K

Water Heater
E1
Thermo Top Evo Parking Heater 00 0258

With FuelFix

Installation Documentation
Ford Mondeo / S-Max / Galaxy (CD 4)

Validity
Manufacturer Model Type EG BE No. / ABE
Ford Mondeo BA7 e13 * 2001 / 116 * 0249 *..

Motorisation Fuel Transmission type Output in kW Displacement in cm³ Engine code

2.0 TDCi Diesel AG / SG 110 1997 T7CE
2.0 TDCi Diesel AG / SG 132 1997 T8CC
2.0 TDCi Biturbo Diesel AG 154 2000 T9CA
1.5 EcoBoost Petrol AG / SG 118 1499 UNCA / UNCB /
UNCE / UNCF
2.0 EcoBoost Petrol AG / SG 177 1997 R9CB / R9CF /
R9CH

SG = manual transmission
AG = automatic transmission

Manufacturer Model Type EG BE No. / ABE

Ford S-Max / Galaxy WA 6 e13 * 2001 / 116 * 0185 *..

Motorisation Fuel Transmission type Output in kW Displacement in cm³ Engine code

2.0 TDCi Diesel AG / SG 110 1997 T7CE
2.0 TDCi Diesel AG / SG 132 1997 T8CC
2.0 TDCi Biturbo Diesel ASG 154 2000 T9CB / T9CC
1.5 EcoBoost Petrol AG / SG 118 1499 UNCA / UNCB /
UNCE / UNCF
2.0 EcoBoost Petrol AG / SG 177 1997 R9CB / R9CF /
R9CH

SG = manual transmission
AG = automatic transmission
ASG = Semi-automatic transmission

From model year 2015

Left-hand drive vehicle

Verified equipment variants: Automatic air-conditioning

2WD / 4WD
Start - Stop
Euro 6

Not verified: Passenger compartment monitoring

Total installation time: approx. 9 hours

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Ford Mondeo / S-Max / Galaxy (CD 4)

Table of Contents
Validity 1 Preparing Installation Location 12
Necessary Components 2 Preparing Heater 13
Installation Overview 2 Installing Heater 16
Information on Total Installation Time 2 Fuel 19
Information on Operating and Installation Instructions 3 FuelFix Installation for Diesel Vehicles 20
Information on Validity 4 FuelFix Installation for Petrol Vehicles 25
Technical Information 4 Coolant Circuit Except for 2.0 TDCi 154 kW 30
Explanatory Notes on Document 4 Coolant Circuit for 2.0 TDCi 154 kW 35
Preliminary Work 5 Final Work 40
Heater Installation Location 5 FuelFix Template for Mondeo Diesel 42
Preparing Electrical System 6 FuelFix Template for S-Max / Galaxy Diesel 43
Electrical System 7 FuelFix Template for Petrol Vehicles 44
Air-Conditioning Control 8
MultiControl CAR Option 8
Remote Option (Telestart) 8
ThermoCall Option 10

Necessary Components
• Basic delivery scope of Thermo Top Evo based on price list
• Installation kit with FuelFix for Ford Mondeo / S-Max / Galaxy (CD 4) 2015 Petrol and diesel: 1323974C
• Additional kit ‘Webasto Standard’ A/C control for Ford Mondeo / S-Max / Galaxy (CD 4): 1324011_
or
Additional kit ‘Webasto Comfort’ A/C control for Ford Mondeo / S-Max / Galaxy (CD 4): 1324050_
• Heater control in accordance with price list and upon consultation with end customer
• In case of Telestart, indicator lamp in accordance with price list and in consultation with end cus-
tomer
• In case of MultiControl CAR installation: MultiControl installation frame: 9030077_
Installation instructions:
• Arrange for the vehicle to be delivered with the tank only about ¼ full.
• The installation location of the push button in case of Telestart or ThermoCall should be confirmed
with the end customer.
• Depending on the space required and the vehicle manufacturer's instructions, we recommend the
use of a vehicle battery with a higher electrical capacity.
Installation Overview
Legend: 1

1. Heater
2. Engine compartment fuse holder
3. Circulating pump
4. MultiControl CAR 3
5. Metering pump
6. FuelFix
4
6

5
2

Information on Total Installation Time

The total installation time includes the time needed for mounting and demounting the vehicle-specific components, the heat-
er specific installation time and all other times required for the system integration and initial start-up of the heater.
The total installation time may vary for vehicle equipment other than provided.

