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 Petrol from Model Year 00 Left-hand drive vehicle Manual / automatic air-conditioning system Gear box WD 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. 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 installation by untrained staff. Ident. No.: 6588C_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tool Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 8 Fan controller for manual air conditioning 9 Automatic air-conditioning fan controller Remote option (Telestart) 4 Preparing installation location 5 Preparing heater 5 heater 9 Coolant circuit 0 Fuel 4 Exhaust gas 7 Final Work 8 Template for Fuel Standpipe 9 Operating Instructions for the End Customer 0 Validity Manufacturer Model Type EG-BE No. / ABE Kia Sportage SL e * 007 / 46 * 06 *... Engine type Engine model Output in kw Displacement in cm³ Gamma Petrol THETA II Petrol 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 a digital timer and summer/winter switch should be confirmed with the end customer before installation. 6588C_EN

3 Heater/Installation Kit Quantity Description Order No.: Basic retail accessories Thermo Top Evo, petrol See Price list Installation kit for Kia Sportage 00 PetrolWD 6587A Heater control See Price list must also be ordered for automatic air-conditioning: Quantity Description Order No.: Automatic air-conditioning kit 59A Foreword This installation documentation apply to vehicles Kia Sportage Petrol - 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. 9). 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 6588C_EN

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! Tightening torque of 5x heater bolts = 8Nm! Tightening torque of 5x5 bolt of water connection piece retaining plate = 7Nm! 6588C_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. - Disconnect battery. - Remove the windscreen wipers - Remove radiator tank cover and radiator tank - Remove horn at the right on the suspension chamber - Remove underride protection - Remove underbody trim at the left before the fuel tank - Remove seating surface of rear bench seat - Open the fuel sender service lid. - Remove the fuel-tank sending unit in accordance with the manufacturers specifications. - Remove gloves compartment - Remove door sill panel on the front passenger side - Remove the A-pillar trim in the front passenger side footwell. - Remove trim of gear change lever (for digital timer only) Heater installation location Heater Remove page 0 "Operating Instructions for the End Customer" and insert with vehicle operating instructions. Installation location 6588C_EN 5

6 4 Preparing electrical system 5 5 Complete connector of metering pump again after installation. Pin allocation is not relevant. Connector housing Lock Blue/brown (bl / br) wires 4 Coding 5 Timer lock Dismantle connector rt/sw rt 4² gn/ws 0,75² Produce connections as shown in wiring diagram. Insert fuse F4 5A, K relay will be installed after assembly. F 86 F a rt 4² Inserting F4, preparing K relay K 85 0 br sw 4² A B Automatic air-conditioning a = 600 b = 400 a b Cut protective sleeving to length gn/ws 0,75² rt sw Connect wires to socket IPCU. Pull red (rt) wire and black (sw) wire through protective sleeving A. Pull green/white (gn/ws) wire and red (rt) wire through protective sleeving B. Red (rt) wire socket IPCU/5 Red (rt) wire socket IPCU/E Black (sw) wire socket IPCU/A Green/white (gn/ws) wire socket IPCU/86 Brown (br) wire socket IPCU/85 Prepare lines 7 br 6588C_EN 6

7 A E 5 IPCU E A 4 5 IPCU view on contact side. IPCU is preprogrammed with the default settings of model year 0. The default values must be checked during the function check on the vehicle and adjusted, if necessary. Model year: 00 0 Duty cycle: 00% 00% Frequency: 4 khz khz Voltage: 4.4V.6V Function: High side High side Prepare IPCU mm dia. hole (short drill) 5 5 Hole for fuse holder for passenger compartment 6588C_EN 7

8 Electrical system Wiring harness pass through Wiring harness of fuse holder inner, heater control Protective rubber plug Digital timer Digital timer 4 5 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 4 Positive wire Nick positive terminal cover Positive wire, original vehicle bolt 6 Engine compartment fuse holder, earth line Install angle bracket loosely! Remove clip, M6x0 bolt, large diameter washer, flanged nut M5x6 bolt, washer, retaining plate for fuse holder, washer, nut 4 Earth wire on original vehicle earth point 5 F- fuses mounted C_EN 8

9 Fan controller for manual air conditioning F F Webasto HG X 5 X Kia F 0 5 Wiring diagram br X0 rt/sw rt/sw rt 4² rt 4² F 86 ge gn/ws 0,75² gn/ws 0,75² F a K rt 4² sw 4² rt 4² rt 4² + M - GR GM GS br br Webasto components Vehicle components Colours 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, 0A F Fuse, A X Cutting point F4 Fuse, 5A Wiring colours may vary. Connect wiring harness of passenger compartment fuse holder to wiring harness of engine compartment fuse holder according to the wiring diagram Legends Connecting wiring harnesses C_EN 9

