corolla verso water heater

8/11/2019 Corolla Verso Water heater

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WARNING!

Hazard warning:

Incorrect installation or repair of Webasto heating systems may cause a fire or resultin the emission o f carbon monoxide, which can be fatal. Serious or fatal injuries canbe caused as a result.

Specialist company training, technical documentation, specialized tools andequipment are required to install and repair Webasto heating and cooling systems.

NEVER attempt to ins tall or repair Webasto heating or cool ing sys tems if you have notsuccessfu lly completed the company training and thereby acquired the requiredtechnical skil ls, or if you do not have access to the required technical documentation,tools and equipment needed to carry out correct installation and repairs.

ALWAYS fo llow all Webasto installation and repair inst ruct ions and observe al lwarnings.

Webasto does not accept any liability for defects and damage that are attributable toinstallation by untrained staff.

Feel the driv e

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 EAddi tional Heater

Thermo Top CAdditional Heater

Thermo Top PAddi tional Heater

Installation Instructions

e1

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00 0104


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Validity

Vehicle and engine types and equipment variants not listed in these installation instructions have notbeen 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 endcustomer 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 cm

2AD-FHV Diesel (D-Cat) 130 2231

2AD-FTV Diesel (D-4D) 100 2231

Validity 2Heater Unit/Installation Kit 3Foreword 3General Instructions 3Special Tools 3

Explanatory Notes on Document 4Preliminary Work 5Heater unit installation location 5Preparing electrical system 6Electrical Connections 7Fan controller for manual air conditioning 8Automatic air-conditioning fan controller 10

Remote option (Telestart) 13Remote option (Thermo Call) 14Preparing installation location 15Installing heater unit 16Coolant connection 17

Combustion air 20Fuel Connection 21Exhaust system 23Final Work 25Operating Instructions for End Customer 26

Table of Contents


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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 thelevel of comfort required by the customer!

ForewordThe 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 thevehicle do not affect installation, any liability claims excluded. Depending on the vehicle version andequipment, modifications may be necessary during installation with respect to these installationinstructions.

However, the stipulations in the "installation instructions" and "operating and maintenance instructions"for the Thermo Top C/P/Emust always be observed.The corresponding rules of technology and any information from the vehicle manufacturer should beobserved during the installation work.

General InstructionsInstallation should be carried out according to the general, standard rules of technology. Unlessspecified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiringharnesses 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


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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 onthe vehicle and the viewingangle.


Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Reference to general installation instructions ofWebasto components or to the manufacturer's vehicle-specific documents.

Reference to a special technical feature.

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Explanatory Notes on Document

To provide you with a quick overview of the individual working steps, you will find an identification markon the outside top right corner of the page in question.


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5


Heater unit installation location

1 Heater unit

Installationlocation

1 1

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


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6


Preparing electrical systemOnly with automatic air-conditioning

Wiring sections 1 and3will be required later

for fan controller.Wiring sections 2 and6will be required laterfor connecting fuse F4.

Cuttingwires tolength

Wiring sections 2, 4 and5will be requiredlater for connecting K3.1 relay!

Cuttingwires tolength

Produce connections as shown in wiringdiagram on page 10. Pull wiring sections 1and3 into protective sleeving provided.Also connect wire 5to K3/86 and wire 6toK3/87 (see wiring diagram on page 10)

PreparingF4, K3 andK3.1 relay

Position 1and 4only with automatic air-conditioning!

2 M 5x16 bolt, washer, retaining plate fuseholder, bracket, M5 flanged nut

3 M 5x16 bolt, washer, K3 relay, bracket,K3.1 relay, M5 flanged nut

Preassem-bling fuseholder

sw 0,75mm

2000

1

rt 0,75mm

1850

6

150

2

100

3

br 0,75mm

150

4

gr/ws 0,75mm

150

5

K3.1

87a8786

85 30

4br sw

35

2

rt

rt

sw

F4 3A

rt

1

6

2

2

1

3

4


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7


Electrical Connections

Fuse holder, K3 relay

Fuse F4 and K3.1 relay only with automatic air-conditioning!

