Ford - Galaxy - Workshop Manual - 2006 - 2006

Water Heater Unit Feel the drive e1 Thermo Top V Additional heater 00 0018 Installation instructions Ford S-MAX / Galaxy Diesel From model year 2006 For left-hand drive vehicles only Only for 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, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. 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 warning instructions. Webasto does not accept any liability for defects and damage that are attributable to an installation by untrained staff. Ident. No.: 1311408A €10 fee © Webasto AG Ford S-MAX / Galaxy Table of Contents Validity Heater Unit / Scope of Delivery Foreword General Instructions Special Tools Explanatory Notes on the Document Preliminary work Heater unit installation location Electrical Connections Preparing the Electronics Preparing the cable harness 2 3 3 3 3 4 5 5 6 7 7 Automatic air conditioning blower control Connection diagram for control elements: Remote Start Option Thermo Call Option Preassembling the heater unit Installing the Heater Unit Assembling the exhaust system Fuel Connection Water Connection Final Work Operating instructions for the end customer 8 11 12 13 14 15 15 17 20 25 26 Validity Manufacturer Ford Model S-MAX / Galaxy Type WA 6 EG-BE No. / ABE e13*2001/116*0185... Engine type 2.0 TDCi 2.0 TDCi Engine model Diesel Diesel Power in kW 96 103 Engine capacity in cm³ 1997 1997 Vehicle and engine types, equipment variants as well as national specifications, which are not listed in these installation instructions, have not been tested. Installation according to these installation instructions may, however, be possible. The installation location of the time switch or the tip switch should be confirmed with the end customer before installation. 1311408A 2 Ford S-MAX / Galaxy Heater Unit / Scope of Delivery Scope of delivery: Amount 1 Description Order No. Scope of delivery for Ford S-Max / Galaxy Diesel without op- 1311401A erating control Additionally for vehicles with automatic air conditioning Amount 1 Description Automatic air conditioning kit Order No. 1311421A Optional control element selection: Amount 1 1 1 1 Description Time switch Remote start T80 T91 remote start Thermo Call II Order No. 9010869A 9010870A 9016028A 9016027A In addition, when Thermo Call and Telestart are used Amount 1 Description Y cable Order No. 9001505A Foreword These installation instructions apply to Ford S-MAX / Galaxy vehicles with Diesel engines - for validity, see page 2 - from model year 2006 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 these installation instructions. However, where this is the case the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top V should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. An error may be stored in the “heater, ventilation and air conditioner” error memory when the auxiliary heating is operated, this must be deleted during the vehicle inspection according to the manufacturer’s instructions. General Instructions Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and cable harnesses to original vehicle lines and cable harnesses using cable clips. Sharp edges should be fitted with edge protectors (split open plastic hose). Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no. 111329). Special Tools - Torque spanner for 2.0 - 10 Nm Vice-grip wrench Riveting nut tool Ford unlocking tool no.: GV 3301 (4x) 1311408A 3 Ford S-MAX / Galaxy Explanatory Notes on the 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. Mechanics Electrics Water connection Fuel connection Exhaust System Combustion air 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 general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. 1311408A 4 Ford S-MAX / Galaxy Preliminary work WARNING! - Open the tank cap, ventilate the tank. Close the tank cap again. Disconnect the battery. Let off pressure in 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. Add the information label on the diagnostic connection cover. Remove the engine design cover. Remove the battery and the battery support. Remove the air filter box. Remove the windshield wipers. Remove the cooling water reservoir cover Remove the cooling water reservoir cover in the engine compartment. Remove the bracket for the coolant hoses (2x plastic nuts on the engine compartment rear bulk) Remove the front right wheel. Remove the right wheel-house panel. Remove the lower engine cover Remove the fuel line