Ford - Grand C Max - Workshop Manual - 2007 - 2007

Water Heater Thermo Top Evo Parking Heater E1 00 0258 Installation Documentation Ford Focus / C-Max / Grand C-Max Validity Manufacturer Ford Ford Ford Model C-Max C-Max / Grand C-Max Focus Type DXA DXA DYB EG-BE-No. / ABE e13 * 2007 / 46 * 1103 * ... e13 * 2007 / 46 * 1103 * ... e13 * 2007 / 46 * 1138 * ... Ford Focus Motorisation 1.0 EcoBoost 1.0 EcoBoost 1.6 Duratec 1.6 Duratec 1.6 Duratec Fuel Petrol Petrol Petrol Petrol Petrol Transmission type Output in kW SG 74 SG 92 SG 77 SG 92 SG 110 Displacement in cm³ 998 998 1560 1560 1560 Engine code M2DA M1DA IQ PN JQ Transmission type Output in kW SG 77 SG 92 SG 110 Displacement in cm³ 1560 1560 1560 Engine code IQ PN JQ Ford C-Max / Grand C-Max Motorisation 1.6 Duratec 1.6 Duratec 1.6 Duratec Fuel Petrol Petrol Petrol SG = manual transmission From Model Year 2011 Left-hand drive vehicle Verified equipment variants: Manual air-conditioning (Focus only) / Automatic air-conditioning Front fog light automatic Start-Stop system Not verified: Passenger compartment monitoring Exclusion: Not for 1.6 EcoBoost from model year 2012! Total installation time: approx. 8 hours Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE Ford Focus / C-Max / Grand C-Max Table of Contents Validity 1 Necessary Components 2 Installation Overview 2 Information on Total Installation Time 2 Information on Operating and Installation Instructions 3 Information on Validity 4 Technical Information 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Preparing Electrical System 6 Electrical System 7 Fan Controller for Manual Air-Conditioning 9 Fan Controller for Automatic Air-Conditioning 11 Option (Telestart) 14 Preparing Installation Location Preparing Heater Installing Heater Fuel Combustion Air Exhaust Gas Coolant Circuit Final Work Operating Instructions for Manual A/C Focus Operating Instructions for Automatic A/C Focus Operating Instructions for Automatic A/C C-Max / Grand C-Max 16 18 19 21 26 27 30 34 35 36 37 Necessary Components • Basic delivery scope Thermo Top Evo in accordance with price list • Installation kit for Ford Focus / C-Max / Grand C-Max 2011 Petrol: 1316972A • Heater control in accordance with price list and upon consultation with end customer • Extension of clock wiring harness (additionally for the installation of the digital timer): 70813B • In case of Telestart, indicator lamp in accordance with price list and in consultation with end customer Note To facilitate the work, the vehicle should only be delivered with a 1/4 filled tank! Installation Overview Legend: 1 1. Heater 2. Engine compartment fuse holder 3. Passenger compartment fuse holder manual air-conditioning and automatic air-conditioning for Focus 4. Passenger compartment fuse holder automatic air-conditioning for C-Max / Grand C-Max 5. Circulating pump 6. Digital timer 7. Metering pump 3 7 4 5 6 2 Information on Total Installation Time The total installation time includes the time needed for mounting and demounting of the vehicle-specific components, the heater specific installation time and all other times required for the system integration and initial start-up of the heater. The total installation time may vary for vehicle equipment other than provided. Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 2 Ford Focus / C-Max / Grand C-Max Information on Operating and Installation Instructions 1 Important Information (not complete) Beginning of excerpt. 1.1 Installation and Repair ANNEX VII The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death. REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR INSTALLATION 1. GENERAL REQUIREMENTS 1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when the combustion heater is switched on or off. 2. VEHICLE INSTALLATION REQUIREMENTS 2.1. Scope 2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed according to the requirements of this Annex. Only use genuine Webasto parts. See the Webasto air and water heaters accessories catalogue for this purpose. 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply with the requirements of this Annex. 1.2 2.2. Positioning of heater To ensure safe operation, we recommend having the heater checked every two years by an authorised Webasto dealer, especially when used over a long period and/or under extreme environmental conditions. 