ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Unit Feel the drive Thermo Top E Additional Heater Thermo Top C Additional Heater Thermo Top P Additional Heater e e e Installation Instructions Kia cee'd Gasoline and Diesel from Model Year 007 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, 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.:3334B_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater Unit/Installation Kit 3 Foreword 3 General Instructions 3 Special Tools 3 Explanatory Notes on Document 4 Preliminary Work 5 Heater unit installation location 5 Electrical Connections 6 Fan controller for manual air conditioning 7 Automatic air-conditioning fan controller 9 Remote option (Telestart) Remote option (Thermo Call) Preparing heater unit for gasoline vehicles 3 Preparing heater unit for diesel vehicles 4 Preparing installation location 5 heater unit 6 Coolant for gasoline engine 8 Coolant for diesel engine Fuel 5 Removing gasoline 5 Removing diesel 7 All vehicles 8 Exhaust gas 30 Final Work 3 Operating Instructions for End Customer 33 Template for Perforated Fastening Strap 34 Template for Fuel Standpipe of Gasoline Engines 35 Validity Manufacturer Model Type EG-BE No./ABE Kia cee'd ED e4 * 00/6 * 0 Engine type Engine model Output in kw Displacement in cm³ G4FC Gasoline D4FB Diesel Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation. 3334B_EN

3 Heater Unit/Installation Kit Quantity Description Order No.: Retail accessories with desired heater control See price list Installation kit for Kia cee'd gasoline 3333A or Installation kit for Kia cee'd diesel 3744A Heater unit recommended for the respective vehicle class: Vehicle Compact car Mid-size car, station wagon Full-size car, van, offroader Heater unit Thermo Top E Thermo Top C Thermo Top P The selection of the heater unit is based on the passenger compartment size of the vehicle and the level of comfort required by the customer! Foreword These installation instructions apply to Kia cee'd Gasoline and Diesel vehicles - for validity, see page - from model year 007 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 these installation instructions. However, the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top C/P/E 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. 39). Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit - Flexible socket wrench, 7 mm 3334B_EN 3

4 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 Water Fuel Exhaust gas Combustion air 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 vehiclespecific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. 3334B_EN 4

5 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. - Attach the duplicate label (type label) in the appropriate place. - Remove door sill trim on front passenger side. - Remove the A-pillar trim in the footwell on the front passenger side. - Remove the trim for radio/a/c control panel. - Remove the lower instrument panel trim on the driver's side. - Remove the rear bench seat. - Open the tank-fitting service lid - Remove the air filter together with the intake hoses. - Detach the trim of the cable pass through on the firewall. - Detach the wheel well trim on the right and left. - Remove the bumper. - Remove the rear left tank trim. Remove page 33 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater unit installation location Heater unit Installation location 3334B_EN 5

6 Electrical Connections Wiring harness pass through Protective rubber plug Digital timer Digital timer 3 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 3 Fuse holder, relay K3 4 4 Ground connection 5 Angle down perforated bracket according to template. Ground point on strut tower Original vehicle bolt 3 Fuse holder, replace F3 5 A fuse with 5 A fuse. 4 M5x6 bolt, washer, retaining plate of fuse holder, K3 relay, nut 3334B_EN 6

7 Fan controller for manual air conditioning Webasto F3 HG X 4 F6 F5 JM03 4 Kia GRs 3 5 M7 ws F Wiring diagram gn/ ws 86 rt/ws 87 rt 4² 87a pk ge rt/sw 0,3² or 0,5²! GM M M K3 rt/sw 0,3² sw ² ge sw 4² pk pk bl or 0,5² pk M4 3 M06-A M06-B br GRr sw sw sw KB 3 Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E GM Fan motor rt red X 6-pin heater unit connector M6 Connector GM ws white F3 5 A replaced with 5 A KB Air-conditioning control sw black fuse. element M06-A 3-pin connector KB or orange K3 Fan relay M06-B Connector KB gn green K3 Fan relay F4 Fuse 40A bl blue F5 0 A fuse ge yellow F6 0 A fuse pk pink GRs Fan relay M7 5-pin connector GRs JM03 Connector Insulate wire end and tie GRr Fan controller back M4 Connector GRr X Cutting point Wiring colors may vary. Legend 3334B_EN 7

