EN

K Installation documentation
for Thermo Top Evo water heater

Toyota LC150
Left-hand drive vehicle
Manufacturer Model Type Model year EG-BE-No. / ABE
Toyota LC 150 J15TM from production 08/2017 e6* 2007/46* 0001*…

Motorisation Fuel Emission standard Transmission Out- Displace- Engine code

type put[kW] ment[cm³]
2.8D Diesel Euro 6 6-speed SG 130 2755 1GD-FTV
2.8D Diesel Euro 6 6-speed AG 130 2755 1GD-FTV

Validity Equipment variants Model

Toyota LC150
Verified Manual air-conditioning x
equipment variants 2 zone automatic air-conditioning x
3 zone automatic air-conditioning x
LED main headlights x
LED daytime running lights x
Halogen main headlights x
Halogen front fog lights x
Headlight washer system x
Short wheelbase x
Long wheelbase x
Unverified
equipment variants

Total installation Note

time
6.7 hours

Toyota LC150 16/11/2018 1326520B_EN 1

Contents
1 List of abbreviations 3 13.2.1 System wiring diagram for manual air-con-
ditioning and 2-zone automatic A/C 43
2 Installation notes 4 13.2.2 System wiring diagram for 3 zone auto-
2.1 Information on Validity 4 matic air-conditioning 44
13.2.3 Legend to the system wiring diagrams 45
2.2 Components used 4
13.3 Fan controller 46
2.3 Information on Total Installation Time 4
2.4 Installation recommendations 4 14 Electrical system of control elements 49
14.1 MultiControl CAR option 49
3 About this document 5
14.2 Telestart option 49
3.1 Purpose of the document 5
14.3 ThermoCall option 50
3.2 Warranty and liability 5
3.3 Safety 5 15 Final Work 51
3.4 Using this document 6 16 Operating instructions for manual air-
conditioning 53
4 Technical Information 7
16.1 A/C control panel settings 53
5 Preparing measures 8 16.2 Installation location of fuses 53
5.1 Vehicle preparation 8
17 Operating instructions for 2 and 3 zone
5.2 Heater preparation 8 automatic air-conditioning 55

6 Installation overview 9 17.1 A/C control panel settings 55

17.2 Installation location of fuses 55
7 Electrical system of engine compart-
ment 10

8 Mechanical system 14
8.1 Installation location preparation 14
8.2 Heater bracket preparation 15
8.3 Premounting heater 18
8.4 Heater mounting 19

9 Fuel 21

10 Coolant 26
10.1 Hose routing diagram 26
10.2 Coolant circuit installation 27

11 Exhaust 33

12 Combustion air 37

13 Electrical system of passenger com-

partment 38
13.1 Electrical system preparation 38
13.1.1 Manual air-conditioning and 2 zone auto-
matic air-conditioning 40
13.1.2 3 zone automatic air-conditioning 41
13.2 System wiring diagrams 43

2 1326520B_EN 16/11/2018 Toyota LC150

1 List of abbreviations
DP Fuel pump

HG Heater

K2 Additional relay

MCC MultiControl (control element)

PWM Pulse width modulator

RSH Relay and fuse holder of passenger

compartment

SH2 Engine compartment fuse holder for F1/F2

UP Coolant pump

Wire Cable

Toyota LC150 16/11/2018 1326520B_EN 3

2 Installation notes
2.1 Information on Validity
This installation documentation applies to vehicles listed on page 1, 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. Vehicle and engine types, equip-
ment variants and other specifications not listed in this installation documentation have not been tested. However, in-
stallation according to this installation documentation may be possible.

2.2 Components used

Designation Order number
Basic delivery scope of Thermo Top Evo in accordance with price list In accordance with price
list
Installation kit for Toyota LC150 diesel 2018 TT-Evo 1326519A
In case of control element as well as Telestart indicator lamp in consultation with end cus- In accordance with price
tomer list
In case of MultiControl CAR installation - installation frame for MultiControl 9030077_

2.3 Information on Total Installation Time

The total installation time includes the time needed for mounting and demounting the vehicle-specific components,
the heater specific installation time and all other times required for the system integration and initial start-up of the
heater.
The total installation time may vary for vehicle equipment other than provided.

2.4 Installation recommendations

Arrange for the vehicle to be delivered with the tank only about ¼ full.
For the MultiControl CAR option, the recommended installation locations for the Telestart or ThermoCall push button
should be confirmed with the end customer.
Depending on the space required and the vehicle manufacturer's instructions, we recommend the use of a vehicle bat-
tery with a higher electrical capacity.

4 1326520B_EN 16/11/2018 Toyota LC150

 The regulations from the heater's general installation and operating in-
3 About this document structions must be observed.

3.1 Purpose of the document

This installation documentation is part of the product and contains all 3.3.1 Safety information on installation
the information required to ensure professional vehicle specific installa-
Danger posed by live parts
tion of the:
u Prior to installation, disconnect the vehicle from the voltage supply.
Thermo Top Evo heater
u Make sure the electrical system is earthed correctly.

u Always comply with legal requirements.

