Webasto Thermo Top E Bedienerhandbuch

Water Heater

Installation documentation

Ident. No.: 1314978D_EN Fee Euro 10.00 © Webasto AG

Mazda 3

1.6 Petrol

from Model Year 2009

Left-hand drive vehicle

Manual transmission

Feel the drive

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.

The initial startup is to be executed with the Webasto Thermo Test Diagnosis.

Webasto does not accept any liability for defects and damage that are attributable to installa-

tion by untrained staff.

Thermo Top E Parking Heater e1

00 0003

Thermo Top C Parking Heater e1

00 0002

Mazda 3

1314978D_EN 2

Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in these installation

instructionshavenotbeentested.However,installation accordingtotheseinstallationinstructionsmay

be possible.

The installation location of a digital timer and summer/winter switch should be confirmed with the end

customer before installation.

Manufacturer Model Type EG-BE No./ ABE

Mazda 3 BL e11 * 2001/116 * 0262 * ...

Engine type Engine model Output in kW Displacement in cm³

Z6 Petrol 77 1598

Validity 2

Heater/installation kit 3

Foreword 3

General instructions 3

Special tools 3

Explanatory notes on document 4

Preliminary work 5

Heater installation location 5

Preparing electrical system 6

Electrical system 7

Fan control for manual air conditioning 8

utomatic air-conditioning fan control 9

Remote option (Telestart) 11

Preparing installation location 12

Installing heater 13

Fuel 14

Coolant circuit 17

Combustion air 21

Exhaust gas 22

Final Work 25

Operating Instructions for End Customer 26

Mazda 3

1314978D_EN 3

Heater/installation kit

Heater recommended for the respective vehicle class:

The selection of the heater is based on the passenger compartment size of the vehicle and the level of

comfort required by the customer!

Foreword

These installation instructions apply to vehicles Mazda 3 1.6 Petrol - for validity, see page 2 - from mod-

el year 2009 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 nec-

essary during installation with respect to these installation instructions.

However,thestipulations in the "installationinstructions"and"operatingandmaintenanceinstructions"

for the Thermo Top C/E must always be observed.

The corresponding rules of technology and any information from the vehicle manufacturer should be

observed during the installation work.

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

Quantity Description Order No.:

1 Retail accessories Thermo Top E / C See Mazda price list

1 Installation kit for Mazda 3 2009 1.6 Petrol 1314977A

Mazda Order No.: 4100-78-771

1 Heater control See price list

Vehicle Heater

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Mazda 3

1314978D_EN 4

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

ReferencetogeneralinstallationinstructionsofWebas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!

Tightening torque of Ejot screws, Ejot studs = 10 Nm!

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Software

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.

Mazda 3

1314978D_EN 5

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.

-Depressurisethe 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.

- Completely remove the battery together with the carrier.

- Remove the windscreen wiper.

- Remove the cover of the coolant reservoir cap at the upper left.

- Remove the windscreen wiper motor.

- Remove the engine underride protection.

- Remove the bumper.

- Remove the rear seat cushion.

- Open the fuel sender service lid and pull off the fuel line and the connector.

- Remove the fuel tank.

- Remove fuel-tank sending unit.

- Remove the lower instrument panel trim on the driver's side.

- Remove the A-pillar trim in the driver's side footwell.

- Remove the centre outlet vents above the radio (only with automatic air-conditioning).

- Remove the radio (only with automatic air-conditioning).

Remove page 26 "Operating Instructions for End Customer" and attach to vehicle operating instruc-

tions.

Heater installation location

1Heater

Installa-

tion loca-

tion

Mazda 3

1314978D_EN 6

Preparing electrical system

Only with automatic air-conditioning

Install wire section 2in protective sleeving

provided. Cutting

wires to

length

Produce connections as shown in wiring dia-

gram. Install wire section 2in protective

sleeving provided.

Preparing

fuse F4

250

2sw

0,75²

85 30

87a87

1 2

Mazda 3

1314978D_EN 7

Electrical system

Fuse holder, K3 relay

15.5 mm dia. hole; retaining plate fuse holder,

M5x16 bolt, washer, flanged nut

2Fuses

3K3 relay

4Existing hole, M5x16 bolt, washer, flanged nut

5Positive wire on positive terminal of battery

Digital timer and summer/winter switch op-

tion

1Digital timer

2Summer/winter switch, drilled hole 12 mm dia.

Wiring har-

ness rout-

ing

diagram

Earth connection

1Earth wire on original vehicle earth support

point

Wiring harness pass through

1Protective rubber plug

2Wiring harnesses of fan control, controls

Do not install the metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

Mazda 3

1314978D_EN 8

Fan control for manual air conditioning

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legends

HG Heater TT-C/E GM Fan motor rt red

X1 6-pin heater connector GR Fan relay sw black

F3 25A fuse GS Fan switch pk pink

K3 Fan relay WG Resistor group hgn light green

F-02 10A fuse vi violet

F17 40A fuse hbl light blue

C-03 A-pillar connector

C-51 Distributor XCutting point

Wiring colours may vary.

Connection on connector C-03 5A-pillar.

Produce connections as shown in wiring dia-

gram.

1Light blue (hbl) wire of fan motor

2Black (sw) wire of K3/30

3Red (rt) wire of K3/87a

4Light blue (hbl) wire of connector C-03

Connect-

ing fan-mo-

tor

Webasto

Mazda

85 30

87a87

X1 4

F-02

C-03

-GM

F17

hbl

vi vi

hgn

4²

C-51

4 3

Mazda 3

1314978D_EN 9

Automatic air-conditioning fan control

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legends

HG Heater TT-C/E GM Fan motor rt red

X1 6-pin heater connector GRs Fan relay sw black

F3 25A fuse GRr Fan controller pk pink

K3 Fan relay 0740-203 Connector GRr hgn light green

F4 10A fuse KB A/C control panel vi violet

0740-201A Connector KB hbl light blue

0740-201B Connector KB br brown

F-02 10A fuse bl blue

F17 40A fuse

F12 15 A fuse Insulate wire end and tie

back

C-03 A-pillar connector

C-51 Distributor XCutting point

Wiring colours may vary.

Webasto

Mazda

85 30

87a87

X1 4

4²

F-02

GRs

-GM

F17

hbl

vi vi

hgn

C-51

GRr

0740-203

0740-201B 2H 2B

0740-201A 1N 1M

C-03

F4 sw

0,75²

1 2

F12

Mazda 3

1314978D_EN 10

Connection on connector C-03 5A-pillar.

Produce connections as shown in wiring dia-

gram.

1Light blue (hbl) wire of fan motor

2Black (sw) wire of K3/30

3Red (rt) wire of K3/87a

4Light blue (hbl) wire of connector C-03

Connect-

ing fan-mo-

tor

Connectionon16-pinconnector0740-201B4

fromA/Ccontrol panel.Insulate pink (pk) wire

1from fuse F02 and tie back.

Produce connections as shown in wiring dia-

gram.

2Black (sw) wire of F4 fuse

3Pink (pk) wire of 16-pin connector, Pin 2H

Connect-

ing A/C

control

panel

Connector 0740-201B on wire side

View of

connector

0740-201B

4 3

LG RY SB RGYGY G

L WR G *BRPLG

2O 2M 2K 2I 2G 2C 2A

2P 2N 2L 2J 2H 2D 2B2F

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