Webasto Mazda 3 MPS Manuale utente

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 warning

instructions.

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

installation by untrained staff.

Water Heater Unit

Installation Instructions

Ident. No.: 1311472A €10 fee © Webasto AG

Mazda 3 MPS

Gasoline

From model year 2006

For left-hand drive vehicles only

Feel the drive

Thermo Top E Auxiliary Heating

00 0003

Thermo Top C Auxiliary Heating

00 0002

Mazda 3 MPS

1311472A 2

Table of Contents

Validity

Vehicle and engine types, equipment variants as well as national specifications, which are not listed in

these installation instructions, have not been tested. Installation according to these installation

instructions may, however, be possible.

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

customer before installation.

Manufacturer Model Type EG-BE No. / ABE

Mazda 3 MPS BK e1 * 2001 / 116 * 0234 * ...

Engine type Engine type Power in kW Engine capacity in cm³

L3 Gasoline 191 2261

Validity 2

Heater Unit / Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on the Document 4

Preliminary Work 5

Heater Unit Installation Location 5

Preparing the Electronics 6

Electrical Connections 8

Automatic air conditioning blower control 9

Remote Start Option 12

Preparing the Installation Location 13

Installing the Heater Unit 15

Exhaust System 17

Fuel Connection 18

Combustion Air 21

Water Connection for Gasoline Engines 22

Final Work 26

Operating instructions for the end customer 27

Tank Extracting Device Template 28

Mazda 3 MPS

1311472A 3

Heater Unit / Installation Kit

Recommended heater unit for the relevant vehicle class:

The choice of heater unit is based on the size of the vehicle passenger compartment and the

customer's comfort requirements.

Foreword

These installation instructions apply to Mazda vehicles with 3 MPS Gasoline – validity, see page 2 –

from model year 2006 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, the stipulations in the "installation instructions" and "operating and maintenance instructions"

for the Thermo Top C/P/E are to be observed in any event.

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 cable harnesses to original vehicle lines and cable

harnesses using cable clips.

Sharp edges should be fitted with edge protectors (split open plastic hose).

Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no.

111329).

Special Tools

- Torque spanner for 2.0 - 10 Nm

- Vice-grip wrench

- Riveting nut tool

Amount Description Order no.:

1 Commercial supply of required control See price list

1 Installation kit for Mazda 3 MPS Gasoline 1,311,467A

Vehicle Heater unit

Compact car Thermo Top E

Mid-class, station wagon Thermo Top C

Luxury, van, off-roader Thermo Top P

Special features are highlighted using the following symbols:

Mechanics

Electrics

water connection

Fuel connection

Exhaust System

combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Mazda 3 MPS

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.

1311472A 4

Explanatory Notes on the 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 MPS

1311472A 5

Preliminary Work

WARNING!

- Open the tank cap, ventilate the tank.

- Close the tank cap again.

- Disconnect the battery.

- Let off pressure in 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.

- Remove the engine design cover.

- Completely remove the battery.

- Completely remove the air filter with intake hose.

- Loosen the top of the thermal insulation cover in the right of the engine compartment.

- Remove the thermal insulation cover in the middle of the engine compartment (2x plastic nuts)

- Hang the hydraulic oil container for servo steering out

- Remove lower engine cover

- Remove the panelling for the rear right axle

- Remove fuel tank according to manufacturer's instructions

- Remove tank mounting according to manufacturer's instructions.

- Remove the glove compartment on the passenger side.

- Remove the A-pillar panel in the passenger side footwell.

- Remove the left cooling water reservoir cover

Remove page 27 "Operating instructions for the end customer" and insert with vehicle operating

instructions.

Heater Unit Installation Location

1Heater unit

Installation

location

Mazda 3 MPS

1311472A 6

Preparing the Electronics

Only for automatic air conditioning

Wire section 4will be needed later for

connecting the resistor. Cutting

wires into

sections

Wire sections

Pre-

assemble

the K3.1

relay

1Thermal insulation cover

2Edge protection profile

Inserting

edge

protection

Cut the accompanying flexible hose 1in the

middle and pull on the ground cable for the

heater unit cable harness / ground cable

resistance 0.9 Ohm 2.

Connect the ground cable to ground 3.

Note the circuit diagram page 9. Ground

connection

1 2 sw 2,5mm²

2250mm250mm

3 4

1000mm1500mm

br 2,5mm²

sw 0,5mm²

1500mm

sw 0,5mm²

250mm

87a

K3.1

br sw

3 2

Mazda 3 MPS

1311472A 7

Put the remaining flexible hose 1on the

positive cable on the heater unit cable

harness 2.

Connect the positive cable to the positive

battery terminal 3.

Positive

connection

Mazda 3 MPS

1311472A 8

Electrical Connections

Cable harness feed-through

1Protective rubber sleeve

Time switch and summer / winter switch

option

1Time switch

2Summer / winter switch

Cable

harness

installation

diagram

Fuse holder, K3 relay, K3.1 relay

1K3 relay, M5x16 bolt, washers, M5 nut

2Original vehicle stay bolts, fastening strap

bent according to the figure, M6 flanged nut

3K3.1 relay fastened to the fastening strap

together with the K3 relay.

4Fuse holder, M5x16 bolt, nut

Run the cables behind the thermal protection

panels.

0.9 Ohm resistor

1Original vehicle stay bolts, body washer [2x],

angle bracket, M6flanged nut

20.9 Ohm resistor, M5 flanged nut, washer,

M5x20 bolt

Connect 0.9 Ohm2resistor according to page 9

in the circuit diagram.

1 2

sw Wait to install the metering pump

cable harness until later,

together with fuel pipe along the

original vehicle fuel lines on the

underbody.

Mazda 3 MPS

1311472A 9

Automatic air conditioning blower control

Circuit

diagram

Webasto components Vehicle components Colors and symbols

Legend

HG Heater unit TT-C/E K1 Blower relay rt red

X1 6-pin connector C-04 Connector C-04 ws white

F3 Fuse, 25A G1 blower motor sw black

K3 Blower relay G2 Blower controller br brown

K3.1 Supplementary relay B air conditioning control gn green

R1 0.9 Ohm resistor R Radio unit bl blue

F44 Fuse, 7.5A or orange

ro pink

PJB Fuse and relay support

Insulate and tie back wire

ends

XSplitting point

Cable colors may vary.

87a

K3.1

R1 sw

sw/bl

sw/gn

bl/sw

sw/or

sw/rt

gn/ws rt

Webasto Mazda

rt/ws

87a

C-04

F44

PJB

J-03

0,5mm²

sw/gn

ro/or

4mm²

ro/or

4mm²

0,5mm²

Mazda 3 MPS

1311472A 10

Connection to the connector 3C-04

Connect with enclosed connectors according

to the circuit diagram.

1Wire (sw) from K3/30

2Pink/orange (ro/or) wire to blower motor.

4Pink/orange (ro/or) wire to connector C-04.

5Red (rt) wire from F3/87a

Positive

connection

to the

blower

motor

1Connector C-04

2Pink/orange (ro/or) slot.

Connector

C-04

Connection to 6-pin connector 4from the

blower control.

1Brown (br) wire from K3.1/87

2Black/green (sw/gn) wire

3Black (sw) wire from K3.1/87a

5Black/green (sw/gn) wire Positive

connection

to the

blower

motor

Connection to 6-pin connector 1from the

blower control.

2Black/green (sw/gn) wire

Blower

controller

connector

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