2.2.1. Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination. Do not operate the heater in closed rooms due to the danger of poisoning and suffocation. 2.2.2. The combustion heater shall not constitute a risk of fire, even in the case of overheating. This requirement shall be deemed to be fulfilled if the installation ensures an adequate distance to all parts and suitable ventilation, by the use of fire resistant materials or by the use of heat shields. 2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in the passenger compartment. However, an installation in an effectively sealed envelope which also complies with the conditions in paragraph 2.2.2 may be used. To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appropriate technical documentation, special tools and special equipment. Installation and repair may ONLY be carried out by persons trained and certified in a Webasto training course. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly. Operation Always switch off the heater before refuelling. The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or petrol (DIN EN 227). The heater may not be cleaned with a high-pressure cleaner. 1.3 Please note 2.2.4. ALWAYS follow all Webasto installation and operating instructions and observe all warnings. The label referred to in paragraph 1.4 or a duplicate, must be positioned so that it can be easily read when the heater is installed in the vehicle. 2.2.5. To become familiar with and understand all functions and properties of the heater, the operating instructions must be read carefully and observed at all times. Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property. 2.3. Fuel supply 2.3.1. The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage. 2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the vehicle is provided, the type of fuel and its filler point must be clearly labelled. Webasto shall assume no liability for defects, damage and injuries resulting from a failure to observe the installation, repair and operating instructions of the information contained in them. 2.3.3. A notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point. In addition a suitable instruction must be included in the manufacturer's operating manual. This liability exclusion particularly applies to improper installations and repairs, installations and repairs by untrained persons or in the case of a failure to use genuine spare parts. 2.4. Exhaust system 2.4.1. The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators, heated air inlets or opening windows. 2.5. Combustion air inlet 2.5.1. The air for the combustion chamber of the heater must not be drawn from the passenger compartment of the vehicle. 2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely. For proper, safe installation and repair work, the installation instructions with all warnings and safety information must be carefully read and observed at all times. Please always contact a workshop authorised by Webasto for all installation and repair work. IMPORTANT The liability due to culpable disregard to life, limb or health and due to damage or injuries caused by a wilful or reckless breach of duty remain unaffected, as does the obligatory product liability. 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. Insulate loose wire ends and tie back. Sharp edges should be fitted with rub protection (split-open fuel hose)! Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329). 2.6. Heating air inlet 2.6.1. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. The heating air supply may be fresh or recirculated air and must be drawn from a clean area not likely to be contaminated by exhaust fumes emitted either by the propulsion engine, the combustion heater or any other vehicle source. 2.6.2. The inlet duct must be protected by mesh or other suitable means. When installing an IPCU, the corresponding settings must be checked or adjusted before the installation. 2.7. Heating air outlet 2.7.1. Any ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it were to be touched. 2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely. Observe the instructions and guidelines of the respective vehicle manufacturer for demounting and mounting vehicle specific components! 