Table of Contents
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Water Heater Unit
Thermo Top E Auxiliary Heating
Thermo Top C Auxiliary Heating
Installation Instructions
Mazda 3 MPS
Gasoline
From model year 2006
For left-hand drive vehicles only
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.
Ident. No.: 1311472A
e1
00 0003
e1
00 0002
€10 fee
Feel the drive
© Webasto AG
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Related Manuals for Webasto Mazda 3 MPS
Summary of Contents for Webasto Mazda 3 MPS
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Page 1: Installation Instructions
For left-hand drive vehicles only 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. -
Page 2: Table Of Contents
Mazda 3 MPS Table of Contents Validity Preparing the Installation Location Heater Unit / Installation Kit Installing the Heater Unit Foreword Exhaust System General Instructions Fuel Connection Special Tools Combustion Air Explanatory Notes on the Document Water Connection for Gasoline Engines... -
Page 3: Heater Unit / Installation Kit
Heater Unit / Installation Kit Amount Description Order no.: Commercial supply of required control See price list Installation kit for Mazda 3 MPS Gasoline 1,311,467A Recommended heater unit for the relevant vehicle class: Vehicle Heater unit Compact car Thermo Top E... -
Page 4: Explanatory Notes On The Document
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. The arrow in the vehicle icon indicates the position on the vehicle and the angle. -
Page 5: Preliminary Work
Mazda 3 MPS 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. -
Page 6: Preparing The Electronics
Mazda 3 MPS Preparing the Electronics sw 2,5mm² Only for automatic air conditioning 250mm 2250mm Wire section 4 will be needed later for connecting the resistor. Cutting br 2,5mm² wires into sections 1500mm 1000mm sw 0,5mm² 1500mm sw 0,5mm² 250mm... - Page 7 Mazda 3 MPS Put the remaining flexible hose 1 on the positive cable on the heater unit cable harness 2. Connect the positive cable to the positive battery terminal 3. Positive connection 1311472A...
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Page 8: Electrical Connections
Mazda 3 MPS Electrical Connections Cable harness feed-through Time switch and summer / winter switch option 1 Protective rubber sleeve 1 Time switch 2 Summer / winter switch Cable harness installation diagram Wait to install the metering pump cable harness until later,... -
Page 9: Automatic Air Conditioning Blower Control
Mazda 3 MPS Automatic air conditioning blower control Webasto Mazda Circuit diagram J-03 rt/ws 0,5mm² sw/bl gn/ws C-04 ro/or 4mm² 0,5mm² sw/or ro/or 4mm² sw/rt sw/gn bl/sw K3.1 sw/gn Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Blower relay... - Page 10 Mazda 3 MPS Connection to the connector 3 C-04 Connect with enclosed connectors according to the circuit diagram. 1 Wire (sw) from K3/30 2 Pink/orange (ro/or) wire to blower motor. Positive 4 Pink/orange (ro/or) wire to connector C-04. connection 5 Red (rt) wire from F3/87a...
- Page 11 Mazda 3 MPS Pull the connection to connector 5 J-03 from the PJB fuse and relay support. Connect with enclosed butt connector 3 according to the circuit diagram. 1 Yellow (ge) wire Relay K3.1 2 Black (sw) wire from K3.1/86...
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Page 12: Remote Start Option
Mazda 3 MPS Remote Start Option 1 Receiver 2 Bracket, drill hole in bracket to Ø6.5mm. 3 M6x12 bolt, original vehicle threaded insert Assem- bling the receiver 1 Antenna Assem- bling the antenna 1311472A... -
Page 13: Preparing The Installation Location
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. 107mm 114mm Preparing the bracket 30mm 18mm Drill open holes 1[2x] in the strut 2 to Ø10mm. - Page 14 Mazda 3 MPS Remove original vehicle bolt 2, this will be used again. 1 M6 rivet nut 3 Hole Ø 7mm Tighten the rivet nut; remove the screw 1 Blower resistance 2 M6x20 bolt, spring washer, body washer, 8mm spacer washer, original vehicle...
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Page 15: Installing The Heater Unit
Mazda 3 MPS Installing the Heater Unit Assemble the pre-assembled bracket according to the illustration. Resistor retaining plate 1 is assembled together with the bracket 3, spring washer 6, Assem- body washer 6, spacer 5mm 6, original bling the vehicle threaded insert 6. - Page 16 Mazda 3 MPS Prepare the strut according to the illustration 1 Original vehicle bolt [see page 14, figure 2 Strut 3 5mm spacer disc Assem- bling the strut 1 Original vehicle bolt 2 Strut 3 Spacer nut M6x30 Assem- bling the...
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Page 17: Exhaust System
Mazda 3 MPS Exhaust System 1 Exhaust pipe a = 440mm 2 Exhaust end section b = 50mm Preparing Dispose of section X exhaust pipe Ensure sufficient distance from adjacent components. 1 Hose bracket 2 Exhaust line, hose clamp on the exhaust... -
Page 18: Fuel Connection
Mazda 3 MPS 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. - Page 19 Mazda 3 MPS Placement of the fuel pipe 2 is done together with the metering pump cable harness 1 to the vehicle underbody along the original vehicle lines, secure with cable ties. Placing the fuel pipe Installation location of the metering pump 1 is to the right next to the vehicle tank.
- Page 20 Mazda 3 MPS Shape, cut into sections, and insert the tank extracting device according to the template, see the Installation Instructions. Re-assemble tank mounting! 1 Tank extracting device Inserting 2 Tank mounting tank extracting device Install the tank mounting according to manufacturer's instructions.
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Page 21: Combustion Air
Mazda 3 MPS Combustion Air Run the combustion air line 1 according to the figure. Placement of the combus- tion air line Note the spatial requirements for the engine filter housing. Fasten the intake silencer 3 to the cable harness 2with cable ties1. -
Page 22: Water Connection For Gasoline Engines
Mazda 3 MPS Water Connection for Gasoline Engines WARNING! Tighten all hose clamps to 2.0 + 0.5 Nm. Any coolant running off should be collected using an appropriate container! Route hoses so that they are kink-free. Unless specified otherwise, always fasten using cable clips. - Page 23 Mazda 3 MPS b = 450mm c = 660mm Dispose of section X Cut the braided protective hose into sections and slide it onto hose B and hose C. Cutting water hoses into sections Cut the braided protective hose in the middle and slide it onto hose B and hose C.
- Page 24 Mazda 3 MPS 1 Original vehicle engine exhaust hose 2 Cut location Splitting point 1 Engine exhaust hose section Connec- tion of moulded hose A: 1 Heater unit Connect- ing hose B on the heater unit Align the rubber profile 1 .
- Page 25 Mazda 3 MPS 1 Heater unit 2 Cable clips Connect- ing hose C on the heater unit Before connecting, fill the water hoses with coolant. Insert the hose bracket 1 as shown in the figure. 2 Heat exchanger inlet hose section...
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Page 26: Final Work
Mazda 3 MPS Final Work WARNING! Reassemble disassembled components in reverse order. Check that all hose lines, clips, and all electrical connections are securely fastened. Secure all loose cables using cable clips. Only use manufacturer-approved coolant. Spray heating unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329). -
Page 27: Operating Instructions For The End Customer
Mazda 3 MPS Operating instructions for the end customer Please remove page and add to the vehicle operating instructions. Before parking the vehicle, make the following settings: 1 Blower rpm is pre-set in auxiliary heating operation 2 Air outlet to windscreen 3 Temperature to "max."... -
Page 28: Tank Extracting Device Template
Mazda 3 MPS Tank Extracting Device Template 100mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize 100mm 1311472A...
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