Webasto Mazda 3 MPS Installation Instructions Manual Download Page 1 | Manualshive

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Webasto Mazda 3 MPS Installation Instructions Manual Download Page 1

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.

Water Heater Unit

Installation Instructions

Ident. No.: 1311472A

€10 fee

© Webasto AG

Mazda 3 MPS

Gasoline

From model year 2006

For left-hand drive vehicles only

Feel the drive

Thermo Top E

Auxiliary Heating

e1

00 0003

Thermo Top C

Auxiliary Heating

e1

00 0002

1
2
3
...
»

Summary of Contents for Mazda 3 MPS

Page 1: ...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 i...

Page 2: ...PS BK e1 2001 116 0234 Engine type Engine type Power in kW Engine capacity in cm L3 Gasoline 191 2261 Validity 2 Heater Unit Installation Kit 3 Foreword 3 General Instructions 3 Special Tools 3 Explanatory Notes on the Document 4 Preliminary Work 5 Heater Unit Installation Location 5 Preparing the Electronics 6 Electrical Connections 8 Automatic air conditioning blower control 9 Remote Start Optio...

Page 3: ...hermo Top C P E are to be observed in any event 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 cable harnesses to original vehicle lines and cable harn...

Page 4: ...njury 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 1311472A 4 Explanatory Notes on the Document To provide you with a quick overview of the individual working steps you will find an identific...

Page 5: ...ion cover in the right of the engine compartment Remove the thermal insulation cover in the middle of the engine compartment 2x plastic nuts Hang the hydraulic oil container for servo steering out Remove lower engine cover Remove the panelling for the rear right axle Remove fuel tank according to manufacturer s instructions Remove tank mounting according to manufacturer s instructions Remove the g...

Page 6: ... cover 2 Edge protection profile Inserting edge protection Cut the accompanying flexible hose 1 in the middle and pull on the ground cable for the heater unit cable harness ground cable resistance 0 9 Ohm 2 Connect the ground cable to ground 3 Note the circuit diagram page 9 Ground connection 1 2 sw 2 5mm 2250mm 250mm 3 4 1000mm 1500mm br 2 5mm sw 0 5mm 1500mm sw 0 5mm 250mm 5 6 85 87a 87 30 86 K3...

Page 7: ...azda 3 MPS 1311472A 7 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 4 1 3 2 ...

Page 8: ...6 flanged nut 3 K3 1 relay fastened to the fastening strap together with the K3 relay 4 Fuse holder M5x16 bolt nut Run the cables behind the thermal protection panels 0 9 Ohm resistor 1 Original vehicle stay bolts body washer 2x angle bracket M6flanged nut 2 0 9 Ohm resistor M5 flanged nut washer M5x20 bolt Connect 0 9 Ohm2 resistor according to page 9 in the circuit diagram 5 1 6 1 2 br bl br sw ...

Page 9: ...r controller br brown K3 1 Supplementary relay B air conditioning control gn green R1 0 9 Ohm resistor R Radio unit bl blue F44 Fuse 7 5A or orange ro pink PJB Fuse and relay support Insulate and tie back wire ends X Splitting point Cable colors may vary 31 br 85 87a 87 30 86 K3 1 br sw sw R1 sw 6 4 br 2 3 1 5 sw bl K1 sw gn bl sw sw or sw rt sw gn ws rt sw 30 15 Webasto Mazda br 4 HG X1 F3 rt ws ...

Page 10: ...87a Positive connection to the blower motor 1 Connector C 04 2 Pink orange ro or slot Connector C 04 Connection to 6 pin connector 4 from the blower control 1 Brown br wire from K3 1 87 2 Black green sw gn wire 3 Black sw wire from K3 1 87a 5 Black green sw gn wire Positive connection to the blower motor Connection to 6 pin connector 1 from the blower control 2 Black green sw gn wire Blower contro...

Page 11: ...om the PJB fuse and relay support Connect with enclosed butt connector 3 according to the circuit diagram 1 Yellow ge wire 2 Black sw wire from K3 1 86 4 Yellow ge wire Relay K3 1 control 1 Connector J 03 2 Yellow ge plug in position Connector J 03 13 5 2 3 4 1 14 1 2 ...

Page 12: ... MPS 1311472A 12 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 1 15 3 2 1 16 ...

Page 13: ...x in the strut 2 to Ø10mm Preparing the strut Assemble the bracket 2 according to the image transfer hole images 3 and 4 1 M6x20 bolt 5 mm spacer washer original vehicle threaded insert 3 Hole image for Ø 9 1 mm hole 4 Hole image for Ø 7 mm hole 5 M6x70 bolt 15mm spacer nut 30 mm spacer original vehicle threaded insert Copying the hole image 17 1 18 2 114mm 107mm 18mm 30mm 1 1 19 1 2 1 20 1 2 4 5 ...

