Webasto Thermo Top E User manual

Water Heater
Installation instructions
Ident. No.: 1314869C_EN Fee Euro 10.00 © Webasto AG
Hyundai i20
Petrol
from Model Year 2009
Left-hand drive vehicle
Feel the drive
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Thermo Top E Parking heater
e1
00 0003
Thermo Top C Parking heater
e1
00 0002
Thermo Top P Parking heater
e1
00 0104

Hyundai i20
1314869C_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructions 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 i20 P/C e11 * 2001/116 * 0333 * ...
Engine type Engine model Output in kW Displacement in cm³
G4LA Petrol 57 1248
G4FA Petrol 74 1396
Validity 2
Heater/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater installation location 5
Preparing electrical system 6
Electrical system 7
Fan controller for manual air conditioning 8
Automatic air-conditioning fan controller 9
Remote option (Telestart) 11
Preparing installation location 12
Installing heater 15
Coolant circuit 16
Fuel 22
Exhaust gas 25
Combustion air 26
Final Work 27
Template for Fuel Standpipe 29
Operating Instructions for End Customer 30

Hyundai i20
1314869C_EN 3
Heater/Installation Kit
To be ordered additionally for vehicles with automatic air-conditioning:
Heater recommended for the respective vehicle class:
The selection of the heater is based on the passenger compartment size of the vehicle and the level of
comfort required by the customer!
Foreword
Theseinstallationinstructionsapplyto Hyundai i20Petrolvehicles- for validity, seepage2 - frommodel
year 2009 and later, assuming technical modifications to the vehicle do not affect installation, any lia-
bility claims excluded. Depending on the vehicle version and equipment, modifications may be neces-
sary during installation with respect to these installation instructions.
However, the stipulations in the"installationinstructions" and "operatingandmaintenanceinstructions"
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 spec-
ified 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
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list
1 Installation kit for Hyundai i20 Petrol 1314868A
1 Heater control See price list
Quantity Description Order No.:
1 Additional Kit for Automatic Air Conditioning on Hyundai i20 1314875A
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Hyundai i20
1314869C_EN 4
Special features are highlighted using the following symbols:
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Referencetogeneralinstallationinstructions of Webas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
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.

Hyundai i20
1314869C_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- 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 battery.
- Remove the air filter together with the intake hose.
- Disconnect the fuse and relay box in the engine compartment and lay aside.
- Detach the wheel well trim on the left
- Remove the bumper
- Open the fuel sender service lid.
- Remove fuel-tank sending unit in accordance with manufacturer's instructions.
- Remove the A/C control panel (only with automatic air-conditioning).
- Remove the instrument panel trim on the driver's side (only with Telestart).
Remove page 30 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
11

Hyundai i20
1314869C_EN 6
Preparing electrical system
Bending
perforated
bracket
Only with automatic air-conditioning
Cutting
wires to
length
Install wire section 2in protective sleeving
provided.
Premount-
ing F4
90°
75
1
250
2sw
O,75²
F4
86
85 30
87a87
K3
1 2

Hyundai i20
1314869C_EN 7
Electrical system
Fuse holder, relay K3
1M5x16 bolt, washers, retaining plate for fuse
holder, K3 relay, flanged nut
2Perforated bracket
3M6x20 bolt, spring lockwasher, existing
threaded hole
Digital timer and summer/winter switch op-
tion
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
Wiring har-
ness in-
stallation
diagram
Earth connection
1Original vehicle earth support point
2Brown (br) earth wire
Wiring harness pass through
1Protective rubber plug
2Wiring harness of digital timer, wiring harness
of fan controller (only with automatic A/C)
2
2 31
3
1
2
Donot install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
2
1 2
5
2
1

