Mazda 6 Training Manual
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Mazda 6 Training Manual

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Mazda6
Training
Manual
FOREWORD
This manual eplains each component or
system operation and function for
the Mazda6.
For proper repair and maintenance,
a thorough familiarization with this manual
is important, and it should always be kept
in a handy place for quick and easy
reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves
the right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or
mechanical—including photocopying and
recording and the use of any kind of
information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN) shown on the following
page.
CONTENTS
Title
General Information
Engine
Lubrication System
Cooling System
Fuel and Emission Control Systems
Engine Electrical System
Clutch
Manual Transale
Automatic Transale
Front and Rear Ales
Steering System
Braking System
Suspension
Body
Body Electrical System
Heater and Air Conditioner Systems
© 2002 Mazda Motor Corporation
PRINTED IN The Netherlands, MARCH 2002
3359–1E–02C
Section
GI
B
D
E
F
G
H
J
K
M
N
P
R
S
T
U

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  • Page 1 Steering System As modifications affecting repair or maintenance occur, relevant information Braking System supplementary to this volume will be made available at Mazda dealers. This manual Suspension should be kept up-to-date. Body Mazda Motor Corporation reserves Body Electrical System...
  • Page 2 VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. JMZ GG12820# 100001— JMZ GG14320# 100001— JMZ GG14820# 100001— JMZ GG12F20# 100001— JMZ GG12F50# 100001— JMZ GG14F20# 100001— JMZ GG14F50# 100001— European (L.H.D.) specs. JMZ GG1232✻# 100001— JMZ GG1282✻# 100001— JMZ GG1432✻# 100001— JMZ GG1482✻# 100001—...

  • Page 3: Table Of Contents

    G ENERAL INFORMATION HOW TO USE THIS MANUAL ......GI-2 VIN CODE............GI-2 UNITS ..............GI-4 UNITS TABLE ............ GI-4 NEW STANDARDS ..........GI-5 NEW STANDARDS TABLE ....... GI-5 GI–1...

  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL VIN CODE A6E201000001T01 European (L.H.D. U.K.) specs. A6E2021T001 GI–2...
  • Page 5 HOW TO USE THIS MANUAL GCC specs. A6E2021T002 End Of Sie GI–3...

  • Page 6: Units

    UNITS UNITS UNITS TABLE A6E201200002T01 Electrical current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm (kilogram force per square Positive pressure...

  • Page 7: New Standards

    NEW STANDARDS NEW STANDARDS NEW STANDARDS TABLE A6E202800020T01 • Following is a comparison of the previous standard and the new standard. New Standard Previous Standard Remark Abbrevi- Abbrevi- Name Name ation ation Accelerator Pedal — Accelerator Pedal Air Cleaner — Air Cleaner Air Conditioning —...
  • Page 8 #3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #4 : Device that controls engine and powertrain #5 : Directly connected to ehaust manifold #6 : Part name of diesel engine End Of Sie GI–6...
  • Page 9 SPECIFICATIONS ..........B-4 STRUCTURAL VIEW...........B-4 ENGINE ..............B-5 CYLINDER HEAD COVER ........B-5 CYLINDER HEAD ..........B-5 CYLINDER HEAD GASKET ........ B-6 CYLINDER BLOCK ..........B-6 CRANKSHAFT, MAIN BEARING......B-8 BALANCER UNIT ..........B-9 CRANKSHAFT PULLEY ........B-11 ENGINE FRONT COVER ........B-12 PISTON, PISTON RING, PISTON PIN ....

  • Page 10: Abbreviations

    ABBREVIATIONS , OUTLINE ABBREVIATIONS ABBREVIATIONS A6E220102000T01 Air conditioner ABDC After bottom dead center ATDC After top dead center BBDC Before bottom dead center BTDC Before bottom dead center DOHC Double overhead camshaft Ehaust Intake Oil control valve Power steering Positive crankcase ventilation Special service tool Top dead center End Of Sie...

  • Page 11: Engine Performance Curve

    OUTLINE ENGINE PERFORMANCE CURVE A6E220202000T04 AME2202N001 Output Engine speed Torque B–3...

  • Page 12: Specifications

    87.5 × 83.1 87.5 × 94.0 Bore × stroke (mm {in}) {3.27 ×3.27} {3.44 ×3.27} {3.44 × 3.70} Compression ratio 10.8:1 10.8:1 10.6:1 1,750 {17.85, 253.8} 1,720 {17.54, 1,430 {14.58, 207.4} Compression pressure (kPa {kgf/cm , psi} [rpm]) [300] 249.5} [300] [290] Open BTDC (°)

  • Page 13: Engine

    ENGINE ENGINE CYLINDER HEAD COVER A6E222410100T01 Structure • The cylinder head cover is made of integrated aluminum alloy, which is lightweight and sound absorbent. • The oil filler cap is a screw-in type. The boss for installing the camshaft position (CMP) sensor is provided at the rear of the cylinder head cover.

  • Page 14: Cylinder Head Gasket

    • The tab for alignment, used to install the upper main journal and the lower main bearing, has been decommissioned. • The main bearing cap bolt is a plastic region tightening bolt, which is to be tightened in two motions. It insures a stable ais during tightening. B–6...
  • Page 15 ENGINE AME2224N003 Oil separator cover Oil separator cover attachment part PCV valve Cylinder block Main bearing cap • The service hole for installing the SST, which is used for detect the No.1 cylinder's TDC position, is located at the right side of the cylinder block. The TDC position can be detected when the SST edge touches the cutting surface of the No.1 counter weight.

  • Page 16: Crankshaft, Main Bearing

    ENGINE End Of Sie CRANKSHAFT, MAIN BEARING A6E222411301T01 Structure • Cast iron 5 ale-hole 4 counter weight has been adopted for the L8 engine models and LF engine models crankshafts. • Cast iron 5 ale-hole 8 counter weight has been adopted for the L3 engine models crankshaft. The shrinkage fitted drive gear is attached to the crankshaft and the crankshaft drives the balance shaft.

  • Page 17: Balancer Unit

    ENGINE AME2224N007 Upper main bearing 2 holes Supplying engine oil Lower main bearing Main bearing cap Thrust bearing Main bearing Supplying engine oil • Three kinds of main bearings are available depending on the oil clearance. (mm {in}) Bearing Color Bearing thickness size Standard...
  • Page 18 ENGINE Structure • The balancer unit is configured with two balancer shafts (No.1 and No.2) with weights, the balancer unit case and the adjust shim which adjusts the amount of backlash in the crankshaft. • The two balancer shafts (No.1 and No.2) are driven by the drive gear which is attached to the crankshaft. •...

  • Page 19: Crankshaft Pulley

    ENGINE AME2224N403 Cylinder block Engraved identification mark (2 digits) End Of Sie CRANKSHAFT PULLEY A6E222411371T01 Structure • The crankshaft position (CKP) signal detecting blade has been adopted for the crankshaft pulley. And the torsional damper, which prevents the crankshaft from wobbling, has also been adopted for the crankshaft. •...
  • Page 20 ENGINE ENGINE FRONT COVER A6E222401001T01 Structure • The engine front cover is made of aluminum alloy, and is integrated with the No.3 engine-mounting bracket, to improve noise absorption and decrease weight. • The hole for crankshaft pulley positioning bolt, the service hole for unlocking the chain adjuster ratchet, and the service hole for securing the tensioner arm when loosening the timing chain, are on the engine front cover.

  • Page 21: Piston, Piston Ring, Piston Pin

    ENGINE PISTON, PISTON RING, PISTON PIN A6E222411010T01 Structure • The pistons are made of aluminium alloy, which withstands heat and is highly conductive. • The piston skirt is coated with graphite to reduce friction. • The offset pistons are used to reduce piston-slapping noise. •...

  • Page 22: Connecting Rod, Connecting Rod Bearing

    ENGINE AME2224N009 Top ring sectional view Side rail Second ring sectional view Epander Oil ring sectional view End Of Sie CONNECTING ROD, CONNECTING ROD BEARING A6E222411211T01 Structure • Connecting rod is made of structural sintered alloy to improve rigidity. • The connecting rod, the piston, and the piston pin are shrinkage fit, and cannot be disassembled. •...

  • Page 23: Drive Belt

    ENGINE Fracture side Connecting rod bearing Connecting rod bearing cap • The upper lower bearing of the connecting rod bearing is made of aluminum alloy. • There are three kinds of connecting rod bearings depending on the oil clearance. Bearing size Color Bearing thickness (mm {in}) 1.496—1.502...

  • Page 24: Engine Mount

    ENGINE ENGINE MOUNT A6E222439000T03 Outline • The layout of the engine mounting is pendulum type, which reduces the noise in the cabin. • The engine supported at three points, and simplification of engine mount composition parts is attained. • The No.3 engine mounting rubber, which is an oil-filled type, has been adopted to reduce the noise in the cabin.
  • Page 25 ENGINE Structure • The surface of No.1 engine mounting rubber is made of aluminum alloy. The form is torque rod structure, which regulates the conventional rubber function and the rotation from the power train, and it has a vibration isolator. •...
  • Page 26 ENGINE AME2224N016 Power train system upper surface Transale No.3 engine mount No.4 engine mount Engine Power train system back Vehicle front Engine front Vehicle rear Torque No.1 engine mount Engine back End Of Sie B–18...

  • Page 27: Valve Mechanism

    VALVE MECHANISM VALVE MECHANISM VALVE MECHANISM A6E221112111T08 Outline • There are two intake ports and two ehaust ports per No. 1 cylinder. Totally 16 valves are directly driven by two camshafts. • The variable valve timing mechanism, which insures the best valve timing depending on the drive condition by constantly changing the phase of the intake port side camshaft, has been adopted for the L3 engine models.

  • Page 28: Camshaft

    VALVE MECHANISM End Of Sie CAMSHAFT A6E221112420T01 Structure • The cast iron 5 ais-hole, which has great rigidity, has been adopted for the camshaft to insure higher reliability. • The endplay of the camshaft is regulated at the rear of the No. 1 journal. •...
  • Page 29 VALVE MECHANISM AME2211N005 AME2211N006 Intake camshaft Cam journal Ehaust camshaft Cam heel Thrust Detection part for CKP sensors Cam nose End Of Sie B–21...

  • Page 30: Camshaft Sprocket

    VALVE MECHANISM CAMSHAFT SPROCKET A6E221112420T02 Structure • The sintered alloy, which has high rigidity, has been adopted for the camshaft sprocket and has been quenched to improve the abrasion resistance at the contact point with the timing chain. • L3 engine models intake port side camshaft sprocket is integrated (cannot be disassembled) with the variable valve timing actuator.

  • Page 31: Crankshaft Sprocket

    ITEM About Outer diameter About 48.495 (mm {in}) 47.955 {1.8880} {1.9093} Tooth width About About (mm {in}) 6.15 {0.242} 5.93 {0.242} AME2211N010 Oil pump drive sprocket Outer diameter Timing chain drive sprocket Tooth width Engine front End Of Sie B–23...

  • Page 32: Timing Chain, Chain Tensioner

    • Engine oil inside the engine front cover lubricates the timing chain and each sprocket. The pin part of the timing chain is nitrite-treated to improve abrasion resistance. Timing Chain Specification. ITEM Pitch size (mm {in}) 8 {0.32} 6.35 {0.25} Pitch number AME2211N002 Camshaft sprocket Timing chain Tensioner arm Pitch size...

  • Page 33: Valve, Valve Spring, Valve Seal, Valve Guide

    A6E221112111T02 Structure • The valves are heat-resistant steel. There are two intake valves, two ehaust valves per No.1 cylinder. VALVE SPEC. ITEM Intake valve: About 101.6 {4.000} Valve full length (mm {in}) Ehaust valve: About102.6 {4.039} Intake valve umbrella diameter (mm {in}) About 32.5 {1.28}...

  • Page 34: Tappet

    VALVE MECHANISM TAPPET A6E221112111T03 Structure • The tappet is a shimless tappet which is integrated with the shim. • Besides the tappet, the grounding surface of the cam is phosphate-coated to smooth the surface and improve abrasion resistance. • To adjust the valve clearance, replace the tappet. There are 35 kinds of tappets depending on the thickness. To distinguish the difference, check the engraved identification mark (3 digits).
  • Page 35 VALVE MECHANISM VALVE MECHANISM A6E221112111T07 Outline • A variable timing mechanism, which realizes optimum valve timing according to engine operation conditions by continuously modifying the phases of the intake camshaft and crankshaft, has been adopted. AME2211N013 Torque High speed engine Engine speed Engine with variable valve timing mechanism Low-middle speed engine...
  • Page 36 VALVE MECHANISM When engine is started or stopped • Startability has been improved because the overlap amount has been minimized to prevent combusted gas from returning to the intake port. AME2211N014 Load Medium load range Engine speed Heavy load, low-middle speed range Idling range Heavy load, high speed range Light load range...
  • Page 37 VALVE MECHANISM Construction • The variable valve timing mechanism consists of a variable valve timing actuator, oil control valve (OCV), CKP sensor, CMP sensor, and the PCM. AME2211N015 CKP sensor Variable valve timing actuator CMP sensor Electric signal Hydraulic pressure Oil control valve (OCV) B–29...
  • Page 38 VALVE MECHANISM Hydraulic Pressure Flow Diagram AME2211N016 Oil pan Oil control valve (OCV) adapter Oil pump Camshaft Oil pipe Variable valve timing actuator Oil filter Cylinder block Oil control valve (OCV) Component and function Variable valve timing actuator • Continuously modifies the phases of the intake camshaft and crankshaft at the forward end of the intake camshaft using hydraulic pressure from the oil control valve (OCV).
  • Page 39 VALVE MECHANISM Operation outline • The variable valve timing actuator has two hydraulic chambers: a valve timing advance chamber and a valve timing retard chamber. They are located between the integrated housing of the camshaft sprocket and the camshaft integrated rotor. The oil pump supplies engine oil. to each chamber. Hydraulic pressure applied to each chamber is controlled by the oil control valve (OCV) and the relative phases of the camshaft sprocket and the camshaft are modified to obtain optimum valve timing according to engine operation conditions.
  • Page 40 VALVE MECHANISM AME2211N018 Housing Oil control valve (OCV) Oil pan Spool valve To valve timing retard chamber Oil pump Valve timing retard chamber Camshaft From valve timing advance chamber Variable valve timing actuator Hydraulic pressure flow Rotor Maintaining intermediate valve timing •...

  • Page 41: Variable Valve Timing Actuator

    VALVE MECHANISM End Of Sie VARIABLE VALVE TIMING ACTUATOR A6E221112111T05 • The variable valve timing actuator consists of the following: a housing case integrated to the camshaft sprocket, a cover, a camshaft integrated rotor, and a stopper pin that retains the rotor and case when the engine stops.
  • Page 42 L UBRICATION SYSTEM ABBREVIATIONS ..........D-2 ABBREVIATIONS ..........D-2 OUTLINE ..............D-2 OUTLINE OF CONSTRUCTION......D-2 FEATURES ............D-2 SPECIFICATIONS ..........D-2 LUBRICATION SYSTEM........D-3 STRUCTURAL VIEW...........D-3 LUBRICATION FLOW DIAGRAM......D-4 OIL PUMP ............D-7 OIL PAN ...............D-9 OIL STRAINER ..........D-10 OIL FILTER ............D-10 OIL JET VALVE ..........D-12 D–1...

  • Page 43: Abbreviations

    Type Full-flow, paper element Bypass pressure Oil filter 80—120 {0.9—1.2, 12.8—17.0} (kPa {kgf/cm , psi}) Total (Dry engine) 4.6 {4.8, 4.0} 4.2 {4.4, 3.6} (L {US qt, lmp qt}) Oil capacity Oil replacement (Approimate 3.9 {4.0, 3.4} 3.1 {3.3, 2.7}...

