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 heat-
er 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 tech-
nical 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 installa-
tion by untrained staff.

Ident. No.: 1311407G_EN Fee Euro 10.00 © Webasto AG

 Ford S-Max / Galaxy / Mondeo

Table of contents
Validity 2 Connection diagram for heater control 14
Heater / delivery scope 3 Digital timer 15
Foreword 3 Remote option (Telestart) 16
General instructions 3 Thermo Call option 17
Special tools 3 Premounting heater 19
Explanatory notes on document 4 Installing heater 20
Preliminary work 5 Installing exhaust system 20
Heater installation location 5 Fuel 22
Electrical system 6 Coolant circuit 2.0 l 25
Preparing electrical system 7 Coolant circuit 2.2 l 30
Preparing wiring harness 7 Final Work 35
Control of automatic air-conditioning version A 8
Control of automatic air-conditioning version B 11

Validity
Manufacturer Model Type EG-BE No./ ABE
Ford (D) S-MAX WA 6 e13 * 2001/116 * 0185 * ...
Ford (D) Galaxy WA 6 e13 * 2001/116 * 0185 * ...
Ford (D) Mondeo BA 7 e13 * 2001/116 * 0249 * ...

S-MAX

Engine type Engine model Output in kW Displacement in cm³

AZ Diesel 96 1997
QX Diesel 103 1997

Galaxy

Engine type Engine model Output in kW Displacement in cm³

AZ Diesel 96 1997
QX Diesel 103 1997
Q4 Diesel 129 2179

Mondeo

Engine type Engine model Output in kW Displacement in cm³

AZ Diesel 96 1997
QX Diesel 103 1997

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 Description Order No.

1 Delivery scope of Ford S-Max/Galaxy/Mondeo Diesel 1311401C
without control element

Required additionally for vehicles with automatic air conditioning:

Quantity Description Order No.

1 Kit for Automatic Air-Conditioning 1311421A

Optional heater control either:

Quantity Description Order No.

1 Digital timer 9010869A
1 Telestart T80 9010870A
1 Telestart T91 9016028A
1 Thermo Call II 9016027A

Required additionally when using Thermo Call and Telestart

Quantity Description Order No.

1 Y-Cable 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 mod-
ifications 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 in-
structions" 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 spec-
ified 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.

1 Heater installation location

1 Heater

Installa-
tion loca-
tion

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 3

sw rt

gn/ws Wiring har-

ness in-
stallation
diagram
Do not install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the under-
body

1 2 3 1

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 Install 2,500 mm green/white (gn/ws) wire

0,75²
2 section 1 in included protective sleeving.
gn/ws 1
0,75² Premount-
ing wiring
86 87 87a harness
K3
85 30

1 Preparing wiring harness

Mount yellow (ge) wire 3 in free socket of 4-
pin connector 2.

1 Insulate brown (br) wire and tie back Preparing

4 Wiring harness of heater wiring har-
5 Insulate violet (vi) wire and tie back ness

5 4 3 2 6

1 Route wiring harness of heater 1 along origi-

nal vehicle wiring harness and secure with
cable ties.

Routing in
engine
compart-
ment

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

30
75

vi/gn
Wiring dia-
F3 bl/sw gram
HG F28
X1 8 ge St A 12 16 15

AD
gn
GRs
86 87 87a M1 M

gn/ws rt/ws
K3.1 C21 2 C2
85 30 A br/bl
0,5²
2
gn ws/vi
br/bl 0,5²
1 rt
0,5²
86 87 87a
br
K3 ws/vi
gr/vi 0,5²
85 30 4²
St A 26 15 St B
sw KB
gr/vi gr/or *
15 4²
gn/ws
IPCU A sw + St C 69
E rt
M GM
- SJB
86 85 gr/or

gr/or

rt
St A 1 2 4 6
gn/ws D sw C2RT
GRr 031
31

Webasto components Vehicle components Colours and symbols

HG TT-V heater GM Fan motor rt red
X1 8-pin connector GRs Fan relay ws white
F3 Fuse 25A GRr Fan controller sw black
K3 Fan relay KB A/C control panel br brown
Legends
K3.1 Additional relay F28 Fan fuse gn green
IPCU Pulse width modulator M1 Positioning motor of air flap bl blue
D Diodes integrated in wir- SJB Smart Junction Box ge yellow
ing harness C21 Black connector vi violet
IPCU adjustment values AD Radio gr gray
Voltage: 10 V C2T031 Receiver WFS
Frequency: 400 Hz * depending on equipment
Duty cycle: 37 % X Cutting point
Function: Low-side Wiring colours may vary.