8 Connection on connector M7 of fan relay on right next to glove compartment. Pull off connector M7. Disconnect red/black (rt/sw) wire, 0.3², at Pin 3. Connector of fan relay M7 6 5 * 3 Produce connection as shown in wiring diagram. Install additional black (sw) wire in protective sleeving. 3 Black (sw) wire from K3/30 3 Red (rt) wire from K3/87a Preparing additional wire 7 Produce connections as shown in wiring diagram. Red (rt) wire from K3/87a Black (sw) wire from K3/30 Connecting fan relay 8 Connection on connector M06-A 4 of A/C control panel. Produce connections as shown in wiring diagram. 3 Insulate orange (or) wire of connector JM03, PIN 4 and tie back Black (sw) additional wire 3 Orange (or) wire, PIN Connecting A/C control panel * * * 3334B_EN 8

9 Automatic air-conditioning fan controller Webasto F3 HG X 4 F6 F5 JM Kia GRs 3 5 M7 ws F Wiring diagram gn/ ws 86 rt/ws 87 rt 4² 87a pk rt rt/sw 0,3² or 0,5²! or 0,5²! GM M M K3 rt/sw 0,3² sw ² ge sw 4² pk pk bl or 0,5² or 0,5² ge M4 3 M05-A M05-B br GRr sw sw sw KB 3 Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E GM Fan motor rt red X 6-pin heater unit connector M6 Connector GM ws white F3 5 A replaced with 5 A KB Air-conditioning control sw black fuse. element M05-A 6-pin connector KB or orange K3 Fan relay M05-B Connector KB gn green F4 Fuse 40A bl blue F5 0 A fuse ge yellow F6 0 A fuse pk pink GRs Fan relay M7 5-pin connector GRs JM03 Connector Insulate wire end and tie GRr Fan controller back M4 Connector GRr X Cutting point Wiring colors may vary. Legend 3334B_EN 9

10 Connection on connector M7 of fan relay on right next to glove compartment. Pull off connector M7. Disconnect red/black (rt/sw) wire, 0.3², at Pin 3. Connector of fan relay M7 0 5 * 3 Produce connection as shown in wiring diagram. Install additional black (sw) wire in protective sleeving. 3 Black (sw) wire from K3/30 3 Red (rt) wire from K3/87a Preparing additional wire Produce connections as shown in wiring diagram. Red (rt) wire from K3/87a Black (sw) wire from K3/30 Connecting fan relay Connection on connector M05-A 3 of A/C control panel. Insulate orange (or) wires, 6 of connector JM03, PIN ; 3 and tie back. Produce connections as shown in wiring diagram. Black (sw) additional wire 4 Orange (or) wire, PIN Orange (or) wire, PIN 3 Connecting A/C control panel * * B_EN 0

11 Remote option (Telestart) Receiver, bracket angled down 5.5 mm dia. hole, M5x6 bolt, flanged nut receiver 4 Antenna antenna 5 Temperature sensor for HTM00 only Temperature sensor, fasten with suitable means temperature sensor B_EN

12 Remote option (Thermo Call) Receiver, Velcro strip receiver 7 Antenna antenna B_EN

13 X D B E X Preparing heater unit for gasoline vehicles b = 00 mm d = 0 mm e = 90 mm Discard section X Cutting coolant hoses to length C A B Push braided protection hose onto hose B and E and cut to length. Cut heat shrink plastic tubing to length. 5 mm heat shrink plastic tubing [4x] Preparing coolant hoses E A A 80 molded hose mm dia. clamp Connecting pipe, dia. 8x0 mm Preparing hose A 9 D C D Hose section, connecting pipe, dia. 0x0 mm, 7 mm dia. clamp [x] C 80 molded hose 9938, connecting pipe, dia. 0x0 mm, 7 mm dia. clamp [x] Preassembling coolant hoses on heater unit B_EN 3