2 Statutory regulations governing installation Guidelines Thermo Top Evo Heating Directive ECE R122 EMC Directive ECE R10 E1 00 0258 E1 03 5627 NOTE End of excerpt. In multilingual versions the German language is binding. The regulations of these guidelines are binding in the scope of the Directive 70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and should also be observed in countries in which there are no special regulations. IMPORTANT Failure to follow the installation instructions will result in the invalidation of the type approval for the heater and therefore invalidation of the general homologation of the vehicle. NOTE For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4 of Annex VIII b to the Road Traffic Act is required. 2.1 Excerpt from the directive 2001/56/EC Appendix VII for the installation of the heater Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 3 Ford Focus / C-Max / Grand C-Max Information on Validity This installation documentation applies to Ford Focus / C-Max / Grand C-Max Petrol vehicles - for validity, 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. Vehicle and engine types, equipment variants and specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. Technical Information Special Tools • Hose clamp pliers for self-clamping hose clamps • Hose clamp pliers for Clic hose clamps of type W • Automatic wire stripper 0.2 - 6mm² • Crimping pliers for cable lug / tab connector 0.5 - 6mm² • Torque wrench for 2.0 - 10 Nm • Hose clamping pliers • Metric thread-setter kit • Webasto Thermo Test diagnosis with current software Dimensions • All dimensions are in mm. Tightening torque values • Tightening torque values of 5x13 heater bolts = 8Nm. • Tightening torque values of 5x15 retaining plate of water connection piece bolts = 7Nm. • Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-art- technology. Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Special features are highlighted using the following symbols: Mechanical system Specific risk of injury or fatal accidents Electrical system Specific risk of damage to components Coolant circuit Specific risk of fire or explosion Combustion air Reference to general installation instructions of the Webasto components or to the manufacturer's vehicle-specific documents Fuel Exhaust gas Reference to a special technical feature The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle Software Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 4 Ford Focus / C-Max / Grand C-Max Preliminary Work Vehicle • • • • • • • • • • • • • • • • • • • • • Open the fuel tank cap. Ventilate the fuel tank. Close the fuel tank cap again. Depressurise the cooling system. Disconnect and remove the battery. Remove the engine cover. Remove the windscreen wiper. Remove the cover of the coolant reservoir. Remove the cover of the coolant reservoir for the engine compartment. Drain the coolant according to the manufacturer's instructions. Remove the intake manifold. Remove the engine underride protection. Remove the underbody trim on the right next to the tank. Detach the heat protection trim of the exhaust system in the area of the tank. Remove the tank according to the manufacturer's instructions. Remove the footwell trim on the front passenger's side. Remove the glove compartment. Remove the shift lever trim. Remove the trim of the centre console. Remove the A/C control panel in accordance with the manufacturer's instructions. Remove the A-pillar trim of the footwell on the front passenger's side (only with Telestart). Heater • Remove years that do not apply from the type and duplicate label. • Attach the duplicate label (type label) at the appropriate place in the engine compartment. Heater Installation Location 1 1 Heater Installation location 1 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 5 Ford Focus / C-Max / Grand C-Max Preparing Electrical System rt/sw rt gn/ws 0,5² 4² 0,75² Wire sections retain their numbering in the entire document. F3 F4 All equipment Inserting F4, Connect wires to socket of K1 relay. Insert preparing 25A fuse F4. K1 relay is inserted only after in- K1 relay stalling the fuse holder. 