Webasto D5W Z User manual

Water heater
D5W Z heater
Legend for Figure 1
1 Blade-type fuse holder and blower relay
2 Digital timer
3 Heater
4 Diode group
1
21 43
Upgrade
D5W Z heater to auxiliary
heating system C
FORD Galaxy
TDI (pump injection)
from model year 2001
All equipment variants
Valid for left-hand drive models only
See page 2 for validity details
An auxiliary ventilation function is only possible
(even with Telestart) if the summer/winter
switch is used.
IMPORTANT!
Danger warning:
The incorrect installation or repair of Webasto heating and cooling systems may cause a fire or
the escape or fatal carbon monoxide. This may result in serious or fatal injuries.
Special company training, technical documentation, special tools and special equipment are
required for the installation and repair of Webasto heating and cooling systems.
NEVER attempt to install or repair Webasto heating or cooling systems unless you have
completed the company training and thus acquired the required technical skills and unless you
have the technical documentation, tools and equipment available to you that are required for
completing proper installation and repair work.
ALWAYS follow all Webasto installation and repair manuals and observe all the warnings.
Webasto cannot accept any liability for defects and damage caused by the system being
installed by untrained personnel.
Ident. No. 90 106 58B Cover charge 10.00 Euros © Webasto AG

D5W Z heater upgrade Galaxy
2
Table of contents
Validity 2
Heater / Installation kit 3
Foreword 3
General information 3
Preparations 4
Circuit diagrams 4
Wiring harness 7
Circulating pump actuation 8
Blower connection 10
Optional digital timer and optional summer/winter switch 12
Telestart T70/T80 option 13
Heater actuation 14
Concluding work 15
Operating instructions for the end customer 15
Validity
NOTE
The vehicle types, engine types and equipment versions not listed in these installation instructions
have not been tested.
It may nevertheless be possible to install the system using these installation instructions.
Manufacturer Trade name Type EC licence No.
FORD Galaxy WGR e1*95/54*0024*--
Engine number
(8th number of the VIN) Engine type Output in kW Displacement in cc
ANU TDI (pump injection) 66 1896
AUY TDI (pump injection) 85 1896
ASZ TDI (pump injection) 96 1896
BTB TDI (pump injection) 110 1896

Galaxy D5W Z heater upgrade
3
Heater / Installation kit
Other parts required for auxiliary ventilation option
Optional control element
IMPORTANT
The kit does not include a control element!
The required control element must be ordered separately!
Foreword
These non-binding installation instructions apply to the FORD Galaxy TDI (see page 2 for validity), model year
2001 and later, with D5W Z, unless technical modifications on the car influence the installation, excluding all
liability claims. Depending on the version and equipment in the car, changes may be required to the installation
work set out in these installation instructions.
The appropriate engineering conventions and any instructions from the vehicle manufacturer must be
observed for the installation work.
General information
- Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating
- Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them
at chafing points
- Fit edge protectors (opened fuel hose) to sharp edges
Quantity Designation Order No.
1UpgradekitD5W Z for FORD Galaxy with auxiliary preheating system 90 103 96A
1 Summer/winter switch 845 87A
1 Digital timer 90 108 69A
1 Telestart kit T80 90 108 79A
1 Telestart kit T100 HTM 90 139 37A
1 Thermo Call TC 1.1 90 108 72A

D5W Z heater upgrade Galaxy
4
Preparations
Under-bonnet compartment
IMPORTANT
Disconnect the battery!
Interior
- Note the radio code is the radio has one
- Remove the bottom footwell trim on the driver’s side
- Remove the left side skirt trim
- Release the fuse/relay holder (1)
For vehicles with automatic air-conditioning
system only
- Remove the air-conditioning control
(ATC module A96)
Circuit diagrams
IMPORTANT
Refer to the circuit diagrams supplied by the
manufacturer for the specific vehicle, particularly if the
cable colours or pin assignments are different!
1
2

