Webasto Thermo Top E Installation Documentation
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Webasto Thermo Top E Installation Documentation

Parking heater for ford focus / focus c-max / focus cc
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Download this manual See also: Instructions for Using, Installation Documentation
Water Heater
Thermo Top E Parking Heater
Installation documentation
Ford Focus / Focus C-MAX / Focus CC
Petrol
from Model Year 2004
For left-hand drive vehicles only
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
e1
00 0003
Fee Euro 10.00
Feel the drive
© Webasto AG

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Summary of Contents for Webasto Thermo Top E

  • 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 / Focus C-MAX / Focus CC Table of contents Validity Preparing installation location Heater/installation kit Premounting heater Foreword Fastening for underride protection General instructions Installing heater Special tools Coolant circuit Preliminary work Fuel Heater installation location Mounting underride protection Preparing electrical system Final Work Electrical system of Focus...

  • 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 E should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work.
  • Page 4 Ford Focus / Focus C-MAX / Focus CC 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 / Focus C-MAX / Focus CC Preliminary work Warning! - Open the fuel tank cap and vent the fuel tank. - Close the fuel tank cap again. - Disconnect the battery earth connection. - Depressurise the cooling system. - Copy the factory number from the original type label to the duplicate type label.

  • Page 6: Preparing Electrical System

    Ford Focus / Focus C-MAX / Focus CC Preparing electrical system Only with automatic air-conditioning Connect additional green/white (gn/ws) wire 5 to K3/86 and pull into protective sleeving. rt/ws gn/ws Wiring dia- gram for additional wire gn/ws Connect provided wires to IPCU as shown in wiring diagram.

  • Page 7: Electrical System Of Focus

    Ford Focus / Focus C-MAX / Focus CC Electrical system of Focus Wiring harness pass through Digital timer 1 Protective rubber plug detached 1 Digital timer 2 Summer/winter switch, drilled hole 12 mm dia. Diagram of wiring harness Do not install the metering pump routing for wiring harness until later togeth- Focus...

  • Page 8: Electrical System For Focus/Focus Cc From 2008

    Ford Focus / Focus C-MAX / Focus CC Electrical system for Focus/Focus CC from 2008 Wiring harness pass through Digital timer 1 Protective rubber plug detached 1 Digital timer Diagram Do not install the metering pump of wiring wiring harness until later togeth- harness er with fuel line along the original routing for...

  • Page 9: Electrical System Of C-Max

    Ford Focus / Focus C-MAX / Focus CC Electrical system of C-Max Wiring harness pass through Digital timer 1 Protective rubber plug detached 1 Digital timer 2 Summer/winter switch, drilled hole 12 mm dia. Wiring Do not install the metering pump harness wiring harness until later togeth- routing di-...

  • Page 10: Fan Control Without Automatic A/C

    C111 gn/or A128 (23) Webasto components Ford components Colours and symbols Heater TT-E Fan fuse Fan fuse Fan relay white Fan relay Central electrical box black C111 Connector on right-hand...

  • Page 11: Automatic A/C Fan Control

    Ford Focus / Focus C-MAX / Focus CC Automatic A/C fan control 2 IPCU socket 1 4 mm dia. hole, 5.5x13 self-tapping screw 3 Brown (br) wire from IPCU/85 4 6 mm dia. cable lug, original vehicle bolt IPCU fas- tening Connection is carried out on 26-pin connector C540, Pin 15.
  • Page 12 Wiring dia- gram for automatic air-condi- A205 tioning C540 C111 IPCU C537 Webasto components Vehicle components Colours and symbols Heater TT-E Fan fuse Connector on heater Fan relay white Fan fuse C111 Connector on right-hand A- black pillar...