Page 14: ...nal vehicle threaded insert Assemble blower resistor Preassemble the bracket 3 with the bracket 2 according to the illustration 1 M6x12 bolt 4x flanged nut 4x Pre assemble the bracket Ejot screw bolt tightening torque 10 Nm 1 Combustion air intake silencer Ø27mm hose clamp 2 Ejot stay bolts 3 Heater unit 4 Hose section Ø 10 mm hose clamps 2x 5 Fuel line Preassem ble the Heater Unit 21 3 1 2 22 1 2...

Page 15: ...M6x70 bolt 15mm spacer nut 30 mm spacer M6 flanged nut Assem bling the bracket Figure 18 is the rear view of figure 17 1 M6x70 bolt 20 mm spacer 30 mm spacer M6 flanged nut 2 M6x70 bolt 15mm spacer 30 mm spacer M6 flanged nut 3 Bracket Assem bling the bracket Ejot screw bolt tightening torque 10 Nm Before assembling the heater unit 3 plug the header unit cable harness 1 Ejot screw bolt 2 Bracket A...

Page 16: ...pare the strut according to the illustration 1 Original vehicle bolt see page 14 figure 21 2 Strut 3 5mm spacer disc Assem bling the strut 1 Original vehicle bolt 2 Strut 3 Spacer nut M6x30 Assem bling the strut 1 29 2 3 2 1 3 30 ...

Page 17: ...he exhaust pipe Ensure sufficient distance from adjacent components 1 Hose bracket 2 Exhaust line hose clamp on the exhaust silencer covered 3 Heat insulation 4 M6x16 bolt spring washer 5 Exhaust silencer 6 Exhaust end section hose clamp 7 Red rt rubber profile with groove Assem bling the silencer a b 1 2 X 31 3 1 2 7 4 5 6 ...

Page 18: ...hould be installed based on the cable harness installation diagram Install the fuel line 1 and the heater unit cable harness 2 on the original vehicle fuel lines and secure with cable ties Placement of the fuel line in the engine compart ment Install the fuel line 1 and the heater unit cable harness 2 on the original vehicle fuel lines and secure with cable ties Run this along the right side of th...

Page 19: ...rom the heater unit on the outake side of the metering pump 3 side with connector Check the position of the components adjust if necessary Check that they have free clearance 1 Fastening strap with holes 2 Rubber tube clamp silentblock flanged nut M6 2x 4 Metering pump cable harness connector 5 Hose section hose clamps 2x 7 Original vehicle bolt loosely fitted Assem bling the metering pump Remove ...

Page 20: ...xtracting device Connect ing and discon necting the fuel pipe Assemble fuel tank according to manufacturer s instructions Fuel line from the tank extracting device on the intake side of the metering pump 1 side without connector Check the position of the components adjust if necessary Check that they have free clearance 2 Hose section Ø 10mm hose clamps 2x 3 Fuel pipe cut into sections Connec tion...

Page 21: ...e 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 1 Combustion air intake pipe Assemble the intake silencer 1 43 2 4 1 44 3 ...

Page 22: ...r Route hoses so that they are kink free Unless specified otherwise always fasten using cable clips Position hose clamps and spring band clamps so that no other hose can be damaged The connection should be inline based on the following diagram Water installation diagram All hose clamps Ø 20 27 mm All undesignated connecting pipes Ø 18x20 1 Rubber profile sw Ø 18x18 A B C 1 Ø 17x20 ...

Page 23: ...ded protective hose in the middle and slide it onto hose B and hose C Cut shrink fit hose to size 1 25 mm shrink fit hose 4x 2 Black sw rubber profile Preparing the water hoses Turn the original vehicle clamp 1 down Remove the hose coating 3 from the engine exhaust hose 2 1 Turn the original vehicle clamp up Preparing the splitting point B X X b c C A B C 1 1 1 1 150 2 45 1 46 1 2 3 60mm ...

Page 24: ...e 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 Connect ing hose B tomoulded hose A 47 1 2 48 A 1 49 B 1 50 B A 1 ...

Page 25: ... Before connecting fill the water hoses with coolant Insert the hose bracket 1 as shown in the figure 2 Heat exchanger inlet hose section Connect ing to the heat exchanger inlet Prepare the water hoses with cable clips 1 according to the figure Hose placement 51 C 1 2 52 C 1 2 B 53 B 1 1 C ...

Page 26: ...wax Tectyl 100K Order No 111329 Connect battery Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications Set the time switch Set the manual air conditioning or automatic air conditioning according to the operating instructions for the end customer Check that the auxiliary heating operates properly see operating instructions installation instructions Attach the Swit...

Page 27: ...ating driving time heating time 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 For vehicles with automatic air condition ing 56 2 3 1 ...

Page 28: ...0 100mm 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 1311472A 28 Tank Extracting Device Template ...

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