Webasto Thermo Top E Installation Instructions 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

e1

00 0003

e1

00 0002

e1

00 0104

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, the stipulations in the "installation instructions" and "operating and maintenance instructions"

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.

-Depressurize the 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 5 to K3/86 and wire 6 to

K3/87 (see wiring diagram on page 10)

Preparing

F4, K3 and

K3.1 relay

Position 1 and 4 only 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

sw

F4 3A

rt

1

6

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

Do not install the metering pump

cable harness until later together

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 4 from connector DF. Insulate

wire 4 and 6 and 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 4 on A/C control panel 5 vehicle-

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/C control

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

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

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 18x20

Ø 27

B

C

18

Toyota Corolla Verso

b = 770 mm

c = 600 mm

Hose A = 90° molded hose, included

Hose C with 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 C with long 90° elbow on heater unit

outlet and hose B with 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 2 from

connection piece of engine outlet. Original

vehicle spring clip 1 will be reused!

1Original vehicle spring clip

2Hose from engine outlet to heat exchanger

inlet Cutting

point

Mount hose A on 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-

tion to heat

exchanger

inlet

1Cable tie

Routing in

engine

compart-

ment

25

1

2

26

B

A

1

27

2

1C

28

1

20

Toyota Corolla Verso

Combustion air

1Combustion-air intake pipe

2 27 mm dia. hose clamp

Installing

intake pipe

6 mm dia. hole 1 in 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

2

i

30

1

31

3

1

2

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