Ford - Mondeo - Workshop Manual - 2001 - 2001

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