Toyota Auris hybrid / Prius / Lexus CT200h

Transcription

1 Water Heater Feel the drive Thermo Top Evo Parking Heater e Installation documentation Toyota Auris hybrid / Prius / Lexus CT00h.8 Petrol from Model Year 00 Left-hand drive vehicle Automatic air-conditioning Automatic transmission WARNING! Hazard warning: Observe the instructions of the vehicle manufacturer, allow jobs to be performed by electrical skilled persons only. 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, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto pas must be used. For this, also see the catalog of air and water heater accessories from Webasto. 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. The initial staup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 65B_EN Fee Euro 0.00 Webasto AG

2 Toyota Auris hybrid / Prius / Lexus CT00h Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document Preliminary Work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 8 Electrical system 8 Auris fan controller 0 Fan controller of Prius Lexus fan controller 6 Combination heater controls 9 Auris digital timer 0 Auris remote option (Telesta) 0 Prius digital timer Prius remote option (Telesta) Lexus digital timer Lexus remote option (Telesta) Preparing installation location Preparing heater 5 heater 6 Exhaust gas 8 Coolant circuit Fuel Final Work 7 Template for fuel standpipe 8 Operating Instructions for End Customer 9 Validity Manufacturer Model Type EG-BE No./ABE Toyota Auris hybrid HE5U (A) e * 007 / 6 * 008 *... Toyota Prius XW (A) e * 00 / 6 * 06 *... Lexus CT00h A0 (A) e * 007 / 6 * 050 *... Engine type Engine model Output in kw Displacement in cm³ ZR-FXE Petrol Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of the digital timer should be confirmed with the end customer before installation. 65B_EN

3 Toyota Auris hybrid / Prius / Lexus CT00h Heater/Installation Kit Quantity Description Order No.: Thermo Top Evo Basic delivery scope See price list Installation kit for Toyota Auris hybrid / Prius / Lexus CT00h 65B 00.8 Petrol Heater control See price list To be ordered from Toyota / Lexus additionally: Quantity Description Toyota / Lexus Order No.: Bracket of fuel pump sensor (fuel-tank sending unit union nut) O-Ring To be ordered from Toyota / Lexus optionally: Quantity Description Toyota / Lexus Order No.: Load status indicator DENGS Charger XS600 (optional) DENGS-XS60-7 Foreword This installation document applies to the Toyota Auris hybrid / Prius / Lexus CT00h.8 Petrol vehicles - for validity, see page - from model year 00 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 this installation documentation. In any case, please follow the specifications of this "installation documentation" and the "operating and installation instructions" of the Thermo Top Evo. 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 00K, Order No. 9). While installing an IPCU, the corresponding settings must be checked or adjusted. Special Tools - Torque wrench for.0-50 Nm - Hose clamping pliers - Metric thread-setter kit - Special tool for removal of fuel pump sensor (fuel-tank sending unit ) Toyota / Lexus Pa No: /0 65B_EN

4 Toyota Auris hybrid / Prius / Lexus CT00h 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. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Software 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 vehiclespecific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of 5x heater bolts = 8Nm! Tightening torque of 5x5 bolt of water connection piece retaining plate = 7Nm! 65B_EN

5 Toyota Auris hybrid / Prius / Lexus CT00h Preliminary Work WARNING! - Open the fuel tank cap, ventilate the tank. - Close the tank cap again. - Disconnect the battery "eah" 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. - Remove the windscreen wiper. - Remove windscreen wiper fully - Remove the entire coolant reservoir. - Remove the rear bench seat - Open the left-hand fuel sender service lid. - Remove the fuel-tank sending unit in accordance with the manufacturer's specifications - Remove the cover on the left below the fuel-tank (Lexus CT00h only) - Remove the output silencer [if available] between the strut towers according to manufacturer's instructions (Lexus CT00h only) - Remove the underride protection of the engine - Remove the trim at the underbody of fuel lines - Remove the centre console trim in the driver- and front seat passenger-side footwell - Remove the driver-side instrument panel trim - Remove the footwell trim on the driver's and front passenger side. Remove page 9 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater installation location Heater Installation location 65B_EN 5