cover under the vehicle. Remove the switch strip or decoration strip above the air conditioning control / radio or the air conditioning unit / navigation (unclip). - Remove the air conditioning control / radio or the air conditioning unit / navigation. - Remove the cover under the right glove compartment. - Remove the lower cover on the right A-pillar panel. Remove page 26 "Operating instructions for the end customer" and add this to the vehicle operating instructions. Heater unit installation location 1 1 Heater unit Installation location 1 1311408A 5 Ford S-MAX / Galaxy Electrical Connections Cable harness feed-through Time switch 1 Protective rubber sleeve 1 Time switch 1 1 1 2 sw 3 rt gn/ws Cable harness installation diagram for the automatic air conditioning bl br don't 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 2 4 6 4 fuse holder, K3 relay 1 Fuse holder retaining plate, M5x16 bolt, washers, M5 nuts, (drill open hole 1 to 5.5 mm). 2 K3 relay, M5x16 bolt, washers, M5 nut 3 Fuse holder 4 M6x12 bolt, original vehicle bore hole, M6 flanged nut 1311408A 5 Power supply for the heater unit cable harness 1 Battery positive terminal connection 2 Original vehicle grounding point 6 Ford S-MAX / Galaxy Preparing the Electronics 1 rt/ws gn/ws 1 Green/white (gn/ws) wire, 2,500 mm, insulation hose. rt gn/ws 2500mm 87 86 Pre-assembling the Cable Harness 87a K3 85 30 br sw Preparing the cable harness 1 Insert the yellow wire 3 in the free slot from the 4 pin plug 2. 1 Insulate and tie back brown (br) wire 4 Heater unit cable harness 5 Insulate and tie back purple (vi) wire 5 4 3 2 Preparing the cable harness 6 Run the heater unit cable harness 1 along the original vehicle cable harness and secure with cable ties. 1 Placement in the engine compartment 7 1 Heater unit cable harness 1 Placement in the engine compartment 8 1311408A 7 Ford S-MAX / Galaxy Automatic air conditioning blower control Webasto Webasto Ford F28 vi/gn F3 Circuit diagram bl/sw HG St A 12 16 15 8 X1 30 75 ge AD GRs gn 86 gn/ws rt/ws C2 87 87a M1 M K3.1 85 2 30 gn br rt br/bl C21 ws/vi A 86 87 87a 85 30 K3 St A sw 26 15 St B KB gr/vi gr/or * St C gn/ws 69 gr/vi SJB 15 IPCU A 86 85 D gr/or + E M GM gr/or rt sw C2RT 031 St A 1 2 GRr 6 4 31 Webasto components HG Heater unit TT-V X1 8-pin connector F3 Fuse 25A K3 blower relay K3.1 Supplementary relay IPCU Pulse width modulator D Diodes integrated in the cable harness IPCU settings Voltage: 10 V Frequency: 400 Hz Duty-Cycle: 37 % Function: Low-side 1311408A Vehicle components GM blower motor GRs blower relay GRr Blower controller KB Air conditioning control F28 blower fuse M1 Servomotor air flap SJB Smart Junction Box C21 Black connector AD Radio C2T031 WFS receiver * Depending on the equipment Colours and symbols rt red ws white sw black br brown gn green bl blue ge yellow vi purple gr grey Legend X Splitting point Cable colors may vary. 8 Ford S-MAX / Galaxy Divide the dual lock 1x in the middle. Fasten the relay K3.1 2 and IPCU 1 with the dual lock as shown in the figure. Watch the spatial requirements for the air conditioning and radio controls and their cable harnesses. 2 IPCU and relay K3.1 assembly 1 9 Connection to white connector B 5 from the air conditioning control pin 15. Connect to existing connectors according to the circuit diagram. 1 2 5 4 3 Connection to blacke connector A 5 from the air conditioning control pin 26. Connect to existing connectors according to the circuit diagram. 3 4 5 Air conditioning control / IPCU connection 10 2 1 1 White/purple (sw/vi) wire to blower controller 2 Black (sw) wire from IPCU/A 3 Red (rt) wire from IPCU/E 4 White/purple (ws/vi) wire from the air conditioning control connector. 1 Brown/blue (bn/bl) wire from air conditioner controller connector 2 Brown/blue (bn/bl) wire to the servomotor flap 3 Green (gn) wire from K3.1/87 4 Green (gn) wire from K3.1/30 Air conditioning control / relay K3.1 connection 11 Connection to connector 3 from the radio. Connect to existing connectors according to the circuit diagram. 5 1 1 2 4 5 Brown (br) wire from K3.1/85 Black/blue (sw/bl) wire Purple/green (vi/gn) wire (terminal 75) Yellow (ge) wire from K3.1/86 Connection K3.1 to the radio 4 2 3 1311408A 12 9 Ford S-MAX / Galaxy Reconnect according to the circuit diagram. 1 1 Green/white (gn/ws) wire from K3/86 2 Green/white (gn/ws) wire Green/ white (gn/ws) wire connection from K3/86 2 13 1 2 Connection to the blue connector 1 pin 69. Reconnect according to the circuit diagram. Depending on the vehicle equipment, there may be two cables on pin 69. 