Webasto Thermo Top Evo Installation Documentation
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Webasto Thermo Top Evo Installation Documentation

Webasto Thermo Top Evo Installation Documentation

Parking heater with fuelfix for kia rio
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Download this manual See also: Workshop Manual, Installation Documentation
K
Water Heater
Thermo Top Evo Parking Heater
With FuelFix
Installation Documentation
Kia Rio

Validity

Manufacturer
Kia
Motorisation
1.4 P CVVT
SG = manual transmission
From model year 2011
Left-hand drive vehicle
Verified equipment variants: Manual / automatic air-conditioning system
Total installation time:
Ident. No.: 1318004J_EN
Model
Rio
Fuel
Transmission type Output in kW
Petrol
6-speed SG
Front fog lights
Euro 5 / Euro 6
approx. 7 hours
Status: 30.03.2016
E
1
00 0258
Type
UB
80
EG BE No. / ABE
e11 * 2007 / 46 * 0195 * ...
Displacement in cm³ Engine code
1396
G4FA
© Webasto Thermo & Comfort SE

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Summary of Contents for Webasto Thermo Top Evo

  • Page 1: Validity

    Water Heater Thermo Top Evo Parking Heater 00 0258 With FuelFix Installation Documentation Kia Rio Validity Manufacturer Model Type EG BE No. / ABE e11 * 2007 / 46 * 0195 * ... Motorisation Fuel Transmission type Output in kW Displacement in cm³...

  • Page 2: Table Of Contents

    MultiControl CAR Option Remote Option (Telestart) ThermoCall Option Necessary Components Basic delivery scope of Thermo Top Evo in accordance with price list • Installation kit with FuelFix Kia Rio 1.2 / 1.4 Petrol 2012: 1318003G • Heater control in accordance with price list and upon consultation with end customer •...

  • Page 3: Information On Operating And Installation Instructions

    To ensure safe operation, we recommend having the heater checked every two years 2.2. Positioning of heater by an authorised Webasto dealer, especially when used over a long period and/or un- der extreme environmental conditions. 2.2.1. Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination.

  • Page 4: Information On Validity

    • Torque wrench for 2.0 - 10 Nm • Hose clamping pliers • Metric thread-setter kit • Deep-hole marker • Webasto Thermo Test Diagnosis with current software Dimensions • All dimensions are in mm. Tightening torque values • Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.

  • Page 5: Preliminary Work

    • Remove years that do not apply from the type and duplicate label. • Attach the duplicate label (type label) visibly in the appropriate place in the engine compart- ment. Heater Installation Location 1 Heater Installation location Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 6: Preparing Electrical System

    Red (rt) wire of fan wiring harness 4² Black (sw) wire of fan wiring harness rt/sw gn/ws 4² 0,5² 0,5² 0,75² Connecting wires to pas- senger com- partment relay and fuse holder 4² 4² Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 7 Cutting to length / as- signing wires 0,75² rt/sw gn/ws 0,5² 4² 0,5² 0,75² 0,5² Connecting wires to pas- senger com- partment relay and fuse holder 0,5² 4² 4² Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 8 All vehicles 1 Fuse holder 2 M5x16 bolt, angle bracket, large di- ameter washer [2x], nut Premounting engine com- partment fuse holder Connector X7 Disman- tling meter- ing pump connector Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 9: Electrical System

    Engine compartment fuse holder 1 Positive wire on positive distributor Remove original vehicle clip at position 2. 1 Angle bracket 2 M6x20 bolt, flanged nut, existing hole 3 Fuses F1-2 Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 10: Manual Air-Conditioning Fan Controller

    4-pin connector of 40A fuse white heater control Fan relay blue 1A fuse Fan motor 25A fuse Resistor group Cutting point Fan relay Fan switch Wiring colours may vary. Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 11 3 Blue (bl) wire of fan relay ing fan mo- 4 Connector I/P-E (see small image) Red (rt) wire of K1/87a, fan wiring har- ness Black (sw) wire of K1/30, fan wiring harness Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 12: Automatic Air-Conditioning Fan Controller

    2-pin connector of GM Fan controller Cutting point 4-pin connector of GRr Insulate wire end and tie back A/C control unit M33A 8-pin connector of KB Wiring colours may vary. Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 13 4 Orange (or) wire of 10-pin connector Connecting M33A, pin 1 A/C control 5 White (ws) wire of 10-pin connector unit M33A, pin 7 Black (sw) wire of fuse F5 Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 14: Multicontrol Car Option

    3 Original vehicle stud bolt, flanged nut receiver 1 Aerial Installing aerial Temperature sensor T100 HTM Fasten temperature sensor 1 using dou- ble-sided adhesive tape. Installing tempera- ture sensor Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 15: Thermocall Option

