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

Ford Focus / C-Max / Grand C-Max
1316981B_EN 11
Automatic air-conditioning fan control
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-Evo 2H102 Fan controller rt red
X1 6-pin heater connector C1 Connector 2H102 sw black
X2 2-pin heater connector C3 Connector 2H102 ge yellow
X10 4-pin connector
Heater control 2H123 Fan motor gn green
B Connector 2H123 br brown
K1 Fan relay 2H101 A/C control unit ws white
F1 Fuse 20A C 2 Connector 2H101 gr gray
F2 Fuse 30A C21 Socket connection vi violet
F3 Fuse 1A R13 Fan relay
F4 Fuse 25A PF3 Fuse 100A
IPCU Pulse width modulator F10 Fuse 40A
IPCU settings: F23 Fuse 5A
Duty cycle: 37%
Frequency: 400Hz
Voltage: 3.6V XCutting point
Function: Low side Wiring colours may vary.
Webasto
31
30
15
Ford
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5²
rt
4²
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
rt
4²
rt/sw
0,5²
F3
br
0,5²
br
0,5²
E
A
IPCU
85 15
86
br
0,5²
br
0,5²
PF3
R13
F10
F23
24
C21
2H101
C2 15 6
2H123
M
B
1
5rt
0,5²
rt
4²
gn/ws
0,5²
2
6
7
sw
4²
3
4
rt
0,5²
sw
0,5²
gr/
vi
gr/
vi
2H102
C1 2 4 3
C3 1 2
ws/
vi
ws/
vi

Ford Focus / C-Max / Grand C-Max
1316981B_EN 12
Focus
1
M5x16 bolt, large diameter washer [2x], nut
2Angle bracket
3Fuse and relay socket
4Mount IPCU socket Premount-
ing K1 re-
lay
1M6x20 bolt, flanged nut
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 1Pin 1 be-
fore the fan controller. Produce connections
as shown in wiring diagram.
2Green/orange (gr/or) wire to fan relay R13
3 Green/orange (gr/or) wire to fan controller 2H102
Red (rt) wire from K1/87a
Black (sw) wire of K1/30
Red (rt) wire of IPCU 15
Connect-
ing fan
controller
14
3
4
21
15
1
16
2
1
17
5
1
2 3
2
1

Ford Focus / C-Max / Grand C-Max
1316981B_EN 13
Connect to connector C2 3Pin15 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)wirefromconnectorC2,
Pin 15
Red (rt) wire of IPCU/E
Black (sw) wire of IPCU/A
Connect-
ing A/C
control
unit
C-Max and Grand C-Max
Engage fuse holder of passenger compart-
ment 2with IPCU socket 3.
1M5x16 bolt, large diameter washer, exist-
ing threaded hole Mounting
fuseholder
of passen-
ger com-
partment
1K1 relay
Mounting
K1 relay
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.
Brown (br) wire of IPCU/85
Green/white (gn/ws) wire of IPCU/86
Connect-
ing wiring
harnesses
18
1
2
4
3
3
19
1
3
2
20
1
21
2
1
7
6

Ford Focus / C-Max / Grand C-Max
1316981B_EN 14
Connect to socket connector C21 3Pin 24
before the fan controller.
Produce connections as shown in wiring dia-
gram.
1 Green/violet (gr/vi) wire to fan controller 2H102
2Gray/violet (gr/vi) wire to fan relay R13
Red (rt) wire from K1/87a
Black (sw) wire of K1/30
Red (rt) wire of IPCU 15
Connect-
ing fan
controller
Connect to connector C2 3Pin15 from A/C
control unit.
Produce connections as shown in wiring dia-
gram.
1 White/violet (ws/vi) wire to fan controller 2H102
2 White/violet(ws/vi)wirefromconnectorC2,
Pin 15
Red (rt) wire of IPCU/E
Black (sw) wire of IPCU/A
Connect-
ing A/C
control
unit
Remote option (Telestart)
C-Max / Grand C-Max
Fasten receiver 1with adhesive tape. Mounting
receiver
1Antenna
Mounting
antenna
22
1
3
2
152
23
1
2
4
3
3
1
24
1
25

Ford Focus / C-Max / Grand C-Max
1316981B_EN 15
Focus
Angle down bracket of receiver 2as shown.
1M6x20 bolt, flanged nut, existing hole
3Receiver Mounting
receiver
1Antenna
Mounting
antenna
Temperature sensor T100 HTM
All vehicles
Fasten temperature sensor 2with cable tie 1
to original vehicle wiring harness. Mounting
tempera-
ture sensor
1
26
2
3
27
1
1
28
2

1316981B_EN 16
Ford Focus / C-Max / Grand C-Max
Preparing installation location
Mount M8 flanged nut 2on original vehicle
stud bolt with flange in front (turn by a half).
1M8x20 spacer nut, original vehicle stud
bolt Mounting
installa-
tion loca-
tion
Preparing heater
1Coolant connecting piece, sealing ring [2x
each]
25x15 self-tapping bolt, retaining plate of
coolant connecting pieces Mounting
coolant
connect-
ing pieces
1Fuel line
290° moulded hose, 10 mm dia. clamp [2x]
Premount-
ing fuel
line
1Bracket
25x13 self-tapping bolt [3x]
Mounting
bracket
29
21
30
1
1
2
31
2 1
32
2
2
21

1316981B_EN 17
Ford Focus / C-Max / Grand C-Max
Discard section X.
1Combustion air pipe
a = 600
Cutting
combus-
tion air
pipe to
length
1Combustion air pipe
225 mm dia. spring clip
Mounting
combus-
tion air
pipe
1M4x12 bolt, nut from the rear
Mounting
twist lock
Position housing notch of silencer 3over bolt
head 1(twist lock).
2M6x16 bolt, spring lockwasher
Mounting
silencer
a
1
X
33
12
34
1
35
3
2
1

1316981B_EN 18
Ford Focus / C-Max / Grand C-Max
193 exhaust end section
2Hose clamp [3x]
3Exhaust pipe 200
Mounting
exhaust
pipe
Discard section X.
Hose A= 180°, 18 mm dia. moulded hose.
Hose B= 90°, 18 mm dia. moulded hose.
C=460 Cutting
hose to
length
All spring clips = 25 mm dia.
1Mount of circulating pump
2Circulating pump
3M6x25 bolt, flanged nut Mounting
hoses and
circulating
pump
1Circulating pump wiring harness
2Cable tie [2x]
Connect-
ing wiring
harness
36
2
1
2
2
3
AB
C
37
3
A
21 B
C
38
1
122

1316981B_EN 19
Ford Focus / C-Max / Grand C-Max
Installing heater
1Bracket
2M8x20 bolt, washer, flanged nut, existing
hole [2x each] Loosely
mounting
heater
Mount heater on original vehicle stud bolt 1,
install M8 flanged nut 2loosely.
Loosely
mounting
heater
Align heater. Ensure sufficient distance from
neighbouring components. Ensure minimum
distance > 5mm from steering components
and > 15mm from parts of transmission, car-
dan shaft and engine.
Tighten M8x20 bolts. Aligning
heater
1Tighten flanged nut M8
Mounting
heater
39
2
1
2
40
1
2
41
42
1

Ford Focus / C-Max / Grand C-Max
1316981B_EN 20
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. When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
The displayed coolant circuit is meant primarily for passenger compartment heating.
Hose rout-
ing dia-
gram
All spring clips = 25 mm dia.
All connecting pipes and = 18x18 dia.
A
BC