Webasto Thermo Top Evo Installation Documentation
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Webasto Thermo Top Evo Installation Documentation

Parking heater for ford focus / c-max / grand c-max
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Download this manual See also: Workshop Manual, Installation Documentation
Water Heater
Thermo Top Evo Parking Heater
Installation documentation
Ford Focus / C-Max / Grand C-Max
Diesel
from model year 2011
Left-hand drive vehicle
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.: 1316981B_EN
e1
00 0258
Fee Euro 10.00
Feel the drive
© Webasto AG

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Summary of Contents for Webasto Thermo Top Evo

  • Page 1 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.

  • Page 2: Table Of Contents

    Ford Focus / C-Max / Grand C-Max Table of contents Validity Preparing installation location Heater/installation kit Preparing heater Foreword Installing heater General instructions Coolant circuit Special tools Combustion air Explanatory notes on document Fuel Preliminary work Exhaust gas Heater installation location Final Work Preparing electrical system Operating instructions for end customer...

  • Page 3: Heater/Installation Kit

    However, where this is the case, the stipulations in this "installation documentation" the "operating in- structions" and "installation instructions" of the Thermo Top Evo should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work.

  • Page 4: Explanatory Notes On Document

    Ford Focus / C-Max / Grand C-Max 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...

  • Page 5: Preliminary Work

    Ford Focus / C-Max / Grand C-Max Preliminary work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the fuel tank cap again. - Depressurise the cooling system. - Copy the factory number from the original type label to the duplicate type label. - Remove year that does not apply from the duplicate label.

  • Page 6: Preparing Electrical System

    Ford Focus / C-Max / Grand C-Max Preparing electrical system rt/sw gn/ws Wire sections retain their numbering in the 0,5² 4² 0,75² entire document. All equipment Inserting Connect wires to socket of K1 relay. Insert F4 Preparing 25A fuse. K1 relay is inserted only after in- K1 relay stalling the fuse holder.

  • Page 7: Electrical System

    Ford Focus / C-Max / Grand C-Max Electrical system Focus Plus and earth wire Wiring harness pass through 1 Earth wire, 8 mm dia. cable lug at original ve- 1 Protective rubber plug hicle earth support point 2 Positive wire on positive battery terminal Wiring har- ness rout- diagram...
  • Page 8 Ford Focus / C-Max / Grand C-Max C-Max / Grand C-Max Plus and earth wire Wiring harness pass through 1 Earth wire, 8 mm dia. cable lug at original ve- 1 Protective rubber plug hicle earth support point 2 Positive wire on positive battery terminal Wiring har- ness rout- diagram...

  • Page 9: Fan Control For Manual Air Conditioning

    0,5² 4² 0,75² 0,5² 2H403 4² 2H123 2H105 0,5² 4² 0,5² Webasto components Vehicle components Colours and symbols Heater TT-Evo 2H403 Resistor group 6-pin heater connector C2 Connector 2H403 black 2-pin heater connector 2H123 Fan motor yellow 4-pin connector...
  • Page 10 Ford Focus / C-Max / Grand C-Max Focus 1 6.5 mm dia. hole Hole for passenger compart- ment fuse holder Mount K1 relay 5 after installation. 1 M5x16 bolt, large diameter washer [2x], nut 2 Angle bracket 3 M6x20 bolt, flanged nut 4 Fuse holder of passenger compartment Mounting fuse holder...

  • Page 11: Automatic Air-Conditioning Fan Control

    4² 0,75² 2H102 0,5² 0,5² 0,5² 0,5² IPCU 2H101 2H123 0,5² 0,5² Webasto components Vehicle components Colours and symbols Heater TT-Evo 2H102 Fan controller 6-pin heater connector C1 Connector 2H102 black 2-pin heater connector C3 Connector 2H102 yellow 4-pin connector...
  • Page 12 Ford Focus / C-Max / Grand C-Max Focus 1 M5x16 bolt, large diameter washer [2x], nut 2 Angle bracket 3 Fuse and relay socket 4 Mount IPCU socket Premount- ing K1 re- 1 M6x20 bolt, flanged nut Mounting fuse holder of passen- ger com- partment...
  • Page 13 Ford Focus / C-Max / Grand C-Max Connect to connector C2 3 Pin15 from A/C control unit. Produce connections as shown in wiring diagram. 1 White/violet (ws/vi) wire to fan controller 2H102 2 White/violet (ws/vi) wire from connector C2, Connect- Pin 15 ing A/C ...

