Webasto thermo top evo Operator's manual

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.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Water Heater
Installation documentation
Ident. No.: 1317762A_EN Fee Euro 10.00 © Webasto AG
Toyota Yaris
Petrol and Diesel
from model year 2012
Left-hand drive vehicle
Manual transmission (5- / 6-gear): Petrol and Diesel
Multidrive transmission (CVT): Petrol
Diesel with MultiMode transmission (MMT) not checked
Thermo Top Evo Parking Heater
e1
00 0258

Toyota Yaris
1317762A_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in this installation
documentationhavenot beentested. However,installationaccordingtothis installationdocumentation
may be possible.
The installation location of the digital timer should be confirmed with the end customer before installa-
tion.
Manufacturer Model Type EG-BE-No. / ABE
Toyota Yaris XP13M e11 * 2007 / 46 * 0152
Engine type Engine model Output in kW Displacement in cm³
1KR-FE Petrol 51 998
1NR-NE Petrol 73 1329
1ND-TV Diesel 66 1364
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 system 7
Fan control for manual air conditioning 9
Automatic air-conditioning fan control 10
Digital timer 11
Remote option (Telestart) 11
Preparing installation location 12
Preparing heater 14
Installing heater 15
Combustion air 17
Fuel 18
Coolant circuit petrol 22
Coolant circuit, diesel 27
Exhaust gas 33
Final Work 35
Fuel templates petrol 36
Diesel template 37
Operating Instructions for End Customer 38

Toyota Yaris
1317762A_EN 3
Heater/Installation Kit
Foreword
This installation document applies to the Toyota Yaris Petrol and Diesel vehicles - for validity, see page
2 - from model year 2012 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 this installation documentation.
In any case, please follow the specifications of this "installation documentation" and the "operating and
installation instructions" of the Thermo Top Evo.
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 speci-
fied otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties. Insulate and tie back loose wires.
Sharp edges should be fitted with rub protection (split-open fuel hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
When installing an IPCU, the corresponding settings must be checked or adjusted before installation.
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
Quantity Designation Order No.:
1Thermo Top Evo Basic delivery scope See price list
1 Installation kit for Toyota Yaris 2012 Petrol and Diesel 1317761A
1 Heater control See price list

Toyota Yaris
1317762A_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.
Referenceto generalinstallationinstructions ofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
All dimensions are in mm!
Tightening torque of 5x13 heater bolts = 8Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
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 Yaris
1317762A_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the tank.
- Close the fuel tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurisethe 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.
- Remove the windscreen wipers.
- Remove the coolant reservoir cap.
- Remove the windscreen wiper motor.
- Remove the entire coolant reservoir.
- Remove the left headlight.
- Detach the wheel well trim on the right and left.
- Remove the bumper.
- Remove the front left-hand underride protection.
- Remove the rear bench seat.
- Open the right-hand tank-fitting service lid.
- Remove the lower instrument panel trim on the driver's side.
- Remove the footwell trim on the driver's side.
Remove page 38 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Toyota Yaris
1317762A_EN 6
Preparing electrical system
Wire sections retain their numbering in the
whole document.
All vehicles
1Angle bracket
2M5x16 bolt, large diameter washer [2x],
retaining plate for engine compartment
fuse holder, nut
3Fuse F1-2
Preparing
fuseholder
of engine
compart-
ment
Connect the wires according to the following
wiring diagram.
1Angle bracket
2M5x16 bolt, large diameter washer [2x],
fuse holder of passenger compartment,
angle bracket, nut
Red (rt) wire to K1/87a
Black (sw) wire from K1/30
Preparing
fuseholder
of passen-
ger com-
partment
Produce connections as shown in wiring dia-
gram. Install fuse F4 25A in manual air condi-
tioning or 7.5A in automatic air-conditioning
system. K1-Relay will be inserted after install-
ing the fuse holder
Red (rt) wire to K1/87a
Black (sw) wire from K1/30
Preparing
fuseholder
of passen-
ger com-
partment
Completing metering pump connector again
after routing. Pin assignment is not relevant.
1Connector housing
2Lock
3Blue/brown (bl/br) wire
4Coding
5Timer lock
Disman-
tling con-
nector
2
1
2
3
1
1 2 3
2
1
2
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
1
2sw
4²
rt
4²
1
2
1 2 3 4
5
5
4

Toyota Yaris
1317762A_EN 7
Electrical system
Positive wire
1Positive wire on positive battery terminal
Wiring harness pass through
1Protective rubber plug
Wiring har-
ness rout-
ing
diagram
Earth wire
1Earth wire on original vehicle earth support
point
Fuse holder of engine compartment
Position fuse holder of engine compartment 1 as
shown. Will be mounted during final work.
5
1
6
1
Do not install the metering pump
wiring harness until later togeth-
erwithfuellinealongtheoriginal
vehicle fuel lines on the under-
body
7
1
8
1

