Water Heater Feel the drive Thermo Top E Parking Heater Thermo Top C Parking Heater e 00 000 e 00 000 Installation documentation Kia Sorento. CRDI from Model Year 00 Left-hand drive vehicle Automatic air-conditioning The use of Thermo Top P is not permitted for priority heating of the passenger compartment displayed in this coolant circuit in this EBA! 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.: 587C_EN Fee Euro 0.00 Webasto AG
Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tool Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Electrical system 6 Fan controller 7 Digital timer 9 Telestart remote option 9 Preparing installation location 0 heater Fuel Exhaust gas 5 Combustion air 8 Coolant circuit 9 Final Work 6 Template for Fuel Standpipe 7 Operating Instructions for the End Customer 8 Validity Manufacturer Model Type EG-BE No. / ABE Kia Sorento XM e * 00 / 6 * 058 *... Engine type Engine model Output in kw Displacement in cm³ D4HB Diesel 45 99 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! 587C_EN
Heater/Installation Kit Quantity Description Order No.: Retail accessories Thermo Top E / C See Price list Installation kit for Kia Sorento. CRDI 00 586B Heater control See Price list Heater recommended for the respective vehicle class: Vehicle Compact car Mid-size car, station wagon Heater Thermo Top E Thermo Top C The selection of the heater is based on the passenger compartment size of the vehicle and the level of comfort required by the customer! Foreword This installation documentation apply to vehicles Kia Sorento. CRDI - 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" and "operating and maintenance instructions" for the Thermo Top E / C 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). Special Tool - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit - Right angle drilling machine 587C_EN
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 hose clamps =.0 + 0.5 Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 587C_EN 4
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 hose. - Remove cover cap from cable pass through of engine compartment - Detach engine control unit and put it aside - Remove left underride protection - Remove the bumper. - Remove left back seat bench - Open the left tank mounting service lid. - Remove instrument panel trim on the driver side fully - Remove the A/C control panel in accordance with the manufacturers specifications. Heater installation location Heater Remove page 8 "Operating Instructions for the End Customer" and insert with vehicle operating instructions. Installation location 587C_EN 5
Electrical system Fuse holder, K relay M5x6 bolt, washer, retaining plate for fuse holder, nut Angle bracket Original vehicle stud bolt, washer, flanged nut 4 K relay Wiring harness pass through Plug Wiring harnesses of fan controller and heater control 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 Positive and ground wire Positive wire on positive battery terminal Ground wire on negative terminal of battery 4 Wiring harness routing Wiring harness on heater Wiring harness of fan controller and digital timer 5 587C_EN 6
Fan controller HG X gn/ ws 4 Webasto rt/ws F 4 bl GRs 5 F IPM I/P-C 6 Kia F I/P-D I/P-F 8 6 F6 I/P-G 0 5 Wiring diagram rt 4² 86 87 87a 85 0 K sw 4² bl M45 M GM sw or or or! br M46 4 GRr M04-B 0 9 4 M04-A KB Webasto components Vehicle components Colours and symbols HG TT-C/E Heater KB Air-conditioning control rt red panel X 6-pin heater connector M04-A 6-pin connector KB ws white F Replace 5 A with 7.5A M04-B Connector KB sw black fuse. F Fuse, 0A br brown K Fan relay F6 Fuse, 7.5A gn green F Fuse, 7.5 A or orange IPM Central electrical system bl blue of passenger com- partment I/P-F 0-pin IPM connector GRs Fan relay GM Fan motor Insulate wire end and tie M45 -pin connector GM back GRr Fan controller X Cutting point M46 4-pin connector, GRr Wiring colours may vary. Legends 587C_EN 7