1311407G_EN 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

1 Connection on white (ws) connector B 5 from

A/C control panel, Pin 15.
Make connections as shown in wiring dia-
gram with existing connectors.

1 White/violet (ws/vi) wire to fan controller Connec-

2 Black (sw) wire from IPCU/A tion of A/C
2 3 Red (rt) wire from IPCU/E control
4 White/violet (ws/vi) wire from connector of panel /
A/C control panel IPCU

5 4 3 9

1 2 Connection on black (sw) connector A 5 from

A/C control panel, Pin 26.
Make connections as shown in wiring dia-
gram with existing connectors.

1 Brown/blue (br/bl) wire from connector of Connec-

3 A/C control panel tion of A/C
2 Brown/blue (br/bl) wire to flap positioning control
4
motor panel /
3 Green (gn) wire from K3.1/87 K3.1 relay
4 Green (gn) wire from K3.1/30

5 10
Connection on connector 3 from radio.
Make connections as shown in wiring dia-
5 gram with existing connectors.

1 1 Brown (br) wire from K3.1/85

2 Black/blue (sw/bl) wire (ground) Connec-
4 Violet/green (vi/gn) wire (Terminal 75) tion of K3.1
5 Yellow (ge) wire from K3.1/86 to radio
4

3 11

1311407G_EN 9
 Ford S-Max / Galaxy / Mondeo

1 Produce connections as shown in wiring dia-

gram.

1 Green/white (gn/ws) wire from K3/86

2 Green/white (gn/ws) wire
Connec-
tion of
2 green/whit
e (gn/ws)
wire from
K3/86

12

1 Connection on blue (bl) connector 1, Pin 69.

2 Produce connections as shown in wiring dia-
gram.

Depending on vehicle equipment, two cables

may be present on Pin 69. Connec-
3 tion of SJB
2 Gray/orange (gr/or) wire to fan controller connector
(see wiring diagram)
3 Black (sw) wire
4 Red (rt) wire
5 Gray/orange (gr/or) wire to SJB connector
(see wiring diagram)

5 4 13

1 2 Connection on black (sw) connector 3.

Produce connections as shown in wiring dia-
gram.

1 Black (sw) wire from relay K3/30

2 Gray/violet (gr/vi) to fan motor Connect-
4 Gray/violet (gr/vi) wire ing fan mo-
5 Red (rt) wire from relay K3/87a tor

5 4 3 14

1311407G_EN 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

30
75

Wiring dia-
F3 bl/sw gram
HG F28
X1 8 St A 12 15

AD
ge gn
GRs
86 87 87a M1 M

gn/ws rt/ws
K3.1 C21 2 C2
85 30 A br/bl
0,5²
br gn
2
ws/vi
br/bl 0,5²
1 rt
0,5²
86 87 87a

K3 ws/vi
gr/vi 0,5²
85 30 ge 4²
St A 26 15 St B
sw KB
gr/vi gr/or *
15 4²
gn/ws
IPCU A sw + St C 69
E rt
M GM
- SJB
86 85 gr/or

gr/or

rt
St A 1 2 4 6
gn/ws D sw C2RT
GRr 031
31

Webasto components Vehicle components Colours and symbols

HG TT-V heater GM Fan motor rt red
X1 8-pin connector GRs Fan relay ws white
F3 Fuse 25A GRr Fan controller sw black
K3 Fan relay KB A/C control panel br brown
Legends
K3.1 Additional relay F28 Fan fuse gn green
IPCU Pulse width modulator M1 Positioning motor of air flap bl blue
D Diodes integrated in wir- SJB Smart Junction Box ge yellow
ing harness C21 Black connector vi violet
IPCU adjustment values AD Radio gr gray
Voltage: 10 V C2T031 Receiver WFS
Frequency: 400 Hz * depending on equipment
Duty cycle: 37 % X Cutting point
Function: Low-side Wiring colours may vary.

