Webasto Thermo Top E User manual

Water Heater
Installation instructions
Ident. No.: 1314945B_EN Fee Euro 10.00 © Webasto AG
Toyota Urban Cruiser
Gasoline
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

Toyota Urban Cruiser
1314945B_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions 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
Toyota Urban Cruiser XP11 e11 * 2001 / 116 * 0263 * ...
Engine type Engine model Output in kW Displacement in cm³
1NR-FE Gasoline 74 1329
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
Electrical system 6
Fan controller for manual air conditioning 7
Remote option (Telestart) 9
Preparing installation location 10
Preparing heater 11
Installing heater 12
Exhaust gas 13
Combustion air 15
Fuel 16
Water 19
Final Work 23
Template for fuel standpipe 24
Operating Instructions for End Customer 25

Toyota Urban Cruiser
1314945B_EN 3
Heater/Installation Kit
Foreword
These installation instructions apply to vehicles Toyota Urban Cruiser Gasoline - for validity, see page
2 - from model year 2009 and later, assuming technical modifications to the vehicle do not affect instal-
lation, any liability claims excluded. Depending on the vehicle version and equipment, modifications
may be necessary during installation with respect to these installation instructions.
However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
for the Thermo Top E/C/P 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
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Toyota Urban Cruiser 2009 Gasoline 1314944A

Toyota Urban Cruiser
1314945B_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.
ReferencetogeneralinstallationinstructionsofWebas-
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
Water
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.

Toyota Urban Cruiser
1314945B_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 completely.
- Remove the entire coolant reservoir.
- Detach the wheel well trim on the right and left.
- Remove the front left underbody trim.
- Remove the bumper.
- Remove the left-hand rear bench seat.
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturer's specifications
- Remove the glove compartment
- Remove the footwell trim on the front passenger side.
Remove page 25 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Toyota Urban Cruiser
1314945B_EN 6
Electrical system
Fuse holder, K3 relay
1Angle bracket
2Fuse F1-3 mounted
3M5x16 bolt, washer, retaining plate of fuse
holder, M5 nut
4K3 relay
5M6x20 bolt, existing threaded hole
Wiring harness pass through
Removesealingplug and replace with protective
rubber plug 1.
Wiring har-
ness in-
stallation
diagram
Positive and ground connection
1Positive wire on positive terminal
2Ground wire on negative terminal
Digital timer and summer/winter switch op-
tion
1Summer/winter switch, drilled hole 12 mm dia.
2Digital timer
1
5
4
2
32
1
3
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
1 2
5
12

Toyota Urban Cruiser
1314945B_EN 7
Fan controller for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E/P GM Fan motor rt red
X1 6-pin heater connector E4 2-pin connector GM ws white
F3 25 A fuse GRs Fan relay sw black
K3 Fan relay GW Fan resistor br brown
GS Fan switch gn green
Fb Gauge fuse
Fa HTR 40 A fuse
XCutting point
Wiring colours may vary.
Connection to 2-pin connector 1from the
blower motor.
Produce connections as shown in wiring dia-
gram.
2Black (sw) wire of fan relay
3Red (rt) wire of K3/87a
4Black (sw) wire of K3/30
5Black (sw) connector E4
Connect-
ing fan-mo-
tor
gn/
ws
sw
br
rt/ws
rt
Webasto
31
30
15
Toyota
sw
HG
4
X1
F3
86
85 30
87a87
K3
GR
Fa
sw
Fb
GM
M
E4 2 1
(B+)
(IG)
(Gnd)
5GS
WG
5
4321
4321
6
1
5
3
2
4

Toyota Urban Cruiser
1314945B_EN 8
Automatic air-conditioning fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E/P GM Fan motor rt red
X1 6-pin heater connector A/C V A/C booster ws white
F3 Replace 25 A fuse with
7.5 A fuse A/C R A/C controller sw black
E11 40-pin connector A/C V br brown
K3 Fan relay E16 5-pin connector A/C R gn green
E17 3-pin connector GM ge yellow
Fa 7.5 A A/C fuse
Fb HTR 40 A fuse XCutting point
Wiring colours may vary.
Connect to the 40-pin connector E11 5of the
A/C booster.
Produce connections as shown in wiring dia-
gram.
1Yellow (ge) wire from 7.5 A fuse
2Red (rt) wire of K3/87a
3Black (sw) wire of K3/30
4Yellow (ge) connector E11 Pin1
Connect-
ing the A/C
booster
Webasto
31
30
15
Toyota
HG
4
X1
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
MGM
E17
1 32
E16 5 3
A/C R
2E11 37 23114
A/C V
Fa
ge
ge
Fb
rt
sw
(B+)
(IG)
(Gnd)
7
1
4 3
5
2

Toyota Urban Cruiser
1314945B_EN 9
Remote option (Telestart)
Fastenreceiver1withdouble-sidedadhesive
tape
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor HTM100
Fasten temperature sensor 1with double-sid-
ed adhesive tape.
Installing
tempera-
ture sensor
1
8
1
9
1
10

1314945B_EN 10
Toyota Urban Cruiser
Preparing installation location
1Resistor with bracket
2Original vehicle bolts [2x] (will be reused)
3Unclip original vehicle wiring harness Removing
resistor
1Bracket
Bending
bracket
1Bracket
2Original vehicle bolts [2x]
Installing
bracket
Angle down perforated bracket Aby 18°.
Turn perforated bracket Bby approx. 10° in
longitudinal axis.
Preparing
perforated
brackets
2
1
2
11
3
12
1
42°
1 2
13
1
14
A
B
18°
approx. 10°
60

