Water heater unit Feel drive Thermo Top E Auxiliary Heating Thermo Top C Auxiliary Heating Thermo Top P Auxiliary Heating e 00 000 e 00 000 e 00 004 Installation instructions Toyota RAV 4 Petrol From model year 006 For left-hand drive vehicles only Automatic air conditioning WARNING! Hazard warning: Incorrect installation or repair of Webasto heating systems may cause a fire or result in 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 company training and reby acquired required technical skills or if you do not have access to 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.: 040A 0 fee Webasto AG
Table of Contents Validity Heater Unit / Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document 4 Preliminary Work 5 Heater Unit Installation Location 5 Preparing Electronics 6 Electrical Connections 7 Automatic air conditio-ning circuit diagram 8 Automatic air conditioning blower control 9 Remote Start Option 0 Thermo Call Option Preparing Heater Unit Preparing Installation Location 4 Installing Heater Unit 5 Fuel Connection 6 Exhaust System Water Connection Combustion Air 5 Final Work 6 Operating instructions for end customer 7 Fastening Strap Template 8 Tank Extracting Device Template 9 Validity Manufacturer Model Type EG-BE No. / ABE Toyota RAV 4 A e6*00/6*05... Engine type Engine model Power in kw Engine capacity in cm³ AZ-FE Petrol 998 Vehicle and engine types as well as equipment variants, which are not listed in se installation instructions, have not been tested. Installation according to se installation instructions may, however, be possible. The installation location of a time switch and summer / winter switch should be confirmed with end customer before installation.
Heater Unit / Installation Kit Amount Description Order no.: Commercial supply of required control See price list Installation kit for Toyota RAV 4 Petrol 090A Recommended heater unit for relevant vehicle class: Vehicle Compact car Mid-class, station wagon Luxury, van, off-roader Heater unit Thermo Top E Thermo Top C Thermo Top P Select heater unit based on size of vehicle passenger compartment and customer's comfort requirements. Foreword These installation instructions apply to vehicles Toyota RAV 4 with Petrol engines. Re. validity, see page from model year 006 and later, assuming technical modifications to vehicle do not affect installation, any liability claims excluded. Depending on vehicle version and equipment, modifications may be necessary during installation with respect to se installation instructions. However, stipulations in "installation instructions" and "operating and maintenance instructions" for Thermo Top C/P/E are to be observed in any event. The corresponding rules of technology and any information from vehicle manufacturer should be observed during installation work. General Instructions Installation should be carried out according to general, standard rules of technology. Unless specified orwise, 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 for example bore holes, with anti-corrosion wax (Tectyl 00K, Order No. 9)! Special Tools - Torque spanner for.0-0 Nm - Vise-grip wrench
Explanatory Notes on Document To provide you with a quick overview of individual working steps, you will find an identification mark on outside top right corner of page in question. Mechanics Electrics Water connection Fuel connection Exhaust system Combustion air Special features are highlighted using following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. i Reference to general installation instructions of Webasto components or to manufacturer's vehiclespecific documents. Reference to a special technical feature. The arrow in vehicle icon indicates position on vehicle and viewing angle. 4
