Corolla Verso Water Heater

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 t he dri ve
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
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 cm
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
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.
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
Heater unit installation location
1 Heater unit
Installation
location
1
1
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
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!
2 M 5x16 bolt, washer, retaining plate fuse
holder, bracket, M5 flanged nut
3 M 5x16 bolt, washer, K3 relay, bracket,
K3.1 relay, M5 flanged nut
Preassem-
bling fuse
holder
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
87a 87 86
85 30
4
br sw
3 5
2
rt
rt
sw
F4 3A
rt
1
6
2
2
1
3
4
7
Electrical Connections
Fuse holder, K3 relay
Fuse F4 and K3.1 relay only with automatic air-
conditioning!
1 Battery holder
3 Fuse holder preassembled
2 7 mm dia. hole, M6x20 bolt, preassembled
fuse holder, M6 flanged nut
Digital timer
1 Digital timer
Wiring
harness
installation
diagram
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 pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
5
1
6
1
8
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
X Cutting 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
Connection on 2-pin connector DF on fuse
and relay carrier.
1 Fuse and relay carrier
2 Connector 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.
1 Black (sw) wire, 4.0 mm, from K3/30
2 Connector (yellow) [2x]
3 Black (sw) wire to fan motor
4 Connector DF
5 Red (rt) wire, 4.0 mm, from K3/87a
Fan
controller
1 2
7
5
4
3
1 2
8
10
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
X Cutting point
sw
4
rt
Webasto
31
30
15
Toyota
rt
sw
rt
0,75
ws/sw
sw
rt
86
85 30
87a 87
K3.1
GRr
+
-
GM M
HG
X1
4
F3 Fb Fa F4
KB
St 01 12/14
GR
!
86
85 30
87a 87
K3
!
4
5
6
2
1
3
sw
0,75
rt
4
rt
*
11
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.
1 Connector DF
Fan control
Remove wire 4 from connector DF. Insulate
wire 4 and 6 and tie back.
1 Connector DF
3 3x distributor
5 Black (sw) wire from K3/30
4 White/black (ws/sw) wire from original
vehicle fan relay, Pin 4
6 Red (rt) wire from K3/87a
Fan control
1 Connector 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.
1 Red (rt) wire, 0.75 mm, from K3.1/87a
2 Connector (red) [2x]
3 Red (rt) wire from 24-pin connector, Pin 12
or from 28-pin connector, Pin 14
4 Connector 01 (24 or 28-pin)
6 Black (sw) wire, 0.75 mm, from K3.1/30
Control of
A/C control
panel
1 2
9
4
5
6
3
1 2
10
1
11
4
3
3 1
6
2
2 5
12
12
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 4 1 2 7 8 5 6 11 12 9 10
15 16 13 14 19 20 17 18 23 24 21 22
3 4 1 2 7 8 5 6 11 12 9 10
17 18 15 16 21 22 19 20 25 26 23 24
13 14
27 28
13
Remote option (Telestart)
1 M5x16 bolt, bracket, M5 flanged nut on
existing hole
2 Receiver, mounted on bracket
Installing
receiver
1 Antenna
Installing
antenna
2
13
1
i
1
14
14
Remote option (Thermo Call)
1 Receiver, M5x20 bolts, flanged nuts,
washer [4x each]
2 Lower footwell cover on front passenger
side
Installing
receiver
1 Antenna
Installing
antenna
1 Pushbutton
2 Blind cap
3 Center console
Installing
push
button
1
2
15
i
1
16
1
17
2
3
15
Preparing installation location
Picture shows bracket with Index F!
2 Bracket
1 7 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.
2 Bracket, loosely mounted
1 M6x20 bolt, large diameter washer [2x
each] on existing threaded holes
Installing
rivet nut
1 Bracket
2 M6x20 bolt, large diameter washer [2x
each] on existing threaded holes
3 Mount M6x20 bolt, spring lockwasher [2x
each] on prepared rivet nuts
4 Spacer nut, 30 mm
5 M6x12 bolt, spring lockwasher
Installing
bracket
18
1
2
36 mm
46 mm
19
1 2
1
3
3
20
3
1 3
4
2
5
2
16
Installing heater unit
Connect wiring harness for heater unit before
installation.
Insert two washers between heater unit and
bracket at Position 3.
Tighten EJ OT screws to 10 Nm!
1 Bracket
2 Ejot screw [2x]
3 Ejot screw
Installing
heater unit
Ejot screw bolt, tightening torque 10 Nm!
2 Bracket
1 Ejot screw
3 Wiring harness of heater unit
Installing
heater unit
21
1 2
3 2
22
1
2
3
17
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
25
25
