ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Feel the drive Thermo Top E Parking Heater Thermo Top C Parking Heater Thermo Top P Parking Heater e e e Installation documentation Mazda 6 Gasoline from Model Year 008 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 heater 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 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.: 33390_EN Fee Euro 0.00 Webasto AG

2 Table of contents Validity Heater/Installation Kit 3 Foreword 3 General instructions 3 Special tools 3 Explanatory notes on document 4 Preliminary work 5 Heater installation location 5 Electrical system 6 Fan controller 7 All vehicles 8 Automatic air-conditioning 8 Manual air conditioner 9 Remote option (Telestart) 0 Preparing installation location Preassembling bracket Premounting heater 3 heater 4 Fuel 5 Combustion air 7 Exhaust gas 8 Coolant circuit 0 All except.0 4KW.0 4 KW only Final Work 4 Template for Fuel Standpipe 5 Operating Instructions for End Customer 6 Validity Manufacturer Model Type EG-E No./AE Mazda 6 GH e * 00/6 * 0448 *... Engine type Engine model Output in kw Displacement in cm³ L8 Gasoline L5 Gasoline LF Gasoline LF Gasoline 488 L5 Gasoline Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of the digital timer should be confirmed with the end customer before installation _EN

3 Heater/Installation Kit Quantity Description Order No.: Retail accessories Thermo Top E / C / P See Mazda price list Installation kit for Mazda 6 Gasoline 33389A Mazda Order No.: Heater control See Mazda price list Heater recommended for the respective vehicle class: Vehicle Compact car Mid-size car, station wagon Full-size car, van, offroader Heater Thermo Top E Thermo Top C Thermo Top P The selection of the heater is based on the passenger compartment size of the vehicle and the level of comfort required by the customer! Foreword This installation document applies to the Mazda 6 Gasoline vehicles - for validity, see page - from model year 008 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 this installation documentation. However, the stipulations in this "installation documentation" and the "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 must be provided with rub protection (cut-open fuel hose)! Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 39). Special tools - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit 33390_EN 3

4 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 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 vehicle-specific 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 = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 33390_EN 4

5 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. - 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 CM in the driver's side footwell. - Remove the instrument panel trim below the steering wheel (only with Telestart T00 HTM). - Remove the A/C control panel according to the manufacturer's instructions (only with automatic air-conditioning). Heater installation location Heater Remove page 6 "Operating Instructions for End Customer" and attach to vehicle operating instructions. Installation location 33390_EN 5

6 Electrical system Fuse holder, K3 relay Replace 5 A fuse F3 with 0 A fuse. Digital timer Digital timer M5x6 bolt, washer, fuse holder, K3 relay, flanged nut on angle bracket Angle bracket 3 Original vehicle bolt 3 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 4 5 wiring harness of heater in corrugated tube Slit 7 mm dia. corrugated tube, pull in wiring harness of heater and route to installation location of heater. Wiring harness pass through Protective rubber plug 33390_EN 6

7 Fan controller Webasto F3 HG Fa Mazda Fb 30 5 Wiring diagram X 4 F-0 CM St A A rt 4² rt/ws ² rt/ws ² rt/ws ² sw ² GRs a sw 4² K3! + M - GM rt/ws ² St * G/O** K GRr 3 Webasto components Vehicle components Colours and symbols HG Heater TT-C/E/P GM Fan motor rt red X 6-pin heater connector GRs Fan relay ws white F3 Replace 5 A with 0 A GRr Fan controller sw black fuse. Fb 40 A heater fuse K3 Fan relay CM ody Control Module STA 4-pin connector of CM, black (0940-0A) FA "AC" 0A fuse F 0 Fuse box K A/C control panel ST * 4-pin connector of K with automatic A/C: (0740-0A) Pin G ** ST * 4-pin connector of K with manual A/C: (0740-0A) Pin O ** Insulate wire ends and tie back X Cutting point Wiring colours may vary. Legends 33390_EN 7