  • Page 44: Lubrication System

    Viscosity (SAE) 40, 30, 20, 20W-20, 10W-30, 10W-40, 10W-50, 5W-30 5W-20 Engine oil 20W-40, 15W-40, 20W-50, 15W-50, 5W-20, 5W-30 Remarks Mazda genuine — — DEXELIA oil End Of Sie LUBRICATION SYSTEM STRUCTURAL VIEW A6E333001003T01 AME3300N001 Chain tensioner spring Oil jet valve...

  • Page 45: Lubrication Flow Diagram

    LUBRICATION SYSTEM End Of Sie LUBRICATION FLOW DIAGRAM A6E333001003T02 L8, LF AME3300N002 AME3300N003 D–4...
  • Page 46 LUBRICATION SYSTEM Camshaft Oil cooler Cylinder head To oil filter Cylinder block From oil pump Oil jet valve Oil pressure switch Crankshaft Orifice Oil filter Piston Oil filter bypass valve Main bearing Oil pump Crankshaft bearing, Connecting rod bearing Oil strainer Oil pressure relief valve Oil pan Elevational view...
  • Page 47 Oil filter bypass valve Elevational view Oil pump Side view Oil strainer Balance shaft Oil pan Oil control valve (OCV) Return oil Variable valve timing actuator Chain tensioner Oil filter (Inner engine front cover) Oil cooler End Of Sie D–6...

  • Page 48: Oil Pump

    Oil pump chain tensioner Oil pump sprocket • An efficient and compact 5-lobe epitrochoid and 6-flank inner envelop type gear has been adopted on the oil pump. • The oil pump consists of the inner and outer rotors, relief valve and oil pump body.
  • Page 49 • The durability has been improved by heating the sintering material on the oil pump sprocket inside of a furnace. OIL PUMP DRIVEN CHAIN SPEC. ENGINE ITEM Pitch size (mm {in}) 8 {0.4} 6.35 {0.25} Number of pitches AME3300N008 D–8...

  • Page 50: Oil Pan

    • The oil pump sprocket is heat forged from sintered metals to improve durability. OIL PUMP SPROCKET SPEC. ENGINE ITEM Outer diameter (mm {in}) 60.78 {2.394} 46.46 {1.829} Drive tooth (mm {in}) 6.15 {0.242} 5.7 {0.23} width Outer diameter Drive tooth width AME3300N009 End Of Sie OIL PAN A6E333010040T01 Structure •...

  • Page 51: Oil Strainer

    LUBRICATION SYSTEM OIL STRAINER A6E333014700T01 Structure • A plastic oil strainer with a resin filter in the middle of the strainer has been adopted for weight reduction. AME3300N011 Appearance figure A - A sectional view Oil supply mouth Oil strainer Oil strainer Filter Oil pump attachment side...
  • Page 52 OIL FILTER SPEC. ENGINE ITEM Outer diameter (mm {in}) 67—69 {2.4—2.7} 65.2—65.8 {2.57—2.59} Height (mm {in}) 73.5—75.5 {2.89—2.97} 72.6—74.4 {2.86—2.92} AME3300N012 Cylinder block Oil pressure switch Oil level gage O-ring Gasket Oil cooler Oil filter To water outlet case Oil filter cover...

  • Page 53: Oil Jet Valve

    LUBRICATION SYSTEM End Of Sie OIL JET VALVE A6E333010730T01 Structure • The oil jet valves are installed in the cylinder block (in the main journal). The piston cooling efficiency by oil injected from the nozzles has been improved by the attachment direction of the oil jet valves which are pointed toward the back surface of each piston.
  • Page 54 LUBRICATION SYSTEM Operation • Oil pressure applied to the check-ball in the oil jet valve opens and closes the oil passage way to the nozzle and controls oil injection start and stop. • Oil pressure greater than the specified value applied to the check-ball in the oil jet valve opens the oil passage to the spring-pressed nozzle, starting injection.
  • Page 55 OUTLINE ..............E-2 OUTLINE OF CONSTRUCTION......E-2 FEATURES ............E-2 SPECIFICATIONS ..........E-2 COOLING SYSTEM..........E-3 STRUCTURAL VIEW...........E-3 COOLING FLOW DIAGRAM ....... E-4 RADIATOR............E-5 COOLING FAN ............ E-5 RADIATOR COWLING, COOLANT RESERVOIR TANK..............E-6 THERMOSTAT ............ E-6 WATER PUMP............. E-7 E–1...

  • Page 56: Abbreviations

    End Of Sie SPECIFICATIONS A6E360201004T03 Engine type Item Cooling system Water-cooled, Electromotive Coolant capacity (L {US qt, lmp qt}) 7.5 {7.9, 6.6} (Approimate quantity) Water pump Type Centrifugal, V-ribbed belt-driven Type Opening temperature (°C {°F}) 80.0—84.0 {176—183.2} Thermostat Full-open temperature (°C {°F})

  • Page 57: Structural View

    COOLING SYSTEM COOLING SYSTEM STRUCTURAL VIEW A6E363001004T02 AME3602N001 Radiator Cooling fan blade Radiator cap Cooling fan motor No.1,Cooling fan motor No.2 Thermostat For Israel and L3 engine model Water pump LF engine model ecept for Israel and L8 engine model End Of Sie E–3...

  • Page 58: Cooling Flow Diagram

    COOLING SYSTEM COOLING FLOW DIAGRAM A6E363001004T03 AME3602N002 Heater Cylinder head Radiator Cylinder block Coolant reservoir tank Oil cooler Thermostat LF and L3 engine models Water pump End Of Sie E–4...

  • Page 59: Cooling Fan

    COOLING SYSTEM RADIATOR A6E363015200T01 Structure • A cross-flow radiator with corrugated fins is used for improved cooling. • The radiator tanks are made of plastic and the core is made of aluminum. • Four rubber-insulated mounting brackets are utilized to decrease vibration. •...

  • Page 60: Radiator Cowling, Coolant Reservoir Tank

    80.0°C {176°F} to 84.0 °C {183.2°F}, the thermostat begins opening the valve and engine coolant flows from the radiator to stabilize engine coolant temperature. AME3602N005 Engine side Thermostat case Radiator side Oil cooler (LF and L3 engine models) Heater hose (L8 engine model) Water pump Lower radiator hose Thermostat body End Of Sie E–6...

  • Page 61: Water Pump

    COOLING SYSTEM WATER PUMP A6E363015010T01 Structure • The water pump body is made of aluminum alloy for weight reduction. • The impeller is built into the cylinder block and the water pump is not seviceable and must be replaced as a unit if faulty.
  • Page 62 OUTLINE ..............F-3 OUTLINE OF CONSTRUCTION ......F-3 FEATURES ............F-3 SPECIFICATIONS ..........F-3 CONTROL SYSTEM DIAGRAM ......F-4 CONTROL SYSTEM WIRING DIAGRAM.... F-6 INTAKE-AIR SYSTEM.......... F-13 INTAKE-AIR SYSTEM OUTLINE ...... F-13 INTAKE-AIR SYSTEM STRUCTURAL VIEW..F-14 VARIABLE AIR DUCT (VAD) SYSTEM OUTLINE (L3) ..........

  • Page 63: Abbreviations

    ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS A6E390118881T01 Air adjust screw Controller area network Drive cycle Freeze frame data KOEO Key on, engine off KOER Key on, engine running Oil control valve Pending code Parameter identification Traction control system Variable air duct Variable intake-air system VLIM Variable length intake manifold VTCS...

  • Page 64: Koeo/Koer Self-Test

    OUTLINE OUTLINE OUTLINE OF CONSTRUCTION A6E390218881T01 • The Mazda6 (GG) has been equipped with the new engine (L series). The features of the L series engines are as follows. End Of Sie FEATURES A6E390218881T02 System simplification • Controller area network has been adopted. •...

  • Page 65: Control System Diagram

    OUTLINE CONTROL SYSTEM DIAGRAM A6E390218881T04 A6E3902T000 F–4...
  • Page 66 OUTLINE Fuel injector Ignition coil Generator CMP sensor VAD shutter valve EGR valve Air cleaner Knock sensor MAF sensor ECT sensor VAD shutter valve actuator PCV valve VAD control solenoid valve CKP sensor Vacuum chamber Heated oygen sensor (front) VAD check valve (one-way) Heated oygen sensor (rear) Charcoal canister Purge solenoid valve...
  • Page 67 OUTLINE CONTROL SYSTEM WIRING DIAGRAM A6E390218881T05 With Immobilizer System A6E3940T901 F–6...
  • Page 68 OUTLINE Heated oygen sensor (front) Heated oygen sensor (rear) Oygen sensor heater (front) TP sensor Oygen sensor heater (rear) MAP sensor A/C relay BARO sensor Cooling fan relay ECT sensor Cooling fan relay MAF/IAT sensor Cooling fan relay IAT sensor Cooling fan relay MAF sensor Fuel pump relay...
  • Page 69 OUTLINE A6E3940T903 F–8...
  • Page 70 OUTLINE Generator Ignition coil Refrigerant pressure switch (middle) Generator PSP switch Purge solenoid valve Blower motor VAD control solenoid valve Refrigerant pressure switch (high and low) EGR valve A/C switch Variable tumble control solenoid valve Brake switch VIS control solenoid valve Neutral switch Clutch switch Valve body...
  • Page 71 OUTLINE Without Immobilizer System A6E3940T902 F–10...
  • Page 72 OUTLINE Heated oygen sensor (front) Fuel injector No.3 Heated oygen sensor (rear) Fuel injector No.4 TP sensor MAP sensor Oygen sensor heater (front) BARO sensor Oygen sensor heater (rear) ECT sensor A/C relay MAF/IAT sensor Cooling fan relay IAT sensor Cooling fan relay MAF sensor Cooling fan relay...
  • Page 73 OUTLINE A6E3940T904 F–12...

  • Page 74: Intake-Air System

    OUTLINE, INTAKE-AIR SYSTEM Generator Refrigerant pressure switch (middle) Ignition coil PSP switch Generator Blower motor Purge solenoid valve Refrigerant pressure switch (high and low) VAD control solenoid valve A/C switch EGR valve Brake switch Variable tumble control solenoid valve Brake light VIS control solenoid valve Neutral switch Clutch switch...

  • Page 75: Intake-Air System Structural View

    INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM STRUCTURAL VIEW A6E391013000T02 A6E3910W036 Air cleaner VTCS shutter valve actuator IAC valve VAD check valve (one-way) (L3) Resonance chamber Accelerator pedal (R.H.D.) VIS control solenoid valve (L3) Accelerator cable (R.H.D.) Variable tumble control solenoid valve Accelerator pedal (L.H.D.) L8, LF engine models Accelerator cable (L.H.D.) Intake manifold...

  • Page 76: Variable Air Duct (Vad) Shutter Valve Description (L3

    INTAKE-AIR SYSTEM A6E3910W029 VAD shutter valve VAD vacuum chamber VAD control solenoid valve VAD check valve (one-way) End Of Sie VARIABLE AIR DUCT (VAD) SHUTTER VALVE DESCRIPTION (L3) A6E391013000T04 Function • Opens and closes the shutter valves. Structure • The VAD shutter valve actuator is composed of a rod, diaphragm chamber, and spring. Operation •...

  • Page 77: Variable Air Duct (Vad) Solenoid Valve Description (L3

    INTAKE-AIR SYSTEM VARIABLE AIR DUCT (VAD) SOLENOID VALVE DESCRIPTION (L3) A6E391013000T05 Function • Switches the intake manifold vacuum passage between the intake manifold and the actuator. Structure • Composed of a solenoid coil, spring, plunger, and filter. Operation Energized • The plunger is pulled back to open the air passage between the A and B ports, which applies the atmosphere to the VAD shutter valve actuator.

  • Page 78: Fuel System

    FUEL SYSTEM FUEL SYSTEM FUEL SYSTEM OUTLINE A6E391201006T01 • The function, structure and operation of each part in the fuel system of the Mazda6 (GG) L3 engine model are the same as those of the 323 (BJ) FS engine models ecept for the following: —...

  • Page 79: Fuel System Structural Vew

    FUEL SYSTEM FUEL SYSTEM STRUCTURAL VEW A6E391201006T02 Engine Room Side A6E3912W048 Fuel tank side A6E3912W049 F–18...

  • Page 80: Fuel Pump Unit Description

    FUEL SYSTEM Fuel tank Fuel pump relay Nonreturn valve Check connector Fuel pump unit Quick release connector Fuel injector Fuel filler cap Pulsation damper End Of Sie FUEL PUMP UNIT DESCRIPTION A6E391213350T01 Note • It is normal to hear the fuel pump operating when the ignition switch is turned to the ON position. Function •...

  • Page 81: Exhaust System

    FUEL SYSTEM, EXHAUST SYSTEM Fuel flow A6E3912W035 Fuel pump unit Fuel jet pump Fuel gauge sender unit One-way valve Fuel pump Main fuel flow Fuel filter (high-pressure) Return fuel flow Fuel filter (low-pressure) To fuel distributor Fuel reservoir cup Fuel tank Pressure regulator End Of Sie EXHAUST SYSTEM...

  • Page 82: Exhaust System Structural View

    EXHAUST SYSTEM End Of Sie EXHAUST SYSTEM STRUCTURAL VIEW A6E391440000T02 A6E3914W001 Main silencer HO2S (front) Middle pipe HO2S (rear) L3 engine model Ehaust manifold F–21...

  • Page 83: Emission System

    EMISSION SYSTEM End Of Sie EMISSION SYSTEM OUTLINE A6E391601007T01 • The function, structure and operation of each part in the emission system of the Mazda6 (GG) L3, LF, and L8 engine models are the same as those of the MPV (LW) FS engine models, ecept for the following: —...

  • Page 84: Emission System Structural View

    EMISSION SYSTEM EMISSION SYSTEM STRUCTURAL VIEW A6E391601007T02 Engine room side A6E3916W024 Fuel tank side A6E3916W025 F–23...

  • Page 85: Pulsation Reduce Chamber Description

    EMISSION SYSTEM EGR valve Charcoal canister (L.H.D.) Purge solenoid valve Charcoal canister (R.H.D.) Evaporative gas check valve (one-way) (L.H.D.) Pulsation reduce chamber (R.H.D.) PCV valve Rollover valve Ventilation hose Check valve (two-way) End Of Sie PULSATION REDUCE CHAMBER DESCRIPTION A6E391601007T03 •...

  • Page 86: Control System

    CONTROL SYSTEM CONTROL SYSTEM OUTLINE A6E394018881T01 • The construction and operation of the Mazda6 (GG) is essentially carried over from that of the current MPV (LW) FS engine model, ecept for the following. New Devices • MAP sensor which monitoring the intake manifold absolute pressure is the same function as BARO sensor. Similar Devices CKP sensor •...
  • Page 87 CONTROL SYSTEM Input Device ×:Applied —: Not applied Current Mazda6 Item Signal MPV (LW) Remark for new model (GG) MAF/IAT sensor MAF and IAT × Same as 323 (BJ) ZM engine model TP sensor × Same function as MPV (LW) FS engine model Same function as BARO sensor of MPV (LW) FS MAP sensor ×...
  • Page 88 CONTROL SYSTEM Output Device ×:Applied —: Not applied Current Mazda6 Item Signal MPV (LW) Remark for new model (GG) Same function as MPV (LW) FS engine model IAC valve × Idle speed is different to match vehicle characteristics. Same function as VICS of MPV (LW) FS engine model VIS solenoid valve ×...

  • Page 89: Structural View

    CONTROL SYSTEM STRUCTURAL VIEW A6E394018881T02 A6E3940T000 F–28...
  • Page 90 CONTROL SYSTEM MAF/IAT sensor Brake switch TP sensor VAD control solenoid valve MAP sensor IAC valve CMP sensor VIC solenoid valve CKP sensor VTCS solenoid valve ECT sensor Knock sensor Fuel injector HO2S (front, rear) Ignition coil P/S pressure switch Purge valve Clutch switch EGR valve...