Galaxy D5W Z heater upgrade
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Circuit diagram for 66 kW and 85 kW engine
Legend for the circuit diagram in Figure 3
Ford Galaxy 85 kW
A96 Self-regulating ATC air-conditioning control
A131 Control module for heater D5W Z
A302 Air-conditioning compressor coupling module
C2 Vehicle plug connector
C6 Vehicle plug connector
C192 Vehicle plug connector
C311 Vehicle plug connector
F2 Blade-type fuse, car
F3 Blade-type fuse, car
F16 Blade-type fuse, car
F22 Blade-type fuse, car
M124 Front blower motor
M151 Refrigerant pump
N289 External temperature switch
P91 Central electrics box
X Isolation point
NOTE
The vehicle’s C311 plug connectoris onthe underfloor
in front of the heater!
Webasto
F1 Blade-type fuse 25 A
F2 Blade-type fuse 5 A
F3 Blade-type fuse 15 A
K3 Blower relay
K3.1 Control relay
K3.2 Ventilation function relay
K3.3 Coolant pump relay
S1 Ventilation function switch
X9 Digital timer plug
(alternatively Telestart T70/T80/T100)
NOTE
Even if the vehicle has a Telestart T70/T80, the
ventilation function can only be controlled using
switch S1!
3
or
or
or
or
Timer
sw (4 mm )
2
rt (4 mm )
2
sw

D5W Z heater upgrade Galaxy
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Circuit diagram for 96 kW and 110 kW engine
Legend for the circuit diagram in Figure 4
Ford Galaxy 96 kW
A96 Self-regulating ATC air-conditioning control
A131 Control module for heater D5W Z
C2 Vehicle plug connector
C6 Vehicle plug connector
C192 Vehicle plug connector
C311 Vehicle plug connector
F3 Blade-type fuse, car
F18 Blade-type fuse, car
F22 Blade-type fuse, car
F34 Blade-type fuse, car
K245 Radiator fan run-on inverter relay
M124 Front blower motor
M151 Refrigerant pump
N289 External temperature switch
P91 Central electrics box
X Isolation point
NOTE
The vehicle’s C311 plug connectorison the underfloor
in front of the heater!
Webasto
F1 Blade-type fuse 25 A
F2 Blade-type fuse 5 A
F3 Blade-type fuse 15 A
K3 Blower relay
K3.1 Control relay
K3.2 Ventilation function relay
K3.3 Coolant pump relay
S1 Ventilation function switch
X9 Digital timer plug
(alternatively Telestart T70/T80/T100)
NOTE
Even if the vehicle has a Telestart T70/T80, the
ventilation function can only be controlled using
switch S1!
4
or
or
or
or
Timer
sw (4 mm )
2
rt (4 mm )
2
sw

Galaxy D5W Z heater upgrade
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Wiring harness
To install the wiring harness
NOTE
The three grey relays (1, 2, 3) are technically identical!
- Release and expose the fuse/relay holder (5)
- Engage the relay sockets (1, 2, 3, 4) into the empty
slots in the fuse/relay holder (5)
NOTE
The order of the various relays depends on the
vehicle’s equipment!
- Connect the black control relay K3.1 (4) to the red
relay socket
- Connect the three grey relays (1, 2, 3) to the black
relay socket
- Drill a 2.5 mm holder for the blade-type fuse holder
in the fuse/relay holder (1)
- Secure the mounting plate of the blade-type fuse
holder using a 3.5 x 13 mm self-tapping screw
- Attach the blade-type fuse holder to the mounting
plate
5
43215
1
26

D5W Z heater upgrade Galaxy
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Circulating pump actuation
For vehicles with 66 kW and 85 kW
engines only
The vehicle’s circulating pump is activated by PIN 6 on
module A302 (1) of the “air-conditioning compressor
coupling” in slot C16 of the central electrics box CJB.
- Disconnect module A302 (1)
Make the connections using the supplied butt
connectors as shown in the figure and in the circuit
diagram in Figure 3 (crimp and shrink).
- Release the socket (4) from the fuse/relay holder
- Cut the green cable (3, 5) from module A302 to the
coolant pump M151 approx. 50 mm behind the
socket (4), PIN 6
- Connect the black cable (1) from relay K3.3/30 to the
green cable (5) to the refrigerant pump M151
- Connect the red cable (2) from relay K3.3/87a to the
green cable (3) from module A302
- Engage the socket (4) in the fuse/relay holder again
and connect module A302
For vehicles with 96 kW and 110 kW
engines only
The vehicle’s circulating pump is activated by PIN 7 on
inversion relay K245 (1) of the “radiator blower slow-
down” in slot C25 of the central electrics box CJB.
- Disconnect inversion relay K245 (1)
Make the connections using the supplied butt
connectors as shown in the figure and in the circuit
diagram in Figure 4 (crimp and shrink).
- Release the socket (2) from the fuse/relay holder
- Cut the green cable (1, 3) from inversion relay K245
to the coolant pump M151 approx. 50 mm behind
the socket (2), PIN 7
- Connect the black cable (5) from relay K3.3/30 to the
green cable (1) to the coolant pump M151
- Connect the red cable (4) from relay K3.3/87a to the
green cable (3) from inversion relay K245
- Engage the socket (2) in the fuse/relay holder again
and inversion relay K245
1
7
5
3
1
4
2
8
1
9
5
2
1
3
10
4

