Webasto Thermo Top E Installation Instructions Manual
Lexus 2006 gs 450h
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Also See for Thermo Top E:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
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Water Heater Unit
Thermo Top E Auxiliary Heating
Thermo Top C Auxiliary Heating
Thermo Top P Auxiliary Heating
Installation Instructions
Lexus GS 450h
Gasoline with the Lexus Hybrid System
From model year 2006
For left-hand drive vehicles only
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 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.
Ident. No.: 1311247A
e1
00 0003
e1
00 0002
e1
00 0104
€10 fee
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top E
Summary of Contents for Webasto Thermo Top E
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Page 1: Installation Instructions
For left-hand drive vehicles only 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. -
Page 2: Table Of Contents
Lexus GS 450h Table of Contents Validity Preparing the Installation Location Heater Unit / Installation Kit Assembling the Bracket Foreword Installing the Heater Unit General Instructions Fuel Connection Special Tools Water Connection Explanatory Notes on the Document Combustion Air Preliminary Work Exhaust System Heater Unit Installation Location Final Work... -
Page 3: Heater Unit / Installation Kit
1,311,239A Recommended heater unit for the relevant vehicle class: Vehicle Heater unit Compact car Thermo Top E Mid-class, station wagon Thermo Top C Luxury, van, off-roader Thermo Top P Select the heater unit based on the size of the vehicle passenger compartment and the customer's comfort requirements. -
Page 4: Explanatory Notes On The Document
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. The arrow in the vehicle icon indicates the position on the vehicle and the angle. -
Page 5: Preliminary Work
Lexus GS 450h Preliminary Work WARNING! - Let off pressure in 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. -
Page 6: Electrical Connections
Lexus GS 450h Electrical Connections Cable harness feed-through Time switch 1 Protective rubber sleeve 1 Time switch Cable harness installation diagram 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: Preparing The Electronics
Lexus GS 450h Preparing the Electronics Bend the fastening strap 3 according to the illustration and fasten with the original vehicle bolt. Prepare 2 Drill a Ø 5 mm bore hole the fuse 1 Fuse holder, M5x12 bolt, flanged nut M5 holder installation Assemble the fuse holder 1 on the... - Page 8 Lexus GS 450h Cut approx. 300mm from the Ø 20mm tube shaft. Install the heater unit cable harness, Mecanyl fuel line, positive connection for the header unit cable harness in the Ø 20mm 1 tube shaft. Run the fuel line, heater cable harness to the heater unit installation location.
- Page 9 Lexus GS 450h 1 Red (rt) wire, Ø 6 mm pointed cable socket 2 Positive base Connec- ting to the positive supply Run the brown (br) wire for the heater unit cable harness ground supply 3 through the cable socket 1 to the grounding point 2 and connect.
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Page 10: Blower Control
Lexus GS 450h Blower Control Connect to 40-pin connector L 52 (A) pin 21 from the A/C amplifier. Connect with enclosed blade receptacles according to the circuit diagram. Replace fuse F3 with 10A. Connec- ting the 1 40-pin connector L52. amplifier 1 Connector L 52 (A), contact side connector... - Page 11 Lexus GS 450h Webasto Lexus ECU- Automatic rt/ws air condi- tioning circuit diagram L52 (A) Webasto components Lexus components Colors and symbols Heater unit TT-C/E ECU-IG Fuse, 10A Fuse, 20A 4E/4D Plug-in connection white Fuse, 1A 5D/5G Plug-in connection black...
