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Webasto Thermo Top Evo Start, Installation Documentation, Page: 1 / 37

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Webasto Thermo Top Evo Start Installation Documentation Download Page 1

Water Heater

Installation Documentation
Kia Carens

Ident. No.:  1321247A_EN

 

Status: 13.09.2013

© Webasto Thermo & Comfort SE

Validity

Manufacturer

Model

Type

EG-BE No./ABE

Kia

Carens

e4 * 2001 / 46 * 0633 * ...

Motorisation

Fuel

Transmission type Output in kW

Displacement in cm³ Engine code

1.6 GDi

Petrol

6-speed SG

99

1591

G4FD

SG = Manual transmission

From Model Year 2014
Left-hand drive vehicle

Verified equipment variants:

Manual / automatic air-conditioning system
Front fog light
LED daytime running lights
Headlight washer system

Not verified:

Xenon

Total installation time:

approx. 8.5 hours

Thermo Top Evo

 Parking Heater

E

1

00 0258

 

Summary of Contents for Thermo Top Evo Start

Page 1: ...Transmission type Output in kW Displacement in cm Engine code 1 6 GDi Petrol 6 speed SG 99 1591 G4FD SG Manual transmission From Model Year 2014 Left hand drive vehicle Verified equipment variants Ma...

Page 2: ...idity 4 Technical Information 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Preparing Electrical System 6 Electrical System 8 Fan Controller for Manual Air Condit...

Page 3: ...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 t...

Page 4: ...e vehicle do not affect installation any liability claims excluded De pending on the vehicle version and equipment modifications may be necessary during installation with respect to this installation...

Page 5: ...nderride protection of the fuel lines on the left Remove the left and middle seat of the second seat row Open the tank fitting service lid in the middle Remove the fuel tank sending unit in accordance...

Page 6: ...bolt angle bracket large diame ter washer self locking nut Red rt wire from K1 87a Black sw wire from K1 30 Premount ing passen ger compart ment relay and fuse holder Automatic air conditioning Prepar...

Page 7: ...gram Insert K1 relay and 25A fuse F4 IPCU will only be inserted after installation of relay and fuse holder Pull wires and into pro tective sleeving Preparing K1 relay IPCU and F4 All vehicles 1 Angle...

Page 8: ...diameter washer 2x re taining plate for fuse holder nut 2 Angle bracket 3 Original vehicle stud bolt flanged nut 4 Fuses F1 2 Wiring har ness rout ing diagram Positive wire 1 Positive wire on positive...

Page 9: ...w F1 20A fuse GRs Fan relay gn green F2 30A fuse M06 Fan resistor bl blue X10 4 pin connector Heater control M27 Fan motor ws white M22A Connector M22 br brown F3 1A fuse M22B Connector M22 pk pink F4...

Page 10: ...unting passenger compart ment relay and fuse holder 1 K1 relay 2 25A fuse F4 Mounting K1 and F4 1 Wiring harness on heater 2 Wiring harness of passenger compart ment relay and fuse holder Connecting s...

Page 11: ...onnector Heater control GRr Fan controller ws white M33 Connector GRr br brown F3 1A fuse M21 B Connector KB F4 25A fuse M21 A C control panel K1 Fan relay M27 Fan motor IPCU Pulse width modulator IPC...

Page 12: ...Mount IPCU Mounting IPCU 1 Wiring harness on heater 2 Wiring harness of passenger compart ment relay and fuse holder Connecting same col ourwiresof wiring har nesses Connection to 2 pin connector 1 f...

Page 13: ...SE 13 Connection to 4 pin connector 3 from fan controller Produce connections as shown in wiring diagram 1 Blue bl wire from A C control panel M21 2 Blue bl wire from connector GRr Red rt wire of IPC...

Page 14: ...digital timer Remote Option Telestart Vehicle with automatic air conditioning 1 Receiver 2 M5x16 bolt of relay and fuse holder 3 Bracket Mounting receiver Vehicle with manual air conditioning 1 Receiv...

Page 15: ...TM Figure shows vehicle with automatic air con ditioning Same procedure for manual air conditioning Fasten temperature sensor 1 with adhesive tape Installing tempera ture sensor Remote Option Thermo C...

Page 16: ...2 Withdraw brackets 1 2x from holes 3 Hose of headlight washer system Preparing installation location 1 7 mm dia hole 2x centred between the bars Holes in cross member Mount headlight washer system ho...

