Water Heater
Feel the drive
e1
Thermo Top V Parking Heater
00 0018
Installation instructions
Ford S-MAX / Galaxy (CD 34*) from Model 2006
Ford Mondeo (CD 34*) from Model 2007
Diesel
Left-hand drive vehicle
Automatic air-conditioning
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 heater 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 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.
Ident. No.: 1311407G_EN
Fee Euro 10.00
© Webasto AG
Ford S-Max / Galaxy / Mondeo
Table of contents
Validity
Heater / delivery scope
Foreword
General instructions
Special tools
Explanatory notes on document
Preliminary work
Heater installation location
Electrical system
Preparing electrical system
Preparing wiring harness
Control of automatic air-conditioning version A
Control of automatic air-conditioning version B
2
3
3
3
3
4
5
5
6
7
7
8
11
Connection diagram for heater control
Digital timer
Remote option (Telestart)
Thermo Call option
Premounting heater
Installing heater
Installing exhaust system
Fuel
Coolant circuit 2.0 l
Coolant circuit 2.2 l
Final Work
14
15
16
17
19
20
20
22
25
30
35
Validity
Manufacturer
Ford (D)
Ford (D)
Ford (D)
Model
S-MAX
Galaxy
Mondeo
Type
WA 6
WA 6
BA 7
EG-BE No./ ABE
e13 * 2001/116 * 0185 * ...
e13 * 2001/116 * 0185 * ...
e13 * 2001/116 * 0249 * ...
Engine model
Diesel
Diesel
Output in kW
96
103
Displacement in cm³
1997
1997
Engine model
Diesel
Diesel
Diesel
Output in kW
96
103
129
Displacement in cm³
1997
1997
2179
Engine model
Diesel
Diesel
Output in kW
96
103
Displacement in cm³
1997
1997
S-MAX
Engine type
AZ
QX
Galaxy
Engine type
AZ
QX
Q4
Mondeo
Engine type
AZ
QX
The installation location of a digital timer or push button should be confirmed with the end customer
before installation.
1311407G_EN
2
Ford S-Max / Galaxy / Mondeo
Heater / delivery scope
Delivery scope:
Quantity
1
Description
Delivery scope of Ford S-Max/Galaxy/Mondeo Diesel
without control element
Order No.
1311401C
Required additionally for vehicles with automatic air conditioning:
Quantity
1
Description
Kit for Automatic Air-Conditioning
Order No.
1311421A
Optional heater control either:
Quantity
1
1
1
1
Description
Digital timer
Telestart T80
Telestart T91
Thermo Call II
Order No.
9010869A
9010870A
9016028A
9016027A
Required additionally when using Thermo Call and Telestart
Quantity
1
Description
Y-Cable
Order No.
9001505A
Foreword
These installation instructions apply to diesel vehicles Ford S-MAX / Galaxy from model year 2006
and Ford Mondeo vehicles from model year 2007 - for validity, see page 2 - assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Vehicle and engine types,
equipment variants and national specifications not listed in these installation instructions have not been
tested. The installation must be according to these "installation instructions“ - Changes are not allowed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
However, where this is the case the stipulations in these "installation instructions" and "operating instructions" for the Thermo Top V should be observed.
A fault may have been stored in the fault memory "Heating, ventilation and air conditioning" by
the operation of the parking heater. This must be deleted in accordance with the manufacturer's
specifications.
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 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).
Special tools
-
Torque wrench for 2.0 - 10 Nm
Hose clamping pliers
Metric thread-setter kit
Unlocking tool, Ford No.: GV 3301 (4x)
1311407G_EN
3
Ford S-Max / Galaxy / Mondeo
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.
Mechanical system
Electrical system
Water
Fuel
Exhaust gas
Combustion air
Software
Special features are highlighted using the following symbols:
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Reference to these, the general installation instructions
of the Webasto operating elements and to
vehicle-specific documents of the manufacturer
Reference to a special technical feature.