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Page 12: Remote Start Option
Lexus GS 450h Remote Start Option Attach the receiver 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 1 Temperature gauge Assem- bling the tempera-... -
Page 13: Thermo Call Option
Lexus GS 450h Thermo Call Option Remove the insulation mat receiver bracket. Attach the receiver with double-sided Velcro tape on the footwell cover on the passenger side. 1 Footwell cover on passenger side Assem- 2 Receiver bling the receiver 1 Antenna Assem- bling the antenna... -
Page 14: Preparing The Installation Location
Lexus GS 450h Preparing the Installation Location Remove original vehicle bolt at position 1 . Drill open the weld nut to to Ø 10.5mm Remove original vehicle bolt 2 , this will be used again. 1 Original vehicle bolt M10, weld nut Drill open weld nut Assembling the Bracket... -
Page 15: Installing The Heater Unit
Lexus GS 450h Assemble the original vehicle cable harness 2 on the drill hole 1 with rubber tube clamp Ø18mm 3 according to the illustration. 4 M6x20 bolt, flanged nut M6 Attaching the cable harness Installing the Heater Unit Prior to assembly, put on the heater unit cable harness Ejot screw bolt tightening torque 10 Nm! 2 Heater unit cable harness... -
Page 16: Fuel Connection
Lexus GS 450h Fuel Connection CAUTION! Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable clips. - Page 17 Lexus GS 450h Run the tube shaft 2 , the Mecanyl fuel pipe and the metering pump cable harness along the original vehicle lines 1 to the underbody and secure with cable clips. Installing lines Run the tube shaft, the Mecanyl fuel pipe and the metering pump cable harness along the original vehicle lines to the underbody and secure with cable clips.
- Page 18 Lexus GS 450h Insert the heater unit cable harness and metering pump cable harness in the Ø 10mm hose shaft 1 , according to the illustration, run to the metering pump installation location 2 and secure with cable clips 3 . Connec- ting to the metering...
- Page 19 Lexus GS 450h Install the tank mounting 1 according to the manufacturer's instructions. Shorten the moulded hose 2 by 10 mm for Ø 3.5 mm. 3 Universal clip Ø 8mm 4 Tank extracting device 5 Universal clip Ø 10 mm 6 Enclosed 2000 long fuel line to the Fuel take- metering pump...
- Page 20 Lexus GS 450h Re-assembling the panelling 1 . Assem- bling the panelling...
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Page 21: Water Connection
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. - Page 22 Lexus GS 450h c = 310mm d = 280mm Dispose of section X Cutting water hose into sections Cut the braided protective hose for hose C to 560 mm and insert. Cut the braided protective hose for hose D to 380mm and insert.
- Page 23 Lexus GS 450h Remove the original vehicle engine moulded hose 1 from the engine exhaust to the heat exchanger inlet, the spring band clamps and moulded hose will no longer be needed. Splitting point 1 heat exchanger inlet connecting piece Connec- ting to the heat...
- Page 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...
- Page 25 Lexus GS 450h Placement in the engine compart- ment The moulded hose from the motor inlet 1 is only disassembled here as a demonstration. 2 Cable clip Connec- ting to the engine exhaust Before connecting, fill the water hoses with coolant.
- Page 26 Lexus GS 450h 1 Cable clips Placement in the engine compart- ment...
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Page 27: Combustion Air
Lexus GS 450h Combustion Air 1 Combustion air pipe a = 280mm Cutting the Dispose of section X 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... -
Page 28: Exhaust System
Lexus GS 450h Exhaust System 1 Exhaust pipe a = 280mm 2 Exhaust end section b = 280mm Preparing Dispose of section X exhaust pipe 1 Angle bracket 2 M6x20 bolt, flanged nut M6 3 Exhaust silencer 4 Red (rt) rubber profile 5 Exhaust pipe 6 Hose clamp Assem-... - Page 29 Lexus GS 450h Assemble the brake coolant air duct 2 ! Align the red (rt) rubber profile on the exhaust line 1 to the ventilation channel and hose (page 28/62). Ensure sufficient distance from adjacent Positio- components. ning the rubber profile 1 Red (rt) rubber profile with groove 2 Lower footwell cover...
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Page 30: Final Work
- Attach the "Switch off auxiliary heating before re-fuelling" sticker onto the left side of the B-pillar. Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf - Hotline 0 18 05 / 93 22 78 Hotfax (0395) 55 92-353 - http://www.webasto.de Printed in Germany 05/06Printed by: Steffen... -
Page 31: Operating Instructions For The End Customer
Lexus GS 450h 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" vehicles with automatic... -
Page 32: Tank Extracting Device Template
Lexus GS 450h Tank Extracting Device Template 100 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. 100 mm...