Webasto Mazda 6 Bedienungsanleitung

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 warnings.

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

installation by untrained staff.

Water Heater Unit

Installation Instructions

Ident. No.:1313440A_EN Fee Euro 10.00 © Webasto AG

Mazda 6

Gasoline

from Model Year 2008

Left-hand drive vehicle

Automatic transmission

Feel the drive

Thermo Top E Additional Heater e1

00 0003

Thermo Top C

Additional Heater

00 0002

Thermo Top P Additional Heater e1

00 0104

Mazda 6

1313440A_EN 2

Table of Contents

Validity

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

instructionshavenotbeentested.However,installation according to these installationinstructions may

be possible.

The installation location of the digital timer should be confirmed with the end customer before

installation.

Manufacturer Model Type EG-BE No./ABE

Mazda 6 GH e1 * 2001/116 * 0448 * ...

Engine type Engine model Output in kW Displacement in cm³

L5X Gasoline 108 1999

Validity 2

Heater Unit/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater unit installation location 5

Electrical system 6

Fan controller 7

ll vehicles 8

utomatic air-conditioning 8

Manual air conditioner 9

Remote option (Telestart) 10

Preparing heater unit 11

Preparing bracket 11

Installing heater unit 13

Fuel 14

Water 16

Exhaust gas 19

Final Work 21

Template for Fuel Standpipe 22

Operating Instructions for End Customer 23

Mazda 6

1313440A_EN 3

Heater Unit/Installation Kit

Heater unit recommended for the respective vehicle class:

The selection of the heater unit 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 Mazda 6 Gasoline vehicles - for validity, see page 2 - from

model year 2008 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,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"

for the Thermo Top C/P/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

specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring

harnesses using cable ties.

Sharp edges should be fitted with edge protectors (split-open plastic 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 with desired heater control See price list

1 Installation Kit for Mazda 6 Gasoline Automatic 1313439A

Vehicle Heater unit

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Full-size car, van, offroader Thermo Top P

Mazda 6

1313440A_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.

Reference to general installation instructions of

Webasto components or to the manufacturer's vehicle-

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

Water

Fuel

Exhaust gas

Combustion air

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 6

1313440A_EN 5

Preliminary Work

WARNING!

- Open fuel tank cap, ventilate 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.

- Completely remove the battery.

- Remove the air filter together with the intake hose.

- Remove the lower engine cover.

- Remove the vehicle underbody trim.

- Detach the wheel well trim on the right and left.

- Remove the bumper.

- Remove the rocker panel trim on the driver's side at the front.

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

- Detach the BCM in the driver's side footwell.

- Remove the instrument panel trim below the steering wheel (only with Telestart T100 HTM).

- Remove the A/C control panel according to the manufacturer's instructions (only with automatic

air-conditioning).

Remove page 23 "Operating Instructions for End Customer" and insert with vehicle operating

instructions.

Heater unit installation location

1Heater unit

Installation

location

Mazda 6

1313440A_EN 6

Electrical system

Fuse holder, relay K3

Replace 25 A fuse F3 with 10 A fuse.

1M5x16 bolt, washer, fuse holder, K3 relay,

flanged nut on angle bracket

2Angle bracket

3Original vehicle bolt

Digital timer

1Digital timer

Wiring

harness

installation

diagram

Installing wiring harness of heater unit in

corrugated tube

Slit 17 mm dia. corrugated tube 1, pull in wiring

harness of heater unit and route to installation

location of heater unit.

Wiring harness pass through

1Protective rubber plug

321

Do not install the metering pump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the

underbody

Mazda 6

1313440A_EN 7

Fan controller

Wiring

diagram

Webasto components Vehicle components Colors and symbols

Legend

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

6-pin heater unit connector

GRs Fan relay ws white

Replace 25 A with 10 A fuse.

GRr Fan controller sw black

Fb 40 A heater fuse

K3 Fan relay BCM Body Control Module

STA 24-pin connector of BCM,

black (0940-01A)

Air-conditioning control panel

STB *

24-pin connector of KB with

automatic air-conditioning:

(0740-201A) Pin 1G

STB *

24-pin connector of KB with

manual air-conditioning:

(0740-101A) Pin 1O

** XCutting point

Wiring colors may vary.

Webasto

Mazda

85 30

87a87

X1 4BCM

St A 1A

-GM

rt/ws

rt/ws sw

rt rt/ws

rt/ws

1²

1²1²

1²

4²

F-02

GRs

GRr

1G/1O

St B ***

Mazda 6

1313440A_EN 8

All vehicles

Connection on 24-pin connector 0940-01A,

color black 1from BCM 2.

Produce connections as shown in wiring

diagram.

Connector is located on rear side of BCM.

3Red/white (rt/ws) wire of connector

4Red (rt) wire from K3/87a

5Black (sw) wire from K3/30

Route black (sw) wire 1² to A/C control panel

7Red/white (rt/ws) wire of fan relay

Connec-

tion of fan

relay on

BCM

24-pin connector 0940-01A, color black 1

from BCM (on wire side)

2Socket 1A, red/white (rt/ws) wire

BCM

connector

Automatic air-conditioning

Connection on connector B 3of A/C control

panel, Pin 1G.

Produce connections as shown in wiring

diagram.

1Black (sw) wire 1²

2Insulate red/white (rt/ws) wire of 10 A air-

conditioner fuse and tie back

Red/white (rt/ws) wire of connector B, Pin 1G

Connect-

ing A/C

control

panel

24-pin connector 0740-201A, white 1of A/C

control panel (on wire side)

2Socket 1G, red/white (rt/ws) wire

Connector

2 3

BL*

*RW

***

RY* * * * *

B G G R

GY GY

1 2

4 3

* * *

BYG

WW B

RGY B

*BR RYB

LG PB

Mazda 6

1313440A_EN 9

Manual air conditioner

Connection on connector B 3of A/C control

panel, Pin 1O.

Produce connections as shown in wiring

diagram.

1Black (sw) wire 1²

2Insulate red/white (rt/ws) wire of 10 A air-

conditioner fuse and tie back

4Red/white (rt/ws) wire of connector B,

Pin 1O

Connect-

ing A/C

control

panel

24-pin connector 0740-101A, white 1of A/C

control panel (on wire side)

2Socket 1O, red/white (rt/ws) wire

Connector

1 2

1B1X

WRWYG

YPB

BR RR

VLRY

B L

* *

W W *

BL BGY B

YR R

Mazda 6

1313440A_EN 10

Remote option (Telestart)

1Receiver,originalvehicle stud bolt, original

vehicle flanged nut

Installing

receiver

1Antenna

Installing

antenna

Temperature sensor HTM100

1Temperature sensor

2Cable tie

3Original vehicle wiring harness Installing

tempera-

ture sensor

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