  • Page 13: Additionally For Automatic A/C From

    Ford Focus / Focus C-MAX / Focus CC Additionally for automatic A/C from 01/06 Produce connections as shown in wiring dia- gram. 1 Cut off green/orange (gn/or) wire of C111/3 Fan con- and insulate troller 2 Green/orange (gn/or) wire of C111/3 3 Connector C111 4 Black (sw) wire of F4 5 Black (sw) wire of F4...
  • Page 14 Wiring dia- gram for automatic air-condi- A205 tioning C540 C111 IPCU C832/834 M3/A97 Webasto components Vehicle components Colours and symbols Heater TT-E Fan fuse Connector on heater Fan relay white Fan fuse C111 Connector on right-hand A- black pillar...
  • Page 15 Ford Focus / Focus C-MAX / Focus CC Remote option (Telestart) Receiver is mounted on existing bolt on posi- tioning motor. 1 Original vehicle bolt Installa- tion loca- tion of receiver 1 Receiver Mounting receiver 1 Antenna Mounting antenna...

  • Page 16: Preparing Installation Location

    Ford Focus / Focus C-MAX / Focus CC Preparing installation location Cross member depends on vehicle equip- ment. 1 Cross member 2 M10 bolts [3x] Removing cross member Design of guard plate (2) depends on the ve- hicle equipment 1 Remove section and discard Adapting guard plate...
  • Page 17 Ford Focus / Focus C-MAX / Focus CC Screw on flanged nut with flange toward front. 1 Original vehicle stud bolt 2 M8 flanged nut Preparing installa- tion loca- tion...

  • Page 18: Premounting Heater

    Ford Focus / Focus C-MAX / Focus CC Premounting heater 1 Delivered heater assembly Heater as- sembly 2 Delivered coolant assembly 1 Black (sw) rubber profile positioned in cen- tre between spring clips 3 Remove connecting cable of circulating pump and discard Coolant assembly Hole in corner of strut is used at position 3 .

  • Page 19: Fastening For Underride Protection

    Ford Focus / Focus C-MAX / Focus CC Fastening for underride protection Vehicle-dependent, if present. 1 M6x25 bolt in existing 7 mm dia. hole 3 10 mm shim 2 Pin lock Premount- ing heater Installing heater Only for 1.4 lt; 1.6 lt; 1.8 lt engine Transport heater to installation location and connect wiring harness as shown.
  • Page 20 Ford Focus / Focus C-MAX / Focus CC Only for 2.0 lt engine Transport heater to installation location and connect wiring harness as shown. Installing heater Use holes in bracket as shown. Check position of all components and adjust if necessary. Check that they have freedom of movement.

  • Page 21: Coolant Circuit

    Ford Focus / Focus C-MAX / Focus CC 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 22 Ford Focus / Focus C-MAX / Focus CC 1 Hose section of heat exchanger inlet 2 Engine outlet hose section Cutting point Remove connection piece according to man- ufacturer's instructions. Locking device (3) must be turned counterclockwise for this pur- pose.

  • Page 23: Fuel

    Ford Focus / Focus C-MAX / Focus CC 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. Unless specified otherwise, always fasten using cable ties.
  • Page 24 Ford Focus / Focus C-MAX / Focus CC Slide metering pump as far as possible up- ward in oblong hole. Route fuel line and wiring harness as shown in following illustration. Fuel line to heater on pressure side of meter- ing pump [side with connector].
  • Page 25 Ford Focus / Focus C-MAX / Focus CC Install fuel-tank sending unit according to manufacturer's instructions. Mount coupling and align; remove clip at Po- sition 3 . 1 Fuel standpipe 2 Coupling piece, mounted on fuel standpipe Connect- 5 Mecanyl fuel line ing fuel 4 10 mm dia.

  • Page 26: Mounting Underride Protection

    Ford Focus / Focus C-MAX / Focus CC Mounting underride protection For all vehicles! Underride protection is dependent on vehicle equipment. Cut out underride protection as shown. Cutting out under- ride pro- tection Only for 1.4 lt; 1.6 lt; 1.8 lt engine Remove plastic threaded insert.

  • Page 27: Final Work

    - Place signboard "Switch off parking heater before refuelling" in the area of the filler neck - See installation instructions for initial startup and function check Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78...

  • Page 28: Operating Instructions For End Customer

    Ford Focus / Focus C-MAX / Focus CC Operating instructions for end customer Please remove page and add to the vehicle operating instructions. WARNING : On vehicles with "Flexyfuel" engine, operation of parking heater is only permissible with petrol. Note: We recommend matching the heating time to the driving time.

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