1311407G_EN 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 1 Installing
IPCU and
K3.1 relay

15

1 Connection on white (ws) connector B 5 from

A/C control panel, Pin 15.
Produce connections as shown in wiring dia-
gram.

1 White/violet (ws/vi) wire to fan controller Connec-

2 Black (sw) wire from IPCU/A tion of A/C
2 3 Red (rt) wire from IPCU/E control
4 White/violet (ws/vi) wire from connector of panel /
A/C control panel IPCU

5 4 3 16

1 2 Connection on black (sw) connector A 5 from

A/C control panel, Pin 26.
Produce connections as shown in wiring dia-
gram.

1 Brown/blue (br/bl) wire from connector of Connec-

3 A/C control panel tion of A/C
2 Brown/blue (br/bl) wire to flap positioning control
4
motor panel /
3 Green (gn) wire from K3.1/87 K3.1 relay
4 Green (gn) wire from K3.1/30

5 17

1 Connection on connector 5 from radio.

Produce connections as shown in wiring dia-
gram.
Connect yellow (ge) wire 1 from K3.1/86 to
6 2 yellow (ge) wire 6 and route in protective
sleeving into footwell on front passenger side. Connec-
tion of
3 2 Brown (br) wire from K3.1/85 K3.1/85 on
3 Black/blue (sw/bl) wire (ground) radio
4 Black/blue (sw/bl) wire (ground) from con-
4 nector Pin 12

5 18

1311407G_EN 12
 Ford S-Max / Galaxy / Mondeo

1 Produce connections as shown in wiring dia-

gram.

1 Green/white (gn/ws) wire from K3/86

2 Green/white (gn/ws) wire
Connec-
tion of
2 green/whit
e (gn/ws)
wire from
K3/86

19

1 Connection on blue (bl) connector 1, Pin 69.

2 Produce connections as shown in wiring dia-
gram.

Depending on vehicle equipment, two cables

may be present on Pin 69. Connec-
3 tion of SJB
2 Gray/orange (gr/or) wire to fan controller connector
(see wiring diagram)
3 Black (sw) wire
4 Red (rt) wire
5 Gray/orange (gr/or) wire to SJB connector
(see wiring diagram)

5 4 20

1 2 Connection on black (sw) connector 4.

Produce connections as shown in wiring dia-
gram.

1 Black (sw) wire from relay K3/30

2 Gray/violet (gr/vi) to fan motor Connect-
6
3 Red (rt) wire from relay K3/87a ing fan mo-
3 5 Gray/violet (gr/vi) from connector tor
6 Yellow (ge) wire from relay K3.1/86

5 4 21

1311407G_EN 13
 Ford S-Max / Galaxy / Mondeo

Connection diagram for heater control

9001505A TT-V

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

1 Digital timer
S-MAX / Galaxy Version A

1 Digital timer
Installing
digital tim-
er

22

1 S-MAX / Galaxy Version B

1 Digital timer

Installing
digital tim-
er

23

1 Mondeo

1 Digital timer

Installing
digital tim-
er

24

1311407G_EN 15
 Ford S-Max / Galaxy / Mondeo

1 Remote option (Telestart)

S-MAX / Galaxy

2 1 Underside of glove compartment

2 Telestart receiver, dual lock Installing
receiver

25

1 1 Antenna

Installing
antenna

26
Mondeo

1 Instrument panel on front passenger side

2 Telestart receiver, dual lock
1
Installing
receiver

2 27

1 1 Antenna

Installing
antenna

28

1311407G_EN 16
 Ford S-Max / Galaxy / Mondeo

1 Thermo Call option

S-MAX and Galaxy

1 Thermo Call, dual lock

Installing
receiver

29

1 2 1 GPS antenna (Thermo Call Locate only)

2 GSM antenna

Installing
antenna

30

1 1 Push button

Installing
push but-
ton

31

1 Mondeo

1 Thermo Call, dual lock

Installing
receiver

32

1311407G_EN 17
 Ford S-Max / Galaxy / Mondeo

1 1 Antenna

Installing
antenna

33
1 Push button

Installing
push but-
ton

1 34

1311407G_EN 18
 Ford S-Max / Galaxy / Mondeo

1 1 Premounting heater
Mark premounted coolant hoses 1 [2x] in ac-
cordance 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 2 35

1 2 Install cable grommet 1 and edge protection

section 2.

