ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Thermo Top Evo Parking Heater e Feel the drive Installation documentation Kia Sportage Diesel from Model Year 00 Left-hand drive vehicle Manual air conditioning Gear box AWD 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. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 36590A_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater/Installation Kit 3 Foreword 3 General Instructions 3 Special Tool 3 Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 7 Fan controller 9 Remote option Telestart 0 Preparing bracket Preparing installation location Preparing heater heater 3 Coolant circuit 5 Fuel 8 Combustion air Final Work 6 Template for Fuel Standpipe 7 Operating Instructions for the End Customer 8 Validity Manufacturer Model Type EG-BE No./ABE Kia Sportage SL e * 007 / 46 * 036 *... Engine type Engine model Output in kw Displacement in cm³ R Diesel 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 installation A_EN

3 Heater/Installation Kit Quantity Description Order No.: Basic retail accessories Thermo Top Evo diesel See Price list Installation kit for Kia Sportage 00 DieselAWD 36590A Heater control See Price list Foreword This installation documentation apply to vehicles Kia Sportage Diesel - for validity, see page - from model year 00 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 "installation 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 specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Sharp edges should be fitted with edge protectors (split-open plastic hose). Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 39). While installing an IPCU, the corresponding settings must be controlled or adjusted before the installation. Special Tool - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit 36590A_EN 3

4 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 Software 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 general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. 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! Install fuel connections without any collisions! Starting torque of 5x3 heater bolts = 8Nm! Starting torque of 5x5 bolts of water branch retaining plate = 7Nm! 36590A_EN 4

5 Preliminary Work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurize 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 air filter together with the intake hoses. - Remove battery with carrier fully - Detach engine control unit and put it aside - Remove underride protection - Remove underbody trim at the left before the fuel tank - Remove lateral wheel well trim at the left - Detach wheel well trim in the front area - Remove the bumper. - Remove seating surface of rear bench seat (a screw joint is accessible from luggage compartment) - Open the fuel sender service lid. - Remove the fuel-tank sending unit in accordance with the manufacturers specifications. - Remove door sill panel on the front passenger side - Remove the A-pillar trim in the front passenger side footwell. - Remove trim of gear shift lever (for digital timer only) Heater installation location Heater Remove page 8 "Operating Instructions for the End Customer" and insert with vehicle operating instructions. Installation location 36590A_EN 5

6 Preparing electrical system Detach blue (bl) wire and brown (br) wire 3 from the metering pump connector. Will be reused. Dismantling connector of metering pump wiring harness 3 rt/sw 0,5² rt 4² gn/ws 0,75² Produce connections as shown in wiring diagram. F3 86 F a rt 4² Inserting F4, preparing K relay br 0,5² K sw 4² 36590A_EN 6

7 Electrical system Wiring harness pass through Wiring harness of fuse holder inner, heater control Protective rubber plug Digital timer Digital timer 3 4 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness installation diagram 3 4 Connecting positive wire Nick positive terminal cover Positive wire to original vehicle bolt 5 Fuse holder outer, ground connection Install angle bracket loosely! Remove clip, M6x0 bolt, large diameter washer, flanged nut 3 Positive wire to original vehicle ground point 4 M5x6 bolt, washer, retaining plate for fuse holder, washer, nut 5 F- fuses mounted A_EN 7

8 Connect wiring harness of passenger compartment fuse holder to wiring harness of engine compartment fuse holder according to the wiring diagram Connecting wiring harnesses 7 Drill hole of 5.5 mm dia. with short drill. 5 5 fuse holder, inner 8 M5x6 bolt, large diameter washer [x], nut Inner fuse holder fuse holder, inner 9 K relay relay A_EN 8