3 5 1 4 2 Green/orange (gn/or) wire to the blower controller (see circuit diagram) 3 Black (sw) wire 4 Red (rt) wire 5 Green/orange (gn/or) wire to the SJB connector (see circuit diagram) 14 Connection to the sw connector 3. Reconnect according to the circuit diagram. 2 1 2 4 5 5 1311408A 4 Connection to the SJB connector 3 Black (sw) wire from relay K3/30 Green/purple (gr/vi) wire to blower motor Grey/purple (gr/vi) wire Red (rt) wire from K3/87a Connection to the blower motor 15 10 Ford S-MAX / Galaxy Connection diagram for control elements: TT-V 9001505A Insert yellow (ge) wire Insulate purple (vi) wire Remove and insulate the black (sw) wire Thermo Call Insulate yellow (ge) wire 9013674A 67089A Insert purple (vi) wire from pin 5 in pin 2 Remote start T80 / T91 tip switch 1311408A 11 Ford S-MAX / Galaxy Remote Start Option 1 1 Bottom side of the glove compartment 2 Remote start receiver, dual lock 2 Assembling the receiver 16 1 Antenna 1 Assembling the antenna 17 1311408A 12 Ford S-MAX / Galaxy Thermo Call Option 1 1 Thermo call, dual lock Assembling the receiver 18 1 1 GPS antenna (thermo call locate only) 2 GSM antenna 2 Assembling the antenna 19 1 Tip switch 1 Assembling the tip switch 20 1311408A 13 Ford S-MAX / Galaxy 1 Preassembling the heater unit 1 Mark the preassembled water hoses 1 [2x] by flow direction and slide on the circulation pump adapter cable harness 3. 2 Heater unit 4 Fuel line, moulded hose, Ø10 mm hose clamp 4 3 21 2 1 Insert the cable sleeve 1 and the edge protection 2. 2 Preparing the Installation Location 22 Insert the M6 1 [2x] rivet nuts in the original vehicle bore holes. 1 Inserting rivet nuts 1 23 Remove water drainage 2 from the wheel arch. 1 Water drainage position is covered. 1 Preparing the exhaust pipe 2 24 1311408A 14 Ford S-MAX / Galaxy 1 1 Feed-through 2 Heater unit cable harness 2 Installing the heater unit cable harness 25 1 Installing the Heater Unit 2 3 4 5 Run the fuel pipe 3 through the grommet 1 into the engine compartment. Run the adapter cable for the circulation pump 4 through the duct 2 into the engine compartment. Slide the heater unit cable harness5 onto the heater unit. 26 1 2 Loosely assemble the heater unit 1 as shown in the figure. 3 2 2 M6x20 bolt [2x], spring washer [2x], body washer [2x] 3 Combustion air pipe 4 Water hoses 5 Feed-through Assembling the Heater Unit 4 5 1 27 Assembling the exhaust system 2 Assemble the exhaust system 4 on the heater unit 2 as shown in the figure. Ensure sufficient distance from adjacent components. 4 1 Hose clamp 3 M6x20 bolt, spring washer, washer 3 1311408A 28 15 Ford S-MAX / Galaxy 1 M6x20 bolt, spring washer, washer 5 29 1 Tighten the M6 bolts1 [2x]. 1 Assembling the Heater Unit 30 1 Twist the protective cover 2 onto the intake hose 1. 2 Assembling the protective cap on the combustion air line 31 1311408A 16 Ford S-MAX / Galaxy Fuel Connection CAUTION! Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable clips! Fit the fuel line and cable harness with edge protectors around sharp edges. WARNING! The fuel line and cable harness to the metering pump should be installed based on the cable harness installation diagram. Run the fuel line 1 and the metering pump cable harness 2 to the underbody, secure with cable ties to the original vehicle fuel lines. 1 Placement of the fuel line and the metering pump cable harness 2 1 32 Run the fuel line and the metering pump cable harness 2 to the underbody, secure with cable ties to the original vehicle fuel lines 1. 2 Placement of the fuel line and the metering pump cable harness 33 1 Secure the lines along the original vehicle fuel line to the underbody with cable ties. 2 1 Fuel pipe, metering pump cable harness Installing lines 34 1311408A 17 Ford S-MAX / Galaxy 1 Bracket, M6x20 bolt, flanged nut Assembling the metering pump 1 35 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 36 3 Fuel line from the heater unit on the pressure side of the metering pump [side with connector]. Check the position of the components; adjust if necessary. Check that they have free clearance. 2 3 1 Assembling the metering pump 1 Fuel pipe, cut into sections 2 Hose section, Ø 10 mm hose clamps [2x] 3 Metering pump cable harness connector Connection to metering pump 37 1 Separate the leading fuel line 1 about 70mm before the connecting piece. 2 2 T section 10x5x10, Ø 12 mm hose clamps [2x]. 