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
All dimensions are in mm! Install fuel connections without impacts.
Tightening torque of 5x13 heater bolts = 7Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
1311407G_EN
4
Ford S-Max / Galaxy / Mondeo
Preliminary work
WARNING!
-
Open the fuel tank cap and vent the fuel tank.
Close the tank cap again.
Disconnect the battery "earth" or "ground" connection.
Depressurize the 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.
Mount the information sign on the cover of the diagnosis connection.
Remove the engine design cover.
Remove the battery and the battery carrier.
Remove the air filter box.
Remove the windshield wipers (S-MAX and Galaxy only).
Remove the coolant reservoir cap (S-MAX and Galaxy only).
Remove the coolant reservoir trim in the engine compartment (S-MAX and Galaxy only).
Remove the bracket of the coolant hoses (S-MAX and Galaxy only).
Remove the right front wheel.
Remove the wheel well trim on the right.
Remove the lower engine cover.
Remove the cover of the fuel line under the vehicle.
Remove the switch or trim strip above the A/C control panel/radio or A/C/navigation control unit
[clipped in] (S-MAX and Galaxy only).
Remove the cover of the center console/shift lever cover.
Remove the A/C control panel/radio or A/C/navigation control unit.
Remove the glove compartment.
Remove the cover of the A-pillar trim on the right (S-MAX and Galaxy only).
Remove the lower instrument panel trim on the front passenger side (Mondeo only).
Detach the fuse box [SJB] and fold it down.
Heater installation location
1
1 Heater
Installation location
1
1311407G_EN
5
Ford S-Max / Galaxy / Mondeo
Electrical system
Wiring harness pass through
Routing in engine compartment
1 Protective rubber plug
1 Wiring harness of heater
1
1
1
2
sw
3
rt
Wiring harness installation
diagram
gn/ws
Do not install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the underbody
1
2
3
1
4
2
6
4
5
Fuse holder, K3 relay
Power supply for wiring harness of heater
Drill out hole at position 1 to 5.5 mm dia.
1 Connection of positive battery terminal
2 Original vehicle ground point
1 Retaining plate of fuse holder, M5x16 bolt,
washers, nut
2 K3 relay, M5x16 bolt, washers, nut
3 Fuse holder
4 M6x12 bolt, original vehicle hole, M6 flanged
nut
1311407G_EN
6
Ford S-Max / Galaxy / Mondeo
Preparing electrical system
gn/ws
gn/ws
0,75²
Install 2,500 mm green/white (gn/ws) wire
section 1 in included protective sleeving.
2
0,75²
1
86
87
85
30
Premounting wiring
harness
87a
K3
Preparing wiring harness
1
Mount yellow (ge) wire 3 in free socket of 4pin connector 2.
1 Insulate brown (br) wire and tie back
4 Wiring harness of heater
5 Insulate violet (vi) wire and tie back
5
4
3
Preparing
wiring harness
6
2
Route wiring harness of heater 1 along original vehicle wiring harness and secure with
cable ties.
1
Routing in
engine
compartment
7
1311407G_EN
7
Ford S-Max / Galaxy / Mondeo
Control of automatic air-conditioning version A
Vehicle equipment if violet/green (vi/gn) wire is present on radio connector A, PIN 16.