1 Battery holder3 Fuse holder preassembled2 7 mm dia. hole, M6x20 bolt, preassembled

fuse holder, M6 flanged nut

Digital timer

1 Digital timer

Wiringharnessinstallationdiagram

Wiring harness pass through

1 Protective rubber plug

Summer/winter switch option

1 Summer/winter switch, drilled hole 12 mm dia.

3

2

3

1

4

1

br

bl

rt

sw

rt

sw

Do not install the metering pumpcable harness until later togetherwith fuel pipe along the original

vehicle fuel lines on theunderbody

i

5

1

6

1


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Fan contro ller for manual air condi tioning

Wiring dia-gram for

manual aircondition-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

X Cutting point

gn/ws

sw

br

rt/ws

Webasto

31

30

15

Toyota

rt

4

HG

X1 F3Fa

M

+

-

GM WG

sw

K3

87a8786

85 30

GR

sw

i


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Connection on 2-pin connector DF on fuseand relay carrier.

1 Fuse and relay carrier2 Connector DF

Fan con-troller formanual aircondition-ing

Connection on 2-pin connector DF on fuseand relay carrier. Make connections asshown in wiring diagram with connectors

(yellow) provided.

1 Black (sw) wire, 4.0 mm, from K3/302 Connector (yellow) [2x]3 Black (sw) wire to fan motor4 Connector DF5 Red (rt) wire, 4.0 mm, from K3/87a

Fancontroller

1 2

7

5

4

3

1 2

8


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Automatic ai r-condi tioning fan control ler

Wiringdiagram

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 andtie back

X Cutting point

sw4

rt

Webasto

31

30

15

Toyota

rt

sw

rt

0,75

ws/sw

sw

rt

86

85 30

87a87

K3.1

GRr

+

-

GMM

HG

X1 4F3 Fb FaF4

KB

St 01 12/14

GR

!

86

85 30

87a87

K3

!

4

5

6

2

1

3

sw

0,75

rt

4

rt

*


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Connection on 3-pin connector DF from fuseand relay carrier. Produce connections asshown in wiring diagram with 3x distributorand tab receptacles provided.

1 Connector DF

2 Black (sw) wire to fan motor

Fan con trol

Remove wire 4from connector DF. Insulatewire 4and 6and tie back.

1 Connector DF2 Black (sw) wire to fan motor3 3x distributor5 Black (sw) wire from K3/304 White/black (ws/sw) wire from original

vehicle fan relay, Pin 46 Red (rt) wire from K3/87a

Fan con trol

1 Connector DF on fuse and relay carrier

Fan con trol

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 wiringdiagram.

1 Red (rt) wire, 0.75 mm, from K3.1/87a2 Connector (red) [2x]3 Red (rt) wire from 24-pin connector, Pin 12

or from 28-pin connector, Pin 144 Connector 01 (24 or 28-pin)6 Black (sw) wire, 0.75 mm, from K3.1/30

Control ofA/C controlpanel

1 2

9

4

5

6

3

1 2

10

1

11

4

3

31

6

2

2 5 12


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Connector of A/C control panel equipment-dependent with automatic air-conditioning

Connector

of A/Ccontrolpanel,24-pin

Connector of A/C control panel equipment-dependent with two-zone automatic air-conditioning

Connectorof A/Ccontrolpanel,28-pin

3 41 2 7 85 6 11 129 10

15 1613 14 19 2017 18 23 2421 22

3 41 2 7 85 6 11 129 10

17 1815 16 21 2219 20 25 2623 24

13 14

27 28


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Remote opt ion (Telestart)

1 M5x16 bolt, bracket, M5 flanged nut onexisting hole

2 Receiver, mounted on bracket

Installingreceiver

1 Antenna

Installingantenna

2 13

1i

1

14


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Remote option (Thermo Call)

1 Receiver, M5x20 bolts, flanged nuts,washer [4x each]

2 Lower footwell cover on front passengerside

Installingreceiver

1 Antenna

Installingantenna

1 Pushbutton2 Blind cap3 Center console

Installingpushbutton

1

2 15

i

1

16

1

17

2

3


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Preparing installation locationPicture shows bracket with Index F!

