Webasto Thermo Top C Installation Instructions Manual Download Page 21 | Manualshive

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21

Lexus GS 450h

Water Connection

WARNING!

Tighten all hose clamps with 2.0 + 0.5 Nm.
Any coolant running off should be collected using an appropriate container.
Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable clips.
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:

Water
installation
diagram

All undesignated clamps are Ø 20-27 mm hose clamps.

Motor

Wärme-

tauscher

B

A

Ø 16-24

Ø 25

Ø 25

Ø 15x18

Ø 22

Ø 15x15

Ø 22

Ø 22

Ø 20x15

Ø 22

Ø 27

Ø 20x15

Ø 27

Ø 22

C

D

E

F

Heat

exchanger

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Summary of Contents for Thermo Top C

Page 1: ...ired the required technical skills or if you do not have access to the required technical documentation tools and equipment to carry out correct installation and repairs ALWAYS follow all Webasto installation and repair instructions and observe all warning instructions Webasto does not accept any liability for defects and damage that are attributable to an installation by untrained staff Feel the ...

Page 2: ... 0106 Engine type Engine Power in kW Engine capacity in cm 2GR FSE Gasoline 218 3456 Validity 2 Heater Unit Installation Kit 3 Foreword 3 General Instructions 3 Special Tools 3 Explanatory Notes on the Document 4 Preliminary Work 5 Heater Unit Installation Location 5 Electrical Connections 6 Preparing the Electronics 7 Blower Control 10 Remote Start Option 12 Thermo Call Option 13 Preparing the In...

Page 3: ...instructions for the Thermo Top C P E are to be observed in any event 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 cable harnesses to original vehicl...

Page 4: ...sk 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 the Document To provide you with a quick overview of the individual working steps you will find an identificat...

Page 5: ...Remove left fuse and relay box Open the tank cap ventilate the tank Close the tank cap again Disconnect the battery Loosen the right and left wheel house panel Remove the underride protection Remove the bumper Lower cover fuel lines Remove the rear seat bench Open the left tank mounting service lid Remove left tank mounting according to manufacturer s instructions Remove the lower cover to the rig...

Page 6: ...h Cable harness installation diagram Fuse holder K3 relay 1 K3 relay 1 Fuse holder Note the assembly instructions on page 7 2 1 3 1 br bl rt sw i 4 2 1 Wait to install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines in the Ø 10 mm tube shaft 2x on the underbody ...

Page 7: ...l vehicle bolt 2 Drill a Ø 5 mm bore hole 1 Fuse holder M5x12 bolt flanged nut M5 Prepare the fuse holder installation Assemble the fuse holder 1 on the preassembled retaining plate 2 Relay K3 M5x12 bolt flanged nut M5 Installing lines Cutting wires into sections Preassem bling fuse F4 5 2 1 3 6 1 2 rt 2 1 500 F4 30A rt 1 rt 2 ...

Page 8: ...un the red rt 1500 lg line through the Ø 10 mm tube shaft 3 to the left fuse and relay holder Installing lines Drill a Ø 9mm bore hole 1 in the cover of the fuse and relay holder 2 according to the figure Preparing the positive supply 1 Cable sleeves Inserting the cable sleeves Drill the Ø 4 5 mm bore hole for the fuse bracket 2 according to the figure fasten the fuse bracket with the 5 5x13 self ...

Page 9: ...unding point 2 and connect Connec ting the ground supply Pull the rt and sw red and black lines from the K3 blower relay and the time switch cable harness into the remaining Ø20 mm tube shaft and to the cable feed though Wrap the tube ends with insulation tape Note Pull the lines from the K3 blower relay and the time switch cable harness from the interior through the feed though Installing lines 1...

Page 10: ...ith enclosed blade receptacles according to the circuit diagram Replace fuse F3 with 10A 1 40 pin connector L52 Connec ting the A C amplifier 1 Connector L 52 A contact side connector L 52 A 14 1 3 4 1 2 7 8 5 6 11 12 9 10 15 16 13 14 19 20 17 18 23 24 21 22 27 28 25 26 31 32 29 30 35 36 33 34 39 40 37 38 1 ...