1 86 87 85 30 87a K1  Red (rt) wire 4²  Black (sw) wire 4² br 2 0,5² Automatic air-conditioning 5 Cutting wires to length 3 rt 0,5² 500 1000 Connect wires to IPCU socket. IPCU view on contact side. The IPCU included in the kit is pre-programmed with the following settings: 5 4 15 A 86 IPCU 15 A 85 E E 86 7 85 3 6 Duty cycle: Frequency: Voltage: Function:      37% 400Hz 3.6V Low side Premounting IPCU 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 3 and 4 into the attached protective sleeving. Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 6 Ford Focus / C-Max / Grand C-Max Electrical System Focus Plus and earth wire Wiring harness pass through 1 Earth wire, 8 mm dia. cable lug at original vehicle earth support point 2 Positive wire on positive battery terminal 1 Protective rubber plug 1 1 2 2 3 Wiring harness routing diagram (manual air-conditioning) Do not install the metering pump wiring harness until later together with fuel line along the original vehicle fuel lines on the underbody 2 1 4 1 3 4 Digital timer Fuse holder of engine compartment 1 Angle bracket 2 M5x16 bolt, large diameter washer [2x], retaining plate of fuse holder, nut 3 Fuses F1-2 4 M6x20 bolt, flanged nut, existing hole Ident. No.: 1316973E_EN 5 Use clock cable extension when installing digital timer. 1 Digital timer Status: 02.01.2013 © Webasto Thermo & Comfort SE 7 Ford Focus / C-Max / Grand C-Max C-Max / Grand C-Max Plus and earth wire Wiring harness pass through 1 Earth wire, 8 mm dia. cable lug at original vehicle earth support point 2 Positive wire on positive battery terminal 1 Protective rubber plug 1 1 2 6 7 Wiring harness routing diagram Do not install the metering pump wiring harness until later together with fuel line along the original vehicle fuel lines on the underbody 1 1 2 8 9 Fuse holder of engine compartment Digital timer When drilling, pay attention to components located behind. Use clock cable extension when installing digital timer. 1 5.5mm dia. hole, M5x16 bolt, large diameter washer, retaining plate of fuse holder, nut 2 Fuses F1-2 Ident. No.: 1316973E_EN 1 Digital timer Status: 02.01.2013 © Webasto Thermo & Comfort SE 8 Ford Focus / C-Max / Grand C-Max Fan Controller for Manual Air-Conditioning Webasto Ford 30 15 HG F2 F1 1 X2 2 2 5 X1 F10 F23 ge R13 0,5² rt/sw 0,5² Wiring diagram PF3 rt gn/ws 4² 0,75² br rt/sw rt gn/ws 0,5² 0,5² 4² 0,75² C21 gr/ vi 2H403 rt 4² X10 F3 F4 1 86 87 br 0,5² 1 2 C2 4 3 2 1 C1 gr/ vi B 30 M br 0,5² 3 87a K1 85 4 2 2H123 sw 4² 2H105 5 C1 31 Webasto components HG Heater TT-Evo X1 6-pin heater connector X2 2-pin heater connector X10 4-pin connector Heater control K1 Fan relay F1 20A fuse F2 30A fuse F3 1A fuse F4 25A fuse Ident. No.: 1316973E_EN Vehicle components 2H403 Resistor group C2 Connector 2H403 2H123 Fan motor B Connector 2H123 2H105 Fan switch C1 Connector 2H426 C21 Socket connection R13 Fan relay PF3 100A fuse F10 40A fuse F23 5A fuse Status: 02.01.2013 Colours and symbols rt red sw black ge yellow gn green or orange ws white br brown gr grey vi violet Legend X Cutting point Wiring colours may vary. © Webasto Thermo & Comfort SE 9 Ford Focus / C-Max / Grand C-Max Focus 1 1 6.5 mm dia. hole Hole for passenger compartment fuse holder 10 10 1 Mount K1 relay 5 after installation. 2 3 1 M5x16 bolt, large diameter washer [2x], nut 2 Angle bracket 3 M6x20 bolt, flanged nut 4 Fuse holder of passenger compartment 5 Mounting fuse holder of passenger compartment 11 4 1 2 Produce connections as shown in wiring diagram. Connect wiring harness of passenger compartment fuse holder 2 to wiring harness of heater 1 according to wiring diagram, in such a way that wires of the same colour are connected to each other. Connecting wiring harnesses 12 Connect to socket connector C21 3 pin 1 before the fan motor. Produce connections as shown in wiring diagram. 