2 Bracket1 7 mm dia. hole

Hole inbracket

Copy hole pattern at Position 3[2x]. Removebracket again.Drill 9.1 mm dia. hole at Position 3[2x] in

frame side member and mount rivet nuts.

2 Bracket, loosely mounted1 M6x20 bolt, large diameter washer [2x

each] on existing threaded holesInstallingrivet nut

1 Bracket2 M6x20 bolt, large diameter washer [2x

each] on existing threaded holes3 Mount M6x20 bolt, spring lockwasher [2x

each] on prepared rivet nuts4 Spacer nut, 30 mm5 M6x12 bolt, spring lockwasher

Installingbracket

18

1

2

36 mm

46 mm

19

1 2

1

3

3

20

3

1 3

4

2

5

2


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Installing heater unit

Connect wiring harness for heater unit beforeinstallation.Insert two washers between heater unit andbracket at Position 3.Tighten EJOT screws to 10 Nm!

1 Bracket2 Ejot screw [2x]3 Ejot screw

Installingheater unit

Ejot screw bolt, tightening torque 10 Nm!

2 Bracket

1 Ejot screw3 Wiring harness of heater unit

Installingheater unit

21

1 2

3 2

22

1

2

3


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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:

Coolantroutingdiagram

All spring clips without a specific designation = 27 mm dia.All connecting pipes without a specific designation = dia. 20x20.

Motor

Heat

exchanger

A

25

25

18x20

27

27B

C


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b = 770 mmc = 600 mm

HoseA= 90 molded hose, includedHose Cwith long 90 elbowDiscard section X

Cuttingcoolanthoses tolength

Push braided protection hoses onto hose Band C. Push on heat shrink plastic tubing andshrink.

x = 50 mmy = 25 mm

1 25 mm heat shrink plastic tubing [4x] Preparingcoolanthoses

Hose Cwith long 90 elbow on heater unitoutlet and hose Bwith 90 elbow on heaterunit inlet.

Connec-tion onheater unit

Routing inenginecompart-ment

c bX X

BXC

A

B

y

1 1

x

C1

y

1

23

B

C

24

BC


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Disconnect original vehicle hose 2fromconnection piece of engine outlet. Originalvehicle spring clip 1will be reused!

1 Original vehicle spring clip2 Hose from engine outlet to heat exchanger

inlet

Cuttingpoint

Mount hoseAon connection piece of engineoutlet and fasten with original vehicle springclip 1.

1 Original vehicle spring clip

Connec-tion to en-gine outlet

Before connecting, fill the water hoses withcoolant.

1 Hose to heat exchanger inlet2 Cable tie

Connec-tion to heatexchangerinlet

1 Cable tie

Routing inenginecompart-ment

25

1

2

26

B

A

1

27

2

1C

28

1

1


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Combustion air

1 Combustion-air intake pipe2 27 mm dia. hose clamp

Installingintake pipe

6 mm dia. hole 1in plastic part of cooling airduct if not yet installed.

Hole forcable tie

1 Combustion-air intake pipe3 Combustion-air intake muffler2 Cable tie

Fasteningmuffler athole

29

1

1

2

i

301

313

1

2


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Fuel Connection

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.Unless 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 harnessrouting diagram.

1 Mecanyl fuel line3 Hose section2 10 mm dia. hose clamp [2x]

Connec-tion onheater unit

1 Mecanyl fuel line2 Metering pump wiring harness

Installinglines

Ensure proper installation position ofmetering pump, see "InstallationInstructions.Installation location in front of vehicle fueltank on left!