Page 11: ...20A 4E 4D Plug in connection ws white F2 Fuse 1A 5D 5G Plug in connection sw black F3 Fuse 10A A C A C amplifier br brown F4 Fuse 30A L52 A 40 pin connector A gn green K3 Blower relay 1 Operating control X Splitting point gn ws sw br rt ws rt F3 10A 4 HG X1 K3 87a 87 86 85 30 Webasto 31 30 15 Lexus A C 21 L52 A ws ws 4D 4 4E 5G 3 5D ECU IG F4 30A X2 F1 20A 1 rt 2 br F2 1A 1 i ...

Page 12: ...with double sided Velcro tape on the blower unit according to the figure 1 Receiver Assem bling the receiver 1 Antenna Assem bling the antenna Temperature gauge only with remote T100 HTM 1 Temperature gauge Assem bling the tempera ture gauge 1 15 i 1 16 1 17 ...

Page 13: ...ver bracket Attach the receiver with double sided Velcro tape on the footwell cover on the passenger side 1 Footwell cover on passenger side 2 Receiver Assem bling the receiver 1 Antenna Assem bling the antenna 1 Tip switch Assem bling the tip switch 1 2 18 i 1 19 20 1 ...

Page 14: ...ng the Bracket 3 Additional bracket 2 Heater unit bracket 1 M6x12 bolt flanged nut 4x each Preparing the bracket Insert two washers between weld nut and bracket 2 Pre assembled bracket 3 Original vehicle bolt 2x 1 M10x45 bolt wacher 2x spring washer M10 nut Assem bling the bracket Bracket opened to approx 120 1 Pre assembled bracket 3 Angle bracket 2 M6x20 bolt body washer M6 flanged nut Assem bli...

Page 15: ...y put on the heater unit cable harness Ejot screw bolt tightening torque 10 Nm 2 Heater unit cable harness 1 Ejot screw bolt 2x Assem bling the heater unit Ejot screw bolt tightening torque 10 Nm 1 Ejot screw bolt 2 Edge protection 2x 100mm long Assem bling the heater unit Assemble the 100 mm edge protection profile 2 accordingly Unclip the original vehicle cable harness 2x Assem bling the edge pr...

Page 16: ...ss with edge protectors around sharp edges WARNING The fuel line and cable harness to the metering pump should be installed based on Cable Harness diagram or page 7 1 Mecanyl fuel line 2 Ø 10mm hose clamps 2x 3 Hose section Connec ting to the heater unit Insert the heater unit cable harness and metering pump cable harness in the Ø 10mm hose shaft 1 Wrap the tube ends with insulation tape Installin...

Page 17: ... to the heat protection sheet 2 Installing lines Insert the heater unit cable harness and metering pump cable harness in the Ø 10mm hose shaft 1 place according to the illustration and secure with cable clips Wrap the tube ends with insulation tape Installing lines Remove the plastic cover from the bracket 2 this will be used again Check the position of the components adjust if necessary Check tha...

Page 18: ...ose clamp Ø 10 mm 2x 2 Hose section 4 Metering pump cable harness Connec ting to the metering pump Remove the tank mounting2 according to the manufacturer s instructions and take it apart Attach the M6 flanged nut 1 according to the illustration transfer the hole image3 for the Ø 6 0 mm hole Complete the tank mounting Fuel take off Shape cut into sections and insert the tank extracting device 2 ac...

Page 19: ... extracting device in the Ø 10mm hose shaft 1 and run to the metering pump installation location secure to existing lines with cable clips Installing lines Fuel line 1 from the tank extracting device on the intake side of the metering pump 4 side without connector Cutt fuel line into sections 2 Hose clamp Ø 10 mm 2x 3 Hose section Connec ting to the metering pump Cut out the underbody protection 1...

Page 20: ...20 Lexus GS 450h Re assembling the panelling 1 Assem bling the panelling 44 1 ...

