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 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
installation by untrained staff.
Feel the drive
Toyota Corolla Verso
Diesel
from Model Year 2005
Left-hand drive vehicle
Ident. No.: 1310512B_EN Fee Euro 10 © Webasto AG
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
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22
Toyota Corolla Verso
Validity
Vehicle and engine types and equipment variants not listed in these installation instructions have not
been tested. However, installation according to these installation instructions 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 Corolla Verso R1 e11 * 2001 / 116 * 0222 * ...
Engine type Engine model Output in kW Displacement in cm³
2AD-FHV Diesel (D-Cat) 130 2231
2AD-FTV Diesel (D-4D) 100 2231
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing electrical system 6
Electrical Connections 7
Fan controller for manual air conditioning 8
Automatic air-conditioning fan controller 10
Remote option (Telestart) 13
Remote option (Thermo Call) 14
Preparing installation location 15
Installing heater unit 16
Coolant connection 17
Combustion air 20
Fuel Connection 21
Exhaust system 23
Final Work 25
Operating Instructions for End Customer 26
Table of Contents

33
Toyota Corolla Verso
Heater Unit/Installation Kit
Heater unit recommended for the respective vehicle class:
The selection of the heater unit is based on the passenger compartment size of the vehicle and the
level of comfort required by the customer!
Foreword
The installation instructions apply to the Toyota Corolla Verso vehicles with a Diesel engine
- For the validity, see page 2 - from model year 2005 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,thestipulationsin 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
specified 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 Corolla Verso Diesel 1310307B
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanical system
Electrical system
Coolant connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Toyota Corolla Verso
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 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
Toyota Corolla Verso
Heater unit installation location
1Heater unit
Installation
location
11
Preliminary Work
WARNING!
- 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.
- Completely remove the battery.
- Remove the air filter together with the intake hose.
- Open fuel tank cap, ventilate tank
- Close the tank cap again.
- Remove the left-hand wheel well trim.
- Remove bumper
- Remove the underride protection on the left
- Remove the left-hand footwell cover
- Remove the fuse cover
- Remove the A/C control panel according to the manufacturer's instructions (only with automatic
air-conditioning)
- Remove page 25 "Operating Instructions for End Customer“ and add the operating instructions

6
Toyota Corolla Verso
Preparing electrical system
Only with automatic air-
conditioning
Wiring sections 1 and 3 will be required later
for fan controller.
Wiring sections 2 and 6 will be required later
for connecting fuse F4. Cutting
wires to
length
Wiring sections 2, 4 and 5 will be required
later for connecting K3.1 relay!
Cutting
wires to
length
Produce connections as shown in wiring
diagram on page 10. Pull wiring sections 1
and 3 into protective sleeving provided.
Also connect wire 5to K3/86 and wire 6to
K3/87 (see wiring diagram on page 10)
Preparing
F4, K3 and
K3.1 relay
Position 1and 4only with automatic air-
conditioning!
2M 5x16 bolt, washer, retaining plate fuse
holder, bracket, M5 flanged nut
3M 5x16 bolt, washer, K3 relay, bracket,
K3.1 relay, M5 flanged nut Preassem-
bling fuse
holder
sw 0,75mm²
2000
1
rt 0,75mm²
1850
6
150
2
100
3
br 0,75mm²
150
4
gr/ws 0,75mm²
150
5
K3.1
87a8786
85 30
4
br sw
35
2
rt
rt
sw
F4 3A
rt
1
6
2
2
1
3
4

7
Toyota Corolla Verso
Electrical Connections
Fuse holder, K3 relay
Fuse F4 and K3.1 relay only with automatic air-
conditioning!
1Battery holder
3Fuse holder preassembled
27 mm dia. hole, M6x20 bolt, preassembled
fuse holder, M6 flanged nut
Digital timer
1Digital timer
Wiring
harness
installation
diagram
Wiring harness pass through
1Protective rubber plug
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
3
2
3
1
4
1
br
bl
rt
sw
rt
sw
Donot installthemeteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
5
1
6
1

