Water heater unit

Feel the drive

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Thermo Top E Additional heating 00 0003

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Thermo Top C Additional heating 00 0002

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Thermo Top P Additional heating 00 0104

Installation instructions

Toyota Prius
Petrol
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 needed 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.: 1311582A €10 fee © Webasto AG

 Toyota Prius

Table of Contents
Validity 2 Preparing the Installation Location 11
Heater Unit / Installation Kit 3 Preparing the Heater Unit 12
Foreword 3 Installing the Heater Unit 12
General Instructions 3 Water Connection 13
Special Tools 3 Fuel Connection 17
Explanatory Notes on the Document 4 Exhaust System 20
Preliminary work 5 Combustion Air 22
Heater unit installation location 5 Final Work 23
Preparing the Electronics 6 Operating instructions for the end customer 24
Electrical Connections 7 Tank Extracting Device Template 25
Air conditioning blower control 8
Remote Start Option 10

Validity
Manufacturer Model Type EG-BE No. / ABE
Toyota Prius NHW 20 e11 * 2001 / 116 * 0200 * ...

Engine type Engine model Power in kW Engine capacity in cm³

1NZ-FXE Petrol 57 1497

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.

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Heater Unit / Installation Kit

Amount Description Order no.:
1 Commercial supply of required control See price list
1 Installation kit for Toyota Prius Petrol 1311580A

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

The choice of heater unit is based on the size of the vehicle passenger compartment and the
customer's comfort requirements.

Foreword
These installation instructions apply to Toyota vehicles with Prius Petrol – validity, see page 2 – from
model year 2006 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 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
- Vice-grip wrench
- Riveting nut tool

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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.

Mechanics

Electrics

Water connection

Fuel connection

Exhaust System

Combustion air

Special features are highlighted using the following symbols:

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.

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

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Preliminary work
WARNING!

- Open the tank cap, ventilate the tank.

- Close the tank cap again.
- Disconnect the battery.
- 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.
- Dismantle the windshield wipers.
- Completely remove the cooling water reservoir cover.
- Remove the left wheel-house panel.
- Remove the bumper cover.
- Remove the left headlight.
- Remove the front underride protection.
- Remove the rear underride protection (rear fuel line covers).
- Remove the rear seat bench.
- Open the tank mounting service lid
- Remove tank mounting according to manufacturer's instructions.
- Remove the footwell panel on the passenger side.
- Remove the lower center middle console.

Remove page 24 "Operating instructions for the end customer" and insert with vehicle operating
instructions.

Heater unit installation location

1 Heater unit

Installation
location

1 1

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Preparing the Electronics

Cutting
1 2 3 4 wires into
sw 0,75mm²
sections
100 100 100 2200

Reconnect according to the circuit diagram.

rt/ Insert wire section 2 in the enclosed
ws insulating hose.
gn/ws rt

86 87 87a Preparing
fuse F4
K3
85 30

br sw

sw sw
1 4
F4

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Electrical Connections

Cable harness feed-through Summer / winter switch option

1 Protective rubber sleeve 1 Summer / winter switch, bore hole Ø 12 mm.

1 1

2 3

Cable
harness
installation
diagram
don't install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the
underbody

1 2 1

4 5

fuse holder, K3 relay Time switch

Remove the fuse holder 1 and K3 relay 2 at the 1 Time switch

installation location only and run the cable
harnesses. The fuse holder 1 and the K3 relay 2
will not be mounted on the cooling water
reservoir until end (see the final work).

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Air conditioning blower control

Webasto Toyota
30
15
Circuit
HG F3 F F diagram
X1 4 (A/C) (HTR)
5
rt/ws
GR
gn/ sw 3 (HTR)
ws
rt

86 87 87a
sw/ge
K3
85 30 D2 2

sw
M GM
sw D1 sw 2 1
sw
1 4 sw
F4 sw
3

B 1 2
sw ws/sw
GS
br B 5 1
A 1 3
A/C
sw

31

Webasto components Vehicle components Colours and symbols

HG heater unit TT-C/E GM blower motor rt red
X1 6-pin connector GS GM controller ws white
F3 Fuse 25A GR blower relay sw black
F4 Fuse 10A A/C A/C controller br brown
Legend
K3 blower relay F(A/C) Fuse 10A gn green
D1 Diode 1A F(HTR) Fuse 40A ge yellow
D2 Diode 1A
X splitting point
Cable colors may vary.