3 90° moulded hose, Ø10 mm hose clamps [2x] 4 Remaining fuel line 4 1311408A 3 Fuel TakeOff 38 18 Ford S-MAX / Galaxy 1 2 Fuel line from the tank extracting device on the intake side of the metering pump [side without connector]. Check the position of the components; adjust if necessary. Check that they have free clearance. 1 Hose section, Ø 10 mm hose clamps [2x] 2 Fuel pipe, cut into sections Assembling the metering pump 39 Assemble the cover 1. 1 Installing 40 1311408A 19 Ford S-MAX / Galaxy Water Connection WARNING! Any coolant running off should be collected using an appropriate container! Install hoses so that they are kink-free! Unless specified otherwise, always fasten using cable clips! 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: Water installation diagram E Ø 15x20 D C Ø 22 B Ø 22 Ø 15x20 A All undesignated clamps = Ø 27mm spring band clamps! All undesignated connecting pipes = Ø 20x20. 1311408A 20 Ford S-MAX / Galaxy Remove the hose bracket 1, it will be used again 1 Preliminary work 41 Unclip the water drainage hose 1, it will be used again 1 Preliminary work 42 1 2 1 Heat exchanger inlet hose section 2 Cut location 3 Engine exhaust hose section 3 Splitting point 43 B Assemble the moulded hoseA according to the diagram on page 20. 1 1 Preassembled circulation pump Pre-assembling the circulation pump assembly A 1311408A 44 21 Ford S-MAX / Galaxy 1 Note the water connection diagrams on page 20. The assembly is on the original vehicle stay bolts 3 [2x]. 2 1 Engine exhaust hose section 2 Circulation pump bracket, plastic nuts [2x] 3 3 Assembly and connection to the engine exhaust 45 A Connection to heater unit inlet C 46 B 1 Circulation pump adapter cable, circulation pump cable 1 Connecting the circulation pump adapter cable harness 47 E Moulded hose E 48 1311408A 22 Ford S-MAX / Galaxy D Note the water connection diagrams on page 20. E 1 Hose bracket Connection to metering pump 4 49 1 Before connecting, fill the water hose with coolant. E 1 Heat exchanger inlet hose section Connecting to the heat exchanger inlet 50 1 E Insert the hose bracket 1 between the hose E and the air condition line 2. 1 Assemble the hose bracket 2 51 Insert the hose bracket 1 as shown in the figure. Assemble the hose bracket 1 52 1311408A 23 Ford S-MAX / Galaxy 1 1 Hose bracket 2 Water drainage hose 2 Assembling the hose bracket and the water drainage 53 1311408A 24 Ford S-MAX / Galaxy Final Work WARNING! Reassemble disassembled components in reverse order. Check that all hose lines, clips, and all electrical connections are securely fastened. Secure all loose cables using cable clips. Only use manufacturer-approved coolant. Spray heating unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329). - Connect 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 time switch. Make automatic air conditioning settings according to the "Operating instructions for the end customer". - Check that the auxiliary heating operates properly, see operating instructions / installation instructions. - Attach the "Switch off auxiliary heating before re-fuelling" sticker onto the left side of the B-pillar. - Decode the radio according to the manufacturer's instructions 1 In the lower panelling 2 (when present) near the exhaust outlet 1, drill a Ø 35mm hole. 2 Cut out the underride protection 54 1 Exhaust outlet 2 Hole Ø 35mm 1 Exhaust outlet 2 55 Feel the drive Webasto AG PO Box 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de 1311408A Printed in Germany 02/2007 Press: Steffen Ford S-MAX / Galaxy Operating instructions for the end customer Please remove page and add to the vehicle operating instructions. Note: We recommend adjusting the heating time to the driving time heating time = driving time Example: For a driving time of 20 minutes (one way) we recommend not exceeding 20 minutes of power on time. Before parking the vehicle, make the following settings: On vehicles with anti-theft warning system, set this system to “reduced protection”; for information on activation, please consult the vehicle operating instructions. Blower rpm is pre-set in auxiliary heating operation 1 Temperature to "HI" 2 Air outlet to windshield For vehicles without touch screen 1 2 1 1 56 Blower rpm is pre-set in auxiliary heating operation 1 1 Temperature to "HI“ 2 Air outlet to windshield For vehicles with touch screen 2 57 The auxiliary heating may only be started if there is enough fuel in the tank (reserve light is not on). 1311408A 26