10 M5x6 bolt, large diameter washer [x], nut Inner fuse holder fuse holder, inner 9 K relay relay 0 Red (rt) wire from fuse Red (rt) wire, fan motor connector Red (rt) wire, K/87a Black (sw) wire, K/0 Connection to -pin connector from fan motor. Produce connections as shown in wiring diagram. Connecting fan motor 6588C_EN 0

11 Automatic air-conditioning fan controller Webasto Kia 0 5 F F HG X 5 X F Wiring diagram ge 4 5 GRs br rt/sw rt 4² rt/sw rt 4² gn/ws 0,75² gn/ws 0,75² rt 4² rt ² X0 F F4 rt ² br 7 br 5 IPCU br E A rt rt sw gn/ws 87a K sw 4² M45 M M45 pk ² GM ws/sw M46 4 GRr M46 sw rt ws/sw 0 9 M04-B AC Webasto components Vehicle components Colours and symbols HG heater TT-Evo GM Fan motor rt red X 6-pin heater connector M45 -pin connector GM sw black X -pin heater connector GRs Fan relay br brown X0 4-pin connector GRr Fan controller gn green Heater control M46 4-pin connector, GRr ws white K Fan relay AC A/C control unit ge yellow F Fuse, 0A M04-B AC connector ro pink F Fuse, 0A F Fuse, 40A F Fuse, A F4 Fuse, 5A IPCU Pulse width modulator IPCU setting values Model year: 00 0 Duty cycle: 00% 00% Frequency: 4 khz khz Voltage: 4.4V.6V X Cutting point Function: High side High side Wiring colours may vary. Legends 6588C_EN

12 M5x6 bolt, large diameter washer [x], nut Passenger compartment fuse holder fuse holder, inner K relay Connect K relay Connect the wiring harness of the fuse holder for the passenger compartment with the wiring harness of the heater according to circuit diagram. Connecting wiring harnesses 4 Connection to -pin connector M45 from fan motor. Produce connections as shown in wiring diagram. Red (rt) wire, M45 connector Red (rt) wire from fan relay Red (rt) wire, K/87a Black (sw) wire, K/0 Red (rt) wire IPCU/5 Green/white (gn/ws) wire IPCU/86 Connecting fan motor C_EN

13 Original vehicle bolt Brown (br) wire IPCU/85 7 IPCU earth connection 6 4 Connection to 4-pin connector M46 from fan controller. Produce connections as shown in wiring diagram. White/black (ws/sw) wire for A/C control unit pin 9 Red (rt) wire from K/87a White/black (ws/sw) wire for connector M46 pin 4 Red (rt) wire IPCU/E Black (sw) wire IPCU/A Fan controller connection 5 7 Socket for connector M46 Install connector C_EN

14 Remote option (Telestart) Receiver installed with adhesive tape. receiver 9 Antenna antenna 0 Only for Telestart T00 HTM Temperature sensor temperature sensor 6588C_EN 4

15 Preparing installation location Detach clip on original vehicle wiring harness at position. Mount one plain washer each on stud bolt [x] and (washers as offset for insulation mat and bracket). Cut out a little insulation mat if necessary! Detaching wiring harness Preparing heater Water nozzle, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water nozzles.6 B C D E X A B A and B = 90 moulded hoses Discard section X C = 0 D = 90 E = 00 Cutting hoses to size D E Slide on 5mm dia. spring clip [x] 90 8x8 mm [x] connecting pipes, 5 mm dia. spring clip [4x] water nozzles Pre-assembling coolant hoses B C C_EN 5

16 D 5 mm dia. spring clip [x] coolant hoses C 5.0 B A, B and E = 90 moulded hoses Discard section X C D X A B E C = 0 D = 40 Cutting coolant hoses to length D E Slide on 5mm dia. spring clip [x] 90 8x8 mm [x] connecting pipes, 5 mm dia. spring clip [4x] B Pre-assembling coolant hoses C 6 D 5 mm dia. spring clip [x] coolant hoses C C_EN 6

17 All vehicles Combustion air silencer 5 mm dia. clamp Combustion air pipe 4 M5x torx bolt, M5 flanged nut 5 Perforated bracket Pre-assemble combustion air silencer Fuel line 90 moulded hose, 0 mm dia. clamp [x] 4 5 mm dia. spring clip 5 Combustion air pipe 6 Mount wiring harness of circulation pump Pre-assembling heater All spring clips = 5 mm dia.! 6 4 M6x0 bolt, flanged nut 50 mm edge protection Rubber-coated pipe clamp, 48 mm dia. 4 Circulation pump 5 8x8 connecting pipe 6 Bracket Premounting bracket A 5 0 5x self-tapping bolt [x] bracket 6588C_EN 7

