Webasto Thermo Top EVO Installation guide

Brand: Webasto

Model: Thermo Top EVO

Type: Installation guide

Webasto Thermo Top EVO is a powerful and versatile parking heater that provides cozy warmth in your vehicle, even on the coldest days. It's programmable, so you can set it to turn on automatically before you need to leave, ensuring a comfortable start to your journey. It also features low fuel consumption and quiet operation, making it an ideal choice for those seeking both comfort and efficiency.

Feel the drive

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 heat-

er 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 tech-

nical 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 installa-

tion by untrained staff.

Water Heater

Installation documentation

Ident. No.: 1317554A_EN Fee Euro 10.00 © Webasto AG

Kia Picanto

Petrol

from model year 2011

Left-hand drive vehicle

Manual transmission

Automatic air-conditioning

Thermo Top Evo Parking Heater

00 0258

Kia Picanto

1317554A_EN 2

Table of Contents

Validity

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.

The installation location of the digital timer is to be coordinated with the end customer before installa-

tion.

Manufacturer Model Type EG-BE No. / ABE

Kia Picanto IM e4 * 2007 / 46 * 0256 * ...

Engine type Engine model Output in kW Displacement in cm³

WJO Petrol 51 998

Validity 2

Heater/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory notes on document 4

Preliminary work 5

Heater installation location 5

Preparing electrical system 6

Electrical system 8

Fan control 9

Remote option (Telestart) 12

Preparing installation location 13

Preparing heater 14

Installing heater 15

Coolant circuit 17

Combustion air 21

Fuel 22

Exhaust gas 25

Final Work 27

Template for fuel standpipe 28

Operating Instructions for the End Customer 29

Kia Picanto

1317554A_EN 3

Heater/Installation Kit

Foreword

This installation documentation applies to Kia Picanto Petrol vehicles - for validity, see page 2 - from

model year 2011 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, the stipulations in the "installation documentation", the "operating instructions" and "installa-

tion instructions" for the Thermo Top Evo must always 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 spec-

ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses

using cable ties. Insulate loose wires 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).

While installing an IPCU, the corresponding settings must be controlled or adjusted before the instal-

lation.

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

Quantity Designation Order No.:

1 Basic delivery scope Thermo Top Evo See Price list

1 Installation kit for Kia Picanto 2011 Petrol 1317553A

1 Heater control See Price list

Kia Picanto

1317554A_EN 4

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Reference to general installation instructions of Webas-

to components or to the manufacturer's vehicle-specific

documents.

Reference to a special technical feature.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Software

All dimensions are in mm!

Tightening torque of 5x13 heater bolts = 8Nm!

Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!

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.

Kia Picanto

1317554A_EN 5

Preliminary work

WARNING!

- Open the fuel tank cap and vent the fuel tank.

- Close the fuel tank cap again.

- Disconnect the battery "earth" or "ground" connection.

-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.

- Completely remove the battery.

- Remove the air filter together with the intake hose.

- Remove the coolant reservoir cap at the left.

- Remove the fuse and relay box.

- Detach the wheel well trim on the right and left.

- Remove the bumper.

- Remove the right headlight.

- Remove the left underride protection.

- Open the right-hand tank-fitting service lid.

- Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.

- Remove the glove compartment.

- Remove the A-pillar trim in the front passenger side footwell.

Remove page 29 "Operating Instructions for the End Customer" and insert in the vehicle operating in-

structions.

Heater installation location

1Heater

Installa-

tion loca-

tion

Kia Picanto

1317554A_EN 6

Preparing electrical system

Wire sections retain their numbering in the

entire document.

Preparing

lines

Connect wires to socket IPCU.

IPCU view on contact side.

The IPCU attached in the kit is pre-pro-

grammed with the following settings:

Duty cycle: 100%

Frequency: 14 kHz

Voltage: 3.6V

Function: High-side

The settings must be checked during the

function check on the vehicle and adjusted if

necessary.

Premount-

ing IPCU

1Angle bracket

2Discard section

Cutting off

angle

bracket

Produce connections as shown in wiring dia-

gram. Connect fan wiring harness to the K1

relay socket. Install F4 25 A fuse and K1 re-

lay.