Galaxy D5W Z heater upgrade
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Permanent positive connection
For all vehicle
The permanent positive connection ismade atplugC6
(1) on the central electrics box P91
- Disconnect plug C6 (1)
Make the connections using the supplied 3-way
distributor (5), blade-type plug sleeves and insulation
sheaths as shown in the figure and the circuit diagram
in Figure 3 or 4.
- Use the supplied blade receptacles with detent
points
- Disconnect the red cable (1, 4) from the standard
wiring harness (6)
- Cut the red cable (1) from the standard main blade-
type fuse F 106, 110 A, to plug C6 (supply to
standard blade-type fuses F51 to F54) as shown in
the figure
IMPORTANT
The black insulation sheath is used on the blade-type
plug sleeve on the red cable (1) of the standard main
blade-type fuse!
- Connect both standard red cables (1, 4) and the red
cable (2) (supply to the Webasto wiring harness) as
shown in the figure using a 3-way distributor (5)
- Insulate the wiring harness (6) again and reconnect
plug C6 (3)
Earth connection
The earth connection is made on the standard earth
post (1) on the left above the fuse/relay holder.
- Secure the earth cable to the earth post (1)
1
11
4
2
3
1
6
5
12
1
13

D5W Z heater upgrade Galaxy
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Blower connection
For all vehicle
The blower motor is activated at the output from the
standard blower fuse F22 (1).
Make the connections using the supplied blade-type
plug connectors as shown in the figure and the circuit
diagram in Figure 3 or 4.
IMPORTANT
The cable colour may be either black/red or red/white
depending on the vehicle’s equipment!
- Cut the black and red or red and white cable (2, 5)
as shown in the figure approx. 50 mm after the
blower fuse F22 (1)
- Connect the black and red or red and white cable (2)
to the red cable (3) from blower relay K3/87a
- Connect the black and red or red and white cable (5)
to the blue cable (4) from blower relay K3/30
For vehicles without automatic air-
conditioning system only
NOTE
Insulate and tie back the longer black cable!
This cable is not required (it is routed in the timer
wiring harness with a crimped PIN)!
For vehicles with automatic air-
conditioning system only
The air-conditioning control (ATC module A96) (1) is
activated on the red plug C192 (2) PIN 20 on the left.
Make the connections as shown in the figure and the
circuit diagram in Figure 3 or 4.
- Route the longer black cable (3) (routed in the timer
wiring harness with a crimped PIN) to the air-
conditioning control (ATC module A96) (1)
- Disconnect and open plug C192 (2)
- Connect the black cable (3) to the empty chamber in
plug C192 (2), PIN 20
- Assemble plug C192 (2) again and reconnect it
- Install the air-conditioning control
(ATC module A96) (1)
For vehicles without interior monitoring
system only
NOTE
Insulate and tie back the short black cable
(with crimped PIN)!
The cable is not required!
1
2
5
3
414
2
1
3
15

Galaxy D5W Z heater upgrade
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For vehicles with interior monitoring
system only
The interior monitoring system is activated at the
green plug C2 (1), PIN 13, in the central electrics box
P91.
Make the connections as shown in the figure and the
circuit diagram in Figure 3 or 4.
- Route the second black cable (2) (with crimped PIN)
to plug C2 (1)
- Disconnect and open plug C2 (1)
- Connect the black cable (2) to the empty chamber in
plug C2 (1), PIN 13
- Assemble plug C2 (1) again and reconnect it 2
1
16

