Webasto Thermo Top E Bedienerhandbuch

Feel the drive

Water Heater

Installation documentation

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, specialised tools and equipment are

required to install and repair Webasto heating and cooling systems.

Only original Webasto parts must be used. For this, also see the catalog of air and water heat-

er 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 tech-

nical 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 startup is to be executed with the Webasto Thermo Test Diagnosis.

Webasto does not accept any liability for defects and damage that are attributable to installa-

tion by untrained staff.

Ident. No.: 1303854F_EN Fee Euro 10.00 © Webasto AG

Ford Focus / Focus C-MAX / Focus CC

Petrol

from Model Year 2004

For left-hand drive vehicles only

Thermo Top E Parking Heater

00 0003

Ford Focus / Focus C-MAX / Focus CC

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation

documentationhavenot beentested. However,installationaccordingtothis installationdocumentation

may be possible.

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

customer before installation.

Manufacturer Model Type EG-BE-No. / ABE

Ford Focus DA3 e13*2001 / 116*0144

Ford Focus DB3 e13*2001 / 116*0144

Ford Focus C-MAX DM2 e13*2001 / 116*0109

Ford Focus CC DB3 e13*2001 / 116*0157

Engine type Engine model Output in kW Displacement in cm³

ASDA Petrol 59 1388

ASDB Petrol 59 1388

HWDB Petrol 74 1596

HXDA Petrol 85 1596

Q7DA Petrol/Flexifuel 92 1798

QQDB Petrol 92 1798

AODA Petrol 107 1999

AODB Petrol 107 1999

Validity 2

Heater/installation kit 3

Foreword 3

General instructions 3

Special tools 3

Preliminary work 5

Heater installation location 5

Preparing electrical system 6

Electrical system of Focus 7

Electrical system for Focus/Focus CC from 2008 8

Electrical system of C-Max 9

Fan control without automatic A/C 10

Automatic A/C fan control 11

Additionally for automatic A/C from 01/06 13

Remote option (Telestart) 15

Preparing installation location 16

Premounting heater 18

Fastening for underride protection 19

Installing heater 19

Coolant circuit 21

Fuel 23

Mounting underride protection 26

Final Work 27

Operating instructions for end customer 28

Table of contents

Ford Focus / Focus C-MAX / Focus CC

Heater/installation kit

Additionally required optional heater control:

Additionally required with automatic air-conditioning up to 2005 Model Year:

Additionally required with automatic air-conditioning from 2006 Model Year:

Foreword

This installation documentation applies to Ford Focus / Focus C-MAX / Focus CC vehicles with Petrol

engine - for validity, see page 2 - from model year 2004 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 doc-

umentation.

However, where this is the case, the stipulations in this "installation documentation" the "operating in-

structions" and "installation instructions" of the Thermo Top E should be observed.

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 spec-

ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses

using cable ties.

Sharp edges must be provided with rub protection (cut-open fuel hose)!

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).

When installing an IPCU, the corresponding settings must be checked or adjusted before installation.

Special tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit for M6 aluminum rivet nut

- Metric thread-setter kit for M10 steel rivet nut (e.g. Würth Order No. 0964948900)

Quan-

tity Designation Order No.:

Ford Delivery Scope for Focus/ Focus C-MAX

Petrol without heater control 1303858C

1 Original fuel standpipe with Ford Finis Code 1233999

Quan-

tity Designation Order No.:

1 Digital timer See price list

1 Telestart See price list

Quan-

tity Designation Order No.:

1 Kit for automatic air-conditioning on Ford Focus/Focus C-MAX 9012822A

Quan-

tity Designation Order No.:

1 Kit for automatic air-conditioning on Ford Focus/Focus C-MAX 9015495A

Special features are highlighted using the following symbols:

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Ford Focus / Focus C-MAX / Focus CC

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Referenceto generalinstallationinstructions ofWebas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

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.

Ford Focus / Focus C-MAX / Focus CC

Heater installation location

Figure shows 1.8 lt engine

1Heater

Installa-

tion loca-

tion

Preliminary work

Warning!

- Open the fuel tank cap and vent the fuel tank.

- Close the fuel tank cap again.

- Disconnect the battery earth connection.

-Depressurisethe 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 engine cover (if present).

- C-MAX only: remove the coolant reservoir trim completely at the top and bottom.

- Remove the underride protection (if present).

- Remove the underbody trim in front of the right rear wheel (no further use).

- Remove the fuel tank according to the manufacturer's instructions.

- Remove the glove compartment.

- Remove the A-pillar trim in the front passenger side footwell.