Preparing
installa-
tion loca-
tion

36

1 Mount M6 rivet nuts 1 [2x] in existing holes as

shown.

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 2 1 Pass through
2 Wiring harness of heater

Installing
wiring har-
ness of
heater

39

1 2 Installing heater
Guide fuel line 3 through grommet 1 into en-
gine compartment.
3 Route adapter cable of circulating pump 4
through pass through 2 into engine compart- Installing
4 ment. heater
Connect wiring harness of heater to heater 5.

40

1 2 3 Loosely mount heater 1 as shown.

2 M6x20 bolt [2x], spring lockwasher [2x],

large diameter washer [2x]
3 Combustion air pipe
4 Coolant hoses Installing
5 Pass through heater
2
4

5 41

1 2 Installing exhaust system

Install exhaust system 4 on heater 2 as
shown.
Ensure sufficient distance to neighbouring
components. Installing
4 exhaust
1 Hose clamp pipe
3 M6x20 screw, spring lock washer, washer

3 42

1311407G_EN 20
 Ford S-Max / Galaxy / Mondeo

1 M6x20 screw, spring lock washer, washer

Installing
exhaust
pipe

43

1 1 Tighten M6 bolt 1 [2x].

Installing
heater

44

1 2 Screw protective cap 2 onto intake hose 1.

Installing
protective
cap on
combus-
tion 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. Un-
less 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.

1 Route fuel line 1 and metering-pump wiring

harness 2 to underbody and secure on origi-
nal vehicle lines with cable ties.

Routing
lines

2 46

1 2 Route fuel line and metering-pump wiring

harness 2 to underbody and secure on origi-
nal vehicle 1 with cable ties.

Routing
lines

47

1 1 2 Secure lines with cable ties.

1 Metering pump wiring harness

2 Fuel line

Routing
lines

48

1311407G_EN 22
 Ford S-Max / Galaxy / Mondeo

1 Version 1

Drill out angle bracket 2 to 8 mm dia. at posi-

tion 1.

1 Original vehicle M8 bolt Installing

metering
2 pump

49

1 Version 2

1 M6x20 bolt, large diameter washer, flang-

ed nut
2 Angle bracket
2
Installing
metering
pump

50

1 2 Check the position of the components; adjust

if necessary. Check that they have free clear-
ance.

1 Metering pump
2 M6x20 bolt, washer, flanged nut Installing
3 Metering pump bracket metering
pump

3 51

1 Route fuel line 1 and wiring harness of meter-

ing pump 2 along original vehicle fuel line and
secure with cable ties.

Routing
lines
2

52

1311407G_EN 23
 Ford S-Max / Galaxy / Mondeo

1 2 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 clear-
ance.
Remount cover of fuel lines. Connect-
ing meter-
1 Hose section, 10 mm dia. hose clamp [2x] ing pump
2 Wiring harness of metering pump, connec-
tor mounted
3

53

1 2 Separate fuel return line 1 approx. 70 mm be-

fore coupling.

2 10x5x10 fuel standpipe, 12 mm dia. hose

clamp [2x]
3 90° moulded hose, hose clamp Removing
10mm dia. [2x] fuel
4 Fuel line

4 3 54

1 2 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 clear-
ance.
Connect-
1 Hose section, 10 mm dia. hose clamp [2x] ing meter-
ing pump

55

1 1 Cover

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 rout-
ing dia-
gram

E
Ø 15x20

D C Ø 22
B

Ø 22

Ø 15x20

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

1 Photo shows S-MAX/Galaxy.

Remove hose bracket 1; will be reused.