14 Hose section, 0 mm dia. clamp [x] Fuel line in corrugated hose Premounting fuel hose on heater unit C A X D X B X Preparing heater unit for diesel vehicles a = 840 mm c = 30 mm d = 790 mm Discard section X Cutting coolant hoses to length D Push braided protection hoses onto hose A and D and cut to length. Cut heat shrink plastic tubing to length. 5 mm heat shrink plastic tubing [4x] Preparing coolant hoses A C B C Hose section, connecting pipe, dia. 0x0 mm, 7 mm dia. clamp [x] B 80 molded hose 9938, connecting pipe, dia. 0x0 mm, 7 mm dia. clamp [x] Preassembling coolant hoses on heater unit 3334B_EN 4

15 Hose section, 0 mm dia. clamp [x] Fuel line in corrugated hose Premounting fuel hose on heater unit 3 Preparing installation location Original vehicle retaining clip released Insert 30 mm edge protection Moving wiring harness 4 35 mm Align bracket, copy hole pattern [4x] Copying hole pattern 45 mm 5 9. mm dia. hole; mount rivet nut [4x each] rivet nut B_EN 5

16 M6x5 bolt, spring lockwasher [4x each] bracket 7 heater unit Tighten EJOT screws to 0 Nm! Insert two washers between heater unit and bracket at position. Ejot screw, washer [x] Ejot screw [x] heater unit 8 Ejot screw bolt, tightening torque 0 Nm. heater unit 9 Route fuel line and wiring harness of metering pump in corrugated tube to firewall and along original vehicle fuel lines to underbody. Cut fuel line to length at installation location of metering pump. Routing fuel line and wiring harness B_EN 6

17 Combustion air Retaining clip Releasing retaining clip of connector 3 Angle bracket [x] M6x0 bolt, flanged nut angle bracket 3 Combustion-air intake pipe 7 mm dia. hose clamp intake pipe 33 Original vehicle connector, cable tie Combustion-air intake muffler, 5 mm dia. p-clamp, M6x0 bolt, flanged nut muffler B_EN 7

18 Coolant for gasoline engine WARNING! Tighten all hose clamps to Nm. 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 hose clamps so that no other hose can be damaged! The connection should be "inline" based on the following diagram: Coolant routing diagram Ø 8x0 D C A Ø 8x0 B E All hose clamps = 0-7 mm dia.! = Black (sw) rubber isolator All connecting pipes without a specific designation = 0x0 mm. 3334B_EN 8

19 Pull original vehicle hose off connection piece of engine outlet. Cutting point 35 A Connecting engine outlet 36 Hose section of heat exchanger inlet Black rubber isolator rubber isolator 37 Retaining clip Releasing retaining clip B_EN 9

20 M6x0 bolt, flanged nut Rubber-coated pipe clamp, 48 mm dia. p-clamp 39 Rubber-coated pipe clamp, 48 mm dia. M6x0 bolt, flanged nut p-clamp 40 E Connecting heater unit outlet 4 B C Connecting heater unit inlet B_EN 0

21 B E 43 B A Routing in engine compartment Connecting engine outlet 44 E Before connecting, fill the coolant hoses with coolant. Hose section of heat exchanger inlet Original vehicle wiring harness, retaining clip removed, cable tie Connecting heat exchanger inlet 45 Ensure sufficient distance to adjacent components; correct if necessary. Install spacer and align black (sw) rubber isolator (covered). Aligning hoses B_EN

22 Coolant for diesel engine WARNING! Tighten all hose clamps to Nm. 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 hose clamps so that no other hose can be damaged! The connection should be "inline" based on the following diagram: Coolant routing diagram D B C A All hose clamps = 0-7 mm dia.! = original vehicle spring clip Al connecting pipes = 0x0 mm 3334B_EN

23 Remove hose section from heat exchanger inlet 3 and discard. Original vehicle spring clip will be reused. Engine outlet hose section Cutting point 3 47 Rubber-coated pipe clamp, 48 mm dia. M6x0 bolt, flanged nut p-clamp 48 D Connecting heater unit outlet 49 A B Connecting heater unit inlet B_EN 3

24 D Route hose A and D through rubber-coated p-clamp. Ensure sufficient distance to neighboring components. A 5 Engine-outlet hose section Routing in engine compartment Connecting engine outlet A D 5 Before connecting, fill the coolant hoses with coolant. Original vehicle spring clip Spacer bracket Connecting heat exchanger inlet A B_EN 4

