Validity 1
Necessary Components 2
Installation Overview 2
Information on Total Installation Time 2
Information on Operating and Installation Instructions 3
Information on Validity 4
Technical Information 4
Explanatory Notes on Document 4
Preliminary Work 5
Heater Installation Location 5
Preparing Electrical System 6
Electrical System 8
Fan Controller for Manual Air-Conditioning 9
Fan Controller for Automatic Air-Conditioning 11
Digital Timer 14
Remote Option (Telestart) 14
Remote Option (Thermo Call TC3) 15
Preparing Installation Location 16
Preparing Heater 17
Installing Heater 19
Fuel 20
Combustion Air 24
Exhaust Gas 26
Coolant Circuit 28
Final Work 34
Template for Fuel Standp ipe 35
Operating Instructions for Manual Air-Conditioning 36
Operating Instructions for Automatic Air-Conditioning 37
• Basic delivery scope of Thermo Top Evo in accordance with price list
• Installation kit for Kia Carens 2014 Petrol: 1321246A
• additionally required in case of automatic air-conditioning:
Automatic air-conditioning kit for Kia Carens: 1321248A
• Heater control in accordance with price list and upon consultation with end customer
• In case of Telestart, indicator lamp in accordance with price list and in consultation with end
customer
7
6
1
5
2
3
4
Table of Contents
Necessary Components
Installation Overview
Legend:
1. Heater
2. Engine compartment fuse
holder
3. Passenger compartment relay
and fuse holder
4. IPCU (only with automatic airconditioning)
5. Circulating pump
6. Digital timer
7. Metering pump
Information on Total Installation Time
The total installation time inclu des the time needed for mo unting and demounting of th e vehicle-specific components,
the heater specific installation time and all other times required for the system integration and initial start-up of the
heater.
The total installation time may vary for vehicle equipment other than provided.
Kia Carens
Information on Operating and Installation Instructions
1Important Information (not complete)
1.1Installation and Repair
The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, lead ing
to serious injury or death.
T o install and repair Webasto heating and cooling systems you need to
have completed a special company training course and have the appropriate technical documentation, special tools and special equipment.
Installation and repair may ONLY be carried out by per sons trained and
certified in a Webasto training co urse. NEVER try to inst all or repair W ebasto heating or cooling systems if you have not completed a W eba st o
training course, you do not have the necessary technical skills and you
do not have the technical documentation, tools and equipment available
to ensure that you can complete the inst allation and repa ir work properly .
Only use genuine Webasto part s. See t he W eba st o air and wa ter hea t-
ers accessories catalogue for this purpose.
1.2Operation
To ensure safe operation, we recommend having the heater checked every two
years by an authorised Webasto de aler, especially when used over a long period
and/or under extreme environmental conditions.
Do not operate the heater in closed rooms due to the danger of poisoning and suffocation.
Always switch off the heater before refuelling.
The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or pet-
rol (DIN EN 227).
The heater may not be cleaned with a high-pressure cleaner.
1.3Please note
ALW A YS follow all Webasto installat ion and operating instructions and observe all
warnings.
T o become familiar with and underst and all functions and properties of the heate r,
the operating instructions must be read carefully and observed at all times.
For proper, safe installation and repair work, the installation instructions with all
warnings and safety information must be carefully read and observed at all times.
Please always contact a workshop authorised by W ebast o for all inst allat ion and
repair work.
Important
Webasto shall assume no liability for defect s, damage and injuries resulting
from a failure to observe the installation, repair and operating instructions
of the information contained in them.
This liability exclusion particularly applies to improper installations and repairs, installations and repairs by untrained persons or in the case of a failure to use genuine spare parts.
The liability due to culpable disregard to life, limb or health and due to damage or injuries caused by a wilful or reckless breach of duty remain unaffected, as does the obligatory product liability.
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.
Insulate loose wire ends and tie back. Connectors on electronic components must audibly snap into place during assembly.
Sharp edges should be fitted with rub protection. Spray
unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl
100K, Order No. 111329).
Observe the instructions and guidelines of the respective vehicle manufacturer for demounting and mounting vehicle specific components!
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
When installing an IPCU, the corresponding settings must be checked or
adjusted before the installation.
The regulations of these guidelines are binding in the scope of the Directive
70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and
should also be observed in countries in which there are no special regulations.