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1 Connection to blower motor 1 controller.

Reconnect according to the circuit diagram.

2 Black wire from blower relay

3 Red (rt) wire to K3/87a
4 Black (sw) wire from K3/30 Connecting
5 5 Black (sw) wire to connector A pin 1 the blower
2 motor

4 3 6

1 Connection to A/C controller 4.

Reconnect according to the circuit diagram.
Check the current pass direction of the
2 diodes.

1 Black (sw) wire from fuse F4 4 A/C

3 2 Black (sw) wire from fuse F(A/C) controller
6 3 Black (sw) wire to A/C controller connector connection
B pin 5
5 Prepared black (sw) 3.
6 Prepared black (sw) wire 2.

5 4 7

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1 Remote Start Option

Secure the receiver in an appropriate manner
(use double-sided adhesive tape).

Assembling
the receiver

8
1 Antenna

Assembling
the antenna

1 9

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1 Preparing the Installation Location

1 Cut 100mm long edge protection to size,
insert.
53mm 2 Ø 9.1mm bore hole, insert rivet nuts
Inserting
rivet nuts
115mm

2 10

1 2 3 1 M6x25 bolt
2 Loosely fit the bracket
3 Transfer hole image, disassemble bracket,
drill Ø 9.1mm bore hole; insert rivet nuts
(3x each)
Copying
the hole
image

3 3 11

1 1 Insert one 5 mm spacer each bracket and

frame side rail.

1 M6x25 bolt, 5 mm spacer (4x each).

Assembling
the bracket

1 1 12

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Preparing the Heater Unit

Ejot stay bolts, tightening torque 10 Nm.

1 Ejot stay bolts

Screw in
Ejot stay
bolts.

1 13

1 Installing the Heater Unit

Prior to assembly, put on the heater unit cable
harness 1.
Ejot screw bolt tightening torque 10 Nm!
Assembling
2 Ejot screw bolt the Heater
3 3 Bracket Unit

2 14
Ejot screw bolt tightening torque 10 Nm!

1 Ejot screw bolt (2x)

2 30 mm spacer nut

Assembling
the bracket
1
1

2 15

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Water Connection
WARNING!
Tighten all hose clamps to 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

A Ø 18x18

All undesignated hose clamps = Ø 20-27 mm.

All undesignated connecting pipes = Ø 18x20.

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a = 960mm
b = 1,080mm

Dispose of section X
B C X
Cutting
X water
hoses into
sections

X a b

Slide the braided protective hoses onto hose

B and hose C and cut into sections.
Cut shrink-fit hose to size.
1 B 1
1 25 mm shrink-fit hose [4x]
Preparing
the water
hoses

1 C 1

1 1 Heat exchanger inlet hose section

Splitting
point

16

1 1 Heat exchanger inlet hose section

Assembling
hose B

17

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1 C 1 Original vehicle clamp

Running
hose C

18

Connecting
the heater
unit outlet
C

19

1 Run hose B along hose C.

1 Spacer bracket
2 Cut 70mm long edge protection to size,
insert.
Connecting
2
the heater
unit inlet

20

A Connect hose A (enclosed 180° bend) with

hose B.

Connecting
engine
outlet

21

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A Before connecting, fill the water hoses with

coolant.

1 Engine outlet hose section / electric water

pump
Connecting
engine
outlet
1

22

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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!
Fit the fuel line and cable harness with edge protectors around sharp edges.

WARNING!
The fuel line and cable harness to the metering pump should be installed on the original vehicle fuel
lines based on the cable harness installation diagram.

1 2 Slide a cloth hose section 1 on the fuel line 2

as an edge protector.

3 Hose section, Ø 10 mm hose clamps

Connection
to heater
3

23

1 Note the installation position of the metering

pump 2, see the “Installation Instructions”.
The installation location is to the right in front
of the vehicle tank.

1 Metering pump cable harness Metering

3 Fuel line from the heater unit pump
installation
location

3 2 24

1 2 Re-assembling the underride protection 4.

Position the fastening strap 2 according to the
illustration, bend as necessary.
Ensure sufficient distance from adjacent
components.
Assembling
1 Silent block, flanged nut [2x] the
3 3 Original vehicle stay bolts, body washer, metering
flanged nut pump
5 Rubberized tube clamp

5 4 25

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1 2 3 Fuel line from the heater unit 1 on the

pressure side of the metering pump [side with
connector].