Preliminary Work WARNING! - Disconnect battery. - Let off pressure in cooling system. - Copy factory number from original type label to duplicate type label. - Remove years that do not apply from duplicate label. - Attach duplicate label (type label) in appropriate place. - Completely remove air filter housing cover assembly. - Remove cooling water reservoir cover - Remove windshield washer arm assembly. - Remove cooling water reservoir cover in engine compartment. - Remove left suspension strut mount. - Open tank cap, ventilate tank. - Close tank cap again. - Remove left underride protection - Remove lower engine cover - Remove air tank according to manufacturer's instructions. - Remove tank mounting according to manufacturer's instructions. - Remove lower glove compartment cover (only for Remote Start or Thermo Call). - Remove glove compartment (only for Remote start or Thermo Call). - Remove side panelling in right footwell of center console (for Remote Start or Thermo Call). - Remove lower cover to driver-side dashboard - Remove side panel in left footwell of center console. - Loosen AC amplifier in middle console (only for automatic air conditioning). - Please remove page 6 Operating instructions for end customer and add this to vehicle operating instructions. Heater Unit Installation Location Heater unit Installation location 5
Preparing Electronics Pre-assemble cable harness according to figure. Fuse holder K blower relay Angle bracket 4 M5/ bolt, washer, M5 flanged nut Preparing Cable Harness Heater Unit 4 6
Electrical Connections Cable harness feed-through Protective rubber sleeve Time switch Time switch 4 i rt sw Wait to install metering pump cable harness until later, toger with fuel pipe along original vehicle fuel lines on Cable harness installation diagram br bl 5 6 Fuse holder, K relay Original vehicle stay bolt Preassembled angle bracket, body washer, M6 flanged nut Summer / winter switch option Summer / winter switch, hole Ø mm 7
Webasto Toyota 0 5 i F Fa Fb Fc Fd Fe HG X 4 rt/ws ge gn/ ws 86 87 87a K 85 0 rt sw ge E6 7 8 E4 7 A/C R A/C V 4 Automatic air conditioning circuit diagram br M E60 GM Webasto components Components Toyota RAV 4 Colours and symbols HG heater unit TT-C/E GM blower motor rt red X 6-pin heater unit A/C R Control (Integration ws white connector Control and Panel F Fuse, new 0A Assembly) sw black K blower relay br brown A/C V A/C amplifier br brown ge yellow Fa Fuse 0A ECU-B Fb Fuse 0A ECU-IG Fc Fuse, 7.5A ACC Fd Fuse 0A ECU-IG Fe Fuse, 50A HTR X splitting point Legend 8
Automatic air conditioning blower control 6 4 Connection to 40-pin connector white E4 from AC amplifier 4. Reconnect according to circuit diagram. Red (rt) wire from K/87a Yellow (ge) wire from fuse ECU-IG 6 Wire (sw) from K/0 5 Yellow (ge) wire to connector pin Connecting blower motor 5 7 Connector E4 pin 4 5 6 7 8 9 0 4 5 6 7 8 9 0 4 5 6 7 8 9 0 4 5 6 7 8 9 40 Connector E4, contact side 8 9
Remote Start Option Receiver, bracket M5x bolt, washer, flanged nut M5x bolt, washer, flanged nut i Assembling receiver 9 Antenna Assembling antenna 0 Temperature sensor for HTM00 only Temperature sensor, cable clip Original vehicle cable harness behind glove compartment under air duct Assembling temperature sensor 0
Thermo Call Option Receiver, dual lock self-adhesive (x) i Assembling receiver Antenna Assembling antenna Tip switch Assembling tip switch 4
Preparing Heater Unit A X B a = 80mm b = 5mm Dispose of section X Cutting water hoses to length X a b X B Heater unit Spring band clamp Ø 7mm Hose section, Ø 0mm hose clamps [x], Mecanyl fuel line cut down to,500 mm Preassemble Heater Unit Exhaust pipe a = 60mm Exhaust end section b = 85mm Dispose of section X Preparing exhaust pipe a b X Bracket Fastening strap with holes M6x bolt, M6 flanged nut 4 M6x bolt, bolt protector Preassembling bracket 4 5
Ejot screw bolts tightening torque 0 Nm! Between bracket and heater unit according to figure 4 4 Heater unit Ejot screw bolt, washer Ejot screw bolt, washer 4 Ejot screw bolt, washer [x] Preassembling bracket 4 6 Exhaust pipe Heater unit, bracket Preassembling exhaust pipe 7 5 4 Exhaust pipe 5 Hose clamp Fastening strap with holes M6x bolt, spring washer, bolt protector 4 Tube clamp, M6x0 bolt, flanged nut M6 Preassembling exhaust pipe 8