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Ford Mondeo / S-Max / Galaxy (CD 4)

Information on Operating and Installation Instructions

1 Important information (not complete) 2.1 Excerpt from ECE regulation 122 (heating system) paragraph
5 for the installation of the heater
1.1 Installation and repair
Beginning of excerpt.
The improper installation or repair of Webasto heating and cooling systems
can cause fire or the leakage of deadly carbon monoxide, leading to serious ANNEX VII
injury or death.
REQUIREMENTS FOR COMBUSTION HEATERS
To install and repair Webasto heating and cooling systems you need to have AND THEIR INSTALLATION
completed a special company training course and have the appropriate tech-
nical documentation, special tools and special equipment. 1. GENERAL REQUIREMENTS
Installation and repair may ONLY be carried out by persons trained and cer- 1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when the
tified in a Webasto training course. NEVER try to install or repair Webasto combustion heater is switched on or off.
heating or cooling systems if you have not completed a Webasto training
course, you do not have the necessary technical skills and you do not have 2. VEHICLE INSTALLATION REQUIREMENTS
the technical documentation, tools and equipment available to ensure that
you can complete the installation and repair work properly. 2.1. Scope
Only use genuine Webasto parts. See the Webasto air and water heaters ac- 2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed according
cessories catalogue for this purpose. to the requirements of this Annex.
1.2 Operation 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply with
the requirements of this Annex.
To ensure safe operation, we recommend having the heater checked every two years
by an authorised Webasto dealer, especially when used over a long period and/or un- 2.2. Positioning of heater
der extreme environmental conditions.
2.2.1. Body sections and any other components in the vicinity of the heater must be
Do not operate the heater in closed rooms due to the danger of poisoning and suffo- protected from excessive heat and the possibility of fuel or oil contamination.
cation.
2.2.2. The combustion heater shall not constitute a risk of fire, even in the case of
Always switch off the heater before refuelling. overheating. This requirement shall be deemed to be fulfilled if the installation
ensures an adequate distance to all parts and suitable ventilation, by the use
The heater may only be used with the prescribed fuel diesel (DIN EN 590) or petrol of fire resistant materials or by the use of heat shields.
(DIN EN 228).
2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in the
The heater may not be cleaned with a high-pressure cleaner. passenger compartment. However, an installation in an effectively sealed en-
velope which also complies with the conditions in paragraph 2.2.2 may be
1.3 Please note used.
ALWAYS follow all Webasto installation and operating instructions and observe all 2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned so
warnings. that it can be easily read when the heater is installed in the vehicle.
To become familiar with and understand all functions and properties of the heater, the 2.2.5. Every reasonable precaution should be taken in positioning the heater to
operating instructions must be read carefully and observed at all times. minimise the risk of injury and damage to personal property.
For proper, safe installation and repair work, the installation instructions with all warn-
ings and safety information must be carefully read and observed at all times. Please 2.3. Fuel supply
always contact a workshop authorised by Webasto for all installation and repair work. 2.3.1. The fuel filler must not be situated in the passenger compartment and must
be provided with an effective cap to prevent fuel spillage.
Important
2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the vehi-
Webasto shall assume no liability for defects, damage and injuries resulting cle is provided, the type of fuel and its filler point must be clearly labelled.
from a failure to observe the installation, repair and operating instructions of the
information contained in them. 2.3.3. A notice, indicating that the heater must be shut down before refuelling, must
be affixed to the fuelling point. In addition a suitable instruction must be in-
This liability exclusion particularly applies to improper installations and repairs, cluded in the manufacturer's operating manual.
installations and repairs by untrained persons or in the case of a failure to use
genuine spare parts. 2.4. Exhaust system
The liability due to culpable disregard to life, limb or health and due to damage 2.4.1. The exhaust outlet must be located so as to prevent emissions from entering
or injuries caused by a wilful or reckless breach of duty remain unaffected, as the vehicle through ventilators, heated air inlets or opening windows.
does the obligatory product liability.
2.5. Combustion air inlet
Installation should be carried out according to the general, standard rules of
technology. Unless specified otherwise, fasten hoses, lines and wiring harness- 2.5.1. The air for the combustion chamber of the heater must not be drawn from the
es to original vehicle lines and wiring harnesses using cable ties. Insulate loose passenger compartment of the vehicle.
wire ends and tie back. Connectors on electronic components have to audibly
click into place during installation. 2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish or lug-
gage is unlikely.
Sharp edges should be fitted with rub protection. Spray unfinished body areas,
e.g. drilled holes, with anti-corrosion wax (Tectyl 100K). 2.6. Heating air inlet
Observe the instructions and guidelines of the respective vehicle manufacturer 2.6.1. The heating air supply may be fresh or recirculated air and must be drawn
for demounting and mounting vehicle specific components! from a clean area not likely to be contaminated by exhaust fumes emitted ei-
ther by the propulsion engine, the combustion heater or any other vehicle
The initial startup is to be executed with the Webasto Thermo Test Diagnosis. source.
When installing a programmable control module (e.g. a PWM Gateway), the cor- 2.6.2. The inlet duct must be protected by mesh or other suitable means.
responding settings must be checked or adjusted.
2.7. Heating air outlet
2 Statutory regulations governing installation
2.7.1. Any ducting used to route the hot air through the vehicle must be so posi-
Guidelines Thermo Top Evo tioned or protected that no injury or damage could be caused if it were to be
touched.
Heating Directive ECE R122 E1 00 0258
EMC Directive ECE R10 E1 04 5627 2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish or
luggage is unlikely.
Note End of excerpt.
The regulations of these guidelines are binding in the scope of the Directive In multilingual versions the German language is binding.
70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and should
also be observed in countries in which there are no special regulations.
Important
Failure to follow the installation instructions will result in the invalidation of the type ap-
proval for the heater and therefore invalidation of the general homologation of the
vehicle.
Note
The heater is licensed in accordance with paragraph 19, section 3, No. 2b of the StV-
ZO (German Road Traffic Licensing Authority).