Connection with I/P-F connector from central electrical system of passenger compartment Produce connections as shown in wiring diagram. 6 5 Blue (bl) connector I/P-F Pin8 Black (sw) additional wire from A/C control panel 4 Red (rt) wire from K/87a 5 Black (sw) wire from K/0 6 Blue (bl) wire from fan relay Connecting central electrical box 4 6 Wire-side view 4 5 6 7 8 9 0 Connector I/P-F 4 5 6 7 8 9 0 7 4 Connection on 6-pin M04-A connector from A/C control panel. Insulate and tie away Orange (or) wire from F6 fuse. Produce connections as shown in wiring diagram. Orange (or) wire of M04-A Pin4 connector 4 Black (sw) additional wire from K fan relay Connecting A/C control panel 8 Wire-side view 4 5 6 7 8 9 0 4 5 6 7 8 9 0 4 5 6 M04-A connector 9 587C_EN 8
Digital timer Pay attention to bolt of digital timer while reaching inside laterally - risk of injury. Shorten bolt of digital timer and paste with foam protection strip. Digital timer digital timer 0 Telestart remote option Drill out bracket at position to 6.5 mm dia. Receiver Original vehicle bolt (fastening of central electrical system) receiver Antenna antenna Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape! temperature sensor 587C_EN 9
Preparing installation location Remove protection plate and discard Removing protection plate 4 Preinstall bracket loosely, align and copy hole pattern at position [x]. M6x0 bolt, existing threaded hole Copying hole pattern 5 Dismantling bracket 9. mm dia. hole; rivet nuts [x each] rivet nut 6 9.mm dia. hole; rivet nut 47 rivet nut 0 7 587C_EN 0
M6x0 bolt, spring lockwasher Angle bracket angle bracket 8 Insert two large diameter washers each between bracket and frame side member at position. Insert 8 mm shim between bracket and angle bracket at position 4. M6x0 bolt [x], spring lockwasher [x], large diameter washer [4x] M6x0 bolt, spring lockwasher 4 M6x0 bolt, 8 mm shim, flanged nut bracket 4 9 heater Before installing, mount wiring harness on heater. Insert two washers between heater and bracket at position. Ejot screw Ejot screw, washer [x] heater 0 Ejot screw heater 587C_EN
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. Push 0 mm corrugated tube on to fuel line. Hose section, 0 mm dia. clamp [x] Connecting heater Route fuel line in 0 mm corrugated tube to the firewall. lines Route fuel line in 0 mm corrugated tube to the firewall. Route wiring harness of metering pump and fuel line in 00mm corrugated tube to underbody. lines 4 587C_EN
Route wiring harness of metering pump and fuel line into 00 mm corrugated tube on underbody to the installation location of the metering pump. lines 5 Angle bracket Original vehicle bolt, bracket of parking brake cable angle bracket 6 Silent block, flanged nut [x] Metering pump Rubber-coated pipe clamp metering pump 7 Wiring harness of metering pump, connector mounted Hose section, 0 mm dia. clamp [x] Fuel line Connecting metering pump 8 587C_EN
Remove and detach fuel-tank sending unit according to manufacturer's instructions. Place 6 mm dia. washer centrally in grid. Copy hole pattern, 6 mm dia. hole Removing fuel 9 Mould fuel standpipe according to template, cut to length and install Insert three 6 mm dia. washers between fuel standpipe and fuel tank sending unit at position for height compensation. fuel standpipe 0 Install fuel-tank sending unit in accordance with manufacturer's specifications. Slide 0 mm corrugated tube onto fuel line 4 and route to metering pump. Fuel standpipe Hose section, 0 mm dia. clamp [x] Connecting fuel line 4 Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section, 0 mm dia. clamp [x] Fuel line Connecting metering pump 587C_EN 4
Exhaust gas Discard section X Exhaust pipe a = 0 Exhaust end section b = 45 Preparing exhaust pipe a b X Ejot stud bolt, M6x0 spacer nut spacer nut Muffler M6x bolt, spring lockwasher muffler 4 Hose clamp [x] Exhaust pipe exhaust pipe 5 587C_EN 5
Exhaust end section Hose clamp Slide on red (rt) rubber isolator [x] exhaust gas endsection 6 Angle bracket M6x0 bolt, pipe clamp, flanged nut M6x0 bolt, large diameter washer, flanged nut, existing hole Fastening exhaust end section 7 Cut out wheel well trim at the marking. 70 Cutting out wheel well trim 8 wheel well trim Position red (rt) rubber isolator Aligning rubber isolator 9 587C_EN 6