3.2 Warranty and liability u Observe data on type label.
Webasto shall assume no liability for defects, damage and injuries res-
ulting from a failure to observe the installation, repair and operating in-
Danger of fire and leaking toxic gases due to
structions of the information contained in them.
improper installation
This liability exclusion particularly applies to improper installations and
u Vehicle parts in the vicinity of the heater must be protected against
repairs by untrained persons or in the case of a failure to use genuine
excessive heating by the following measures:
spare parts.
ð Maintain minimum safety distances.
The liability due to culpable disregard to life, limb or health and due to
damage or injuries caused by a wilful or reckless breach of duty remain ð Ensure adequate ventilation.
unaffected, as does the obligatory product liability. ð Use fire-resistant materials or heat shields.
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
Danger due to sharp edges
cable ties. Insulate loose wire ends and tie back. Connectors on elec- – Lacerations
tronic components must audibly snap into place during assembly.
– Short circuit due to electrical wire damage
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax u Fit protectors on sharp edges.
(Tectyl 100K).

Observe the instructions and guidelines of the respective vehicle manu-

facturer for demounting and mounting vehicle specific components.

The initial start-up is to be executed with the Webasto Thermo Test Dia-
gnosis.

When installing a programmable control module (e.g. a PWM Gate-

way), the corresponding settings must be checked or adjusted.

3.2.1 Statutory regulations governing

installation
The Thermo Top Evo heater has been type-tested and approved in ac-
cordance with ECE-R 10 (EMC) and ECE-R 122 (heater). The regulations
of these guidelines are binding in the scope of the Directive 70/156/EEC
and/or 2007/46/EC (for new vehicle models from 29/04/2009) and
should also be observed in countries in which there are no special regu-
lations.

The heater is licensed in accordance with paragraph 19, section 3, No.

2b of the StVZO (German Road Traffic Licensing Authority).

3.3 Safety
Qualifications of installation personnel
The installation personnel must have the following qualifications:

– Successful completion of Webasto training

– Corresponding qualification for working on technical systems

Regulations and legal requirements

Toyota LC150 16/11/2018 1326520B_EN 5

3.4 Using this document Type and source of the risk
Before installing and operating the heater, read this installation docu- Consequences: Failure to follow the instructions can lead
mentation, the installation instructions of the heater, the operating in- to material damage
structions and supplementary sheets provided. u Actions to protect yourself against risks.

3.4.1 Explanatory Notes on the Reference to the vehicle manufacturer's specific docu-
Document ments.

There is an identification mark near the respective work step to allow

a note on a special technical feature
you to quickly allocate the other applicable documents to the Webasto
components to be installed:

Generally valid Webasto documentation

3.4.3 Work step identification marks
The ongoing work step is indicated on the outside top corner of the
Vehicle-specific installation documentation K
F
page:

Webasto Comfort A/C control H

F Mechanical Electrical Sys- High-voltage Coolant
system tem
Webasto Standard A/C control G
F

Tank extracting device (e.g. FuelFix) F

F

Exhaust end fastener (EFIX) E

F
Combustion Fuel Exhaust gas Software
air
Combustion air intake silencer L
F

Spacer bracket (ASH) S

F

3.4.2 Use of symbols

3.4.4 Orientation aid
DANGER
Type and source of the risk
Consequences: Failure to follow the instructions can result
in death
The arrow indicates the position on the vehicle and the viewing angle
u Actions to protect yourself against risks.

3.4.5 Use of highlighting

WARNING
Type and source of the risk Highlight Explanation
Consequences: Failure to follow the instructions can lead Necessary action
to serious or even fatal injuries ð Result of an action
u Actions to protect yourself against risks. Position numbers for the image descriptions
1 12 a1 A
/ Position numbers for the image descriptions
CAUTION for electrical wires and wiring harnesses
Type and source of the risk and coolant hose sections

Consequences: Failure to follow the instructions can lead

to minor injuries
u Actions to protect yourself against risks.

6 1326520B_EN 16/11/2018 Toyota LC150

4 Technical Information
Dimension specifications
– All dimensions specified in mm

Tightening torque specifications

– Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm
– Tightening torque values of 5x15 retaining plate of water connection piece bolts = 7Nm
– 5x12 bolt tightening torque of 2-part heater bracket = 6Nm
– Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-
art-technology

Specified temperature for fabric heat shrink tubing

– Shrink temperature max. 230°C

Necessary special tools

– Hose clamp pliers for self-clamping hose clamps
– Hose clamp pliers for Clic hose clamps of type W
– Hose clamping pliers
– Hose cutter
– Automatic wire stripper 0.2 - 6 mm²
– Crimping pliers for cable lugs 0.5 – 10 mm²
– Crimping pliers for tab connector 0.14 – 6 mm²
– Crimping pliers for connector 0.25 – 6 mm²
– Torque wrench for 2.0 - 10 Nm
– Deep-hole marker
– Metric thread-setter kit
– Webasto Thermo Test Diagnosis with current software

Toyota LC150 16/11/2018 1326520B_EN 7

5 Preparing measures
5.1 Vehicle preparation

Further information can be found in the vehicle manufacturer's technical documentation.

u Open the fuel tank cap

u Ventilate the fuel tank
u Close the fuel tank cap again
u Depressurise the cooling system
u Disconnect the battery
u Remove the engine design cover
u Completely remove the air filter with the intake hose
u Remove the top, side and lower A-pillar trim on the front passenger's side
u Remove the entrance strip on the front passenger's side
u Remove the lower footwell trim on the front passenger's side
u Remove the glove compartment
u Remove the grove box trim

5.2 Heater preparation

Observe the general installation instructions of the heater.

u Remove years that do not apply from the type and duplicate label.
u Attach the duplicate label (type label) in the appropriate place in the engine compartment.