  • Page 91: Block Diagram

    CONTROL SYSTEM BLOCK DIAGRAM A6E394018881T03 A6E3940T001 F–30...
  • Page 92 CONTROL SYSTEM MAF/IAT sensor Fuel injector TP sensor Fuel pump relay MAP sensor Ignition coil CMP sensor Purge valve CKP sensor EGR valve ECT sensor Oygen sensor heater (front, rear) Knock sensor A/C relay HO2S (front, rear) Cooling fan relay P/S pressure switch Generator (terminal D: field coil) Vehicle speedometer sensor...

  • Page 93: Control Devices And Control Relationship Chart

    CONTROL SYSTEM CONTROL DEVICES AND CONTROL RELATIONSHIP CHART A6E394018881T04 Engine Control System Input devices : Applicable Component IAT sensor × MAF sensor TP sensor MAP sensor ECT sensor CMP sensor CKP sensor Knock sensor Front HO2S Rear HO2S BARO sensor Neutral switch Clutch switch TR switch...
  • Page 94 CONTROL SYSTEM Output devices ×: Applicable Component IAC valve × VAD control solenoid valve × VIC solenoid valve × VTCS solenoid valve × Oil control valve (OCV) × Fuel injectors × × Fuel pump relay × Ignition coil × × Purge solenoid valve ×...

  • Page 95: Camshaft Position (Cmp) Sensor

    CONTROL SYSTEM CAMSHAFT POSITION (CMP) SENSOR A6E394018881T05 Outline • For cylinder identification, the CMP sensor detects a camshaft angle of 30 degree after the top dead center in cylinder No. 1. • The wave form of CMP sensor output is shown in the figure. A6E3940T021 CMP sensor CMP sensor output signal...

  • Page 96: Idle Air Control (Iac

    CONTROL SYSTEM Pulse wheel Crankshaft angle CKP sensor CKP sensor output signal End Of Sie IDLE AIR CONTROL (IAC) A6E394018881T07 Outline • The IAC of the Mazda6 (GG) is essentially carried over from the current MPV (LW) FS engine models ecept for the followings.

  • Page 97: Variable Valve Timing Control

    CONTROL SYSTEM Operation Conditions • The PCM turns the VTCS solenoid valve ON to close the VTCS shutter valve in the intake manifold when all of the following conditions are met: — Engine speed: below 3,750 rpm — Throttle opening angle is below as followings: Below 1,500 rpm: CTP Between 2,000 rpm and 3,000 rpm: 26—29% Above 2,500 rpm: WOT...

  • Page 98: Electric Fan Control

    CONTROL SYSTEM Operation Conditions • While A/C is operating, the PCM cuts off the power supply to the A/C relay as shown below. A/C cut-off condition A/C cut-off time Purpose During cranking For appro. 4.0 s Startability improvement Acceleration performance Throttle valve is open more than 50% For appro.

  • Page 99: Controller Area Network (Can

    CONTROL SYSTEM A6E3940T220 Cooling fan motor No. 1 Cooling fan relay No. 4 Cooling fan motor No. 2 Cooling fan relay No. 1 L3 engine models Cooling fan relay No. 2 LF, L8 engine models (Intensely hot area) Cooling fan relay No. 3 L8, LF (General area) engine models Cooling fan motor No.
  • Page 100 CONTROL SYSTEM Transmit Information • Torque reduction inhibit • Engine speed • Vehicle Speed • TP • ECT • Travelled distance • Fuel injection amount • MIL condition • Generator warning light conditions • Engine displacement • Number of cylinders •...

  • Page 101: On-Board Diagnostic

    ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC OUTLINE A6E397018881T01 • The construction and operation of the on-board diagnostic system is essentially carried over from that of the current MPV (LW) GY/FS engine model, ecept for the following. (See MPV Workshop Manual supplement 1700-1*-00H.) —...

  • Page 102: Diagnostic Test Mode

    ON-BOARD DIAGNOSTIC DIAGNOSTIC TEST MODE A6E397018881T03 • To match the OBD regulations, the following diagnostic test modes have been supported. Diagnostic test mode Item Mode 01 Sending diagnostic data (PID data monitor/On-board system readiness test) Mode 02 Sending freeze frame data Mode 03 Sending emission-related malfunction code (Diagnostic trouble code: DTC) Mode 04...
  • Page 103 ON-BOARD DIAGNOSTIC Sending Freeze Frame Data (FFD) (Mode 02) • The FFDs are shown in the table. FFD monitor table Full names Condition/unit DTC that caused required FFD storage – Fuel system loop status OPEN: NON-F/B, CLOSE: F/B Engine load calculated value Engine coolant temperature °C °F...
  • Page 104 ON-BOARD DIAGNOSTIC Memory DTC No. Condition Monitor item function P0303 Cylinder No.3 misfire detected Flash / ON 1 or 2 Misfire × P0304 Cylinder No.4 misfire detected Flash / ON 1 or 2 Misfire × P0327 Knock sensor circuit low input ×...

  • Page 105: Dtc

    ON-BOARD DIAGNOSTIC Sending Intermittent Monitoring System Test Results (Mode 06) • The items supported by the sending intermittent monitoring system are shown in the table. TEST ID Description Related system 10:01:0A Rich to lean sensor threshold voltage 10:02:0A Lean to rich sensor threshold voltage 10:03:0A Low sensor voltage for switching time calculation 10:04:0A...
  • Page 106 • The PCM monitors ECT sensor signal at the PCM terminal 1M. If the PCM detects ECT sensor voltage above 4.6 V, the PCM determines that the ECT sensor circuit has a malfunction. Ecessive time to enter closed loop fuel control (P0125) •...
  • Page 107 • The PCM monitors input voltage from the rear HO2S. If input voltage from the rear HO2S sensor is above 0.45 V for 6.4 s during deceleration fuel cut, the PCM determines that the circuit input is high. Rear HO2S circuit no activity detected (P0140) •...
  • Page 108 ON-BOARD DIAGNOSTIC Fuel System Fuel trim system too lean (P0171) • The PCM monitors short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) values during closed loop fuel control. If fuel trim eceeds preprogrammed criteria, the PCM determines that the fuel system is too lean. Fuel trim system too rich (P0172) •...
  • Page 109 ON-BOARD DIAGNOSTIC Vehicle Speed Sensor (VSS) VSS circuit malfunction (P0500) (MTX vehicles without ABS) • Vehicle speed signal does not input after the following conditions are met: — Gear is in other than neutral position — Load is above 40% —...
  • Page 110 ON-BOARD DIAGNOSTIC Neutral Switch Neutral switch input malfunction (P0850) • The PCM monitors changes in input voltage from the neutral switch. If the PCM does not detect the PCM terminal 1W voltage changes while running vehicle with vehicle speed above 30 km/h {19 mph} and the clutch pedal is depressed and released 10 times repeatedly, PCM determines that neutral switch circuit has a malfunction.

  • Page 111: Pid/Data Monitor And Record

    ON-BOARD DIAGNOSTIC PCM cannot receive any signals from instrument cluster (U0155) • PCM cannot receive any signals from the instrument cluster. End Of Sie PID/DATA MONITOR AND RECORD A6E397018881T05 • The PID/DATA monitoring items for the fuel and emission control systems are as shown in the table below. Monitor item table —: Not applicable PID item...
  • Page 112 ON-BOARD DIAGNOSTIC PID item Definition Unit/Condition PCM terminal O2S12 Rear HO2S signal voltage PSP switch ON/OFF RFCFLAG Adaptive memory condition — — RO2FT1 Rear O2 fuel trim — — Engine speed 2D,2G SEGRP EGR valve (stepping motor) position in PCM No.
  • Page 113 ON-BOARD DIAGNOSTIC SIMULATION TEST A6E397018881T06 • The simulation test items for the fuel and emission control systems are as shown in the table below. Simulation item table ×: Applied —: Not applied Test condition Simulation Applicable component Operation item terminal IG ON Idle ACCS...
  • Page 114 ON-BOARD DIAGNOSTIC KOEO/KOER self-test function table ×: Applicable —: Not applicable DTC No. Condition KOEO KOER P0010 CMP actuator circuit malfunction × × P0011 CMP timing over advanced — × P0012 CMP timing over retarded — × P0031 Front HO2S heater circuit low ×...
  • Page 115 ON-BOARD DIAGNOSTIC DTC No. Condition KOEO KOER P0703 Brake switch input malfunction — — P0704 Clutch switch input malfunction — — P0850 Neutral switch input malfunction — — P1410 Variable air duct valve circuit malfunction × × P1562 PCM +BB voltage low ×...
  • Page 116 OUTLINE OF CONSTRUCTION......G-2 FEATURES ............G-2 SPECIFICATIONS ..........G-2 STRUCTURAl VIEW ........... G-3 CHARGING SYSTEM ..........G-4 GENERATOR ............. G-4 IGNITION SYSTEM ..........G-5 IGNITION COIL........... G-5 SPARK PLUG ............. G-6 STARTING SYSTEM ..........G-6 STARTER ............G-6 G–1...

  • Page 117: Abbreviations

    ABBREVIATIONS , OUTLINE ABBREVIATIONS ABBREVIATIONS A6E470102000T01 Battery positive voltage Distributorless Ignition End Of Sie OUTLINE OUTLINE OF CONSTRUCTION A6E470201008T01 • Adoption of a DLI system eliminates the distributor. End Of Sie FEATURES A6E470201008T02 Improved marketability and durability • Iridium spark plug has been adopted. Improved reliability •...

  • Page 118: Structural View

    OUTLINE STRUCTURAL VIEW A6E470201008T04 AME4702N001 Spark plug Ignition coil Generator Starter High-tension lead Battery End Of Sie G–3...

  • Page 119: Charging System

    CHARGING SYSTEM CHARGING SYSTEM GENERATOR A6E471001008T02 Structure • The voltage regulator has been eliminated, and generator control is carried out by the PCM. • A Generator duct made of plastic and generator heat insulator made of iron have been adopted to protect the generator from the ehaust manifold heat.

  • Page 120: Ignition System

    IGNITION SYSTEM End Of Sie IGNITION SYSTEM IGNITION COIL A6E471201008T04 Structure • The ignition coil contains two coils. They are for cylinder numbers 1 and 4, and cylinder numbers 2 and 3 respective.(Matched pairs) • The two secondary terminals contain the secondary coils positive and negative terminals. The closed circuit of secondary coils is formed through the high-tension leads, two spark plugs and the cylinder head.

  • Page 121: Spark Plug

    • The iridium spark plug with ecellent durability and firing performance has been adopted. • The etremely thin, center electrode has a diameter of 0.6 mm {0.023 in} and is made of iridium alloy. Also, durability has been improved by the use of a platinum-tipped grounding electrode.
  • Page 122 C LUTCH OUTLINE ..............H-2 OUTLINE OF CONSTRUCTION......H-2 SPECIFICATIONS ..........H-2 H–1...
  • Page 123 OUTLINE OUTLINE OUTLINE OF CONSTRUCTION A6E490216003T01 • The construction and operation of the clutch is essentially carried over from that of the current MPV (LW) models. (See Mazda MPV Training Manual 3340-1E-99F) End Of Sie SPECIFICATIONS A6E490216003T03 Mazda6 (GG) Current MPV...
  • Page 124 M ANUAL TRANSAXLE OUTLINE ..............J-2 OUTLINE OF CONSTRUCTION......J-2 FEATURES ............J-2 SPECIFICATIONS ..........J-2 MANUAL TRANSAXLE.......... J-3 CROSS-SECTION VIEW ........J-3 J–1...
  • Page 125 A6E510201025T01 • The construction and operation of the transale are the same as those of the current G15M-R type manual transale, ecept for the following features. (See Mazda MPV Training Manual 3340-1E-99F) However, the following items have been changed. End Of Sie...

  • Page 126: Manual Transaxle

    MANUAL TRANSAXLE MANUAL TRANSAXLE CROSS-SECTION VIEW A6E511201025T02 A6E5112T001 1st gear Secondary 2nd gear 2nd gear Secondary 3rd gear 3rd gear Secondary 4th gear 4th gear Secondary 5th gear 5th gear Clutch hub sleeve (reverse gear) Reverse gear Reverse idler gear Secondary 1st gear Diffential End Of Sie...
  • Page 127 A UTOMATIC TRANSAXLE ABBREVIATIONS ..........K-2 ABBREVIATIONS ..........K-2 OUTLINE ..............K-2 OUTLINE OF CONSTRUCTION......K-2 FEATURES ............K-2 SPECIFICATIONS ..........K-2 AUTOMATIC TRANSAXLE........K-3 OUTLINE..............K-3 CROSS-SECTIONAL VIEW......... K-4 OUTLINE OF OPERATION ......... K-5 EC-AT OPERATION CHART....... K-7 POWERFLOW ............. K-8 ELECTRONIC CONTROL SYSTEM ...... K-9 OUTLINE..............K-9 CONSTRUCTION ..........

  • Page 128: Abbreviations

    ATF M-III or equivalent (e.g. Type ATF M-V ® Deron Capacity (Approimate L {US qt, lmp qt) 7.2 {7.6, 6.3} quantity) Torque converter stall torque ratio 1.950 Forward clutch (number of drive/ driven plates) 3-4 clutch (number of drive/driven plates)

  • Page 129: Automatic Transaxle

    OUTLINE , AUTOMATIC TRANSAXLE Item Mazda6 (GG) Current PREMACY (CP) Engine Rear sun gear Rear planetary gear Rear pinion gear (number of teeth) Rear internal gear Primary gear Secondary gear Output gear Ring gear Bold frames:New specifications End Of Sie AUTOMATIC TRANSAXLE OUTLINE A6E561401030T01...

  • Page 130: Cross-Sectional View

    AUTOMATIC TRANSAXLE CROSS-SECTIONAL VIEW A6E561401030T02 A6E5614T001 Torque converter 2-4 brake band Oil pump Low and reverse brake Forward clutch One-way clutch Front planetary gear Primary gear Rear planetary gear Secondary gear 3-4 clutch Output gear Reverse clutch Differential K–4...

  • Page 131: Outline Of Operation

    AUTOMATIC TRANSAXLE End Of Sie OUTLINE OF OPERATION A6E561401030T03 • The operation of the electronic automatic transale is classified into three systems: the electronic control mechanism, the hydraulic pressure control mechanism, and the powertrain mechanism (includes the torque converter mechanism). The operation of each system is as follows: —...
  • Page 132 Control valve body Clutches, brakes engagement, relase pressure Shift solenoid D, E (ON/OFF type) Powerflow Pressure control solenoid (linear type) Hydraulic pressure control signal Shift solenoid A, B, C (duty-cycle type) Electronic signal Oil pump Tire End Of Sie K–6...

  • Page 133: Ec-At Operation Chart

    AUTOMATIC TRANSAXLE EC-AT OPERATION CHART A6E561401030T04 A6E5614T003 End Of Sie K–7...

  • Page 134: Powerflow

    AUTOMATIC TRANSAXLE POWERFLOW A6E561401030T05 Outline • In the powertrain mechanism, hydraulic pressure is transported from the control valves or shift solenoid A, B, or C (duty cycle type) to operate the clutches and brakes, and the planetary gear changes the gear ratio according to the vehicle driving condition.

  • Page 135: Electronic Control System

    AUTOMATIC TRANSAXLE, ELECTRONIC CONTROL SYSTEM Operation Component description Component Function Forward clutch • Transmits input torque from turbine shaft to front sun gear • Operates in forward range of first, second, or third gear position 3-4 clutch • Transmits input torque from turbine shaft to rear planetary carrier •...

  • Page 136: Construction

    ELECTRONIC CONTROL SYSTEM CONSTRUCTION A6E561501030T02 A6E5614T007 HOLD indicator light Engine coolant temperature sensor Speedometer Vehicle speed sensor Brake switch Input /turbine speed sensor Crankshaft position sensor HOLD switch Control valve (With transale fluid temperature sensor and solenoid valves) Throttle position sensor Transale range swich Oil pressure switch Mass air flow sensor...

