Webasto Thermo Top EVO Installation Documentation

Brand: Webasto

Model: Thermo Top EVO

Type: Installation Documentation

Webasto Thermo Top EVO is a parking heater that provides warmth and comfort in your vehicle, even on the coldest days. It's easy to use, with a digital timer and remote control option, so you can pre-heat your car before you even get in. The heater is also fuel-efficient and quiet, so you can enjoy the warmth without worrying about wasting gas or disturbing your neighbors.

Water Heater

Installation Documentation

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE

Validity

Manufacturer Model Type EG-BE No. / ABE

Toyota GT 86 ZN e13 * 2007 / 46 * 1287 *...

Subaru BRZ ZC6 e13 * 2007 / 46 * 1281 *...

Motorisation Fuel

Transmission type

Output in kW

Displacement in cm³

Engine code

2.0 Petrol 6-speed AT 147 1998 FA20

2.0 Petrol 6-speed SG 147 1998 FA20

AT = Automatic transmission

SG = Manual transmission

From Model Year 2012

Left-hand drive vehicle

verified equipment variants:

Automatic air-conditioning

Front fog light

Xenon, Headlight cleaning device

LED Daytime Running Lights

not verified: Passenger compartment monitoring

Manual A/C system

Total installation time: about 7 hours

Thermo Top Evo Parking Heater

00 0258

Toyota GT 86 / Subaru BRZ

The total installation time includes the time needed for mounting and demounting of the vehicle-specific components,

the heater specific installation time and all other times required for the system integration and initial start-up of the

heater.

The total installation time may vary for vehicle equipment other than provided.

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 2

Table of Contents

Necessary Components

Installation Overview

Notes on Total Installation Time

Legend:

1. Heater

2. Fuse holder of engine com-

partment

3. Fuse holder of passenger

compartment

4. Circulating pump

5. Digital timer

6. Metering pump

Validity 1

Necessary Components 2

Installation Overview 2

Notes on Total Installation Time 2

Information on Operating and Installation Instructions 3

Notes on Validity 4

Technical Instructions 4

Explanatory Notes on Document 4

Preliminary Work 5

Heater Installation Location 5

Preparing Electrical System 6

Electrical System 8

Fan Controller 9

Digital Timer 12

Remote Option (Telestart) 12

Preparing Installation Location 13

Preparing Heater 13

Installing Heater 14

Coolant Circuit 16

Combustion Air 20

Fuel 21

Exhaust Gas 24

Final Work 28

Template of Bracket 29

Template for Fuel Standpipe 30

Operating Instructions for End Customer 31

• Basic delivery scope Thermo Top Evo in accordance with price list

• Installation kit for Toyota GT 86 / Subaru BRZ 2012 Petrol: 1318740A

• Heater control in accordance with price list and upon consultation with final customer

• In case of Telestart, indicator lamp in accordance with price list and upon consultation with fi-

nal customer

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 3

1 Important Information (not complete)

1.1 Installation and Repair

The improper installation or repair of Webasto heating and cooling sys-

tems can cause fire or the leakage of deadly carbon monoxide, leading

to serious injury or death.

To install and repair Webasto heating and cooling systems you need to

have completed a special company training course and have the appro-

priate technical documentation, special tools and special equipment.

Installation and repair may ONLY be carried out by persons trained and

certified in a Webasto training course. NEVER try to install or repair We-

basto heating or cooling systems if you have not completed a Webasto

training course, you do not have the necessary technical skills and you

do not have the technical documentation, tools and equipment available

to ensure that you can complete the installation and repair work properly.

Only use genuine Webasto parts. See the Webasto air and water heat-

ers accessories catalogue for this purpose.

1.2 Operation

To ensure safe operation, we recommend having the heater checked every two

years by an authorised Webasto dealer, especially when used over a long period

and/or under extreme environmental conditions.

Do not operate the heater in closed rooms due to the danger of poisoning and suf-

focation.

Always switch off the heater before refuelling.

The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or pet-

rol (DIN EN 227).

The heater may not be cleaned with a high-pressure cleaner.

1.3 Please note

ALWAYS follow all Webasto installation and operating instructions and observe all

warnings.

To become familiar with and understand all functions and properties of the heater,

the operating instructions must be read carefully and observed at all times.

For proper, safe installation and repair work, the installation instructions with all

warnings and safety information must be carefully read and observed at all times.

Please always contact a workshop authorised by Webasto for all installation and

repair work.