1 Metering pump wiring harness2 Fuel line from heater unit3 Metering pump

Installationlocation ofmeteringpump

32

1

32

2

33

1

2

34

1

3

2

i


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Fasten metering pump on existing hole onfuel tank with rubber-coated p-clamp,silentblock and flanged nut [2x].

1 Rubber-coated p-clamp, silentblock, largediameter washer, flanged nut [2x]

2 Metering pumpInstallingmeteringpump

Fuel line from heater unit on pressure side ofmetering pump [side with connector].

4 Metering pump1 Wiring harness for metering pump, single-

wire sealing [2x], tab connector, connectorhousing

2 Fuel line3 Hose section, 10 mm dia. hose clamps [2x]

Connect-ing meter-ing pump

Cut off fuel supply line approx. 50 mm beforecoupling as shown.Mount support sleeves in both ends of fuelsupply line.

2 Cutting point, fuel standpipe1 Hose section, 12 mm dia. hose clamps [2x]3 Hose section, 12 mm dia. hose clamps [2x]5 Remaining end of fuel line4 Hose section, 10 mm dia. hose clamps [2x]

Removingfuel

Fuel line from fuel standpipe on intake side ofmetering pump [side without connector].Check the position of the components; adjustif necessary. Check that they have freeclearance.

2 Metering pump3 Fuel line1 Hose section, 10 mm dia. hose clamps [2x]

Connec-tion to me-teringpump

35

1 2

36

2

1

34

374

5

321

38

1 2

3


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Exhaust system

1 Exhaust pipe a = 240 mm2 Exhaust end section b = 230 mm

Discard section X

Preparingexhaustpipe

2 Muffler1 M6x20 bolt, spring lockwasher

Installingmuffler

3 Exhaust muffler1 Exhaust pipe2 Hose clamp [2x]

Installingexhaustpipe

1 Wheel well trim2 42 mm dia. hole

Hole inwheel welltrim

a b

1 2

X

39

1

2

3

1

2 40

2

2

1

41


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2 Exhaust end section1 Hose clamp3 Red (rt) rubber isolator with groove,

pushed on

Installingexhaustendsection

First position red (rt) rubber isolator 2onexhaust end section 3from below, then insertwith groove in underride protection 1. Align

end cap of exhaust end section 3flush on red(rt) rubber isolator 2as shown.

1 Underride protection2 Red (rt) rubber isolator with groove3 Exhaust end section

Mountingrubberisolator

1

42

2

3

2

43

1

3


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Webasto AGPostfach 80 - 82132 Stockdorf, Germany - Hotline +49-(0)1805-932278Hotfax +49-(0)395-5592-353 - http://www.webasto.de

Feel the dr ive

Printed in Germany 12/07 Printing:Steffen

Final Work

WARNING!Reassemble the disassembled components in reverse order.Check all hoses, clamps and all electrical connections for firm seating.Secure all loose cables using cable ties.Only use manufacturer-approved coolant.Spray the heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).

- Connect the battery- Fill and bleed the coolant circuit according to the vehicle manufacturers specifications.- Set the digital timer.- Make settings on A/C control panel according to the "Operating Instructions for End Customer".- Check the proper operation of the additional heater, see the operating instructions/installation

instructions.- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.

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Operating Instructions for End CustomerPlease remove page and add to the vehicle operating instructions.

Note:We recommend matching the heating time to the driving time.Heating time = driving timeExample:For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on timeof 20 min.

If the summer/winter switch option has been installed, this must be switched in accordance with thetime of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior inthe position Winter heat and in the position Summer .

Before parking the vehicle, make the following settings:

1 Air outlet to windshield2 Set fan to level "1"3 Set temperature to "max."

Withoutautomaticair-condi-tioning

1 Air outlet to windshield2 Set fan to level "1"3 Set temperature to "HI

With auto-matic air-condition-ing

1 Air outlet to windshield2 Set temperature on both sides to "HI".3 Set fan to level "1"

With 2-zone auto-matic air-condition-ing

21 3

44

45

32 1

2 2

corolla verso water heater

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