6 Toyota Auris hybrid / Prius / Lexus CT00h Preparing electrical system Wire sections retain their numbering in the whole document. Fuse-holder of passenger compament of all vehicles Pull black () wire 8 into protection sleeving. Cutting wires to length 50 br A E 5 IPCU A E 5 IPCU view on the contact side. Connect wires to IPCU. The pre-programmed settings are to be checked during the function control of the vehicle and adjusted if necessary. Duty cycle: 60% Frequency: 00 Hz Voltage: 0 V Function: Low-side Premounting IPCU / ² F 86 gn/ws 0,75² F 87 87a 7 ² Inse F 0A in the fuse carrier. Inse red () wire 7 in socket K/87a and black () wire 6 in socket K/0. Produce connections as shown in wiring diagram. Plug in K relay. Preparing fuse F br 85 0 K 6 ² Auris only K relay plugged in M5x6 bolt, large diameter washer [x], retaining plate for fuse holder, nut Angle bracket Fuses F = A and F = 0A plugged-in Preinstallin g fuse holder of passenger compame nt 65B_EN 6

7 Toyota Auris hybrid / Prius / Lexus CT00h 60 Lexus only Discard section Perforated bracket Cutting perforated bracket to length K relay is inseed only after installation M5x6 bolt, large diameter washer [x], retaining plate for fuse holder, nut Perforated bracket Fuses F = A and F = 0A plugged-in Preinstallin g fuse holder of passenger compame nt Fuse-holder of engine compament of all vehicles 5 Angle bracket 0 mm spacer nut M6x bolt, spring lockwasher, large diameter washer M5x6 bolt, large diameter washer [x], retaining plate for fuse holder, nut 5 Fuses F- mounted Preinstallin g fuse holder of engine compame nt 5 5 Wiring harness of metering pump all vehicles Completing metering pump connector again after routing. Pin assignment is not relevant Connector housing Lock Blue (bl) / brown (br) wires Coding 5 Time lock Dismantlin g connector 5 65B_EN 7

8 Toyota Auris hybrid / Prius / Lexus CT00h Electrical system Fuse-holder of Auris hybrid / Prius engine compament M6x bolt, spring lockwasher, large diameter washer, existing hole Positive wire of Auris hybrid / Prius Crimp the tab receptacle at the positive wire and inse it into the free socket (+0). 6 7 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness installation diagram Prius eah wire Eah wire on original vehicle eah suppo point 8 Eah wire of Auris hybrid Eah wire on original vehicle eah suppo point 9 65B_EN 8

9 Toyota Auris hybrid / Prius / Lexus CT00h Electrical system Fuse holder of Lexus engine compament M6x bolt, spring lockwasher, large diameter washer, existing hole Wiring harness pass through of all vehicles. For wiring harness routing, see Install heater Protective rubber plug Wiring harness of heater, heater control 0 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness installation diagram Positive wire of Lexus Crimp the tab receptacle at the positive wire and inse it into the free socket (+0). Eah wire of Lexus Eah wire, original vehicle bolt 65B_EN 9

10 Toyota Auris hybrid / Prius / Lexus CT00h Auris fan controller Webasto Toyota 0/B 5/IG F F HG X 5 X HTR HTR -IG Wiring diagram ge br X0 / / ² ² F gn/ws 0,75² gn/ws 0,75² F ² E0 A/C-V a 7 br br IPCU 85 5 br E A 5 K 6 ² M GE /Gnd Webasto components Vehicle components Colours and symbols HG Heater TT-Evo HTR 50A fuse red X 6-pin heater connector HTR-IG 0 A fuse black X -pin heater connector A/C V A/C booster ge yellow X0 -pin connector E0 0-pin connector A/C V gn green Heater control GE Fan unit bl blue K Fan relay ws white F 0A fuse br brown F 0A fuse F A fuse F 0 A fuse IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 60% Frequency: 00 Hz X Cutting point Voltage: 0 V Cable colours and pin Function: Low-side designations may vary Legend 65B_EN 0

11 Toyota Auris hybrid / Prius / Lexus CT00h Auris hybrid Original vehicle bolt Angle bracket passenger compame nt fuses Connect wiring harness of heater and passenger compament fuse holder of the same colour according to circuit diagram. Connectin g wiring harnesses 5 Fasten IPCU socket on control unit with adhesive tape. IPCU mounted IPCU 6 5 Connection to the 0-pin connector E0 (A) of the A/C booster. Produce connections as shown in wiring diagram. Black () wire to 0-pin connector E0 (A) Pin Black () wire to terminal 5 Red () wire to IPCU/5 5 Red () wire 7 to K/87a 6 Black () wire to IPCU/86 7 Black () wire 6 to K/0 Connectin g the A/C booster B_EN

