Water Heater Unit Installation Instructions Mazda 6

Water Heater Unit
Feel the drive
e1
Thermo Top E Additional Heater 00 0003
e1
Thermo Top C Additional Heater 00 0002
e1
Thermo Top P Additional Heater 00 0104
Installation Instructions
Mazda 6
Gasoline
from Model Year 2008
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, 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.:1313390A_EN
Fee Euro 10.00
© Webasto AG
Mazda 6
Table of Contents
Validity
Heater Unit/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater unit installation location
Electrical system
Fan controller
All vehicles
Automatic air-conditioning
Manual air conditioner
Remote option (Telestart)
2
3
3
3
3
4
5
5
6
7
8
8
9
10
Preparing installation location
Preassembling bracket
Premounting heater unit
Installing heater unit
Fuel
Combustion air
Exhaust gas
Coolant
Final Work
Template for Fuel Standpipe
Operating Instructions for End Customer
11
11
13
14
15
17
18
20
23
24
25
Validity
Manufacturer
Mazda
Model
6
Type
GH
EG-BE No./ABE
e1 * 2001/116 * 0448 * ...
Engine type
L8D
L5X
LFX
Engine model
Gasoline
Gasoline
Gasoline
Output in kW
88
108
122
Displacement in cm³
1798
1999
2488
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructions have not been tested. However, installation according to these installation instructions may
be possible.
The installation location of the digital timer should be confirmed with the end customer before
installation.
1313390A_EN
2
Mazda 6
Heater Unit/Installation Kit
Quantity
1
1
Description
Retail accessories with desired heater control
Installation kit for Mazda 6 Gasoline
Order No.:
See price list
1313389A
Heater unit recommended for the respective vehicle class:
Vehicle
Compact car
Mid-size car, station wagon
Full-size car, van, offroader
Heater unit
Thermo Top E
Thermo Top C
Thermo Top P
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, the stipulations in the "installation instructions" and "operating and maintenance instructions"
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
1313390A_EN
3
Mazda 6
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
Water
Fuel
Exhaust gas
Combustion air
Special features are highlighted using the following symbols:
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 vehiclespecific documents.
Reference to a special technical feature.
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
1313390A_EN
4
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.
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 left-hand vehicle underbody trim.
Remove the lower engine cover.
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 25 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
Heater unit installation location
1
1 Heater unit
Installation
location
1
1313390A_EN
5
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
1
2
3
1
2
3
Do not install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the
underbody
Wiring
harness
installation
diagram
1
1
4
5
Installing wiring harness of heater unit in
corrugated tube
Wiring harness pass through
Slit 17 mm dia. corrugated tube, pull in wiring
harness of heater unit and route to installation
location of heater unit.
1 Protective rubber plug
1313390A_EN
6
Mazda 6
Fan controller
Webasto
Mazda
30
15
F3
HG
X1
Wiring
diagram
Fa
4
Fb
BCM
F-02
1A
St A
rt
rt/ws
4²
1²
rt/ws
1²
rt/ws
1²
86
87
85
30
GRs
sw
1²
87a
K3
sw
+
M
!
GM
-
4²
rt/ws
1²
GRr
St B*
1G/1O**
KB
31
Webasto components
HG
Heater unit TT-C/E
X1
6-pin heater unit connector
F3
Replace 25 A with 10 A
fuse.
K3
Fan relay
Vehicle components
Colors and symbols
GM
Fan motor
rt
red
GRs
Fan relay
ws
white
GRr
Fan controller
sw
black
Fb
40 A heater fuse
BCM Body Control Module
24-pin connector of BCM,
STA
black (0940-01A)
KB
Air-conditioning control panel
STB * 24-pin connector of KB with
automatic air-conditioning:
(0740-201A) Pin 1G **
Legend
STB * 24-pin connector of KB with
manual air-conditioning:
X
Cutting point
(0740-101A) Pin 1O **
Wiring colors may vary.
