Webasto Thermo Top Evo Installation Manual
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Webasto Thermo Top Evo Installation Manual

Parking heater for kia picanto
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See also: Workshop Manual , Instruction and Installation Manual
Water Heater
Thermo Top Evo Parking Heater
Installation documentation
Kia Picanto
Petrol
from model year 2011
Left-hand drive vehicle
Manual transmission
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, 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.
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 installa-
tion by untrained staff.
Ident. No.: 1317554A_EN
e1
00 0258
Fee Euro 10.00
Feel the drive
© Webasto AG

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Summary of Contents for Webasto Thermo Top Evo

  • Page 1 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

    Kia Picanto Table of Contents Validity Preparing installation location Heater/Installation Kit Preparing heater Foreword Installing heater General Instructions Coolant circuit Special Tools Combustion air Explanatory notes on document Fuel Preliminary work Exhaust gas Heater installation location Final Work Preparing electrical system Template for fuel standpipe Electrical system Operating Instructions for the End Customer 29...

  • Page 3: Heater/Installation Kit

    However, the stipulations in the "installation documentation", the "operating instructions" and "installa- tion 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.

  • Page 4: Explanatory Notes On Document

    Kia Picanto 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

    Kia Picanto Preliminary work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the fuel tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurise 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

    Kia Picanto Preparing electrical system Wire sections retain their numbering in the entire document. 0,5² 0,5² Preparing lines 0,5² gn/ws 0,5² 1000 Connect wires to socket IPCU. IPCU view on contact side. The IPCU attached in the kit is pre-pro- grammed with the following settings: IPCU Duty cycle: 100%...
  • Page 7 Kia Picanto Insert K1 relay 1 after the installation. 2 Angle bracket 3 M5x16 bolt, large diameter washer [2x], 4 Passenger compartment fuse holder Premount- ing pas- senger compart- ment fuse holder Complete connector of metering pump again after routing. Pin assignment is not relevant. 1 Connector housing 2 Lock 3 Blue/brown (bl / br) wires...

  • Page 8: Electrical System

    Kia Picanto Electrical system Wiring harness pass through, earth wire Digital timer 1 Protective rubber plug 1 Digital timer 2 Earth wire on original vehicle earth support point Do not install the metering pump wiring harness until later togeth- er with fuel pipe along the origi- nal vehicle fuel lines on the underbody Wiring har-...

  • Page 9: Fan Control

    0,75² 0,5² 0,5² 4² 0,5² 0,5² 4² IPCU gn/ws 0,5² 0,5² Webasto components Vehicle components Colours and symbols Heater TT-Evo Fan controller 6-pin heater connector D 4-pin connector GR black 2-pin heater connector KB A/C control panel yellow 4-pin connector of...
  • Page 10 Kia Picanto Route wiring harness of heater and fuel line in 17 mm dia. corrugated tube 1 to original vehi- cle wiring harness on the right hand side of vehicle. Routing wiring har- ness 1 Wiring harness on heater 2 Fuel line 3 17 mm dia.
  • Page 11 Kia Picanto Drill hole at position 1 to 6.5 mm dia. 1 M6x12 bolt, flanged nut 2 IPCU socket Mounting IPCU sock- 1 IPCU Connect- ing IPCU 1 Original vehicle bolt Brown (br) wire of IPCU/85 IPCU earth connection Connection to 4-pin connector 1 from fan controller.

  • Page 12: Remote Option (Telestart)

    Kia Picanto Connection to 2-pin connector 1 from fan mo- tor. Produce connections as shown in wiring diagram. 2 Blue (bl) wire from GM connector 3 Blue (bl) wire from fuse Connect- Red (rt) wire from K1/87a ing the fan Black (sw) wire from K1/30 motor Green/white (gn/ws) wire from IPCU/86...

  • Page 13: Preparing Installation Location

    Kia Picanto Preparing installation location 1 Remove original vehicle bolt (will be re- used here) 2 Drill hole to 9.1 mm dia.; rivet nut Installing rivet nut 1 Perforated bracket a Angling down per- forated bracket 47° 45° 1 Perforated bracket b Preparing perforated bracket...