  • Page 137: Block Diagram

    ELECTRONIC CONTROL SYSTEM BLOCK DIAGRAM End Of Sie A6E561501030T03 A6E5614T006 Vehicle speed sensor Engine control system Transale fluid temperature sensor Transale control system Transale range switch On-board diagnostic system Oil pressure switch Input signals Output signals Throttle position sensor Shift solenoid A Crankshaft position sensor Shift solenoid B Mass air flow sensor...

  • Page 138: Electronic Control Items And Contents

    ELECTRONIC CONTROL SYSTEM End Of Sie ELECTRONIC CONTROL ITEMS AND CONTENTS A6E561501030T04 Item Content Line pressure control • With linear type pressure control solenoid, adjusts to suitable line pressure for engine load condition and vehicle driving condition Shift control • Detects engine load condition and vehicle speed, and switches to the most suitable gear position according to the preset shift diagram •...

  • Page 139: Input/Output Signal And Related Controls

    ELECTRONIC CONTROL SYSTEM INPUT/OUTPUT SIGNAL AND RELATED CONTROLS A6E561501030T06 Control item Clutch pressure direct Engine- Torque Line Slope On-board Component Shift control Feedback transale converter pressure mode diagnostic control (Direct control total clutch control control function electric control control shift control) Input HOLD switch...

  • Page 140: Automatic Transaxle Shift Mechanism

    AUTOMATIC TRANSAXLE SHIFT MECHANISM AUTOMATIC TRANSAXLE SHIFT MECHANISM OUTLINE A6E561646010T01 • The mechanical type shift lock system is essentially carried over from that of the current PREMACY (CP) models. (See Mazda PREMACY Training Manual 3351-1A-01A) End Of Sie STRUCTURAL VIEW A6E561646010T02 A6E5616T001...
  • Page 141 AUTOMATIC TRANSAXLE SHIFT MECHANISM When the brake pedal is depressed, the slider pin moves freely in direction B. The slider block also starts to move freely. The interlock cable and interlock cam are not locked, thus shifting out of P position becomes possible.

  • Page 142: On-Board Diagnostic

    ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC OUTLINE A6E567001030T01 • The construction and operation of the on -board diagnostic system is essentially carried over from that of the previous 626 (GF) FN4A-EL models, ecept for the following. (See 626 626 Station Wagon Workshop Manual Supplement 1688-1*-00G).
  • Page 143 ON-BOARD DIAGNOSTIC DTC Table HOLD indicator Monitor Memory DTC No. Condition light item function flashes P0500 VSS circuit malfunction (ATX) × P0706 Transale range (TR) switch circuit range/performance × P0707 Transale range (TR) switch circuit low input × P0708 Transale range (TR) switch circuit high input ×...
  • Page 144 • Revolution ratio of forward clutch drum revolution to differential gear case revolution is below 0.863 or above 1.249 while in 3GR. Gear 4 incorrect (P0734) • Revolution ratio of forward clutch drum revolution to differential gear case revolution is below 0.6 or 1.249 or above while in 4GR. Torque converter clutch (TCC) (Stuck off) (P0741) •...

  • Page 145: Fail-Safe Function

    ON-BOARD DIAGNOSTIC Shift solenoid D malfunction (stuck on) (P0767) • Revolution ratio of forward clutch drum revolution to differential gear case revolution below 0.863 or 1.249 or above in driving in D range. Shift solenoid D malfunction (electrical) (P0768) • If voltage is stuck at 0V or B+ in shift solenoid D valve control terminal 3S of the PCM when the solenoid valve operates according to PCM calculation.

  • Page 146: Parameter Identification (Pid) Access

    ON-BOARD DIAGNOSTIC DTC No. Definition Fail-safe Inhibits 3GR and 4GR and maimizes line P0762 Shift solenoid C malfunction (Stuck on) Available pressure Inhibits 1GR and 2GR and maimizes line P0763 Shift solenoid C malfunction (Electrical) Available pressure P0766 Shift solenoid D malfunction (Stuck off) Inhibits 4GR and maimizes line pressure Available Inhibits 2GR, 4GR, and TCC and maimizes...

  • Page 147: Front And Rear Axles

    FRONT AND REAR AXLES ABBREVIATIONS ..........M-2 ABBREVIATIONS ..........M-2 OUTLINE ............... M-2 OUTLINE OF CONSTRUCTION......M-2 FEATURES ............M-2 SPECIFICATIONS ..........M-2 CROSS-SECTIONAL VIEW........ M-3 DRIVE SHAFT ............M-4 DRIVE SHAFT OUTLINE........M-4 DRIVE SHAFT (LF ATX) CROSS- SECTIONAL VIEW........... M-4 M–1...
  • Page 148 ABBREVIATIONS , OUTLINE ABBREVIATIONS ABBREVIATIONS A6E630100000T03 Automatic transale Manual transale 4 door sedan 5 door hatchback End Of Sie OUTLINE OUTLINE OF CONSTRUCTION A6E630201018T01 • The construction and operation of the front and rear ales is essentially carried over from that of the 626 (GF) model, ecept for the following features.
  • Page 149 OUTLINE CROSS-SECTIONAL VIEW A6E630201018T03 A6E6302T001 Front ale Rear ale End Of Sie M–3...

  • Page 150: Drive Shaft

    DRIVE SHAFT DRIVE SHAFT DRIVE SHAFT OUTLINE A6E631625500T01 • Construction of the joint is essentially carried over from that of the previous tripod joint. • A free ring has been adopted for the transale side joint. A contact region between the outer ring and free ring has been formed to reduce aial vibratory force when the joint slides (LF ATX model).
  • Page 151 S TEERING SYSTEM ABBREVIATIONS ..........N-2 ABBREVIATIONS ..........N-2 OUTLINE ..............N-2 OUTLINE OF CONSTRUCTION......N-2 FEATURES ............N-2 SPECIFICATIONS ..........N-2 STRUCTURAL VIEW...........N-3 ENGINE SPEED SENSING POWER STEERING ..N-4 ENERGY ABSORBING SYSTEM......N-4 N–1...
  • Page 152 • Steering shaft with energy absorbing system has been adopted. End Of Sie SPECIFICATIONS A6E660201036T03 Item Mazda6 (GG) (4SD, 5HB) 626 (GF) (4SD, 5HB) Outer diameter mm {in} 370 {14.6} 380 {15.0} Steering wheel Lock-to-lock (turns) 2.75 Type Rack-and-pinion Rack-and-pinion...
  • Page 153 OUTLINE STRUCTURAL VIEW A6E660201036T04 A6E6602T001 L.H.D. Steering column and shaft R.H.D. Steering gear Power steering oil pump Fluid reservoir Steering wheel End Of Sie N–3...
  • Page 154 ENGINE SPEED SENSING POWER STEERING ENGINE SPEED SENSING POWER STEERING ENERGY ABSORBING SYSTEM A6E661432010T01 Structure and Operation • The steering gear is joined to the steering shaft through the intermediate shaft. • In a collision, the intermediate shaft is crushed as the steering gear moves rearward, thereby absorbing the impact.
  • Page 155 B RAKING SYSTEM ABBREVIATIONS ..........P-2 ABBREVIATIONS ..........P-2 OUTLINE ..............P-2 OUTLINE OF CONSTRUCTION......P-2 FEATURES ............P-2 SPECIFICATIONS ..........P-3 STRUCTURAL VIEW...........P-4 CONVENTIONAL BRAKE SYSTEM ...... P-5 INTRUSION-MINIMIZING BRAKE PEDAL ..P-5 ABS/TCS ..............P-7 OUTLINE..............P-7 DYNAMIC STABILITY CONTROL ......P-9 OUTLINE..............P-9 DSC INDICATOR LIGHT ........

  • Page 156: Abbreviations

    ABBREVIATIONS , OUTLINE ABBREVIATIONS ABBREVIATIONS A6E690100000T01 Controller area network Control module Dynamic stability control Electronic brakeforce distribution Hydraulic unit Ignition switch Left front Left rear Right front Right rear 4 door sedan 5 door hatchback End Of Sie OUTLINE OUTLINE OF CONSTRUCTION A6E690201020T01 •...

  • Page 157: Specifications

    57.15 {2.250} Pad dimensions (area × thickness) L8: 4,220 {6.75} × 10.0 {0.39} Front brake 4,800 {7.44} × 10.0 {0.39} LF, L3: 4,010 {6.42} × 12.5 {0.02} } × mm {in}) (disc) Disc plate dimensions L8: 274 {10.8} × 24.0 {0.945} (outer diameter ×...

  • Page 158: Structural View

    OUTLINE STRUCTURAL VIEW A6E690201020T04 A6E6912T001 L.H.D. Front brake (disc) R.H.D. Rear brake (disc) Brake pedal Without ABS Master cylinder Dual proportioning valve Power brake unit End Of Sie P–4...

  • Page 159: Conventional Brake System

    CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM INTRUSION-MINIMIZING BRAKE PEDAL A6E691201020T01 Function • An intrusion-minimizing brake pedal construction, which minimizes the amount of backward thrust of the pedal, has been adopted. It has been designed to soften the force of impact on the lower body of the driver. Structure/operation •...
  • Page 160 CONVENTIONAL BRAKE SYSTEM After collision A6E6912T003 Backward thrust Pivot away from the driver End Of Sie P–6...

  • Page 161: Abs/Tcs

    ABS/TCS ABS/TCS OUTLINE A6E692143000T01 • The hydraulic pressure control mechanism in the ABS (ABS/TCS) hydraulic unit (HU) and the system control strategy is essentially carried over from that of the current 323 (BJ), ecept for the following: — Input/output terminals of ABS (ABS/TCS) HU/CM have been changed. —...
  • Page 162 ABS/TCS System Diagram A6E6921T001 IG switch Cruise actuator SUS 15 A fuse TCS OFF switch (with TCS only) ABS 60 A fuse DLC-2 Meter CAN-H ABS warning light CAN-L Brake system warning light ABS Wheel-speed sensor TCS OFF light Battery TCS indicator light (with TCS only) Brake switch CAN driver...

  • Page 163: Dynamic Stability Control

    DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL OUTLINE A6E692067650T01 • The hydraulic pressure control mechanism in the DSC HU/CM and the system control strategy is essentially carried over from that of the previous 323 (1704-1*-00J), ecept for the following: — DSC unit and hydraulic unit has been integrated to improve service ability. —...
  • Page 164 DYNAMIC STABILITY CONTROL Components and Functions • The DSC system consists of the following components. Moreover, the function of common components in other systems as they are related to each DSC structural component is eplained in terms of DSC system functions.
  • Page 165 DYNAMIC STABILITY CONTROL System Diagram A6E6920T001 Wheel speed sensor Combine sensor Sensor rotor Audio unit, Wiper and washer switch, Car-navigation unit, Cruise actuator, and Auto leveling control unit Steering angle sensor Master cylinder DSC indicator light Electric signal DSC OFF light Brake fluid BRAKE system warning light CAN line...
  • Page 166 DYNAMIC STABILITY CONTROL Wiring Diagram A6E6920T005 P–12...
  • Page 167 DYNAMIC STABILITY CONTROL IG switch DLC-2 SUS 15A fuse CAN-H ABS 60 A fuse CAN-L Meter Wheel-speed sensor ABS warning light Combine sensor Brake system warning light Steering angle sensor DSC OFF light Brake switch DSC indicator light Brake light CAN driver Back-up light switch (MTX only) Battery...

  • Page 168: Dsc Off Switch, Dsc Off Light

    DYNAMIC STABILITY CONTROL DSC OFF SWITCH, DSC OFF LIGHT A6E692067650T15 Function • The DSC OFF switch is installed in the instrument panel and cancels the DSC activation by pressing the DSC OFF switch. • The DSC OFF light is integrated in the instrument cluster and notifies the driver of DSC activation is cancelled by pressing the DSC OFF switch.

  • Page 169: Combine Sensor

    DYNAMIC STABILITY CONTROL COMBINE SENSOR A6E692067650T05 Function • Yaw rate sensor and lateral-G sensor have been integrated to combine sensor. • The combine sensor is installed on the left side of the parking brake lever (L.H.D.), or right side of the parking brake lever (R.H.D.) and detects vehicle yaw rate (vehicle cornering angle velocity) and lateral G, and transmits the signal to the DSC HU/CM.

  • Page 170: Dsc Hu/Cm

    DYNAMIC STABILITY CONTROL DSC HU/CM A6E692067650T09 Function • The integrated DSC HU/CM, which is compact and lightweight, highly reliable has been adapted. • The DSC HU/CM calculates the input signal of each sensor and controls each solenoid valve and the pump motor (ON/OFF), adjusts fluid pressure to the caliper pistons, and activates each function of the DSC system (ABS, Electronic Brakeforce Distribution (EBD), TCS, DSC and electrical brake assist).

  • Page 171: Controller Area Network (Can

    DYNAMIC STABILITY CONTROL A6E6920T015 Normal brake mode Pressure-reduction solenoid valve Brake assist reduction mode Pump motor Master cylinder Traction switch solenoid valve Stability control solenoid valve Pump Pressure-retention solenoid valve caliper piston End Of Sie CONTROLLER AREA NETWORK (CAN) A6E692067650T17 •...

  • Page 172: On-Board Diagnostic

    A6E697067650T03 • The operation of the on-board diagnostic system for ABS (ABS/TCS) or DSC is essentially carried over from that of the previous 323 (BJ) model ecept for the following. (See Mazda 323 Workshop Manual Supplement 1704-1*-99H.) — Changed of DTC code, PID data monitor function, and active command function —...
  • Page 173 ON-BOARD DIAGNOSTIC Fail-safe Function • If a failure is detected in the self-diagnostic function, the fail-safe illuminates the ABS warning light, BRAKE system warning light, DSC indicator light, and/or TCS (DSC) OFF light to notify the driver. At the same time, the ABS (ABS/TCS) or DSC HU/CM controls the ABS, EBD, TCS, DSC and brake assist.
  • Page 174 C1194 C1198 C1210 C1214 C1242 C1246 Illuminated Illuminated Illuminated Solenoid valve Stop Stop Stop Stop Stop *6, 7 *7, 8 illuminated C1250 C1254 C1400 C1410 C1957 C1958 DSC HU/CM Availa- C1140 Stop (pump) illuminated illuminated Solenoid valve,...
  • Page 175 : If a malfunction was detected in the previous driving mode, the light remains illuminated until the system is verified to be normal when the vehicle is driven at a speed of 10 km/h {6.2 mph} or more. : The warning light does not illuminates only during stability control solenoid valve or traction switch solenoid valve off stuck malfunction.
  • Page 176 ON-BOARD DIAGNOSTIC PID/DATA Monitor Function • This function allows access to certain data values, input signal, calculated values, and system status information. PID/DATA monitor table Operation/unit PID name Input/output part (WDS or equivalent) ABS_LAMP ABS warning light driver output state ON/OFF ABSLF_ I LF ABS pressure retention valve output state...
  • Page 177 ON-BOARD DIAGNOSTIC Active Command Modes Function • This function allows control of devices through the WDS or equivalent. Active Command Modes Table Command Name Definition Operation Note RF_DSC_V Stability control solenoid valve (RF-LR) ON/OFF LF_DSC_V Stability control solenoid valve (LF-RR) ON/OFF ABS_POWER Fail-safe relay...
  • Page 178 OUTLINE ..............R-2 OUTLINE OF CONSTRUCTION......R-2 FEATURES ............R-2 SPECIFICATIONS ..........R-3 SUSPENSION DESCRIPTION ......R-4 FRONT SUSPENSION ...........R-5 OUTLINE..............R-5 STRUCTURAL VIEW...........R-5 FRONT SUSPENSION DESCRIPTION....R-6 FRONT SHOCK ABSORBER AND COIL SPRING ...........R-9 FRONT CROSSMEMBER .........R-10 REAR SUSPENSION ...........R-11 OUTLINE............R-11 STRUCTURAL VIEW.........R-11 REAR SUSPENSION DESCRIPTION ....R-12 REAR CROSSMEMBER........R-13...