Important

Webasto shall assume no liability for defects, damage and injuries resulting

from a failure to observe the installation, repair and operating instructions

of the information contained in them.

This liability exclusion particularly applies to improper installations and re-

pairs, installations and repairs by untrained persons or in the case of a fail-

ure to use genuine spare parts.

The liability due to culpable disregard to life, limb or health and due to dam-

age or injuries caused by a wilful or reckless breach of duty remain unaf-

fected, as does the obligatory product liability.

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.

Insulate loose wire ends and tie back.

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).

Observe the instructions and guidelines of the respective vehicle manufac-

turer for demounting and mounting vehicle specific components!

The initial startup is to be executed with the Webasto Thermo Test Diagno-

sis.

When installing an IPCU, the corresponding settings must be checked or

adjusted before the installation.

2 Statutory regulations governing installation

Note

The regulations of these guidelines are binding in the scope of the Directive

70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and

should also be observed in countries in which there are no special regulations.

Important

Failure to follow the installation instructions will result in the invalidation of the type

approval for the heater and therefore invalidation of the general homologation of

the vehicle.Note

For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4

of Annex VIII b to the Road Traffic Act is required.

2.1 Excerpt from the directive 2001/56/EC Appendix VII for the

installation of the heater

Beginning of excerpt. ANNEX VII

REQUIREMENTS FOR COMBUSTION HEATERS

AND THEIR INSTALLATION

1. GENERAL REQUIREMENTS

1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when

the combustion heater is switched on or off.

2. VEHICLE INSTALLATION REQUIREMENTS

2.1. Scope

2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed ac-

cording to the requirements of this Annex.

2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply

with the requirements of this Annex.

2.2. Positioning of heater

2.2.1. Body sections and any other components in the vicinity of the heater

must be protected from excessive heat and the possibility of fuel or oil

contamination.

2.2.2. The combustion heater shall not constitute a risk of fire, even in the case

of overheating. This requirement shall be deemed to be fulfilled if the in-

stallation ensures an adequate distance to all parts and suitable ventila-

tion, by the use of fire resistant materials or by the use of heat shields.

2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in

the passenger compartment. However, an installation in an effectively

sealed envelope which also complies with the conditions in paragraph

2.2.2 may be used.

2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned

so that it can be easily read when the heater is installed in the vehicle.

2.2.5. Every reasonable precaution should be taken in positioning the heater

to minimise the risk of injury and damage to personal property.

2.3. Fuel supply

2.3.1. The fuel filler must not be situated in the passenger compartment and

must be provided with an effective cap to prevent fuel spillage.

2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the

vehicle is provided, the type of fuel and its filler point must be clearly la-

belled.

2.3.3. A notice, indicating that the heater must be shut down before refuelling,

must be affixed to the fuelling point. In addition a suitable instruction

must be included in the manufacturer's operating manual.

2.4. Exhaust system

2.4.1. The exhaust outlet must be located so as to prevent emissions from en-

tering the vehicle through ventilators, heated air inlets or opening win-

dows.

2.5. Combustion air inlet

2.5.1. The air for the combustion chamber of the heater must not be drawn

from the passenger compartment of the vehicle.

2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish

or luggage is unlikely.

2.6. Heating air inlet

2.6.1. The heating air supply may be fresh or recirculated air and must be

drawn from a clean area not likely to be contaminated by exhaust fumes

emitted either by the propulsion engine, the combustion heater or any

other vehicle source.

2.6.2. The inlet duct must be protected by mesh or other suitable means.

2.7. Heating air outlet

2.7.1. Any ducting used to route the hot air through the vehicle must be so po-

sitioned or protected that no injury or damage could be caused if it were

to be touched.

2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish

or luggage is unlikely.

End of excerpt.

In multilingual versions the German language is binding.

Guidelines Thermo Top Evo

Heating Directive ECE R122 E1 00 0258

EMC Directive ECE R10 E1 03 5627

Information on Operating and Installation Instructions

Special features are highlighted using the following symbols:You will find an identification mark on the outside

top right corner of the page in question to provide

you with a quick overview of the individual working

steps.

Toyota GT 86 / Subaru BRZ

Mechanical system

Electrical system

Coolant circuit

Combustion air

Fuel

Exhaust gas

Software

Specific risk of injury or

fatal accidents

Specific risk of damage to

components

Specific risk of fire and explosion

Reference to general installation instructions

of the Webasto components or to the

manufacturer's vehicle-specific documents

Reference to a special technical feature

The arrow in the vehicle icon

indicates the position on the vehicle

and the viewing angle

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 4

Notes on Validity

This installation documentation applies to Toyota GT 86 / Subaru BRZ Petrol vehicles - for validity, see page 1 - from

model year 2012 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 installa-

tion with respect to this installation documentation.

Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation

have not been tested. However, installation according to this installation documentation may be possible.

Technical Instructions

Explanatory Notes on Document

Special Tools

• Hose clamp pliers for self-clamping hose clamps

• Hose clamp pliers for Clic hose clamps of type W

• Automatic wire stripper 0.2 - 6mm²

• Crimping pliers for cable lug / tab connector 0.5 - 6mm²

• Torque wrench for 2.0 - 10 Nm

• Hose clamping pliers

• Metric thread-setter kit

• Webasto Thermo Test diagnosis with current software

Dimensions

• All dimensions are in mm.

Tightening torque values

• Tightening torque values of 5x13 heater bolts = 8Nm.

• Tightening torque values of 5x15 retaining plate of water connection piece bolt = 7Nm.

• Tighten other screw connections in accordance with manufacturer's instructions or in accordance with state-of-

the-art-technology.

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 5

Preliminary Work

Vehicle

• Open the fuel tank cap.

• Ventilate the fuel tank.

• Close the fuel tank cap again.

• Depressurise the cooling system.

• Disconnect the battery and remove it completely, including the carrier.

• Remove the right-hand / left-hand underbody trim.

• Remove the lower engine cover.

• Remove the lower cover of the fuel tank.

• Remove the left rear bench area.

• Open the tank-fitting service lid.

• Remove the fuel-tank sending unit according to manufacturer's instructions.

• Removing the glove compartment.

• Loosen the gear lever trim of the centre console.

• Remove the centre console.

• Remove the A/C control panel.

Heater

• Remove years that do not apply from the type and duplicate label.

• Attach the duplicate label (type label) in the appropriate place inside the engine compartment.

Heater Installation Location

1Heater

Installation

location

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 6

Preparing Electrical System

Discard section X.

Wire sections retain their numbering in the

entire document. Cutting

wires to

length

IPCU view on the contact side!

The IPCU included in the kit must be pro-

grammed with the following settings:

Duty-Cycle: 100%

Frequency: 1kHz

Voltage: 2.4V

Function: High-side

The adjustment values are to be checked

upon start-up of the heater and adjusted if

necessary.

Preparing

IPCU

Produce connections as shown in wiring dia-

gram.

Install wire section 6 and 8 in protective sleev-

ing provided. Install wire section 9 in protec-

tive sleeving provided.

Brown (br) wire of K1/85 - IPCU/85

Brown (br) wire of IPCU/85 - K2/2

Green/white (gn/ws) wire of K1/86 - IPCU/86

Red (rt) wire of K1/87a - K2/1

Red (rt) wire of IPCU/A - K2/4

Red (rt) wire of K2/5

Black (sw) wire from K1/30 - fuse F5

Black (sw) wire of K2/3

Black (sw) wire of fuse F5

Red (rt) wire of K1/87a

Black (sw) wire of K1/30

Connect-

ing wires

100

2gn/ws

0,75²

100

5rt

0,5²

800

100

8sw

0,5²

800

100

100 100

0,5²

86 85

IPCU

86 85

85 30

87a87

gn/ws

0,75²

0,5²

4²

rt/sw

0,5²

85 30

87a87

0,5²

gn/ws

0,75²

0,5² 4

0,5²

8sw

0,5²

7sw

0,5²

8685

IPCU

9sw

0,5²

10 rt

4²

11 sw

4²

6rt

0,5²

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 7

Snap fuse holder of passenger compartment

together with socket of IPCU

and socket of

K2 relay

Brown (br) wire of K1/85 - IPCU/85

Brown (br) wire of IPCU/85 - K2/2

Green/white (gn/ws) wire of K1/86 - IPCU/86

Red (rt) wire of K1/87a - K2/1

Red (rt) wire of IPCU/A - K2/4

Red (rt) wire of K2/5

Black (sw) wire from K1/30 - fuse F5

Black (sw) wire of K2/3

Black (sw) wire of fuse F5

Red (rt) wire of K1/87a

Black (sw) wire of K1/30

Complet-

ing fuse

holder of

passenger

compart-

ment

1Angle bracket

2M5x16 bolt, washer [2x], nut

3K1 relay

410A fuse F5

525A fuse F4

6IPCU

7K2 relay Complet-

ing fuse

holder of

passenger

compart-

ment

Four diodes with connectors premounted as

shown. Watch direction of flow of diodes.