- Only with automatic air-conditioning: Remove the A/C control panel according to the manufactur-

er's specifications.

Ford Focus / Focus C-MAX / Focus CC

Preparing electrical system

Only with automatic air-conditioning

Connect additional green/white (gn/ws) wire

to K3/86 and pull into protective sleeving.

Wiring dia-

gram for

additional

wire

Connect provided wires to IPCU as shown in

wiring diagram.

Connect 6 mm dia. cable lug to end of brown

(br) wire from IPCU/85 3.

Premount-

ing IPCU

connec-

tion

rt/ws

gn/ws

87a8786

85 30

0,75mm²

86 85

IPCU

0,75mm² 4

Ford Focus / Focus C-MAX / Focus CC

Electrical system of Focus

Wiring harness pass through

1Protective rubber plug detached

Digital timer

1Digital timer

2Summer/winter switch, drilled hole 12 mm dia.

Diagram

of wiring

harness

routingfor

Focus

Fuse holder, K3 relay

When drilling, watch components located behind.

2K3 relay, 4 mm dia. hole, 5.5x13 self-tapping

screw

3Fuse holder, 4 mm dia. hole, 5.5x13 mm self-

tapping screw

1Wiring harnesses routed to right and fastened

with cable ties

Connection to battery

Route wires (1) to left and fasten with cable ties.

2Earth wire on negative battery terminal

3Positive wire on positive battery terminal

Do not install the metering pump

wiring harness until later togeth-

erwithfuelline alongtheoriginal

vehicle fuel lines on the under-

body

1 2 3

Ford Focus / Focus C-MAX / Focus CC

Electrical system for Focus/Focus CC from 2008

Wiring harness pass through

1Protective rubber plug detached

Digital timer

1Digital timer

Diagram

of wiring

harness

routingfor

Focus

Fuse holder, K3 relay

When drilling, watch components located behind.

2K3 relay, 4 mm dia. hole, 5.5x13 self-tapping

screw

3Fuse holder, 4 mm dia. hole, 5.5x13 mm self-

tapping screw

1Wiring harnesses routed to right and fastened

with cable ties

Connection to battery

Route wires (1) to left and fasten with cable ties.

2Earth wire on negative battery terminal

3Positive wire on positive battery terminal

Donotinstallthe meteringpump

wiring harness until later togeth-

erwithfuellinealongtheoriginal

vehicle fuel lines on the under-

body

1 2 3

Ford Focus / Focus C-MAX / Focus CC

Electrical system of C-Max

Wiring harness pass through

1Protective rubber plug detached

Digital timer

1Digital timer

2Summer/winter switch, drilled hole 12 mm dia.

Wiring

harness

routing di-

agram for

C-Max

Fuse holder, K3 relay

Fastening will not be carried out until later after

reinstalling the coolant reservoir cap. When drill-

ing, watch components located behind.

1Fuse holder, 4 mm dia. hole, 5.5x13 mm self-

tapping screw

2K3 relay, 4 mm dia. hole, 5.5x13 self-tapping

screw

Wiring harness routing

Connect earth wire to negative battery pole and

positive wire to positive battery pole.

Route wiring harness (1) to right and fasten with

cable ties as shown.

Donotinstallthe meteringpump

wiring harness until later togeth-

erwith fuellinealongtheoriginal

vehicle fuel lines on the under-

body

1 2

Ford Focus / Focus C-MAX / Focus CC

Fan control without automatic A/C

Connection is carried out on connector C111,

Pin 22, at bottom of right-hand A-pillar.

Produce connections as shown in wiring dia-

gram with blade connectors provided.

3Connector C111

1Red (rt) wire to K3/87a

2Green/orange (gn/or) wire from original ve-

hicle fan relay K14

4Wire to connector C111, Pin 22

5Black (sw) wire from K3/30

Connect-

ing fan

motor

Wiring dia-

gram with-

out

automatic

air-condi-

tioning

Webasto components Ford components Colours and symbols

Legend

HG Heater TT-E F10 Fan fuse rt red

F3 Fan fuse K14 Fan relay ws white

K3 Fan relay P91 Central electrical box sw black

C111 Connectoronright-hand

A-pillar br brown

gn green

M3 Fan motor bl blue

R21 Resistor group or orange

A128 Heater control module

23 Fan switch XCutting point

gn/ws

rt/ws

Webasto

Ford

25A

F10

30A

87a8786

85 30

P91

C95

22 C111

R21

A128

(23)

K14

sw/bl gn/or

gn/or

sw/rt

sw/or

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