  • Page 179: Abbreviations

    ABBREVIATIONS , OUTLINE ABBREVIATIONS ABBREVIATIONS A6E740101013T01 Left front Left rear Right front Right hand Right rear 4 door sedan 5 door hatchback End Of Sie OUTLINE OUTLINE OF CONSTRUCTION A6E740201013T01 • Both front and rear suspension systems, unique to the Mazda6 (GG) model, have been adopted as follows. —...

  • Page 180: Specifications

    OUTLINE SPECIFICATIONS A6E740201013T03 Specification Item Mazda6 (GG) (4SD, 5HB) 626 (GF) (4SD, 5HB) High-mount double wishbone Type (with double-pivoted lower Strut arm(s)) Spring type Coil spring Cylindrical, double-acting (Low- Cylindrical, double-acting Shock absorber type pressure gas charged with (Low-pressure gas charged) rebound spring) Type Torsion bar...

  • Page 181: Suspension Description

    OUTLINE SUSPENSION DESCRIPTION A6E740201013T04 Vehicle Platform Feature • The newly developed platform of Mazda6 (GG) model is 50 mm wider than the platform of the 626 (GF) model. This feature gives a benefit equivalent to that of a 20 mm {0.79 in} reduction in the vehicle's center of gravity. As a result, handling stability and cornering capability are improved.

  • Page 182: Front Suspension

    FRONT SUSPENSION FRONT SUSPENSION OUTLINE A6E741401015T01 • A high-mount double wishbone (with double-pivoted lower arm(s)) front suspension, unique to the Mazda6 (GG) model, has been adopted. • The front suspension design includes a link layout that provides both handling stability and riding comfort, and creates suitable camber control characteristics.

  • Page 183: Front Suspension Description

    King-pin ais High-mount double wishbone front suspension King-pin inclination Strut front suspension (626 (GF) model) King-pin offset View from horizontal ais of the vehicle King-pin to wheel-center offset View from vertical ais of the vehicle Wheel center Front Imaginary pivot R–6...
  • Page 184 FRONT SUSPENSION Camber Control • The camber change during a front suspension stroke is properly controlled by optimizing the ratio of the front upper arm and the front lower arm(s) lengths. Camber control characteristic comparison Rebound stroke area Bump stroke area Camber angle (°) Wheel stroke (mm) Vehicle roll angle (°)
  • Page 185 FRONT SUSPENSION Front Lower Arm (Rear) • An oil-filled bushing is used with the front lower arm (rear) to reduce vibrations such as shimmy, judder, and road noise. A6E7414T005 RH front lower arm (rear) Cross-section A—A Vertical view Oil-filled bushing Horizontal view Front End Of Sie...

  • Page 186: Front Shock Absorber And Coil Spring

    FRONT SUSPENSION FRONT SHOCK ABSORBER AND COIL SPRING A6E741434700T01 Outline • A rebound spring is included in the shock absorber which controls the increase in the spring rate to improve handling stability and rolling feeling when cornering, thereby improving riding comfort. •...

  • Page 187: Front Crossmember

    FRONT SUSPENSION FRONT CROSSMEMBER A6E741434400T01 Outline • A perimeter frame structure type front crossmember has been adopted to increase rigidity. • The main parts of the front crossmember are made from a high-tension steel by hydro-formed process to improve strength without increasing weight. •...

  • Page 188: Rear Suspension

    REAR SUSPENSION REAR SUSPENSION OUTLINE A6E741601016T01 • An E-type multi-link rear suspension, unique to the Mazda6 (GG) model, has been adopted. • The rear suspension design includes a link layout that provides both handling stability and riding comfort, and creates suitable camber control characteristics. •...

  • Page 189: Rear Suspension Description

    REAR SUSPENSION REAR SUSPENSION DESCRIPTION A6E741601016T03 Camber Control • The camber change during a suspension stroke of the E-type multi-link rear suspension is properly controlled by optimizing the ratio of the rear lower arm and the rear upper arm. Camber control characteristic comparison Rebound stroke area Bump stroke area Camber angle (°)

  • Page 190: Rear Crossmember

    REAR SUSPENSION REAR CROSSMEMBER A6E741628400T01 Outline • The rear crossmember main frame is made from a steel pipe, improving strength without increasing weight. • To reduce the noise from the suspension system to the body, rubber mounts are used at the four connecting points of ther ear crossmember to the body.

  • Page 191: Wheel And Tire

    WHEEL AND TIRE WHEEL AND TIRE OUTLINE A6E741701014T01 • In consideration of the environment, an adhesive-type balance weight made of steel has been adopted to reduce amount of lead used in the vehicle (16-inch and 17-inch aluminum alloy wheel). • An adhesive-type balance weight is fastened on the inner side of the wheel. Since it is not visible from the styled side of the wheel, the design of the wheel is favored.
  • Page 192 OUTLINE..............S-3 STRUCTURAL VIEW...........S-3 POWER WINDOW SYSTEM ........S-4 OUTLINE..............S-4 STRUCTURAL VIEW...........S-4 SYSTEM WIRING DIAGRAM ......S-5 DRIVER SIDE POWER WINDOW SYSTEM ..S-6 POWER WINDOW MOTOR ........ S-7 POWER DOOR LOCK SYSTEM ......S-8 OUTLINE..............S-8 STRUCTURAL VIEW...........S-8 SYSTEM WIRING DIAGRAM ......S-9 KEYLESS ENTRY SYSTEM........

  • Page 193: Outline

    OUTLINE OUTLINE ABBREVIATION A6E770201086T01 Battery positive voltage Ignition L.H.D. Left hand drive Motor P/W CM Power window control module SEC. Section 4 door sedan 5 door hatchback End Of Sie OUTLINE OF CONSTRUCTION A6E770201086T02 • The construction and operation of the body system is essentially carried over from that of the current PREMACY (CP) model, ecept for the following features.

  • Page 194: Door

    DOOR DOOR OUTLINE A6E771458010T01 • A ripple-shaped side impact bar has been adopted to improve rigidity in case of a collision. • The inner construction of the door, including the power window regulator, inner handle, door speaker, harness and others, have been integrated into a single door unit. •...

  • Page 195: Power Window System

    POWER WINDOW SYSTEM POWER WINDOW SYSTEM OUTLINE A6E771658000T01 • The function, structure and operation of power window system is essentially carried over from that of the current PREMACY (CP) model, ecept for the following. — The driver-side power window system, which previously operated on the basis of the limit switch and the pulse signal, has been changed to a system that operates on the basis of two kinds of pulse signals.

  • Page 196: System Wiring Diagram

    POWER WINDOW SYSTEM SYSTEM WIRING DIAGRAM A6E771658000T03 A6E7716T001 Power window main switch Hall effect switch No. 1 Manual close Hall effect switch No. 2 Manual open Front power window motor (Passenger’s side) Auto Rear power window motor (Right side) Power-cut switch Rear power window motor (Left side) Close With rear power window system...

  • Page 197: Driver Side Power Window System

    W main switch. Hall effect switches No. 1 and No. 2 operation malfunction • Hall effect switches No. 1 and No. 2 pulse signal not detected after down movement was initiated from the fully closed position. End Of Sie S–6...

  • Page 198: Power Window Motor

    POWER WINDOW SYSTEM POWER WINDOW MOTOR A6E771658000T05 Structure and Operation • The power window motor consists of a motor, connector and gear. • Two Hall effect switches are set in the connector. • The Hall effect switch utilizes magnets set on a rotating ais to sense the power window motor rotation, and outputs a synchronized pulse to the power window main switch.

  • Page 199: Power Door Lock System

    POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM OUTLINE A6E771866000T01 • The keyless unit and the door lock timer unit have been integrated. • The power door lock system has the following functions. These functions are the same as those of current MPV (LW).

  • Page 200: System Wiring Diagram

    POWER DOOR LOCK SYSTEM SYSTEM WIRING DIAGRAM End Of Sie A6E771866000T03 A6E7718T002 Door lock timer unit Security light Door lock actuator With double locking system • Trunk lid lock actuator (4SD) Without double locking system • Liftgate lock actuator (5HB) Driver’s side Key cylinder switch Passenger’s side...

  • Page 201: Liftgate Lock Actuator

    POWER DOOR LOCK SYSTEM End Of Sie LIFTGATE LOCK ACTUATOR A6A771862310T01 Outline • Models equipped with the keyless entry system do not have a liftgate key cylinder. If there are malfunctions in the keyless entry system with the liftgate locked, the liftgate cannot be unlocked. Instead, the liftgate lock actuator can be unlocked manually from a newly- adopted access hole on the liftgate lower trim.

  • Page 202: Outside Mirror

    OUTSIDE MIRROR OUTSIDE MIRROR OUTLINE A6E773269110T01 • The function, structure and operation is the same as that of the current PREMACY (CP) model. (See PREMACY Training Manual 3336-1*-99C.) End Of Sie STRUCTURAL VIEW A6E773269110T02 A6E7732T001 Power outside mirror switch Power outside mirror Heated filament End Of Sie SYSTEM WIRING DIAGRAM...

  • Page 203: Rear Window Defroster

    REAR WINDOW DEFROSTER REAR WINDOW DEFROSTER OUTLINE A6E773663000T01 • The function, structure and operation is the same as that of the current PREMACY (CP) model. End Of Sie STRUCTURAL VIEW A6E773663000T02 A6E7736T002 Rear window defroster relay Rear window defroster switch Heated outside mirror Climate control unit (full auto air conditioner type)

  • Page 204: System Wiring Diagram

    REAR WINDOW DEFROSTER SYSTEM WIRING DIAGRAM A6E773663000T03 A6E7736T001 DEFOG 40 A fuse Rear defroster switch METER IG 15 A fuse Rear defroster indicator light Rear defroster relay Rear window defroster Climate control unit Heated outside mirror Microcomputer End Of Sie S–13...

  • Page 205: Outline

    SLIDING SUNROOF SLIDING SUNROOF OUTLINE A6E774001049T01 • The construction and operation (slide open/close and tilt up/down) are the same as the 626 (GF) 5HB model. ×: Available –: Not available Item Mazda6 (GG) 626 (GF) 5HB Slide open/close function × ×...

  • Page 206: System Wiring Diagram

    SLIDING SUNROOF SYSTEM WIRING DIAGRAM A6E774001049T03 A6E7740T002 Sunroof switch Sunroof motor Sunroof relay Slide open Motor control circuit Slide close Motor lock current detection circuit Tilt down Relay Tilt up Limit switch No. 1 Slide open/tilt down Limit switch No. 2 Slide close/tilt up Limit switch No.

  • Page 207: Dashboard And Console

    DASHBOARD AND CONSOLE DASHBOARD AND CONSOLE OUTLINE A6E774255000T01 • The center module, which integrates the audio and climate control units, is located at the center of the dashboard panel. This improves the functionality and gives it a unified appearance. • Various storage spaces have been kept. End Of Sie STRUCTURAL VIEW A6E774255000T02...

  • Page 208: Seat

    SEAT SEAT OUTLINE A6E775257100T01 Front Seat • Three types of seats are available: — Manual seat with seat lifter (driver’s side) — Manual seat without seat lifter (passenger’s side) — Power seat • A lumber support has been adopted for driver’s seat. Rear seat •...
  • Page 209 SEAT FRONT SEAT A6E775257100T03 Outline • Three types of seats are available. — Manual seat with seat lifter (Driver’s side) — Manual seat without seat lifter (Passenger’s side) — Power seat (Driver’s side) • A lumber support has been adopted for driver’s seat. •...
  • Page 210 SEAT Structural View A6E7752T003 Rear seat (4SD) Tether strap anchor (5HB) Rear seat (5HB) Remote handle lever (4SD) ISOFIX anchor Remote handle lever (5HB) Tether strap anchor (4SD) Push knob (5HB) End Of Sie S–19...

  • Page 211: Easy Fold-Down Function

    SEAT EASY FOLD-DOWN FUNCTION A6E775257200T02 Outline • Operating the remote handle lever or the push knob (5HB only), automatically folds down the seat for etra cargo space. Operation 1. When the remote handle lever is operated, the seat back catch unlocks via the wire. 2.
  • Page 212 SEAT 1. When the remote handle lever or push knob is operated, the seat back catch unlocks via the wire. 2. The unlocked seat back folds forward under its own weight. 3. Continuing to press the seat back down causes the seat cushion hinge to fold in and the seat back to slide forward into the lower recess.

  • Page 213: Body Shell

    BODY SHELL BODY SHELL OUTLINE A6E775407000T01 • The body shell has been designed to increase vehicle structural rigidity and reduce shock to the body, thus improving safety. • The crushable zone, an H-shaped frame (triple-H structure), absorbs impact energy and prevents it from reaching the occupants.

  • Page 214: Crushable Zone

    BODY SHELL CRUSHABLE ZONE A6E775407000T03 • To reduce cabin damage, the front and rear of the frame are designed to deform when incurring an impact, and effectively absorb/disperse energy from a collision. — In moderate collisions at the front bumper reinforcement, impact is diffused to the front side frames and front suspension members.

  • Page 215: Cabin

    BODY SHELL CABIN A6E775407000T04 • The floor, the side frame and the roof form three rigid, H-shaped frames (triple-H structure) that resist impact forces in the event of a side collision. • Handling stability is improved by preventing body torsion. A6E7754T003 Roof reinforcement Crossmember No.

  • Page 216: Front Bumper Reinforcement

    BODY SHELL FRONT BUMPER REINFORCEMENT A6E775450031T01 Outline • A large sectional form has been adopted for improved strength. • The frame and connection area have adopted a crushable structure. At low-speed collisions, impact is absorbed and diffused, reducing impact to the frame and other parts. Structural View A6E7754T005 Front bumper reinforcement...
  • Page 217 BASE UNIT ............T-58 OUTLINE ............. T-5 AUTO LEVEL CONTROL (ALC) FUNCTION ..T-59 STRUCTRURAL VIEW ........T-5 ON-BOARD DIAGNOSTIC SYSTEM SYSTEM WIRING DIAGRAM ......T-6 (AUDIO SYSTEM)........... T-59 MECHANISM OF CAN SYSTE-RELATED OUTLINE (CAR-NAVIGATION SYSTEM) ..T-63 MODULE............T-6 STRUCTURAL VIEW (CAR-NAVIGATION TWIST PAIR ............

  • Page 218: Abbreviations

    ABBREVIATIONS ABBREVIATIONS ABBREVIATIONS A6E810101088T01 Antilock brake system Accessories Auto level control Automatic transale Controller area network Control module Central processing unit Drive information system Daytime running light Dynamic stability control Diagnostic trouble code Electronic brakeforce distribution Engine coolant temperature Global positioning system High Hydraulic unit Ignition...

  • Page 219: Outline

    OUTLINE OUTLINE OUTLINE OF CONSTRUCTION A6E810201088T01 • The construction and operation of the body electrical system is essentially carried over from that of the 626 (GF) model, ecept the following features. End Of Sie FEATURES A6E810201088T02 Improved Serviceability • A controller area network (CAN) system has been adopted for communication between the PCM, ABS (ABS/ TCS) HU/CM or DSC HU/CM, and instrument cluster.

  • Page 220: Power System

    POWER SYSTEM POWER SYSTEM RELAY LOCATION A6E811067730T01 A6E8110T102 Main relay Cooling fan relay No.2 Headlight relay Horn relay TNS relay Cooling fan relay No.3 Cooling fan relay No.1 Stater relay Headlight cleaner relay Cooling fan relay No.4 Front fog light relay Woofer relay Fuel pump relay Rear window defroster relay...