Important
Failure to follow the installation instructions will result in the invalidation of th e type
approval for the heater and therefore invalidation o f the general homologation of the vehicle.
For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4
of Annex VIII b to the Road Traffic Act is required.
Note
2.1Excerpt from the directive 2001/56/EC Appendix VII for the
installation of the heater
Beginning of excerpt.
ANNEX VII
REQUIREMENTS FOR COMBUSTION HEATERS
AND THEIR INSTALLATION
1.GENERAL REQUIREMENTS
1.7.1.A clearly visible tell-tale in the operator's field of vie w sh all infor m when
the combustion heater is switched on or off.
2.VEHICLE INSTALLATION REQUIREMENTS
2.1.Scope
2.1.1.Subject to paragraph 2.1.2. combustion heaters shall be installed according to the requirements of this Annex.
2.1.2.Vehicles of category O having liquid fuel heate rs are deemed to compl y
with the requirements of this Annex.
2.2.Positioning of heater
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.
2.2.2.The combustion heater shall not constitute a risk of fire, even in the case
of overheating. This requirement shall be deemed to be fulfilled if the installation ensures an adequate distance to all part s and suit able vent ilation, by the use of fire resistant materials or by the use of heat shields.
2.2.3.In the case of M2 and M3 vehicles, the heate r must not be positioned in
the passenger compartment. However, an installation in an effectively
sealed envelope which also complies with the conditions in paragraph
2.2.2 may be used.
2.2.4.The label referred to in paragr aph 1.4 or a duplicate, must be posi tioned
so that it can be easily read when the heater is installed in the vehicle.
2.2.5.Every reasonable precaution should be taken in positioning the heater
to minimise the risk of injury and damage to personal property.
2.3.Fuel supply
2.3.1.The fuel filler must not be situated in the passenger compartment and
must be provided with an effective cap to prevent fuel spillage.
2.3.2.In the case of liquid fuel heaters, where a supp ly sep ar ate to t hat of the
vehicle is provided, the type of fuel and its filler point must be clearly labelled.
2.3.3.A notice, indicating that the heater must be shut down before ref uelling,
must be affixed to the fuelling point. In addition a suitable instruction
must be included in the manufacturer's operating manual.
2.4.Exhaust system
2.4.1.The exhaust outlet must be locat ed so as t o pr event emissions f rom entering the vehicle through ventilators, heated air inlets or opening windows.
2.5.Combustion air inlet
2.5.1.The air for the combustion chamber of the heater must not be drawn
from the passenger compartment of the vehicle.
2.5.2.The air inlet must be so positioned or guarded that blocking by rubbish
or luggage is unlikely.
2.6.Heating air inlet
2.6.1.The heating air supply may be fresh or recirculated air and must be
drawn from a clean area not likely to be contaminated by exhaust fumes
emitted either by the propulsion engine, the combustion heater or any
other vehicle source.
2.6.2.The inlet duct must be protected by mesh or other suitable means.
2.7.Heating air outlet
2.7.1.Any ducting used to route the ho t ai r th roug h th e vehicle must be so positioned or protected that no injury or damage could be caused if it were
to be touched.
2.7.2.The air outlet must be so positioned or guarded that blockin g by rubbish
or luggage is unlikely.
End of excerpt.
In multilingual versions the German language is binding.
• 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.
• Tightening torque values of 5x15 retaining plate of water connection piece bolt = 7Nm.
• Tighten other bolt connections in accordance with manufacturer's instr uctions or in accordance with state-of-theart-technology.
Information on Validity
This installation documentation applies to Kia Carens Petrol vehicles - for validity, see page 1 - from model year 2014
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 this
installation documentation.
Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation
have not been tested. However, installation according to this installation documentation may be possible.
Technical Information
Explanatory Notes on Document
top right corner of the page in question to provide
you with a quick overview of the individual working
steps.
Mechanical system
Electrical system
Coolant circuit
Combustion air
Fuel
Exhaust gas
Special features are highlighted using the following symbols:You will find an identification mark on the outside
Specific risk of injury or
fatal accidents
Specific risk of damage to
components
Specific risk of fire and explosion
Reference to general installation instructions
of the Webasto component s 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 viewing angle
Wire sections retain their numbering in the
entire document.