Cut out underride protection at the marking. 5 Cutting out underride protection 40 underride protection Ensure sufficient distance to neighbouring components, correct if necessary. Position red (rt) rubber isolator Aligning exhaust gas endpiece 4 587C_EN 7
Combustion air a Discard section X Combustion air pipe a = 400 Cutting combustion air pipe to length X 7 mm dia. clamp Combustion air pipe combustion air pipe 4 Muffler M6x0 bolt, flanged nut, existing hole Combustion air pipe 4 48 mm dia. clamp, remove rubber coating 4 muffler 4 587C_EN 8
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: The coolant circuit deviating from the standard has a technical routing-related background. Hose installation diagram 4 T C A B All hose clamps = 0-7 mm dia. = Black (sw) rubber isolator [x]! = 8x8mm non-return valve. = 8x8x8 T-section! 4= 8x8x8mm combi valve T. 587C_EN 9
Discard section X X B C X A A = 00 B = 5 C = 840 Cutting hoses to size A X Push braided protection hoses onto hose A and C and cut to length. Cut heat shrink plastic tubing to length. Heat shrink plastic tubing, 50mm length [4x] Preparing coolant hoses C 40 mm edge protection Inserting edge protection 44 Flanged nut, original vehicle stud bolt Rubber-coated pipe clamp, 48 mm dia. 50 mm edge protection rubbercoated p- clamp 45 587C_EN 0
Remove hose of heat exchanger outlet/engine inlet and hose of heat exchanger inlet/engine outlet. Spring clip will be reused! Cutting point 46 Remove protection plate, will be reused. Hose section of heat exchanger inlet Engine-outlet hose section Preparing hose of heat exchanger inlet 47 Engine-outlet hose section Combi valve Hose section of heat exchanger inlet Preparing hose of heat exchanger inlet 48 4 Original vehicle spring clip [x]. Hose on heat exchanger inlet Hose of engine outlet 4 Combi valve hose on heat exchanger inlet 49 587C_EN
Remove protection plate, will be reused. Cut out 0 mm hose section and discard. Hose section of heat exchanger outlet Engine inlet hose section Preparing hose of heat exchanger outlet 50 Hose section of heat exchanger outlet T-section Engine inlet hose section Preparing hose of heat exchanger outlet 5 Original vehicle spring clip [x]. Hose on heat exchanger outlet T-section 4 Hose of engine inlet hose of heat exchanger outlet 4 5 Route hose B through rubber-coated p-clamp. B Connecting heater outlet 5 587C_EN
Check throughflow direction. Insert non-return valve C Routing in engine compartment B 54 C Cable tie Routing in engine compartment 55 Slide on black (sw) rubber isolator [x] Slide on protection hose C 56 Hose of engine outlet Combi valve Hose on heat exchanger inlet C Routing in engine compartment Connecting combi valve 57 587C_EN
Route hose A through rubber-coated p-clamp. Connecting heater inlet A 58 Cable tie Routing in engine compartment A A 59 Cable tie Routing in engine compartment 60 A Slide on protection hose Hose of engine inlet Cable tie 4 Hose on heat exchanger outlet 4 Routing in engine compartment 6 587C_EN 4
air filter box Align protection hoses on hose A and D to air filter box. Position black rubber isolator [x]. Ensure sufficient distance to neighbouring components. Aligning hoses 6 587C_EN 5
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. 9). - 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". - Place signboard "Switch off parking heater before refuelling" in the area of the filling connection pieces - Check the proper operation of the parking heater, see the operating instructions/installation instructions. Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: 0805 9 78 (4 Cent aus dem deutschen Festnetz) Hotfax: 095 559 5 Hotmail: hotline@webasto.de http://www.webasto.de 587C_EN Printed in Germany /00 Printing: Steffen 6
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 0 587C_EN 7
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! To avoid damage during start response of vehicle, only the vehicle passenger compartment is heated. Before parking the vehicle, make the following settings: Air outlet to windshield and foot well via MODE key Set temperature on both sides to "HI Set fan to level "", or max. "" Automatic air-conditioning 6 587C_EN 8