18x20
27
27 B
C
18
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
1 25 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
c b
X X
B X C
A
B
y
1 1
x
C
1
y
1
23
B
C
24
B
C
19
Disconnect original vehicle hose 2 from
connection piece of engine outlet. Original
vehicle spring clip 1 will be reused!
1 Original vehicle spring clip
2 Hose 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.
1 Original vehicle spring clip
Connec-
tion to en-
gine outlet
Before connecting, fill the water hoses with
coolant.
1 Hose to heat exchanger inlet
2 Cable tie
Connec-
tion to heat
exchanger
inlet
1 Cable tie
Routing in
engine
compart-
ment
25
1
2
26
B
A
1
27
2
1 C
28
1
1
20
Combustion air
1 Combustion-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
1 Combustion-air intake pipe
3 Combustion-air intake muffler
2 Cable tie
Fastening
muffler at
hole
29
1
1
2
i
30
1
31
3
1
2
21
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 harness
routing diagram.
1 Mecanyl fuel line
3 Hose section
2 10 mm dia. hose clamp [2x]
Connec-
tion on
heater unit
1 Mecanyl fuel line
2 Metering pump wiring harness
Installing
lines
Ensure proper installation position of
metering pump, see "Installation
Instructions.
Installation location in front of vehicle fuel
tank on left!
1 Metering pump wiring harness
2 Fuel line from heater unit
3 Metering pump
Installation
location of
metering
pump
32
1
3
2
2
33
1
2
34
1
3
2
i
22
Fasten metering pump on existing hole on
fuel tank with rubber-coated p-clamp,
silentblock and flanged nut [2x].
1 Rubber-coated p-clamp, silentblock, large
diameter washer, flanged nut [2x]
2 Metering pump
Installing
metering
pump
Fuel line from heater unit on pressure side of
metering pump [side with connector].
4 Metering pump
1 Wiring harness for metering pump, single-
wire sealing [2x], tab connector, connector
housing
2 Fuel line
3 Hose section, 10 mm dia. hose clamps [2x]
Connect-
ing meter-
ing pump
Cut off fuel supply line approx. 50 mm before
coupling as shown.
Mount support sleeves in both ends of fuel
supply line.
2 Cutting point, fuel standpipe
5 Remaining end of fuel line
Removing
fuel
Fuel line from fuel standpipe on intake side of
metering pump [side without connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
2 Metering pump
3 Fuel line
Connec-
tion to me-
tering
pump
35
1 2
36
2
1
3 4
37
4
5
3 2 1
38
1 2
3
23
Exhaust system
1 Exhaust pipe
a =240 mm
2 Exhaust end section
b =230 mm
Discard section X
Preparing
exhaust
pipe
2 Muffler
1 M6x20 bolt, spring lockwasher
Installing
muffler
3 Exhaust muffler
1 Exhaust pipe
2 Hose clamp [2x]
Installing
exhaust
pipe
1 Wheel well trim
2 42 mm dia. hole
Hole in
wheel well
trim
a b
1 2
X
39
1
2
3
1
2
40
2
2
1
41
24
1 Hose clamp
3 Red (rt) rubber isolator with groove,
pushed on
Installing
exhaust
end
section
First position red (rt) rubber isolator 2 on
exhaust end section 3 from below, then insert
with groove in underride protection 1. Align
end cap of exhaust end section 3 flush on red
(rt) rubber isolator 2 as shown.
1 Underride protection
2 Red (rt) rubber isolator with groove
Mounting
rubber
isolator
1
42
2
3
2
43
1
3
Webasto AG
Postfach 80 - 82132 Stockdorf, Germany - Hotline +49-
(0)1805-932278
Hotfax +49-(0)395-5592-353 - http://www.webasto.de
Feel t he dri ve
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.
i
26 26
Operating Instructions for End Customer
Please remove page and add to the vehicle operating instructions.
Note:
We recommend matching the heating time to the driving time.
Heating time =driving time
Example:
For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time
of 20 min.
If the summer/winter switch option has been installed, this must be switched in accordance with the
time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in
the position Winter heat and in the position Summer .
Before parking the vehicle, make the following settings:
1 Air outlet to windshield
2 Set fan to level "1"
3 Set temperature to "max."
Without
automatic
air-condi-
tioning
3 Set temperature to "HI
With auto-
matic air-
condition-
ing
2 Set temperature on both sides to "HI".
With 2-
zone auto-
matic air-
condition-
ing
2 1 3
44
45
3 2 1
46
1
2 2
3

Corolla Verso Water Heater

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