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Ford Mondeo / S-Max / Galaxy (CD 4)

Information on Validity
This installation documentation applies to Ford Mondeo / S-Max / Galaxy (CD 4) Petrol and diesel vehicles - for validity, see
page 1 - from model year 2015 and later, assuming technical modifications to the vehicle do not affect installation, any lia-
bility claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation
with respect to this ‘installation documentation’.
Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation have not
been tested. However, installation according to this installation documentation may be possible.

Technical Information

Special Tools
• Hose clamp pliers for auto-tightening hose clamps
• Hose clamp pliers for Clic hose clamps of type W
• Automatic wire stripper, 0.2 - 6mm²
• Crimping pliers for cable lug / tab connector, 0.5 - 6mm²
• Torque wrench for 2.0 - 10 Nm
• Hose clamping pliers
• Metric thread-setter kit
• Deep-hole marker
• Webasto Thermo Test Diagnosis with current software
Dimensions
• All dimensions are in mm.
Tightening torque values
• Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.
• Tightening torque value of 5x15 water connection piece retaining plate bolt = 7Nm.
• Tighten other bolt connections in accordance with manufacturer’s instructions or in accordance with state-of-the-art-
technology.

Explanatory Notes on Document

You will find an identification mark on the outside top Special features are highlighted using the following symbols:
right corner of the page in question to provide you
with a quick overview of the individual working steps.

Mechanical System Specific risk of damage to components.

Electrical System Specific risk due to electrical voltage.

Specific risk of injury or fatal accidents.

Coolant Circuit

Specific risk of fire or explosion.

Combustion Air
Reference to the manufacturer's vehicle-
specific documents or to the general in- F
stallation instructions of Webasto com-
Fuel ponents.

Reference to a special technical feature.

Exhaust Gas The arrow in the vehicle

icon indicates the
position on the vehicle
and the viewing angle.

!
Software Nm
Tightening torque according to the manufac-
turer's vehicle-specific documents.

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Ford Mondeo / S-Max / Galaxy (CD 4)

Preliminary Work
Vehicle

• Open the fuel tank cap.

• Ventilate the fuel tank.
• Close the fuel tank cap again.
• Depressurise the cooling system.
• Completely remove the air filter box.
• Disconnect and remove the battery together with the battery carrier.
• Remove the windscreen wipers.
• Remove the brake fluid container and put it aside (Galaxy only).
• Remove the engine control unit on the right.
• Remove the cover of the coolant reservoir and the coolant reservoir.
• Remove the front underride protection (to drain the coolant).
• Remove the engine underride protection.
• Remove the left underbody protection.
• Remove the fuel tank underbody protection on the right and left.
• Remove the right front wheel.
• Remove the right wheel-well inner panel.
• Lower the exhaust pipe and middle silencer.
• Remove the fuel tank according to the manufacturer's instructions.
• Remove the lower footwell trim on the front passenger's side (only in case of Telestart and/or
ThermoCall).
• Remove the trim strip and air outlet trim above the glove box (only in case of Telestart and/or
ThermoCall).
• Remove the glove box (only in case of Telestart and/or ThermoCall).