8
Toyota Corolla Verso
Fan controller for manual air conditioning
Wiring dia-
gram for
manual air
condition-
ing
Webasto components Toyota components Colors and symbols
Legend
HG Heater unit Fa Fan fuse rt red
F3 25 A fuse GM Fan motor ws white
K3 Fan relay GR Fan relay sw black
WG Resistor group br brown
gn green
XCutting point
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Toyota
rt
4
HG X1 F3 Fa
M
+
-
GM WG
sw
K3
87a
87
86
85 30
GR
sw
i

9
Toyota Corolla Verso
Connection on 2-pin connector DF on fuse
and relay carrier.
1Fuse and relay carrier
2Connector DF
Fan con-
troller for
manual air
condition-
ing
Connection on 2-pin connector DF on fuse
and relay carrier. Make connections as
shown in wiring diagram with connectors
(yellow) provided.
1Black (sw) wire, 4.0 mm², from K3/30
2Connector (yellow) [2x]
3Black (sw) wire to fan motor
4Connector DF
5Red (rt) wire, 4.0 mm², from K3/87a
Fan
controller
1 2
7
5
4
3
1 2
8

10
Toyota Corolla Verso
Automatic air-conditioning fan controller
Wiring
diagram
Webasto components Toyota components Colors and symbols
Legend
HG Heater unit TT-C GM Fan motor rt red
F3 25 A fuse GR Fan relay ws white
F4 Additional 3 A fuse GRr Fan controller sw black
K3 Fan relay KB Air-conditioning control panel br brown
K3.1 Additional relay Fa Fan fuse gn green
Fb Fuse bl blue
St 01 * 24-pin connector KB Pin 12
(single-zone automatic air-
conditioning)
St 01 *
28-pin connector KB Pin 14 (two-
zone automatic air-conditioning)
uncrimp, insulate and
tie back
XCutting point
sw
4²
rt
Webasto
31
30
15
Toyota
rt
sw
rt
0,75²
ws/sw
sw
rt
86
85 30
87a87
K3.1
GRr
+
-GM
M
HG
X1 4F3 Fb FaF4
KB
St 01 12/14
GR
!
86
85 30
87a87
K3
!
4
5
6
2
1
3
sw
0,75²
rt
4²
rt
*

11
Toyota Corolla Verso
Connection on 3-pin connector DF from fuse
and relay carrier. Produce connections as
shown in wiring diagram with 3x distributor
and tab receptacles provided.
1Connector DF
2Black (sw) wire to fan motor
Fan control
Remove wire 4from connector DF. Insulate
wire 4and 6and tie back.
1Connector DF
2Black (sw) wire to fan motor
33x distributor
5Black (sw) wire from K3/30
4White/black (ws/sw) wire from original
vehicle fan relay, Pin 4
6Red (rt) wire from K3/87a Fan control
1Connector DF on fuse and relay carrier
Fan control
Connector 4on A/C control panel 5vehicle-
dependent (single or two-zone automatic air-
conditioning). 24-pin connector, Pin 12 or 28-
pin connector, Pin 14.
Produce connection as shown in wiring
diagram.
1Red (rt) wire, 0.75 mm², from K3.1/87a
2Connector (red) [2x]
3Red (rt) wire from 24-pin connector, Pin 12
or from 28-pin connector, Pin 14
4Connector 01 (24 or 28-pin)
6Black (sw) wire, 0.75 mm², from K3.1/30
Control of
A/Ccontrol
panel
1 2
9
4
5
6
3
1 2
10
1
11
4
3
31
6
2
2 5 12

12
Toyota Corolla Verso
Connector of A/C control panel equipment-
dependent with automatic air-conditioning
Connector
of A/C
control
panel,
24-pin
Connector of A/C control panel equipment-
dependent with two-zone automatic air-
conditioning
Connector
of A/C
control
panel,
28-pin
3 41 2 7 85 6 11 12910
15 1613 14 19 2017 18 23 2421 22
3 41 2 7 85 6 11 12910
17 1815 16 21 2219 20 25 2623 24
13 14
27 28