8 1326520B_EN 16/11/2018 Toyota LC150

6 Installation overview

PWM K2
RSH
HG

UP MCC

DP

SH2

Fig. 1

Legend to installation overview

Abbreviation Component
DP Fuel pump
HG Heater
K2 Relay K2 (only in case of 3 zone automatic air-conditioning)
MCC MultiControl CAR (control element)
PWM Pulse width modulator
RSH Relay and fuse holder of passenger compartment
SH2 Fuse holder of engine compartment
UP Coolant pump

Heater installation location

1 1 Heater

Fig. 2

Toyota LC150 16/11/2018 1326520B_EN 9

7 Electrical system of engine compartment
Preparing angle bracket
1 1 Drill out hole to 8.5mm dia.

Fig. 3
Premounting fuse holder retaining plate
1 1 M5x16 bolt, large diameter washer, fuse holder,
angle bracket, large diameter washer, nut

Fig. 4
Fuse F1/F2 retaining plate installation
Nm 1 Original vehicle bolt, premounted angle bracket
! 2 Premounted fuse F1/F2 bracket

2
Fig. 5

10 1326520B_EN 16/11/2018 Toyota LC150

Fuse F1/F2 installation
1 Fuse F1: 20A and F2: 30A

1
Fig. 6
Detaching original vehicle positive wire
1 1 Original vehicle positive wire
2 Positive support point

2
Fig. 7
Routing positive wire
1 1 u Drawcable lug 1 of positive wire 2 through cable
duct 3 .

Fig. 8

Toyota LC150 16/11/2018 1326520B_EN 11

Premounting positive wire
1 1 Cable lug of positive wire
2 Positive support point

Fig. 9
Mounting positive wire
1
DANGER
Fire hazard due to insufficient tightening
Nm torque
! u Observe tightening torque
2
1 Flanged nut of positive support point
2 Positive wire

Fig. 10
Earth connection

DANGER
Fire hazard due to insufficient tightening
Nm torque
! u Observe tightening torque
2
1 Earth wire
2 Original vehicle earth point

Tectyl
(Wachs)

1
Fig. 11

12 1326520B_EN 16/11/2018 Toyota LC150

Wiring harness routing
1 1 Heater wiring harness, control element, passen-
ger compartment

Fig. 12
1 1 Heater wiring harness, control element, passen-
ger compartment
1 2 Heater wiring harness connector

2
Fig. 13
Passenger compartment wiring harness pass through
1 u Route passenger compartment and control element
wiring harness 2 through protective rubber plug 1
into the passenger compartment.

Fig. 14

Toyota LC150 16/11/2018 1326520B_EN 13

8 Mechanical system
8.1 Installation location preparation
Detaching wiring harness
1 u Remove and discard original vehicle wiring harness
bracket 1 .

Fig. 15
Preparing angle bracket
1 Drill out hole to 8.5mm dia.

24

1
90°

Fig. 16
Premounting angle bracket
1 M6x16 bolt, large diameter washer, angle
bracket, lock washer

1
Fig. 17

14 1326520B_EN 16/11/2018 Toyota LC150

Mounting angle bracket loosely
1 Original vehicle stud bolt, premounted angle
bracket, M8 flanged nut

Fig. 18
8.2 Heater bracket preparation
Cutting hoses to length
800
65
90
C D B A E 65
900

Fig. 19
Preparing hoses and
u Slideon fabric heat shrink tubings, cut to length and
shrink.

Fig. 20

Toyota LC150 16/11/2018 1326520B_EN 15

Mounting sleeve in UP mount
Preparing coolant pump mount
1 1 UP mount
2 Sleeve

Fig. 21
Premounting coolant pump
1 2 1 Coolant pump mount
2 Coolant pump
3
3 18x18mm dia. 90° connecting pipe
4 Coolant pump wiring harness connector
B 5 Cable tie

4 C
Fig. 22
Premounting UP onto bracket
1 M6x25 bolt, UP mount, HG bracket, flanged nut
2 M6x20 bolt, HG bracket, lock washer

2
Fig. 23

16 1326520B_EN 16/11/2018 Toyota LC150

Mounting HG bracket onto mounting plate
1 Heater bracket
2 Mounting plate of HG bracket
3 M6x16 bolt, HG bracket, mounting plate,
1 flanged nut

3 3 3 2
Fig. 24
Mounting mounting plate loosely
1 1 Premounted mounting plate
2 Mount original vehicle stud bolt, mounting
plate, M8 flanged nut loosely
2 3 Edge clip cable tie

Fig. 25
1 1 Premounted mounting plate
2 Premounted M6x16 bolt, mounting plate,
flanged nut
u Align bracket as shown and tighten all screw connec-
tions.

2
Fig. 26

Toyota LC150 16/11/2018 1326520B_EN 17

8.3 Premounting heater
Premounting bolts
1 1 u Screw5x13 self-tapping bolt 1 in available holes by a
max. of 3 thread turns.

1 1
Fig. 27
Mounting water connection piece
1 Observe the general installation instructions of
the heater.

