Webasto Ford Focus User manual

Water Heater Unit
Installation Instructions
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.
Feel the drive
Ford Focus / Focus C-MAX / Focus CC
Gasoline
from Model Year 2004
For left-hand drive vehicles only
Thermo Top E Additional Heater e1
00 0003
Ident. No.: 1303854E_EN Fee Euro 10 © Webasto AG

2
Ford Focus / Focus C-MAX / Focus CC
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructionsmay
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 Gasoline 59 1388
ASDB Gasoline 59 1388
HWDB Gasoline 74 1596
HXDA Gasoline 85 1596
Q7DA Gasoline/Flexifuel 92 1798
QQDB Gasoline 92 1798
AODA Gasoline 107 1999
AODB Gasoline 107 1999
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
Special Tools 3
Explanatory Notes on the Document 3
Preliminary Work 5
Heater Unit Installation Location 5
Preparing Electrical System 6
Electrical Connection on Focus 7
Electrical Connection on Focus/Focus CC
from 2008 8
Electrical Connection on C-MAX 9
Fan Controller without Automatic
Air-Conditioning 10
Automatic Air-Conditioning Fan Controller 11
In Addition with Automatic Air-Conditioning
from 12/05 12
Remote Option (Telestart) 15
Thermo Call Option on Focus 16
Thermo Call Option on C-MAX 17
Preparing Installation Location 18
Premounting Coolant Connection 20
Preassembling Heater Unit 21
Fastening for Underride Protection 22
Installing Heater Unit 23
Coolant Connection 25
Fuel Connection 26
Installing Underride Protection 29
Final Work 30
Operating Instructions for End Customer 31
Table of Contents

3
Ford Focus / Focus C-MAX / Focus CC
Heater Unit/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
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. Depending on the vehicle version and
equipment, modifications may be necessary during installation with respect to these installation
instructions.
However,thestipulations in the "installationinstructions"and"operatingandmaintenanceinstructions"
for the Thermo Top C/P/E must always 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
specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring
harnesses using cable ties.
Sharp edges should be fitted with edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.
111329).
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)
Quantity Description Order No.:
1 Ford Delivery Scope for Focus/ Focus C-MAX Gasoline without Heater
Control 1303858C
1 Original Fuel Standpipe with Ford Finis Code 1233999
Quantity Description Order No.:
1 Digital Timer 9010869A
1 Telestart T80 9010870A
1 Telestart T100 HTM 9010148C
1 Thermo-Call Connect, Comfort, Locate See price list
Quantity Description Order No.:
1 Kit for Automatic Air-Conditioning on Ford Focus/Focus C-MAX 9012822A
Quantity Description 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 work
Electrical connection
Coolant connection
Fuel connection
Exhaust system
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.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehicle-
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 unit installation location
Photo shows 1.8 liter
1Heater unit
Installa-
tion loca-
tion
1
1
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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 footwell on the front passenger side.
- Only with automatic air-conditioning: Remove the A/C control panel according to the
manufacturer's specifications.
Prelimi-
nary Work
i

6
Ford Focus / Focus C-MAX / Focus CC
Preparing electrical system
Only with automatic air-conditioning
Connect additional green/white (gn/ws)
wire 5to K3/86 and pull into protective
sleeving. Wiring
diagram
for
additional
wire
Connect lines provided 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
Heater
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 Connection on 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, relay K3
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.
2Ground wire on negative battery terminal
3Positive wire on positive battery terminal
2
1
3
1
2
sw
rt br
bl
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
4
4
5
1 2 3
5
2
3
1

8
Ford Focus / Focus C-MAX / Focus CC
Electrical Connection on 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, relay K3
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.
2Ground wire on negative battery terminal
3Positive wire on positive battery terminal
6
1
7
1
sw
rt br
bl
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
8
1 2 3
9
2
3
1

9
Ford Focus / Focus C-MAX / Focus CC
Electrical Connection on C-MAX
Wiring harness pass through
1Protective rubber plug detached
Digital timer
1Digital timer
1Summer/winter switch, drilled hole 12 mm dia.
Wiring
harness
installa-
tion dia-
gram
for C-Max
Fuse holder, relay K3
Fastening will not be carried out until later after
reinstalling the coolant reservoir cap! When
drilling, 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 ground 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
sw
rt br
bl
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
12
1 2
13
11

