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26

Ford Focus / Focus C-MAX / Focus CC

Mounting underride protection

For all vehicles!

Underride protection is dependent on vehicle 
equipment.
Cut out underride protection as shown.

Cutting 
out under-
ride pro-
tection

Only for 1.4 lt; 1.6 lt; 1.8 lt engine

Remove plastic threaded insert.
Drill out hole to 9 mm dia. and insert M6 rivet 
nut.

1

Bracket of heater

2

M6 rivet nut, 10 mm shim

3

Underride protection

4

M6x40 bolt, spring lock washer, large di-
ameter washer

Mounting 
underride 
protection 
for 1.4 lt; 
1.6 lt; 1.8 lt 
engine

Only for 2.0 lt engine.

1

Bracket of heater

2

Premounted bolt

4

Underride protection

3

M6 flanged nut, large diameter washer

Mounting 
underride 
protection 
for 2.0 lt 
engine

For all vehicles!

Figure shows 1.8 lt engine

Check positioning of underride protection. In 
particular, ensure sufficient distance from 
heater exhaust system. Rework cut-out if 
necessary.

Also fasten underride protection for stabiliza-
tion with cable ties at position 

(1)

.

Mounting 
underride 
protection 
for all ve-
hicles

53

54

1

2

4

3

55

1

2

4

3

56

1

Summary of Contents for Thermo Top E

Page 1: ...tall or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required tech nical skills or if you do not have access to the re...

Page 2: ...DA Petrol 59 1388 ASDB Petrol 59 1388 HWDB Petrol 74 1596 HXDA Petrol 85 1596 Q7DA Petrol Flexifuel 92 1798 QQDB Petrol 92 1798 AODA Petrol 107 1999 AODB Petrol 107 1999 Validity 2 Heater installation...

Page 3: ...llation work General instructions Installation should be carried out according to the general standard rules of technology Unless spec ified otherwise fasten hoses lines and wiring harnesses to origin...

Page 4: ...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 Webas to components or to the manu...

Page 5: ...o 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 to...

Page 6: ...6 and pull into protective sleeving Wiring dia gram for additional wire Connect provided wires to IPCU as shown in wiring diagram Connect 6 mm dia cable lug to end of brown br wire from IPCU 85 3 Prem...

Page 7: ...ehind 2 K3 relay 4 mm dia hole 5 5x13 self tapping screw 3 Fuse holder 4 mm dia hole 5 5x13 mm self tapping screw 1 Wiring harnesses routed to right and fastened with cable ties Connection to battery...

Page 8: ...elay 4 mm dia hole 5 5x13 self tapping screw 3 Fuse holder 4 mm dia hole 5 5x13 mm self tapping screw 1 Wiring harnesses routed to right and fastened with cable ties Connection to battery Route wires...

Page 9: ...the coolant reservoir cap When drill ing watch components located behind 1 Fuse holder 4 mm dia hole 5 5x13 mm self tapping screw 2 K3 relay 4 mm dia hole 5 5x13 self tapping screw Wiring harness rout...

Page 10: ...ing fan motor Wiring dia gram with out automatic air condi tioning Webasto components Ford components Colours and symbols Legend HG Heater TT E F10 Fan fuse rt red F3 Fan fuse K14 Fan relay ws white K...

Page 11: ...unit 7 Blue white bl ws wire from A C control module 2 Red rt wire to IPCU E Connect ing air condition ingcontrol panel 1 Connector C540 2 Pin 15 View of connector Connection is carried out on connect...

Page 12: ...lectrical box gn green IPCU settings C95 Connector on P91 bl blue Duty cycle 60 M3 Fan unit or orange Frequency 400Hz C537 Connector on M3 Voltage 10V A205 A C control module EATC X Cutting point Func...

Page 13: ...e 2 Green orange gn or wire of C111 3 3 Connector C111 4 Black sw wire of F4 5 Black sw wire of F4 Fan con troller Complete fuse holder with materials provided and fasten it with double sided adhesive...

Page 14: ...n green IPCU settings C95 Connector on P91 bl blue Duty cycle 27 M3 Fan unit or orange Frequency 400Hz C537 Connector on M3 Voltage 10V A205 A C control module EATC X Cutting point Function Low side C...

Page 15: ...Focus CC Remote option Telestart Receiver is mounted on existing bolt on posi tioning motor 1 Original vehicle bolt Installa tion loca tion of receiver 1 Receiver Mounting receiver 1 Antenna Mounting...

Page 16: ...equipment 1 Remove section and discard Adapting guard plate If threaded inserts are not present at position 1 then mount M10 rivet nuts provided in hexagonal holes Use special tool as shown on page 3...

Page 17: ...17 Ford Focus Focus C MAX Focus CC Screw on flanged nut with flange toward front 1 Original vehicle stud bolt 2 M8 flanged nut Preparing installa tion loca tion 28 2 1...

Page 18: ...ard Coolant assembly Hole in corner of strut is used at position 3 Mount Ejot screw 3 only loosely so that strut 2 can still be aligned during installation Connect wiring harness 4 to the circulating...

Page 19: ...d connect wiring harness as shown Installing heater Use holes in bracket as shown Check position of all components and adjust if necessary Check that they have freedom of movement 1 M10x30 bolt with l...

Page 20: ...heck position of all components and adjust if necessary Check that they have freedom of movement 1 M10x30 bolt spring lockwasher 2x Installing heater Use hole in strut as shown Check position of all c...

Page 21: ...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 follo...

Page 22: ...pen clamp 1 Discard hose Preparing coolant 1 Connection piece of heat exchanger inlet mounted and locked Preparing coolant Before connecting fill the coolant hoses with coolant 1 Black sw rubber isola...

Page 23: ...ing harness of the metering pump are routed as shown in the wiring harness routing diagram 1 Mecanyl fuel line 2 10 mm dia Caillau clamp Route mecanyl fuel line to firewall and fasten with cable ties...

Page 24: ...unting metering pump 1 Mecanyl fuel line and metering pump wir ing harness Wiring routing Removing fuel Remove fuel tank sending unit 4 in accord ance with manufacturer s instructions Break out connec...

Page 25: ...0 mm dia Caillau clamp 3 Clip Reinstall fuel tank Connect ing fuel line Fuel line from fuel standpipe on intake side of metering pump side without connector 1 Fuel line 2 10 mm dia Caillau clamp Check...

Page 26: ...ing lock washer large di ameter washer Mounting underride protection for 1 4 lt 1 6 lt 1 8 lt engine Only for 2 0 lt engine 1 Bracket of heater 2 Premounted bolt 4 Underride protection 3 M6 flanged nu...

Page 27: ...al 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 bat...

Page 28: ...les with automatic air condi tioning 57 1 2 3 58 2 1 1 59 2 1 1 Operating instructions for end customer Please remove page and add to the vehicle operating instructions WARNING On vehicles with Flexyf...

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