1 3 1 Grey/violet (gr/vi) wire of fan motor 2H123 2 Grey/violet (gr/vi) wire of fan relay R13  Red (rt) wire of K1/87a  Black (sw) wire of K1/30 2 1 Ident. No.: 1316973E_EN 2 Connecting fan motor 13 Status: 02.01.2013 © Webasto Thermo & Comfort SE 10 Ford Focus / C-Max / Grand C-Max Fan Controller for Automatic Air-Conditioning Webasto Ford 30 15 HG F2 1 X2 F1 2 2 5 F10 F23 X1 Wiring diagram PF3 R13 ge gr/vi 0,5² C21 rt/sw 0,5² rt gn/ws 4² 0,75² gr/ or rt 4² gn/ws br 0,5² rt/sw rt gn/ws 0,5² 4² 0,75² F3 F4 X10 sw 0,5² 4² gr/ or C1 2 2H102 1 86 87 87a C3 K1 85 br br 0,5² 0,5² 3 4 1 2 sw 30 0,5² rt 2 0,5² 7 IPCU 86 A ws/ vi B 4 E M 3 br 0,5² 85 6 ws/ vi 15 5 C2 2H123 15 6 2H101 rt 0,5² 31 Webasto components HG Heater TT-Evo X1 6-pin heater connector X2 2-pin heater connector X10 4-pin connector Heater control K1 Fan relay F1 20A fuse F2 30A fuse F3 1A fuse F4 25A fuse IPCU Pulse width modulator IPCU settings: Duty cycle: 37% Frequency: 400Hz Voltage: 3.6V Function: Low side Ident. No.: 1316973E_EN Vehicle components 2H102 Fan controller C1 Connector 2H102 C3 Connector 2H102 2H123 Fan motor B Connector 2H123 2H101 A/C control unit C2 Connector 2H101 C21 Socket connection R13 Fan relay PF3 100A fuse F10 40A fuse F23 5A fuse Colours and symbols rt red sw black ge yellow gn green br brown ws white gr grey vi violet Legend X Cutting point Wiring colours may vary. Status: 02.01.2013 © Webasto Thermo & Comfort SE 11 Ford Focus / C-Max / Grand C-Max 1 Focus 2 1 M5x16 bolt, large diameter washer [2x], nut 2 Angle bracket 3 Fuse and relay socket 4 Mount IPCU socket Premounting K1 relay 4 3 14 1 M6x20 bolt, flanged nut Mounting fuse holder of passenger compartment 1 15 1 2 5 16 Connect to socket connector C21 1 Pin 1 before the fan controller. Produce connections as shown in wiring diagram. 1 2 1 2 Ident. No.: 1316973E_EN Produce connections as shown in wiring diagram. Connect wiring harness of passenger compartment fuse holder 2 to wiring harness of heater 1 according to wiring diagram, in such a way that wires of the same colour are connected to each other. Connecting wiring harnesses 3 2 Green/orange (gr/or) wire of fan relay R13 3 Green/orange (gr/or) wire of fan control- Connectler 2H102 ing fan con Red (rt) wire of K1/87a troller  Black (sw) wire of K1/30  Red (rt) wire of IPCU/15 17 Status: 02.01.2013 © Webasto Thermo & Comfort SE 12 Ford Focus / C-Max / Grand C-Max Connect to connector C2 3 Pin 15 from A/C control unit. Produce connections as shown in wiring diagram. 1 4 3 2 1 White/violet (ws/vi) wire of fan controller 2H102 2 White/violet (ws/vi) wire of connector C2, Pin 15  Red (rt) wire of IPCU/E  Black (sw) wire of IPCU/A Connecting A/C control unit 18 3 C-Max and Grand C-Max 1 Engage fuse holder of passenger compartment 2 in IPCU socket 3. 2 1 M5x16 bolt, large diameter washer, exist- Mounting ing threaded hole fuse holder of passenger compartment 19 3 1 K1 relay Mounting K1 relay 1 20 1 2 7 6 Ident. No.: 1316973E_EN Produce connections as shown in wiring diagram. Connect wiring harness of passenger compartment fuse holder 2 to wiring harness of heater 1 according to wiring diagram, in such a way that wires of the same colour are connected to each other. Connecting wiring  Brown (br) wire of IPCU/85 harnesses  Green/white (gn/ws) wire of IPCU/86 21 Status: 02.01.2013 © Webasto Thermo & Comfort SE 13 Ford Focus / C-Max / Grand C-Max 1 Connect to socket connector C21 3 Pin 24 before the fan controller. Produce connections as shown in wiring diagram. 2 1 Green/violet (gr/vi) wire of fan controller 2H102 2 Grey/violet (gr/vi) wire of fan relay R13  Red (rt) wire of K1/87a  Black (sw) wire of K1/30  Red (rt) wire of IPCU/15 3 2 5 1 22 1 4 Connect to connector C2 3 Pin 15 from A/C control unit. Produce connections as shown in wiring diagram. 1 White/violet (ws/vi) wire of fan controller 2H102 2 White/violet (ws/vi) wire of connector C2, Pin 15  Red (rt) wire of IPCU/E  Black (sw) wire of IPCU/A 3 2 3 Connecting fan controller Connecting A/C control unit 23 Remote Option (Telestart) 1 C-Max / Grand C-Max Fasten receiver 1 with adhesive tape. Mounting receiver 24 1 Antenna 1 Mounting antenna 25 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 14 Ford Focus / C-Max / Grand C-Max Focus 1 Angle down bracket of receiver 2 as shown. 2 3 1 M6x20 bolt, flanged nut, existing hole 3 Receiver Mounting receiver 26 1 Antenna 1 Mounting antenna 27 Temperature sensor T100 HTM 1 All vehicles 2 Fasten temperature sensor 2 with cable tie 1 to original vehicle wiring harness. Mounting temperature sensor 28 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 15 Ford Focus / C-Max / Grand C-Max 1 Preparing Installation Location 2 C-Max / Grand C-Max Remove insulating tape 1 from original vehicle wiring harness, uncover connector. 