12 Toyota Auris hybrid / Prius / Lexus CT00h Auris hybrid Connector E0 (A) on contact side [from front] Pin Connector E0 (A) Brown (br) wire IPCU/85, cable lug 6mm dia. M6x0 bolt, flanged nut, existing hole Eah connection for IPCU 8 Connection to -pin connector from the fan unit. Produce connections as shown in wiring diagram. 5 Red () wire of A/C booster Red () wire 5 to IPCU/E Black () wire to IPCU/A 5 Red () wire to fan motor connector pin Connectin g fan unit 9 65B_EN

13 Toyota Auris hybrid / Prius / Lexus CT00h Fan controller of Prius Webasto Toyota 0/B 5/IG F F HG X 5 X HTR * A/C Wiring diagram / ² ge gn/ws 0,75² GR 5 ws/ br / ² gn/ws 0,75² X0 F F ² a 7 L7A br br IPCU 85 5 br E A 5 K 6 ² bl bl M GE A/C-V /Gnd Webasto components Vehicle components Colours and symbols HG Heater TT-Evo HTR 50A fuse red X 6-pin heater connector A/C 0 A fuse black X -pin heater connector GR Fan relay L0 ge yellow X0 -pin connector A/C V A/C booster gn green Heater control GM Fan unit bl blue K Fan relay ws white F 0A fuse br brown F 0A fuse F A fuse F 0 A fuse IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 60% * Original connection Frequency: 00 Hz X Cutting point Voltage: 0 V Cable colours and pin Function: Low-side designations may vary Legend 65B_EN

14 Toyota Auris hybrid / Prius / Lexus CT00h Prius Produce connections as shown in wiring diagram. 5.5mm dia. hole at position in fuse box. M5x0 bolt, large diameter washer, flanged nut Fuse holder, K relay, fuses F = A and F = 0A Passenger compame nt fuses 0 Connect wiring harness of heater and passenger compament fuse holder of the same colour according to circuit diagram. Connectin g wiring harnesses 5 Connection to fan relay. Detach red () wire 5 from fan relay Pin and connect it to wire. Connect black () wire8 and black () wire together to fan relay Pin. Produce connections as shown in wiring diagram. Black () wire8 of the A/C booster Black () wire to IPCU/86 Base of IPCU Red () wire to IPCU/5 5 Red () wire of A/C fuse Connectio n for IPCU Fasten IPCU with adhesive tape on fan relay. IPCU 65B_EN

15 Toyota Auris hybrid / Prius / Lexus CT00h Prius Produce connections as shown in wiring diagram. Brown (br) wire IPCU/85, 8mm dia. cable lug Original vehicle bolt Eah connection for IPCU Connection to -pin connector from the fan unit. Produce connections as shown in wiring diagram. 5 Blue (bl) wire to A/C booster Red () wire 5 to IPCU/E Black () wire to IPCU/A 5 Blue (bl) wire to fan unit connector Pin Connectin g fan unit 5 Connect to the 0-pin connector L7A 6 of the A/C booster. Produce connections as shown in wiring diagram. Black () wire of 0-pin connector L7A pin Black () wire 8 to fan relay pin Black () wire 6 to K/0 Red () wire 7 to K/87a 5 Black () wire of fuse A/C Connectin g the A/C booster Connector L7A on contact side [from front] Pin Connector L7A 65B_EN 5

16 Toyota Auris hybrid / Prius / Lexus CT00h Lexus fan controller F F Webasto HG X 5 X HTR Lexus A/C 0/B 5/IG Wiring diagram ge br X0 / / ² ² F gn/ws 0,75² gn/ws 0,75² F ² H85 A/C-V a 7 br br IPCU 85 5 br E A 5 K 6 ² ws ws M GE /Gnd Webasto components Vehicle components Colours and symbols HG Heater TT-Evo HTR 50A fuse red X 6-pin heater connector A/C 0 A fuse black X -pin heater connector A/C V A/C booster ge yellow X0 -pin connector H85 0-pin connector A/C V gn green Heater control GE Fan unit bl blue K Fan relay ws white F 0A fuse br brown F 0A fuse F A fuse F 0 A fuse IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 60% Frequency: 00 Hz X Cutting point Voltage: 0 V Cable colours and pin Function: Low-side designations may vary Legend 65B_EN 6

