Webasto Thermo Top E User manual

Water Heater
Installation instructions
Ident. No.: 1315129B_EN Fee Euro 10.00 © Webasto AG
Toyota Verso
Diesel
from Model Year 2009
For left-hand drive vehicles only
Automatic air-conditioning
Manual / automatic transmission
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 Verso
1315129B_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 Verso AR2 e11 * 2001/116 * 0350 * ...
Engine type Engine model Output in kW Displacement in cm³
1AD-FTV Diesel 93 1998
2AD-FHV Diesel 110 2231
2AD-FHV Diesel 130 2231
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 Connections 7
Fan controller 9
Remote option (Telestart) 10
Preparing installation location 11
Installing heater 12
Water 14
Fuel 18
Exhaust system 20
Combustion air 21
Final Work 22
Operating Instructions for End Customer 23

Toyota Verso
1315129B_EN 3
Heater/Installation Kit
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
These installation instructions apply to vehicles Toyota Verso Diesel - for validity, see page 2 - from
model year 2009 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,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
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 with desired heater control See price list
1 Installation kit for Toyota Verso Diesel 1315128A
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Toyota Verso
1315129B_EN 4
Mechanical system
Electrical system
Coolant connection
Fuel connection
Exhaust system
Combustion air
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!
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 Verso
1315129B_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 air filter together with the intake hose.
- Remover the left-hand side wheel well trim and detach on the right.
- Remove the bumper.
- Remove the underride protection.
- Remove the fuel line cover on the underbody.
- Remove the footwell trim on the driver's side
- Remove the side trim of the centre console in the driver's side footwell.
- Remove the AC booster.
- Remove the loudspeaker cover at the upper left on the instrument panel (only with Telestart).
Remove page 23 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Toyota Verso
1315129B_EN 6
Preparing electrical system
All vehicles
Cut corrugated tube provided to length.
110 mm dia. corrugated tube, 2,100 mm
long
217 mm dia. corrugated tube, 700 mm long
Cutting
corrugat-
ed tube to
length
Replace 25 A fuse F3 with 10 A fuse.
1M5x20 bolt, washer, flanged nut
2Retaining plate for fuse holder
3Fuses pushed on
4Perforated bracket turned (approx. 80°)
5K3 relay Preparing
wiring har-
ness
400
500
1
2
2
3
4
1
5
2

Toyota Verso
1315129B_EN 7
Electrical Connections
Wiring harness pass through
1Protective rubber plug
Wiring harness pass through
1Wiring harnesses of digital timer and fan con-
troller
2Corrugated tube
Wiring har-
ness in-
stallation
diagram
Fuse holder, K3 relay
1Original vehicle bolt
2
Routepositive and groundwire in 10 mmdia. cor-
rugated tube, 400 mm long, to connection points
3Perforated bracket
Wiring harness pass through
1Route wiring harnesses of digital timer, fan
controller and metering pump in 17 mm dia.
corrugated tube, 500 mm long, to firewall
3
1
4
1
2
Do not install the metering pump cable har-
nessuntillatertogetherwithfuelpipealong
the original vehicle fuel lines in the corru-
gated tube on the underbody
5
1
3 2
6
1

Toyota Verso
1315129B_EN 8
Positive wire
1Positive battery terminal
2Cut positive wire to length, 8 mm dia. cable lug
Digital timer and summer/winter switch op-
tion
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
Wiring har-
ness in-
stallation
diagram
Ground wire
1Original M6 bolt of vehicle
2Ground wire,6 mm dia. cable lug
Wiring harness routing
Route wiring harness of heater 1 to installation
location.
7
1
2
8
1
2
9
1
2
10
1

Toyota Verso
1315129B_EN 9
Fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E GE Fan unit rt red
X1 6-pin connector E23 GE connector ws white
F3 Replace 25 A with 10 A
fuse. ACC AC control sw black
D47 40-pin ACC connector br brown
K3 Fan relay HTR 30A fuse gn green
HTR-
IG 10 A fuse ge yellow
XCutting point
Wiring colours may vary.
1Connector D47 on contact side (PIN 1)
Connector
D47
15/IG
30/B
Webasto Toyota
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
GE
M
E23
123
HTR
ws/sw
ACC
D47 1 23
HTR
-IG
ge
0,5²
rt
31/Gnd
ge
0,5²
rt
4²
sw
4²
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

Toyota Verso
1315129B_EN 10
Connection to 40-pin connector 1from ACC
Produce connections as shown in wiring dia-
gram.
2Yellow (ge) wire HTR/IG
3Red (rt) wire of K3/87a
4Black (sw) wire of K3/30
5Yellow (ge) wire of connector D47/1
Connec-
tion to ACC
Remote option (Telestart)
Fasten receiver 1with adhesive tape.
Installing
receiver
Remove loudspeaker cover.
1Antenna
Installing
antenna
Temperature sensor only with T100
Fasten receiver 1with adhesive tape.
Installing
tempera-
ture sensor
11
1
4
2
3
5
1
12
1
13
14
1

1315129B_EN 11
Toyota Verso
Preparing installation location
1Bracket
2Drill out hole to 8.5 mm dia.
Drilling
bracket
When installing bracket, align it parallel to
original vehicle edge 2.
Insert 20mm shim between bracket and vehi-
cle!
1M8x40 bolt, 20 mm shim
3Copy hole pattern, 7 mm dia. hole Copying
hole pat-
tern
1M6x40 bolt, 20 mm shim, pin lock
2M6x35 bolt, 20 mm shim, pin lock
Cutting
edge pro-
tection to
length
Cut edge protection to length as shown.
Cutting
edge pro-
tection to
length
15
1
2
16
3
2
3
1
17
12
70 70 60
18