18 B.6 B Mount wiring harness of circulating pump. 5 mm dia. spring clip hose B.0 B Mount wiring harness of circulating pump 5 mm dia. spring clip hose B B All vehicles Discard section X. Exhaust pipe a = 580 Exhaust end section b = 0 Preparing exhaust pipe a b X Hose clamp Exhaust pipe M6x0 bolt, pipe clamp, flanged nut exhaust pipe C_EN 8

19 heater Large diameter washer, flanged nut [4x each] heater 5 Mount wiring harness and on heater. Routing wiring harness 6 Refasten original vehicle wiring harness on stud bolt [x]. Fasten wiring harnesses of fuse holder inner, heater control and heater Fastening wiring harness C_EN 9

20 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 D E A B C All spring clips without a specific designation = 5 mm dia. = Original vehicle spring clip! All connecting pipes and = 8x8 mm dia. 6588C_EN 0

21 .6 B The heater was dismantled for better display. Remove engine outlet hose on heat exchanger inlet connection piece. Spring clip will be reused. Cutting point 8 Hose of engine outlet Original vehicle spring clip A Connecting engine outlet 9 Original vehicle spring clip Hose E on heat exchanger inlet E Connecting heat exchanger inlet 40 Align hoses. Ensure sufficient distance to neighbouring components. Hose on heat exchanger outlet Hose of engine outlet Routing C_EN

22 .0 B The heater and heat exchanger outlet hose were dismantled for better display. Remove hose section from connecting piece of heat exchanger inlet and discard. Spring clip will be reused. Hose of engine outlet Cutting point 4 Hose of engine outlet Original vehicle spring clip Connecting engine outlet D A 4 Hose E on heat exchanger inlet Connecting heat exchanger inlet D 44 Aligning hoses Ensure sufficient distance to neighbouring components. Hose on heat exchanger outlet Hose of engine outlet Routing C C_EN

23 Remove original vehicle plastic nut at position and discard. Perforated bracket Original vehicle stud bolt M6 flanged nut silencer C_EN

24 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 as shown in the wiring harness routing diagram. Perforated bracket Drill hole up to 8.5 mm dia. 65 Preparing perforated bracket 5 47 Metering pump Cable tie M6x5 bolt, flanged nut 4 Perforated bracket Premounting metering pump 4 48 Draw fuel line and wiring harness of metering pump into 00 mm corrugated tube and route to original vehicle fuel lines in the underbody. lines C_EN 4

25 Route fuel line and wiring harness of metering pump into corrugated tube in underbody to the installation location of the metering pump. lines 50 Fasten pre-assembled metering pump between parking brake cable and large diameter washer with original vehicle bolt. metering pump 5 Wiring harness of metering pump, connector mounted Fuel line of heater Hose section, 0 mm dia. clamp [x] Connecting metering pump 5 Remove and detach fuel-tank sending unit according to manufacturer's instructions. Position plain washer (dia. d a = ) centrally between the fixed members. Copy hole pattern, 6 mm dia. hole Removing fuel C_EN 5

26 Mould fuel standpipe according to template, cut to length and install fuel standpipe 54 Insert five plain washers at position of dia. d a = as height compensation. fuel standpipe 55 Install fuel-tank sending unit in accordance with manufacturer's instructions. Route fuel line in 0 mm corrugated tube to the metering pump. Fuel line, hose section, 0 mm dia. Caillau clamp [x] Connecting fuel line 56 Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section, 0 mm dia. clamp [x] Fuel line of fuel tank standpipe Connecting metering pump C_EN 6

27 Exhaust gas Silencer M6x6 bolt, spring lockwasher Angle bracket Preassembling silencer Original vehicle stud bolt, angle bracket, original vehicle flanged nut silencer 58 Exhaust pipe Hose clamp Fastening exhaust pipe 59 Align exhaust gas end section. Hose clamp Aligning end section C_EN 7

28 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate all loose lines and tie back. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer, teach telestart transmitter - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Place signboard "Switch off parking heater before refuelling" in the area of the filling connection pieces - See installation instructions for initial start-up and function test Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de C_EN Printed in Germany 0/0 Printing: Steffen 8

29 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 minimise margins and 00% of the normal size. 00mm C_EN 9

30 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: Set fan to level "", or max. "" Air outlet to windscreen Set temperature to "max." Manual air conditioning 6 Air outlet faces "upward" Set temperature on both sides to "HI Automatic air-conditioning C_EN 0