Hyundai i20
1314869C_EN 8
Fan controller for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E GM Fan motor rt red
X1 6-pin heater connector GRs Fan relay pk pink
F3 Replace 25 A with 5 A
fuse. WG Resistor group sw black
GS Fan switch
K3 Fan relay F2 IGN 15A fuse
F Blower 40 A fan fuse
XCutting point
Wiring colours may vary.
Connection to fuse and relay box 5in engine
compartment. Replace 25 A fuse F3 with 5 A
fuse.Produceconnectionsasshowninwiring
diagram.
1Pink (pk) wire of fan relay, Pin 4
2Black (sw) wire from K3/30
3Red (rt) wire from K3/87a
4Pink (pk) wire of fuse F2
Connect-
ing fan-mo-
tor
Webasto
31
30
15
Hyundai
F3
86
85 30
87a87
K3
HG
X1 4
F2
1
5GRs 2
4
F
Blower
+
-GM
M
3GS
4 1 5 6
WG
3124
4²
sw
4²
rt
pk
0,5²
pk
0,5²
6
1
4
3
2
5

Hyundai i20
1314869C_EN 9
Automatic air-conditioning fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E GM Fan motor rt red
X1 6-pin heater connector GRs Fan relay pk pink
F4 5A fuse GRr Fan controller sw black
F3 Replace 25 A fuse with
15 A fuse KB A/C control panel or orange
M04-A 26-pin connector KB
K3 Fan relay F2 IGN 15A fuse
F Blower 40 A fan fuse Insulate wire ends and
tie back
XCutting point
Wiring colours may vary.
Webasto
31
30
15
Hyundai
F3
86
85 30
87a87
K3
HG
X1 4
F2
1
5GRs 2
4
F
Blower
+
-GM
M
4²
sw
4²
rt
pk
0,5²
pk
0,5²
F4
!
0,75²
sw
KB
M04-A 14 15 16 17 25
GRr
M16 1 2 4 3
1 2
or
0,5² or 0,5²
or
0,5²
or
0,5²

Hyundai i20
1314869C_EN 10
Connection to fuse and relay box 4in engine
compartment.Replace fuse F3 25 Awith 15A
fuse. Insulate pink (pk) wire 1from fuse F2
IGN and tie back.
Produce connections as shown in wiring dia-
gram.
2Additional black (sw) wire of K3/30
3Pink (pk) wire of fan relay, Pin 4
Connect-
ing fan re-
lay
Connection on 26-pin connector M04-A 4of
A/C control panel.
Produce connections as shown in wiring dia-
gram.
1Red (rt) wire from K3/87a
2Black (sw) wire from K3/30
3Orange (or) wire [2x] of connector M04-A,
Pin 14 and 15
5Orange (or) wire [2x] of fuse F2 IGN
Connect-
ing A/C
control
panel
7
1
3
2
4
8
1
4
2
5
3

Hyundai i20
1314869C_EN 11
Remote option (Telestart)
Drill out bracket 1to 6.5 mm dia. at position 3.
2Receiver
3Original vehicle stud bolt, flanged nut Installing
receiver
1Antenna
Installing
antenna
Temperature sensor HTM100
Fasten temperature sensor 1with adhesive
tape.
Installing
tempera-
ture sensor
1
29
3
1
10
11
1

1314869C_EN 12
Hyundai i20
Preparing installation location
1Remove side trim
2Remove original vehicle bolts and discard
Preparing
installa-
tion loca-
tion
Cut out side trim 1at marking.
Cuttingout
side trim
Cut out side trim at marking. 7 mm dia. hole
at position 1
Cuttingout
side trim
1500 mm edge protection, circumferential
Installing
edge pro-
tection
12
2
1
2
13
1
14
185
75
15
1

1314869C_EN 13
Hyundai i20
1Bracket
27 mm dia. hole
Preparing
bracket
Insertone 10mmshim eachbetweenbracket
and frame side member at position 1.
1M6x25 bolt, spring lockwasher, 10 mm
shim, original vehicle earth wire, existing
threaded hole [2x each]
2Bracket Installing
bracket
Shorten angle bracket 1[2x] by 22 mm.
2Discard cut-off sections
Shorten-
ing angle
bracket
Insertone 10mmshim eachbetweenbracket
1and angle bracket 2.
1Bracket
2Bolt
3M6x25 bolt, spring lockwasher, 10 mm
shim, existing threaded hole [2x each] Loosely
mounting
angle
bracket
16
12
45
13
17
1
2
1
18
11
22
19
1
3
22
3