25 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 in as shown in the wiring harness routing diagram. Removing gasoline Remove and dismantle fuel-tank sending unit according to manufacturer's instructions. Mount rivet nut for centering in center of cover segment and predrill 5.5 mm dia. Copying hole pattern 54 Drill out 6 mm dia. hole Drilling hole in fuel-tank sending unit 55 Shape fuel standpipe according to template, cut to length and install, see "installation instructions". Insert 4x 6 mm dia. washers between cover of fuel-tank sending unit and nut of fuel standpipe to adjust height. fuel standpipe B_EN 5

26 Hose section, 0 mm dia. Caillau clamp Aligning fuel standpipe 57 Cut out mounting flange in area of marking Laying on mounting flange 58 Install fuel-tank sending unit according to manufacturer's specifications. Fuel line Hose section, 0 mm dia. Caillau clamp Connecting fuel line B_EN 6

27 Removing diesel Remove protective sleeving on fuel supply line Removing protective sleeving 60 Cut off fuel supply line 3 approx. 50 mm before coupling and insert fuel standpipe. 3 6x5x6 fuel standpipe, 8 mm dia. clamp [x] Fuel line, hose section, 0 mm dia. clamp [x] Mounting fuel standpipe B_EN 7

28 All vehicles Angle bracket, M6x0 bolt, large diameter washer, flanged nut on existing hole Fuel line from fuel standpipe angle bracket 6 Silent block, rubber-coated p-clamp, flanged nut Hose section, 0 mm dia. clamp [x each] 3 Metering pump Preassembling metering pump 3 63 Ensure proper installation position of metering pump, see "Installation Instructions. M6 flanged nut on angle bracket metering pump 64 Fuel line from fuel standpipe on intake side of metering pump. Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section (scuff guard), cable tie [x] 0 mm dia. clamp Connecting fuel line B_EN 8

29 Detach line duct 3 and fold down, cut out edge at Pos. for corrugated tube. Fuel line from heater unit in corrugated tube Cutting out line duct 3 66 Fuel line in corrugated tube Metering pump wiring harness 3 Line duct Guiding lines into cover 3 67 Metering pump wiring harness Fuel line lines on underbody 68 4 Fuel line from heater unit on pressure side of metering pump. Check the position of the components; adjust if necessary. Check that they have free clearance. 0 mm dia. clamp Hose section (scuff guard), cable tie [x] 3 Installed line duct 4 Wiring harness of metering pump, connector mounted Connecting to metering pump B_EN 9

30 Exhaust gas Exhaust pipe a = 30 mm Exhaust end section b = 75 mm Discard section X Preparing exhaust pipe a b X Disconnect ground cable and fasten to adjacent ground point. Refastening ground wire 70 Angle bracket, M6x0 bolt, large diameter washer, flanged nut Radiator cross member angle bracket 7 Angle bracket, original vehicle bolt Exhaust muffler, 40 mm spacer, M6x50 bolt, flanged nut muffler B_EN 30

31 Hose clamp [x] Red (rt) rubber isolator 3 Exhaust pipe exhaust pipe 3 73 Hose clamp Exhaust end section 3 P-clamp, M6x0 bolt, flanged nut on angle bracket exhaust end section B_EN 3

32 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 unit components with anti-corrosion wax (Tectyl 00K, Order No. 39). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer. - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. E Gasoline Cable tie Fastening hoses B B_EN 3

33 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. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in the position Winter heat and in the position Summer. Before parking the vehicle, make the following settings: Air outlet to windshield Set fan to level "", or possibly "" 3 Set temperature to "max." Manual air conditioning 3 76 Air outlet to windshield Set fan to level "", or possibly "" 3 Set temperature to "HI Automatic air-conditioning 3 77 Feel the drive Webasto AG Postfach Stockdorf Hotline 0805 / Hotfax 0395 / B_EN Printed in Germany 08/007 Printing: Steffen

34 Template for Perforated Fastening Strap 57mm mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimize margins and 00% of the normal size. 00 mm B_EN 34

35 Template for Fuel Standpipe of Gasoline Engines 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimize margins and 00% of the normal size. 00 mm B_EN 35