Page 17: ...M6x30 bolt 15 mm shim pin lock Inserting bolt Preparing Heater 1 Water connection pieces sealing ring 2x each 2 5x15 self tapping bolt retaining plate of water connection pieces Mounting water con nec...

Page 18: ...bolt Mounting perforated bracket a 1 Discard section 2 Perforated bracket b Preparing perforated bracket b 1 Perforated bracket c Preparing perforated bracket c 1 5x13 self tapping bolt 2x 2 Perforat...

Page 19: ...acket b 3 M6 flanged nut 4 M6x20 bolt flanged nut 2x each 5 Perforated bracket c Mounting heater Slit 10 mm dia corrugated tube lengthwise Route heater wiring harness 1 in 10 mm dia corrugated tube 2...

Page 20: ...ways 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 h...

Page 21: ...nderride protection of fuel lines Routing lines Route fuel line and wiring harness of meter ing pump 1 along original vehicle lines behind the underride protection to the installation lo cation of the...

Page 22: ...ump 1 Wiring harness of metering pump con nector mounted 2 Fuel line of heater 3 10 mm dia clamp Connect ing meter ing pump Remove fuel tank sending unit 1 in accord ance with manufacturer s instructi...

Page 23: ...r s instructions 1 Fuel line of fuel standpipe 2 Fuel standpipe 4 Moulded hose 10 mm dia clamp 2x Connect ing fuel line Mount fuel line of fuel standpipe 1 with 10 mm dia clamp on 180 moulded hose 2 C...

Page 24: ...mp 2 Silencer 3 Angle bracket 4 M5x16 bolt flanged nut Premount ing silencer 1 Remove horn Preparing installation location 1 Drill out existing hole to 9 1 mm dia rivet nut Installing rivet nut Reinst...

Page 25: ...Kia Carens Ident No 1321247A_EN Status 13 09 2013 Webasto Thermo Comfort SE 25 1 Combustion air pipe Installing combus tion air pipe 54 1...

Page 26: ...xhaust pipe a 360 2 Exhaust end section b 110 Preparing exhaust pipe 1 7 mm dia hole Hole for ex haust end section 1 Original angle bracket 2 Adapted angle bracket Preparing angle bracket 1 Silencer 2...

Page 27: ...hole Installing silencer Slide exhaust gas insulation 1 330 mm long on exhaust pipe 2 Hose clamp 2x Mounting exhaust pipe 1 Hose clamp 2 Exhaust end section 3 M6x20 bolt pipe clamp flanged nut 4 M6x20...

Page 28: ...asten 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 dia...

Page 29: ...tic tubing to length 1 Heat shrink plastic tubing 50 mm length 4x 2 Heat shrink plastic tubing 100 mm Preparing hoses Detach original vehicle spring clip 3 and push back Pull original vehicle hose 2 o...

Page 30: ...ting pump Connec tion of heater inlet 1 Slide black sw rubber isolator onto hose G 2 Hose bracket between hose E and F Connec tion of heat er outlet Align black sw rubber isolator 3 with gear shift ca...

Page 31: ...1 Routing in engine compart ment 6 5 mm dia hole in cross member at pos 1 1 M6x25 bolt with screw lock Preparing installation location Remove original vehicle bolt 1 and discard Routing in engine comp...

Page 32: ...ket 2 1 Engine outlet connection piece Connect ing engine outlet Route hose B to installation location of circu lating pump 1 M6x35 bolt 38 mm dia rubber coated p clamp 20 mm shim original vehicle thr...

Page 33: ...A_EN Status 13 09 2013 Webasto Thermo Comfort SE 33 Align hoses Ensure sufficient distance from neighbouring components correct if neces sary 1 Hose bracket between hose B and A C line Connec tion of...

Page 34: ...n wax Tectyl 100K Order No 111329 Connect the battery Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications Set the digital timer teach telestart transmitter Make s...

Page 35: ...o Thermo Comfort SE 35 Template for Fuel Standpipe 0 100mm 100mm Scale 1 1 Compare the size of the printed version with dimension lines Permitted tolerance a maximum of 2 Set the printer settings to n...

Page 36: ...monitoring if installed must be deactivated in addition to the vehicle settings for the heating operation Instructions for de activation may be obtained from the operating instructions of the vehicle...

Page 37: ...ompartment monitoring if installed must be deactivated in addition to the vehicle settings for the heating operation Instructions for de activation may be obtained from the operating instructions of t...

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