Webasto Mazda 3 MPS User manual

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
e1
00 0003
Thermo Top C Auxiliary Heating
e1
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
11

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
5
6
85
87a
87
30
86
K3.1
sw
6
1
2
3
5
sw
br
br sw
2
21
3
1
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
4
1
3
2

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.
5
1
6
1 2
br
bl
br
sw
sw
rt
sw Wait to install the metering pump
cable harness until later,
together with fuel pipe along the
original vehicle fuel lines on the
underbody.
7
4
2
3
1
8
1
2

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.
31
br
85
87a
87
30
86
K3.1
br
sw
sw
R1 sw
6
4
br
2
3
1
5
sw/bl
K1
sw/gn
bl/sw
sw/or
sw/rt
sw
gn/ws rt
sw
30
15
Webasto Mazda
br
4
HG
X1
F3
rt/ws
85
87a
87
30
86
K3
C-04
sw
G2
G1
M
B
F44
75
PJB
J-03
ge
0,5mm²
R
sw
sw/gn
ro/or
4mm²
ro/or
4mm²
ge
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
9
2
4
5
3
1
10
2
1
11
2
4
13
5
12
1
2

Mazda 3 MPS
1311472A 11
Pull the connection to connector 5J-03 from
the PJB fuse and relay support.
Connect with enclosed butt connector 3
according to the circuit diagram.
1Yellow (ge) wire
2Black (sw) wire from K3.1/86
4Yellow (ge) wire
Relay K3.1
control
1Connector J-03
2Yellow (ge) plug-in position
Connector
J-03
13
5
2
3
4
1
14
1
2

Mazda 3 MPS
1311472A 12
Remote Start Option
1Receiver
2Bracket, drill hole in bracket to Ø6.5mm.
3M6x12 bolt, original vehicle threaded insert
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
1
15
32
1
16

1311472A 13
Mazda 3 MPS
Preparing the Installation Location
Remove the blower resistor 1
Drill Ø 7mm holes1[2x] in the bracket 2
according to the illustration.
Preparing
the bracket
Drill open holes 1[2x] in the strut 2to Ø10mm.
Preparing
the strut
Assemble the bracket 2according to the
image, transfer hole images 3and 4.
1M6x20 bolt, 5 mm spacer washer, original
vehicle threaded insert
3Hole image for Ø 9.1 mm hole
4Hole image for Ø 7 mm hole
5M6x70 bolt, 15mm spacer nut, 30 mm
spacer, original vehicle threaded insert
Copying
the hole
image
17
1
18
2
114mm
107mm
18mm
30mm
11
19
1
2
1
20
1 2
4
5
3

1311472A 14
Mazda 3 MPS
Remove original vehicle bolt 2, this will be
used again.
1M6 rivet nut
3Hole Ø 7mm
Tighten the
rivet nut;
remove the
screw
1Blower resistance
2M6x20 bolt, spring washer, body washer,
8mm spacer washer, original vehicle
threaded insert
Assemble
blower
resistor
Preassemble the bracket 3 with the bracket 2
according to the illustration.
1M6x12 bolt [4x], flanged nut [4x]
Pre-
assemble
the bracket
Ejot screw bolt tightening torque 10 Nm!
1Combustion air intake silencer, Ø27mm
hose clamp
2Ejot stay bolts
3Heater unit
4Hose section, Ø 10 mm hose clamps [2x]
5Fuel line
Preassem-
ble the
Heater Unit
21
3
1
2
22
1
2
23
1 1
1
2
3
1
24
1
2
3
5
4

1311472A 15
Mazda 3 MPS
Installing the Heater Unit
Assemble the pre-assembled bracket
according to the illustration.
Resistor retaining plate 1is assembled
together with the bracket 3, spring washer 6,
body washer 6, spacer 5mm 6, original
vehicle threaded insert 6.
2M6x20 bolt, spring washer, rivet nut
4M6x70 bolt, 20 mm spacer, 30 mm spacer,
M6 flanged nut
5M6x70 bolt, 15mm spacer nut, 30 mm
spacer, M6 flanged nut
Assem-
bling the
bracket
Figure 18 is the rear view of figure 17.
1M6x70 bolt, 20 mm spacer, 30 mm spacer,
M6 flanged nut
2M6x70 bolt, 15mm spacer, 30 mm spacer,
M6 flanged nut
3Bracket
Assem-
bling the
bracket
Ejot screw bolt tightening torque 10 Nm!
Before assembling the heater unit 3, plug the
header unit cable harness.
1Ejot screw bolt
2Bracket Assem-
bling the
Heater Unit
Ejot screw bolt tightening torque 10 Nm!
1Ejot screw bolt
2Bracket
Assem-
bling the
strut
25
3
1 2
4
6
5
26
3
1 2
27
1
3
2
28
1
2

