Webasto Ford Focus Bedienungsanleitung

Water Heater Unit

Installation Instructions

WARNING!

Hazard warning:

Incorrect installation or repair of Webasto heating systems may cause a fire or result

in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can

be caused as a result.

Specialist company training, technical documentation, specialized tools and

equipment are required to install and repair Webasto heating and cooling systems.

NEVER attempt to install or repair Webasto heating or cooling systems if you have not

successfully completed the company training and thereby acquired the required

technical skills, or if you do not have access to the required technical documentation,

tools and equipment needed to carry out correct installation and repairs.

ALWAYS follow all Webasto installation and repair instructions and observe all

warnings.

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

installation by untrained staff.

Feel the drive

Ford Focus / Focus C-MAX / Focus CC

Gasoline

from Model Year 2004

For left-hand drive vehicles only

Thermo Top E Additional Heater e1

00 0003

Ident. No.: 1303854E_EN Fee Euro 10 © Webasto AG

Ford Focus / Focus C-MAX / Focus CC

Validity

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

instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructionsmay

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 Gasoline 59 1388

ASDB Gasoline 59 1388

HWDB Gasoline 74 1596

HXDA Gasoline 85 1596

Q7DA Gasoline/Flexifuel 92 1798

QQDB Gasoline 92 1798

AODA Gasoline 107 1999

AODB Gasoline 107 1999

Validity 2

Heater Unit/Installation Kit 3

Foreword 3

Special Tools 3

Explanatory Notes on the Document 3

Preliminary Work 5

Heater Unit Installation Location 5

Preparing Electrical System 6

Electrical Connection on Focus 7

Electrical Connection on Focus/Focus CC

from 2008 8

Electrical Connection on C-MAX 9

Fan Controller without Automatic

Air-Conditioning 10

Automatic Air-Conditioning Fan Controller 11

In Addition with Automatic Air-Conditioning

from 12/05 12

Remote Option (Telestart) 15

Thermo Call Option on Focus 16

Thermo Call Option on C-MAX 17

Preparing Installation Location 18

Premounting Coolant Connection 20

Preassembling Heater Unit 21

Fastening for Underride Protection 22

Installing Heater Unit 23

Coolant Connection 25

Fuel Connection 26

Installing Underride Protection 29

Final Work 30

Operating Instructions for End Customer 31

Table of Contents

Ford Focus / Focus C-MAX / Focus CC

Heater Unit/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

The installation instructions apply to the Ford Focus / Focus C-MAX / Focus CC vehicles with a

Gasoline engine

- For the 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 these installation

instructions.

However,thestipulations in the "installationinstructions"and"operatingandmaintenanceinstructions"

for the Thermo Top C/P/E must always 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

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 100K, Order No.

111329).

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)

Quantity Description Order No.:

1 Ford Delivery Scope for Focus/ Focus C-MAX Gasoline without Heater

Control 1303858C

1 Original Fuel Standpipe with Ford Finis Code 1233999

Quantity Description Order No.:

1 Digital Timer 9010869A

1 Telestart T80 9010870A

1 Telestart T100 HTM 9010148C

1 Thermo-Call Connect, Comfort, Locate See price list

Quantity Description Order No.:

1 Kit for Automatic Air-Conditioning on Ford Focus/Focus C-MAX 9012822A

Quantity Description Order No.:

1 Kit for Automatic Air-Conditioning on Ford Focus/Focus C-MAX 9015495A

Special features are highlighted using the following symbols:

Mechanical work

Electrical connection

Coolant connection

Fuel connection

Exhaust system

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.

Reference to general installation instructions of

Webasto components or to the manufacturer's vehicle-

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 unit installation location

Photo shows 1.8 liter

1Heater unit

Installa-

tion loca-

tion

WARNING!

- Open fuel tank cap, ventilate tank.

- Close the tank cap again.

- Disconnect the battery "earth" or "ground" connection.

-Depressurizethe 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 footwell on the front passenger side.

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

manufacturer's specifications.

Prelimi-

nary Work

Ford Focus / Focus C-MAX / Focus CC

Preparing electrical system

Only with automatic air-conditioning

Connect additional green/white (gn/ws)

wire 5to K3/86 and pull into protective

sleeving. Wiring

diagram

for

additional

wire

Connect lines provided 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

Heater

0,75mm²

86 85

IPCU

0,75mm² 4

Ford Focus / Focus C-MAX / Focus CC

Electrical Connection on 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, relay K3

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.

2Ground wire on negative battery terminal

3Positive wire on positive battery terminal

rt br

Donot installthe meteringpump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the

underbody

1 2 3

Ford Focus / Focus C-MAX / Focus CC

Electrical Connection on 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, relay K3

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.

2Ground wire on negative battery terminal

3Positive wire on positive battery terminal

rt br

Donot installthe meteringpump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the

underbody

1 2 3

Ford Focus / Focus C-MAX / Focus CC

Electrical Connection on C-MAX

Wiring harness pass through

1Protective rubber plug detached

Digital timer

1Digital timer

1Summer/winter switch, drilled hole 12 mm dia.

Wiring

harness

installa-

tion dia-

gram

for C-Max

Fuse holder, relay K3

Fastening will not be carried out until later after

reinstalling the coolant reservoir cap! When

drilling, 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 ground 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.

rt br

Donot installthe meteringpump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the

underbody

1 2

Ford Focus / Focus C-MAX / Focus CC

Fan Controller without Automatic

Air-Conditioning

Connection is carried out on connector C111,

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

Produce connections as shown in wiring

diagram with blade connectors provided.

3Connector C111

1Red (rt) wire to K3/87a

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

vehicle 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 Colors and symbols

Legend

HG Heater unit TT-C/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 Focus/ Focus C-Max

without autom. air-conditioning

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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