17 Toyota Auris hybrid / Prius / Lexus CT00h Lexus Perforated bracket M6x0 bolt, flanged nut, existing hole Fuse holder, fuses F = A and F = 0A passenger compame nt fuses 7 K relay Mounting K relay 8 Connect wiring harness of heater and passenger compament fuse holder of the same colour according to circuit diagram. Connectin g wiring harnesses 9 Fasten IPCU socket on control unit with adhesive tape. IPCU mounted Brown (br) wire IPCU/85, 8mm dia. cable lug, oringinal vehicle bolt IPCU 0 65B_EN 7

18 Toyota Auris hybrid / Prius / Lexus CT00h Lexus 5 Connect to the 0-pin connector H85 (A) 5 of the A/C booster. Produce connections as shown in wiring diagram. White (ws) wire to fan unit connector Pin Black () wire to IPCU/A Red () wire 5 to IPCU/E White (ws) wire to 0-pin connector H85 (A) Pin Connectin g the A/C booster 7 Connect to the 0-pin connector H85 (A) 6 of the A/C booster. Produce connections as shown in wiring diagram. 6 Red () wire 7 to K/87a Red () wire to IPCU/5 Black () wire 6 to K/0 Black () wire to IPCU/86 5 Black () wire to 0-pin connector H85 (A) Pin 7 Black () wire to terminal 5 Connectin g the A/C booster 5 Connector H85 (A) on contact side [from front] Pin Connector H85 (A) on contact side [from front] Pin Connector H85 (A) 65B_EN 8

19 Toyota Auris hybrid / Prius / Lexus CT00h Combination heater controls Only for Telesta "silver". Follow attached installation manual for Telesta "black". Telesta T9 with and without keys. Figure 5 (Y-adapter connector) Detach violet (vi) wire from 6-pin connector Pin 5 and inse it in Pin Preparing connector Digital timer and Telesta T9. Figure 6a (Y-adapter coupling, wire-side view) 5 Detach violet (vi) wire from -pin coupling Pin, insulate and tie away. Detach black () wire 5 from -pin coupling Pin, and inse it in Pin. Preparing connector Figure 6b (Y-adapter connector) Detach black () wire from 6-pin connector Pin and inse it in Pin. a b Telesta T00 HTM with and without keys. Figure 7 (Y-adapter connector) Detach violet (vi) wire from 6-pin connector Pin 5. Cut yellow (ge) wire approx. 50mm before connector. Connect violet (vi) wire and yellow (ge) wire with connectors. Preparing connector 5 Digital timer and Telesta T00 HTM. Figure 8a (Y-adapter coupling, wire-side view) 6 Detach violet (vi) wire 5 from -pin coupling Pin, insulate and tie away. Detach black () wire 6 from -pin coupling Pin, and inse it in Pin. Preparing connector Figure 8b (Y-adapter connector) 6a 5 6b Detach black () wire from 6-pin connector Pin. Cut yellow (ge) wire approx. 50mm before connector. Connect black () wire and yellow (ge) wire with connectors. 65B_EN 9

20 Toyota Auris hybrid / Prius / Lexus CT00h wiring harness heater 90058A digital timer Heater controls diagram Telesta Push button Auris digital timer Digital timer digital timer 7 Auris remote option (Telesta) Fasten receiver with adhesive tape. receiver 8 Paste antenna in the black area of the disk. antenna 9 65B_EN 0

21 Toyota Auris hybrid / Prius / Lexus CT00h Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. temperatur e sensor 0 Prius digital timer Digital timer digital timer Prius remote option (Telesta) Fasten receiver with adhesive tape. receiver Paste antenna antenna 65B_EN

22 Toyota Auris hybrid / Prius / Lexus CT00h Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. temperatur e sensor Lexus digital timer Digital timer digital timer 5 Lexus remote option (Telesta) Fasten receiver with adhesive tape. receiver 6 Paste antenna antenna 7 65B_EN

23 Toyota Auris hybrid / Prius / Lexus CT00h Temperature sensor T00 HTM Fasten temperature sensor to original vehicle wiring harness with cable tie. temperatur e sensor 8 65B_EN