8 3 All vehicles Connection on 4-pin connector A from CM. Produce connections as shown in wiring diagram. Connector is located on rear side of CM. 3 Red/white (rt/ws) wire of connector 4 Red (rt) wire from K3/87a 5 lack (sw) wire from K3/30 6 Route black (sw) wire ² to A/C control panel 7 Red/white (rt/ws) wire of fan relay Connection of fan relay on CM pin connector A from CM (on wire side) Socket A, red/white (rt/ws) wire W A * LG GY GY * R L G G * * * R Y * R * * * * L V R G W L * W * * R W X Cable colours: R - red W - white - black L - blue V - violet G - green GY - gray LG - light green Y - yellow CM connector 7 Automatic air-conditioning Connection on connector 3 of A/C control panel, Pin G. Produce connections as shown in wiring diagram. lack (sw) wire ² Insulate red/white (rt/ws) wire of 0 A airconditioner fuse and tie back 4 Red/white (rt/ws) wire of connector, Pin G Connecting A/C control panel pin connector A of A/C control panel (on wire side) Socket G, red/white (rt/ws) wire G W LG GY R V W W L V R L R G W W W L V * R LG Y P R W * * * X R G * Y A W Cable colours: R - red W - white - black L - blue V - violet G - green GY - gray LG - light green Y - yellow R - brown P - pink Connector K _EN 8

9 Manual air conditioner Connection on connector 3 of A/C control panel, Pin O. Produce connections as shown in wiring diagram. lack (sw) wire ² Insulate red/white (rt/ws) wire of 0 A airconditioner fuse and tie back 4 Red/white (rt/ws) wire of connector, Pin O Connecting A/C control panel pin connector A of A/C control panel (on wire side) W W Y X L V Y W W R L O R L V R W Y R L GY R * Y A R LG P V R G LG L W R * * Socket O, red/white (rt/ws) wire Cable colours: R - red W - white - black L - blue V - violet G - green GY - gray LG - light green Y - yellow R - brown P - pink Connector K 33390_EN 9

10 Remote option (Telestart) Receiver, original vehicle stud bolt, original vehicle flanged nut receiver Antenna antenna 3 Temperature sensor for T00 HTM only 3 Temperature sensor Cable tie 3 Original vehicle wiring harness temperature sensor _EN 0

11 Preparing installation location Align hydraulic line for clutch actuation approx. 5-7 mm toward transmission and insert 4x7 line holder. Inserting line holder 5 Preassembling bracket end perforated brackets Preparing perforated brackets 6 end perforated bracket by 90. Preparing perforated bracket 5 7 The screw fitting of the perforated brackets [x] and 3 on bracket must be tightened manually. 3 Perforated bracket [x], M6x6 bolt [x], flanged nut [x] 3 Perforated bracket, M6x6 bolt, flanged nut Preassembling bracket _EN

12 9. mm dia. hole; M6 rivet nut 3 97 rivet nut 9 Align bracket and perforated brackets 3 to surfaces. M6x60 bolt, spring lockwasher, 40 mm shim 3 Hole pattern for 9. mm dia. hole [x] Copying hole pattern Align perforated bracket relative to surface, copy hole pattern for 9. mm dia. hole Remove bracket. Copying hole pattern M6 rivet nut [3x] rivet nut 33390_EN

13 Tighten screw fittings of the perforated brackets [x] on bracket. 3 M6x0 bolt [x], spring lockwasher [x] 3 40 mm spacer, M6x60 bolt, spring lockwasher bracket 3 M6x0 bolt, spring lockwasher bracket 4 Premounting heater end perforated bracket by 90. Preparing perforated bracket 45 5 Combustion air pipe a = 50 Discard section X a Cutting combustion air pipe to length X 33390_EN 3

14 Hose section, 0 mm dia. clamp [x] Fuel line Premounting heater Ejot screw Perforated bracket 3 Retaining clip, pin lock 4 Muffler 5 Combustion air pipe, 7mm dia. clamp Premounting heater 3 7 heater Ejot screw racket heater 8 racket Ejot screw [x] heater _EN 4

15 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 0 mm dia.,,00 mm long corrugated tube on fuel line and route to underbody. lines 30 Route fuel line and wiring harness of metering pump along original vehicle lines and secure with cable ties. Wiring routing Drill out hole in angle bracket 5 on short leg to 8.5 mm dia. and install with original vehicle bolt 6. 5 Metering pump Rubber-coated p-clamp, silent block, flanged nut [x] 3 Wiring harness of metering pump, connector mounted 4 Hose section, 0 mm dia. clamp [x], fuel line metering pump _EN 5

