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Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
Mazda 6
Gasoline
from Model Year 2008
Left-hand drive vehicle
Automatic 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, 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.
Ident. No.:1313440A_EN
e1
00 0003
e1
00 0002
e1
00 0104
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Mazda 6
Summary of Contents for Webasto Mazda 6
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Page 1: Installation Instructions
Automatic 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, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. -
Page 2: Table Of Contents
Mazda 6 Table of Contents Validity Preparing heater unit Heater Unit/Installation Kit Preparing bracket Foreword Installing heater unit General Instructions Fuel Special Tools Water Explanatory Notes on Document Exhaust gas Preliminary Work Final Work Heater unit installation location Template for Fuel Standpipe... -
Page 3: Heater Unit/Installation Kit
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. -
Page 4: Explanatory Notes On 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 6 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. -
Page 6: Electrical System
Mazda 6 Electrical system Digital timer Fuse holder, relay K3 1 Digital timer Replace 25 A fuse F3 with 10 A fuse. 1 M5x16 bolt, washer, fuse holder, K3 relay, flanged nut on angle bracket 2 Angle bracket 3 Original vehicle bolt... -
Page 7: Fan Controller
Mazda 6 Fan controller Webasto Mazda Wiring diagram F-02 St A rt/ws 4² 1² rt/ws 1² rt/ws 1² 1² 4² rt/ws 1² St B 1G/1O Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Fan motor 6-pin heater unit connector GRs... -
Page 8: All Vehicles
Mazda 6 All vehicles Connection on 24-pin connector 0940-01A, color black 1 from BCM 2. Produce connections as shown in wiring diagram. Connec- tion of fan Connector is located on rear side of BCM. relay on 3 Red/white (rt/ws) wire of connector... -
Page 9: Manual Air Conditioner
Mazda 6 Manual air conditioner Connection on connector B 3 of A/C control panel, Pin 1O. Produce connections as shown in wiring diagram. Connect- ing A/C 1 Black (sw) wire 1² control 2 Insulate red/white (rt/ws) wire of 10 A air-... -
Page 10: Remote Option (Telestart)
Mazda 6 Remote option (Telestart) 1 Receiver, original vehicle stud bolt, original vehicle flanged nut Installing receiver 1 Antenna Installing antenna Temperature sensor HTM100 1 Temperature sensor 2 Cable tie 3 Original vehicle wiring harness Installing tempera- ture sensor 1313440A_EN... -
Page 11: Preparing Heater Unit
Mazda 6 Preparing heater unit b = 910 c = 160 d = 750 Cutting Hose A = 180° elbow, 18x18 coolant Discard section X hoses to length Push braided protection hoses onto hose B and D and cut to length. - Page 12 Mazda 6 1 Copy hole pattern [2x] 2 Bracket 3 Original vehicle bolt Copying hole pattern Remove bracket 1 9.1 mm dia. hole; M6 rivet nut [2x each] Installing rivet nut 1 M6x20 bolt, spring lockwasher [2x each] on rivet nut...
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Page 13: Installing Heater Unit
Mazda 6 Cut edge protection to length accordingly and mount. 1 30 mm edge protection 2 25 mm edge protection 3 100 mm edge protection Installing edge protection Secure muffler 2 with cable tie 1 . 3 Shape combustion air pipe... -
Page 14: Fuel
Mazda 6 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. - Page 15 Mazda 6 Pull fuel-tank vent line 1 off fuel tank and cut to length; hose section 1 and 2 will be reused. Removing fuel Shape fuel standpipe 4 according to template and cut to length. Mount 3.5 mm dia., 90° molded hose 1 on connection piece of fuel standpipe 4 .
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Page 16: Water
Mazda 6 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. - Page 17 Mazda 6 1 Angle bracket 2 Mount M6x20 bolt, large diameter washer, flanged nut in existing hole Installing angle bracket Connect- ing heater unit 1 29 mm dia. rubber-coated p-clamp [2x] 2 M6x20 bolt, flanged nut on angle bracket 3 Align black (sw) rubber isolator [2x]...
- Page 18 Mazda 6 1 Edge protection 60 Connect- ing engine outlet 1 4x20 mm spacer bracket 2 Hose section of heat exchanger inlet 3 20x22 mm spacer bracket Connect- ing heat exchanger inlet Aligning coolant hoses 1313440A_EN...
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Page 19: Exhaust Gas
Mazda 6 Exhaust gas 1 Exhaust pipe a = 220 2 Exhaust end section b = 75 Preparing exhaust Discard section X pipe Slide exhaust-gas insulation 2 onto muffler. 1 Flanged nut on preassembled bolt Installing muffler 1 Hose clamp [2x]... - Page 20 Mazda 6 1 Underride protection 2 Wheel well trim 3 Strut 4 Original vehicle bolt Mounting underride protection 1 Exhaust end section 2 Hose clamp Installing exhaust section 42 mm dia. hole at Position 3 in wheel well trim 2 . Align exhaust end section 3 flush on red (rt) rubber isolator 1 .
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Page 21: Final Work
Mazda 6 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329). -
Page 22: Template For Fuel Standpipe
Mazda 6 Template for Fuel Standpipe 57mm 252mm 100 mm 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 margins” and 100% of the normal size. -
Page 23: Operating Instructions For End Customer
Mazda 6 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.
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