  • Page 14: Remote Option (Telestart)

    Ford Focus / C-Max / Grand C-Max Connect to socket connector C21 3 Pin 24 before the fan controller. Produce connections as shown in wiring dia- gram. 1 Green/violet (gr/vi) wire to fan controller 2H102 Connect- 2 Gray/violet (gr/vi) wire to fan relay R13 ing fan ...
  • Page 15 Ford Focus / C-Max / Grand C-Max Focus Angle down bracket of receiver 2 as shown. 1 M6x20 bolt, flanged nut, existing hole 3 Receiver Mounting receiver 1 Antenna Mounting antenna Temperature sensor T100 HTM All vehicles Fasten temperature sensor 2 with cable tie 1 to original vehicle wiring harness.

  • Page 16: Preparing Installation Location

    Ford Focus / C-Max / Grand C-Max Preparing installation location Mount M8 flanged nut 2 on original vehicle stud bolt with flange in front (turn by a half). 1 M8x20 spacer nut, original vehicle stud Mounting bolt installa- tion loca- tion Preparing heater 1 Coolant connecting piece, sealing ring [2x...
  • Page 17 Ford Focus / C-Max / Grand C-Max Discard section X . 1 Combustion air pipe a = 600 Cutting combus- tion air pipe to length 1 Combustion air pipe 2 25 mm dia. spring clip Mounting combus- tion air pipe 1 M4x12 bolt, nut from the rear Mounting twist lock...
  • Page 18 Ford Focus / C-Max / Grand C-Max 1 93 exhaust end section 2 Hose clamp [3x] 3 Exhaust pipe 200 Mounting exhaust pipe Discard section X . Hose A = 180°, 18 mm dia. moulded hose. Hose B = 90°, 18 mm dia. moulded hose. Cutting hose to length...

  • Page 19: Installing Heater

    Ford Focus / C-Max / Grand C-Max Installing heater 1 Bracket 2 M8x20 bolt, washer, flanged nut, existing hole [2x each] Loosely mounting heater Mount heater on original vehicle stud bolt 1 , install M8 flanged nut 2 loosely. Loosely mounting heater Align heater.

  • Page 20: Coolant Circuit

    Ford Focus / C-Max / Grand C-Max Coolant circuit WARNING! Any coolant running off should be collected in an appropriate container. Route hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged.
  • Page 21 Ford Focus / C-Max / Grand C-Max Cut hose of engine outlet / heat exchanger in- let at the markings. 1 Hose section of heat exchanger inlet 2 Engine outlet hose section 3 Discard section Cutting point 1 Hose on heat exchanger inlet Connect- ing heat exchanger...

  • Page 22: Combustion Air

    Ford Focus / C-Max / Grand C-Max Combustion air Drill out angle bracket 2 on the short shank to 8.5 mm dia. 1 M8x15 spacer nut, original vehicle stud bolt Fastening 3 25 mm dia. rubber-coated p-clamp [2x] hose C and 4 M6x20 bolt, flanged nut combus- 5 M8 flanged nut...

  • Page 23: Fuel

    Ford Focus / C-Max / Grand C-Max Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Collect any discharged fuel in an appropriate container. Install fuel line and metering pump wiring harness so that they are protected against stone impact. Un- less specified otherwise, always fasten using cable ties.
  • Page 24 Ford Focus / C-Max / Grand C-Max Remove fuel tank according to manufactur- er's instructions. Cut off fuel supply line 2 at position 1 . Removing fuel 1 Paste insulation strip 2 8x5x8 fuel standpipe, 10 mm dia. hose clamp [2x] 3 Fuel line 4 Hose section, 10 mm dia.
  • Page 25 Ford Focus / C-Max / Grand C-Max 1 Perforated bracket 2 Original vehicle bolt 3 Fuel line of fuel standpipe in corrugated tube 4 10 mm dia. clamp Mounting metering pump Check the position of the components; adjust if necessary. Check that they have freedom of movement.
  • Page 26 Ford Focus / C-Max / Grand C-Max Detach retaining clip of original vehicle wiring harness 1 at Position 2 . 2 Drill out 9.1 mm dia. hole, rivet nut Installing rivet nut 1 M6x20 bolt, spring lockwasher 2 Perforated bracket Mounting metering pump...

  • Page 27: Exhaust Gas

    Ford Focus / C-Max / Grand C-Max Exhaust gas 1 Drill out 9.1 mm dia. hole, rivet nut Installing rivet nut 1 Exhaust end section 2 M6x20 bolt, flanged nut 3 Angle bracket 4 M6x20 bolt, spring lockwasher, large diam- eter washer 5 P-clamp Mounting...

  • Page 28: Final Work

    1 . Ensure sufficient distance from neighbouring components. Aligning exhaust end sec- tion Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: technikcenter@webasto.com http://www.webasto.com...

  • Page 29: Operating Instructions For End Customer

    Ford Focus / C-Max / Grand C-Max 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. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.

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