D5W Z heater upgrade Galaxy
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Optional digital timer and
optional summer/winter switch
IMPORTANT
Do not press on the LCD display as you install the
digital timer!
NOTE
The installation site for the digital timer (1) and the
summer/winter switch (2) shown in the figure is only a
recommendation!
Before installation, please agree the installation site
with your customer!
- Affix the drilling template for the digital timer (1) in
the required position
- Drill two holes using the template
- Remove the template
- Connect the plug of the digital timer wiring harness
to the digital timer (1)
- Secure the digital timer (1) to the instrument panel
with the self-tapping screw
- Mark the holes for the summer/winter switch (17/2)
in the required position and drill the holes with a
diameter of 12 mm
- Draw the nut and toothed washer over both cables
- Release the tied back brown and violet cables from
the auxiliary heating wiring harness, thread them
through the hole and connect them to the plug as
shown (bottom contacts)
- Secure the summer/winter switch with a toothed
washer and nut
2
1
17
18

Galaxy D5W Z heater upgrade
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Telestart T70/T80/T100 option
Telestart receiver installation
NOTE
Refer to the supplied general “installation instructions”
for the T70/T80/T100 Telestart option!
No ventilation function is possible using the Telestart
T78/T80/T100!
The Telestart receiver (17/1) is installed in the footwell
on the driver side.
- Secure the holder for the Telestart receiver (1) using
the existing screw in position 2 with the fuse/relay
holder
- Place the Telestart receiver (1) on the holder
Telestart aerial installation
NOTE
Clean/degrease the area to which the Telestart aerial
is to be affixed before you affix it!
The Telestartaerial (1) is installed on the front left
triangular window.
- Clean and degrease the affixing area on the
triangular window
- Stick on the Telestart aerial (1)
NOTE
Make the connections in accordance with the general
“installation instructions” and secure the cables using
cable ties!
2
1
19
120

D5W Z heater upgrade Galaxy
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Heater activation
The electrical actuation of the heater takes place on
the standardwiringharness (1)tothe heaterunder the
side skirt trim (interior of the vehicle) near the left rear
door.
- Cut the insulation on the wiring harness (1) as
shown in the figure
IMPORTANT
The cable colour may be either black/red or black/blue
depending on the vehicle’s equipment!
The electrical activation is made:
1. On the black/red or black/blue cable (1, 2) on the
standard blade-type fuse F3 to plug connector C311,
PIN 7.
NOTE
The vehicle’s C311 plug connectoris on the underfloor
in front of the heater!
2. On the black cable (1, 2) from exterior temperature
switch N289 to plug connector C311, PIN 6.
Make the connections using the supplied butt
connectors as shown in the figure and in the circuit
diagram in Figure 3 or 4 (crimp and shrink).
- Cut the black and red or black and blue cable (1, 4)
and the black cable (2, 3) as shown in the figure
- Route the wiring harness with diode group (5) to the
isolation point
- Check and mark the flow direction ofthe diode group
(5) as shown in the circuit diagram in Figure 3 or 4
121
2
1
22
2
1
23
3
21
4
5
24

Galaxy D5W Z heater upgrade
15
- Connect the black and red or black and blue cable
(6) from blade-type fuse F3 to the blue cable (8) to
the diode group (input)
- Connect the black and red or black and blue cable
(3) to the heater (plug C311, PIN 7) to the blue cable
(1) from the diode group (output)
- Connect the black cable (5) from external
temperature switch N289to theblack cable (7) to the
diode group (input)
- Connect the black cable(4) to the heater (plugC311,
PIN 6) to the black cable (2) from the diode group
(output)
Concluding work
- Install all the removed parts in reverse
- Check that all electrical connections are tight
- Secure all loose lines and cables with cable ties
- Connect the car battery
- Affix the filling station sticker in a clearly visible position
- Switch on the heater as described in the operating manual for the digital timer or Telestart T70/80
Operating instructions for the end
customer
(Cut out and add to the vehicle operating manual.)
Make the following settings before you shut down
the car:
For vehicles without automatic
air-conditioning system only
1. Air vent to “WINDSCREEN”
2. Temperature control to “MAX”
3. Blower control to setting “2”
5
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6
8
1
7
2
25

Printed in Germany 07/04 Printed by: Steffen
Webasto AG
Kraillinger Straße 5 - 82131 Stockdorf
http://www.webasto.de