    Kia Rio ThermoCall Option Fasten receiver 1 with double-sided adhe- sive tape. Installing receiver 1 Aerial (optional) Installing aerial Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 16: Preparing Installation Location

    1 for 7mm dia. hole and drill. 2 M6x12 bolt, flanged nut [4x each] 4 Drill hole to 12mm dia., coat with cor- Preparing rosion protection [3x] bracket Bending perforated bracket 63° 70° Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 17: Preparing Heater

    Slide braided protection hoses onto hoses B and G and cut to length. Cut heat shrink plastic tubing to size. 1 50 mm long heat shrink plastic tubing [4x] Preparing hoses Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 18: Installing Bracket

    2 Original vehicle bolt 3 Bracket 4 Original vehicle bracket Installing bracket 1 Original vehicle bolt 2 M6x16 bolt, flanged nut 3 Loosely mount perforated bracket Premount- ing perfo- rated bracket Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 19: Installing Heater

    Cutting self- adhesive foam to size Installing self-adhe- sive foam to size Installing Heater Insert heater 3 in bracket 1 and tighten self-tapping bolts 2 [2x]. Installing heater Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 20 Kia Rio Tighten self-tapping bolts 1 [2x]. Installing heater Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 21: Combustion Air

    4 Silencer Installing combus- tion air pipe and silenc- 1 Heater wiring harness connector [2x] 2 Cable tie 3 Combustion air pipe Installing heater wir- ing har- ness Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 22: Coolant Circuit

    All spring clips without a specific designation = 25 mm dia. 1 = Original vehicle spring clip 2 = Black (sw) rubber isolator . All connecting pipes without a specific designation = 18x18mm dia. Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 23 2 Wiring harness of circulating pump Installing 3 Circulating pump circulating pump Original vehicle hose 2 has been removed for illustrative purposes. Twist original ve- hicle spring clips 1 [2x] upwards. Preparing hose rout- Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 24 3 Original vehicle spring clip will be re- used. Cutting point 1 Circulating pump Connect- ing circu- lating pump Connect- ing circu- lating pump 1 Engine outlet connection piece Connect- ing engine outlet Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 25 3 Rubber isolator Connect- ing heat ex- changer inlet Ensure sufficient distance and freedom of movement with regard to parts of the gear change, correct if necessary. Aligning hoses Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 26: Fuel

    Route fuel line, wiring harness of metering pump in 10mm dia. corrugated tube 1 along original vehicle lines to the under- body and secure using cable ties. Routing lines Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 27 1 M6x20 bolt, flanged nut, original vehi- cle hole Installing 2 Metering pump metering pump Connector X7 Complet- ing meter- ing pump connector Pin assignment is not relevant. Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 28: Installing Fuelfix

    2 Position washer with outer dia. = 21.6mm as template against the raised parts. Copying 3 Hole pattern hole pattern Work step F3. 1 Hole made with provided drill Hole for FuelFix Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 29 Kia Rio Work steps F4 and F5. Bend FuelFix 1 according to template and cut to length. Inserting FuelFix Inserting FuelFix Inserting FuelFix Inserting FuelFix Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 30 F 7.1. F 7.3. F 7.4. - max F 7.2. Installing <1... 0 mm F 7.5. FuelFix 0 mm 90° F 7.6. Work step F8. Checking firm seating of FuelFix Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...
  • Page 31 Check that they have freedom of movement. 1 Hose section, 10mm dia. clamp [2x] 2 Fuel line of FuelFix Connect- 3 10 mm dia. corrugated tube ing meter- ing pump Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 32: Exhaust Gas

    1 Hose clamp [2x] Installing exhaust pipe a1 Ensure sufficient distance from neighbour- ing components. 1 Silencer 2 Hose clamp 3 Spacer bracket Installing exhaust pipe a2 Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 33: Final Work

    1 centrally in hole and flush with underride protection 2 . Aligning exhaust end section Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 34: Fuelfix Template

    Compare size of printout with dimension lines. Allowed tolerance a maximum of 2%. Set the printer settings to ‘no margin’ or ‘minimise mar- gins’ and 100% of the normal size. 100mm Ident. No.: 1318004J_EN Status: 30.03.2016 © Webasto Thermo & Comfort SE...

  • Page 35: Operating Instructions For Manual Air-Conditioning

    Kia Rio Operating Instructions for Manual Air-Conditioning 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.

  • Page 36: Operating Instructions For Automatic Air-Conditioning

    Kia Rio Operating Instructions for Automatic Air-Conditioning 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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