Webasto Thermo Top E Manual de usuario

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.

Feel the drive

Lexus GS 450h

Gasoline with the Lexus Hybrid System

From model year 2006

For left-hand drive vehicles only

Ident. No.: 1311247A €10 fee © Webasto AG

Water Heater Unit

Thermo Top E Auxiliary Heating

Thermo Top C Auxiliary Heating

Thermo Top P Auxiliary Heating

Installation Instructions

00 0003

00 0002

00 0104

Lexus GS 450h

Validity

Vehicle and engine types, equipment variants as well as national specifications, which are not listed in

these installation instructions, have not been tested. Installation according to these installation

instructions may, however, be possible.

The installation location of a time switch and summer / winter switch should be confirmed with the end

customer before installation.

Manufacturer Model Type EG-BE No. / ABE

Lexus GS 450h HS 19 (a) e6 * 2001 / 116 * 0106 * ...

Engine type Engine Power in kW Engine capacity in cm³

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 Installation Location 14

Assembling the Bracket 14

Installing the Heater Unit 15

Fuel Connection 16

Water Connection 21

Combustion Air 27

Exhaust System 28

Final Work 30

Operating instructions for the end customer 31

Tank Extracting Device Template 32

Table of Contents

Lexus GS 450h

Heater Unit / Installation Kit

Recommended heater unit for the relevant vehicle class:

Select the heater unit based on the size of the vehicle passenger compartment and the customer's

comfort requirements.

Foreword

These installation instructions apply to the vehicles Lexus GS 450h Gasolineengine with the Lexus

Hybrid System.

– Re. validity, see page 2 – from model year 2006 and later, assuming technical modifications to the

vehicle do not affect installation and any liability claims are 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 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 vehicle lines and cable

harnesses using cable clips.

Sharp edges should be fitted with edge protectors (split open plastic hose).

Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no.

111329).

Special Tools

- Torque spanner for 2.0 - 10 Nm

- Vise-grip wrench

- Riveting nut tool

Amount Description Order no.:

1 Commercial supply of required control See price list

1 Installation kit for Lexus GS 450h 1,311,239A

Vehicle Heater unit

Compact car Thermo Top E

Mid-class, station wagon Thermo Top C

Luxury, van, off-roader Thermo Top P

Special features are highlighted using the following symbols:

Mechanics

Electrics

Water connection

Fuel connection

Exhaust system

Combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Lexus GS 450h

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.

Explanatory Notes on the 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.

Lexus GS 450h

Heater Unit Installation Location

1Heater unit

Installation

location

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.

- Completely remove the air filter with intake hose.

- 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 right footwell

- Remove the side cover on the right-center console (only for Telestart T100 HTM).

- Please remove page 31 “Operating instructions for the end customer” and add this to the vehicle

operating instructions.

Lexus GS 450h

Electrical Connections

Cable harness feed-through

1Protective rubber sleeve

Time switch

1Time switch

Cable

harness

installation

diagram

Fuse holder, K3 relay

1K3 relay

1Fuse holder

Note the assembly instructions on page 7.

brbl

rtsw

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.

Lexus GS 450h

Preparing the Electronics

Bend the fastening strap 3 according to the

illustration and fasten with the original vehicle

bolt.

2Drill a Ø 5 mm bore hole

1Fuse holder, M5x12 bolt, flanged nut M5

Prepare

the fuse

holder

installation

Assemble the fuse holder 1on the

preassembled retaining plate.

2Relay K3, M5x12 bolt, flanged nut M5

Installing

lines

Cutting

wires into

sections

Preassem-

bling fuse

500

F4 30A

1rt

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.

Connect the red (rt) 1500 lg. wire with

shrinkable butt connectors 2to the positive

supply cable on the cable harness.

Shorten Ø 10 mm tube shaft by 100 mm.

Run the red (rt) 1500 lg line through the Ø 10

mm tube shaft 3to the left fuse and relay

holder.

Installing

lines

Drill a Ø 9mm bore hole 1in the cover of the

fuse and relay holder 2according to the

figure.

Preparing

the

positive

supply

1Cable sleeves

Inserting

the cable

sleeves

Drill the Ø 4.5 mm bore hole for the fuse

bracket 2according to the figure, fasten the

fuse bracket with the 5.5x13 self-tapping

screw.

Insert the red (rt) 500 mm line in the

remaining 100 mm tube shaft 4and pull this

through the cable sleeve 3.

Wrap the tube ends with insulation tape.

1Red (rt) wire, tube shaft

Installing

lines

234

Lexus GS 450h

1Red (rt) wire, Ø 6 mm pointed cable socket

2Positive base

Connec-

ting to the

positive

supply

Run the brown (br) wire for the heater unit

cable harness ground supply 3through the

cable socket 1to the grounding point 2and

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

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.

140-pin connector L52.

Connec-

ting the

A/C

amplifier

1Connector L 52 (A), contact side

connector

L 52 (A)

3 41 2 7 85 6 11 12910 15 1613 14 19 2017 18

23 2421 22 27 2825 26 31 3229 30 35 3633 34 39 4037 38

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