Page 21: ...specified otherwise always fasten using cable clips 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 Water installation diagram All undesignated clamps are Ø 20 27 mm hose clamps Motor Wärme tauscher B A Ø 16 24 Ø 25 Ø 25 Ø 15x18 Ø 22 Ø 15x15 Ø 22 Ø 22 Ø 20x15 Ø 22 Ø 27 Ø 20x15 Ø 27 Ø 22 C D E F Heat exc...

Page 22: ...lustration Cut the moulded hoses E and E into sections according to the illustration a 70mm e 440mm f 860mm The entire length of the Ø 15mm moulded hose B is used Dispose of section X Cutting water hose into sections Cut the braided protective hose for hose E to 600mm and insert Cut the braided protective hose for hose F to 1 000mm and insert Insert the entire length of the braided protective hose...

Page 23: ...mps and moulded hose will no longer be needed Splitting point 1 heat exchanger inlet connecting piece Connec ting to the heat exchanger inlet Position the hose F according to the illustration behind the original vehicle panelling 2 and lines 1 Installing in the engine compart ment Connec ting to the heater unit 45 1 46 F 1 47 F D 1 2 48 D ...

Page 24: ...24 Lexus GS 450h Placement in the engine compart ment Placement in the engine compart ment Connec ting to the heater unit Installing in the engine compart ment 49 F E D 50 E D 51 C 52 B C ...

Page 25: ...g to the engine exhaust Before connecting fill the water hoses with coolant 1 Engine exhaust hose Connec ting to the engine outlet Assemble the rubberized Ø 29mm tube shaft 1 to the original vehicle hole according to the illustration with M6x20 bolt and M6 flanged nut 2 Ø 27mm cable clip Assem bling the rubberized tube clamp 53 B 54 B 1 2 55 A B 1 56 C D E 1 B 2 ...

Page 26: ...26 Lexus GS 450h 1 Cable clips Placement in the engine compart ment 57 1 ...

Page 27: ...tting the combus tion air pipe into sections 1 Angle bracket 2 Original vehicle stay bolts M8 flanged nut Assem bling the angle bracket 4 Combustion air intake pipe 1 Ø 27 mm hose clamp 3 Combustion air intake silencer 2 Cable clip Assemble the intake silencer a 1 X 58 1 2 59 2 3 4 1 i ...

Page 28: ... clamp 2 Exhaust end section 3 Red rt rubber profile 4 Tube clamp M6x20 bolt flanged nut M6 5 Bracket existing hole M6x20 bolt flanged nut M6 Assem bling the exhaust pipe Drill Ø 42mm hole 5 in the wheel house panel 4 according to the illustration position insert the red rt rubber profile with groove 3 Align the red rt rubber profile 1 to the hose 6 according to the illustration 2 Exhaust end sect...

Page 29: ...ile on the exhaust line 1 to the ventilation channel and hose page 28 62 Ensure sufficient distance from adjacent components Positio ning the rubber profile 1 Red rt rubber profile with groove 2 Lower footwell cover 3 Exhaust end section Positio ning the rubber profile 2 1 63 1 3 64 2 ...

Page 30: ... heating unit components with anti corrosion wax Tectyl 100K Order No 111329 Connect battery Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications Set the time switch Set the manual air conditioning or automatic air conditioning according to the operating instructions for the end customer Check that the auxiliary heating operates properly see operating instructi...

Page 31: ...uxiliary heating driving time heating time Operating instructions for the end customer Please remove page and add to the vehicle operating instructions Before parking the vehicle make the following settings 1 Temperature to TEMP HI 2 Air outlet to windscreen 3 Blower set to LO or 1 For vehicles with automatic air condi tioning 65 1 2 1 3 ...

Page 32: ...00 mm Scale 1 1 Compare the size of the printed version with dimension lines Permitted tolerance a maximum of 2 Set the printer settings to no margin or minimize margins and 100 of the normal size Tank Extracting Device Template ...

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