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)
14
1
3 41 2 7 85 6 11 12910 15 1613 14 19 2017 18
23 2421 22 27 2825 26 31 3229 30 35 3633 34 39 4037 38
1

11
Lexus GS 450h
Automatic
air condi-
tioning
circuit
diagram
Webasto components Lexus components Colors and symbols
Legend
HG Heater unit TT-C/E ECU-IG Fuse, 10A rt red
F1 Fuse, 20A 4E/4D Plug-in connection ws white
F2 Fuse, 1A 5D/5G Plug-in connection sw black
F3 Fuse, 10A A/C A/C amplifier br brown
F4 Fuse, 30A L52 (A) 40-pin connector A gn green
K3 Blower relay
1 Operating control
XSplitting point
gn/
ws
sw
br
rt/ws
rt
F3
10A
4
HG
X1
K3
87a8786
85 30
Webasto
31
30
15
Lexus
A/C
21 L52 (A)
ws
ws
4D
44E
5G
35D
ECU-
IG
F4
30A
X2
F1
20A
1
rt
2
br F2
1A
1
i

12
Lexus GS 450h
Remote Start Option
Attach the receiver with double-sided Velcro
tape on the blower unit according to the
figure.
1Receiver
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
Temperature gauge only with remote T100
HTM
1Temperature gauge
Assem-
bling the
tempera-
ture gauge
115
i
1
16
117

13
Lexus GS 450h
Thermo Call Option
Remove the insulation mat receiver bracket.
Attach the receiver with double-sided Velcro
tape on the footwell cover on the passenger
side.
1Footwell cover on passenger side
2Receiver
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
1Tip switch
Assem-
bling the
tip switch
1
218
i
119
20
1

14
Lexus GS 450h
Preparing the Installation Location
Remove original vehicle bolt at position 1.
Drill open the weld nut to to Ø 10.5mm
Remove original vehicle bolt 2, this will be
used again.
1Original vehicle bolt M10, weld nut Drill open
weld nut
Assembling the Bracket
3Additional bracket
2Heater unit bracket
1M6x12 bolt, flanged nut [4x each]
Preparing
the bracket
Insert two washers between weld nut and
bracket.
2Pre-assembled bracket
3Original vehicle bolt [2x]
1M10x45 bolt, wacher [2x], spring washer,
M10 nut
Assem-
bling the
bracket
Bracket opened to approx. 120°.
1Pre-assembled bracket
3Angle bracket
2M6x20 bolt, body washer, M6 flanged nut
Assem-
bling the
bracket
21
1
2
22
2
1
1
1
3
1
23
2
3
3
1
24
1
2
3

15
Lexus GS 450h
Assemble the original vehicle cable harness2
on the drill hole 1with rubber tube clamp
Ø18mm 3according to the illustration.
4M6x20 bolt, flanged nut M6
Attaching
the cable
harness
Installing the Heater Unit
Prior to assembly, put on the heater unit cable
harness
Ejot screw bolt tightening torque 10 Nm!
2Heater unit cable harness
1Ejot screw bolt [2x] Assem-
bling the
heater unit
Ejot screw bolt tightening torque 10 Nm!
1Ejot screw bolt
2Edge protection [2x 100mm long]
Assem-
bling the
heater unit
Assemble the 100 mm edge protection profile
2accordingly.
Unclip the original vehicle cable harness [2x]
Assem-
bling the
edge
protection
25
1 2
3
4
26
1 1
2
27
1
2
2
28
1
2

16
Lexus GS 450h
Fuel Connection
CAUTION!
Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable clips.
Fit the fuel line and cable harness with edge protectors around sharp edges.
WARNING!
The fuel line and cable harness to the metering pump should be installed based on Cable Harness
diagram or page 7.
1Mecanyl fuel line
2Ø 10mm hose clamps [2x]
3Hose section
Connec-
ting to the
heater unit
Insert the heater unit cable harness and
metering pump cable harness in the Ø 10mm
hose shaft 1 .
Wrap the tube ends with insulation tape.
Installing
lines
Run the tube shaft 1, the Mecanyl fuel pipe
and the metering pump cable harness along
the original vehicle lines to the underbody.
Installing
lines
29
2
1 2 3
30
1
31
1

17
Lexus GS 450h
Run the tube shaft 2, the Mecanyl fuel pipe
and the metering pump cable harness along
the original vehicle lines 1to the underbody
and secure with cable clips.
Installing
lines
Run the tube shaft, the Mecanyl fuel pipe and
the metering pump cable harness along the
original vehicle lines to the underbody and
secure with cable clips.
Ensure sufficient distance to the heat
protection sheet 2.
Installing
lines
Insert the heater unit cable harness and
metering pump cable harness in the Ø 10mm
hose shaft 1 , place according to the
illustration and secure with cable clips.
Wrap the tube ends with insulation tape.
Installing
lines
Remove the plastic cover from the bracket 2,
this will be used again.
Check the position of the components; adjust
if necessary. Check that these rotate freely.
1Metering pump
3Rubberized tube shaft, silentblock, flanged
nut [2x], prepared bore hole Metering
pump
installation
location
32
1
2
33
1
2
34
1
1
35
1
2
3
i

18
Lexus GS 450h
Insert the heater unit cable harness and
metering pump cable harness in the Ø 10mm
hose shaft 1 , according to the illustration, run
to the metering pump installation location 2
and secure with cable clips 3.
Connec-
ting to the
metering
pump
Fuel line from the heater unit 3on the
pressure side of the metering pump [side with
connector].
1Hose clamp Ø 10 mm [2x]
2Hose section
4Metering pump cable harness Connec-
ting to the
metering
pump
Remove the tank mounting2according to the
manufacturer's instructions and take it apart.
Attach the M6 flanged nut 1according to the
illustration, transfer the hole image3for the Ø
6.0 mm hole.
Complete the tank mounting.
Fuel take-
off
Shape, cut into sections, and insert the tank
extracting device 2according to the template,
see the Installation Instructions.
1Tank mounting
Inserting
tank
extracting
device
36
2
1
3
3
3
3
3
37
1 3
4
12
38
1
2
3
39
2
1
i

19
Lexus GS 450h
Install the tank mounting1according to the
manufacturer's instructions. Shorten the
moulded hose 2by 10 mm for Ø 3.5 mm.
3Universal clip Ø 8mm
4Tank extracting device
5Universal clip Ø 10 mm
6Enclosed 2000 long fuel line to the
metering pump Fuel take-
off
Insert the fuel line from the tank extracting
device in the Ø 10mm hose shaft 1and run to
the metering pump installation location,
secure to existing lines with cable clips.
Installing
lines
Fuel line 1from the tank extracting device on
the intake side of the metering pump 4[side
without connector].
Cutt fuel line into sections.
2Hose clamp Ø 10 mm [2x]
3Hose section Connec-
ting to the
metering
pump
Cut out the underbody protection 1on the
marking 2according to the illustration.
Preparing
the
panelling
40
1 2
6
4
5
3
41
1
1
42
31
4
22
43
1
2

20
Lexus GS 450h
Re-assembling the panelling 1.
Assem-
bling the
panelling
44
1