lock MAZDA 6 2002 Suplement Owners Manual

LIFTGATE
S–9
S
9. To remove the stay damper, remove the bolt B.
10. Install in the reverse order of removal.
End Of Sie
LIFTGATE DISASSEMBLY/ASSEMBLYA6E772262010202WGN
1. Disconnect the negative battery cable.
2. Remove the liftgate lower trim.
3. To remove the liftgate outer handle and liftgate key cylinder, remove the rear finisher.
4. To remove the stud ball, separate the stud ball and the stay damper.
5. Disassemble in the order indicated in the table.
6. Assemble in the reverse order of disassembly.
.
BOLT B
HINGE
STAY DAMPER
BOLT A
NUT
LIFTGATE
N·m {kgf·cm, in·lbf} 8.8—12.7
{90—130,
78—112}
32.4—48.5 N·m
{3.3—4.9 kgf·m,
24—35 ft·lbf} 7.8—10.8
{80—110, 70—95}
A6E77221102
A
2
N·m {kgf·cm, in·lbf}
A
31
B
6.90—9.80
{70—100,
60.8—86.7}
4.0—5.8
{39.8—60.1,
34.6—52.2}
4
B
16—23 N·m
{1.6—2.4 kgf·m,
12—17 ft·lbf}3.9—5.9
{39.8—60.1,
34.6—52.2}
5
7
6
A6A7722W103
1 Liftgate latch and lock actuator
2 Liftgate outer handle
3 Liftgate key cylinder
4Clip5Stud ball
6 Liftgate
7 Stopper

T–6
MULTIPLEX COMMUNICATION SYSTEM
ON-BOARD DIAGNOSTIC FUNCTIONA6E811155430205Outline
•The on-board diagnostic function is incorporated into the PCM, TCM, ABS (ABS/TCS) HU/CM (with ABS (ABS/
TCS)), DSC HU/CM (with DSC), 4WD control module, and instrument cluster. This function can narrow down
CAN system malfunction locations.
•Due to the adoption of the TCM and the 4WD CM, some DTCs and PID/data monitor items have been added.
Other functions are the same as those of the current Mazda6 (GG) model.
Block Diagram
.
Fail-Safe Function
•When the failure detection function detemines that there is a malfunction, the fail-safe function illuminates a
warning light to advise the driver of the malfunction.
1
3
24
5
6
A6E81111103
1PCM
2 TCM (JA5AX-EL)
3 ABS (ABS/TCS) HU/CM or DSC HU/CM4 4WD control module (4WD)
5 Instrument cluster
6Twist pair
Module Fail-safe function
PCM•MIL illuminated
TCM•AT warning light illuminated
•ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS))
•DSC HU/CM (with DSC)•ABS (ABS/TCS) suspended (with ABS (ABS/TCS))
•DSC suspended (with DSC)
•ABS warning light illuminated
•DSC/TCS indicator light illuminated
•DSC OFF light illuminated
•TCS OFF light illuminated
4WD control module•4WD indicator light illuminated
Instrument cluster•Speedometer, tachometer, water temperature gauge: 0 displayed

LOCATION INDEX
T–15
T
POWER SYSTEMA6E810001072201
.
End Of Sie
EXTERIOR LIGHTING SYSTEMA6E810001052201
.
LOCATION INDEX
1
A6E81101124
1 Main fuse block
(See T–19 RELAY LOCATION)
(See T–19 RELAY INSPECTION)
11
2
A6E81121162
1 High-mount brake light
(See T–20 HIGH-MOUNT BRAKE LIGHT
REMOVAL/INSTALLATION)2 Rear auto leveling sensor (4WD)
(See T–20 REAR AUTO LEVELING SENSOR
REMOVAL/INSTALLATION)