Webasto
Webasto
Ford
F3
Wiring diagram
vi/gn
bl/sw
F28
HG
X1
30
75
ge
8
St A
12
16
15
AD
gn
GRs
86
gn/ws
M1
87 87a
rt/ws
C2
2
C21
K3.1
85
M
A
30
br/bl
0,5²
2
gn
ws/vi
0,5²
br/bl
rt
1
0,5²
86
87 87a
br
K3
85
ws/vi
gr/vi
30
0,5²
4²
St A
26
15
St B
KB
sw
gr/vi
15
gn/ws
IPCU
A
E
86
gr/or *
4²
sw
rt
+
St C
GM
M
69
SJB
gr/or
85
gr/or
rt
gn/ws
D
St A
1
2
sw
GRr
4
6
C2RT
031
31
Webasto components
HG
TT-V heater
X1
8-pin connector
F3
Fuse 25A
K3
Fan relay
K3.1
Additional relay
IPCU Pulse width modulator
D
Diodes integrated in wiring harness
IPCU adjustment values
Voltage: 10 V
Frequency: 400 Hz
Duty cycle: 37 %
Function: Low-side
1311407G_EN
Vehicle components
GM
Fan motor
GRs
Fan relay
GRr
Fan controller
KB
A/C control panel
F28
Fan fuse
Positioning motor of air flap
M1
SJB
Smart Junction Box
C21
Black connector
AD
Radio
C2T031 Receiver WFS
*
depending on equipment
Colours and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
bl
blue
ge
yellow
vi
violet
gr
gray
Legends
X
Cutting point
Wiring colours may vary.
8
Ford S-Max / Galaxy / Mondeo
Cut dual lock 1x in centre.
Fasten relay K3.1 2 and IPCU 1 with dual lock
as shown.
Watch space requirement of A/C control unit
or radio and their wiring harnesses.
Installing
IPCU and
K3.1 relay
2
1
8
Connection on white (ws) connector B 5 from
A/C control panel, Pin 15.
Make connections as shown in wiring diagram with existing connectors.
1
2
5
4
3
Connection of A/C
control
panel /
IPCU
Connection on black (sw) connector A 5 from
A/C control panel, Pin 26.
Make connections as shown in wiring diagram with existing connectors.
3
4
5
White/violet (ws/vi) wire to fan controller
Black (sw) wire from IPCU/A
Red (rt) wire from IPCU/E
White/violet (ws/vi) wire from connector of
A/C control panel
9
2
1
1
2
3
4
1 Brown/blue (br/bl) wire from connector of
A/C control panel
2 Brown/blue (br/bl) wire to flap positioning
motor
3 Green (gn) wire from K3.1/87
4 Green (gn) wire from K3.1/30
Connection of A/C
control
panel /
K3.1 relay
10
Connection on connector 3 from radio.
Make connections as shown in wiring diagram with existing connectors.
5
1
1
2
4
5
Brown (br) wire from K3.1/85
Black/blue (sw/bl) wire (ground)
Violet/green (vi/gn) wire (Terminal 75)
Yellow (ge) wire from K3.1/86
Connection of K3.1
to radio
4
2
3
1311407G_EN
11
9
Ford S-Max / Galaxy / Mondeo
Produce connections as shown in wiring diagram.
1
1 Green/white (gn/ws) wire from K3/86
2 Green/white (gn/ws) wire
Connection of
green/whit
e (gn/ws)
wire from
K3/86
2
12
1
2
Connection on blue (bl) connector 1, Pin 69.
Produce connections as shown in wiring diagram.
Depending on vehicle equipment, two cables
may be present on Pin 69.
3
2 Gray/orange (gr/or) wire to fan controller
(see wiring diagram)
3 Black (sw) wire
4 Red (rt) wire
5 Gray/orange (gr/or) wire to SJB connector
(see wiring diagram)
5
1
4
13
Connection on black (sw) connector 3.
Produce connections as shown in wiring diagram.
2
1
2
4
5
5
1311407G_EN
4
Connection of SJB
connector
3
Black (sw) wire from relay K3/30
Gray/violet (gr/vi) to fan motor
Gray/violet (gr/vi) wire
Red (rt) wire from relay K3/87a
Connecting fan motor
14
10
Ford S-Max / Galaxy / Mondeo
Control of automatic air-conditioning version B
Vehicle equipment if violet/green (vi/gn) wire is not present on radio connector A, PIN 16.