9 Fan controller F F Webasto HG X 5 X Kia F 30 5 Wiring diagram br 0,5² X0 rt/sw 0,5² rt/sw 0,5² rt 4² rt 4² F3 86 ge 0,5² gn/ws 0,75² gn/ws 0,75² F a K rt 4² sw 4² rt 4² rt 4² + M - GR GM GS br 0,5² br 0,5² 3 Legends Red (rt) wire from fuse 3 Red (rt) wire from K/87a 4 Black (sw) wire from K/30 5 Red (rt) wire from GM connector Webasto components Vehicle components Colors and symbols HG heater TT-Evo GM Fan motor rt red X 6-pin heater connector GR Fan relay sw black X -pin heater connector GS Fan switch br brown X0 4-pin connector F Fuse gn green Heater control ws white K Fan relay ge yellow F Fuse, 0A F Fuse, 30A F3 Fuse, A X Cutting point F4 Fuse, 5A Wiring colours may vary. Connection to -pin connector from fan motor. Produce connections as shown in wiring diagram. Connecting fan motor A_EN 9

10 Remote option Telestart Receiver installed with adhesive tape. receiver Antenna antenna 3 Only for T00 HTM Temperature sensor temperature sensor A_EN 0

11 Preparing bracket Bracket 7 mm dia. hole 50 Drilling bracket 5 Perforated bracket M6x5 bolt, pin lock Preassembling perforated bracket of circulating pump 6 Preparing installation location Detach retaining clip of original vehicle wiring harness from vehicle Detaching wiring harness 7 Align bracket according to figure Copy hole pattern, 9. mm dia. hole [x] Copy hole pattern, 7 mm dia. hole [x] Copying hole pattern A_EN

12 50 mm long edge protection Mount rivet nut [x] rivet nut 9 3 M6x0 bolt, spring lockwasher [x each] Preinstalled circulating pump perforated bracket 3 Original vehicle bolt 4 M6x0 bolt, flanged nut 5 M6x0 bold, to be fastened later to exhaust gas muffler bracket Preparing heater Discard section X. A B C D E X A = 700 B = 60 C = 50 D = 60 E = 800 Cutting coolant hoses to length 4 D B x8 connecting pipe [x] Circulation pump 3 Circulating pump intake 4 5 mm dia. spring clip [4x] 5 Slide on 5mm dia. spring clip [x] Pre-assembling coolant hoses 5 C 36590A_EN

13 Install 5x3 self-tapping bolt [4x] loosely (turn max. 3 threads)! Heater Pre-installing bolts loosely a b Water nozzle, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water nozzles water nozzles 3 5 mm dia. spring clip [x] C D coolant hoses 4 heater Tighten 5x3 self-tapping bolt [3x] heater A_EN 3

14 Tighten 5x3 self-tapping bolt [3x] heater 6 Mount wiring harness on heater Mount wiring harness of circulation pump [x] wiring harnesses 7 Fasten original vehicle wiring harness with cable tie [x] Fastening wiring harness A_EN 4

15 Coolant circuit WARNING! Any coolant running off should be collected using an appropriate container! Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose installation diagram E A B C D All spring clips without a specific designation = 5 mm dia. = Original vehicle spring clip! All connecting pipes and = 8x8 mm dia A_EN 5

16 Engine-outlet hose section Cutting point Cutting point 35 9 Hose preinstalled on heat exchanger inlet Hose on engine outlet preinstalled Preinstalling hoses Turn perforated bracket on bending line by 90 Discard section X. Preparing perforated bracket X Rubber-coated pipe clamp, 48 mm dia. M6x0 bolt, flanged nut Preassembling perforated bracket A_EN 6

17 M6x0 bolt, original vehicle hole, flanged nut perforated bracket 3 A D Cable tie [x] B Connection to heater E E 33 Rubber-coated pipe clamp, 48 mm dia. Cable tie [x] E A 34 Hose bracket [x] A Routing in engine compartment Connection on engine outlet and heat exchanger inlet A_EN 7

18 Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with 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 in as shown in the wiring harness routing diagram. Perforated bracket Drill hole up to 8.5 mm dia. 65 Preparing perforated bracket 5 3 Metering pump Cable tie 3 M6x5 bolt, flanged nut 4 Perforated bracket Premounting metering pump 4 36 Wiring harness of metering pump in corrugated tube 00 mm long corrugated tube 3 Fuel line in corrugated tube 4 Hose section, 0 mm dia. clamp [x] Connecting heater A_EN 8