Heater

• Remove years that do not apply from the type and duplicate label.
• Attach the duplicate label (type label) visibly in the appropriate place in the engine compart-
ment.

1 Heater Installation Location

1 Heater

Installation
location

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 2 Preparing Electrical System

1 Fuses F1-2
2 Wiring harnesses of heater and heat-
er control
3 13mm dia., 700 long slit open corru- Pulling wiring
gated tube harnesses
into corrugat-
ed tube

3 2

Connector X7

Disman-
tling meter-
ing pump
connector

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Electrical System
Wiring Harness Routing Wiring harness pass through
1 Wiring harnesses of heater, heater control 1 Protective rubber plug
in corrugated tube 2 Wiring harnesses of heater, heater control

1 1 2

4 5

Route the metering pump wiring

harness later, together with the
fuel line, along the original vehi-
Wiring har-
cle fuel lines on the underbody.
ness routing
diagram

! !
1 2 Nm 1 Nm

3 6 2 7

Engine compartment fuse holder Positive and earth wire

Replace 30A fuse F2 with 1A fuse only in 1 Earth wire on original vehicle earth support
case of ‘Comfort’ fan controller! point
2 Positive wire on positive distributor
1 Fuses F1-2
2 M6x12 bolt, large diameter washer, original
vehicle hole, flanged nut
3 M5x16 bolt, washer [2x], retaining plate of
fuse holder, angle bracket, nut

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Air-Conditioning Control
Connect the A/C control in accordance with the separate installation documentation:
! Installation documentation ‘Webasto Standard’ A/C control G
for Ford Mondeo / S-Max / Galaxy (CD 4)

or

Installation documentation ‘Webasto Comfort’ A/C control H

for Ford Mondeo / S-Max / Galaxy (CD 4)

MultiControl CAR Option

Mondeo

1 MultiControl CAR
Installing
MultiControl
CAR
1

8
S-Max / Galaxy

1 MultiControl CAR with installation

frame

Installing
MultiControl
CAR
1

Remote Option (Telestart)

3 All vehicles

Bend receiver bracket 3 as shown!

View of re-
1 Receiver ceiver with
1 2 Bracket with oblong hole bracket

3 2 10

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Mondeo

1 Receiver
2 Existing hole, M5x16 bolt, flanged nut

1 Installing
receiver

11

1 1 Aerial

Installing
aerial

12

1 Temperature sensor T100 HTM

Fasten temperature sensor 1 with double-

sided adhesive tape.

Installing
temperature
sensor

13
S-Max / Galaxy

1 M5x16 bolt, existing hole, flanged nut

2 Receiver

Installing
1 receiver

14

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1 1 Aerial

Installing
aerial

15

1 Temperature sensor T100 HTM

Fasten temperature sensor 1 with double-

sided adhesive tape.

Installing
temperature
sensor

16

1 ThermoCall Option
All vehicles

Shown on Mondeo!
Removing in-
1 Insulation mat sulation mat
2 Front passenger's side footwell trim in shaded
area

17

1 2 Position receiver 1 in front of fastening,

ensure freedom of movement and fasten
with double-sided adhesive tape.

2 Footwell trim
Installing
receiver

18

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1 1 Aerial (optional)

Installing
aerial

19

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 Preparing Installation Location

Remove original vehicle relay 1 and route
with wiring harness 2 through opening 3 in
the engine compartment.
Removing
original ve-
2 hicle relay

3 20

1 1 Rivet nut, existing hole [2x each]

Installing
rivet nuts

1 21

1 1 Pass through
2 Heater wiring harness
3 Edge protection

3 Routing
heater wir-
ing harness
2

22

1 1 Area for fastening adhesive base

Cleaning
body sur-
face

23

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Ford Mondeo / S-Max / Galaxy (CD 4)

X 1 When not cut off at the factory.

1 Underbody protection

X = Cutting out
underbody
protection

24

1 Preparing Heater
1 Water connection piece, sealing ring
[2x each]
2 5x15 self-tapping bolt, retaining plate
of water connection piece Installing
water con-
2
nection
piece

1 25
All vehicles except 2.0 TDCi 154 kW

A = 60
B = 500
C = 130
A B C D E D = 130 Cutting hos-
E = 500 es to length
F = 90°, 15x18mm dia.

26

C 1 All spring clips = 25 mm dia.