  • Page 14: Preparing Heater

    Kia Picanto 1 Original vehicle bolt 2 Perforated bracket a 3 M6x40 bolt, spring lockwasher, 20 mm shim, original vehicle threaded hole 4 Bracket section A 5 M6x20 bolt, spring lockwasher, perforat- Mounting ed bracket b bracket A Preparing heater 1 Water connection pieces, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of...

  • Page 15: Installing Heater

    Kia Picanto All spring clips = 25 mm dia. Connecting pipe = 90°, 18x18mm dia. Premount- ing hoses 1 5x13 self-tapping bolt [3x] 2 Bracket section B Mounting bracket B 1 25 mm dia. clamp 2 Mount wiring harness of circulating pump 3 Combustion air pipe 4 90°...
  • Page 16 Kia Picanto 1 Bracket 2 7 mm dia. hole 3 M6x20 bolt, spring lockwasher, flanged nut 4 M6x20 bolt, large diameter washer 5 5x13 self-tapping bolt Mounting heater 1 10 mm dia. clamp 2 Fuel line Connect- ing fuel line 1317554A_EN...

  • Page 17: Coolant Circuit

    Kia Picanto Coolant circuit WARNING! Any coolant running off should be collected in a suitable container. Install hoses so that they are kink- free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline"...
  • Page 18 Kia Picanto 1 Perforated bracket Angling down per- forated bracket 90° All spring clips = 25 mm dia. Connecting pipe = 90°, 18x18mm dia. 1 Perforated bracket 2 M6x25 bolt, flanged nut 3 Circulating pump Premount- 4 Mounting of circulating pump ing circu- lating pump...
  • Page 19 Kia Picanto Cutting out insulation mat at the marking. 1 Original vehicle stud bolt, 5 mm shim Mounting shim Cutting out insulation mat at the marking. 1 Original vehicle stud bolt, 5 mm shim Mounting shim Connect- ing heat exchanger inlet 1 Perforated bracket 2 Mount wiring harness of circulating pump...
  • Page 20 Kia Picanto Connect- ing heater inlet 1 Hose of engine outlet Connect- ing engine outlet Ensure sufficient distance from neighbouring components. 1 25 mm dia. rubber coated p-clamp, flang- ed nut of original vehicle stud bolt 2 Mount hose on heat exchanger outlet Aligning hoses 1317554A_EN...

  • Page 21: Combustion Air

    Kia Picanto Combustion air 1 10 mm shim, original vehicle stud bolt Mounting shim 1 Angle bracket 2 Combustion air pipe 3 Flanged nut 4 M6x20 bolt, flanged nut 5 Silencer 6 25 mm dia. rubber-coated p-clamp Mounting silencer 1317554A_EN...

  • Page 22: Fuel

    Kia Picanto Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off in a suitable 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 Kia Picanto 1 Wiring harness of metering pump, con- nector mounted 2 Fuel line of heater 3 Hose section, 10 mm dia. clamp [2x] Connect- ing meter- ing pump Separate fuel-tank vent line 1 approx. 50mm before the fuel tank connection piece. Re- move hose section 3 .
  • Page 24 Kia Picanto Slide 10 mm dia. corrugated tube 1 on to fuel line of fuel standpipe 3 . Check the position of the components; adjust if necessary. Check that they have freedom of movement. 2 Hose section, 10 mm dia. clamp [2x] Connect- ing meter- ing pump...

  • Page 25: Exhaust Gas

    Kia Picanto Exhaust gas Discard section X 1 Exhaust pipe Preparing 2 Exhaust end section exhaust pipe 1 Perforated bracket 2 10.5 mm dia. hole Preparing perforated bracket 70° 90° 90° 1 Hose clamp [2x] 2 Silencer 3 Exhaust end section 4 Perforated bracket 5 M6x16 bolt, spring lockwasher 6 Exhaust pipe...
  • Page 26 Kia Picanto Ensure sufficient distance from neighbouring components. 1 M10x20 bolt, spring lockwasher 2 Tighten hose clamp Mounting silencer 1317554A_EN...

  • Page 27: Final Work

    - Place signboard "Switch off parking heater before refuelling" in the area of the filler neck - See installation instructions for initial start-up and function test Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78...

  • Page 28: Template For Fuel Standpipe

    Kia Picanto Template for fuel standpipe 100mm 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 “minimise mar- gins” and 100% of the normal size. 100mm 1317554A_EN...

  • Page 29: Operating Instructions For The End Customer

    Kia Picanto 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. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.

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