Webasto Thermo Top E Operator's manual

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
e1
00 0003

2
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

3
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.:
1
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

4
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
i
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.

5
Ford Focus / Focus C-MAX / Focus CC
Heater installation location
Figure shows 1.8 lt engine
1Heater
Installa-
tion loca-
tion
1
1
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.

6
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.
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
F3
rt
sw
rt/ws
gn/ws
gn/ws
br
K3
87a8786
85 30
5
4
HG
X1
br
0,75mm²
sw
0,75mm²
rt
0,75mm²
86 85
A
E
15
IPCU
3
12
rt
0,75mm² 4

7
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
2
1
3
1
2
Do not install the metering pump
wiring harness until later togeth-
erwithfuelline alongtheoriginal
vehicle fuel lines on the under-
body
i
4
1 2 3
5
2
3
1

8
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
6
1
7
1
Donotinstallthe meteringpump
wiring harness until later togeth-
erwithfuellinealongtheoriginal
vehicle fuel lines on the under-
body
i
8
1 2 3
9
2
3
1

9
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.
10
1
11
1
2
Donotinstallthe meteringpump
wiring harness until later togeth-
erwith fuellinealongtheoriginal
vehicle fuel lines on the under-
body
i
12
1 2
13
11

10
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
14
1
4
5
2
3
i
gn/ws
sw
br
rt/ws
Webasto
31
30
15
Ford
rt
4
HG
X1
F3
25A
F10
30A
M
+
-
M3
K3
87a8786
85 30
32
P91
C95
22 C111
R21
A128
(23)
K14
5
2
13
rt
sw/bl gn/or
gn/or
gn/or
sw
sw/rt
sw/or
i

11
Ford Focus / Focus C-MAX / Focus CC
Automatic A/C fan control
2IPCU socket
14 mm dia. hole, 5.5x13 self-tapping screw
3Brown (br) wire from IPCU/85
46 mm dia. cable lug, original vehicle bolt
IPCU fas-
tening
Connectioniscarriedouton 26-pinconnector
C540, Pin 15.
Produce connections as shown in wiring dia-
gram.
6Connector C540
1Connect IPCU
3Green/white (gn/ws) wire from K3/86
4Black (sw) wire from IPCU/A
5Blue/white (bl/ws) wire to fan unit
7Blue/white (bl/ws) wire from A/C control
module
2Red (rt) wire to IPCU/E
Connect-
ing air-
condition-
ingcontrol
panel
1Connector C540
2Pin 15
View of
connector
Connection is carried out on connector C111,
Pin 22, at bottom of right-hand A-pillar.
Produce connections as shown in wiring dia-
gram.
From 12/05, see page 12.
3Connector C111
1Red (rt) wire from K3/87a
6Red (rt) wire from IPCU/15
2Green/orange (gn/or) wire from original ve-
hicle fan relay K14
4Green/orange (gn/or) wire to connector
C111, Pin 22
5Black (sw) wire from K3/30 (on vehicles
from 12/05, see page 12)
Connec-
tion to fan
unit
15
3
2
1
4
16
1
6
4
5
2
7
3
17
1 2
18
1
4
6
2
3
5

12
Ford Focus / Focus C-MAX / Focus CC
Wiring dia-
gram for
automatic
air-condi-
tioning
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-E F10 Fan fuse rt red
X1 Connector on heater K14 Fan relay ws white
F3 Fan fuse C111 Connector on right-hand A-
pillar sw black
K3 Fan relay br brown
IPCU
Pulse width modulator P91 Central electrical box gn green
IPCU settings: C95 Connector on P91 bl blue
Duty cycle: 60% M3 Fan unit or orange
Frequency: 400Hz C537 Connector on M3
Voltage: 10V A205 A/C control module (EATC) XCutting point
Function: Low side C540 Connector on A205 Wiring colours may vary.
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Ford Focus/Focus C-Max
Automatic A/C until 12/05
rt
4
HG
X1
F3
25A
F10
30A
32
P91
C95
K14
5
2
13
rt
sw/bl gn/
or
gn/
or
gn/
or
6
M3
M
231C537
A205
1615
C540
gn/
ws
K3
87a8786
85 30
22 C111
br
sw
rt
bl/
ws
bl/
ws
br/
bl
sw
86 85
A
E
15
IPCU
3
1
2
4
5
rt
i

13
Ford Focus / Focus C-MAX / Focus CC
Additionally for automatic A/C
from 01/06
Produce connections as shown in wiring dia-
gram.
1Cutoffgreen/orange (gn/or) wire ofC111/3
and insulate
2Green/orange (gn/or) wire of C111/3
3Connector C111
4Black (sw) wire of F4
5Black (sw) wire of F4
Fan con-
troller
Completefuse holderwith materialsprovided
and fasten it with double-sided adhesive
tape.
Produce connections as shown in wiring dia-
gram.
1Central electrical box in right-hand footwell
2Black (sw) wires, 500 mm
3Fuse holder, 10 A fuse Fuse F4
19
4
3
1
52
20
2
3
1