2 Remove cable tie (cable bracket) Preparing installation location 29 1 Wind connector 2 with insulation strips and fasten with cable tie 1 to original vehicle wiring harness. 2 Tying back connector 30 1 1 Angle bracket 25 1 Cutting angle bracket to length 1 Angle bracket 2 Original vehicle stud bolt, plate nut 1 Mounting angle bracket 2 31 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 16 Ford Focus / C-Max / Grand C-Max 1 1 Cable tie, angle bracket 2 Cable tie 3 Passenger compartment wiring harnesses, heater control 4 Original vehicle wiring harness 2 4 Fastening wiring harnesses 3 32 1 Position wiring harness of circulating pump 3 and route on the firewall to the centre. 1 1 Cable tie 2 Wiring harness of heater Routing wiring harnesses 3 2 33 All vehicles 1 Screw on M8 flanged nut 1 approx. 25mm on original vehicle stud bolt. Premounting flanged nut 34 Screw on one M8 flanged nut 1 each approx. 25mm on original vehicle stud bolts. 1 1 Premounting flanged nut 35 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 17 Ford Focus / C-Max / Grand C-Max Preparing Heater 1 1 Water connection piece, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of water connection pieces 2 Mounting water connection pieces 36 1 1 Discard section 2 90° moulded hose 1 Cutting 90° moulded hose to length 37 1 Mount combustion air pipe 2 on heater with insulation strip 1 as installation aid. 1 3 Air-intake manifold 4 Fuel line 5 90° moulded hose, 10 mm dia. clamp [2x] Premounting heater 2 5 1 4 3 38 1 5x13 self-tapping bolt [3x] 2 50 mm edge protection [2x], divide at centre 3 Bracket 1 3 Mounting bracket 2 1 Ident. No.: 1316973E_EN 2 39 Status: 02.01.2013 © Webasto Thermo & Comfort SE 18 Ford Focus / C-Max / Grand C-Max 1 Fasten fuel line 2 on bracket with a half insulation strip 1 each. 1 Mounting fuel line 40 2 115 kW Focus, C-Max and Grand C-Max 1 M6x16 bolt, spring lockwasher 2 Exhaust silencer Mounting exhaust silencer 2 41 1 1 Installing Heater 2 Install heater on firewall. 1 Wiring harness of heater [2x] 2 Circulating pump wiring harness 42 1 1 Attaching wiring harnesses 1 Mount heater on original vehicle stud bolt [3x]. Pull fuel line 2 with wiring harness of metering pump into 10 mm dia., 2100 mm long corrugated tube and route to the underbody along original vehicle lines. 2 1 M8 flanged nut [2x] Mounting heater 43 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 19 Ford Focus / C-Max / Grand C-Max 1 M8 flanged nut 1 Mounting heater 44 Align heater as shown. Ensure sufficient distance from neighbouring components, especially from A/C line 1. Correct if necessary. 1 Mounting heater 45 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 20 Ford Focus / C-Max / Grand C-Max Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Any fuel running off should be collected in an appropriate container. Install fuel line and metering pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Mount the fuel line and wiring harness with rub protection on sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. 1 2 3 Complete connector of metering pump after routing. Pin assignment is not relevant. 4 5 1 2 3 4 5 Connector housing Lock Blue/brown (bl / br) wires Coding Timer lock Dismantling connector 5 46 1 Fuel line and wiring harness of metering pump in corrugated tube 1 Routing lines 1 47 Remove fuel tank according to manufacturer's instructions. Remove and dismantle fueltank sending unit 1 according to manufacturer's instructions. Cut off 5mm from connection piece 2 and countersink gently. 1 Fuel extraction 2 48 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 21 Ford Focus / C-Max / Grand C-Max 1 Drill out 5.1 mm dia. hole Fuel extraction 1 49 Cut standpipe 2 to length at centre in the bulge as shown. 1 1 Cutting point 3 Discard section Shortening fuel standpipe 3 2 50 1 Connection pieces Installing fuel standpipe 1 51 Paste fuel standpipe 2 in the connection piece 1 with suitable contact adhesive. Cut standpipe 2 to length obliquely at the end (measured from standpipe passage). 1 2 Installing fuel standpipe 180 52 Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 22 Ford Focus / C-Max / Grand C-Max 1 Installing retaining clamp 2 Standpipe 1 1 Fixing of fuel standpipe 2 53 2 Install fuel-tank sending unit 1 in accordance with manufacturer's instructions. Mount coupling piece 2 on connection piece 1 2 Fuel extraction 54 Install fuel-tank according to manufacturer's instructions. 