Webasto
Webasto
Ford
F3
Wiring diagram
bl/sw
F28
HG
X1
30
75
St A
8
12
15
AD
ge
gn
GRs
86
gn/ws
rt/ws
M1
87 87a
A
30
br/bl
0,5²
gn
br
2
C2
2
C21
K3.1
85
M
ws/vi
0,5²
br/bl
rt
1
0,5²
86
87 87a
85
30
K3
ws/vi
gr/vi
ge
0,5²
4²
St A
26
15
St B
KB
sw
gr/vi
15
gn/ws
IPCU
A
E
86
gr/or *
4²
sw
rt
+
St C
GM
M
69
SJB
gr/or
85
gr/or
rt
gn/ws
D
St A
1
2
sw
GRr
4
6
C2RT
031
31
Webasto components
HG
TT-V heater
X1
8-pin connector
F3
Fuse 25A
K3
Fan relay
K3.1
Additional relay
IPCU Pulse width modulator
D
Diodes integrated in wiring harness
IPCU adjustment values
Voltage:
10 V
Frequency: 400 Hz
Duty cycle: 37 %
Function: Low-side
1311407G_EN
Vehicle components
GM
Fan motor
GRs
Fan relay
GRr
Fan controller
KB
A/C control panel
F28
Fan fuse
Positioning motor of air flap
M1
SJB
Smart Junction Box
C21
Black connector
AD
Radio
C2T031 Receiver WFS
*
depending on equipment
Colours and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
bl
blue
ge
yellow
vi
violet
gr
gray
Legends
X
Cutting point
Wiring colours may vary.
11
Ford S-Max / Galaxy / Mondeo
Cut dual lock 1x in centre.
Fasten relay K3.1 2 and IPCU 1 with dual lock
as shown.
Watch space requirement of A/C control unit
or radio and their wiring harnesses.
2
Installing
IPCU and
K3.1 relay
1
15
Connection on white (ws) connector B 5 from
A/C control panel, Pin 15.
Produce connections as shown in wiring diagram.
1
2
5
4
3
1
2
3
4
1311407G_EN
1 Brown/blue (br/bl) wire from connector of
A/C control panel
2 Brown/blue (br/bl) wire to flap positioning
motor
3 Green (gn) wire from K3.1/87
4 Green (gn) wire from K3.1/30
Connection of A/C
control
panel /
K3.1 relay
17
5
5
Connection of A/C
control
panel /
IPCU
Connection on black (sw) connector A 5 from
A/C control panel, Pin 26.
Produce connections as shown in wiring diagram.
3
4
6
White/violet (ws/vi) wire to fan controller
Black (sw) wire from IPCU/A
Red (rt) wire from IPCU/E
White/violet (ws/vi) wire from connector of
A/C control panel
16
2
1
1
2
3
4
Connection on connector 5 from radio.
Produce connections as shown in wiring diagram.
Connect yellow (ge) wire 1 from K3.1/86 to
yellow (ge) wire 6 and route in protective
sleeving into footwell on front passenger side.
2 Brown (br) wire from K3.1/85
3 Black/blue (sw/bl) wire (ground)
4 Black/blue (sw/bl) wire (ground) from connector Pin 12
Connection of
K3.1/85 on
radio
18
12
Ford S-Max / Galaxy / Mondeo
Produce connections as shown in wiring diagram.
1
1 Green/white (gn/ws) wire from K3/86
2 Green/white (gn/ws) wire
Connection of
green/whit
e (gn/ws)
wire from
K3/86
2
19
1
2
Connection on blue (bl) connector 1, Pin 69.
Produce connections as shown in wiring diagram.
Depending on vehicle equipment, two cables
may be present on Pin 69.
3
2 Gray/orange (gr/or) wire to fan controller
(see wiring diagram)
3 Black (sw) wire
4 Red (rt) wire
5 Gray/orange (gr/or) wire to SJB connector
(see wiring diagram)
4
5
1
20
Connection on black (sw) connector 4.
Produce connections as shown in wiring diagram.