1314869C_EN 14
Hyundai i20
Insert one 15 mm spacer nut each between an-
gle bracket and frame side member. Copy hole
patterntoframesidememberatposition
2 [2x].
Remove angle bracket.
Drill 9.1 mm dia. hole in frame side member
and mount rivet nut [2x each]. Copying
hole pat-
tern
1M6x30 bolt, spring lockwasher, 15 mm
shim, rivet nut [2x each]
Installing
bracket
20
1
2
2
1
21
11

1314869C_EN 15
Hyundai i20
Installing heater
1Ejot screw [2x]
Installing
heater
Connect wiring harness of heater prior to in-
stallation.
1Ejot screw
Installing
heater
22
1
1
23
1

Hyundai i20
1314869C_EN 16
Coolant circuit
WARNING!
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 clamps so that no
other hose can be damaged! When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Hose in-
stallation
diagram
All spring clips = 27 mm dia.! All hose clamps = 20-27 mm dia.
All connecting pipes without a specific designation = dia. 20x20 mm.
1= Black (sw) rubber isolator [3x]! 2= Black (sw) rubber isolator only with 1.4 petrol engine!
D
C
B
E
A
21
1
1
Ø 18x20
Ø 18x20

Hyundai i20
1314869C_EN 17
Discard section X.
A= 90° elbow
B= 1150
C= 200
D= 200
E= 1250 Cutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and C and cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
Bending
perforated
bracket
Insert clip-type cable tie 3in existing hole.
1Perforated bracket
2Ejot screw
Installing
perforated
bracket
A
BC
X
X
ED
X
X
B
E
1 1
1 1
33°
57
24
1 2
3

Hyundai i20
1314869C_EN 18
Connect-
ing heater
inlet
1Close clip-type cable tie
Connect-
ing heater
outlet
Mount side trim 2. Route hose Band Efrom
engine compartment through cut-out in side
trim to outside and connect to hose Cand D.
Slide one heat protection hose 1each onto
hose Band E.Routing in
wheel well
Align heat protection hose on hose Band E.
148 mm dia. rubber-coated p-clamp
2M6x20 bolt, large diameter washer [2x],
flanged nut, prepared hole Routing in
engine
compart-
ment
25
C
26
D
1
27
D
B
C
E
1
1
2
28
E
2 B1

Hyundai i20
1314869C_EN 19
Slide black (sw) rubber isolator onto hose B
and [2x] onto hose
E . Cut open fabric protec-
tive hose
2 and slide onto brake line. Discard
originalvehicleboltatposition
3 .Routehose B
and
E to cutting point.
148 mm dia. rubber-coated p-clamp
3M6x20 bolt, spring lockwasher, existing
threaded hole
Routing in
engine
compart-
ment
1.2 Petrol
1Hose section of heat exchanger inlet
2Engine-outlet hose section
Cutting
point of
heat ex-
changer
1Hose on heat exchanger inlet
Connect-
ing heat
exchanger
inlet
Position black (sw) rubber isolator 1and fas-
ten on brake line with cable tie.
2Position black (sw) rubber isolator
Routing in
engine
compart-
ment
29
E
1
B
3
2
30
1
2
31
E1
32
1
2
E

Hyundai i20
1314869C_EN 20
1Discard hose section
2Engine-outlet hose section
Cutting
point of en-
gine outlet
1Hose of engine outlet
Connect-
ing engine
outlet
Position black (sw) rubber isolator 1and fas-
ten on brake line with cable tie.
Ensure sufficient distance to neighboring
components.
Routing in
engine
compart-
ment
33
1
2
34
A
1
B
35
B 1