16 Disconnect fuel tank venting wire from fuel tank and cut to size. Original vehicle spring clip as well as hose sections and will be reused. 55 Removing fuel 33 3 Shape fuel standpipe 3 according to template and cut to length. 6-4 mm dia. clamp Hose section of 55 mm ventilation line 4 90 moulded hose, 0 mm dia. clamp Premounting fuel standpipe 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 mm dia. corrugated tube Fuel line 3 0 mm dia. clamp 4 Fuel-tank vent line mm dia. clamp fuel standpipe Hose section, 0 mm dia. clamp [x] Metering pump 3 Fuel line 4 0 mm dia. corrugated tube Check the position of the components; adjust if necessary. Check that they have free clearance. Connecting metering pump _EN 6

17 Combustion air Insert muffler in retaining clip. Inserting muffler _EN 7

18 Exhaust gas Exhaust pipe a = 90 Exhaust end section b = 380 Discard section X Preparing exhaust pipe a b X end perforated bracket by 90. Preparing perforated bracket Fasten angled down perforated bracket at position in the middle through the existing hole. M6x0 bolt, flanged nut Preparing installation of exhaust system 39 Fasten angled down perforated bracket at position in the middle through the existing hole. M6x0 bolt, flanged nut Preparing installation of exhaust system _EN 8

19 Turn original vehicle spring clips [x] upward. Preparing installation of exhaust system 4 Ensure sufficient distance to neighbouring components. Hose clamp [x] Exhaust muffler, M6x0 bolt, flanged nut 3 Perforated bracket 4 Exhaust pipe exhaust muffler Ensure sufficient distance to neighbouring components. Hose clamp Exhaust end section 3 Red (rt) rubber profile [3x] exhaust end section 43 Ensure sufficient distance to neighbouring components. Aligning red (rt) rubber isolator. 3 Pipe clamp, M6x0 bolt, flanged nut 3 Perforated bracket, angled down exhaust end section _EN 9

20 Coolant circuit WARNING! Any coolant running off should be collected using an appropriate container! Route hoses kink-free! Unless 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" based on the following diagram: Hose routing diagram A All connecting pipes = 7x0 dia. All hose clamps without a specific designation = 0-7 mm dia _EN 0

21 All except.0 4KW A X Discard section X. Shorten hose A. A = 50 = 90 Cutting coolant hoses to length 5 X X Hose section on engine inlet Hose section on heat exchanger outlet Cutting point 45 A Hose on heat exchanger outlet Connecting heat exchanger outlet 46 Connection of heater _EN

22 Hose section on engine inlet, turned toward heater Connection of engine inlet 48 A Align coolant hose. Ensure sufficient distance to neighbouring components. Spacer bracket spacer bracket KW only A X Discard section X. Shorten hose A. Hose with long 90 elbow A = 60 = 90 Cutting coolant hoses to length 5 X X Hose section on engine inlet Hose section on heat exchanger outlet Cutting point _EN

23 Turn hose on engine inlet by about 90 to the left. Remove insulation of hose on heat exchanger outlet as shown. Cutting point 5 Hose on heat exchanger outlet A Connecting heat exchanger outlet 5 Connection of heater 53 A Aligning hoses Ensure sufficient distance to adjacent components; correct if necessary. Spacer bracket Hose section on engine inlet, turned toward heater Connection of engine inlet _EN 3

24 Final Work WARNING! Mount removed parts 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 heater components with anti-corrosion wax (Tectyl 00K, Order No. 39). - Connect the battery. - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Adjust digital timer, learn telestart remote option - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the parking heater, see the operating instructions/installation instructions. - Place the instruction label "Switch off parking heater before re-fuelling" in the area of the filling necks 4 mm dia. hole Underride protection Preparing underride protection Align exhaust end section flush on red rubber isolator. Mounting rubber isolator 56 Feel the drive Webasto AG Postfach 80 D-83 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de _EN Printed in Germany 0/0 Printing: Steffen 4

25 Template for Fuel Standpipe 57mm 00mm 5mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm _EN 5

26 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. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. In vehicles with passenger compartment monitoring it is to be deactivated additionally, over and above the vehicle settings for the heating operation. For information on deactivation, please see the vehicle owner's manual. efore parking the vehicle, make the following settings: 3 Air outlet to windshield Set fan to level "", or possibly "" 3 Set temperature to "max." Manual air conditioning 57 3 Air outlet to windshield Set temperature on both sides to "9 " 3 Set fan to level "", or possibly "" Automatic air-conditioning _EN 6