2
6
3
5
1311407G_EN
4
Connection of SJB
connector
1
2
3
5
6
Black (sw) wire from relay K3/30
Gray/violet (gr/vi) to fan motor
Red (rt) wire from relay K3/87a
Gray/violet (gr/vi) from connector
Yellow (ge) wire from relay K3.1/86
Connecting fan motor
21
13
Ford S-Max / Galaxy / Mondeo
Connection diagram for heater control
TT-V
9001505A
Installing yellow (ge) line
Insulate violet (vi) wire
Remove black (sw) wire and insulate
Thermo Call
Insulate yellow (ge) wire
9013674A
67089A
Insert violet (vi) wire from Pin 5 into Pin 2
Telestart T80/T91
Push button
1311407G_EN
14
Ford S-Max / Galaxy / Mondeo
Digital timer
1
S-MAX / Galaxy Version A
1 Digital timer
Installing
digital timer
22
S-MAX / Galaxy Version B
1
1 Digital timer
Installing
digital timer
23
Mondeo
1
1 Digital timer
Installing
digital timer
24
1311407G_EN
15
Ford S-Max / Galaxy / Mondeo
Remote option (Telestart)
1
S-MAX / Galaxy
2
1 Underside of glove compartment
2 Telestart receiver, dual lock
Installing
receiver
25
1 Antenna
1
Installing
antenna
26
Mondeo
1 Instrument panel on front passenger side
2 Telestart receiver, dual lock
1
Installing
receiver
27
2
1 Antenna
1
Installing
antenna
28
1311407G_EN
16
Ford S-Max / Galaxy / Mondeo
Thermo Call option
1
S-MAX and Galaxy
1 Thermo Call, dual lock
Installing
receiver
29
1
1 GPS antenna (Thermo Call Locate only)
2 GSM antenna
2
Installing
antenna
30
1 Push button
1
Installing
push button
31
Mondeo
1
1 Thermo Call, dual lock
Installing
receiver
32
1311407G_EN
17
Ford S-Max / Galaxy / Mondeo
1 Antenna
1
Installing
antenna
33
1 Push button
Installing
push button
1
1311407G_EN
34
18
Ford S-Max / Galaxy / Mondeo
1
Premounting heater
1
Mark premounted coolant hoses 1 [2x] in accordance with direction of flow and connect
adapter wiring harness of circulating pump 3.
2 Heater
4 Fuel line, moulded hose, 10 mm dia. hose
clamp
4
3
35
2
1
Install cable grommet 1 and edge protection
section 2.
2
Preparing
installation location
36
Mount M6 rivet nuts 1 [2x] in existing holes as
shown.
1
Installing
rivet nuts
1
37
Remove water drain 1 from wheel arch.
1
1
Preparing
exhaust
pipe
38
1311407G_EN
19
Ford S-Max / Galaxy / Mondeo
1
1 Pass through
2 Wiring harness of heater
2
Installing
wiring harness of
heater
39
1
Installing heater
2
3
4
Guide fuel line 3 through grommet 1 into engine compartment.
Route adapter cable of circulating pump 4
through pass through 2 into engine compartment.
Connect wiring harness of heater to heater 5.
Installing
heater
5
40
1
2
Loosely mount heater 1 as shown.
3
2 M6x20 bolt [2x], spring lockwasher [2x],
large diameter washer [2x]
3 Combustion air pipe
4 Coolant hoses
5 Pass through
Installing
heater
2
4
5
1
41
Installing exhaust system
2
Install exhaust system 4 on heater 2 as
shown.
Ensure sufficient distance to neighbouring
components.
4
1 Hose clamp
3 M6x20 screw, spring lock washer, washer
3
1311407G_EN
Installing
exhaust
pipe
42
20
Ford S-Max / Galaxy / Mondeo
1 M6x20 screw, spring lock washer, washer
Installing
exhaust
pipe
1
43
1
Tighten M6 bolt 1 [2x].
1
Installing
heater
44
1
Screw protective cap 2 onto intake hose 1.
2
Installing
protective
cap on
combustion air
pipe
45
1311407G_EN
21
Ford S-Max / Galaxy / Mondeo
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with 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 in as shown in the wiring harness
routing diagram.
