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Thermo Top EVO

Webasto Thermo Top EVO Installation guide

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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
e1
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
1
1
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
4
500
rt
0,5²
5
500
sw
0,5²
6
500
br
0,5²
3
1000
gn/ws
0,5²
86 85
A
E
IPCU
4
5
6
A
15
86 85
E
3
2
1
2
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
1
2sw
4²
rt
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
3
3
4
21
4
1 43
5
5
2
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
5
1 2
6
1
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
7
1
8
4
2
3
1
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.
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
9
11
10
1
2
3
11
1
2
1
12
2
1
Kia Picanto
1317554A_EN 11
Drill hole at position 1 to 6.5 mm dia.
1M6x12 bolt, flanged nut
2IPCU socket
Mounting
IPCU sock-
et
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
13
1
2
14
1
15
1
6
6
16
1
4
2
35
4
5
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
17
1
3
2
21
3
1
2
3
1
318
2
1
19
1
20
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
A
21
2
1
48 38
42
45°
47°
1
45°
47°
15
22
40
28
1
22
1
4
2
3
5
2
6
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
23
3
4
1
5
2
24
1
1
2
AFX
C D E
BG
D
25
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
26
G
F
27
1 1
1
2
28
1
4
2
3
29
1
1
1317554A_EN 16
Kia Picanto
1Bracket
27 mm dia. hole
3
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
30
1
1
31
2
1
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.
E
A
B
C
D
F
G
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
4
and spring clip
2
.
1Hose on heat exchanger outlet removed
3Engine outlet hose section Cutting
point
60
84
90°
1
32
3
C
4
1 2
B
33
A
34
3
1 2
4
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
35
1
36
1
37
G
F
38
2
3
1
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
39
D
C
40
1
A
41
1
A
2
/