1314945B_EN 11
Toyota Urban Cruiser
Align holes to each other at position 3.
1Loosely mount M6x12 bolt, flanged nut [2x
each]
2Perforated bracket A
4Resistor bracket
5Perforated bracket BLoosely
mounting
perforated
brackets
Mount original vehicle wiring harness at posi-
tion 4and connect connector 3.
1Loosely mount M6x12 bolt, flanged nut
2Resistor Loosely
mounting
perforated
brackets
Preparing heater
1Exhaust pipe
a = 290
2Exhaust end section
b = 260
Discard section X
Preparing
exhaust
pipe
1Fuel line
2Hose section, 10 mm dia. clamp [2x]
3Exhaust pipe
4Hose clamp [2x]
5Exhaust manifold Preparing
heater
15
2
4
5
1
1
3
16
2
1
4
3
a b
1 2
X
517
1 2
4
3
4

1314945B_EN 12
Toyota Urban Cruiser
Installing heater
Route fuel line in the engine compartment
during installation.
Insert two washers between heater and
bracket 3at position 2.
1Ejot screw [2x]
2Ejot screw, washer [2x]
Installing
heater
Tighten bolts at position 1[3x].
2Perforated bracket
3Ejot screw, resistor bracket, perforated
bracket Installing
heater
18
1 2
1
3
19
3
1 1 2
1

Toyota Urban Cruiser
1314945B_EN 13
Exhaust gas
1Angle bracket
Bending
angle
bracket
1Muffler
2Angle bracket
3M6x20 bolt, flanged nut
Preparing
muffler
1M6x20 bolt, large diameter washer, flang-
ed nut, existing hole
2Muffler
3Exhaust pipe
4Hose clamp Installing
exhaust
pipe and
muffler
1Hose clamp
2Exhaust end section
3M6x20 bolt, angle bracket, large diameter
washer, flanged nut, existing hole
4P-clamp, M6x20 bolt, angle bracket, large
diameter washer, flanged nut
5Red (rt) rubber isolator with groove
must be positioned
Installing
exhaust
end sec-
tion
20
1
45°
3
1 2
21
3
1 2
4
22
3
1 2
5
4
23

Toyota Urban Cruiser
1314945B_EN 14
1Underride protection
242 mm dia. hole
Cuttingout
underride
protection
Mount underride protection 1. Align exhaust
end section 3flush on red rubber isolator 2.
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance. Mounting
rubber iso-
lator
1
2
24
25
3
1 2

Toyota Urban Cruiser
1314945B_EN 15
Combustion air
1Combustion air pipe
a = 210
Discard section XCutting
combus-
tion air
pipe to
length
1Combustion air pipe
227 mm dia. clamp
3Retaining clip in hole
4Muffler
Installing
combus-
tion air
pipe
a
1
X
26
2
1
4
3

Toyota Urban Cruiser
1314945B_EN 16
Fuel
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. 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 in as shown in the wiring harness
routing diagram.
Route corrugated tube with fuel line 1to fire-
wall.
Installing
lines
Route fuel line and wiring harness of meter-
ing pump 1along original vehicle fuel lines to
installation location of metering pump.
Installing
lines
Fasten metering pump 3with rubber-coated
p-clamp4,silentblock andflanged nut[2x]on
angle bracket 1.
2Original vehicle bolt Installa-
tion loca-
tion of
metering
pump
27
1
1
28
1
29
2
4 3

Toyota Urban Cruiser
1314945B_EN 17
1Wiring harness of metering pump, connec-
tor mounted
2Fuel line
3Hose section, 10 mm dia. clamp [2x]
Connect-
ing meter-
ing pump
Remove the fuel-tank sending unit in accord-
ance with the manufacturer's specifications
1Fuel sender
2Flanged nut
3Copy hole pattern, 6 mm dia. hole Removing
fuel
Cut fuel standpipe to length according to tem-
plate and install.
1Fuel standpipe
Removing
fuel
Install fuel-tank sending unit in accordance
with manufacturer's instructions.
1Fuel line
2Fuel standpipe
3Moulded hose, 10mm dia Caillau clamp
[2x] Connect-
ing fuel
line
3
30
21
31
1
3
2
32
1
1
33
1
3
2

Toyota Urban Cruiser
1314945B_EN 18
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Hose section, 10 mm dia. clamp [2x]
2Fuel line Connect-
ing meter-
ing pump
34
1 2

Toyota Urban Cruiser
1314945B_EN 19
Water
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 coolant hose, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing di-
agram
All connecting pipes = 17x20 dia.
All hose clamps without a specific designation = 20-27 mm dia. 2= Original vehicle spring clip
.
1= Black (sw) rubber isolator .
1
A
B
2
2

Toyota Urban Cruiser
1314945B_EN 20
a = 400
b = 760
Discard section X
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Band cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
Remove original vehicle hose on engine out-
let/heat exchanger inlet 2. Spring clips 1[2x]
will be reused.
Removing
hose
Discard section X.
1Hose section for engine outlet
2Hose section for heat exchanger inlet
Cutting
point
X
B
A
X
X
1 1
1 B
A
1
35
1 1
2
36
1 2
X