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 to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all warning
instructions.
Webasto does not accept any liability for defects and damage that are attributable to an
installation by untrained staff.
Feel the drive
Lexus GS 450h
Gasoline with the Lexus Hybrid System
From model year 2006
For left-hand drive vehicles only
Ident. No.: 1311247A €10 fee © Webasto AG
Water Heater Unit
Thermo Top E Auxiliary Heating
Thermo Top C Auxiliary Heating
Thermo Top P Auxiliary Heating
Installation Instructions
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22
Lexus GS 450h
Validity
Vehicle and engine types, equipment variants as well as national specifications, which are not listed in
these installation instructions, have not been tested. Installation according to these installation
instructions may, however, be possible.
The installation location of a time switch and summer / winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No. / ABE
Lexus GS 450h HS 19 (a) e6 * 2001 / 116 * 0106 * ...
Engine type Engine Power in kW Engine capacity in cm³
2GR-FSE Gasoline 218 3456
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
Electrical Connections 6
Preparing the Electronics 7
Blower Control 10
Remote Start Option 12
Thermo Call Option 13
Preparing the Installation Location 14
Assembling the Bracket 14
Installing the Heater Unit 15
Fuel Connection 16
Water Connection 21
Combustion Air 27
Exhaust System 28
Final Work 30
Operating instructions for the end customer 31
Tank Extracting Device Template 32
Table of Contents

33
Lexus GS 450h
Heater Unit / Installation Kit
Recommended heater unit for the relevant vehicle class:
Select the heater unit based on the size of the vehicle passenger compartment and the customer's
comfort requirements.
Foreword
These installation instructions apply to the vehicles Lexus GS 450h Gasolineengine with the Lexus
Hybrid System.
– Re. validity, see page 2 – from model year 2006 and later, assuming technical modifications to the
vehicle do not affect installation and any liability claims are 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 are to be observed in any event.
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 cable harnesses to original vehicle lines and cable
harnesses using cable clips.
Sharp edges should be fitted with edge protectors (split open plastic hose).
Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no.
111329).
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vise-grip wrench
- Riveting nut tool
Amount Description Order no.:
1 Commercial supply of required control See price list
1 Installation kit for Lexus GS 450h 1,311,239A
Vehicle Heater unit
Compact car Thermo Top E
Mid-class, station wagon Thermo Top C
Luxury, van, off-roader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanics
Electrics
Water connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Lexus GS 450h
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 the 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
Lexus GS 450h
Heater Unit Installation Location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Let off pressure in 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.
- Completely remove the air filter with intake hose.
- Remove left fuse and relay box.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Disconnect the battery.
- Loosen the right and left wheel-house panel.
- Remove the underride protection.
- Remove the bumper.
- Lower cover fuel lines.
- Remove the rear seat bench.
- Open the left tank mounting service lid
- Remove left tank mounting according to manufacturer's instructions.
- Remove the lower cover to the right footwell
- Remove the side cover on the right-center console (only for Telestart T100 HTM).
- Please remove page 31 “Operating instructions for the end customer” and add this to the vehicle
operating instructions.

6
Lexus GS 450h
Electrical Connections
Cable harness feed-through
1Protective rubber sleeve
Time switch
1Time switch
Cable
harness
installation
diagram
Fuse holder, K3 relay
1K3 relay
1Fuse holder
Note the assembly instructions on page 7.
2
1
3
1
brbl
rtsw
i
4
21
Wait to install the metering pump
cable harness until later,
together with fuel pipe along the
original vehicle fuel lines in the Ø
10 mm tube shaft [2x] on the
underbody.

7
Lexus GS 450h
Preparing the Electronics
Bend the fastening strap 3 according to the
illustration and fasten with the original vehicle
bolt.
2Drill a Ø 5 mm bore hole
1Fuse holder, M5x12 bolt, flanged nut M5
Prepare
the fuse
holder
installation
.
Assemble the fuse holder 1on the
preassembled retaining plate.
2Relay K3, M5x12 bolt, flanged nut M5
Installing
lines
Cutting
wires into
sections
Preassem-
bling fuse
F4
5
2
1
3
6
1
2
rt
21
500
F4 30A
rt
1rt 2

8
Lexus GS 450h
Cut approx. 300mm from the Ø 20mm tube
shaft. Install the heater unit cable harness,
Mecanyl fuel line, positive connection for the
header unit cable harness in the Ø 20mm 1
tube shaft.
Run the fuel line, heater cable harness to the
heater unit installation location.
Connect the red (rt) 1500 lg. wire with
shrinkable butt connectors 2to the positive
supply cable on the cable harness.
Shorten Ø 10 mm tube shaft by 100 mm.
Run the red (rt) 1500 lg line through the Ø 10
mm tube shaft 3to the left fuse and relay
holder.
Installing
lines
Drill a Ø 9mm bore hole 1in the cover of the
fuse and relay holder 2according to the
figure.
Preparing
the
positive
supply
1Cable sleeves
Inserting
the cable
sleeves
Drill the Ø 4.5 mm bore hole for the fuse
bracket 2according to the figure, fasten the
fuse bracket with the 5.5x13 self-tapping
screw.
Insert the red (rt) 500 mm line in the
remaining 100 mm tube shaft 4and pull this
through the cable sleeve 3.
Wrap the tube ends with insulation tape.
1Red (rt) wire, tube shaft
Installing
lines
3
2
1
7
8
2
1
9
1
10
234
1

9
Lexus GS 450h
1Red (rt) wire, Ø 6 mm pointed cable socket
2Positive base
Connec-
ting to the
positive
supply
Run the brown (br) wire for the heater unit
cable harness ground supply 3through the
cable socket 1to the grounding point 2and
connect.
Connec-
ting the
ground
supply
Pull the rt and sw (red and black) lines from
the K3 blower relay and the time switch cable
harness into the remaining Ø20 mm tube
shaft and to the cable feed-though.
Wrap the tube ends with insulation tape.
Note:
Pull the lines from the K3 blower relay and the
time switch cable harness from the interior
through the feed-though.
Installing
lines
11
12
12
2
3
1
13
1

10
Lexus GS 450h
Blower Control
Connect to 40-pin connector L 52 (A) pin 21
from the A/C amplifier.
Connect with enclosed blade receptacles
according to the circuit diagram.
Replace fuse F3 with 10A.
140-pin connector L52.
Connec-
ting the
A/C
amplifier
1Connector L 52 (A), contact side
connector
L 52 (A)
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