Prelimi-
nary work

57

1 Unclip water drain hose 1; will be reused.

Prelimi-
nary work

58

1 2 3 1 Hose section of heat exchanger inlet

2 Cutting point
3 Engine outlet hose section

Cutting
point

59

B 1 Install moulded hose A.

1 Premount circulating pump

Premount-
ing circu-
lating
pump

A 60

1311407G_EN 26
 Ford S-Max / Galaxy / Mondeo

1 2 See coolant connection diagram.

Installation is carried out on original vehicle
stud bolt 3 [2x]!

1 Hose section on engine outlet

2 Bracket of circulating pump, plastic nuts Connec-
[2x] tion to en-
gine outlet
3 3

A 61

Connec-
tion of
heater inlet
C

B 62

1 1 Adapter wiring harness of circulating

pump, cable of circulating pump

Connect-
ing adapter
wiring har-
ness of cir-
culating
pump

63

Moulded
hose E

64

1311407G_EN 27
 Ford S-Max / Galaxy / Mondeo

D E See coolant connection diagram.

1 Hose bracket

Connec-
tion of
4
heater out-
let

1 65

E Before connecting, fill the coolant hoses with

coolant.

1 Hose section on heat exchanger inlet

Connec-
tion to heat
exchanger
inlet

1 66

E 1 Install hose bracket 1 between hose E and

A/C line 2.

Installing
hose
bracket

2 67
Mount hose bracket 1 as shown.

Installing
hose
1 bracket

68

1311407G_EN 28
 Ford S-Max / Galaxy / Mondeo

1 2 1 Hose bracket
2 Water drain hose

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 rout-
ing dia-
gram

E
D C
Ø 15x20
Ø 22

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

1 Photo shows S-MAX/Galaxy.

Remove hose bracket 1; will be reused. [if
present]

Prelimi-
nary work

70

1 Unclip water drain hose 1; will be reused.

Prelimi-
nary work

71

1 Remove hose 1 from engine outlet to heat ex-

changer inlet.

Removing
hose

72

1 2 3 1 Hose section of heat exchanger inlet

2 Discard hose section
3 Engine outlet hose section

Separating
hose

73

1311407G_EN 31
 Ford S-Max / Galaxy / Mondeo

1 Discard hose section

70 270

Cutting
moulded
hose to
length

A E 1 74
1 Engine outlet hose section

Preparing
hose sec-
tion

1 A 75
1 Hose section of heat exchanger inlet

Preparing
hose sec-
tion

1 E 76
Replace axial cover of circulating pump with
193° cover.

Replacing
circulating
pump cov-
er

77

1311407G_EN 32
 Ford S-Max / Galaxy / Mondeo

B 1 1 Premount circulating pump

Premount-
ing circu-
lating
pump

78

1 1 See coolant connection diagram.

Installation is carried out on original vehicle
stud bolt 1 [2x].

1 Bracket of circulating pump, plastic nuts

[2x] Installing
circulating
pump

79

Connec-
tion of
heater inlet
C

B 80
1 Adapter wiring harness of circulating
pump, cable of circulating pump

Connect-
ing adapter
wiring har-
ness of cir-
culating
pump

1 81

1311407G_EN 33
 Ford S-Max / Galaxy / Mondeo

D E 1 1 1 See coolant connection diagram.

1 Hose bracket [3x]

Connec-
tion of
heater out-
let

82

E 1 Hose section of heat exchanger inlet

Connect-
ing heat
exchanger
inlet

1 83
Before connecting, fill the coolant hoses with
coolant.

1 Engine outlet hose section

Connec-
tion to en-
A gine outlet

1 84

1 2 1 Hose bracket
2 Water drain hose

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 2 Cut out at marking in lower trim 1 (if installed)

in area of exhaust outlet 2.

Cutting out
underride
protection

86

1 Ensure sufficient distance to neighbouring

components.

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: hotline@webasto.de
http://www.webasto.de

1311407G_EN Printed in Germany 01/2011 Printing: Steffen