1 90°, 18x18mm dia. connecting pipe [2x]

Installing
hoses
1

D 27

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Ford Mondeo / S-Max / Galaxy (CD 4)

2.0 TDCi 154 kW only

A = 230
B = 120
C = 60
A B C D E F G H D = 60 Cutting hos-
E = 200 es to length
F = 130
G = 130
H = 500
J J = 90°, 15x18mm dia.

28

F 1 All spring clips = 25 mm dia.

1 90°, 18x18mm dia. connecting pipe [2x]

Installing
hoses
1

G 29

1 All vehicles

Screw 5x13 self-tapping bolts 2 [3x] into

existing holes according to hole pattern of
bracket.
2
Installing
1 Bracket bracket

2 2 30
s1 = 400
s2 = 50

X =
Cutting
X combus-
tion air pipe
to length
s1 s2

31

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s1 1 1 25 mm dia. clamp
2 M5x13 self-tapping bolt in existing
hole

Installing
combus-
tion air
pipe s1

2 32

X 1 1 Combustion air silencer

X =

Preparing
combustion
air silencer

33

1 s2 2 3 Fasten adhesive base 4 with cable tie 2 to

combustion air silencer 3 as shown.

1 Protective cap
5 30 mm heat shrink plastic tubing
Premount-
ing combus-
tion air
silencer

5 4 34

1 s1 1 Combustion air silencer

Installing
combustion
air silencer

35

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1 10 mm dia., 300 mm long corrugated tube

2 onto fuel line 1.

3 90° moulded hose, 10 mm dia. clamp [2x]

Installing
fuel line

3 36
Only in case of heater installation version
2 (see following figures)!

45
Shortening
perforated
bracket

37

1 Installing Heater

2 Route corrugated tube with fuel line 4

through pass through 2 into the engine
compartment.
3 Mounting wir-
1 Connector of circulating pump wiring ing harness-
harness es
3 Heater wiring harness connector [2x]
3

4 38

1 Version 1

Mount heater 2 as shown.

1 M6x16 bolt, spring lockwasher, large

1 diameter washer [2x each], original Installing
vehicle hole heater

2 39

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1 2 3 Version 2

Mount heater 4 as shown.

1 Perforated bracket
2 M6x20 bolt, large diameter washer, Installing
original vehicle hole, flanged nut heater
3 3 M6x16 bolt, spring lockwasher, large
diameter washer [2x each], original
vehicle hole

4 40
All vehicles

1 Mount M6x20 bolt, spring lockwasher,

large diameter washer, loosely
2 Combustion air silencer
3 Adhesive base on cable tie Fixing com-
1
bustion air
silencer with
3 2 adhesive
base

41

1 2 S-Max only

Straighten exhaust tube lug 2 in area 1 as

1 shown.

Preparing ex-
haust tube

42

1 2 All vehicles

Install exhaust system 1 on heater 2 as

shown.
Ensure sufficient distance from neighbour-
ing components. Installing ex-
3 haust system
3 Hose clamp
4 M6x20 bolt, spring lockwasher, large
diameter washer

4 43

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 M6x20 bolt, spring lockwasher, large

diameter washer
2 Exhaust system

Installing ex-
haust system

2 1

44

1 2 3 Install baffle plate 1 on vehicle underbody

protection 4 (if present) as shown.

2 Original vehicle stud bolt, original ve-

hicle plate nut
3 Exhaust tube Installing baf-
fle plate
4

45

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Fuel
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.

Catch any fuel running off in an appropriate container.

Route fuel line and metering pump wiring harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable ties.
Provide rub protection for fuel line and wiring harness in areas where there are sharp edges.

The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness
routing diagram.

1 2 Pull fuel line 1 and metering pump wiring

harness 3 into 1300 mm long 10 mm dia.
corrugated tube 2 and route to the driver's
side!

Routing
lines
3

46

1 1 Fuel line and metering pump wiring

harness in corrugated tube
2 Cable tie [3x]

2
Routing on
firewall
2

2 47
Route fuel line and metering pump wiring
harness 1 on the underbody along original
vehicle fuel lines to the installation location
of the metering pump.

Routing
lines
1

48

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 FuelFix Installation for Diesel

Vehicles
Mondeo

Remove the fuel tank according to the

manufacturer's instructions.
F
Work step F1.
Moving bar-
1 Fuel tank sending unit code label
2 Reposition barcode label

2 49

1 2 3 Work step F2. F

1 Fuel tank sending unit
2 Position washer with outer dia.
da = 24 mm as template against the
raised parts as shown Copying
3 Hole pattern hole pattern

2mm

50
Work step F3.

1 Hole made with provided drill

Hole for
FuelFix

1 51

1 Work steps F4 and F5.

Bend FuelFix 1 according to template and

cut to length.
Insert into hole 2.
Inserting
FuelFix

52

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Inserting
FuelFix

53

Inserting
FuelFix

54
Work steps F5.3 and F5.4.

Align FuelFix 1 as shown.