1 1 Fuel line 2 Moulded hose 3 10mm dia. clamp 3 55 2 1 2 Focus / C-Max 3 1 2 3 4 5 6 7 7 6 Ident. No.: 1316973E_EN 5 Connecting fuel line 4 Perforated bracket Cable tie Metering pump 180° moulded hose, 10 mm dia. clamp M6x25 bolt, flanged nut Mounting of metering pump 90° moulded hose, 10 mm dia. clamp Premounting metering pump 56 Status: 02.01.2013 © Webasto Thermo & Comfort SE 23 Ford Focus / C-Max / Grand C-Max 1 Perforated bracket 2 Original vehicle bolt 3 Fuel line of fuel standpipe in corrugated tube 4 10 mm dia. clamp 4 Mounting metering pump 1 3 57 2 1 2 Check the position of the components; adjust if necessary. Check that they have freedom of movement. 3 1 2 3 4 Fuel line of heater 10 mm dia. clamp Cable tie Wiring harness of metering pump, connector mounted Connecting metering pump 58 4 Grand C-Max 1 1 Perforated bracket Angling down perforated bracket 57 90° 1 1 2 3 4 5 2 M6x25 bolt, washer, flanged nut Cable tie Mounting of metering pump Metering pump Perforated bracket 3 5 Ident. No.: 1316973E_EN 4 Premounting metering pump 59 Status: 02.01.2013 © Webasto Thermo & Comfort SE 24 Ford Focus / C-Max / Grand C-Max Detach retaining clip of original vehicle wiring harness 1 at position 2. 1 2 Drill out 9.1 mm dia. hole, rivet nut Installing rivet nut 60 2 1 M6x20 bolt, spring lockwasher 2 Perforated bracket Mounting metering pump 2 61 1 1 2 1 180° moulded hose, 10 mm dia. clamp [2x] 2 Fuel line of fuel standpipe in corrugated tube 3 Wiring harness of metering pump, connector mounted 4 Fuel line of heater Connect5 Hose section, 10 mm dia. clamp [2x] ing metering pump 3 5 1 4 62 Check the position of the components; adjust if necessary. Check that they have freedom of movement. 2 1 Fuel line of fuel standpipe in corrugated tube 2 Cable tie 3 Adhesive base, cable tie 4 Fuel line of heater and wiring harness of metering pump in corrugated tube 4 Ident. No.: 1316973E_EN 3 Routing lines 63 Status: 02.01.2013 © Webasto Thermo & Comfort SE 25 Ford Focus / C-Max / Grand C-Max 1 2 Combustion Air 3 1 2 3 4 4 Ident. No.: 1316973E_EN Silencer 51 mm dia. clamp Combustion air pipe Original vehicle stud bolt, washer, original vehicle nut (covered by clamp) Mounting silencer 64 Status: 02.01.2013 © Webasto Thermo & Comfort SE 26 Ford Focus / C-Max / Grand C-Max 1 Exhaust Gas 2 1 Exhaust pipe a = 190 2 Exhaust end section b = 350 a Preparing exhaust pipe b 1 Perforated bracket 1 Angling down perforated bracket 78 90° 1 Perforated bracket 2 M6x20 bolt, flanged nut, existing hole 1 Mounting perforated bracket 65 2 77kW Focus 1 1 2 3 4 4 3 Ident. No.: 1316973E_EN 2 Silencer M6x16 bolt M6x16 bolt, spring lockwasher Perforated bracket Premounting silencer 66 Status: 02.01.2013 © Webasto Thermo & Comfort SE 27 Ford Focus / C-Max / Grand C-Max 1 Flanged nut 2 Bracket 1 Mounting silencer 67 2 1 Hose clamp [2x] 2 Exhaust pipe 1 Mounting exhaust pipe 2 68 1 1 Hose clamp 2 Exhaust end section 1 Mounting exhaust end section 2 69 92kW / 110kW Focus, C-Max and Grand C-Max 1 1 Hose clamp [2x] 2 Exhaust pipe Mounting exhaust pipe 2 Ident. No.: 1316973E_EN 1 70 Status: 02.01.2013 © Webasto Thermo & Comfort SE 28 Ford Focus / C-Max / Grand C-Max 1 Hose clamp 2 Exhaust end section 1 Mounting exhaust end section 2 71 All vehicles 1 2 1 2 3 4 Exhaust end section M6x20 bolt, flanged nut Perforated bracket P-clamp 4 3 Fastening exhaust end section 72 1 Underride protection 2 60 mm dia. hole 1 Cutting out underride protection 170 105 73 2 Mount underride protection of engine 1. Align exhaust end section 2 flush on underride protection 1. Ensure sufficient distance from neighbouring components. 1 Aligning exhaust end section 2 Ident. No.: 1316973E_EN 74 Status: 02.01.2013 © Webasto Thermo & Comfort SE 29 Ford Focus / C-Max / Grand C-Max 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: Hose routing diagram B C 1 A All spring clips = 25 mm dia. Hose clamp All connecting pipes = 18x18 mm dia. 1 = Black (sw) rubber isolator Ident. No.: 1316973E_EN = 20-27 mm dia. Status: 02.01.2013 © Webasto Thermo & Comfort SE 30 Ford Focus / C-Max / Grand C-Max Discard section X. Hose C = 180°, 18 mm dia. moulded hose. A B A = B = X 260 225 Cutting hoses to length C 1 100 mm long heat shrink plastic tubing B 35 Preparing hose B 75 1 Cut hose of engine outlet / heat exchanger inlet at the marking. Open lock of original vehicle hose bracket 3, will be relocked. 