  • Page 221: Mulitiple Communication System

    MULITIPLE COMMUNICATION SYSTEM End Of Sie MULITIPLE COMMUNICATION SYSTEM OUTLINE A6E811155430T01 • Due to the simplification of the wiring harness, a controller area network (CAN) system for transmission of multiple input/output signals among electrical modules has been adopted. • Twisted-pair wiring is used for connections between the following modules (Each electrical module hereafter referred to as a CAN system-related module): —...

  • Page 222: System Wiring Diagram

    Transmits to computation processing block data received from bus line. In addition, sends to bus line transmitted data stored from computation processing block. Input/Output interface Electrically converts information signals from switches practically input to CPU, and signals output from CPU for operating actuator or indicator lights. T–6...
  • Page 223 MULITIPLE COMMUNICATION SYSTEM A6E8111T003 Input signal Conventional module Output signal CAN harness Connector Conventional wiring harness Input interface Multiple block Output interface Computation processing block CAN system-related module End Of Sie TWIST PAIR A6E811155430T05 • The multichannel use two spirally twisted wires called the twist pair, and each wire, bus line A and bus line B, has its own special function.

  • Page 224: Can System Outline

    MULITIPLE COMMUNICATION SYSTEM CAN SYSTEM OUTLINE A6E811155430T06 Time Division Multiple • For information echange between the electrical modules in the conventional system, a wire connection was necessary for each information signal. However, by sending the different signal at varying times over one channel, it is possible to send a large amount of information via a small harness.

  • Page 225: Can Signal-Chart

    MULITIPLE COMMUNICATION SYSTEM CAN SIGNAL-CHART End Of Sie A6E811155430T08 OUT: Output (sends signal) IN: Input (receives signal) Multiple module Audio unit Signal ABS (ABS/TCS) HU/ Instrument cluster (information CM or DSC HU/CM display) Engine condition Torque reduction inhibit Engine speed Wheel speed With ABS (ABS/ (front left/front...

  • Page 226: On-Board Diagnostic Function

    MULITIPLE COMMUNICATION SYSTEM ON-BOARD DIAGNOSTIC FUNCTION A6E811155430T09 Outline • The on-board diagnostic function is incorporated into the PCM, ABS (ABS/TCS) HU/CM (with ABS (ABS/ TCS)), DSC HU/CM (with DSC), and instrument cluster. This function can narrow down CAN system malfunction locations. •...
  • Page 227 MULITIPLE COMMUNICATION SYSTEM Self-Malfunction Diagnostic Function • The self-malfunction diagnostic function determines that there is a malfunction, and outputs a signal, as a DTC, to the DLC-2. The DTC can be read out using an SST (WDS or equivalent). DTC table Malfunction location Related module U0073...
  • Page 228 MULITIPLE COMMUNICATION SYSTEM Flowchart A6E8111TH01 Eample (Open circuit in PCM-related wiring harness) A6E8111T008 Instrument cluster Twist pair Circuit open Note • This eample is for vehicles not equipped with a TCS or DSC. 1. DTCs for the PCM, ABS HU/CM and instrument cluster can be verified using a SST (WDS or equivalent). Module Displayed DTC Probable malfunction location...

  • Page 229: Exterior Lighting System

    MULTIPLE COMMUNICATION SYSTEM, EXTERIOR LIGHTING SYSTEM 2. PID/data monitor information for the PCM, ABS HU/CM can be verified using an SST (WDS or equivalent). Module PID name (definition) Condition Probable malfunction point PCM MSG Not Present Communication error between ABS HU/CM and PCM (Missing message from the PCM) ABS HU/CM IC MSG...

  • Page 230: Structural View

    EXTERIOR LIGHTING SYSTEM STRUCTURAL VIEW A6E811201052T02 A6E8112T102 High-mount brake light Front combination light High-mount brake light (rear spoiler type) Rear combination light Steering angle sensor (with DSC) Inboard combination light Disc (with DSC) Front side turn light License plate light End Of Sie T–14...

  • Page 231: Discharge Headlight

    EXTERIOR LIGHTING SYSTEM FRONT COMBINATION LIGHT A6E811201052T03 Outline • Projector type headlights (low-beam) and front fog lights have been adopted, and these have been incorporated, along with the front turn light and the parking light, into a single unit to improve size reduction. •...

  • Page 232: Discharge Headlight Control Unit

    EXTERIOR LIGHTING SYSTEM Structre And Operation 1. The high voltage pulse (alternating current appro. 25,000 V) traveling from the discharge headlight control unit is applied between both discharge headlight bulb terminals, energizing the enon gas in the bulb. 2. Based on the energizing of the enon gas, the temperature of the discharge headlight bulb interior increases, vaporizing the mercury and discharging the arc.

  • Page 233: Headlight Auto Leveling System

    EXTERIOR LIGHTING SYSTEM Failure Detection Function Abnormal input detection function • If the discharge headlight control unit input voltage (9—16 V) fails to maintain operational voltage (ecept for the drop in voltage immediately after the headlights are turned on), the discharge headlight control unit turns off the headlights for protection or to prevent part operation errors.
  • Page 234 EXTERIOR LIGHTING SYSTEM Varying Passenger And Cargo Conditions Operation 1. According to the fluctuation of the suspension, the auto leveling sensors installed in the front and rear of the vehicle send a signal to auto leveling control unit (main). 2. When a difference between two of the signal inputted from the auto leveling sensors is detected, the auto leveling control unit (main) verifies the vehicle attitude, then calculates the amount of optical ais adjustment and sends signal to the auto leveling control unit (sub).
  • Page 235 EXTERIOR LIGHTING SYSTEM A6E8112T118 A6E8112T119 Vehicle attitude Zero setting Acceleration degree calculation Acceleration Change in vehicle speed Deceleration Optical ais adjustment amount Auto leveling control unit (main) Optical ais Auto leveling control unit (sub) Zero reference Front auto leveling sensor High Rear auto leveling sensor Headlight leveling actuator (LH)

  • Page 236: Auto Leveling Control Unit

    EXTERIOR LIGHTING SYSTEM End Of Sie AUTO LEVELING CONTROL UNIT A6E811201052T07 Function • In order to prevent the blinding of oncoming traffic and improve visibility, the auto leveling control units automatically control the optical ais direction for optimal illumination based on signal inputted from the ABS (DSC) HU/CM and the auto leveling sensor.

  • Page 237: Running Light System

    EXTERIOR LIGHTING SYSTEM RUNNING LIGHT SYSTEM A6E811201052T08 Outline • The running light system operates the low-beam headlight and TNS automatically when the ignition switch turns on. It is controlled by the running light unit. System Diagram A6E8112T122 Parking light/taillight/license plate light Running light unit Front fog light relay Relay A...
  • Page 238 EXTERIOR LIGHTING SYSTEM System Operation When the ignition switch turns to on: 1. Two transistors are turned on with current (1) flowing in transistor 1, and current (2) in transistor 2. 2. When transistors 1 and 2 are on, the headlight relay and TNS relay turn on, and the headlights (low-beam), parking lights/taillights/license plate light illuminate.
  • Page 239 EXTERIOR LIGHTING SYSTEM When the ignition switch is at ON and the headlight switch is at TNS position: 1. When the headlight switch is turned to the TNS position, battery voltage from the TNS relay flows from the headlight switch to the ground, and the TNS relay is turned on. 2.
  • Page 240 EXTERIOR LIGHTING SYSTEM When the ignition switch is at ON and when the flash-to-pass is on: 1. When the headlight switch is turned to the flash-to-pass position, battery voltage from the headlight relay flows from the headlight switch to the ground, and the headlight relay is turned on. 2.

  • Page 241: Rear Combination Light And Inboard Combination Light

    EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT AND INBOARD COMBINATION LIGHT A6E811201052T09 Outline • A step reflector that diffuses and reflects the light of the rear combination and inboard combination light bulbs, has been adopted. A flat, uncut lens has been adopted to control illumination distribution. •...

  • Page 242: Interior Lighting System

    INTERIOR LIGHTING SYSTEM INTERIOR LIGHTING SYSTEM STRUCTURAL VIEW A6E811401052T01 A6E8114T101 Courtesy light Front map light (with sliding sunroof) Ignition key illumination Front map light (without sliding sunroof) Cargo compartment light Rear map light Trunk compartment light Glove compartment light Ashtray illmination light End Of Sie T–26...

  • Page 243: Outline

    INTERIOR LIGHTING SYSTEM OUTLINE A6E811401052T02 • The interior lights are shown below. • The interior light control system turns on, turns off, or dims the interior light when the interior light switch is in the DOOR position. ×: Equipped —: Not equipped Installation Interior light Type...

  • Page 244: Interior Light Control System

    INTERIOR LIGHTING SYSTEM INTERIOR LIGHT CONTROL SYSTEM A6E811401052T03 System Diagram A6E8114T102 Door lock timer unit Door switch Key reminder switch Door lock-link switch Front map light Lock Rear map light Unlock Courtesy light DOOR T–28...
  • Page 245 INTERIOR LIGHTING SYSTEM System Operation • The interior light switch must be at DOOR position. Interior light Condition before operation Cancel condition (When any (When all conditions are Operation condition Illumination condition is safisfied) Brightness satisfied) time • Ignition switch at LOCK or •...

  • Page 246: Wiper And Washer

    INTERIOR LIGHTING SYSTEM, WIPER AND WASHER Timing Chart A6E8114T103 Door lock-link switch View A Door switch Appro. 30 seconds Key reminder switch Appro. 15 seconds Appro. 1 seconds Front map light, Rear map light, courtesy light Appro. 5 minutes Lock 100% Unlock End Of Sie...
  • Page 247 WIPER AND WASHER STRUCTURAL VIEW A6E811601052T02 A6E8116T101 Headlight cleaner motor Windshield wiper arm and blade Headlight cleaner nozzle Windshield wiper motor Headlight cleaner hose Windshield washer nozzle Headlight cleaner switch Washer tank Rear wiper arm and blade (5HB) Windshield washer motor Rear wiper motor (5HB) Rear washer motor (5HB) Rear washer nozzle (5HB)

  • Page 248: Structural View

    2. Based on the vehicle speed signal sent from the ABS (DSC) HU/CM, the intermittent wiper relay controls the timing is as follows: • Vehicle speed of 0 km/h: — INT volume ma.—appro. once each 11.6 seconds — INT volume min. —appro. once each 4.2 seconds • Vehicle speed of 30 km/h and above: —...
  • Page 249 WIPER AND WASHER A6E8116T105 INT volume ma. Vehicle speed (km/h) INT volume min. Time (S) A6E8116T103 Intermittent wiper relay Washer switch Wiper and washer switch Autostop switch One-touch switch Windshield wiper motor Windshield washer motor INT volume ABS/TCS HU/CM or DSC HU/CM Wiper and washer switch RH side Wiper switch T–33...
  • Page 250 WIPER AND WASHER 3. When the controlled intermittent time is passed, the intermittent wiper relay is turned off, stopping the flow of current to the windshield wiper motor, and the autostop function returns the wipers to the resting position. This action is repeated intermittently.

  • Page 251: Warning And Indicator System

    WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR SYSTEM OUTLINE A6E811801069T01 • A CAN system has been adopted for the control signals of the input/output communication circuit of the meters, gauges and warning and indicator lights. (See T–5 OUTLINE.) • LEDs have been adopted for all warning and indicator lights installed on the instrument cluster. •...
  • Page 252 Input signal communication system CAN system temperature Input signal source gauge Rated voltage DC 12 Display Indication digits Odometer: 6 digits, Tripmeter: 4 digits Input signal communication system CAN system Odometer/ Vehicles with ABS (ABS/TCS) ABS (ABS/TCS) HU/CM Tripmeter HU/CM Input signal...

  • Page 253: System Wiring Diagram

    WARNING AND INDICATOR SYSTEM SYSTEM WIRING DIAGRAM A6E811855430T02 A6E8118T002 Key reminder switch Cruise main indicator light Ignition key illumination To PCM, ABS (ABS/TCS) HU/CM (with (ABS/TCS)) or DSC HU/CM (with DSC) Speedometer Audio unit Tachometer Panel light control switch Fuel gauge Fuel gauge sender unit Water temperature gauge Brake fluid-level sensor...
  • Page 254 WARNING AND INDICATOR SYSTEM A6E8118T003 Turn switch Turn indicator light (left) Flasher unit Turn indicator light (right) Hazard warning switch Front fog light indicator light Turn light (left) Rear fog light indicator light Turn light (right) Instrument cluster illumination Front fog light relay DSC/TCS indicator light Front fog light switch DSC OFF light...

  • Page 255: Input/Output Check Mode

    WARNING AND INDICATOR SYSTEM INPUT/OUTPUT CHECK MODE A6E811855430T03 • The microcomputer built into instrument cluster detects the quality of input signal or individual part. • Input/output check mode has both input circuit check and individual part check functions. • The operating order of the input/output check mode is the same as that of the current MPV (LW) model. •...

  • Page 256: Drive Information System

    WARNING AND INDICATOR SYSTEM DRIVE INFORMATION SYSTEM A6E811801069T02 Outline • The microcomputer in the instrument cluster calculates ambient temperature data, distance driven and specified time data, fuel consumption data, and fuel remaining data according to signal from signal source. • Using these data, the microcomputer displays the following in the information display; —...
  • Page 257 WARNING AND INDICATOR SYSTEM Operation Drive information system switch • The drive information system switch comprises an INFO switch. • The modes can be charged in a cyclic pattern by pressing the INFO switch. A6E8118T202 • The data displayed at the time can be reset by holding the INFO switch for 1 second or more. Data are calculated as soon as the INFO switch is released.
  • Page 258 WARNING AND INDICATOR SYSTEM Average fuel economy mode • Average fuel economy is calculated from trip distance and fuel consumption since the time when the battery is connected or the average fuel economy data is reset. • Average fuel economy is updated every 1 minute. Calculation Average fuel economy (L/100 km or L/100 mile)= Cumulative fuel consumption (L) / Cumulative trip distance (km or mile) ×...
  • Page 259 THEFT-DETERRENT SYSTEM THEFT-DETERRENT SYSTEM OUTLINE A6E812050000T01 • The theft-deterrent system includes sound and light alarms that activate when the bonnet, the trunk lid (4SD) or liftgate (5HB), or a door is opened by means other than the transmitter. The turn lights flash and the horn and the theft-deterrent siren sound.
  • Page 260 THEFT-DETERRENT SYSTEM End Of Sie SYSTEM WIRING DIAGRAM A6E812050000T03 A6E8120T001 Theft-deterrent control module Door switch (driver’s side) Key reminder switch Door switch (ecept driver’s side) Flasher unit Passenger’s door lock-link switch Turn light Rear door lock-link switch (right) Hazard warning switch Rear door lock-link switch (left) Door lock timer unit Trunk compartment light switch (4SD)

  • Page 261: System Flowchart

    THEFT-DETERRENT SYSTEM SYSTEM FLOWCHART A6E812050000T04 A6E8120T007 End Of Sie T–45...

  • Page 262: Theft-Deterrent Siren

    THEFT-DETERRENT SYSTEM THEFT-DETERRENT SIREN A6E812050000T05 • The theft-deterrent siren is located on the rear, left side of the trunk lid (4SD) or liftgate (5HB). • Controlled by the following vehicle conditions: — Standard alert control — Open circuit alert control Standard Alert Control •...

  • Page 263: Intruder Sensor

    THEFT-DETERRENT SYSTEM INTRUDER SENSOR A6E812050000T06 Outline • The intruder sensor is located in center part of the roof on sliding sunroof-equipped vehicles or the forward part of the roof on sliding sunroof non-equipped vehicles. • The intruder sensor detects movement in the vehicle by radio waves and sends the detection signal to the theft-deterrent control module.

  • Page 264: Immobilizer System

    IMMOBILIZER SYSTEM End Of Sie IMMOBILIZER SYSTEM OUTLINE A6E812267000T01 • The immobilizer system is essentially carried over from that of the current TRIBUTE (BU/CU/YU) model’s passive anti-theft system (PATS). However, some items have been changed and/or added to improve security. Refer to the following table.