Preparing

K1 relay

and F4

500

0,5²

500

0,5²

500

0,5²

1000

gn/ws

0,5²

86 85

IPCU

86 85

85 30

87a87

gn/ws

0,75²

0,5²

4²

rt/sw

0,5²

2sw

4²

Kia Picanto

1317554A_EN 7

Insert K1 relay 1 after the installation.

2Angle bracket

3M5x16 bolt, large diameter washer [2x],

nut

4Passenger compartment fuse holder Premount-

ing pas-

senger

compart-

ment fuse

holder

Complete connector of metering pump again

after routing. Pin assignment is not relevant.

1Connector housing

2Lock

3Blue/brown (bl / br) wires

4Coding

5Timer lock

Disman-

tling con-

nector

1 43

Kia Picanto

1317554A_EN 8

Electrical system

Wiring harness pass through, earth wire

1Protective rubber plug

2Earth wire on original vehicle earth support

point

Digital timer

1Digital timer

Wiring har-

ness rout-

ing

diagram

Positive wire

1Positive wire on positive battery terminal

Fuse holder for engine compartment

1Original vehicle bolt

2Angle bracket

3M5x16 bolt, washer [2x], retaining plate for

fuse holder, nut

4F1-2 fuses

1 2

Do not install the metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

Kia Picanto

1317554A_EN 9

Fan control

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-Evo GR Fan controller rt red

X1 6-pin heater connector D 4-pin connector GR sw black

X2 2-pin heater connector KB A/C control panel ge yellow

X10 4-pin connector of

heater control A 26-pin connector KB gn green

B 22-pin connector KB or orange

K1 Fan relay GM Fan motor ws white

F1 Fuse, 20A C 2-pin connector GM br brown

F2 Fuse, 30A IGN1 Fuse bl blue

F3 Fuse, 1A IGN2 Fuse

F4 Fuse, 25A Fa Fuse

IPCU Pulse width modulator Fb Fuse

IPCU settings:

Duty cycle: 100%

Frequency: 14 kHz

Voltage: 3.6V XCutting point

Function: High-side Wiring colours may vary.

Webasto

Kia

X2 1 2 X1

F2 F1

gn/ws

0,75²

0,5²

rt/sw

0,5²

4²

X10

85 30

87a87

gn/ws

0,75²

4²

rt/sw

0,5²

85 86

IPCU

0,5²

4²

gn/ws

0,5²

4²

IGN

FaFb

Kia Picanto

1317554A_EN 10

Route wiring harness of heater and fuel line in

17 mm dia. corrugated tube 1 to original vehi-

cle wiring harness on the right hand side of

vehicle.

Routing

wiring har-

ness

1 Wiring harness on heater

2Fuel line

317 mm dia. corrugated tube

Routing

wiring har-

ness

Detach original vehicle bolts 1. Insert angle

bracket 2 of fuse holder between bolts 1 and

instrument panel mounting. Tighten original

vehicle bolts 1 again.

Mounting

passenger

compart-

ment fuse

holder

Connect-

ing wiring

harnesses

Kia Picanto

1317554A_EN 11

Drill hole at position 1 to 6.5 mm dia.

1M6x12 bolt, flanged nut

2IPCU socket

Mounting

IPCU sock-

1IPCU

Connect-

ing IPCU

1Original vehicle bolt

Brown (br) wire of IPCU/85

IPCU earth

connection

Connection to 4-pin connector 1 from fan

controller. Produce connections as shown in

wiring diagram.

2Orange (or) wire GR connector

3Orange (or) wire of A/C control unit

Red (rt) wire of IPCU/E

Black (sw) wire of IPCU/A

Fan con-

troller con-

nection

Kia Picanto

1317554A_EN 12

Connection to 2-pin connector 1 from fan mo-

tor. Produce connections as shown in wiring

diagram.

2Blue (bl) wire from GM connector

3Blue (bl) wire from fuse

Red (rt) wire from K1/87a

Black (sw) wire from K1/30

Green/white (gn/ws) wire from IPCU/86

Connect-

ing the fan

motor

Remote option (Telestart)

Drill out bracket 2 at position 3 to 6.5 mm dia.

1Receiver

3Original vehicle stud bolt, original vehicle

flanged nut Mounting

receiver

1Antenna

Mounting

antenna

Temperature sensor T100 HTM

Fasten temperature sensor 1 with adhesive

tape.