Aligning
FuelFix

1 55

1 Work step F6.

1 Hose section, 10mm dia. clamp [2x]

2 Fuel line
3 FuelFix
Connect-
ing fuel line

3 2 56

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Ford Mondeo / S-Max / Galaxy (CD 4)

F 7.1. F 7.3. F 7.4. Work step F7. F

F 7.2.
50 - max 200 min-1

<1... 0 mm
Installing
F 7.5. FuelFix
0 mm
90°
F 7.6.

57
Work step F8.

Ensuring
firm seating
of FuelFix

58

1 2 1 Tank
2 Fuel line of FuelFix
3 FuelFix

Routing
fuel line

3 59

1 1 2 1 Install tank 3 according to the manufactur-

er's instructions.
Route FuelFix fuel line 2 along original ve-
hicle wiring harness and secure with cable
tie 1 [3x] as tension relief .
Routing
fuel line

3 60

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 2 S-Max / Galaxy

Remove the fuel tank according to the

manufacturer's instructions.

Work step F1. F

1 Reposition barcode label Moving bar-

2 Fuel tank sending unit code label

61
Work step F2. F
1 Position washer with outer dia.
da = 24 mm as template at the outline
as shown
2 Hole pattern Copying
hole pattern

2 62
Work step F3.

1 Hole made with provided drill

Hole for
FuelFix
1

63
Work steps F4 and F5.

Bend FuelFix 2 according to template and

cut to length.
Insert into hole 1.
Inserting
FuelFix

2
1

64

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Ford Mondeo / S-Max / Galaxy (CD 4)

Inserting
FuelFix

65

Inserting
FuelFix

66
Work steps F5.3 and F5.4.

Align FuelFix 1 as shown.

Aligning
FuelFix
1

67

1 Work step F6.

1 Hose section, 10mm dia. clamp [2x]

2 Fuel line

Connect-
ing fuel line

2 68

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Ford Mondeo / S-Max / Galaxy (CD 4)

F 7.1. F 7.3. F 7.4. Work step F7. F

F 7.2.
50 - max 200 min-1

<1... 0 mm
Installing
F 7.5. FuelFix
0 mm
90°
F 7.6.

69
Work step F8.

Ensuring
firm seating
of FuelFix

70

1 2 2 Fuel line of FuelFix

3 FuelFix mounted
4 Cable tie as tension relief

3 Securing
fuel line
Install tank 1 according to the manufactur-
er's instructions.

4 71

1 2 FuelFix Installation for Petrol

Vehicles
Remove the fuel tank according to the
manufacturer's instructions.
F
Work steps F1, F2 and F3.
3 Copying
1 Position washer with outer dia. hole pat-
da = 24 mm as template centrally on tern, Hole for
circular raised part as shown FuelFix
2 Fuel tank sending unit
3 Hole pattern, hole made with provided
drill
72

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 Work steps F4 and F5.

Bend FuelFix 1 according to template and

cut to length.
Insert into hole 2.
Inserting
FuelFix
2

73

Inserting
FuelFix

74

Inserting
FuelFix

75
Work steps F5.3 and F5.4.

Align FuelFix 1 as shown.

Aligning
FuelFix

1 76

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 2 Work step F6.

1 Hose section, 10mm dia. clamp [2x]

2 Fuel line
3 FuelFix
Connect-
ing fuel line

3 77

F 7.1. F 7.3. F 7.4. Work step F7. F

F 7.2.
50 - max 200 min-1

<1... 0 mm
Installing
F 7.5.
FuelFix
0 mm
90°
F 7.6.

78
Work step F8.

Ensuring
firm seating
of FuelFix

79

1 1 Fuel line of FuelFix

2 FuelFix
3 Tank

Routing
fuel line

3 2 80

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 2 Route FuelFix fuel line 2 along original ve-

hicle wiring harness and secure with cable
tie 3 [2x] as tension relief .

Routing
fuel line
Install tank 1 according to the manufactur-
3 er's instructions.