13
Toyota Corolla Verso
Remote option (Telestart)
1M5x16 bolt, bracket, M5 flanged nut on
existing hole
2Receiver, mounted on bracket
Installing
receiver
1Antenna
Installing
antenna
213
1
i
1
14

14
Toyota Corolla Verso
Remote option (Thermo Call)
1Receiver, M5x20 bolts, flanged nuts,
washer [4x each]
2Lower footwell cover on front passenger
side
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
2Blind cap
3Center console
Installing
push
button
1
215
i
1
16
1
17
2
3

15
Toyota Corolla Verso
Preparing installation location
Picture shows bracket with Index F!
2Bracket
17 mm dia. hole
Hole in
bracket
Copy hole pattern at Position 3[2x]. Remove
bracket again.
Drill 9.1 mm dia. hole at Position 3[2x] in
frame side member and mount rivet nuts.
2Bracket, loosely mounted
1M6x20 bolt, large diameter washer [2x
each] on existing threaded holes Installing
rivet nut
1Bracket
2M6x20 bolt, large diameter washer [2x
each] on existing threaded holes
3Mount M6x20 bolt, spring lockwasher [2x
each] on prepared rivet nuts
4Spacer nut, 30 mm
5M6x12 bolt, spring lockwasher Installing
bracket
18
1
2
36 mm
46 mm
19
1 2
1
3
3
20
3
1 3
4
2
5
2

16
Toyota Corolla Verso
Installing heater unit
Connect wiring harness for heater unit before
installation.
Insert two washers between heater unit and
bracket at Position 3.
Tighten EJOT screws to 10 Nm!
1Bracket
2Ejot screw [2x]
3Ejot screw
Installing
heater unit
Ejot screw bolt, tightening torque 10 Nm!
2Bracket
1Ejot screw
3Wiring harness of heater unit
Installing
heater unit
21
1 2
3 2
22
1
2
3

17
Toyota Corolla Verso
Coolant connection
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water 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 hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Coolant
routing
diagram
All spring clips without a specific designation = 27 mm dia.
All connecting pipes without a specific designation = dia. 20x20.
Motor
Heat
exchanger
A
Ø 25
Ø 25
Ø 18x20
Ø 27
Ø 27
B
C

18
Toyota Corolla Verso
b = 770 mm
c = 600 mm
Hose A= 90° molded hose, included
Hose Cwith long 90° elbow
Discard section X
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and C. Push on heat shrink plastic tubing and
shrink.
x = 50 mm
y = 25 mm
125 mm heat shrink plastic tubing [4x] Preparing
coolant
hoses
Hose Cwith long 90° elbow on heater unit
outlet and hose Bwith 90° elbow on heater
unit inlet.
Connec-
tion on
heater unit
Routing in
engine
compart-
ment
cb
X X
BXC
A
B
y
1 1
x
C
1
y
1
23
B
C
24
BC

19
Toyota Corolla Verso
Disconnect original vehicle hose 2from
connection piece of engine outlet. Original
vehicle spring clip 1will be reused!
1Original vehicle spring clip
2Hose from engine outlet to heat exchanger
inlet Cutting
point
Mount hose Aon connection piece of engine
outlet and fasten with original vehicle spring
clip 1.
1Original vehicle spring clip
Connec-
tion to en-
gine outlet
Before connecting, fill the water hoses with
coolant.
1Hose to heat exchanger inlet
2Cable tie
Connec-
tionto heat
exchanger
inlet
1Cable tie
Routing in
engine
compart-
ment
25
1
2
26
B
A
1
27
2
1C
28
1
1

20
Toyota Corolla Verso
Combustion air
1Combustion-air intake pipe
227 mm dia. hose clamp
Installing
intake pipe
6 mm dia. hole 1in plastic part of cooling air
duct if not yet installed.
Hole for
cable tie
1Combustion-air intake pipe
3Combustion-air intake muffler
2Cable tie
Fastening
muffler at
hole
29
1
1
2
i
30
1
31
3
1
2