Webasto Thermo Top E User manual

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.
Feel the drive
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
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Hyundai Sonata
Gasoline
from Model Year 2005
Left-hand drive vehicle
Automatic air-conditioning
Ident. No.: 1310033B_EN Fee Euro 10 © Webasto AG

2
Hyundai Sonata
Validity
Vehicle and engine types and equipment variants 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.
Manufacturer Model Type EG-BE No./ABE
Hyundai Sonata NF e11 * 2001/116 * 0241
Engine type Engine model Output in kW Displacement in cm³
G4KC Gasoline 119 2359
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on the Document 4
Preliminary Work 5
Heater Unit Installation Location 5
Preparing Electrical System 6
Electrical Connections 7
Automatic Air-Conditioning Fan Controller 8
Automatic Air-Conditioning Circuit Diagram 9
Remote Option (Telestart) 10
Thermo Call option 11
Preparing Installation Location 12
Preparing Heater Unit 14
Installing Heater Unit 15
Coolant Connection Diagram 16
All Vehicles 17
Combustion Air Connection 18
Fuel Connection 19
Installation Location of Metering Pump 19
Removing Fuel 20
Exhaust-Gas Connection 21
Final Work 23
Operating Instructions for End Customer 24
Template for Perforated Fastening Strap 25
Template for Fuel Sender 26
Template for Fuel Standpipe 27
Table of Contents

33
Hyundai Sonata
Heater Unit/Installation Kit
Heater unit recommended for the respective vehicle class:
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
The installation instructions apply to the Hyundai Sonata vehicles with a Gasoline engine
- For the validity, see page 2 - from model year 2005 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, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Thermo Top C should 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 100K, Order No.
111329).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Hyundai Sonata Gasoline 1310031A
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanical work
Electrical connection
Coolant connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Hyundai Sonata
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 vehicle-
specific documents.
Reference to a special technical feature.
i
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.

5
Hyundai Sonata
Heater unit installation location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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 the coolant reservoir cap.
- Remove the entire air filter
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Detach the trim of the fuel lines on the underbody
- Remove the instrument panel trim in the right footwell
- Remove the A/C control panel.
- Remove the A-pillar trim on the right (only with Telestart)
Pre-
liminary
Work

6
Hyundai Sonata
Preparing electrical system
Only with automatic air-conditioning
Wire section 1will be required later for
connection of additional fuse.
Cutting
wires to
length
Make connections as shown in the wiring
diagram with the tab receptacles provided.
Pull wire section 2into protective sleeving
provided and route into passenger
compartment together with clock and fan
wiring harness.
Preassem-
bling K3
relay
sw 1,0mm²
2850
21
150
K3
87a8786
85 30
F4
br
br
rt
rt/
ws
1 2 swsw
sw

7
Hyundai Sonata
Electrical Connections
Wiring harness pass through
1Remove protective rubber plug and lay in
cable
Digital timer and summer/winter switch option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
Wiring
harness
installation
diagram
Connecting power supply
1Positive wire on positive support point
2Ground wire on battery terminal grounding
pole
Fuse holder, relay K3
1Retaining plate of fuse holder, 4 mm dia. hole,
5.5x13 self-tapping screw
2K3 relay, 4 mm dia. hole, 5.5x13 self-tapping
screw
310 A additional fuse
2
1
3
1
2
rt
sw
br
bl
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
4
2
1
5
1 2
3

8
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.
12-pin connector
23x connector
Con-
nectingfan
motor
Connection to 26-pin connector M 21-1 from
air conditioning control.
Make connections as shown in wiring
diagram with connectors provided.
1A/C control panel
226-pin connector Con-
necting air-
con-
ditioning
control
element
Connector view M21-1 on contact side
Connector
for A/C
control
panel
6
12
7
1
2
13 12 10 9
23 22 20 19 18 17
64
3
15 14
21
24
26 25
*
21 16
***

9
Hyundai Sonata
Automatic
air-con-
ditioning
circuit
diagram
Webasto components Hyundai components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
F3 Fuse GR Fan relay ws white
K3 Fan relay LT Power transistor sw black
F4 10 A additional fuse KSM A/C control module br brown
FG Fan fuse gn green
F4 GR fuse bl blue
F12 KSM fuse ge yellow
or orange
ro pink
Insulate wire ends and
tie back
XCutting point
sw
br
rt/ws
rt
4
HG
X1
F3
25A FG
40A
10
ge
rt
gn/ws
rt/ws
Webasto
31
30
15
Hyundai Sonata
M
+
-
GM KSM
ro
sw
1
2
LT
3
I34
I34
9
F4
F12
10A
!!
sw
sw
ge
rt rt
12 13 M21-1
M21-2
ro
bl
sw
K3
87a
87
86
85 30
F4
10A
!
rt rt
GR
i

10
Hyundai Sonata
Remote option (Telestart)
1Receiver, double-sided adhesive Velcro
strip
2Instrument panel trim
Installing
receiver
Routeantennacable to receiverin lower area
of A-pillar trim.
1Antenna
Installing
antenna
1
28
i
1
9