Route fuel line 1 and metering-pump wiring
harness 2 to underbody and secure on original vehicle lines with cable ties.
1
Routing
lines
46
2
1
Route fuel line and metering-pump wiring
harness 2 to underbody and secure on original vehicle 1 with cable ties.
2
Routing
lines
47
1
1
Secure lines with cable ties.
2
1 Metering pump wiring harness
2 Fuel line
Routing
lines
48
1311407G_EN
22
Ford S-Max / Galaxy / Mondeo
Version 1
1
Drill out angle bracket 2 to 8 mm dia. at position 1.
1 Original vehicle M8 bolt
2
Installing
metering
pump
49
Version 2
1
1 M6x20 bolt, large diameter washer, flanged nut
2 Angle bracket
2
Installing
metering
pump
50
1
Check the position of the components; adjust
if necessary. Check that they have free clearance.
2
1 Metering pump
2 M6x20 bolt, washer, flanged nut
3 Metering pump bracket
3
Installing
metering
pump
51
Route fuel line 1 and wiring harness of metering pump 2 along original vehicle fuel line and
secure with cable ties.
1
Routing
lines
2
52
1311407G_EN
23
Ford S-Max / Galaxy / Mondeo
1
Fuel line from heater 3 on pressure side of
metering pump.
Check the position of the components; adjust
if necessary. Check that they have free clearance.
Remount cover of fuel lines.
2
1 Hose section, 10 mm dia. hose clamp [2x]
2 Wiring harness of metering pump, connector mounted
3
Connecting metering pump
53
1
Separate fuel return line 1 approx. 70 mm before coupling.
2
2 10x5x10 fuel standpipe, 12 mm dia. hose
clamp [2x]
3 90° moulded hose, hose clamp
10mm dia. [2x]
4 Fuel line
4
Removing
fuel
54
3
1
Fuel line from fuel standpipe 2 on intake side
of metering pump.
Check the position of the components; adjust
if necessary. Check that they have free clearance.
2
1 Hose section, 10 mm dia. hose clamp [2x]
Connecting metering pump
55
1 Cover
1
Installing
cover
56
1311407G_EN
24
Ford S-Max / Galaxy / Mondeo
Coolant circuit 2.0 l
WARNING!
Any coolant running off should be collected using an appropriate container!
Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties. Position
hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Hose routing diagram
E
Ø 15x20
D
C
Ø 22
B
Ø 22
Ø 15x20
A
All clamps without a specific designation = 27 mm dia. spring clips.
All connecting pipes without a specific designation = 20x20mm dia.
1311407G_EN
25
Ford S-Max / Galaxy / Mondeo
Photo shows S-MAX/Galaxy.
Remove hose bracket 1; will be reused.
1
Preliminary work
57
Unclip water drain hose 1; will be reused.
1
Preliminary work
58
1
2
1 Hose section of heat exchanger inlet
2 Cutting point
3 Engine outlet hose section
3
Cutting
point
59
B
Install moulded hose A.
1
1 Premount circulating pump
Premounting circulating
pump
A
1311407G_EN
60
26
Ford S-Max / Galaxy / Mondeo
1
See coolant connection diagram.
Installation is carried out on original vehicle
stud bolt 3 [2x]!
2
1 Hose section on engine outlet
2 Bracket of circulating pump, plastic nuts
[2x]
Connection to engine outlet
3 3
61
A
Connection of
heater inlet
C
62
B
1 Adapter wiring harness of circulating
pump, cable of circulating pump
1
Connecting adapter
wiring harness of circulating
pump
63
E
Moulded
hose E
64
1311407G_EN
27
Ford S-Max / Galaxy / Mondeo
D
See coolant connection diagram.
E
1 Hose bracket
Connection of
heater outlet
4
65
1
Before connecting, fill the coolant hoses with
coolant.
E
1 Hose section on heat exchanger inlet
Connection to heat
exchanger
inlet
66
1
E
Install hose bracket 1 between hose E and
A/C line 2.