Manual air-conditioning
Produce connections as shown in wiring diagram.
Connect wires in accordance with wiring diagram. 25A fuse F4 and K1 relay will only be
inserted after installation of relay and fuse
holder of passenger compartment.
1 Passenger compartment relay and fuse
holder
2 M5x16 bolt, angle bracket, large diame-
ter washer, self-locking nut
Red (rt) wire from K1/87a
Black (sw) wire from K1/30
Premounting passenger
compartment relay
and fuse
holder
Premounting passenger
compartment relay
and fuse
holder
Automatic air-conditioning
Preparing
lines
Connect wires to socket IPCU.
IPCU view on contact side.
The IPCU attached in the kit is pre-programmed with the following settings:
The settings must be checked during the
start-up of the heater and adjusted if necessary.
Premounting IPCU
6
Page 7
Kia Carens
3
2
26
4
1
135
123
456
86
8530
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
1
2
sw
4²
rt
4²
A
E
IPCU
85
86
6
4
3
5
gn/ws
0,75²
rt
0,75²
sw
0,75²
br
0,75²
3
4
90°
28
1
4
143
5
5
2
Connect wires in accordance with wiring diagram.
Interlock socket IPCU
partment relay and fuse holder
2 and passenger com-
1.
Red (rt) wire from K1/87a
Black (sw) wire from K1/30
Red (rt) wire of IPCU/E
Black (sw) wire of IPCU/A
Green/white (gn/ws) wire from IPCU/86
and K1/86
Brown (br) wire of IPCU/85 and K1/85
Produce connections as shown in wiring diagram. Insert K1 relay and 25A fuse F4. IPCU
will only be inserted after installation of relay
and fuse holder . Pull wires and into protective sleeving.
Connecting
wires
Preparing
K1 relay,
IPCU and
F4
All vehicles
Angle bracket for engine compartment
1
fuse holder
Complete connector of metering pump again
after routing. Pin assignment is not relevant.
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 again st stone impact. Un-
less 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 as shown in the wiring harne ss rout ing diagram.
Pull fuel line 1 and wiring harness of metering
pump
Install fuel-tank sending unit 3 in accordance
with manufacturer's instructions.
1 Fuel line of fuel standpipe
2 Fuel standpipe
4 Moulded hose, 10 mm dia. clamp [2x]
Mount fuel line of fuel standp ipe 1 with 10 mm
dia. clamp on 180° moulded hose
the position of the components; adjust if necessary. Check that they have freedom of
movement.
Any coolant running off should be collected in a suitable container. Install hoses so that they are kinkfree. 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" based on the following diagram:
Hose installation
diagram
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 and = 18x18 mm dia.
Reassemble the components in reverse order. Check all hoses, clamp s and all e lectrical conne ction s
for firm seating. Insulate all loose lines and tie back.
Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax
(Tectyl 100K, Order No. 111329).
• Connect the battery
• Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.
• Set the digital timer, teach telestart transmitter
• Make settings on A/C control panel according to the "Operating Instructions for End Customer".
• 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
1 Underride protection
2 60 mm dia. hole
Cutting out
underride
protection
Centrally align exhaust end section 2 in hole
and so that it is flush with underride
protection
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.
Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings
for the heating operation.
Instructions for de-activation may be obtained from the operating instructions of the vehicle.
Before parking the vehicle, make the following settings:
1 Set temperature to "max."
2 Set fan to level "1", or max. "2"
3 Air outlet to windscreen
A/C control
panel
30A main fuse F2 of passenger compart-
1
ment
2 20A heater fuse F1
1A fuse F3 of heater control
1
2 25A fan fuse F4
Fuses of
engine
compartment
Fuses of
passenger
compartment
Page 37
Kia Carens
81
1
2
1
82
2
18321
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.
Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings
for the heating operation.
Instructions for de-activation may be obtained from the operating instructions of the vehicle.
Before parking the vehicle, make the following settings:
1 Set temperature on both sides to "HI“
2 Air outlet faces "upward"
A/C control
panel
30A main fuse F2 of passenger compart-
1
ment
2 20A heater fuse F1
Fuses of
engine
compartment
1A fuse F3 of heater control
1
2 25A fan fuse F4
Fuses of
passenger
compartment
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