1Diode group D1

2Connection to heater Premount-

ing diode

group

Complete connector of metering pump again

after routing. Pin assignment is not relevant.

1Connector housing

2Lock

3Blue/brown (bl / br) wires

4Coding

5Timer lock

Disassem-

bling con-

nector

1 43

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 8

Electrical System

Fuse holder of engine compartment

1Fuses F1-2

2M5x16 bolt, washer [2x], retaining plate of

fuse holder, nut

3M6x20 bolt, large diameter washer, flanged

nut

4Angle bracket

Positive wire

1Positive wire on positive battery terminal

Wiring har-

ness rout-

ing

diagram

Earth wire

1Earth wire on original vehicle earth support

point

Wiring harness pass through

1Heater wiring harnesses, heater control

2Protective rubber plug

Do not install the metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 9

Fan Controller

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG TT-Evo heater GRs Fan relay rt red

X1 6-pin heater connector GRr Fan controller sw black

X2 2-pin heater connector A27 5-pin connector of GRr ge yellow

X10 4-pin connector

Heater control AC-V AC booster gn green

D19(A)

16-pin connector of AC-V

br brown

K1 Fan relay GM Fan motor ws white

K2 Additional relay A31 2-pin GM connector

F1 20A fuse St 2 24-pin connector of KB

F2 30A fuse F Heater 50A fuse

F3 1A fuse F IG 10A fuse

F4 10A fuse F Radio 7.5A fuse

F5 25A fuse

IPCU Pulse width modulator

D1 Premounted diode

group IPCU settings:

Duty-Cycle: 100%

Frequency: 1kHz

Voltage: 2.4V XCutting point

Function: High-side Wiring colours may vary.

Webasto

Toyota

X2 1 2 X1

F2 F1

gn/ws

0,75²

0,5²

rt/sw

0,5² rt

4²

X10

0,5²

85 30

87a87

gn/ws

0,75²

4²

rt/sw

0,5²

85 30

87a87

0,5²

gn/ws

0,75²

5rt

0,5²

86 85

IPCU

9sw

0,5²

4²

0,5²

GRs 1

Heater F

0,5²

A31 2 1

GRr

A27 5 43 1

AC-V

D19(A) 10 8 6 14

sw/rt

gn/ws

Radio

rt/sw

0,5²

Toyota GT 86 / Subaru BRZ

Ident. No.: 1318741A_EN Status: 18.01.2013 © Webasto Thermo & Comfort SE 10

17.0mm dia. hole

Installing

fuse holder

of passen-

ger com-

partment

1Fuse holder of passenger compartment

premounted

2M6x12 bolt, angle bracket, flanged nut

Installing

fuse holder

of passen-

ger com-

partment

Connect the wiring harness of passenger

compartment fuse holder 1 with the wiring

harness of heater 2 according to the wiring di-

agram, in such a way that the wires of the

same colour are connected. Connect-

ing wiring

harnesses

Connection to 2-pin connector A31 1 of fan

motor. Produce connections as shown in wir-

ing diagram.

2Black/red (sw/rt) wire of fan relay

3Black/red (sw/rt) wire of connector A31,

Pin 2

Red (rt) wire of K1/87a

Black (sw) wire of K1/30

Connector A31

on contact side.

Connect-

ing fan mo-

tor

1011

1 2

Toyota GT 86 / Subaru BRZ

Connection to 5-pin connector A27 1 from fan

controller. Produce connections as shown in

wiring diagram.

2Green/white (gn/ws) wire of A/C control

unit

Green/white (gn/ws) wire of connector A27,

Pin 1

Red (rt) wire of K2/5

Black (sw) wire of K2/3

Connector A27

on contact side.

Connec-

tion of fan

controller

Connection to 16-pin connector D19(A) 1

from A/C control unit. Produce connections

as shown in wiring diagram.

1Black/red (sw/rt) wire of connector

D19(A), Pin 1

2Black/red (rt/sw) wire of radio fuse

3Green (gn) wire of IG fuse

Green (gn) wire of connector D19(A), Pin 10

Black (sw) wire of fuse F5

Connector D19(A)

on contact side.