  • Page 265: System Wiring Diagram

    IMMOBILIZER SYSTEM, AUDIO AND NAVIGATION SYSTEM SYSTEM WIRING DIAGRAM A6E812267000T03 A6E8122T002 Instrument cluster Coil Security light Key (transponder) End Of Sie AUDIO AND NAVIGATION SYSTEM OUTLINE (AUDIO SYSTEM) A6E812401066T01 • The center panel module installed with the audio unit and climate control unit (automatic A/C only), and the audio switch, A/C switch, hazard warning switch and rear window defroster switch built into the center panel has been adopted.

  • Page 266: Structural View (Audio System

    AUDIO AND NAVIGATION SYSTEM STRUCTURAL VIEW (AUDIO SYSTEM) A6E812401066T02 A6E8124T013 Center panel module (built-in audio unit) Audio amplifier (BOSE) Audio control switch Condenser Tweeter (BOSE) Woofer (BOSE) Woofer relay (BOSE) Noise filter (rear window defroster) Noise filter (brake switch) Center roof antenna Antenna feeder Glass antenna Front door speaker...
  • Page 267 AUDIO AND NAVIGATION SYSTEM BLOCK DIAGRAM (AUDIO SYSTEM) A6E812401066T03 A6E8124T019 Audio control switch Audio amplifier TNS signal Woofer relay Vehicle speed signal Tweeter (left) Information display Front door speaker (left) Center panel module (built-in audio unit) Front door speaker (right) Audio control circuit Tweeter (right) Antenna...

  • Page 268: Specifications (Audio System

    AUDIO AND NAVIGATION SYSTEM SPECIFICATIONS (AUDIO SYSTEM) A6E812401066T04 Audio Unit Specification Item BOSE Standard Type A Type B Type C Type D Rated voltage (kHz) 153—279 — Frequency (kHz) 531—1602 522—1629 530—1620 band (MHz) 87.5—108.0 Information system — 25×4 Audio amplifier maimum (Eternal type audio 25×4 output power...
  • Page 269 AUDIO AND NAVIGATION SYSTEM CENTER PANEL MODULE A6E812466900T01 Outline • The center panel module is composed of the installed audio unit and climate control unit (automatic A/C only) with the audio switch, A/C switch, hazard warning switch, and rear window defroster switch built into the center panel.
  • Page 270 AUDIO AND NAVIGATION SYSTEM Terminal Layout and Signal Audio unit Terminal Signal Left front speaker (+) B+ (Power back up) Left front speaker (–) Right front speaker (+) Illumination (+) Right front speaker (–) Illumination (–) — Vehicle speed signal AMP.
  • Page 271 AUDIO AND NAVIGATION SYSTEM Information display harness Terminal Signal LCD DRV+ LCD PL+ Switch check LCD DATA LCD AC LCD RS LCD CS LCD CLK LCD RST Illumination (+) Digital ground Digital ground Power ground Power ground Circuit board (manual A/C only) Terminal Signal Ground...
  • Page 272 AUDIO AND NAVIGATION SYSTEM Climate control unit (auto A/C only) Terminal Signal Blower motor feedback +5 V Blower motor control — Rear window defroster relay On-board diagnostic Wiper deicer relay — Sensor ground HNTI A/C ambient temperature sensor HNTI Cabin temperature sensor —...
  • Page 273 Preset button “4” Audio system AM button Audio system Preset button “5” Audio system CD button Audio system Preset button “6” Audio system TAPE/MD button Audio system Rear window defroster switch Rear window (auto A/C) defroster system SEEK button (upper) (type A)

  • Page 274: Base Unit

    AUDIO AND NAVIGATION SYSTEM AUDIO UNIT A6E812466900T02 Outline • The audio unit is composed of the base unit, upper module, and lower module. • Upper and lower module availability depends on vehicle grade. • The construction and operation of upper module and lower module are the same as that of current XEDOS 9, MILLENIA (TA) models.

  • Page 275: Auto Level Control (Alc) Function

    AUDIO AND NAVIGATION SYSTEM AUTO LEVEL CONTROL (ALC) FUNCTION A6E812466900T04 Function • Adjusts the audio volume so that the sound is balanced against wind and road noise while driving. Operation • The audio unit changes the volume automatically based on the vehicle speed signal sent from the instrument cluster.
  • Page 276 AUDIO AND NAVIGATION SYSTEM Memory function • The memory function detects a malfunction, changes it to a DTC, and stores it in the memory. The memory can store a maimum of three DTCs. If another malfunction is detected when three DTCs are already stored, the memory function clears the oldest DTC and stores the new one.
  • Page 277 AUDIO AND NAVIGATION SYSTEM Screen display Malfunction location Output signal 09:Er22 — Base unit (peripheral circuit) 09:Er20 — Power supply circuit of base unit 00:Er10 — Cassette deck—base unit communication line 03:Er10 — CD player—base unit communication line 05:Er10 — CD changer (eternal type)—base unit communication line 06:Er10 —...
  • Page 278 AUDIO AND NAVIGATION SYSTEM Switch • The diagnostic assist function sounds the buzzer when the switches are pressed to check the switches. A6E8124T010 Speaker • The diagnostic assist function outputs sound to the speakers in the following order to determine condition of the speakers and wiring harness between the base unit and each speaker.

  • Page 279: Outline (Car-Navigation System

    Dutch, Spanish, and Italian. However, the language used in this manual is in English only. • The following parts and position detecting functions are the same as those of the XEDOS 9/MILLENIA (TA) model. (See XEDOS 9/Mazda MILLENIA Workshop Manual Supplement 1694-1*-00H.) — GPS antenna —...

  • Page 280: Block Diagram (Car-Navigation System

    AUDIO AND NAVIGATION SYSTEM BLOCK DIAGRAM (CAR-NAVIGATION SYSTEM) A6E812466000T03 A6E8126T051 DSC HU/CM (with DSC) or ABS/TCS HU/CM (with TILT switch ABS/TCS) (vehicle speed signal) OPEN/CLOSE switch TR switch (ATX) or back-up light switch (MTX) Information display (R-range signal) Remote control Car-navigation unit Cradle Audio unit...

  • Page 281: Component Part And Functions

    AUDIO AND NAVIGATION SYSTEM Speaker • Refer to audio system. (See T–52 SPECIFICATIONS (AUDIO SYSTEM).) End Of Sie COMPONENT PART AND FUNCTIONS A6E812466000T05 Item Function Car-navigation unit • Reads the data (map,voice and other) from the DVD-ROM. • Calculates and displays the vehicle’s position from various signals. •...

  • Page 282: Car-Navigation Unit

    AUDIO AND NAVIGATION SYSTEM CAR-NAVIGATION UNIT A6E812466902T01 Outline • Using eterior signal input and DVD-ROM information, this unit detects vehicle position, provides destination route guidance, and displays color maps. Structure • The car-navigation unit is located in the glove compartment. •...
  • Page 283 AUDIO AND NAVIGATION SYSTEM Signals Terminal 24-pin connector – – – – – – – – – – – – – Monitor serial input Shield GND Monitor serial output Shield GND Video (composite sync) – Video (B) Video GND Video (G) –...

  • Page 284: Lcd Unit

    AUDIO AND NAVIGATION SYSTEM LCD UNIT A6E812466902T02 Outline • The car-navigation system LCD and the information display are incorporated into one unit. Based on signals from the car-navigation unit and remote control, the LCD displays navigational information. Based on signals from a specialized systems (audio, DIS and A/C) module, the LCD displays information about these systems •...
  • Page 285 Shield GND – Monitor serial output – Monitor serial input – Control illumination – – Shield GND R-range UART2 Illumination UART1 – Signals Terminal 6-pin connector Remote-data Power Shield GND – Illumination Signal Terminal 1-pin connector End Of Sie T–69...

  • Page 286: Remote Control And Cradle

    AUDIO AND NAVIGATION SYSTEM REMOTE CONTROL AND CRADLE A6E812400174T01 Outline • A remote control for the car-navigation system, with simplified design for easy operation, has been adopted. • A cradle to hold the remote control has been adopted. Structure • The remote control and cradle are located on the console. •...
  • Page 287 AUDIO AND NAVIGATION SYSTEM NAVIGATION FUNCTION A6E812466000T06 Outline • A vehicle's position is measured by a hybrid method of autonomous navigation (using yaw-rate signals from the gyro sensor and vehicle speed signals from the DSC unit (with DSC) or ABS/TCS HU/CM (with ABS/TCS) and GPS navigation (using signals from GPS satellites).

  • Page 288: Distance To The NeT Turn

    AUDIO AND NAVIGATION SYSTEM Map Screen Selection Current position map • The location of the vehicle and surrounding area are shown. • By pressing the [POS] button, the display switches to guide mode. (Only while in route guidance.) A6E8126T063 Map orientation GPS reception indicator •...
  • Page 289 AUDIO AND NAVIGATION SYSTEM Intersection zoom map • An enlarged map is displayed when approaching a roundabout or intersection. (While in route guidance.) Activated by selecting Zoom (On) in setup mode. A6E8126T065 Distance to the net turn Current road name Distance to the turn after the net turn Pop Up Menu •...
  • Page 290 AUDIO AND NAVIGATION SYSTEM Destination Setting Function Outline • The following instructions eplain how destinations can be chosen and set. Note • A destination can be set to where the crosshair cursor indicates by selecting the Destination option of the scroll map mode pop-menu.
  • Page 291 AUDIO AND NAVIGATION SYSTEM POI categories • When setting POI destination, the following categories can be selected. Data for categories according to the selected country will be displayed. A6E8126T067 Auto services Night life Parking garage Recreation facility Open parking area Theater Park &...
  • Page 292 AUDIO AND NAVIGATION SYSTEM Detour function • The following settings are available when using the detour function: Items Contents Alt route setting • Searches for a maimum of three routes. Detour distance ( km) setting • Calculates a detour for the current route based on inputted ( km) detour distance.
  • Page 293 AUDIO AND NAVIGATION SYSTEM Contents Selected items Default Sets map screen color (daytime). Green, Beige, Black Beige Sets map screen color (nighttime). Green, Beige, Black Beige Sets map direction. North up, Head up North up Sets display of the vehicle position indicator on the map Center: The current vehicle position Center screen.
  • Page 294 AUDIO AND NAVIGATION SYSTEM Simple junction guidance • The following voice guidance is provided: A6E8126T072 Right turn guidance eample In 700 meters right turn Right turn point In 300 meters right turn Net turn point Right turn ahead X m (X>750 m) Continuous junction guidance •...
  • Page 295 AUDIO AND NAVIGATION SYSTEM Multiple junction guidance • A multiple junction condition occurs when the distance from the first to the second turn point is less than or equal to 150 meters. • When the last guidance for the first turn point is announced, guidance for the second turn point is also provided.
  • Page 296 AUDIO AND NAVIGATION SYSTEM Continuous highway junction guidance • A continuous highway junction condition occurs when the distance from the first to the second turn point is more than 500 meters and less than or equal to 750 meters. • After passing the first turn point, the net voice guidance is provided. A6E8126T073 Right turn followed by left turn guidance eample In 2 kilometers right turn to eit motorway...

  • Page 297: Distance To The Turn After The NeT Turn

    AUDIO AND NAVIGATION SYSTEM Intersection Distance Display • When approaching the net guidance point, the distance to that point is counted down. • In case of a continuous or multiple junction, guidance point bars for the net two turns will be displayed. •...

  • Page 298: Detour

    AUDIO AND NAVIGATION SYSTEM Operation While Driving Display Function Screen activation • The following operation while driving warning screen appears when the unit determines from the pulse of the speedometer sensor that the vehicle is moving. A6E8126T076 Activation condition • When driving and the following screens are displayed, operating the following buttons will activate the warning screen.

  • Page 299: Cruise Control System

    CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM OUTLINE A6E812801011T01 • The cruise control system allows the driver to maintain selected vehicle speed without operating the accelerator when driving on an open highway. • The cruise actuator controls the throttle valve to maintain vehicle speed. •...

  • Page 300: System Wiring Diagram

    CRUISE CONTROL SYSTEM End Of Sie SYSTEM WIRING DIAGRAM A6E812801011T03 A6E8128T002 Brake switch Cruise actuator (includes control module) Brake light ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS)) Cruise set indicator light DSC HU/CM (with DSC) Cruise main indicator light Cruise control switch Brake switch 2 Cruise control main switch Clutch switch...

  • Page 301: Cruise Actuator

    • When the vehicle is driving at a constant speed sat by the cruise control system, and a signal from either the SET/COAST or RESUME/ACCEL switch is sent to the control module (in cruise actuator) for a very short period (a one-touch control function), the control module increases or decreases the vehicle speed by 1.6 km/h {1.0 mph}.

  • Page 302: On-Board Diagnostic

    (in cruise actuator) with the on-board diagnostic has been changed. For details, see the workshop manual. Operation code list Diagnosed circuit Output pattern Mazda 6 626 (GF) model Cruise control switch Cruise control switch (SET/COAST switch)

  • Page 303: Air Bag System

    AIR BAG SYSTEM AIR BAG SYSTEM OUTLINE A6E813001046T01 • The air bag system is a device that supplements the passenger restraint function of the seat belts. The air bag system will not have the designed effect if the seat belts are not worn properly. •...

  • Page 304: System Wiring Diagram

    AIR BAG SYSTEM End Of Sie SYSTEM WIRING DIAGRAM A6E813001046T03 A6E8130T002 SAS unit Clock spring Occupancy sensor Inflator No.1 Poor connection detector bar Inflator No.2 Crash zone sensor Driver-side air bag module Twist pair Passenger-side air bag module Data link connector Driver-side pre-tensioner seat belt Instrument cluster Driver-side curtain air bag module...

  • Page 305: Sas Unit

    : To scrap the air bag module, inflator No. 2 is deployed. 6. The SAS unit completes an ignition circuit for the pre-tensioner seat belts that is synchronized to the deployment of the driver and passenger-side air bag modules, and an operation signal is sent to the pre- tensioner seat belts.
  • Page 306 AIR BAG SYSTEM Side air bag system 1. During a lateral collision to the vehicle, the crash sensors in the side air bag sensor and SAS unit detect the collision. 2. The degree of impact detected by the crash sensor in the side air bag sensor is converted to an electrical signal and sent to the SAS unit through the signal amplification circuit.

  • Page 307: Driver-Side Air Bag Module

    AIR BAG SYSTEM DRIVER-SIDE AIR BAG MODULE A6E813057010T01 Outline • A dual inflator, 1 inflator divided into 2, has been adopted in accordance with the front air bag system 2-step deployment control. Inflator Operation 1. The igniter built into the inflator begins to build up heat when the operation (deployment) signal is sent from the SAS unit.

  • Page 308: Passenger-Side Air Bag Module

    AIR BAG SYSTEM PASSENGER-SIDE AIR BAG MODULE A6E813057050T01 Outline • A dual inflator, 1 inflator divided into 2, has been adopted in accordance with the front air bag system 2-step deployment control. Inflator Operation 1. The igniter built into the inflator begins to build up heat when the operation (deployment) signal is sent from the SAS unit.

  • Page 309: Side Air Bag Module

    AIR BAG SYSTEM SIDE AIR BAG MODULE A6E813000147T01 Function • During a collision to the side of the vehicle, the air bag operates (deploys) after receiving an operation signal from the SAS unit, defusing impact to the chest area of the driver and front passenger. Construction •...

  • Page 310: Curtain Air Bag Module

    AIR BAG SYSTEM CURTAIN AIR BAG MODULE A6E813000171T01 Function • During a lateral collision to the vehicle, the air bag operates (deploys) after receiving an operation signal from the SAS unit, defusing impact to the side of the head of the driver and other passengers (passenger-side and rear outboard-seated passenger).

