83.70-P-1001-01G Nut, tank remover to fuel pump with fuel level sensor Nm 5
Fig 4: Identifying Twist Drill Bit Set (450 589 01 70 00)
G07246369Courtesy of MERCEDES-BENZ USA
Fig 5: Identifying Hot Air Blower (450 589 01 63 00)
G10979403Courtesy of MERCEDES-BENZ USA
Fig 6: Identifying Wiring Harness Repair Kit (452 589 02 99 00)
G10979320Courtesy of MERCEDES-BENZ USA
Fig 7: Identifying Graduated Drill (450 589 00 28 00)
G10979323Courtesy of MERCEDES-BENZ USA
REPAIR MATERIALS

Number Designation Order number
BR00.45-Z-1009-05A Teroson multi-wax spray, art. no. 119.48M Henkel Loctite
BR00.45-Z-1141-02A Adhesive parts kit (with isopropanol cleaner) A 451 989 00 71
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