19 Draw fuel line and wiring harness of metering pump into corrugated tube of firewall route to original vehicle fuel lines in the underbody. lines 38 Route fuel line and wiring harness of metering pump into corrugated tube in underbody to the installation location of the metering pump. Slide on 00 mm corrugated tube B and cut to length. lines 39 Fasten pre-assembled metering pump between clamp of parking brake cable and large diameter washer 3 with original vehicle bolt. metering pump 3 40 Wiring harness of metering pump, connector mounted Corrugated tube B cut to length 3 Fuel line of heater 4 Hose section, 0 mm dia. clamp [x] Connecting metering pump A_EN 9

20 Remove and detach fuel-tank sending unit according to manufacturer's instructions. Position plain washer (dia. d a = ) centrally between the fixed members. 3 Copy hole pattern, 6 mm dia. hole Removing fuel 3 4 Mould fuel standpipe according to template, cut to length and install Insert five plain washers at position of dia. d a = as height compensation. fuel standpipe 43 Install fuel-tank sending unit in accordance with manufacturer's instructions. Route fuel line in remaining corrugated tube to the metering pump. Fuel line, hose section, 0 mm dia. Caillau clamp [x] Connecting fuel line 3 44 Check the position of the components; adjust if necessary. Check that they have free clearance. Cut corrugated tube 3 to size. Hose section, 0 mm dia. clamp [x] Fuel line of fuel tank standpipe Connecting metering pump A_EN 0

21 Combustion air a Discard section X Combustion air pipe a = 300 Cutting combustion air pipe to length X Perforated bracket 60 Preparing perforated bracket Muffler M5x6 bolt, flanged nut 3 Perforated bracket 4 M6x0 bolt, pin lock 5 5 mm dia. clamp Preassembling muffler 46 Align muffler after installation to the position [x] if necessary. Perforated bracket preinstalled 3 Original vehicle hole, flanged nut muffler A_EN

22 Fasten wiring harness of heater and corrugated tube with cable tie to combustion air pipe. 3 5 mm dia. spring clip combustion air pipe A_EN

23 Discard section X. Exhaust pipe a = 80 Exhaust end section b = 90 Preparing exhaust pipe a X b Muffler M6x6 bolt, spring lockwasher 3 Angle bracket Preassembling muffler Cut out lateral wheel well trim 3 at the cutting line 4 and discard section. Dismantle -section dowel 5 [x] at position [x]. They will be needed later. 5 Preparing lateral wheel well trim 4 50 Drill 6.5 mm dial. hole, install dowel [x each] Preparing lateral wheel well trim A_EN 3

24 Align exhaust muffler. Ensure sufficient distance to neighbouring components. Flanged nut muffler 5 Ensure sufficient distance. lateral wheel well trim 53 M6x0 bolt, existing hole, large diameter washer, flanged nut Strut strut 54 Hose clamp [x] Exhaust pipe exhaust pipe A_EN 4

25 Exhaust end section Hose clamp 3 M6x0 bolt, clamp, flanged nut exhaust gas endsection Cut out insulation, discard section X. Underride protection 5 X Cutting out underride protection mm dia. hole 70 Drilling underride protection Align exhaust end section as justified on underride protection. Ensure sufficient distance to neighbouring components, correct if necessary. underride protection A_EN 5

26 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. 39). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer, try out telestart - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the parking heater, see the operating instructions/installation instructions. - Place signboard "Switch off parking heater before refuelling" in the area of the filling connection pieces Note: Before installation, paste edge protector on air filter box. Pasting edge protection 60 Feel the drive Webasto AG Postfach 80 D-83 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de A_EN Printed in Germany 09/00 Printing: Steffen 6

27 Template for Fuel Standpipe 00mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimize margins and 00% of the normal size. 00mm A_EN 7

28 Operating Instructions for the End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. It must be deactivated in vehicles with passenger compartment monitoring in addition to the vehicle settings for the heating process. For instructions on deactivation, please refer to the operating instructions of the vehicle! Before parking the vehicle, make the following settings: 3 3 Set fan to level "", or max. "" Air outlet to windshield 3 Set temperature to "max." Manual air conditioning A_EN 8