Webasto Thermo Top E Installation Documentation
Parking heater for mazda 3 1.6 petrol from model year 2009
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Also See for Thermo Top E:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
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Water Heater
Thermo Top E Parking Heater
Thermo Top C Parking Heater
Installation documentation
Mazda 3
1.6 Petrol
from Model Year 2009
Left-hand drive vehicle
Manual transmission
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.
Ident. No.: 1314978D_EN
e1
00 0003
e1
00 0002
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top E
Summary of Contents for Webasto Thermo Top E
- Page 1 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...
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Page 2: Table Of Contents
Mazda 3 Table of Contents Validity Preparing installation location Heater/installation kit Installing heater Foreword Fuel General instructions Coolant circuit Special tools Combustion air Explanatory notes on document Exhaust gas Preliminary work Final Work Heater installation location Operating Instructions for End Customer Preparing electrical system Electrical system Fan control for manual air conditioning... -
Page 3: Heater/Installation Kit
Mazda 3 Heater/installation kit Quantity Description Order No.: Retail accessories Thermo Top E / C See Mazda price list Installation kit for Mazda 3 2009 1.6 Petrol 1314977A Mazda Order No.: 4100-78-771 Heater control See price list Heater recommended for the respective vehicle class:... -
Page 4: Explanatory Notes On Document
Mazda 3 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. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air... -
Page 5: Preliminary Work
Mazda 3 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. - Depressurise 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. -
Page 6: Preparing Electrical System
Mazda 3 Preparing electrical system Only with automatic air-conditioning Install wire section 2 in protective sleeving provided. Cutting wires to length 0,75² Produce connections as shown in wiring dia- gram. Install wire section 2 in protective sleeving provided. Preparing fuse F4 1314978D_EN... -
Page 7: Electrical System
Mazda 3 Electrical system Fuse holder, K3 relay Digital timer and summer/winter switch op- tion 1 5.5 mm dia. hole; retaining plate fuse holder, M5x16 bolt, washer, flanged nut 1 Digital timer 2 Fuses 2 Summer/winter switch, drilled hole 12 mm dia. 3 K3 relay 4 Existing hole, M5x16 bolt, washer, flanged nut 5 Positive wire on positive terminal of battery... -
Page 8: Fan Control For Manual Air Conditioning
Mazda 3 Fan control for manual air conditioning Webasto Mazda Wiring dia- gram F-02 C-51 C-03 4² 4² Webasto components Vehicle components Colours and symbols Heater TT-C/E Fan motor 6-pin heater connector Fan relay black 25A fuse Fan switch pink... -
Page 9: Automatic Air-Conditioning Fan Control
Mazda Wiring dia- gram F-02 C-51 C-03 4² 0740-201B 4² 0740-201A 0,75² 0740-203 0,75² Webasto components Vehicle components Colours and symbols Heater TT-C/E Fan motor 6-pin heater connector GRs Fan relay black 25A fuse Fan controller pink Fan relay 0740-203... - Page 10 Mazda 3 Connection on connector C-03 5 A-pillar. Produce connections as shown in wiring dia- gram. 1 Light blue (hbl) wire of fan motor 2 Black (sw) wire of K3/30 Connect- 3 Red (rt) wire of K3/87a ing fan-mo- 4 Light blue (hbl) wire of connector C-03 Connection on 16-pin connector 0740-201B 4 from A/C control panel.
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Page 11: Remote Option (Telestart)
Mazda 3 Remote option (Telestart) Fasten receiver 1 with adhesive tape. Installing receiver 1 Antenna Installing antenna Temperature sensor T100 HTM Fasten temperature sensor 1 with adhesive tape. Installing tempera- ture sensor 1314978D_EN... -
Page 12: Preparing Installation Location
Mazda 3 Preparing installation location 1 Drill out 9.1 mm dia. hole 2 9.1 mm dia. hole Preparing installa- tion loca- tion Original vehicle bolt removed at position 2 . 1 Rivet nut [2x] Installing rivet nut Cut perforated bracket A to size. Angle down perforated bracket B by approx. -
Page 13: Installing Heater
Mazda 3 1 Loosely 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. -
Page 14: Fuel
Mazda 3 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. - Page 15 Mazda 3 Shape fuel standpipe 1 as shown. Preparing fuel stand- pipe 1 Fuel-tank vent line 2 24 mm dia. clamp [2x] 3 Fuel standpipe 4 Hose section, 10 mm dia. clamp [2x] 5 Fuel line Installing fuel stand- pipe Insert fuel standpipe 1 through ventilation connecting piece.
- Page 16 Mazda 3 Fix fuel line 1 in 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 1 Original vehicle bolt 2 Bracket of metering pump 3 Silent block, flanged nut [2x] 4 Loosely install rubber-coated p-clamp...
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Page 17: Coolant Circuit
Mazda 3 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"... - Page 18 Mazda 3 Discard section X . A = 1000 B = 135 C = 920 Cutting hoses to length Connect hose B and C . Slide on red (rt) rub- ber isolator 1 [2x] and black (sw) rubber isola- tor 2 [2x]. Premount- ing hoses 1 Perforated bracket...
- Page 19 Mazda 3 Align black (sw) rubber isolator 2 to connector Connec- tion of heater Routing in engine compart- ment Cut off original vehicle hose on engine out- let/heat exchanger inlet 1 at marking. Cutting point Hose section on engine outlet 3 on connec- tion piece turned by approx.
- Page 20 Mazda 3 Route hose A through rubber-coated p-clamp 1 Engine outlet hose section Connect- ing engine outlet Route hose C through rubber-coated p- clamp. Align black (sw) rubber isolator 2 to brake line. Ensure sufficient distance to neighbouring components. 1 Hose on heat exchanger inlet Connect- ing heat exchanger...
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Page 21: Combustion Air
Mazda 3 Combustion air Discard section X . 1 Combustion air pipe a = 180 Cutting combus- tion air pipe to length 1 Combustion air pipe 2 27 mm dia. clamp Installing combus- tion air pipe 1 Original vehicle stud bolt, flanged nut 2 Silencer 3 52 mm dia. -
Page 22: Exhaust Gas
Mazda 3 Exhaust gas Discard section X . 1 Exhaust pipe a = 380 Preparing 2 Exhaust end section exhaust b = 380 pipe Turn perforated bracket 1 by 90° in longitudi- nal axis Preparing perforated bracket 1 Perforated bracket 2 M6x20 bolt, flanged nut 3 Silencer Premount-... - Page 23 Mazda 3 1 Hose clamp [2x] 2 Exhaust pipe Installing exhaust pipe When drilling, watch components located be- hind! 1 6.5 mm dia. hole Drilling hole in cross member Angle down perforated bracket 1 by 90° Preparing perforated bracket 1 Perforated bracket 2 M6x20 bolt, large diameter washer, flang- ed nut Installing...
- Page 24 Mazda 3 1 M6x20 bolt, M6 flanged nut 2 25 mm dia. p-clamp 3 Exhaust end section Fastening exhaust end sec- tion Detach horn 1 and twist. Ensure sufficient dis- tance to adjacent components, especially to the silencer! Twisting horn Cut out underride protection 1 on marking.
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Page 25: Final Work
- Place the sticker "Switch off parking heater before re-fuelling" in the area of the filler neck - For initial startup and function test, see installation instructions Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78... -
Page 26: Operating Instructions For End Customer
Mazda 3 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.