11
Hyundai Sonata
Remote option (Thermo Call)
1Receiver
2Cross member under steering column
3Double-sided adhesive Velcro strip
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
3
2
10
i
1
11
1
12

12
Hyundai Sonata
Preparing installation location
Disconnect hose section from heat
exchanger inlet 1and shorten by approx.
25 mm. Original vehicle clamp will be
reused.
2Cutting point [3x]
3Discard hose section Cutting
point for
coolant
1Remaining hose on heat exchanger inlet,
turned upward by approx. 25°
2Original vehicle clamp
Preparing
coolant
1Bracket
2Cutting point
3Discard section
Preparing
bracket
1Bracket
2Bend tab approx. 30°
Preparing
bracket
13
1 2
2
3
2
14
1
2
15
1
32
16
1 2

13
Hyundai Sonata
17 mm dia. hole
Copying
hole
pattern
1Bracket
2Copy hole pattern, 7 mm dia. drilled hole
3Perforated plate with M6 flanged nut on
original vehicle stud bolt
4Bracket with M6x20 bolt, large diameter
washer, M6 flanged nut on perforated
bracket
5M6x20 bolt, M6 flanged nut Copying
hole
pattern
17
1
85 mm 25 mm
18
1 2
4 3
5

14
Hyundai Sonata
Preparing heater unit
a = 25 mm
b = 55 mm
Discard section XCutting
coolant
hoses to
length
Tighten EJOT screws to 10 Nm!
Insert two washers between heater unit and
bracket at position x.
1Heater unit
2Bracket
3Ejot screw, washer [3x] Preassem-
bling
bracket on
heater unit
127 mm dia. hose clamp [2x]
218x20 connecting pipe
Pre-
mounting
water hose
on heater
unit
110 mm dia. hose clamp [2x]
2Hose section
3Mecanyl fuel line
Pre-
mounting
fuel hose
on heater
unit
ab
BA X
19
3
1 2
3
3
B
20
1
1
2
21
1 2
1
3

15
Hyundai Sonata
Installing heater unit
Tighten EJOT screws to 10 Nm!
1Perforated bracket on original vehicle stud
bolt, M6 flanged nut
2Hose section of heat exchanger inlet
327 mm dia. clamp Installing
heater unit
1M6x20 bolt [2x], large diameter washer
[4x], M6 flanged nut [2x]
Installing
heater unit
22
1 2
3
B
23
1 1

16
Hyundai Sonata
Coolant
routing
diagram
Wärme-
tauscher
Motor
Heat
exchanger
All clamps without a specific designation are 20-27 mm dia. hose clamps
All connecting pipes are 18x20 dia.
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.
The connection should be "inline" based on the following diagram:

17
Hyundai Sonata
Turn hose section 1on engine outlet by 180°.
Con-
nection on
engine
outlet
Con-
nection on
heater unit
24
1
25
A

18
Hyundai Sonata
Combustion air connection
1Combustion air pipe
a = 280 mm
Discard section XCutting
com-
bustion air
pipe to
length
1Combustion-air intake muffler
2Retaining clip in hole
3Combustion-air intake pipe
427 mm dia. hose clamp
Installing
intake
muffler
a
1
X
26
4
1 2 3
i

19
Hyundai Sonata
Ensure proper installation position of
metering pump, see "Installation
Instructions“.
Installation location on left next to vehicle fuel
tank.
1Original vehicle bolt
2Silentblock, M6 flanged nut
3Angle bracket Installation
location of
metering
pump
Fuel line from heater unit on pressure side of
metering pump [side with connector].
1Metering pump
2Rubber-coatedp-clamponsilentblock,M6
flanged nut
3Wiring harness of metering pump,
protective rubber plug, tab connector,
connector housing
4Mecanyl fuel line
5Included hose section as protection
6Hose section, 10 mm dia. clamp [2x]
Installing
metering
pump
1Mecanyl fuel line
2Metering pump wiring harness
3Cover for fuel lines
Installing
lines
27
1 2
3
i
28
1
6
5
32 4
29
1 2 3
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.
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.

20
Hyundai Sonata
Removeanddismantle fuel-tanksendingunit
according to manufacturer's instructions.
1Fuel-tank sending unit
2Template
3Copy hole pattern, 6 mm dia. hole
Removing
fuel
Shape fuel standpipe according to template,
cut to length and install, see "installation
instructions".
1Fuel-tank sending unit
2Fuel standpipe
Installing
fuel
standpipe
Install fuel-tank sending unit according to
manufacturer's specifications.
1Fuel sender
2Remaining end of Mecanyl fuel line
3Hose section, 10 mm dia. clamp [2x]
4Fuel standpipe Con-
necting
fuel line
Fuel line from fuel standpipeon intake side of
metering pump [side without connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Fuel line
2Hose section, 10 mm dia. clamp [2x]
3Metering pump
Con-
nection to
metering
pump
30
1 2
3
31
1
2
i
32
3
1 2
4
33
1 2 3