  • Page 311: Pre-Tensioner Seat Belt

    AIR BAG SYSTEM PRE-TENSIONER SEAT BELT A6E813057630T01 Function • When a vehicle is involved in a frontal or frontal offset collision, the pre-tensioner seat belt system receives an operation signal from the SAS control module, retracting and tightening the belt webbing instantly on the driver and front passenger restraints.
  • Page 312 AIR BAG SYSTEM Operation Before Activation (Normal Condition) • The spool has a pinion on its end, which rotates with the spool when the belt webbing is retracted or withdrawn. • There is a ring gear around the pinion. Because the pinion does not engage with the ring gear during normal operation, the ring gear does not rotate even when the belt webbing is retracted or withdrawn.

  • Page 313: On-Board Diagnostic Function

    AIR BAG SYSTEM After Activation 1. Directly after the activation of the pre-tensioner seat belt system and the application of a load to the seat belt in the direction of withdrawal, the ELR lock mechanism operates and the pawl engages the housing gear. 2.
  • Page 314 AIR BAG SYSTEM Self-Malfunction Diagnostic Function • The self-malfunction diagnosis function determines that there is a malfunction, outputs a signal, as a DTC, to the DLC-2, and at the same time, flashes the air bag system warning light to advise the driver of a malfunction. •...
  • Page 315 AIR BAG SYSTEM Air bag system warning light Malfunction location WDS or Priority equivalent Flashing pattern ranking Passenger-side pre-tensioner seat belt system B1886 resistance low Passenger-side air bag cut-off indicator light B1890 system circuit short to power supply Driver-side air bag module (inflator No.1) system circuit short to ground B1913 Passenger-side air bag module (inflator No.1)
  • Page 316 AIR BAG SYSTEM Air bag system warning light Malfunction location WDS or Priority equivalent Flashing pattern ranking Driver-side air bag module (inflator No.2) system B2228 circuit short to ground Passenger-side air bag module (inflator No.2) B2229 system circuit short to ground Driver-side air bag module (inflator No.2) system B2230 circuit short to power supply...
  • Page 317 AIR BAG SYSTEM Air bag system warning light Malfunction location WDS or Priority equivalent Flashing pattern ranking Passenger-side curtain air bag module system B2777 resistance low Passenger-side curtain air bag module system B2778 resistance high Passenger-side curtain air bag module system B2779 circuit short to ground Passenger-side curtain air bag module system...
  • Page 318 AIR BAG SYSTEM SAS unit PID name (definition) Unit/condition Condition/specification terminal NORMAL/ • Related wiring harness normal: NORMAL DS2_STAT OPEN/ • Related wiring harness circuit open: OPEN (Driver-side air bag module 1G, 1J SHRT GND/ • Related wiring harness short to ground: SHRT GND (inflator No.2) circuit state) SHRT B+ •...
  • Page 319 AIR BAG SYSTEM SAS unit PID name (definition) Unit/condition Condition/specification terminal PABAGR (Passenger-side air bag Under any condition: 1.4—2.9 ohm 1M, 1P module (inflator No.1) resistance) PCRSH_SNSR • Sensor normal: OK (Passenger-side side air bag COMM FAIL/ • Sensor communication error: COMM FAIL 2B, 2C sensor state) INT FAIL...
  • Page 320 H EATER AND AIR CONDITIONER SYSTEMS OUTLINE ..............U-2 ABBREVIATION...........U-2 OUTLINE OF CONSTRUCTION......U-2 FEATURES ............U-2 SPECIFICATIONS ..........U-2 BASIC SYSTEM .............U-6 BASIC SYSTEM...........U-6 AIR FILTER............U-7 A/C UNIT..............U-7 CONDENSER ............U-10 REFRIGERANT LINES ........U-10 CONTROL SYSTEM..........U-11 CONTROL SYSTEM..........U-11 CLIMATE CONTROL UNIT........U-13 MANUAL AIR CONDITIONER CONTROL SYSTEM ............U-15...

  • Page 321: Outline

    Airflow volume (during air Blower motor conditioner operation) Electricity consumption Blower motor (during air conditioner Magnetic clutch operation) Fan type Blower motor Sirocco fan Type R-134a Regular amount Refrigerant 470 {16.6} (L.H.D.) (approimate quantity) 430 {15.2} (R.H.D.) (g {oz}) U–2...

  • Page 322: Specifications

    Type Multiflow (sub-cooling type) 4.69 {4,030}: European (L.H.D.) specs. Radiated heat (kW {kcal/h}) 5.96 {5,130}: European (U.K.), GCC specs. Condenser Receiver/drier (ml {cc, fl oz}) 190 {190, 6.42} capacity Desiccant Synthetic zeolite Epansion valve Type Block type Evaporator Type Double-tank drawn cup...
  • Page 323 (during air conditioner Magnetic clutch operation) Fan type Blower motor Sirocco fan Type R-134a Regular amount Refrigerant 470 {16.6} (L.H.D.) (approimate quantity) 430 {15.2} (R.H.D.) (g {oz}) Type Vane-rotary Discharge capacity 120 {120, 4.06} (ml {cc, fl oz}) Ma. allowable speed...
  • Page 324 OUTLINE Item Specification Type Dual-pressure: General area Operating pressure (MPa {kgf/cm , psi}) Type Triple-pressure: L3 engine, intensely hot area Operating pressure (MPa {kgf/cm , psi}) Refrigerant pressure switch Type Bimetallic (Indirect sensing type) Operating temperature (°C {°F}) Thermal protector Solar radiation sensor Photodiode Ambient temperature sensor...

  • Page 325: Basic System

    BASIC SYSTEM BASIC SYSTEM BASIC SYSTEM A6E851601040T01 A6E8500T001 A6E8500T002 Blower unit Condenser Air filter Refrigerant lines A/C unit Rear heat duct A/C compressor Heater hose End Of Sie U–6...

  • Page 326: Air Filter

    BASIC SYSTEM AIR FILTER A6E851613988T01 • An air filter that can deodorize and remove pollen and dust have been added. • The air filter consists of deodorizer surrounded by dust filter. • The dust filter removes pollen and dust. The deodorizer removes odors containing aldehyde. •...
  • Page 327 BASIC SYSTEM Airflow Mode Door Operation • The airflow mode doors move to VENT, BI-LEVEL, HEAT, HEAT/DEF, or DEFROSTER position, depending on the position of the airflow mode selector dial. As a result, airflow mode changes. A6E8516T006 Airflow To defroster and side demister Airflow mode door VENT Evaporator...
  • Page 328 BASIC SYSTEM Evaporator • The double-tank drawn cup is the same as the previous model ecept that a new refrigerant flow pattern has been adopted. Due to this, size and weight reduction is achieved while maintaining performance. A6E8516T007 Epansion Valve •...

  • Page 329: Refrigerant Lines

    BASIC SYSTEM End Of Sie CONDENSER A6E851661480T01 Construction • A sub cool condenser has been adopted. It is a multi-flow condenser which is equipped with a sub cooling part and integrated with a receiver/drier. • The sub cool condenser separates liquid-gas refrigerant initially cooled at the condenser via the receiver/drier, where it returns again to the condenser sub cooling part and is cooled, accelerating liquefaction and improving cooling capacity.

  • Page 330: Control System

    CONTROL SYSTEM End Of Sie CONTROL SYSTEM CONTROL SYSTEM A6E854001042T10 L.H.D. A6E8500T003 A6E8500T004 U–11...
  • Page 331 CONTROL SYSTEM R.H.D. A6E8500T005 A6E8500T006 Manual air conditioner Solar radiation sensor Full-auto air conditioner Ambient temperature sensor Air intake actuator Cabin temperature sensor Air mi actuator Evaporator temperature sensor Airflow mode actuator Water temperature sensor Blower motor Refrigerant pressure switch Resister Thermal protector Power MOS FET...

  • Page 332: Climate Control Unit

    CONTROL SYSTEM CLIMATE CONTROL UNIT A6E854061190T01 Manual Air Conditioner • A wire-type climate control unit is used with the manual air conditioner. • The airflow mode selector dial, temperature control dial, fan switch have been enlarged to improve ease of operation.
  • Page 333 CONTROL SYSTEM Full-auto Air Conditioner • A logic-type climate control unit is used with the full-auto air conditioner. • The airflow mode selector dial, temperature setting dial, fan switch have been enlarged to improve ease of operation. • The A/C, REC/FRESH and rear defroster switches equipped in the current climate control unit have been relocated to the center panel.
  • Page 334 CONTROL SYSTEM MANUAL AIR CONDITIONER CONTROL SYSTEM A6E854001081T01 Block Diagram • The climate control unit carries out the defroster control base on signal sent from the airflow mode selector dial, and sends an operating signal to the air intake actuator. •...
  • Page 335 CONTROL SYSTEM System Wiring Diagram A6E8540T039 Blower relay Ambient temperature sensor Blower motor Evaporator temperature sensor Resistor Air intake actuator Climate control unit Center panel Defroster switch A/C relay From PCM Magnetic clutch Refrigerant pressure switch To PCM Outline of Control System •...
  • Page 336 CONTROL SYSTEM Defroster Control 1. When the airflow mode selector dial is turned to DEFROSTER position, a wire moves the airflow mode main link, turning the airflow mode to DEFROSTER. 2. The defroster switch turns on at the same time, and the CPU sends a signal to turn the air intake mode to FRESH.
  • Page 337 CONTROL SYSTEM A/C Compressor Control • The center panel sends an A/C signal to the PCM via the refrigerant pressure switch based on signals sent from the A/C switch, fan switch and evaporator temperature sensor. • The PCM controls the A/C relay and IAC valve based on the input signal from the center panel. A6E8540T049 Evaporator temperature sensor A/C relay...
  • Page 338 CONTROL SYSTEM FULL-AUTO AIR CONDITIONER CONTROL SYSTEM A6E854001044T01 Block Diagram • The control system consists of input components (sensors), output components (actuators, magnetic clutch, power MOS FET, and other parts), and a control device (climate control unit). A6E8540T050 Ambient temperature sensor Power MOS FET Cabin temperature sensor Blower motor...
  • Page 339 CONTROL SYSTEM System Wiring Diagram A6E8540T040 Ambient temperature sensor Refrigerant pressure switch Cabin temperature sensor Airflow mode actuator Evaporator temperature sensor Air mi actuator Water temperature sensor Air intake actuator Solar radiation sensor From blower relay From TNS relay Blower motor Panel light control Power MOS FET Climate control unit...

  • Page 340: Airflow Temperature Control

    CONTROL SYSTEM Outline of Control System • In the full-auto air conditioner system, the climate control unit carries out five basic types of controls based on signals from various sensors and control signals from the climate control unit. The climate control unit also has three supplementary functions.

  • Page 341: Airflow Volume Control

    CONTROL SYSTEM Control Transition Air mi, airflow volume control Air mi control Airflow volume control Control before Control before switched switched Operation switch Manual control Automatic Defroster Automatic control control correction OFF switch AUTO AUTO switch AUTO AUTO AUTO AUTO AUTO MANUAL MANUAL...
  • Page 342 CONTROL SYSTEM Airflow mode control Air intake control A/C compressor control Control before switched Control before switched Control before switched Operation switch Automatic Manual Automatic Manual Automatic Manual control control control control control control 15.0 (18.0) Temperatur 15.5—28.5 e setting (18.5—...
  • Page 343 CONTROL SYSTEM Airflow Temperature Automatic Control • Based on the set temperature and sunlight intensity, the climate control unit calculates the air mi actuator opening angle characteristic. The higher the sunlight intensity, the lower the air mi actuator opening angle characteristic.
  • Page 344 CONTROL SYSTEM A/C correction • When the A/C compressor is switched from A/C ON mode to OFF mode, the basic opening angle of the air mi actuator is switched from the A/C ON mode opening angle to the A/C OFF mode opening angle. This prevents a rise in airflow temperature.
  • Page 345 CONTROL SYSTEM Fail-safe function • When the potentiometer of air mi actuator is malfunctioning, the air mi door is fied. Under this situation, if the ignition switch is turned to the ON/LOCK position, the air mi door is controlled to be fully opened (MAX HOT) or closed (MAX COLD) based on the ambient temperature.
  • Page 346 CONTROL SYSTEM Airflow Volume Automatic Control • Based on the set temperature, the ambient temperature, and sunlight intensity, the climate control unit calculates the blower motor voltage characteristic (AUTO voltage). It compares the differences among this voltage characteristic, and the target temperature (control computation value T2) and then determines the voltage to be applied to the blower motor.
  • Page 347 • To prevent the air blown from the defroster when the heater is started in winter from clouding the windows, the blower motor and the A/C signal output are switched off for 6 seconds after the ignition is turned to the ON position.
  • Page 348 4.4 (V) ), manual 1st (–) or OFF (+ or –) Airflow volume automatic control, manual 1st →manual 2nd Power MOS FET 6.1 (V) (+), or manual 4th (–) Airflow volume automatic control, manual 2nd →manual 3rd Power MOS FET 7.8 (V)
  • Page 349 CONTROL SYSTEM Airflow Mode Automatic Control • The climate control unit uses the present opening angle of the air mi actuator and the control condition of the A/C compressor to determine the airflow mode. When the A/C compressor is in OFF mode, the climate control unit varies the determined value of airflow mode according to the temperature signals received from the evaporator temperature sensor.

  • Page 350: Air Intake Control

    CONTROL SYSTEM Fail-safe function • When the potentiometer of airflow mode actuator is malfunctioning, the airflow mode door is fied. Under this situation, if the ignition switch is turned to the ON/LOCK position, the airflow mode door is controlled to be fully opened (DEFROSTER) or closed (VENT) based on the ambient temperature.
  • Page 351 CONTROL SYSTEM Air Intake Automatic Control • Based on the ambient temperature and sunlight intensity, the climate control unit calculates the cabin temperature computation value. By comparison with this cabin temperature computation value and actual cabin temperature, air intake mode is determined. A6E8540T008 Cabin temperature computation value Cabin temperature...
  • Page 352 • To prevent the air blown from the defroster when the heater is started in winter from clouding the windows, the blower motor and the A/C signal output are switched off for 6 seconds after the ignition is turned to ON position.
  • Page 353 CONTROL SYSTEM MAX COLD correction • When temperature is set to MAX COLD (temperature setting dial is turned to the left), the A/C signal ON/OFF temperature is at 5.0/4.0° ° ° ° C. However, when in ambient temperature correction, MAX COLD correction does not take place.

  • Page 354: Sensor Fail-Safe Function

    CONTROL SYSTEM SENSOR FAIL-SAFE FUNCTION A6E854001044T09 • If the input signals received from the sensors are abnormal, the climate control unit will assume a malfunction and fi the values for the temperature signals from the sensors as shown below to prevent abnormal A/C control.

  • Page 355: On-Board Diagnostic Function

    CONTROL SYSTEM ON-BOARD DIAGNOSTIC FUNCTION A6E854001044T11 Outline • Based on the sunlight intensity and temperature signals from the various sensors, the climate control unit performs very comple control to the output actuation devices. Therefore, the operating condition of the output devices may vary due to input conditions, even though the controls on the climate control unit are not changed.
  • Page 356 CONTROL SYSTEM Present Failure Indication Mode • In present failure indication mode, present failures in the control system circuits (open, short circuits) are detected, and the flashing of the rear defroster indicator light on the climate control unit indicates the DTCs shown in the table below.
  • Page 357 CONTROL SYSTEM Diagnostic trouble codes Memo Indicator pattern Diagnosed circuit Detected condition rized Open circuit in solar radiation sensor Solar radiation sensor circuit (present) Short circuit in solar radiation sensor circuit (terminal B side only) Open/short circuit is in cabin Cabin temperature temperature sensor circuit sensor (present)
  • Page 358 CONTROL SYSTEM Output device operation check table Moni Step Operating device Operating conditions Other device conditions Blower motor • Air mi actuator operation speed — 50% • Airflow mode actuator operation — VENT • Air intake actuator operation — FRESH •...

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