Webasto thermo top evo Operator's manual

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.
Water Heater
Installation documentation
Ident. No.: 1316981B_EN Fee Euro 10.00 © Webasto AG
Ford Focus / C-Max / Grand C-Max
Diesel
from model year 2011
Left-hand drive vehicle
Feel the drive
Thermo Top Evo Parking Heater
e1
00 0258

Ford Focus / C-Max / Grand C-Max
1316981B_EN 2
Table of contents
Validity
Ford C-Max / Grand C-Max
Ford Focus
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 the digital timer should be confirmed with the end customer before installa-
tion.
Manufacturer Model Type EG-BE-No. / ABE
Ford C-Max DXA e13 * 2007 / 46 * 1103 * ...
Ford Grand C-Max DXA e13 * 2007 / 46 * 1103 * ...
Ford Focus DYB e13 * 2007 / 46 * 1138 * ...
Engine type Engine model Output in kW Displacement in cm³
T3 Diesel 70 1560
T1 Diesel 85 1560
Engine type Engine model Output in kW Displacement in cm³
T3 Diesel 70 1560
T1 Diesel 85 1560
Validity 2
Heater/installation kit 3
Foreword 3
General instructions 3
Special tools 3
Explanatory notes on document 4
Preliminary work 5
Heater installation location 5
Preparing electrical system 6
Electrical system 7
Fan control for manual air conditioning 9
Automatic air-conditioning fan control 11
Remote option (Telestart) 14
Preparing installation location 16
Preparing heater 16
Installing heater 19
Coolant circuit 20
Combustion air 22
Fuel 23
Exhaust gas 27
Final Work 28
Operating instructions for end customer 29

Ford Focus / C-Max / Grand C-Max
1316981B_EN 3
Heater/installation kit
To be ordered additionally for the installation of digital timer:
Foreword
This installation documentation applies to Ford Focus / C-Max / Grand C-Max Diesel vehicles - for va-
lidity, see page 2 - from model year 2011 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 documentation.
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.
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. Insulate loose wires and tie back.
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
- Punching tool 60 mm dia.
Quantity Designation Order No.:
1 Basic delivery scope Thermo Top Evo See price list
1
Installation Kit Ford Focus / C-Max / Grand C-Max 2011 Diesel 1316980A
1 Heater control See price list
Quantity Designation Order No.:
1 Extension of clock wiring harness 70813B

Ford Focus / C-Max / Grand C-Max
1316981B_EN 4
Special features are highlighted using the following symbols:
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
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.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
All dimensions are in mm!
Tightening torque of 5x13 heater bolts = 8Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
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 / C-Max / Grand C-Max
1316981B_EN 5
Preliminary work
WARNING!
- Open the fuel tank cap and vent the fuel tank.
- Close the fuel tank cap again.
-Depressurisethe 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.
- Attach the duplicate label (type label) in the appropriate place.
- Declamp and remove battery.
- Remove engine cover
- Remove windscreen wiper
- Remove cover of coolant reservoir
- Remove cover of coolant reservoir for engine compartment
- Discharge coolant according to the manufacturer's instructions
- Remove intake manifold
- Remove engine underride protection
- Remove underbody trim at the near the tank
- Detach heat protection trim of exhaust system in the area of the tank
- Remove tank
- Remove the footwell trim on the front passenger side.
- Remove the glove compartment.
- Remove shift lever trim
- Remove trim of centre console
- Remove A/C control panel in accordance with manufacturer's instructions.
- Remove A-pillar trim of the footwell on the front passenger side (only with Telestart)
Remove page 29 "Operating instructions for end customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Ford Focus / C-Max / Grand C-Max
1316981B_EN 6
Preparing electrical system
Wire sections retain their numbering in the
entire document.
All equipment
Connect wires to socket of K1 relay. Insert F4
25A fuse. K1 relay is inserted only after in-
stalling the fuse holder.
Red (rt) wire 4²
Black (sw) wire 4²
Inserting
F4,
Preparing
K1 relay
Automatic air-conditioning
Wire sections retain their numbering in the
entire document.
Cutting
wires to
length
Connect wires to IPCU socket.
IPCU view on contact side.
The IPCU included in the kit is pre-pro-
grammed with the following settings:
Duty cycle: 37%
Frequency: 400Hz
Voltage: 3.6V
Function: Low side
Red (rt) wire 0.5²
Black (sw) wire 0.5²
Red (rt) wire 0.5²
Brown (br) wire 0.5²
Green/white (gn/ws) wire 0.5²
The settings are to be checked during the
function check on the vehicle, and adjusted if
necessary.
Pull wires 3and 4intothe attached protective
sleeving.
Premount-
ing IPCU
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
1
2
5
500
3rt
0,5²
1000
86 85
E
A
15
IPCU
5
4
3
6
A
15
86 85
E
7