1 Water connection piece 90°, sealing ring

2 5x15 self-tapping bolt, water connection piece
retaining plate
2 3 180° water connection piece, sealing ring

3
Fig. 28
Mounting hose
D All spring clips, 25mm dia.

1 90° connecting pipe

1

Fig. 29

18 1326520B_EN 16/11/2018 Toyota LC150

Mounting fuel line
5 N
≥1 Observe the general installation instructions of

3
! the heater.

1 Fuel line
2 90° moulded hose, 10mm dia. clamp [2x]

N
3
! 2 1
Fig. 30
Mounting combustion air intake pipe s1

L
F Observe the installation instructions of the
combustion air intake silencer.

s1

Fig. 31
8.4 Heater mounting
Mounting heater
Observe the general installation instructions of
the heater.

u Insert heater into bracket.

u Tighten 5x13 self-tapping bolt 1 . (Tighten also the 2
bolts on the back)

1 1
Fig. 32

Toyota LC150 16/11/2018 1326520B_EN 19

Mounting hose

B
D

C
Fig. 33
Mounting wiring harnesses
1 Heater wiring harness connector
2 Coolant pump wiring harness connector

2 1 1
Fig. 34

20 1326520B_EN 16/11/2018 Toyota LC150

9 Fuel
DANGER
Risk of fire and explosion due to leaking fuel and escaping fuel vapours.
The Incorrect installation of the fuel extractor can cause damage and fire.
u Avoid electrostatic discharges and open fire.
u When working on the fuel system, ensure sufficient ventilation and bleeding.
u Open the fuel tank cap of the vehicle.
u Ventilate the fuel tank
u Re-close the tank lock.
u Catch any fuel running off with an appropriate container.

Danger of damage to components

u Install fuel line and fuel pump wiring harness so that they are protected against stone impact.
u Provide rub protection for fuel line and wiring harness in areas where there are sharp edges.

Dismantling fuel pump connector X7

~ 1mm
~ 1mm

Fig. 35
Connection to heater
1 u Draw
fuel line 2 and fuel pump wiring harness 1 into
10mm dia. corrugated tube and route to firewall.

2
Fig. 36

Toyota LC150 16/11/2018 1326520B_EN 21

Routing in engine compartment
u Route fuel line and fuel pump wiring harness in corrug-
ated tube 1 in engine compartment to fuel pump in-
stallation location and fasten.

Fig. 37
Premounting fuel pump
1 2 3 4 Observe the general installation instructions of
the heater.

1 DP mount
2 DP
3 Hose section, 10mm dia. clamp [2x]
4 Fuel line of tank extracting device
5
5 90° moulded hose, 10mm dia. clamp

N N
! 0 3
!
3 3
Fig. 38
Mounting fuel pump
1 2 Observe the general installation instructions of
the heater.

1 Original vehicle stud bolt, flanged nut

2 DP premounted

Fig. 39

22 1326520B_EN 16/11/2018 Toyota LC150

Mounting fuel pump connector X7

P
P
click

P
click

P
click
~1mm
Fig. 40
Fuel pump connection
1 5 N 1 Heater fuel line
≥1

3
! 2 Fuel pump wiring harness, connector X7 moun-
ted
3 10mm dia. clamp

2
Fig. 41
Routing to fuel extraction
u Draw fuel line of tank extracting device into 10mm dia.
corrugated tube 1 and route to the firewall.

Fig. 42

Toyota LC150 16/11/2018 1326520B_EN 23

 1 u Routefuel line of tank extracting device in corrugated
tube 1 on the firewall to the driver's side.

Fig. 43
1 u Routefuel line of tank extracting device in corrugated
tube 1 to the fuel filter.

Fig. 44
Detaching original vehicle fuel supply line
1 1 Original vehicle fuel supply line
2 Original vehicle spring clip, will be reused

2
Fig. 45

24 1326520B_EN 16/11/2018 Toyota LC150

Premounting T-piece
N 1 Observe maximum torque of screw clamp.

3
! Nm
! ≤ 1.2Nm
1 Hose section with 4.5mm inner dia., 10mm dia.
4
clamp
2 Hose section with 10mm inner dia.
3 14mm dia. screw clamp
4 T-piece (10x5x10) used as tank extracting device

3 2
Fig. 46
Mounting fuel line of tank extracting device
1 5 N 1 Premounted T-piece
≥1

3
! 2 10mm dia. clamp
3 Fuel line of tank extracting device

Fig. 47
Mounting tank extracting device
1 2 3 4 Observe maximum torque of screw clamp.
Nm
! ≤ 1.2Nm
1 Original vehicle fuel supply line
2 Original vehicle spring clip
3 T piece
4 Fuel line of tank extracting device
5 Connection piece of fuel supply line
6 14mm dia. screw clamp

6 5
Fig. 48

Toyota LC150 16/11/2018 1326520B_EN 25

10 Coolant
10.1 Hose routing diagram
'Inline' coolant circuit

E 1

A
D B
2

Fig. 49
1 Original vehicle spring clip
2 Only in case of vehicles with 2 heat exchangers
u All spring clips without a specific designation = 25mm dia.
u All connecting pipes = 18x18mm dia.

