Webasto Thermo Top E Operator's manual

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

Mazda 3
1314978D_EN 11
Remote option (Telestart)
Fasten receiver 1with adhesive tape.
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor T100 HTM
Fasten temperature sensor 1with adhesive
tape.
Installing
tempera-
ture sensor
19
1
10
1
11

1314978D_EN 12
Mazda 3
Preparing installation location
1Drill out 9.1 mm dia. hole
29.1 mm dia. hole
Preparing
installa-
tion loca-
tion
Original vehicle bolt removed at position 2.
1Rivet nut [2x]
Installing
rivet nut
Cut perforated bracket Ato size.
Angle down perforated bracket Bby approx.
70°.
Preparing
perforated
brackets
1Perforated bracket C
2Loosely mount M6x20 bolt, flanged nut [2x
each]
3Bracket
Preparing
bracket
12
1 2
17
15
13
1
2
1
14
50
80
80
B
A
15
2
1
3
A
2

1314978D_EN 13
Mazda 3
1Loosely mount M6x20 bolt, flanged nut
Preparing
bracket
Insert 5 mm shim at position 1, 10 mm shim
at position 2 and 40 mm shim at position 4 be-
tween bracket and frame side member. Tight-
en all loose mounting hardware.
1M6x30 bolt, spring lockwasher, 5 mm shim
2M6x30 bolt, spring lockwasher, 10 mm
shim
3M6x20 bolt, spring lockwasher
4M6x60 bolt, spring lockwasher, large diam-
eter washer, 40 mm shim
Installing
bracket
Installing heater
Mount wiring harness on heater before in-
stalling
1Ejot screw [2x] Installing
heater
1Ejot screw [2x]
Installing
heater
16
B1
17
2
3
4
1
2
1
18
1
1
19
1
1

Mazda 3
1314978D_EN 14
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with an appropriate container.
Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Un-
less specified otherwise, always fasten using cable ties.
Mount the fuel line and wiring harness with rub protection on sharp edges.
WARNING!
The fuel line and wiring harness are routed to the metering pump in as shown in the wiring harness
routing diagram.
Route fuel line in corrugated tube 1along fire-
wall to underbody.
2Hose section, 10 mm dia. clamp [2x]
Connec-
tion of
heater
Route fuel line and wiring harness of meter-
ing pump in corrugated tube 1along original
vehicle lines to installation location of meter-
ing pump. Cut 1,000 mm off fuel line (for con-
nection to fuel standpipe). Installing
lines
Remove fuel tank according to manufactur-
er's instructions. Remove fuel-tank sending
unit according to manufacturer's instructions.
Remove fuel-tank vent line 1and shorten by
approx. 50 mm.
Slide section 2onto fuel tank connection
piece Removing
fuel
20
2
1
21
1
22
1
50
2

Mazda 3
1314978D_EN 15
Shape fuel standpipe 1as shown.
Preparing
fuel stand-
pipe
1Fuel-tank vent line
224 mm dia. clamp [2x]
3Fuel standpipe
4Hose section, 10 mm dia. clamp [2x]
5Fuel line Installing
fuel stand-
pipe
Insert fuel standpipe 1through ventilation
connecting piece. Slide hose section 3with
3.2 mm dia. onto fuel standpipe 1and fasten
with 8 mm dia. clamp 2.
Removing
fuel
Align removal pipe of fuel standpipe to fuel
tank bottom.
Installing
fuel stand-
pipe
23
410
1
185
24
1 2 2
4
3
5
25
1
2
3
26

Mazda 3
1314978D_EN 16
Fix fuel line 1in place on fuel tank with adhe-
sive tape. Install fuel tank in accordance with
manufacturer's instructions
Fastening
fuel line
Shorten 180° moulded hose 1.
Cutting
moulded
hose to
length
1Original vehicle bolt
2Bracket of metering pump
3Silent block, flanged nut [2x]
4Loosely install rubber-coated p-clamp
Installing
metering
pump
bracket
Tighten flanged nuts on silent block.
Check the position of the components; adjust
ifnecessary. Checkthattheyhavefreedomof
movement.
1Metering pump
2Fuel line, hose section, 10 mm dia. clamp
[2x]
3Fuel line of heater, wiring harness of me-
tering pump in corrugated tube
4Wiring harness of metering pump, connec-
tor mounted
5Fuel line of fuel standpipe
6180° moulded hose, 10 mm dia. clamp [2x]
Installing
and con-
necting
metering
pump
27
11
28
10
1
29
2
1
4
3
30
5
6
1 2 3
4

Mazda 3
1314978D_EN 17
Coolant circuit
WARNING!
Any coolant running off should be collected using an appropriate container! Route hoses kink-free! Un-
less specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be
damaged! When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Hose rout-
ing dia-
gram
All connecting pipes without a specific designation = dia. 18x20.
All hose clamps = 20-27 mm dia. All spring clips = 27 mm dia.
1= Red (rt) rubber isolator . 2= Black (sw) rubber isolator .
C
A
Ø 20x20
1
2
B
1
2

Mazda 3
1314978D_EN 18
Discard section X.
A= 1000
B= 135
C= 920 Cutting
hoses to
length
Connect hose Band C. Slide on red (rt) rub-
ber isolator 1[2x] and black (sw) rubber isola-
tor 2[2x].
Premount-
ing hoses
1Perforated bracket
Angling
down per-
forated
bracket
1M6x20 bolt, flanged nut, existing hole
2M6x20 bolt, flanged nut
348 mm dia. rubber-coated p-clamp
4Perforated bracket
Installing
perforated
bracket
X
AB
X
X
C
C A
2 1
B
1
2
31
90°
80
1
32
3
1
42

Mazda 3
1314978D_EN 19
Alignblack(sw)rubberisolator2toconnector
1.
Connec-
tion of
heater
Routing in
engine
compart-
ment
Cut off original vehicle hose on engine out-
let/heat exchanger inlet 1at marking.
Cutting
point
Hose section on engine outlet 3on connec-
tion piece turned by approx. 180°. Install
18x20 mm connecting pipe 2[2x].
1Hose section of heat exchanger inlet Turning
hose on
engine out-
let
33
2
A
B
1
34
A
C
35
1
36
1
3
2
2

Mazda 3
1314978D_EN 20
RoutehoseAthroughrubber-coatedp-clamp
2.
1Engine outlet hose section
Connect-
ing engine
outlet
Route hose Cthrough rubber-coated p-
clamp. Align black (sw) rubber isolator 2to
brake line. Ensure sufficient distance to
neighbouring components.
1Hose on heat exchanger inlet Connect-
ing heat
exchanger
inlet
Align and position red (rt) rubber isolator 1
[2x] on oil return line.
Aligning
hoses
1Cable tie [3x]
Fastening
hoses
37
1
A
2
38
1 2 C
39
1
1
C
A
40
1
1
1