1313390A_EN
7
Mazda 6
1
2
All vehicles
3
Connection on 24-pin connector 0940-01A,
color black 1 from BCM 2.
Produce connections as shown in wiring
diagram.
4
Connector is located on rear side of BCM.
5
3
4
5
6
6
6
7
Red/white (rt/ws) wire of connector
Red (rt) wire from K3/87a
Black (sw) wire from K3/30
Route black (sw) wire 1² to A/C control
panel
7 Red/white (rt/ws) wire of fan relay
Connection of fan
relay on
BCM
24-pin connector 0940-01A, color black 1
from BCM (on wire side)
1
2 Socket 1A, red/white (rt/ws) wire
1A
1W
*
*
LG
R
B
R
GY
GY
*
Y
*
L
G
*
*
G
B
R
L
*
*
V
B
G
W
*
*
*
L
*
R
*
W
R
W
1X
1B
G - green
GY - gray
LG - light green
Y - yellow
Automatic air-conditioning
2
Connection on connector B 3 of A/C control
panel, Pin 1G.
Produce connections as shown in wiring
diagram.
1 Black (sw) wire 1²
2 Insulate red/white (rt/ws) wire of 10 A airconditioner fuse and tie back
4 Red/white (rt/ws) wire of connector B,
Pin 1G
4
BCM
connector
7
2
1
Cable colors:
R - red
W - white
B - black
L - blue
V - violet
Connecting A/C
control
panel
8
3
24-pin connector 0740-201A, white 1 of A/C
control panel (on wire side)
1
2 Socket 1G, red/white (rt/ws) wire
1G
1A
1W
GY
LG
R
*
V
W
B
*
R
*
W
B
B
BR
R
G
Y
LG
V
L
W
L
P
B
R
L
W
B
W
W
*
1X
B
G
Y
B
1B
2
1313390A_EN
V
W
*
R
Cable colors:
R - red
W - white
B - black
L - blue
V - violet
G - green
GY- gray
LG - light green
Y - yellow
BR - brown
P - pink
Connector
KB
9
8
Mazda 6
1
Manual air conditioner
2
Connection on connector B 3 of A/C control
panel, Pin 1O.
Produce connections as shown in wiring
diagram.
1 Black (sw) wire 1²
2 Insulate red/white (rt/ws) wire of 10 A airconditioner fuse and tie back
4 Red/white (rt/ws) wire of connector B,
Pin 1O
4
Connecting A/C
control
panel
10
3
24-pin connector 0740-101A, white 1 of A/C
control panel (on wire side)
1
2 Socket 1O, red/white (rt/ws) wire
1O
1A
1W
W
B
B
Y
L
V
Y
W
R
R
R
W
L
L
L
R
B
1X
Y
*
R
GY
B
Y
*
BR
LG
R
*
P
V
B
B
B
W
L
G
LG
R
1B
2
1313390A_EN
V
W
Cable colors:
R - red
W - white
B - black
L - blue
V - violet
G - green
GY- gray
LG - light green
Y - yellow
BR - brown
P - pink
Connector
KB
11
9
Mazda 6
Remote option (Telestart)
1
1 Receiver, original vehicle stud bolt, original
vehicle flanged nut
Installing
receiver
12
1 Antenna
Installing
antenna
13
1
1
Temperature sensor for HTM100 only
2
1 Temperature sensor
2 Cable tie
3 Original vehicle wiring harness
3
Installing
temperature sensor
14
1313390A_EN
10
Mazda 6
1
Preparing installation location
2
Align hydraulic line 1 for clutch actuation
approx. 5-7 mm toward transmission and
insert 4x7 line holder 2.
Inserting
line holder
15
Preassembling bracket
1
Bend 2 perforated brackets 1.
90°
90°
40
30
Preparing
perforated
brackets
16
Bend perforated bracket 1 by 90°.
1
Preparing
perforated
bracket
25
17
1
The screw fitting of perforated brackets 2 [2x]
and 3 on bracket 1 must be tightened handtight.