26 1326520B_EN 16/11/2018 Toyota LC150

10.2 Coolant circuit installation
Mounting edge protection
1 Only necessary in case of a vehicle with a
second heat exchanger.

u Cut edge protection in sections of 80 and 100mm

1 80mm edge protection
2 100mm edge protection

2
Fig. 50
Cutting point
Vehicle with a second heat exchanger.

u Remove hose of engine outlet / heat exchanger inlet

1 . Original vehicle spring clips will be reused.

1
Fig. 51

Vehicle with one heat exchanger.

u Remove hose of engine outlet / heat exchanger inlet

2 from heat exchanger inlet connection piece 1 . Ori-
ginal vehicle spring clip will be reused.

2
Fig. 52

Toyota LC150 16/11/2018 1326520B_EN 27

Preparing hose of heat exchanger inlet / engine outlet
1 2 Only necessary in case of a vehicle with a
second heat exchanger.

1 Position original vehicle spring clip

2 Hose of heat exchanger inlet / engine outlet, be-
comes engine outlet hose section

20

Fig. 53
Premounting hose
A Only necessary in case of a vehicle with a
second heat exchanger.

1 Engine outlet hose section

A
Fig. 54
Mounting hose
A This and next figures show a vehicle with a
second heat exchanger, but apply to all
vehicles.

B
Fig. 55

28 1326520B_EN 16/11/2018 Toyota LC150

Routing hose
A 1 Cable tie

1
Fig. 56
A 1 Cable tie

1
Fig. 57
Engine outlet connection
A Vehicle with a second heat exchanger.

1 Engine outlet hose section

2 Original vehicle spring clip
3 Engine outlet connection piece

3 2 1
Fig. 58

Toyota LC150 16/11/2018 1326520B_EN 29

 A Vehicle with one heat exchanger.

1 Engine outlet hose section

1
Fig. 59
Heat exchanger inlet connection
Vehicle with a second heat exchanger.

1 Heat exchanger inlet connection piece

2 Original vehicle spring clip

E 2
Fig. 60
1 Vehicle with one heat exchanger.

1 1 Heat exchanger inlet connection piece

2 Original vehicle spring clip
2
E

E
Fig. 61

30 1326520B_EN 16/11/2018 Toyota LC150

Routing hose
A 1 This and next figures show a vehicle with a
1 second heat exchanger, but apply to all
vehicles.

1 Cable tie

E
Fig. 62
A 1 1 Cable tie

E
Fig. 63
Mounting hose
A 1 Cable tie

1 E
Fig. 64

Toyota LC150 16/11/2018 1326520B_EN 31

Mounting hose bracket
Danger of damage to components
E u Ensure
sufficient distance from neighbouring
components, correct if necessary.

u Hosebracket 1 around hose and engine outlet

hose section.

2 1
Fig. 65

32 1326520B_EN 16/11/2018 Toyota LC150

11 Exhaust
Preparing exhaust pipes
for vehicles with rear for vehicles without
A/C rear A/C
a1 780 700
a2 450 450
a1

a2

Fig. 66
Bending exhaust pipe a1 , premounting spacer bracket
1 Spacer bracket

a1 1 1 1
Fig. 67
Bending perforated bracket

15 18

170°

100°

Fig. 68

Toyota LC150 16/11/2018 1326520B_EN 33

Premounting exhaust silencer
1 1 Exhaust silencer
2 M6x16 bolt, spring lockwasher, perforated
bracket

2
Fig. 69
Mounting rivet nut
u Drill
out original vehicle hole at position 1 to 9mm
and insert rivet nut.

1
Fig. 70
Mounting exhaust silencer
1 M6x20 bolt, spring lockwasher, premounted
perforated bracket, rivet nut

1
Fig. 71

34 1326520B_EN 16/11/2018 Toyota LC150

Mounting exhaust pipe a1 onto HG
1 Premounted M6x16 bolt, p-clamp, flanged nut
2 Hose clamp

2
1

a1
Fig. 72
Fastening original vehicle wiring harness
1 Original vehicle wiring harness
2 Edge clip cable tie

1 1

2
Fig. 73
Routing exhaust pipe a1
The figure shows a vehicle with rear A/C.

Danger of damage to components

u Ensure sufficient distance between exhaust
pipe a1 and neighbouring components, cor-
rect if necessary.

u Position spacer brackets 1 on A/C lines as shown.

a1 1 1
Fig. 74

Toyota LC150 16/11/2018 1326520B_EN 35

Mounting exhaust pipe a1 onto exhaust silencer
a1 Danger of damage to components
u Ensure sufficient distance between exhaust
pipe a1 and neighbouring components, cor-
rect if necessary.
1
1 Exhaust silencer
2 Hose clamp
u Position spacer bracket 3 on A/C line as shown.