1311472A 16
Mazda 3 MPS
Prepare the strut according to the illustration
1Original vehicle bolt [see page 14, figure
21]
2Strut
35mm spacer disc Assem-
bling the
strut
1Original vehicle bolt
2Strut
3Spacer nut M6x30
Assem-
bling the
strut
1
29
2
3
2
1
3
30

Mazda 3 MPS
1311472A 17
Exhaust System
1Exhaust pipe
a = 440mm
2Exhaust end section
b = 50mm
Dispose of section X
Preparing
the
exhaust
pipe
Ensure sufficient distance from adjacent
components.
1Hose bracket
2Exhaust line, hose clamp on the exhaust
silencer [covered]
3Heat insulation
4M6x16 bolt, spring washer
5Exhaust silencer
6Exhaust end section, hose clamp
7Red (rt) rubber profile with groove
Assem-
bling the
silencer
a b
1 2
X
31
3
1 2
7
4
5
6

Mazda 3 MPS
1311472A 18
Fuel Connection
CAUTION!
Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable clips.
Fit the fuel line and cable harness with edge protectors around sharp edges.
WARNING!
The fuel line and cable harness to the metering pump should be installed based on the cable harness
installation diagram.
Install the fuel line 1and the heater unit cable
harness 2on the original vehicle fuel lines
and secure with cable ties.
Placement
of the fuel
line in the
engine
compart-
ment
Install the fuel line 1and the heater unit cable
harness 2on the original vehicle fuel lines
and secure with cable ties.
Run this along the right side of the vehicle,
behind the thermal insulation covers and
along the original vehicle lines. Placing the
fuel pipe
Placement of the fuel pipe 2is done together
with the metering pump cable harness 1to
the vehicle underbody behind the insulation
3.
Placing the
fuel pipe
32
1
7
2
33
1 2
34
123

Mazda 3 MPS
1311472A 19
Placement of the fuel pipe 2is done together
with the metering pump cable harness 1to
the vehicle underbody along the original
vehicle lines, secure with cable ties.
Placing the
fuel pipe
Installation location of the metering pump 1is
to the right next to the vehicle tank.
Run the fuel pipe from the heater unit 2and
metering pump cable harness 3to the
metering pump installation location 1.
Placing the
fuel pipe
Fuel pipe 6from the heater unit on the outake
side of the metering pump 3[side with
connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Fastening strap with holes
2Rubber tube clamp, silentblock, flanged
nut M6 [2x]
4Metering pump cable harness, connector
5Hose section, hose clamps [2x].
7Original vehicle bolt, loosely fitted
Assem-
bling the
metering
pump
Remove the tank mounting according to the
manufacturer's instructions and take it apart.
Attach the M6 flanged nut 2according to the
illustration, transfer the hole image for the Ø
6.0 mm hole.
1Tank mounting Fuel take-
off
35
1 2
36
3 2
1
37
1
7
23
5 46
38
1 2

Mazda 3 MPS
1311472A 20
Shape, cut into sections, and insert the tank
extracting device according to the template,
see the Installation Instructions.
Re-assemble tank mounting!
1Tank extracting device
2Tank mounting Inserting
tank
extracting
device
Install the tank mounting according to
manufacturer's instructions.
1Fuel line 1500 mm
2Hose section, Ø 10 mm hose clamps [2x]
3Tank extracting device Connect-
ing and
discon-
necting the
fuel pipe
Assemble fuel tank according to
manufacturer's instructions.
Fuel line from the tank extracting device on
the intake side of the metering pump 1[side
without connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
2Hose section, Ø 10mm hose clamps [2x]
3Fuel pipe, cut into sections
Connec-
tion to
metering
pump
Assemble the panelling on the rear axle 1.
2Original vehicle bolt (see page 19 figure
37).
Assem-
bling the
panelling
for the rear
axle
39
1
2
40
31
2
41
1 2 3
42
2
1