24 Toyota Auris hybrid / Prius / Lexus CT00h Preparing installation location Cut out insulation mat in area of marking. Remove retaining clip and discard. Cutting out insulation mat 9 M6x0 spacer nut, silent block, existing stud bolt M6x0 spacer nut, silent block, existing stud bolt spacer nut 50 Auris hybrid / Prius Install loosely M6x0 spacer nut, M6x bolt, spring lockwasher, large diameter washer, existing hole spacer nut 5 Lexus Cable duct Removing cable duct 5 65B_EN

25 Toyota Auris hybrid / Prius / Lexus CT00h Cut out cable duct at the markings. Cover of cable duct Discard sections Cutting out cable duct 5 Cable duct installed with cover Install loosely M6x0 spacer nut, M6x bolt, spring lockwasher, large diameter washer, existing hole spacer nut 5 Preparing heater Fasten combustion air pipe with two cable ties 6 to silencer 5. Bracket M5x6 bolt, flanged nut 5 mm dia. p-clamp silencer Water connection piece, sealing ring [x each] 5x5 self-tapping screw, retaining plate of water connection piece water connection piece 56 65B_EN 5

26 Toyota Auris hybrid / Prius / Lexus CT00h 5x self-tapping screw (hex. Torx) [x] Bracket Preassemb ling bracket on heater 57 5 mm dia. spring clip Combustion air pipe 90 Moulded hose, 0 mm dia. clamp [x] Fuel line Premounti ng heater 58 heater Before installing heater, plug-in cable ties of circulating pump and heater. Tighten spacer nut at position. M6x bolt, spring lockwasher M6x0 bolt, spring lockwasher, existing threaded hole heater 59 M6 flanged nut Original vehicle brake line 5 mm dia. rubber-coated p-clamp M5x0 bolt, 0 mm shim, flanged nut heater 60 65B_EN 6

27 Toyota Auris hybrid / Prius / Lexus CT00h M6 flanged nut strut 6 Slit open 7 mm dia. corrugated tube lengthwise. Route wiring harness of heater, fuel line and wiring harness of metering pump in 7 mm dia. corrugated tubing (700) to the left vehicle side. 5 mm dia. rubber-coated p-clamp Original vehicle bolt Routing wiring harnesses 6 65B_EN 7

28 Toyota Auris hybrid / Prius / Lexus CT00h Exhaust gas Discard section X. Exhaust pipe a = 70 Exhaust end section b = 0 Preparing exhaust pipe a b X Exhaust pipe Tighten hose clamp slightly Silencer Hose clamp Preassemb ling silencer 6 Perforated bracket 65 Angling down perforated bracket 90 Rivet nut, existing hole rivet nut 6 65B_EN 8

29 Toyota Auris hybrid / Prius / Lexus CT00h Perforated bracket M6x0 bolt, spring lockwasher perforated bracket 65 M6x6 bolt, spring lockwasher Perforated bracket Tighten hose clamp silencer 66 Exhaust pipe Tighten hose clamp exhaust pipe 67 Ensure adequate distance from steering sleeve. Exhaust end section Hose clamp exhaust end section 68 65B_EN 9

30 Toyota Auris hybrid / Prius / Lexus CT00h Exhaust end section Routing exhaust end section 69 Exhaust end section M6x0 bolt, 5 mm dia. p-clamp, large diameter washer, flanged nut Angle bracket M6x6 bolt, pin lock, existing hole Fastening exhaust end section 70 Ensure sufficient distance to adjacent components, especially to heat protection plate and crossbeam line. Aligning exhaust end section 7 Install trim of underbody. Align exhaust end section, ensure adequate distance from neighbouring components, correct if necessary. Large diameter washer, M6 flanged nut Fastening exhaust end section 7 65B_EN 0

31 Toyota Auris hybrid / Prius / Lexus CT00h Coolant circuit WARNING! 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 ties. Position clamps so that no other hose can be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram D E C B A All spring clips = 5 mm dia. = Original vehicle spring clip. All connecting pipes and = 8 mm dia. x8. 65B_EN

