Webasto Mazda 6 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 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
e1
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
A
ll vehicles 8
A
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
11

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
2
321
3
1
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
4
15
1

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
X1
6-pin heater unit connector GRs Fan relay ws white
F3
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)
KB
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
31
30
15
Mazda
F3
86
85 30
87a87
K3
HG
X1 4BCM
St A 1A
Fb
+
-GM
M
Fa
!
rt/ws
rt/ws sw
sw
rt rt/ws
rt/ws
1²
1²
1²1²
1²
4²
4²
F-02
GRs
GRr
KB
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
6 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
4 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
KB
6
1
7
2 3
4
5
6
RW BL*
*RW *
VW LG
***
LR
**
RY* * * * *
B G G R
1A
1B
1X
1W
B
GY GY
LG
7
1
2
8
1 2
4 3
*
VW
L
R
* * *
1A
1B
1X
1W
W
RW
B
BYG V
LR
LW
W
B
G
WW B V
RGY B
LG
*BR RYB
LG PB
1G
9
2
1

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
KB
10
1 2
43
1A
1B1X
1W
WRWYG
V
YPB
B
LG
BR RR
VLRY B L
V
* *
L
W W *
BR
LG
L
W
BL BGY B YR R
1O
11
2
1

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
1
12
13
1
1
14
3
2

1313440A_EN 11
Mazda 6
Preparing heater unit
b = 910
c = 160
d = 750
Hose A= 180° elbow, 18x18
Discard section X
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and Dand cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
127 mm dia. clamp
Premount-
ing hose C
Preparing bracket
1Bracket
2M6x40 bolt, 5 mm spacer sleeve, 20 mm
spacer sleeve, pin lock
3M6x12 bolt, pin lock Preparing
bracket
BC
X
X
X
D
A
D
B
1
1
1 1
15
1C
16
1
3
2

1313440A_EN 12
Mazda 6
1Copy hole pattern [2x]
2Bracket
3Original vehicle bolt
Copying
hole
pattern
Remove bracket
19.1 mm dia. hole; M6 rivet nut [2x each]
Installing
rivet nut
1M6x20 bolt, spring lockwasher [2x each]
on rivet nut
2Bracket
3Original vehicle bolt
Installing
bracket
Strut 2will be mounted on engine support
later
1Flanged nut
Loosely
mounting
strut
17
2
3
1
1
18
1
1
19
2
3
1 1
20
2
1

1313440A_EN 13
Mazda 6
Cutedgeprotection to lengthaccordinglyand
mount.
130 mm edge protection
225 mm edge protection
3100 mm edge protection Installing
edge
protection
Secure muffler 2with cable tie 1.
3Shape combustion air pipe
Preassem-
bling muf-
fler
Installing heater unit
Mount wiring harness before installing heater
unit.
Insert two washers between heater unit and
bracket 1at Position 2.
1Bracket
2Ejot screw, washer [2x]
3Ejot screw [2x]
Installing
heater unit
124-27 mm dia. clamp
2Combustion air pipe
Installing
combus-
tion air
pipe
21
2
1
3
22
2
1
3
3
2
23
21
33
24
2 1

Mazda 6
1313440A_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.
Unless 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.
190° molded hose, 10 mm dia. clamp [2x]
2Fuel line
Connect-
ing heater
unit
Route fuel line and wiring harness of
metering pump 1along original vehicle lines
and secure with cable ties.
Wiring
routing
Drillout hole in angle bracket 5on short leg to
8.5 mm dia. and install with original vehicle
bolt 6.
1Metering pump
2Rubber-coated p-clamp, silent block,
flanged nut [2x]
3Wiring harness of metering pump,
connector mounted
4Hose section, 10 mm dia. clamp [2x], fuel
line
Installing
metering
pump
25
2
2
1
26
1
27
5
2 3
6
41

Mazda 6
1313440A_EN 15
Pull fuel-tank vent line 1off fuel tank and cut
to length; hose section 1and 2will be reused.
Removing
fuel
Shape fuel standpipe 4according to template
and cut to length.
Mount 3.5 mm dia., 90° molded hose 1on
connection piece of fuel standpipe 4.
216-24 mm dia. clamp
3Hose section of 55 mm ventilation line
58 mm dia. clamp
Premount-
ing fuel
standpipe
Insert fuel standpipe while aligning
standpipe 7relative to bottom of fuel tank.
Secure hose section 6of ventilation line on
fuel tank again with original vehicle clamp.
110 mm dia. corrugated tube
2Fuel line
310 mm dia. clamp
4Fuel-tank vent line
516-24 mm dia. clamp
Installing
fuel
standpipe
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Hose section, 10 mm dia. clamp [2x]
2Fuel line in 10 mm dia. corrugated tube Connect-
ing meter-
ing pump
28
2
1
55
29
1 2 3 4
5
30
5
2 3 4
6
1
7
31
1
2

Mazda 6
1313440A_EN 16
Water
WARNING!
Any coolant running off should be collected using an appropriate container. Install hoses so that they
are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no
other hose can be damaged! When installing the coolant hose, the heater unit must be filled with
coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing
diagram
All connecting pipes without a specific designation = dia. 18x20.
All hose clamps = 20-27 mm dia.!
1= Black (sw) rubber isolator .
A
B
D
Ø 20x20
C
1
1

Mazda 6
1313440A_EN 17
1Angle bracket
2Mount M6x20 bolt, large diameter washer,
flanged nut in existing hole
Installing
angle
bracket
Connect-
ing heater
unit
129 mm dia. rubber-coated p-clamp [2x]
2M6x20 bolt, flanged nut on angle bracket
3Align black (sw) rubber isolator [2x]
Routing in
engine
compart-
ment
Disconnect hose to engine outlet/heat
exchanger inlet 1at connection piece of
engine outlet. Discard original vehicle spring
clip 2.
Cutting
point
32
1
2
33
BD
C
34
1
3
1
3
D
B2
35
2
1

Mazda 6
1313440A_EN 18
1Edge protection 60
Connect-
ing engine
outlet
14x20 mm spacer bracket
2Hose section of heat exchanger inlet
320x22 mm spacer bracket
Connect-
ing heat
exchanger
inlet
Aligning
coolant
hoses
36
A
1
B
37
D
1
3
2
38
A
B
D

Mazda 6
1313440A_EN 19
Exhaust gas
1Exhaust pipe
a = 220
2Exhaust end section
b = 75
Discard section X
Preparing
exhaust
pipe
Slide exhaust-gas insulation 2onto muffler.
1Flanged nut on preassembled bolt
Installing
muffler
1Hose clamp [2x]
2Exhaust pipe
Installing
exhaust
pipe
Hold on wheel well trim 2and cut out along
marking.
1Discard section
Cuttingout
wheel well
trim
a B
1 2
X
39
1
2
1
140
2
41
1
2

Mazda 6
1313440A_EN 20
1Underride protection
2Wheel well trim
3Strut
4Original vehicle bolt
Mounting
underride
protection
1Exhaust end section
2Hose clamp
Installing
exhaust
end
section
42 mm dia. hole at Position 3 in wheel well
trim 2. Align exhaust end section 3flush on
red (rt) rubber isolator 1.
Mounting
rubber
isolator
42
1
4
2
3
43
1 2
2
44
1
3