Webasto Thermo Top E Manuale dell'operatore
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
A
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
1
1
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
1
250
2sw
0,75²
F4
86
85 30
87a87
K3
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
2
1
2
3
5
4
3
1
2
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
4
1
5
2
1
2
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
31
30
15
Mazda
F3
86
85 30
87a87
K3
HG
X1 4
F-02
GR
BA
C-03
+
-GM
M
WG
GS
01
02
03
04
0
F17
sw
sw
pk
hbl
hbl
hbl
vi vi
vi
hgn
rt
4²
sw
4²
C-51
6
1
4 3
2
5
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
31
30
15
Mazda
F3
86
85 30
87a87
K3
HG
X1 4
rt
4²
sw
4²
F-02
GRs
+
-GM
M
F17
sw
sw
pk
hbl
hbl
hbl
vi vi
vi
hgn
C-51
GRr
0740-203
KB
0740-201B 2H 2B
0740-201A 1N 1M
!
pk
pk
BA
C-03
F4 sw
0,75²
sw
0,75²
1 2
F12
br
bl
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
7
1
4 3
2
5
8
3
2
4
1
LG RY SB RGYGY G
L WR G *BRPLG
2O 2M 2K 2I 2G 2C 2A
2E
2P 2N 2L 2J 2H 2D 2B2F
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