32 Toyota Auris hybrid / Prius / Lexus CT00h Hose E = 90, 8 mm dia. moulded hose Discard section X. A B C D X A = 0 B = 60 C = 0 D = 0 Cutting hoses to length E M6x0 spacer nut, original vehicle stud bolt spacer nut 7 Inse wiring harness of circulating pump and route in slit open 7mm dia. corrugated tube. M6x5 bolt Circulating pump Circulating pump mounting circulating pump 7 Slide back braided protection hose at the cutting point. Cut the engine outlet hose / heat exchanger inlet at the marking. Spring clip will be reused. Remove hose section and discard. Cutting point 75 65B_EN

33 Toyota Auris hybrid / Prius / Lexus CT00h D Original vehicle spring clip E Connectin g heat exchanger inlet 76 D A Hose of engine outlet Hose bracket Connectin g engine outlet 77 C D Connectin g circulating pump B A D 78 Hose D at heater outlet. Hose C at heater inlet. Ensure sufficient distance to neighbouring components. Hose bracket [x] Connectin g heater C 79 65B_EN

34 Toyota Auris hybrid / Prius / Lexus CT00h Fuel 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. Route fuel line and wiring harness of metering pump in 0mm dia. corrugated tube (0 and 00) along original vehicle fuel lines to installation location of metering pump. lines 80 Rivet nut, existing hole rivet nut 8 5 Metering pump mounting Metering pump Angle bracket M6x5 bolt, flanged nut 5 Cable tie Premounti ng metering pump 8 65B_EN

35 Toyota Auris hybrid / Prius / Lexus CT00h M6x0 bolt, spring lockwasher Angle bracket metering pump 8 Remove the fuel-tank sending unit with the special tool in accordance with the manufacturer's instructions. Washer dia. d a = 7.6 Copy hole pattern, 6 mm dia. hole Removing fuel 6 8 Discard section 90 moulded hose Shoening 90 moulded hose 85 Shape fuel standpipe according to template, cut to length, install and align. Install 90 moulded hose with shoened side on fuel standpipe. 9 mm dia. clamp fuel standpipe 86 65B_EN 5

36 Toyota Auris hybrid / Prius / Lexus CT00h Install fuel tank sending unit using specified spare pas and tools according to manufacturer's specifications. Ensure adequate distance of the fuel line from the cover. 9 mm dia. clamp Cable tie Connectin g fuel line 87 Slide corrugated tube onto fuel line of fuel standpipe. Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section [x], 0 mm dia. Caillau clamp [x] Wiring harness of metering pump, connector mounted Fuel line of heater Connectin g metering pump 88 65B_EN 6

37 Toyota Auris hybrid / Prius / Lexus CT00h 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 components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer. - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the fan function (IPCU): adjust fan output to maximum. Then itch off ignition and itch on parking heater. On reaching the activation temperatur of 50 C the fan speed must correspond to the value of approx. / of the maximum speed specified by IPCU. - Check the proper operation of the parking heater, see the operating instructions/installation instructions. - Mount information label "Switch off parking heater before refueling" in area of filler neck. - During initial sta up, proceed as follows with the Webasto Thermo Test Diagnosis: Control coolant temperature under Menu Component test, check coolant level Pump fuel for the heater under the menu Pipe filling. CO - Check settings; take setting values from the general installation manual During the trial run, all water and fuel connections must be checked for leakage and stable seat. A error search is to be conducted in case of fault Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: ( Cent aus dem deutschen Festnetz) Hotfax: Hotmail: technikcenter@webasto.com 65B_EN Printed in Germany 05/0 Printing: Steffen 7

38 Toyota Auris hybrid / Prius / Lexus CT00h Template for fuel standpipe 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise 00 mm 0 65B_EN 8

39 Toyota Auris hybrid / Prius / Lexus CT00h 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. 0 min. (in one direction), we recommend not exceeding a itch-on time of 0 min. For vehicles with a factory-installed alarm system, the passenger compament monitoring is to be deactivated in accordance with the vehicle operating instructions. Before parking the vehicle, make the following settings: Auris hybrid There is no need to preselect the fan speed! Set temperature to "HI" Air outlet to windscreen Automatic airconditioni ng 89 Prius There is no need to preselect the fan speed! Set temperature to "max." Air outlet to windscreen Automatic airconditioni ng 90 Lexus CT00h There is no need to preselect the fan speed! Set temperature to "HI" Air outlet to windscreen Automatic airconditioni ng 9 65B_EN 9