Connec-

tion of A/C

control unit

4 5

1 32

1 2

Toyota GT 86 / Subaru BRZ

Digital Timer

1Digital timer

Installing

digital tim-

Remote Option (Telestart)

Fasten receiver 1 to control unit 2 with adhe-

sive tape.

Installing

receiver

1Antenna

Installing

antenna

Temperature sensor T100 HTM

Fasten temperature sensor 1 with adhesive

tape (hidden).

Installing

tempera-

ture sensor

Toyota GT 86 / Subaru BRZ

Preparing Installation Location

Remove original vehicle retaining clip at posi-

tion 1.

2Hole cable tie Relocating

sound gen-

erator hose

Position 2 shows later installation of retaining

clip into hole 1.

16.0mm dia. hole

Copying

hole pat-

tern

Mind components located behind!

19.1 mm dia. hole; rivet nut [2x each]

Copying

hole pat-

tern

Preparing Heater

1Water connection piece, sealing ring [2x

each]

25x15 self-tapping bolt, retaining plate of

water connection piece Installing

water con-

nection

piece

Toyota GT 86 / Subaru BRZ

190° moulded hose, 10 mm dia. clamp [2x]

2Fuel line

Installing

fuel line

1Perforated bracket

Angling

down per-

forated

bracket

Shape bracket 1 according to template.

2M6x12 bolt, flanged nut [3x each]

3Perforated bracket

4Perforated bracket angled down Premount-

ing bracket

Installing Heater

1M6x30 bolt, spring lockwasher, 10 mm

shim

2M6x20 bolt, spring lockwasher

3Bracket Installing

bracket

2 1 24

20 20

160°160°

1 2

3 2

Toyota GT 86 / Subaru BRZ

1M6x12 bolt, flanged nut, existing hole

Installing

bracket

Check for freedom of movement between

bracket 2 and battery 1 at position 3

[min.10mm], align/adjust if necessary. Re-

move battery again.

Aligning

bracket

15x13 self-tapping bolt [3x]

Installing

heater

Mount wiring harness of circulating pump 1

and route to installation location of circulating

pump.

2Wiring harness of heater [2x] Mounting

wiring har-

ness

1 2

Toyota GT 86 / Subaru BRZ

Coolant Circuit

WARNING!

Any coolant running off should be collected in a suitable 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 hoses, the heater must be filled with coolant.

The connection should be "inline" based on the following diagram:

Hose rout-

ing dia-

gram

All spring clips without a specific designation = 25 mm dia.

All connecting pipes = 16x18mm dia.

CØ 23

Ø 23

Toyota GT 86 / Subaru BRZ

Discard section X.

Hose A = 90°, 18 mm dia. moulded hose

B=350

C=250 Cutting

hoses to

length

Remove hose bracket 2; will be reused.

Cut off hose on engine outlet / heat exchang-

er inlet at the marking.

1Hose section of heat exchanger inlet

3Engine outlet hose section Cutting

point

Turn hose section of heat exchanger inlet 1

on connection piece to the right.

Cutting

point

1Perforated bracket

28.5 mm dia. hole

Preparing

perforated

bracket

331

110

16 25

90°

45°

Toyota GT 86 / Subaru BRZ

1M6x25 bolt, flanged nut

2Perforated bracket

3Circulating pump

4Circulating pump mounting

Premount-

ing circu-

lating

pump

1Original vehicle bolt

2Perforated bracket

3Attach wiring harness of circulating pump

Installing

circulating

pump

1Connection piece of heater outlet

2Hose on heat exchanger inlet

Connect-

ing heat ex-

changer

inlet / heat-

er outlet

1Insert hose bracket

2Connection piece of heater inlet

Connect-

ing heater

inlet / circu-

lating

pump

1 2

C 2

Toyota GT 86 / Subaru BRZ

Align hoses. Ensure sufficient distance from

neighbouring components, correct if neces-

sary.

1Hose of engine outlet Connect-

ing circu-

lating

pump / en-

gine outlet

A 1

Toyota GT 86 / Subaru BRZ

Combustion Air

1Adhesive base [2x]

2Retaining clip in hole

Inserting

retaining

clip

1Silencer

2Combustion air pipe

3Combustion air pipe on heater

Installing

combus-

tion air pipe

1Silencer

2Cable tie [2x]

3Combustion air pipe on silencer

Installing

silencer

1 2

Page is loading ...

Webasto Thermo Top EVO Installation Documentation

Webasto Thermo Top EVO Installation Documentation

Webasto Thermo Top EVO Installation Documentation

Related papers

Other documents