2
2 Perforated bracket [2x], M6x16 bolt [2x],
flanged nut [2x]
3 Perforated bracket, M6x16 bolt, flanged
nut
3
2
1313390A_EN
Preassembling
bracket
18
11
Mazda 6
1 9.1 mm dia. hole; M6 rivet nut
1
Installing
rivet nut
97
31
19
1
Align bracket 2 and perforated brackets 3
relative to surfaces.
2
1 M6x60 bolt, spring lockwasher, 40 mm
shim
3 Hole pattern for 9.1 mm dia. hole [2x]
Copying
hole
pattern
3
3
20
Align perforated bracket 2 relative to surface,
copy hole pattern 1 for 9.1 mm dia. hole.
Remove bracket.
2
1
Copying
hole
pattern
21
1 M6 rivet nut [3x]
1
Installing
rivet nut
1
1
1313390A_EN
22
12
Mazda 6
Tighten screw fittings of perforated brackets
[2x] on bracket 1.
1
2 M6x20 bolt [2x], spring lockwasher [2x]
3 40 mm spacer, M6x60 bolt, spring
lockwasher
3
Installing
bracket
2
23
2
1 M6x20 bolt, spring lockwasher
1
Installing
bracket
24
Premounting heater unit
1
Bend perforated bracket 1 by 90°.
Preparing
perforated
bracket
45
25
1 Combustion air pipe
a = 250
1
Discard section X
Cutting
combustion air
pipe to
length
a
X
1313390A_EN
13
Mazda 6
1 Hose section, 10 mm dia. clamp [2x]
2 Fuel line
2
1
Premounting heater
unit
26
1
2
3
4
5
1
5
4
Ejot screw
Perforated bracket
Retaining clip, pin lock
Combustion-air intake muffler
Combustion-air intake pipe, 27 mm dia.
clamp
2
3
Premounting heater
unit
27
Installing heater unit
1
1 Ejot screw
2 Bracket
Installing
heater unit
2
28
1 Bracket
2 Ejot screw [2x]
1
Installing
heater unit
2
2
1313390A_EN
29
14
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.
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.
Mount 10 mm dia., 1,100 mm long corrugated
tube 1 on fuel line and route to underbody.
Installing
lines
1
1
30
Route fuel line and wiring harness of
metering pump 1 along original vehicle lines
and secure with cable ties.
Wiring
routing
1
31
1
2
3
Drill out hole in angle bracket 5 on short leg to
8.5 mm dia. and install with original vehicle
bolt 6.
4
5
6
1313390A_EN
1 Metering pump
2 Rubber-coated p-clamp, silent block,
flanged nut [2x]
3 Wiring harness of metering pump,
connector mounted
4 Hose section, 10 mm dia. clamp [2x], fuel
line
Installing
metering
pump
32
15
Mazda 6
Pull fuel-tank vent line 1 off fuel tank and cut
to length; hose section 1 and 2 will be reused.
1
Removing
fuel
55
2
33
1
2
3
Shape fuel standpipe 4 according to template
and cut to length.
Mount with 3.5 mm dia. molded hose 1 on
connection piece of fuel standpipe 4.
4
2 16-24 mm dia. clamp
3 Hose section of 55 mm ventilation line
5 8 mm dia. clamp
Premounting fuel
standpipe
34
5
1
2
3
Insert fuel standpipe while aligning
standpipe 7 relative to bottom of fuel tank.
Secure hose section 6 of ventilation line on
fuel tank again with original vehicle clamp.
4
5
6
7
1
1
2
3
4
5
10 mm dia. corrugated tube
Fuel line
10 mm dia. clamp
Fuel-tank vent line
16-24 mm dia. clamp
Installing
fuel
standpipe
35
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
2
4
1
2
3
4
3
Hose section, 10 mm dia. clamp [2x]
Metering pump
Fuel line
10 mm dia. corrugated tube
Connecting metering pump
36
1313390A_EN
16
Mazda 6
Combustion air
1
Insert muffler 1 in retaining clip 2.