1315129B_EN 12
Toyota Verso
1Angle bracket
2M6x35 bolt, largediameter washer, 20 mm
shim, flanged nut
3Exhaust muffler
Preassem-
bling ex-
haust
muffler
A 20 mm shim must be positioned between
bracket and vehicle at position 2.
170 mm edge protection [2x]
2M8x40 bolt, spring lockwasher, 20mm
shim, existing threaded hole
3M6 flanged nut [2x]
460 mm edge protection
Installing
bracket
Installing heater
1Wiring harness of heater
Connect-
ing wiring
harness
1Loosely mount Ejot screw
Installing
heater
19
1
3
2
20
2
1
3
3
1
4
21
1
22
1

1315129B_EN 13
Toyota Verso
1Loosely mount Ejot screw [2x]
Installing
heater
Position angle bracket 2between heater and
bracket. Tighten all bolts.
1Ejot screw
3Preassembled exhaust muffler Installing
heater
23
1 1
24
1
3
2

Toyota Verso
1315129B_EN 14
Water
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
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. Po-
sition hose and spring clips so that no other hose can be damaged!
The connection should be "inline" based on the following diagram:
Coolant
routing di-
agram
All spring clips without a specific designation = 27 mm dia. All hose clamps = 20-27 mm dia.
All connecting pipes without a specific designation = dia. 18x20.
1= Original vehicle spring clip . 2= Black (sw) rubber isolator .
1
Ø 20x20
Ø 17x20
Ø 25
Ø 22
Ø 20x20
A
2
BE
D
C

Toyota Verso
1315129B_EN 15
A15x18 90° molded hose provided
C20x20 90° molded hose provided
D20x20 180° molded hose provided
Discard sections X.
b = 900
d = 40
e = 560
Cutting
coolant
hoses to
length
Push braided protection hose onto hose B
and E and cut to length.
Cut heat shrink plastic tubing to length.
125 mm heat shrink plastic tubing [4x] Preparing
coolant
hoses
Pull off hose section 2from engine outlet.
Spring clip 1will be reused!
Cutting
point
Premount hose section 1and route as
shown.
Premount-
ing hose
d
D
X
C
X
X
A
BE
B
E
25
1
2
26
1

Toyota Verso
1315129B_EN 16
ConnecthoseAonengineoutletandconnect
to 180° elbow from hose B.
Connect-
ing engine
outlet
Cut rub protection 1provided in half. Glue
one section onto charge-air tube in area of
spring clips 2.
Gluing rub
protection
Slide black (sw) rubber isolator 1onto
hose B.
Routing in
engine
compart-
ment
Connect-
ing heater
inlet
27
B
A
28
A 1
29
1B
30
C
B

Toyota Verso
1315129B_EN 17
1Original vehicle line
2Hose on heat exchanger inlet
3Spacer bracket
Fastening
hose to
heat ex-
changer in-
let
1Hose on heat exchanger inlet
Connect-
ing heat
exchanger
inlet
1M6x20 bolt, pin lock in existing hole [2x
each]
2Rubber-coated pipe clamp [2x]
Installing
hose E
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
Connect-
ing heater
outlet
31
2
1
3
32
E1
33
E 1
2
2
1
34
E
D

Toyota Verso
1315129B_EN 18
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.
Connect fuel line 3to heater and pull into 10
mm dia. corrugated tube 1.
2Hose section, 10 mm dia. hose clamps [2x]
Connect-
ing heater
Route corrugated tube with fuel line 1to fire-
wall. Route wiring harness of metering pump
and fuel line in second section of 10 mm dia.
corrugated tube from firewall
Installing
lines
Route wiring harness of metering pump and
fuel line in second section of 10 mm dia. cor-
rugatedtube1alongoriginalvehiclefuellines
to installation location of metering pump and
fasten with cable tie. Installing
lines
35
1
2
3
36
1
37
1

Toyota Verso
1315129B_EN 19
Remove rubber plugs and mount rivet nut at
position 1.
Installing
rivet nut
1Silent block, flanged nut
2Metering pump
3Rubber-coated pipe clamp
Installing
metering
pump
1Wiring harness of metering pump, connec-
tor mounted
2Hose section, 10 mm dia. hose clamp [2x]
3Fuel line in corrugated tube
Connect-
ing meter-
ing pump
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
18 mm dia. hose clamp [2x]
2Original vehicle fuel return line
3Hose section [2x], 10 mm dia. hose clamp
[4x]
4Fuel line
56x5x6 fuel standpipe
Mounting
fuel stand-
pipe
38
1
39
1
3
2
40
1
2
3
41
3
4
2
1
3
5

Toyota Verso
1315129B_EN 20
Exhaust system
1Exhaust pipe
a = 180
2Exhaust end section
b = 260
Discard section X
Preparing
exhaust
pipe
1Hose clamp [2x]
2Exhaust pipe
Installing
exhaust
pipe
1Hose clamp
2Exhaust end section
3Red (rt) rubber isolator with groove
4Position red (rt) rubber isolator
Installing
end sec-
tion
Drill out existing hole to 42 mm dia. 1and
mount exhaust end section with red (rt) rub-
ber isolator with groove.
Installing
exhaust
end sec-
tion
a b
1 2
X
1 2
1
42
1
23
4
43
44
1