Preparing Installation Location Remove original vehicle nut Remove original vehicle bolt, this will be used again. Remove retaining clip 9 Drill and bend fastening strap according to template Fastening strap with holes 0 7 M6x0 spacer nut, retaining clamp, original vehicle stay bolt Fastening strap, retaining clamp, original vehicle stay bolts, original vehicle flanged nut M6x0 spacer nut, Ø5mm rubber tube clamp, original vehicle line Preparing Installation Location 4
Installing Heater Unit Pre-assembled heater unit Pre-assembled M6x bolt, spring washer, M6x0 spacer nut Assembling Heater Unit Heater unit Pre-assembled M6x0 bolt, flanged nut M6, hole sheet Assembling Heater Unit Check position of all components; adjust if necessary. Check that y have free clearance. Tighten all bolt connections. Pre-assembled M6x6 bolt Pre-assembled M6x0 spacer nut, Ø5mm rubber tube clamp Assembling heater unit 4 5
Fuel Connection CAUTION! Open vehicle's tank-cap lock, ventilate tank and n re-close tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering pump cable harness so that y are protected against stone impact. Unless specified orwise, always fasten using cable clips! Fit fuel line and cable harness with edge protectors around sharp edges. WARNING! The fuel line and cable harness to metering pump should be installed based on cable harness installation diagram. Remove tank ventilation line. Fuel tank Tank ventilation line Preparing fuel take-off 5 Remove quick coupling, coupling piece will not be used again, spring band clamp will be used again. Place marking at position X Tank ventilation line Quick coupling Quick coupling Preparing fuel take-off X 6 Remove inside 90 hose bend for tank ventilation, this will be used again. Tank ventilation pipe line 90 tank ventilation pipe angle Fuel tank Preparing fuel take-off 7 6
Drill pipe angle at position (Ø mm). Molded hose Drill Ø -4mm bore hole Preparing fuel take-off 8 Replace tank ventilation pipe angle Tank ventilation pipe line 90 tank ventilation pipe angle Fuel tank Preparing fuel take-off 9 Tank extracting device 400mm Cut down tank extracting device 0 Bend tank extracting device to size according to template. Tank extracting device Molded hose Ø.5 mm x 4.5 mm, universal clip Ø 8 mm Preparing tank extracting device 7
X Assemble tank ventilation line according to illustration, note X marking! Tank ventilation line Original vehicle spring band clamp Tank extracting device Tank extracting device Fuel tank Tank extracting device, ventilation line Hose clamps Ø 6-4mm Insert fuel take-off Shape tank extracting device according to figure. Tank ventilation hose section in tank fuel extractor Fuel tank Insert fuel take-off 4 Assemble tank mounting according to manufacturer's instructions. Fasten fuel line to original vehicle fuel line with cable clips. Fuel tank Molded hose Ø.5 mm x 4.5 mm, universal clip Ø 0mm Mecanyl fuel line Placement of fuel line 5 8
X Dispose of section X Molded hose Preparing tank ventilation molded hose X 6 Tank ventilation molded hose Hose clamps Ø 6-4mm Tank ventilation pipe line Tank ventilation line assembly 7 Assemble fuel tank according to manufacturer's instructions. Connect pre-assembled molded hose with tank extracting device connecting pieces 4 Fuel tank Tank ventilation molded hose Hose clamps Ø 6-4mm Tank ventilation hose, tank extracting device Tank ventilation line assembly 4 8 Use 8x molded hose as edge protector. Molded hose 8x, cable clips Mecanyl fuel line Molded hose 8x, cable clips Placement of fuel line 9 9
Slide enclosed flexible hose on Mecanyl fuel pipe and run this toger with cables for metering pump along original vehicle fuel lines to vehicle underbody. Heater unit Pre-assembled Mecanyl fuel line Flexible hose Connecting to heater unit 40 Bend and drill fastening strip according to figure Fastening strip Hole Ø 8.5mm Angle 90 Working fastening strap 4 Note installation position of metering pump, see Installation Instructions. i M6x0 bolt, spring washer, existing threaded insert M8 Metering pump, silentblock, flanged nut M6, rubber tube clamp Fastening strip Metering pump installation location 4 Fuel line from fuel extractor on intake side of metering pump [side without connector]. Check position of components; adjust if necessary. Check that y have free clearance. Mecanyl fuel line Mecanyl fuel line Hose section, Ø 0mm hose clamps [x] Connecting to metering pump 4 0
