Webasto Thermo Top E Installation Instructions Manual
Hyundai 2009 i20
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Also See for Thermo Top E:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
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Water Heater
Thermo Top E Parking heater
Thermo Top C Parking heater
Thermo Top P Parking heater
Installation instructions
Hyundai i20
Petrol
from Model Year 2009
Left-hand drive vehicle
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1314869C_EN
e1
00 0003
e1
00 0002
e1
00 0104
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top E
Summary of Contents for Webasto Thermo Top E
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Page 1: Installation Instructions
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. -
Page 2: Table Of Contents
Hyundai i20 Table of Contents Validity Preparing installation location Heater/Installation Kit Installing heater Foreword Coolant circuit General Instructions Fuel Special Tools Exhaust gas Explanatory Notes on Document Combustion air Preliminary Work Final Work Heater installation location Template for Fuel Standpipe Preparing electrical system Operating Instructions for End Customer Electrical system... -
Page 3: Heater/Installation Kit
Hyundai i20 Heater/Installation Kit Quantity Description Order No.: Retail accessories Thermo Top E / C / P See price list Installation kit for Hyundai i20 Petrol 1314868A Heater control See price list To be ordered additionally for vehicles with automatic air-conditioning:... -
Page 4: Explanatory Notes On Document
Hyundai i20 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... -
Page 5: Preliminary Work
Hyundai i20 Preliminary Work WARNING! - Open the fuel tank cap, ventilate the 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. -
Page 6: Preparing Electrical System
Hyundai i20 Preparing electrical system Bending perforated bracket 90° Only with automatic air-conditioning Cutting wires to length O,75² Install wire section 2 in protective sleeving provided. Premount- ing F4 1314869C_EN... -
Page 7: Electrical System
Hyundai i20 Electrical system Fuse holder, relay K3 Digital timer and summer/winter switch op- tion 1 M5x16 bolt, washers, retaining plate for fuse holder, K3 relay, flanged nut 1 Digital timer 2 Perforated bracket 2 Summer/winter switch, drilled hole 12 mm dia. 3 M6x20 bolt, spring lockwasher, existing threaded hole Do not install the metering pump... -
Page 8: Fan Controller For Manual Air Conditioning
Fan controller for manual air conditioning Webasto Hyundai Wiring dia- gram Blower 0,5² 4² 0,5² 4² Webasto components Vehicle components Colours and symbols Heater TT-C/E Fan motor 6-pin heater connector GRs Fan relay pink Replace 25 A with 5 A Resistor group black fuse. -
Page 9: Automatic Air-Conditioning Fan Controller
0,5² 0,5² 4² 0,5² 0,5² 4² 0,5² 0,5² 0,75² M04-A 14 15 16 17 Webasto components Vehicle components Colours and symbols Heater TT-C/E Fan motor 6-pin heater connector GRs Fan relay pink 5A fuse Fan controller black Replace 25 A fuse with... - Page 10 Hyundai i20 Connection to fuse and relay box 4 in engine compartment. Replace fuse F3 25 A with 15A fuse. Insulate pink (pk) wire 1 from fuse F2 IGN and tie back. Produce connections as shown in wiring dia- gram. Connect- ing fan re- 2 Additional black (sw) wire of K3/30...
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Page 11: Remote Option (Telestart)
Hyundai i20 Remote option (Telestart) Drill out bracket 1 to 6.5 mm dia. at position 3 . 2 Receiver 3 Original vehicle stud bolt, flanged nut Installing receiver 1 Antenna Installing antenna Temperature sensor HTM100 Fasten temperature sensor 1 with adhesive tape. -
Page 12: Hyundai I20
Hyundai i20 Preparing installation location 1 Remove side trim 2 Remove original vehicle bolts and discard Preparing installa- tion loca- tion Cut out side trim 1 at marking. Cutting out side trim Cut out side trim at marking. 7 mm dia. hole at position 1 Cutting out side trim... - Page 13 Hyundai i20 1 Bracket 2 7 mm dia. hole Preparing bracket Insert one 10 mm shim each between bracket and frame side member at position 1 . 1 M6x25 bolt, spring lockwasher, 10 mm shim, original vehicle earth wire, existing threaded hole [2x each] Installing 2 Bracket...
