Water heater
D5W Z heater
Upgrade
D5W Z heater to auxiliary
heating system C
21 43
Legend for Fi gure 1
1 Blade-type fuse holder and blower relay
2 Digital timer
3 Heater
4 Diode group
IMPORTANT!
Danger war ni ng:
The incorrect installation or repair of Webasto heating and cooling systems may cause a fire or
the escape or fatal carbon monoxide. This may result in serious or fatal injuries.
Special company training, technical documentation, special tools and special equipment are
required for the installation and repair of Webasto heating and cooling systems.
NEVER attempt to install or repair Webasto heating or cooling systems unless you have
completed the company training and thus acquired the required technical skills and unless you
have the technical documentation, tools and equipment available to you that are required for
completing proper installation and repair work.
ALWAYS follow all Webasto installation and repair manuals and observe all the warnings.
Webasto cannot accept any liability for defects and damage caused by the system being
installed by untrained personnel.
FORD Galaxy
TDI ( pump in je ction)
from model year 2001
All equipment variants
Valid for left-hand drive models only
1
See page 2 for validity details
An auxiliary ventilation function is only possible
(even with Telestart) if the summer/winter
switch is used.
Ident. No. 90 106 58B Cover charge 10.00 Euros © Webasto AG
D5W Z heate r up g rade Galaxy
Table of contents
Validity 2
Heater / Installation kit 3
Foreword 3
General information 3
Preparations 4
Circuit diagrams 4
Wiring harness 7
Circulating pump actuation 8
Blower connection 10
Optional digital timer and optional summer/winter switch 12
Telestart T70/T80 option 13
Heater actuation 14
Concluding work 15
Operating instructions for the end customer 15
Validity
Manufacturer Trade name Type EC licence No.
FORD Galaxy WGR e1*95/54*0024*--
Engine number
(8th number of the VIN)
ANU TDI (pump injection) 66 1896
AUY TDI (pump injection) 85 1896
ASZ TDI (pump injection) 96 1896
BTB TDI (pump injection) 110 1896
NOTE
The vehicle types, engine types and equipment version s not listed in these installation instructions
have not been tested.
It may nevertheless be possible to install the system using these installation instructions.
Engine t ype Output in kW Displac e m ent in cc
2
Galaxy D5W Z heater upgrade
Heater / Installation kit
Quantity Designation Order No.
1Upgrade kit D5W Z for FORD Galaxy with auxiliary preheating system 90 103 96A
Other parts required for auxiliary ventilation option
1 Summer/winter switch 845 87A
Optional control element
1 Digital timer 90 108 69A
1 Telestart kit T80 90 108 79A
1 Telestart kit T100 HTM 90 139 37A
1 Thermo Call TC 1.1 90 108 72A
IMPORTANT
The kit does not include a control element!
The required control element must be ordered separately!
Foreword
These non-binding installation instructions apply t o the FORD Gal axy TD I (see page 2 for va lidity), mode l year
2001 and later, with D5W Z, unless technical modifications on the car influence the installation, excluding all
liability claims. Depending on the version and equipment in the car, changes may be required to the installation
work set out in these installation instructions.
The appropriate engineering conventio ns and any instru ctions from the veh icle manu facturer m ust be
observed for the installation work.
General information
- Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating
- Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them
at chafing points
- Fit edge protectors (opened fuel hose) to sharp edges
3
D5W Z heate r up g rade Galaxy
Preparations
Under-bonnet compartment
IMPORTANT
Disconnect the battery!
Interior
- Note the radio code is the radio has one
- Remove the bottom footwell trim on the driver’s side
- Remove the left side skirt trim
- Release the fuse/relay holder (1)
For vehicles with automatic air-conditioning
system only
- Remove the air-conditioning control
(ATC module A96)
1
2
Circuit diagrams
IMPORTANT
Refer to the circuit diagrams supplied by the
manufacturer for the specific vehicle, particularly if the
cable colours or pin assignments are different!
4
Galaxy D5W Z heater upgrade
Circuit diagram for 66 kW and 85 kW engine
2
rt (4 mm )
or
or
or
sw
sw (4 mm )
or
2
Timer
Legend for t he c i rcui t dia gram in Fi gure 3
Ford Galaxy 85 kW
A96 Self-regulating ATC air-conditioning control
A131 Control module for heater D5W Z
A302 Air-conditioning compressor coupling module
C2 Vehicle plug connector
C6 Vehicle plug connector
C192 Vehicle plug connector
C311 Vehicle plug connector
F2 Blade-type fuse, car
F3 Blade-type fuse, car
F16 Blade-type fuse, car
F22 Blade-type fuse, car
M124 Front blower motor
M151 Refrigerant pump
N289 External temperature switch
P91 Central electrics box
X Isolation point
NOTE
The vehicle’s C31 1 plug connector is on the underfloor
in front of the heater!
3
Webasto
F1 Blade-type fuse 25 A
F2 Blade-type fuse 5 A
F3 Blade-type fuse 15 A
K3 Blower relay
K3.1 Control relay
K3.2 Ventilation function relay
K3.3 Coolant pump relay
S1 Ventilation function switch
X9 Digital timer plug
(alternatively Telestart T70/T80/T100)
NOTE
Even if the vehicle has a Tel est art T70/T80, the
ventilation function can only be controlled using
switch S1!
5
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