Webasto Thermo Top E Installation Instructions Manual
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- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
Table of Contents
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Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
Hyundai Sonata
Gasoline
from Model Year 2005
Left-hand drive vehicle
Automatic air-conditioning
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, specialized tools and
equipment are required to install and repair Webasto heating and cooling systems.
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.: 1310033B_EN
e1
00 0003
e1
00 0002
e1
00 0104
Fee Euro 10
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, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. 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. -
Page 2: Table Of Contents
Hyundai Sonata Table of Contents Validity Preparing Heater Unit Heater Unit/Installation Kit Installing Heater Unit Foreword Coolant Connection Diagram General Instructions All Vehicles Special Tools Combustion Air Connection Explanatory Notes on the Document Fuel Connection Preliminary Work Installation Location of Metering Pump Heater Unit Installation Location Removing Fuel Preparing Electrical System... -
Page 3: Heater Unit/Installation Kit
1310031A Heater unit recommended for the respective vehicle class: Vehicle Heater unit Compact car Thermo Top E Mid-size car, station wagon Thermo Top C Full-size car, van, offroader Thermo Top P The selection of the heater unit is based on the passenger compartment size of the vehicle and the... -
Page 4: Explanatory Notes On The Document
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 angle. -
Page 5: Preliminary Work
Hyundai Sonata Preliminary Work WARNING! - 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. -
Page 6: Preparing Electrical System
Hyundai Sonata Preparing electrical system Only with automatic air-conditioning sw 1,0mm² Wire section 1 will be required later for connection of additional fuse. 2850 Cutting wires to length Make connections as shown in the wiring diagram with the tab receptacles provided. Pull wire section 2 into protective sleeving provided and route into passenger compartment together with clock and fan... -
Page 7: Electrical Connections
Hyundai Sonata Electrical Connections Wiring harness pass through Digital timer and summer/winter switch option 1 Remove protective rubber plug and lay in 1 Digital timer cable 2 Summer/winter switch, drilled hole 12 mm dia. Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the... -
Page 8: Automatic Air-Conditioning Fan Controller
Hyundai Sonata Automatic air-conditioning fan controller Connection to 2-pin connector from blower motor. Make connections as shown in the wiring diagram with the tab receptacles provided. Con- necting fan 1 2-pin connector motor 2 3x connector Connection to 26-pin connector M 21-1 from air conditioning control. -
Page 9: Automatic Air-Conditioning Circuit Diagram
Webasto Hyundai Sonata rt/ws rt/ws gn/ws Automatic air-con- ditioning circuit diagram M21-1 M21-2 Webasto components Hyundai components Colors and symbols Heater unit TT-C/E Fan motor Fuse Fan relay white Fan relay Power transistor black 10 A additional fuse A/C control module... -
Page 10: Remote Option (Telestart)
Hyundai Sonata Remote option (Telestart) 1 Receiver, double-sided adhesive Velcro strip 2 Instrument panel trim Installing receiver Route antenna cable to receiver in lower area of A-pillar trim. 1 Antenna Installing antenna... -
Page 11: Thermo Call Option
Hyundai Sonata Remote option (Thermo Call) 1 Receiver 2 Cross member under steering column 3 Double-sided adhesive Velcro strip Installing receiver 1 Antenna Installing antenna 1 Pushbutton Installing push button... -
Page 12: Preparing Installation Location
Hyundai Sonata Preparing installation location Disconnect hose section from heat exchanger inlet 1 and shorten by approx. 25 mm. Original vehicle clamp will be reused. Cutting 2 Cutting point [3x] point for 3 Discard hose section coolant 1 Remaining hose on heat exchanger inlet, turned upward by approx. - Page 13 Hyundai Sonata 1 7 mm dia. hole 25 mm Copying 85 mm hole pattern 1 Bracket 2 Copy hole pattern, 7 mm dia. drilled hole 3 Perforated plate with M6 flanged nut on original vehicle stud bolt 4 Bracket with M6x20 bolt, large diameter washer, M6 flanged nut on perforated bracket Copying...
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Page 14: Preparing Heater Unit
Hyundai Sonata Preparing heater unit a = 25 mm b = 55 mm Discard section X Cutting coolant hoses to length Tighten EJOT screws to 10 Nm! Insert two washers between heater unit and bracket at position x . 1 Heater unit 2 Bracket 3 Ejot screw, washer [3x] Preassem-... -
Page 15: Installing Heater Unit
Hyundai Sonata Installing heater unit Tighten EJOT screws to 10 Nm! 1 Perforated bracket on original vehicle stud bolt, M6 flanged nut 2 Hose section of heat exchanger inlet 3 27 mm dia. clamp Installing heater unit 1 M6x20 bolt [2x], large diameter washer [4x], M6 flanged nut [2x] Installing heater unit... -
Page 16: Coolant Connection Diagram
Hyundai Sonata Coolant connection WARNING! Tighten all hose clamps to 2.0 + 0.5 Nm. Any cold water 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 hose clamps and spring band clamps so that no other hose can be damaged. -
Page 17: All Vehicles
Hyundai Sonata Turn hose section 1 on engine outlet by 180°. Con- nection on engine outlet Con- nection on heater unit... -
Page 18: Combustion Air Connection
Hyundai Sonata Combustion air connection 1 Combustion air pipe a = 280 mm Cutting Discard section X com- bustion air pipe to length 1 Combustion-air intake muffler 2 Retaining clip in hole 3 Combustion-air intake pipe 4 27 mm dia. hose clamp Installing intake muffler... -
Page 19: Fuel Connection
Hyundai Sonata Fuel Connection 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. -
Page 20: Removing Fuel
Hyundai Sonata Remove and dismantle fuel-tank sending unit according to manufacturer's instructions. 1 Fuel-tank sending unit 2 Template 3 Copy hole pattern, 6 mm dia. hole Removing fuel Shape fuel standpipe according to template, cut to length and install, see "installation instructions". -
Page 21: Exhaust-Gas Connection
Hyundai Sonata Exhaust-gas connection 1 Exhaust pipe a = 700 mm 2 Exhaust end section b = 70 mm Preparing exhaust Discard section X pipe 1 Heater unit 2 Hose clamp 3 Exhaust pipe Installing exhaust pipe 1 Original vehicle stud bolt, large diameter washer, angle bracket, M6 flanged nut 2 Pipe clamp, M6x20 bolt, M6 flanged nut 3 Exhaust pipe... - Page 22 Hyundai Sonata 1 Hose clamp [2x] 2 Exhaust muffler 3 Exhaust end section 4 Exhaust pipe Installing exhaust pipe and exhaust section...
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Page 23: Final Work
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf, Germany - Hotline +49- (0)1805-932278 Hotfax +49-(0)395-5592-353 - http://www.webasto.de Printed in Germany 05/07Printed by: Steffen... -
Page 24: Operating Instructions For End Customer
Hyundai Sonata Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Before parking the vehicle, make the following settings: 1 Air outlet to windshield 2 Set fan to level "3" 3 Set temperature to "max." vehicles with automatic... -
Page 25: Template For Perforated Fastening Strap
Hyundai Sonata Template for Perforated Fastening Strap 100 mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Correct major differences in the printer settings or request an original printout. 100 mm... -
Page 26: Template For Fuel Sender
Hyundai Sonata Template for Fuel sender 6 mm dia. 100 mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Correct major differences in the printer settings or request an original printout. 100 mm... -
Page 27: Template For Fuel Standpipe
Hyundai Sonata 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%. Correct major differences in the printer settings or request an original printout. 100 mm...
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