Fuel line from heater unit on pressure side of metering pump [side with connector]. Check position of components; adjust if necessary. Check that y have free clearance. Metering pump Hose section, Ø 0mm hose clamps [x] Metering pump connector, cables 4 Flexible hose, Mecanyl fuel pipe, metering pump wire harness Connecting to metering pump 4 44
Exhaust System Slide on red rubber spacer (x) according to figure Red rubber spacer Pre-assembled exhaust line from heater unit Red rubber spacer Assembling exhaust pipe 45 Ensure sufficient distance from adjacent components. 6 4 6 Exhaust pipe Exhaust silencer Hose clamp 4 Angle bracket M6x0 bolt, flanged nut M6 5 M6x0 bolt, flanged nut M6 Assembling silencer 5 46 Ensure sufficient distance from adjacent components. 4 Exhaust silencer, hose clamp Exhaust end section 4 M6x0 bolt, spring washer, angle bracket, original vehicle threaded insert Tube clamp, M6x0 bolt, flanged nut M6 Assembling exhaust pipe 47 Ensure sufficient distance from adjacent components. Red rubber spacer Red rubber spacer Align spacer rubber 48
Water Connection WARNING! Tighten all hose clamps to.0 + 0.5 Nm. Any coolant running off should be collected using an appropriatecontainer. Install hoses so that y are kink-free! Unless specified orwise, always fasten using cable clips! Position hose clamps and spring band clamps so that no or hose can be damaged! The connection should be "inline" based on following diagram: Heat exchanger Wärmetauscher B Water installation diagram A Motor All hose clamps = Ø 0-7 mm. All connecting pipes = Ø 7x0. Position = black rubber profile.
Engine outlet exhaust hose splitting point 49 B Before connecting, fill water hoses with coolant. Heat exchanger inlet hose section Engine exhaust hose section Black rubber profile Installing in engine compartment A 50 Inserting spacer bracket according to figure. Spacer bracket Inserting spacer bracket 5 4
Combustion Air Punch out perforated hole in heater unit cover, insert cable clips. i 4 5 Heater unit Combustion air intake pipe 4 Ø 7mm hose clamp Clip-on cable clip Assembling vacuum line. 5 5 Combustion air intake silencer Retaining clip in bore hole i Assembling silencer 5 5
Final Work WARNING! Reassemble disassembled components in reverse order. Check that all hose lines, hose, spring band clamps and universal 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 00K, Order No. 9). - Connect battery. - Start engine, bleed coolant circuit according to vehicle manufacturer's specifications, top up with coolant. - Set time switch. - Make settings according to "Operating instructions for end customer". - Check that auxiliary heating operates properly, see operating instructions / installation instructions. - Attach "Switch off auxiliary heating before re-fuelling" sticker onto left side of B-pillar. i Feel drive Webasto AG Postfach 80-8 Stockdorf - Hotline 0 8 05 / 9 78 Hotfax (095) 55 9-5 - http://www.webasto.de Printed in Germany 0/06Printed by: Steffen
Operating instructions for end customer Please remove page and add to vehicle operating instructions. Before parking vehicle, make following settings: Temperature to "HI Air outlet to windscreen, AC off Blower to setting "", max. For vehicles with automatic airconditioning 54 For short distance trips, it is not recommended that rear window heating be used. Rule of thumb for operating auxiliary heating: driving time = heating time. 7
Fastening Strap Template Ø 7mm bore hole 90 angle 90 angle 00mm Scale : Compare size of printed version with dimension lines. Permitted tolerance a maximum of %. Set printer settings to no margin or minimize margins and 00% of normal size. 00mm 0 8
Tank Extracting Device Template 00mm Scale : Compare size of printed version with dimension lines. Permitted tolerance a maximum of %. Set printer settings to no margin or minimize margins and 00% of normal size. 00mm 0 9