Inserting
muffler
2
37
1313390A_EN
17
Mazda 6
1
Exhaust gas
2
1 Exhaust pipe
a = 190
2 Exhaust end section
b = 380
Discard section X
a
Preparing
exhaust
pipe
B
X
Bend perforated bracket 1 by 90°.
Preparing
perforated
bracket
38
38
1
Drill 7 mm dia. hole in center through existing
hole at Position 2.
1
1 Perforated bracket, angled down
2 M6x20 bolt, flanged nut
Preparing
installation
of exhaust
system
39
2
Drill 7 mm dia. hole in center through existing
hole at Position 2.
1
1 Perforated bracket
2 M6x20 bolt, flanged nut
Preparing
installation
of exhaust
system
2
1313390A_EN
40
18
Mazda 6
1
Turn original vehicle spring clips 1 [2x]
upward.
1
Preparing
installation
of exhaust
system
41
1
1
Ensure sufficient distance to neighboring
components.
2
1
2
3
4
4
1
2
3
Installing
exhaust
muffler
42
3
3
Hose clamp [2x]
Exhaust muffler, M6x20 bolt, flanged nut
Perforated bracket
Exhaust pipe
Ensure sufficient distance to neighboring
components.
3
1 Hose clamp
2 Exhaust-pipe end section
3 Red (rt) rubber profile [3x]
Installing
exhaustpipe end
section
43
1
Ensure sufficient distance to neighboring
components.
Aligning red (rt) rubber isolator 1.
2
2 Pipe clamp, M6x20 bolt, flanged nut
3 Perforated bracket, angled down
3
Installing
exhaustpipe end
section
44
1313390A_EN
19
Mazda 6
Coolant
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
A
B
All connecting pipes
= 17x20 dia..
All hose clamps without a specific designation
1313390A_EN
= 20-27 mm dia.
20
Mazda 6
a = 150
b = 190
Discard section X
A
B
X
Cutting
coolant
hoses to
length
X
X
15
1
1 Hose section on engine inlet
2 Hose section on heat exchange outlet
2
Cutting
point
45
A
1 Hose section on heat exchange outlet
1
Connection of heat
exchange
outlet and
heater unit
46
B
Connecting heater
unit
47
1313390A_EN
21
Mazda 6
1 Hose section on engine inlet, turned
toward heater unit
1
Connection of engine inlet
B
48
Align coolant hose. Ensure sufficient distance
to neighboring components.
A
1 Spacer bracket
Installing
spacer
bracket
B
1
1313390A_EN
49
22
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).
-
Connect the battery
Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.
Set the digital timer.
Make settings on A/C control panel according to the "Operating Instructions for End Customer".
Check the proper operation of the additional heater, see the operating instructions/installation
instructions.
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.
1 42 mm dia. hole
2 Underride protection
1
Preparing
underride
protection
2
100
270
50
Align exhaust end section 1 flush on red
rubber isolator 2.
1
Mounting
rubber
isolator
2
51
Feel the drive
Webasto AG
Postfach 80 - 82132 Stockdorf
Hotline 01805 / 932278 - Hotfax 0395 / 5592-353
http://www.webasto.de
1313390A_EN
Printed in Germany
04/2008
Printing:
Steffen
Mazda 6
Template for Fuel Standpipe
57mm
100 mm
252mm
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.
0 1313390A_EN
100 mm
24
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.
WARNING:
The alarm system must be deactivated for the duration of the heater operation!
Before parking the vehicle, make the following settings:
3
2
1
1 Air outlet to windshield
2 Set fan to level "1", or possibly "2"
3 Set temperature to "max."
Manual air
conditioning
52
2
3
1
2
1 Air outlet to windshield
2 Set temperature on both sides to "29°"
3 Set fan to level "1", or possibly "2"
1
Automatic
air-conditioning
2
1313390A_EN
3
2
53
25