14
Ford Focus / Focus C-MAX / Focus CC
Wiring dia-
gram for
automatic
air-condi-
tioning
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-E F10 Fan fuse rt red
X1 Connector on heater K14 Fan relay ws white
F3 Fan fuse C111 Connector on right-hand A-
pillar sw black
K3 Fan relay br brown
IPCU
Pulse width modulator P91 Central electrical box gn green
IPCU settings: C95 Connector on P91 bl blue
Duty cycle: 27% M3 Fan unit or orange
Frequency: 400Hz C537 Connector on M3
Voltage: 10V A205 A/C control module (EATC) XCutting point
Function: Low side C540 Connector on A205 Wiring colours may vary.
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Ford Focus/Focus C-Max
Automatic A/C from 01/06
rt
4
HG
X1
F3
25A
F10
30A
32
P91
C95
K14
5
2
13
rt
sw/bl gn/
or
gn/
or
gn/
or
6
M3/A97
M
421 C832/834
A205
1615
C540
gn/
ws
K3
87a8786
85 30
br
sw
rt
bl/
ws
bl/
ws
gn/
or
sw
86 85
A
E
15
IPCU
3
1
2
4
5
rt
F29
10A
C111 3
22
F4
10A !
gn/
or
i

15
Ford Focus / Focus C-MAX / Focus CC
Remote option (Telestart)
Receiver is mounted on existing bolt on posi-
tioning motor.
1Original vehicle bolt
Installa-
tion loca-
tion of
receiver
1Receiver
Mounting
receiver
1Antenna
Mounting
antenna
121
i
1
22
1
23

16
Ford Focus / Focus C-MAX / Focus CC
Preparing installation location
Cross member depends on vehicle equip-
ment.
1Cross member
2M10 bolts [3x] Removing
cross
member
Design of guard plate (2) depends on the ve-
hicle equipment
1Remove section and discard
Adapting
guard
plate
Ifthreadedinsertsare notpresentatposition (1),
thenmountM10rivetnutsprovidedinhexagonal
holes.
Use special tool as shown on page 3.
For alternative, see next figure.
1M10 steel rivet nut [2x]
2Stud bolt Installing
rivet nuts
1M10 rivet nut (steel)
2Washer
3M10 nut
4M10 bolt
Alterna-
tive rivet-
down tool
24
1
2 2 2
25
1
2
26
1 1
2
27
4
1 2 3

17
Ford Focus / Focus C-MAX / Focus CC
Screw on flanged nut with flange toward front.
1Original vehicle stud bolt
2M8 flanged nut
Preparing
installa-
tion loca-
tion
28
2
1

18
Ford Focus / Focus C-MAX / Focus CC
Premounting heater
1Delivered heater assembly
Heater as-
sembly
2Delivered coolant assembly
1Black (sw) rubber profile positioned in cen-
tre between spring clips
3Remove connecting cable of circulating
pump and discard
Coolant
assembly
Hole in corner of strut is used at position 3.
Mount Ejot screw 3 only loosely, so that strut 2
canstillbealignedduringinstallation.Connect
wiring harness
4 to the circulating pump.
1Retainingclip withintakesilencerengaged
in hole Connect-
ing as-
semblies
General view.
Fix hoses Band Cand wiring harness of cir-
culating pump in place with cable ties.
Connect-
ing as-
semblies
29
1
B
30
A
C1D 2
3
31
3
1 2
4
B C
32
D C
A B

19
Ford Focus / Focus C-MAX / Focus CC
Fastening for underride protection
Vehicle-dependent, if present.
1M6x25 bolt in existing 7 mm dia. hole
310 mm shim
2Pin 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.
Installing
heater
Use holes in bracket as shown.
Check position of all components and adjust
ifnecessary.Checkthattheyhavefreedomof
movement.
1M10x30 bolt with locking toothing [2x]
Installing
heater
Use hole in strut as shown.
Check position of all components and adjust
ifnecessary.Checkthattheyhavefreedomof
movement.
1M8 flanged nut (premounted)
3Flanged nut
2Strut
Tighten Ejot screw (10 Nm).
Mounting
heater
33
1
3
2
34
35
1
1
36
2
1
3

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
ifnecessary.Checkthattheyhavefreedomof
movement.
1M10x30 bolt, spring lockwasher [2x]
Installing
heater
Use hole in strut as shown.
Check position of all components and adjust
ifnecessary.Checkthattheyhavefreedomof
movement.
1M8 flanged nut (premounted)
3Flanged nut
2Strut
Tighten Ejot screw (10 Nm).
Mounting
heater
37
38
11
39
2
1
3