3
Fig. 75
Mounting angle bracket
1 1 Exhaust silencer connection piece
2 Original vehicle bolt, angle bracket

2
Fig. 76
Mounting exhaust pipe a2
1 2 a2 1 Hose clamp
2 Position spacer bracket as shown
3 M6x20 bolt, premounted angle bracket, p-
clamp, flanged nut

a2

3
Fig. 77

36 1326520B_EN 16/11/2018 Toyota LC150

12 Combustion air
Mounting combustion air intake silencer
1 Observe the installation instructions of the
L
F
combustion air intake silencer.
s1
1 Combustion air intake silencer

Fig. 78
1 1 1 Cable tie

Fig. 79

Toyota LC150 16/11/2018 1326520B_EN 37

13 Electrical system of passenger compartment
13.1 Electrical system preparation
Preparing / assigning wiring harness and wires
Wire sections retain their numbering in the en-
tire document.

rt Red (rt) wire of fan wiring harness

1 0,5²
sw Black (sw) wire of fan wiring harness
2 0,5² Red (rt) wire (for all vehicles)
Red (rt) wire (only in case of 3 zone automatic
air-conditioning)

50 51 rt
0,5²
100 100

Fig. 80
Premounting wiring harness and wires
Only in case of manual air-conditioning and 2-
zone automatic air-conditioning.

1 6.3mm blade receptacle

1 Red (rt) wire of fan wiring harness
50 rt
Black (sw) wire of fan wiring harness
1 rt
0,5² 6.3
1 0,5²
6.3
sw
2 0,5²

Fig. 81

Only in case of 3 zone automatic air-condition-

ing.

2 rt
1 4.8mm blade receptacle
51 1
6.3 0,5² 2 6.3mm blade receptacle
50 rt
Red (rt) wire of fan wiring harness
2 rt
0,5² 4.8

1 0,5²
Black (sw) wire of fan wiring harness
6.3
sw
2 0,5²

Fig. 82

38 1326520B_EN 16/11/2018 Toyota LC150

Assigning wires
Green (gn) wire from wiring harness of PWM
control
Green/black (gn/sw) wire from wiring harness of
gn PWM control
3 0,5²
White (ws) wire of isolating relay wiring harness
gn/sw
4 0,5²
(only for vehicles with 3 zone automatic air-con-
ditioning)
ws Black/white (sw/ws) wire of isolating relay wiring
18 0,5² harness (only for vehicles with 3 zone automatic
sw/ws air-conditioning)
19 0,5²

Fig. 83
View of PWM Gateway
u Check PWM Gateway settings when starting-up the
heater, adjust if necessary.

Parameters Setting
Duty cycle 60%
IN
Frequency 500Hz
KL 15
GND SH Voltage not relevant
OUT Function Low side

Fig. 84

Connecting wires to PWM GW socket

PWM
__ IN __
2.8 2.8
gn 6.3
3
0,5²

GND KL15 SH
6.3 6.3 6.3
gn/sw
4
0,5²
__ OUT __
6.3
2.8 2.8

Fig. 85

Toyota LC150 16/11/2018 1326520B_EN 39

13.1.1 Manual air-conditioning and 2 zone automatic air-conditioning
Preparing RSH and PWM Gateway socket
u Connect wires.
u Connect connector and socket.
u Assemble RSH and PWM GW socket together.

br rt rt/sw gn/ws
0,5² 4² 0,5² 0,5²

gn
3 RSH
0,5²

F4 F3 F5
4.8 4.8 4.8
gn/sw
4
0,5² F4 F3 F5
4.8 4.8 4.8
PWM

__ sw
IN 2
2.8 __ __ 0,5²
6.3 30
rt 2.8 2.8
6.3
50 rt
0,5² 1
0,5²
GND KL15 SH 85 86
6.3 6.3 6.3 87a
6.3 6.3 6.3

__ OUT __ __ 87 __
6.3 2.8 6.3 2.8
2.8 2.8

Fig. 86

40 1326520B_EN 16/11/2018 Toyota LC150

13.1.2 3 zone automatic air-conditioning
Preparing relay K2
u Uncrimp blue (bl) wires with blade receptacle from socket of terminal 86.
u Secure open blade receptacles either by using the provided receptacle housings or by insulating them individually
with insulating tape as shown.

rt rt
0,5²
0,5²
ge ge
0,5² 0,5²
bl
0,5²

K2 K2
30 30
6.3 6.3

87 bl 1. 2. 87
6.3 3. 6.3
0,5²

85 87a 86 85 87a 86
4.8 4.8 4.8 4.8 4.8 4.8

CLICK

2x 0x

rt rt
0,5²
0,5²
ge ge
0,5² 0,5²
bl bl
0,5² 0,5²

K2 K2
30 30
6.3 6.3

87 87
6.3 6.3

85 87a 86 85 87a 86
4.8 4.8 4.8 4.8 4.8 4.8

Fig. 87

Toyota LC150 16/11/2018 1326520B_EN 41

Mounting wires
u Connect wires to relay K2 socket

K2
30 19
sw/ws
6.3 0,5²

87 ws
18
6.3 0,5²

85 87a 86
4.8 4.8 4.8

Fig. 88

Preparing RSH, relay K2 socket and PWM Gateway socket

u Connect wires.
u Connect connectors and sockets.
u Assemble RSH , relay K2 socket and PWM GW socket together.

br rt rt/sw gn/ws
0,5² 4² 0,5² 0,5²
ws
18
0,5²
gn RSH
3
0,5²
sw/ws
19 F4 F3 F5
gn/sw 0,5² 4.8 4.8 4.8
4
0,5²
F4 F3 F5
4.8 4.8 4.8
PWM
K2 rt
50 sw
__ __ 0,5² 2
2.8
IN 2.8 0,5²
6.3 30 __ 30 __
rt 6.3 2.8 2.8
6.3 rt
51
0,5² 1
87 0,5²
GND KL15 SH 6.3 85 86
6.3 6.3 6.3 87a
6.3 6.3 6.3