Ford Focus / C-Max / Grand C-Max
1316981B_EN 7
Electrical system
Focus
Plus and earth wire
1Earth wire, 8 mm dia. cable lug at original ve-
hicle earth support point
2Positive wire on positive battery terminal
Wiring harness pass through
1Protective rubber plug
Wiring har-
ness rout-
ing
diagram
(manual
A/C sys-
tem)
Fuse holder of engine compartment
1Angle bracket
2M5x16 bolt, large diameter washer [2x], re-
taining plate of fuse holder, nut
3Fuses F1-2
4M6x20 bolt, flanged nut, existing hole
Digital timer
Use clock cable extension when installing digital
timer.
1Digital timer
2
1
2
3
1
Donotinstallthe meteringpump
wiring harness until later togeth-
erwith fuellinealongtheoriginal
vehicle fuel lines on the under-
body
4
4
12
3
5
1

Ford Focus / C-Max / Grand C-Max
1316981B_EN 8
C-Max / Grand C-Max
Plus and earth wire
1Earth wire, 8 mm dia. cable lug at original ve-
hicle earth support point
2Positive wire on positive battery terminal
Wiring harness pass through
1Protective rubber plug
Wiring har-
ness rout-
ing
diagram
Fuse holder of engine compartment
When drilling, watch components located be-
hind.
15.5mm dia. hole, M5x16 bolt, large diameter
washer, retaining plate of fuse holder, nut
2Fuses F1-2
Digital timer
Use clock cable extension when installing digital
timer.
1Digital timer
6
1
2
7
1
Donotinstallthe meteringpump
wiring harness until later togeth-
erwith fuellinealongtheoriginal
vehicle fuel lines on the under-
body
8
2
1
9
1

Ford Focus / C-Max / Grand C-Max
1316981B_EN 9
Fan control for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-Evo 2H403 Resistor group rt red
X1 6-pin heater connector C2 Connector 2H403 sw black
X2 2-pin heater connector 2H123 Fan motor ge yellow
X10 4-pin connector
Heater control B Connector 2H123 gn green
2H105 Fan switch or orange
K1 Fan relay C 1 Connector 2H426 ws white
F1 Fuse 20A C21 Socket connection br brown
F2 Fuse 30A R13 Fan relay gr gray
F3 Fuse 1A PF3 Fuse 100A vi violet
F4 Fuse 25A F10 Fuse 40A
F23 Fuse 5A XCutting point
Wiring colours may vary.
Webasto
31
30
15
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5² rt
4²
br
0,5²
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
br
0,5²
Ford
PF3
R13
F10
F23
C21
rt
4²
sw
4²
gr/
vi
gr/
vi
2H403
21
3
4
2H123
M
B
5
2H105
4 3 2 1
2
1
C2
C1
C1

Ford Focus / C-Max / Grand C-Max
1316981B_EN 10
Focus
16.5 mm dia. hole
Hole for
passenger
compart-
ment fuse
holder
Mount K1 relay 5after installation.
1 M5x16 bolt, large diameter washer [2x], nut
2Angle bracket
3M6x20 bolt, flanged nut
4Fuse holder of passenger compartment Mounting
fuseholder
of passen-
ger com-
partment
Produce connections as shown in wiring dia-
gram. Connect wiring harness of passenger
compartment fuse holder 2with wiring har-
ness of heater 1according to wiring diagram,
so that wires of the same colour are connect-
ed to each other. Connect-
ing wiring
harnesses
Connect to socket connector C21 3Pin 1 be-
fore the fan motor.
Produce connections as shown in wiring dia-
gram.
1Gray/violet (gr/vi) wire to fan motor 2H123
2Gray/violet (gr/vi) wire to fan relay R13
Red (rt) wire from K1/87a
Black (sw) wire of K1/30
Connect-
ing fan mo-
tor
10
1
10
11
3
5
1 2
4
12
2
1
13
1
3
21
2