Mounting

tempera-

ture sensor

318

1317554A_EN 13

Kia Picanto

Preparing installation location

1Remove original vehicle bolt (will be re-

used here)

2Drill hole to 9.1 mm dia.; rivet nut Installing

rivet nut

1Perforated bracket a

Angling

down per-

forated

bracket

1Perforated bracket b

Preparing

perforated

bracket

1Loosely mount perforated bracket a

2M6x12 bolt, flanged nut [2x each]

3Loosely mount perforated bracket b

4Bracket section A

57 mm dia. hole Premount-

ing bracket

48 38

45°

47°

45°

47°

27.5

1317554A_EN 14

Kia Picanto

1Original vehicle bolt

2Perforated bracket a

3M6x40 bolt, spring lockwasher, 20 mm

shim, original vehicle threaded hole

4Bracket section A

5M6x20 bolt, spring lockwasher, perforat-

ed bracket bMounting

bracket A

Preparing heater

1Water connection pieces, sealing ring [2x

each]

25x15 self-tapping bolt, retaining plate of

water connection pieces Mounting

water con-

nection

pieces

Discard section X

Hose B =180°, 18 mm dia. moulded hose

Hose G = 90°, 18 mm dia. moulded hose

A=430

C=75

D=85

E=60

F=360

Cutting

hoses to

length

All spring clips = 25 mm dia.

All connecting pipes = 90°, 18x18 mm dia.

Premount-

ing hoses

AFX

C D E

1317554A_EN 15

Kia Picanto

All spring clips = 25 mm dia.

Connecting pipe = 90°, 18x18mm dia.

Premount-

ing hoses

15x13 self-tapping bolt [3x]

2Bracket section B

Mounting

bracket B

125 mm dia. clamp

2Mount wiring harness of circulating pump

3Combustion air pipe

490° moulded hose, 10 mm dia. clamp

Premount-

ing heater

Installing heater

Suspend section B of bracket from heater in

bracket section A

15x13 self-tapping bolt [2x] Mounting

heater

1 1

1317554A_EN 16

Kia Picanto

1Bracket

27 mm dia. hole

M6x20 bolt, spring lockwasher, flanged nut

4M6x20 bolt, large diameter washer

55x13 self-tapping bolt Mounting

heater

110 mm dia. clamp

2Fuel line

Connect-

ing fuel

line

Kia Picanto

1317554A_EN 17

Coolant circuit

WARNING!

Any coolant running off should be collected 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. The heater must be filled with coolant when installing the hoses.

The connection should be "inline" based on the following diagram:

Hose in-

stallation

diagram

All spring clips without a specific designation = 25 mm dia.

All connecting pipes and = 18x18 mm dia.

Ø 27

Kia Picanto

1317554A_EN 18

1Perforated bracket

Angling

down per-

forated

bracket

All spring clips = 25 mm dia.

Connecting pipe = 90°, 18x18mm dia.

1Perforated bracket

2M6x25 bolt, flanged nut

3Circulating pump

4Mounting of circulating pump Premount-

ing circu-

lating

pump

All spring clips = 25 mm dia.

Connecting pipe = 18x18mm dia.

Premount-

ing circu-

lating

pump

Separate hose of engine outlet / heat ex-

changer inlet at the marking. Remove and dis-

card hose section of heat exchanger inlet

and spring clip

1Hose on heat exchanger outlet removed

3Engine outlet hose section Cutting

point

90°

1 2

Kia Picanto

1317554A_EN 19

Cutting out insulation mat at the marking.

1Original vehicle stud bolt, 5 mm shim

Mounting

shim

Cutting out insulation mat at the marking.

1Original vehicle stud bolt, 5 mm shim

Mounting

shim

Connect-

ing heat

exchanger

inlet

1Perforated bracket

2Mount wiring harness of circulating pump

3M6 Flanged nut, original vehicle stud bolt

Mounting

circulating

pump

Kia Picanto

1317554A_EN 20

Connect-

ing heater

inlet

1Hose of engine outlet

Connect-

ing engine

outlet

Ensure sufficient distance from neighbouring

components.

125 mm dia. rubber coated p-clamp, flang-

ed nut of original vehicle stud bolt

2Mount hose on heat exchanger outlet Aligning

hoses

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Webasto Thermo Top EVO Installation guide

Webasto Thermo Top EVO Installation guide

Webasto Thermo Top EVO Installation guide

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