1 35 1 Hose on heat exchanger inlet 2 Hose of engine outlet 2 3 Cutting point 76 1 Black (sw) rubber isolator 2 Hose on heat exchanger inlet C 2 Ident. No.: 1316973E_EN 1 Connecting heat exchanger inlet 77 Status: 02.01.2013 © Webasto Thermo & Comfort SE 31 Ford Focus / C-Max / Grand C-Max B Connection on heater outlet C 78 1 65 2 20 1 Perforated bracket 2 Discard section Cutting to length and bending perforated bracket 26 46 45° 1 1 2 3 4 2 M6x25 bolt, flanged nut Perforated bracket Circulating pump Circulating pump mounting Premounting circulating pump 4 79 3 1 1 Perforated bracket 2 Original vehicle stud bolt, with nut 3 Mount wiring harness of circulating pump 2 Mounting circulating pump 3 Ident. No.: 1316973E_EN 80 Status: 02.01.2013 © Webasto Thermo & Comfort SE 32 Ford Focus / C-Max / Grand C-Max 1 Hose of engine outlet 2 Hose bracket 3 Close lock of hose bracket 1 Connecting engine outlet 2 81 3 Align hoses. Ensure sufficient distance from neighbouring components. Connection on heater inlet A Ident. No.: 1316973E_EN 82 Status: 02.01.2013 © Webasto Thermo & Comfort SE 33 Ford Focus / C-Max / Grand C-Max Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose wires. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). • • • • Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. Adjust digital timer, teach Telestart transmitter. Make settings on A/C control panel according to the "Operating Instructions for End Customer". • Place the "Switch off parking heater before refuelling" signboard in the area of the filler neck. • See installation instructions for initial startup and function check. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1316973E_EN Status: 02.01.2013 © Webasto Thermo & Comfort SE 34 Ford Focus / C-Max / Grand C-Max Operating Instructions for Manual A/C Focus Please remove this page in case of manual air-conditioning and add it to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. Passenger compartment monitoring , if installed, must be deactivated in addition to the vehicle settings for the heating operation. Instructions for deactivation can be taken from the operating instructions manual of the vehicle. Before parking the vehicle, make the following settings: 1 2 1 Set fan to level "1", or max. "2" 2 Air outlet to windscreen 3 Set temperature to "max." A/C control panel 83 3 1 30A main fuse F2 of passenger compartment 2 20A fuse F1 of heater 1 Fuses of engine compartment 2 84 1 1A fuse F3 of heater control 2 25A fan fuse F4 Fuses of passenger compartment 2 1 85 Ford Focus / C-Max / Grand C-Max Operating Instructions for Automatic A/C Focus Please remove this page in case of automatic air-conditioning and add it to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. Passenger compartment monitoring , if installed, must be deactivated in addition to the vehicle settings for the heating operation. Instructions for deactivation can be taken from the operating instructions manual of the vehicle. Before parking the vehicle, make the following settings: 1 Fan speed need not be pre-set. 1 1 Set temperature to "HI" 2 Air outlet to windscreen A/C control panel 2 86 1 30A main fuse F2 of passenger compartment 2 20A fuse F1 of heater 1 Fuses of engine compartment 2 87 1 1A fuse F3 of heater control 2 25A fan fuse F4 Fuses of passenger compartment 2 1 88 Ford Focus / C-Max / Grand C-Max Operating Instructions for Automatic A/C C-Max / Grand C-Max Please remove this page in case of automatic air-conditioning and add it to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. Passenger compartment monitoring , if installed, must be deactivated in addition to the vehicle settings for the heating operation. Instructions for deactivation can be taken from the operating instructions manual of the vehicle. Before parking the vehicle, make the following settings: 1 Fan speed need not be pre-set. 1 1 Set temperature to "HI" 2 Air outlet to windscreen A/C control panel 2 89 1 30A main fuse F2 of passenger compartment 2 20A fuse F1 of heater 1 Fuses of engine compartment 2 90 1 1A fuse F3 of heater control 2 25A fan fuse F4 Fuses of passenger compartment 2 1 91