Toyota Yaris
1317762A_EN 8
Remove original vehicle bolt at position 1and
discard.
1M6x25 bolt, 8 mm shim, angle bracket,
flanged nut
2K1 relay Mounting
fuseholder
of passen-
ger com-
partment
Connect same colour wires from wiring har-
ness of passenger compartment fuse holder
2
and wiring harness of heater
1 as shown on
wiring diagram.
Connect-
ing wiring
harnesses
9
2
1
10
1
2
2
10
1

Toyota Yaris
1317762A_EN 9
Fan control for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-Evo GRs Fan relay rt red
X1 6-pin heater connector WG Resistor group sw black
X2 2-pin heater connector GS Fan switch ge yellow
X10 4-pin connector
Heater control A/C-V A/C booster gn green
GM Fan motor vi violet
K1 Fan relay F 35 2-pin connector GM ws white
F1 20A fuse HTR 40A fuse br brown
F2 30A fuse A/C 7.5A fuse bl blue
F3 1A fuse gr grey
F4 25A fuse X Cutting point
Wiring colours may vary.
Connection to 2-pin connector F35 from fan
motor. Produce connections as shown in wir-
ing diagram.
1Blue (bl) wire to connector F35 Pin 2
2Blue (bl) wire of fan relay
Red (rt) wire to K1/87a
Black (Sw) wire from K1/30
Connect-
ing fan mo-
tor
Webasto
31
30
15
Toyota
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5² rt
4²
br
0,5²
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
br
0,5²
HTR
GM
M
F35 2 1
WG
1324 F34
GS
10 6 7
F39
vi
vi
vi
GRs
A/C
A/C-V
F41 14 17 9 5
rt
vi
gr
rt
4²
sw
4²
2
1
bl
4²
bl
4²
11
1 2
2
1
1
2

Toyota Yaris
1317762A_EN 10
Automatic air-conditioning fan control
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-Evo GE Fan unit rt red
X1 6-pin heater connector KB A/C control panel sw black
X2 2-pin heater connector A/C-V A/C booster ge yellow
X10 4-pin connector
Heater control F42 40-pin connector A/C V gn green
HTR 40A fuse vi violet
K1 Fan relay A/C 7.5A fuse ws white
F1 20A fuse br brown
F2 30A fuse
F3 1A fuse X Cutting point
F4 7.5A fuse Wiring colours may vary.
Connect to the 40-pin connector F42 2of the
A/C booster. Establish connections as shown
on wiring diagram.
1Violet (vi) wire of fuse A/C
3Violet (vi) wire of connector F42 A/C
booster pin 1
Red (rt) wire to K1/87a
Black (Sw) wire from K1/30
View of F42 connector from contact side
Connect-
ing the A/C
booster
Webasto
31
30
15
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5² rt
4²
br
0,5²
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
br
0,5²
HTR
GE
M
F36 32
rt
A/C
A/C-V
F42 114
vi
rt
4²
sw
4²
2
1
vi
0,5²
F42 37 22
vi
0,5²
1
KB
F40 5 2 8
Toyota
12
2
1
3
1
2
1
2
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

Toyota Yaris
1317762A_EN 11
Digital timer
1Digital timer
Mounting
digital tim-
er
Remote option (Telestart)
Fasten receiver 1with adhesive tape.
Mounting
receiver
1Antenna
Mounting
antenna
Temperature sensor T100 HTM
Fasten temperature sensor 1with cable tie.
Mounting
tempera-
ture sensor
113
1
14
1
15
1
16

1317762A_EN 12
Toyota Yaris
Preparing installation location
Resistor with bracket and connector 1re-
moved for better display.
2Cable tie mounted on connector Preparing
resistor
Fastenoriginalvehicleconnector2with cable
tie to original vehicle wiring harness (close
cable tie 1)
3Resistor with bracket mounted at same
position Mounting
resistor
19.1 mm dia. hole; rivet nut
Installing
rivet nut
1Bracket
2M6x60 bolt, spring lockwasher, 5 mm
shim, 30 mm shim, washer, pin lock
Preparing
bracket
17
1
2
2
18
2
1
3
19
1
33
20
20
1
2

1317762A_EN 13
Toyota Yaris
Align bracket 3and mount loosely.
1M6x60 bolt
2Copy hole pattern [3x]
Copying
hole pat-
tern
Remove the bracket.
19.1 mm dia. hole; rivet nut [3x each]
Installing
rivet nut
1Bracket
2M6x60 bolt, spring lockwasher, 5 mm
shim, 30 mm shim, washer, pin lock [3x
each]
Preparing
bracket
1Tighten M6x60 bolt [4x]
Mounting
bracket
21
1 2
3 22
22
1
1
1
2 1 2
2
23
24
1 1
1 1