3 81

1 2 3 4 All vehicles

1 50 mm hose section, 10 mm dia.

clamp
2 Metering pump mount
3 Metering pump Preparing me-
4 90° moulded hose, 10 mm dia. clamp tering pump

82
1 Support angle bracket, M6x25 bolt,
original vehicle hole, flanged nut
2 Metering pump
3 Metering pump mount

1 Installing me-
tering pump

3 2 83
Connect FuelFix fuel line 1 on 90° mould-
ed hose 3.
1
2 10 mm dia. clamp

Installing
fuel line
2

84

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Ford Mondeo / S-Max / Galaxy (CD 4)

Connector X7

Complet-
ing meter-
ing pump
connector

Pin assignment is not relevant. 85

1 2 3 4 Pull heater fuel line 6 and metering pump

wiring harness 2 into 10 mm dia. corrugat-
ed tube 1 and route to metering pump 4.
Ensure sufficient distance from neighbour-
ing components, correct if necessary.
Connect-
3 Metering pump wiring harness, con- ing meter-
nector X7 mounted ing pump
5 Hose section, 10 mm dia. clamp

6 5 86

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Ford Mondeo / S-Max / Galaxy (CD 4)

Coolant Circuit Except for 2.0 TDCi 154 kW

Any coolant running off should be collected in an appropriate container. Route hoses kink-free. Un-
less specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot
be damaged. The heater must be filled with coolant when installing the hoses.

The connection should be modelled on an ‘inline’ circuit and based on the following diagram:

Hose rout-
ing diagram

Ø 23

F
D
E
C

B
A

All spring clips without a specific designation = 25 mm dia. All connecting pipes and = 18x18mm dia.
1 = Original vehicle spring clip

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 Pull off engine outlet / heat exchanger inlet

hose 2. Original vehicle spring clip 1 will
be reused.

Cutting
point

87

E 1 1 28 mm dia., 500 mm heat protection

hose [2x]

F
Premounting
hoses

B 1 88

E 1 1 Connecting piece of heat exchanger

inlet

Connect-
F ing heat ex-
changer
inlet

89

D E

Connect-
ing heater
outlet

90

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 2 3 1 Circulating pump mount

2 Circulating pump
3 M6x25 bolt, flanged nut
4 Angle bracket

Preparing
circulating
pump
4

91

1 2 3 1 Original vehicle stud bolt, M6 plastic

nut
2 M6x25 bolt, angle bracket, flanged
nut
3 Circulating pump
4 Circulating pump mount Loosely in-
stalling cir-
culating
pump

4 92

1 2 1 Circulating pump
2 Circulating pump mount
3 Angle bracket
4 Original vehicle stud bolt, M6 plastic
nut
4 3 Aligning
circulating
pump

93

1 2 1 Wiring harness circulating pump

2 Cable tie

Connect-
ing heater
inlet

B 94

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 E 1 1 Align hoses and fasten with cable tie 1

[3x]. Ensure sufficient distance from
neighbouring components, correct if nec-
essary.

Routing in
engine
compart-
ment

B 95

1 1 Circulating pump
2 Connector of circulating pump wiring
harness

Connect-
ing circulat-
ing pump
2 A

B 96

1 2 1 Original vehicle spring clip

2 Engine outlet hose

Connect-
ing engine
outlet

97

24 23

Preparing
perforated
bracket

90°
90°

98

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 2 3 1 Original vehicle relay

2 Perforated bracket
3 M6 plastic nut, original vehicle stud
bolt
4 Original vehicle bolt
Installing
original ve-
hicle relay
4

99

1 Only in case of vehicles with 2 heat ex-

changers

Pull off hose of heat exchanger outlet 1,

cut off 20mm and re-mount.
Secure hoses using cable tie 2. Shortening
hose of
heat ex-
2 changer
outlet

100

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Ford Mondeo / S-Max / Galaxy (CD 4)

Coolant Circuit for 2.0 TDCi 154 kW

Any coolant running off should be collected in an appropriate container. Route hoses kink-free. Un-
less specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot
be damaged. The heater must be filled with coolant when installing the hoses.

The connection should be modelled on an ‘inline’ circuit and based on the following diagram:

Hose rout-
ing diagram

Ø 23

J
G
H
F

E D

C
B 1

All spring clips without a specific designation = 25 mm dia. All connecting pipes and =
18x18mm dia.
1 = Original vehicle spring clip

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 Pull off engine outlet / heat exchanger inlet

hose 2. Original vehicle spring clip 1 will
be reused.

Cutting
point

101

H 1 28mm dia., 430mm heat protection

hose

Premounting
hoses

1 102

H 1 1 Spring clip

Connect-
J ing heat ex-
changer
inlet

103

G H

Connect-
ing heater
outlet

104

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 When drilling, be careful of components

located behind!