85 87a 86
__ OUT __ 4.8 4.8 4.8 __ 87 __
2.8 6.3 2.8 2.8 6.3 2.8

Fig. 89

42 1326520B_EN 16/11/2018 Toyota LC150

13.2 System wiring diagrams
13.2.1 System wiring diagram for manual air-conditioning and 2-zone automatic A/C

Webasto Toyota
30
rt
15
6² HG

F2 F1
Fx1

br rt/sw rt gn/ws
0,5² 0,5² 4² 0,75²
X10
br rt/sw rt gn/ws
0,5² 0,5² 4² 0,5²

F4 F3
bl
0,5²
rt
0,5²
1
K1
sw
0,5² 2
bl
0,5²

23 1 A
bl
0,5²
PWM gn
3
KSG
0,5²
GW
gn/sw
0,5² 4
bl
0,5²

C 2

GE-V M
br
4²
31

Fig. 90

Toyota LC150 16/11/2018 1326520B_EN 43

13.2.2 System wiring diagram for 3 zone automatic air-conditioning

Webasto Toyota
30
rt
15
6² HG

F2 F1
Fx1

br rt/sw rt gn/ws
0,5² 0,5² 4² 0,75²

X10
br rt/sw rt gn/ws
0,5² 0,5² 4² 0,5²

F4 F3
bl
0,5²
rt
0,5²
1
K1
sw
0,5² 2
bl
0,5²

GE-H M

3 D

ws
30 sw/ws 0,5²
19
0,5²
K2 ws
0,5² 18
87
ws
0,5²

22 B 1 23 A

KSG
bl
0,5²
PWM gn
0,5²
3
GW
gn/sw
0,5² 4
bl
0,5²

C 2

GE-V M
br
4²
31
Fig. 91

44 1326520B_EN 16/11/2018 Toyota LC150

13.2.3 Legend to the system wiring diagrams
Vehicle components Symbols
Abbreviation Component Abbreviation Explanation
Fx1 Fuse X Cutting point
KSG Air-conditioning control unit
A KSG connector
B KSG connector
GE-V Fan unit for front area
C Connector of GE-V
GE-H Fan unit for rear area
D Connector of GE-H

Webasto components Cable colours

Abbreviation Component Abbreviation Colour
A Connector of CLR module wiring harness br brown
B Socket of CLR module wiring harness bg beige
CCL GW CAN CAN LIN Gateway dbl dark blue
CL GW CAN LIN Gateway dgn dark green
CLR Cold start module ge yellow
D1 Diode gn green
D2 Diode group gr grey
F0 Additional fuse for power supply hbl light blue
F1 Heater main fuse hgn light green
F2 Passenger compartment fan controller main fuse or orange
F3 Heater control fuse pk pink
F4 Fan controller fuse rt red
F5 Additional fuse sw black
HG Heater TT-Evo vi violet
K1 Relay K1 ws white
K2 Relay K2
K3 Relay K3
LIN GW LIN Gateway
PWM GW Pulse width modulator gateway
RSH Relay and fuse holder of passenger compartment
RTD Temperature sensor
X10 4-pin socket of heater control

Toyota LC150 16/11/2018 1326520B_EN 45

13.3 Fan controller
Moving original vehicle wiring harness
1 2 u Detach clip-type cable tie 1 from original vehicle wir-
ing harness 2 .

Fig. 92
u Fastenoriginal vehicle wiring harness 2 using cable tie
1 as shown.

2 1
Fig. 93
Mounting RSH
1 2 The figure shows a vehicle with a 3 zone auto-
matic air-conditioning but it applies to all
vehicles.

Produce all following electrical connections as

shown in the system wiring diagram.

1 Fuse F4:10A
3 2 M5x16 bolt, large diameter washer with 15mm
outer dia., RSH, original vehicle hole, large dia-
meter washer with 22mm outer dia., large dia-
meter washer with 15mm outer dia., M5
flanged nut
2
3 Premounted RSH
Fig. 94

46 1326520B_EN 16/11/2018 Toyota LC150

Mounting PWM GW and relay
1 PWM GW
2 Relay K2 (only in case of 3 zone automatic air-
conditioning)
3 Relay K1
1

Fig. 95
Connecting same colour wires of wiring harnesses
1 1 Wiring harness of passenger compartment relay
and fuse holder
2 Heater wiring harness

2
Fig. 96
View of A/C control unit connector
1 KSG connector A
2 KSG connector B
4 3 Slot for connector B
4 Slot for connector A
3

1
Fig. 97

Toyota LC150 16/11/2018 1326520B_EN 47

Connection to air-conditioning control unit
Produce all the following electrical connections only with shrinkable butt connectors.
u 1. crimp
u 2. shrink

1 2 1 Blue (bl) wire of KSG connector A / pin 1

2 Blue (bl) wire of fuse Fx1
3 Air-conditioning control unit connector A
Red (rt) wire of K1/87a fan wiring harness
3 Black (sw) wire of K1/30 fan wiring harness
View of KSG connector A on wiring side:
1

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
2 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21

Fig. 98
1 3 1 Blue (bl) wire of KSG connector A / pin 23
2 Blue (bl) wire of GE-V connector C / pin 2
3 Air-conditioning control unit connector A
Green (gn) wire of PWM GW/IN wiring harness
3 from PWM control
Green/black (gn/sw) wire of PWM GW/OUT wir-
ing harness from PWM control
4
View of KSG connector A on wiring side:

2
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21

Fig. 99
1 18 Only necessary in case of vehicles with 3 zone
3 automatic air-conditioning.

