Table of Contents
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Water Heater Unit
Thermo Top E Additional Heater
Installation Instructions
Ford Focus / Focus C-MAX / Focus CC
Gasoline
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, 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.
Ident. No.: 1303854E_EN
e1
00 0003
Fee Euro 10
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Ford Focus
Summary of Contents for Webasto Ford Focus
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Page 1: Installation Instructions
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. -
Page 2: Table Of Contents
Ford Focus / Focus C-MAX / Focus CC Table of Contents Validity Remote Option (Telestart) Heater Unit/Installation Kit Thermo Call Option on Focus Foreword Thermo Call Option on C-MAX Special Tools Preparing Installation Location Explanatory Notes on the Document Premounting Coolant Connection... -
Page 3: Heater Unit/Installation Kit
9015495A 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. -
Page 4: Explanatory Notes On The Document
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. -
Page 5: Preliminary Work
Ford Focus / Focus C-MAX / Focus CC WARNING! - Open fuel tank cap, ventilate tank. - Close the tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurize 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 Heater 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 diagram additional wire gn/ws Connect lines provided to IPCU as shown in wiring diagram. -
Page 7: Electrical Connection On Focus
Ford Focus / Focus C-MAX / Focus CC Electrical Connection on 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 Do not install the metering pump... -
Page 8: Electrical Connection On Focus/Focus Cc
Ford Focus / Focus C-MAX / Focus CC Electrical Connection on 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 cable harness until later together... -
Page 9: Electrical Connection On C-Max
Ford Focus / Focus C-MAX / Focus CC Electrical Connection on C-MAX Wiring harness pass through Digital timer 1 Protective rubber plug detached 1 Digital timer 1 Summer/winter switch, drilled hole 12 mm dia. Wiring harness Do not install the metering pump... -
Page 10: Fan Controller Without Automatic
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. Connect- 3 Connector C111... -
Page 11: From
Ford Focus / Focus C-MAX / Focus CC Fan controller with automatic air- conditioning 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... - Page 12 Ford Focus / Focus C-MAX / Focus CC Ford Focus/Focus C-Max Webasto autom. air-cond. up to 12/05 rt/ws sw/bl Wiring dia- gram for automatic air-condi- A205 tioning C540 C111 IPCU C537 Webasto components Ford components Colors and symbols Heater unit TT-C/E...
- Page 13 Ford Focus / Focus C-MAX / Focus CC Additionally for automatic air- conditioning from 12/05 Produce connections as shown in wiring diagram. 1 Cut off green/orange (gn/or) wire of C111/3 and insulate controller 2 Green/orange (gn/or) wire of C111/3 3 Connector C111...
- Page 14 Ford Focus / Focus C-MAX / Focus CC Ford Focus/Focus C-Max Webasto autom. air-cond. from 12/05 rt/ws sw/bl Wiring dia- gram for automatic air-condi- A205 tioning C540 C111 IPCU C832/834 M3/A97 Webasto components Ford components Colors and symbols Heater unit TT-C/E...
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Page 15: Remote Option (Telestart)
Ford Focus / Focus C-MAX / Focus CC Remote option (Telestart) Receiver is mounted on existing bolt on positioning motor. 1 Original vehicle bolt Installa- tion loca- tion of receiver 1 Receiver Installing receiver 1 Antenna Installing antenna... -
Page 16: Thermo Call Option On Focus
Ford Focus / Focus C-MAX / Focus CC Thermo Call Option on Focus Countersink holes (1) for M4 countersunk head screws from inside. 2 Receiver, 1 4.5 mm dia. hole, M4x10 countersunk head screw (from inside), nut [2x] 3 Self-adhesive Velcro strip as rattle... -
Page 17: Thermo Call Option On C-Max
Ford Focus / Focus C-MAX / Focus CC Thermo Call Option on C-MAX 2 Receiver, self-adhesive Velcro strip Installing receiver 1 Antenna Installing antenna 1 Pushbutton Installing push button... -
Page 18: Preparing Installation Location
Ford Focus / Focus C-MAX / Focus CC Preparing installation location Cross member is dependent on vehicle equipment! 1 Cross member 2 M10 bolts [3x] Removing cross member Design of guard plate ( 2 ) is dependent on vehicle equipment! - Page 19 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 20 Ford Focus / Focus C-MAX / Focus CC Preparing coolant connection WARNING! Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position spring clips so that no other hose can be damaged! The connection should be "inline" based on the following diagram:...
- Page 21 Ford Focus / Focus C-MAX / Focus CC Premounting heater unit 1 Delivered heater unit assembly Heater unit assembly 2 Delivered coolant assembly 1 Black (sw) rubber profile positioned in center between spring clips Coolant assembly Hole in corner of strut is used at Position (3) ! Only loosely mount Ejot screw (3) so that strut (2) can still be aligned during installation.
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Page 22: 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 unit Installing heater unit Only for 1.4 liter; 1.6 liter; 1.8 liter engine Guide heater unit to installation location and connect wiring harness as shown. - Page 23 Ford Focus / Focus C-MAX / Focus CC Only for 2.0 liter engine Guide heater unit to installation location and connect wiring harness as shown. Installing heater unit Use holes in bracket as shown. Check position of all components and adjust if necessary.
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Page 24: Coolant Connection
Ford Focus / Focus C-MAX / Focus CC Coolant connection WARNING! Any coolant running off should be collected using an appropriate container! Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position spring clips so that no other hose can be damaged! The connection should be "inline"... - Page 25 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 manufacturer's instructions. Locking device (3) must be turned counterclockwise for this purpose. 2 Carefully saw open clamp...
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Page 26: Fuel Connection
Ford Focus / Focus C-MAX / Focus CC Fuel Connection CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering-pump wiring harness so that they are protected against stone impact. - Page 27 Ford Focus / Focus C-MAX / Focus CC Slide metering pump as far as possible upward in oblong hole. Route fuel line and wiring harness as shown in following illustration. Fuel line to heater unit on pressure side of metering pump [side with connector].
- Page 28 Ford Focus / Focus C-MAX / Focus CC Removing fuel Remove fuel-tank sending unit (4) in accordance with manufacturer's specifications. Break out connection piece (2) at rupture joint (1) with suitable tool (3) according to manufacturer's instructions. Removing fuel Install fuel standpipe (Ford Order No. Finis Code 1233999) according to manufacturer's instructions.
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Page 29: Installing 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 underride protection Only for 1.4 liter; 1.6 liter; 1.8 liter engine! Remove plastic threaded insert. -
Page 30: Final Work
Ford Focus / Focus C-MAX / Focus CC Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, hose, spring and Caillau clamps, as well as all electrical connections for firm seating. Secure all loose cables using cable ties. -
Page 31: 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. Note : On vehicles with "Flexyfuel engine, operation of additional heater is only permissible with gasoline! Before parking the vehicle, make the following settings: 1 Set fan to level "2", or possibly "1"...