1 Original vehicle stud bolt

2 2 7 mm dia. hole
Copying
hole pattern

80

105
1 Circulating pump mount
2 Circulating pump
1 3 28mm dia., 30mm heat protection
hose
4 28mm dia., 140mm heat protection
hose Premount-
ing circulat-
2 ing pump /
3 hoses

E 4 106

1 2 3 1 M6x35 bolt, flanged nut

2 Circulating pump mount
3 Circulating pump
4 Connector of circulating pump wiring
harness
Installing
circulating
pump

E 4 107

Connecting
hose sec-
tion E with
hose sec-
tion F

E 108

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Ford Mondeo / S-Max / Galaxy (CD 4)

C 1 1 28mm dia., 30mm heat protection

hose
2 28mm dia., 170mm heat protection
hose
3 28mm dia., 80mm heat protection
hose Premount-
3
ing hoses
B

2 A 109

1 2 A Route hose A after the connection along

engine outlet hose 1 to the front passen-
ger's side.

2 Original vehicle spring clip

Connect-
ing engine
outlet

110

Connect-
ing circulat-
ing pump

B A 111

J Align hoses and fasten with cable tie. En-

sure sufficient distance from neighbouring
components, correct if necessary.

1 Hose bracket between hose A and

hose J Installing
hose bracket
1

112

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Ford Mondeo / S-Max / Galaxy (CD 4)

24 23

Preparing
perforated
bracket

90°
90°

113

1 2 3 1 Perforated bracket
2 M6 plastic nut, original vehicle stud
bolt
3 Original vehicle bolt
4 Original vehicle relay
Installing
original ve-
hicle relay
4

114

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Ford Mondeo / S-Max / Galaxy (CD 4)

1 Final Work
2
Mondeo

1 Wheel-well inner panel

2 Insulation Removing
insulation in
shaded area

115

1 S-Max / Galaxy
2
1 Wheel-well inner panel
2 Insulation

Removing in-
sulation in
shaded area

116
1 Heat protection film

Sticking on
heat protec-
tion film

117

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Ford Mondeo / S-Max / Galaxy (CD 4)

All vehicles

Reassemble the components in reverse order. Check all hoses, clamps and all electrical connec-
tions for firm seating. Insulate and tie back loose lines.
Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax
(Tectyl 100K).

• Connect the battery.

• Fill and bleed the coolant circuit according to the vehicle manufacturer’s instructions.
• Program MultiControl CAR, teach Telestart transmitter.
• For initial startup and function check, please see installation instructions.
• If the fan function or A/C control panel settings need to be checked, see the installation
documentation in the additional kit ‘Webasto Standard’ or ‘Webasto Comfort’ A/C con-
trol, section ‘Final Work’.
• Place the ‘Switch off parking heater before refuelling’ caution label near the filler neck.

Webasto Thermo & Comfort SE

Postfach 1410
82199 Gilching
Germany
Internet: www.webasto.com
Technical Extranet:
http://dealers.webasto.com

Ident. No.: 1323975E_EN Status: 21.12.2016 © Webasto Thermo & Comfort SE 41

Ford Mondeo / S-Max / Galaxy (CD 4)

FuelFix Template for Mondeo Diesel

Top view

100mm

Scale 1:1

Compare size of printout with dimension lines.

Allowed tolerance a maximum of 2%.

Set the printer settings to ‘no margin’ or ‘minimise mar-

gins’ and 100% of the normal size.
100mm

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Ford Mondeo / S-Max / Galaxy (CD 4)

FuelFix Template for S-Max / Galaxy Diesel

Top view

100mm

Scale 1:1

Compare size of printout with dimension lines.

Allowed tolerance a maximum of 2%.

Set the printer settings to ‘no margin’ or ‘minimise mar-

gins’ and 100% of the normal size.
100mm

Ident. No.: 1323975E_EN Status: 21.12.2016 © Webasto Thermo & Comfort SE 43

Ford Mondeo / S-Max / Galaxy (CD 4)

FuelFix Template for Petrol Vehicles

Top view

100mm

Scale 1:1

Compare size of printout with dimension lines.

Allowed tolerance a maximum of 2%.

Set the printer settings to ‘no margin’ or ‘minimise mar-

gins’ and 100% of the normal size.
100mm

Ident. No.: 1323975E_EN Status: 21.12.2016 © Webasto Thermo & Comfort SE 44