1 White (ws) wire of KSG connector B / pin 22

2 White (ws) wire of GE-H connector D / pin 3
19 3 Air-conditioning control unit connector B
White (ws) wire of K2/87 from isolating relay
wiring harness
Black/white (sw/ws) wire of K2/30 from isolating
2 relay wiring harness
View of KSG connector B KSG on wiring side:

Fig. 100
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13

48 1326520B_EN 16/11/2018 Toyota LC150

14 Electrical system of control elements
14.1 MultiControl CAR option
Mounting MultiControl CAR
1 1 MultiControl CAR

Fig. 101
14.2 Telestart option
Mounting receiver
1 2 Observe the Telestart installation documenta-
tion.

u Widen
existing oblong hole 1 in receiver bracket to
6.5mm.
2 Receiver
3 M6x16 bolt, receiver bracket, original vehicle
3 thread

Fig. 102
Mounting temperature sensor, only in case of T100 HTM
u Fasten temperature sensor 1 with a cable tie.

1
Fig. 103

Toyota LC150 16/11/2018 1326520B_EN 49

Mounting aerial
1 1 Aerial

Fig. 104
14.3 ThermoCall option
Mounting receiver
1 Observe the ThermoCall installation document-
ation.

u Fasten receiver 1 using double-sided adhesive tape.

Fig. 105
Mounting aerial (optional)
1 1 Aerial

Fig. 106

50 1326520B_EN 16/11/2018 Toyota LC150

15 Final Work

Further information can be found in the vehicle manufacturer's technical documentation.

u Mount removed parts in reverse order.

u Check all hoses, clamps and all electrical connections for firm seating.
u Insulate and tie back loose lines
u Spray heater and electrical components with anti-corrosion wax (Tectyl 100K).
u Connect the battery. Tectyl
(Wachs)

Only use manufacturer-approved coolant.

u Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.

Further information can be found in the general installation and operating instructions of the
Webasto components.
u Program MultiControl CAR, teach Telestart transmitter
u Make settings on A/C control panel according to the ‘Operating Instructions‘.
u Initial operation and functional test
u Affix ‘Switch off parking heater before refueling’ caution label in area of filler neck

Toyota LC150 16/11/2018 1326520B_EN 51

 Ident No. 1326520B_EN • 11/18 • Errors and omissions excepted • © Webasto Thermo & Comfort SE • 2018
These are the original instructions. The German language is binding.
You can request your language if it is missing. The telephone number of each country can be found in the Webasto service centre
leaflet or the website of the respective Webasto representative of your country.

Webasto Thermo & Comfort SE

Postfach 1410
82199 Gilching
Germany

Company address:
Friedrichshafener Str. 9
82205 Gilching
Germany

Technical Extranet: https://dealers.webasto.com

Only within Germany

Tel: 0395 5592 444
E-mail: [email protected] WWW.WEBASTO.COM

52 Toyota LC150
16 Operating instructions for manual air-conditioning
Information regarding the heating time:
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.

Vehicles with passenger compartment monitoring:

Further information can be found in the vehicle operating instructions.
u Deactivate passenger compartment monitoring for the heating operation

Note for parking heater function

Your vehicle is equipped with a passenger compartment and engine preheating unit.

16.1 A/C control panel settings

Manual air-conditioning control panel
2 1

No need to pre-select the fan speed.

Before parking the vehicle, make the following
settings:

1 Air outlet to windscreen / footwell

2 Set temperature to ‘max.’

Fig. 107
16.2 Installation location of fuses
Fuses in engine compartment
1 F1 - 20A heater fuse (yellow)
2 F2 - 30A passenger compartment main fuse
(light green)

2 1
Fig. 108

Toyota LC150
Fuses in passenger compartment
1 F3 - 1A control element fuse (black)
2 F4 - 10A fan controller fuse (red)

Fig. 109

Toyota LC150
17 Operating instructions for 2 and 3 zone automatic air-
conditioning
Information regarding the heating time:
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.

Vehicles with passenger compartment monitoring:

Further information can be found in the vehicle operating instructions.
u Deactivate passenger compartment monitoring for the heating operation

Note for parking heater function

Your vehicle is equipped with a passenger compartment and engine preheating unit.

17.1 A/C control panel settings

2 / 3 zone automatic air-conditioning control panel
1 1 No need to pre-select the fan speed.
Before parking the vehicle, make the following
settings:

1 Temperature on both sides to ‘HI’

2 Air outlet to windscreen / footwell

2
Fig. 110
17.2 Installation location of fuses
Fuses in engine compartment
1 F1 - 20A heater fuse (yellow)
2 F2 - 30A passenger compartment main fuse
(light green)

2 1
Fig. 111

Toyota LC150
Fuses in passenger compartment
1 F3 - 1A control element fuse (black)
2 F4 - 10A fan controller fuse (red)

Fig. 112

Toyota LC150