- Page 14 Hyundai i20 Insert one 15 mm spacer nut each between an- gle bracket and frame side member. Copy hole pattern to frame side member at position 2 [2x]. Remove angle bracket. Drill 9.1 mm dia. hole in frame side member and mount rivet nut [2x each].
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Page 15: Installing Heater
Hyundai i20 Installing heater 1 Ejot screw [2x] Installing heater Connect wiring harness of heater prior to in- stallation. 1 Ejot screw Installing heater 1314869C_EN... -
Page 16: Coolant Circuit
Hyundai i20 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"... - Page 17 Hyundai i20 Discard section X . A = 90° elbow B = 1150 C = 200 D = 200 Cutting E = 1250 coolant hoses to length Push braided protection hoses onto hose A and C and cut to length. Cut heat shrink plastic tubing to length.
- Page 18 Hyundai i20 Connect- ing heater inlet 1 Close clip-type cable tie Connect- ing heater outlet Mount side trim 2 . Route hose B and E from engine compartment through cut-out in side trim to outside and connect to hose C and D . Slide one heat protection hose 1 each onto hose B and E .
- Page 19 Hyundai i20 Slide black (sw) rubber isolator onto hose B and [2x] onto hose E. Cut open fabric protec- tive hose 2 and slide onto brake line. Discard original vehicle bolt at position 3. Route hose B and E to cutting point. Routing in 1 48 mm dia.
- Page 20 Hyundai i20 1 Discard hose section 2 Engine-outlet hose section Cutting point of en- gine outlet 1 Hose of engine outlet Connect- ing engine outlet Position black (sw) rubber isolator 1 and fas- ten on brake line with cable tie. Ensure sufficient distance to neighboring components.
- Page 21 Hyundai i20 1.4 Petrol 1 Engine-outlet hose section 2 Hose section of heat exchanger inlet 3 Discard hose section Cutting point 1 Hose on heat exchanger inlet 2 Spacer bracket Connect- ing heat exchanger inlet Slide black (sw) rubber isolator 1 onto hose A. 2 Hose of engine outlet Connect- ing engine...
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Page 22: Fuel
Hyundai i20 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. Un- less specified otherwise, always fasten using cable ties. - Page 23 Hyundai i20 Slide corrugated tube C onto fuel line and wir- ing harness of metering pump 1 , then route along original vehicle lines to installation loca- tion of metering pump. Installing lines Drill out existing hole to 9.1 mm dia. at posi- tion 1 and mount rivet nut.
- Page 24 Hyundai i20 Remove and detach fuel-tank sending unit 1 according to manufacturer's instructions. 2 6 mm dia. washer 3 Copy hole pattern, 6 mm dia. hole Removing fuel Shape fuel standpipe 1 according to tem- plate, cut to length and install. Insert three 6 mm dia.
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Page 25: Exhaust Gas
Hyundai i20 Exhaust gas Discard section X . 1 Exhaust pipe a = 180 Preparing 2 Exhaust end section exhaust b = 120 pipe Insert 5 mm shim between perforated bracket 1 and heater and 20 mm shim between silencer 3 and perforated bracket 1. -
Page 26: Combustion Air
Hyundai i20 Combustion air Discard section X . 1 Combustion air pipe a = 250 Cutting combus- tion air pipe to length 1 Combustion air pipe 2 27 mm dia. clamp Installing combus- tion air pipe Secure silencer 2 with cable tie 1 . Installing silencer 1314869C_EN... -
Page 27: Final Work
Hyundai i20 Final Work Fasten water hoses on wheel well trim with M6x20 bolt 2 , rubber-coated p-clamp 1 and flanged nut. Fastening hoses Install wheel well trim and underride protec- tion 1 . Large diameter washer and flanged nut 2 on M6x20 bolt. Fastening wheel well trim and... - Page 28 - Check the proper operation of the parking heater, see the operating instructions/installation in- structions. - Attaching information label "Switch off parking heater before refueling" in the area of the filler neck Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78...
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Page 29: Template For Fuel Standpipe
Hyundai i20 Template for Fuel Standpipe 100 mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize mar- gins” and 100% of the normal size. 100 mm 1314869C_EN... -
Page 30: Operating Instructions For End Customer
Hyundai i20 Operating Instructions for 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. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.
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