2 Hose section, Ø 10 mm hose clamps [2x]

3 Metering pump cable harness, wire seals, Connection
flat connector, connector housing to metering
pump

26

1 Remove the tank mounting1 according to the

manufacturer's instructions and take it apart.

2 Align the flanged nut to the left on the

struts, copy the hole image, bore hole
Ø 6mm Fuel take-
off

2 27
Shape, cut into sections, and insert the tank
extracting device 1 according to the template,
see the Installation Instructions.

1
Inserting
tank
extracting
device
1

28

1 2 3 Install the tank mounting according to

manufacturer's instructions. Shorten the
moulded hose 2 by 10 mm for Ø 3.5 mm.

1 Universal clip Ø 9mm

2 Molded hose Ø 3.5 mm x 4.5 mm Connecting
3 Universal clip Ø 10 mm and
4 Fuel line disconnecti
4 5 Tank extracting device ng the fuel
pipe

5 29

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1 2 Slide the cloth hose section 1 on the fuel line

3 as an edge protector and connect to the
intake side of the metering pump [side without
connector].
Check the position of the components; adjust
if necessary. Check that they have free Connection
clearance. to metering
3 pump
2 Cable clip
4 Hose section, Ø 10 mm hose clamps [2x]

4 30

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1 2 Exhaust System
1 Exhaust pipe
a = 200mm
2 Exhaust end section
b = 250mm Preparing
the
Dispose of section X exhaust
pipe

a b

X
1 2 3 4 1 Hose clamp [2x]
2 30 mm spacer nut
3 M6x16 bolt on spacer nut
4 Silencer
5 Exhaust pipe
1 Assembling
the silencer
/ exhaust
line

5 31

1 1 Hose clamp
2 Exhaust end section

Assembling
the exhaust
pipe.
2

32

1 1 Left wheel house

2 Ø 42 mm bore hole

Bore hole
wheel
house

33

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Reassemble the wheel house

1 Exhaust end section

2 Red (rt) rubber profile with groove

Inserting
rubber
1 profile

2 34

1 Align the exhaust end section 2 flush on the

red rubber profile 1.
Ensure sufficient distance from adjacent
components.

Inserting
rubber
profile

2 35

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1 Combustion Air
1 Combustion air pipe
a = 160mm

Dispose of section X Cutting the

combustion
air pipe into
sections

X
Insert retaining clip 1 in the existing bore hole
in the frame side rail.

Assembling
1 the
retaining
clip

36

1 2 1 Combustion air intake pipe

2 Ø 27 mm hose clamp
3 Combustion air intake silencer

Assembling
the silencer

3 37

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Final Work
WARNING!
Reassemble disassembled components in reverse order.
Check that all hose lines, clips, and all electrical connections are securely fastened.
Secure all loose cables using cable clips.
Only use manufacturer-approved coolant.
Spray 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.
- Make settings according to "Operating instructions for the end customer".
- Check that the auxiliary heating operates properly, see operating instructions / installation
instructions.
- Attach the "Switch off auxiliary heating before re-fuelling" sticker onto the left side of the B-pillar.

1 2 Installation location on the cooling water

reservoir as shown in the figure.

1 Ø 4mm bore hole, 5.5x13 self-tapping

screw; fuse holder retaining plate.
4 3 2 Ø 4mm bore hole, 5.5x13 self-tapping Assembling
screw the
3 K3 relay electronics
4 Fitted fuse holder

38

Feel the drive

Webasto AG
PO Box 80 - 82132 Stockdorf
Hotline 01805 / 932278 - Hotfax 0395 / 5592-353
http://www.webasto.de

1311582A Printed in Germany 12/2006 Press: Steffen

 Toyota Prius

Operating instructions for the end customer

Please remove page and add to the vehicle operating instructions.

For short distance trips, it is not recommended that the rear window heating be used.

Rule of thumb for operating the auxiliary heating: driving time = heating time.

Before parking the vehicle, make the following settings:

1 1 Temperature to "HI."
2 Blower set to level "2"
3 Air outlet to windscreen

Air
condition-
ing
settings

3 2 39

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Tank Extracting Device Template

100mm

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. 100mm

0
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