1
Installing
hose
bracket
2
67
Mount hose bracket 1 as shown.
Installing
hose
bracket
1
68
1311407G_EN
28
Ford S-Max / Galaxy / Mondeo
1
1 Hose bracket
2 Water drain hose
2
Installing
hose
bracket
and water
drain
69
1311407G_EN
29
Ford S-Max / Galaxy / Mondeo
Coolant circuit 2.2 l
WARNING!
Any coolant running off should be collected using an appropriate container!
Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties. Position
hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Hose routing diagram
E
D
C
Ø 15x20
Ø 22
B
A
Ø 15x20 Ø 22
All clamps without a specific designation = 27 mm dia. spring clips.
All connecting pipes without a specific designation = 20x20mm dia.
1311407G_EN
30
Ford S-Max / Galaxy / Mondeo
Photo shows S-MAX/Galaxy.
Remove hose bracket 1; will be reused. [if
present]
1
Preliminary work
70
Unclip water drain hose 1; will be reused.
1
Preliminary work
71
Remove hose 1 from engine outlet to heat exchanger inlet.
1
Removing
hose
72
1
2
1 Hose section of heat exchanger inlet
2 Discard hose section
3 Engine outlet hose section
3
Separating
hose
73
1311407G_EN
31
Ford S-Max / Galaxy / Mondeo
1 Discard hose section
70
270
Cutting
moulded
hose to
length
A
E
74
1
1 Engine outlet hose section
Preparing
hose section
1
A
75
1 Hose section of heat exchanger inlet
Preparing
hose section
1
E
76
Replace axial cover of circulating pump with
193° cover.
Replacing
circulating
pump cover
77
1311407G_EN
32
Ford S-Max / Galaxy / Mondeo
B
1 Premount circulating pump
1
Premounting circulating
pump
78
1
See coolant connection diagram.
Installation is carried out on original vehicle
stud bolt 1 [2x].
1
1 Bracket of circulating pump, plastic nuts
[2x]
Installing
circulating
pump
79
Connection of
heater inlet
C
B
80
1 Adapter wiring harness of circulating
pump, cable of circulating pump
Connecting adapter
wiring harness of circulating
pump
1
1311407G_EN
81
33
Ford S-Max / Galaxy / Mondeo
D
E
1
1
See coolant connection diagram.
1
1 Hose bracket [3x]
Connection of
heater outlet
82
1 Hose section of heat exchanger inlet
E
Connecting heat
exchanger
inlet
83
1
Before connecting, fill the coolant hoses with
coolant.
1 Engine outlet hose section
Connection to engine outlet
A
84
1
1
1 Hose bracket
2 Water drain hose
2
Installing
hose
bracket
and water
drain
85
1311407G_EN
34
Ford S-Max / Galaxy / Mondeo
Final Work
WARNING!
Mount removed parts in reverse order.
Check all hoses, clamps and all electrical connections for firm seating.
Secure all loose cables using cable ties.
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.
Bleed the fuel system according to the manufacturer's instructions.
Set the digital timer.
Make A/C control panel adjustments according to "operating instructions"
Check the proper operation of the parking heater, see the "operating instructions".
Place signboard "Switch off parking heater before refuelling" in the area of the filling connecting
piece
- Decode the radio according to the manufacturer's instructions
1
Cut out at marking in lower trim 1 (if installed)
in area of exhaust outlet 2.
2
Cutting out
underride
protection
86
Ensure sufficient distance to neighbouring
components.
1
1 Exhaust outlet
2 Lower trim
Exhaust
outlet
2
87
Feel the drive
Webasto AG
Postfach 80
D-82132 Stockdorf / Germany
National Hotline: 01805 93 22 78
(14 Cent aus dem deutschen Festnetz)
Hotfax: 0395 5592 353
Hotmail:
[email protected]
http://www.webasto.de
1311407G_EN
Printed in Germany
01/2011
Printing: Steffen