1317762A_EN 14
Toyota Yaris
Preparing heater
1Water connection piece, sealing ring [2x
each]
25x15 self-tapping bolt, retaining plate of
water connection piece Mounting
water con-
nection
piece
Tapthreads with5x13 self-tappingscrew 1 [2x]
and mount loosely (turn max. 3 threads).
Premount-
ing bolt
loosely
Tapthreads with5x13 self-tappingscrew 1 [2x]
at positions
1 and 3 and install loosely (turn
max. 3 threads). Loosely mount 51 mm dia.
clamp
2 at position 3 .
Premount-
ing bolt
loosely
Petrol
Discard section X.
Cutting
hoses to
length
25
1
1
2
1 1
26
1 2
327
X
A B CD E F G
1.0l
A=75
B=520
C=60
D=130
E=80
F=140
G=500
1.33l
A=75
B= 470
C=60
D= 130
E=80
F= 140
G= 500

1317762A_EN 15
Toyota Yaris
Diesel
Discard section X.
Hose A= 180°, 18 mm dia. moulded hose
B=160
C=360
D=60
E=130
F=80
G=160
H=360
I=160
Cutting
hoses to
length
All vehicles
All spring clips 25 mm dia.. All connecting
pipes 90°, 18x18 mm dia.
Petrol Cand D
Diesel Dand EPremount-
ing hoses
of heater
inlet
All spring clips 25 mm dia.. All connecting
pipes 90°, 18x18 mm dia.
Petrol Eand F
Diesel Fand GPremount-
ing hoses
of heater
outlet
Installing heater
1Combustion air silencer
2Tighten 5x13 self-tapping bolt [2x]
Mounting
heater
X
B C DE F G H
A
I
C / D 28 D / E
29
E / FF / G
30
1 2
2

1317762A_EN 16
Toyota Yaris
1Tighten 5x13 self-tapping bolt [2x]
Mounting
heater
31
1
1

Toyota Yaris
1317762A_EN 17
Combustion air
Discard section X.
1Combustion air pipe
a = 270 Cutting
combus-
tion air
pipe to
length
1Silencer
2Combustion air pipe
327 mm dia. clamp
Mounting
combus-
tion air
pipe
1Cable tie
2Mount wiring harness of heater [2x]
Wiring har-
ness of
heater
a
1
X
32
4
1 2
6
3
5
33
1 1 2

Toyota Yaris
1317762A_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 as shown in the wiring harness rout-
ing diagram.
1Fuel line and wiring harness of metering
pump in corrugated tube
290° moulded hose, 10 mm dia. clamp [2x]
Connect-
ing heater
1Route fuel line and wiring harness of me-
tering pump in corrugated tube to firewall
Routing
lines
1Fuel line and wiring harness of metering
pump in corrugated tube
Routing
lines
34
1
2
35
1
1
36
1
1

Toyota Yaris
1317762A_EN 19
1Perforated bracket
2Discard section
Preparing
perforated
bracket
1Metering pump
2Metering pump mounting
3Perforated bracket
4M6x25 bolt, existing hole in strut, flanged
nut Mounting
metering
pump
1Wiring harness of metering pump, con-
nector mounted
2Fuel line of heater
3Hose section, 10 mm dia. clamp [2x]
Connect-
ing meter-
ing pump
Petrol
Remove fuel-tank sending unit 1in accord-
ancewithmanufacturer'sinstructions.Cutout
template 2and place as shown.
3Copy hole pattern, 6 mm dia. hole Fuel ex-
traction
37
35
35°
2
1
38
1
4
3
2
39
1
3 2
40
1
23

Toyota Yaris
1317762A_EN 20
Shape fuel standpipe 1according to tem-
plate, cut to length and install.
Installing
fuel stand-
pipe
Install fuel-tank sending unit 1in accordance
with manufacturer's instructions. Slide corru-
gated tube onto fuel line 3.
2Cable tie
4Hose section, 10 mm dia. clamp [2x]
5Fuel standpipe Connect-
ing fuel
line
Diesel
Remove fuel-tank sending unit 1in accord-
ance with manufacturer's instructions. Drill 6
mm dia. hole in centre at position 2Fuel ex-
traction
Shape fuel standpipe 1according to tem-
plate, cut to length and install. Install 18 mm
dia. large diameter washer from below.
2Large diameter washer Installing
fuel stand-
pipe
41
1
1
1
42
3
1 2
5
4
43
1
2
44
1
2