10
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.
3Connector C111
1Red (rt) wire to K3/87a
2Green/orange (gn/or) wire from original
vehicle 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 Colors and symbols
Legend
HG Heater unit TT-C/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 Focus/ Focus C-Max
without autom. air-conditioning
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
Fan controller with automatic air-
conditioning
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
fastening
Connectioniscarriedouton26-pinconnector
C540, Pin 15.
Produce connections as shown in wiring
diagram.
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
element
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
diagram.
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
vehicle 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 Pg. 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 Ford components Colors and symbols
Legend
HG Heater unit TT-C/E F10 Fan fuse rt red
F3 Fan fuse K14 Fan relay ws white
K3 Fan relay C111 Connector on right-hand A-
pillar sw black
IPCU Intelligent Pulse
Control Unit br brown
P91 Central electrical box gn green
X1
Connector on heater unit C95 Connector on P91 bl blue
M3 Fan unit or orange
C537 Connector on M3
A205 A/C control module (EATC)
C540 Connector on A205 XCutting point
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Ford Focus/Focus C-Max
autom. air-cond. up to 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 air-
conditioning from 12/05
Produce connections as shown in wiring
diagram.
1Cutoffgreen/orange(gn/or)wire of C111/3
and insulate
2Green/orange (gn/or) wire of C111/3
3Connector C111
4Black (sw) wire of F4
5Black (sw) wire of F4
Fan
controller
Completefuseholderwithmaterialsprovided
and fasten it with double-sided adhesive
tape.
Produce connections as shown in wiring
diagram.
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 Ford components Colors and symbols
Legend
HG Heater unit TT-C/E F10 Fan fuse rt red
F3 Fan fuse K14 Fan relay ws white
K3 Fan relay C111 Connector on right-hand A-
pillar sw black
IPCU Intelligent Pulse
Control Unit br brown
P91 Central electrical box gn green
X1
Connector on heater unit C95 Connector on P91 bl blue
F4 10 A fuse M3 Fan unit or orange
C832/
834 Connector on M3/A97 Insulate wire ends and tie back
A205 A/C control module (EATC)
C540 Connector on A205 XCutting point
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Ford Focus/Focus C-Max
autom. air-cond. from 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/A97
M
421C832/834
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
positioning motor.
1Original vehicle bolt
Installa-
tion loca-
tion of
receiver
1Receiver
Installing
receiver
1Antenna
Installing
antenna
121
i
1
22
1
23

16
Ford Focus / Focus C-MAX / Focus CC
Thermo Call Option on Focus
Countersink holes (1) for M4 countersunk
head screws from inside.
2Receiver,
14.5 mm dia. hole, M4x10 countersunk
head screw (from inside), nut [2x]
3Self-adhesive Velcro strip as rattle
protection Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
1
3
24
2
i
1
25
1
26

17
Ford Focus / Focus C-MAX / Focus CC
Thermo Call Option on C-MAX
2Receiver, self-adhesive Velcro strip
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
27
i
1
28
1
29

18
Ford Focus / Focus C-MAX / Focus CC
Preparing installation location
Cross member is dependent on vehicle
equipment!
1Cross member
2M10 bolts [3x] Removing
cross
member
Design of guard plate (2) is dependent on
vehicle equipment!
1Remove section and discard
Adapting
guard
plate
If threaded inserts are not present at position
(1), then mount M10 rivet nuts provided in
hexagon holes.
Use special tool as shown on Page 3.
For alternative, see next illustration.
1M10 steel rivet nut [2x]
2Stud bolt Installing
rivet nut
1M10 rivet nut (steel)
2Washer
3M10 nut
4M10 bolt
Alterna-
tive rivet-
down tool
30
1
2 2 2
31
1
2
32
1 1
2
33
4
1 2 3

19
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
34
2
1

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:
Coolant
routing
diagram
Heat
exchanger
Motor
Ø 20x18 Ø 25
A
B
C
D
All clamps without a specific designation = 27 mm dia. spring clips!
All connecting pipes without a specific designation are dia. 20x20!