AIR BAG SYSTEM
T–33
T
•A live (undeployed) air bag module placed
face down on a surface is dangerous. If the air
bag module deploys, the motion of the
module can cause serious injury. Always face
the front surface up to reduce the motion of
the module in case it accidentally deploys.
Side Air Bag Module Handling
•When the side air bag module deploys due to a collision, the interior of the seat back (pad, frame, etc.)
may become damaged. If the seat back is reused and the side air bag module does not deploy properly,
a serious accident may result. When the side air bag module deploys, always replace both the side air
bag module and the seat back (pad, frame, trim) with new parts. After service, confirm that the seat
operates normally and that the harness is positioned properly.
SAS Unit Handling
•Disconnecting the SAS unit connector or removing the SAS unit with the ignition switch at ON position
can cause the air bag modules to deploy, which may seriously injure you. Before disconnecting the
SAS unit connector or removing the SAS unit, turn the ignition switch to LOCK position, then
disconnect the negative battery cable and wait for more than 1 minute to allow the backup power
supply of the SAS unit to deplete its stored power.
•Connecting the SAS unit connector without firmly installing the SAS unit to the vehicle is dangerous.
The crash sensor inside the control module may send an electrical signal to the air bag modules. This
will deploy the air bag modules, which may result in serious injury. Therefore, before connecting the
connector, firmly mount the control module to the vehicle.
•For vehicles with a single point sensor, once an air bag module is deployed due to an accident or other
causes, the SAS unit must be replaced with a new one even if the used one does not have any external
signs of damage. The used SAS unit may have been damaged internally which may cause improper
operation, resulting in major injuries or even death. The used single point SAS unit cannot be
bench-checked or self-checked.
Crash Zone Sensor Handling
•Disconnecting the crash zone sensor connector or removing the crash zone sensor with the ignition
switch at ON position can cause the crash zone sensor to operate and the air bag modules and pre-
tensioner seat belts to deploy, which may seriously injure you. Before disconnecting the crash zone
sensor connector or removing the crash zone sensor, always turn the ignition switch to LOCK position,
then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power
supply of the SAS control module to deplete its stored power.
•If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bag modules and
pre-tensioner seat belts may operate (deploy) suddenly and cause injury, or it may fail to operate
normally and cause a serious accident. Do not subject the crash zone sensor to shock or disassemble
the sensor.
•Because a sensor is built into the crash zone sensor, when the air bag modules and pre-tensioner seat
belts operates (deploys), there may be a problem, such as an internal malfunction, even if there is not
any external damage or deformation. If the crash zone sensor is reused, the air bag modules and pre-
tensioner seat belts may fail to operate normally and cause a serious injury. Always replace the crash
zone sensor with a new part. The crash zone sensor cannot be bench-checked or self-checked.
A6E8130W021

T–34
AIR BAG SYSTEM
Side Air Bag Sensor Handling
•Disconnecting the side air bag sensor connector or removing the side air bag sensor with the ignition
switch at ON position can cause the side air bag sensor to operate and the side air bag module to
deploy, which may seriously injure you. Before disconnecting the side air bag sensor connector or
removing the side air bag sensor, always turn the ignition switch to LOCK position, then disconnect the
negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS
control module to deplete its stored power.
•If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag module
may operate (deploy) suddenly and cause injury, or it may fail to operate normally and cause a serious
accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
•Because a sensor is built into the side air bag sensor, when the side air bag module operates (deploys),
there may be a problem, such as an internal malfunction, even if there is not any external damage or
deformation. If the side air bag sensor is reused, the side air bag module may fail to operate normally
and cause a serious injury. Always replace the side air bag sensor with a new part. The side air bag
sensor cannot be bench-checked or self-checked.
Pre-tensioner Seat Belt Inspection
•Inspecting a pre-tensioner seat belt using an
ohmmeter can deploy the pre-tensioner seat
belt, which can cause serious injury. Do not
use an ohmmeter to inspect the pre-tensioner
seat belt. Always use the on-board diagnostic
to diagnose the pre-tensioner seat belt for
malfunctions.
Component Handling
•Oil, grease, water, etc on components may cause the air bag modules and pre-tensioner seat belts to
fall to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on
components.
•Inserting a screwdriver, etc., into the
connector of an air bag module or a pre-
tensioner seat belt may damage the connector
and cause the air bag module or the pre-
tensioner seat belt to deploy improperly,
which may cause serious injury. Do not insert
any foreign objects into the connector.
Component Reuse
•Even if an air bag module or a pre-tensioner seat belt does not deploy in a collision and does not have
any external signs of damage, it may have been damaged internally, which may cause improper
operation. Improper operation may cause serious injury. Always self-check the undamaged air bag
module or pre-tensioner seat belt to determine whether it can be reused.
End Of Sie
A6E8130W025
A6E8130W023

AIR BAG SYSTEM
T–35
T
CURTAIN AIR BAG MODULE REMOVAL/INSTALLATIONA6E813000171201
Warning
•Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag
module. (See T–32 SERVICE WARNINGS.)
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable and wait for more than 1 minute.
3. Remove the headliner.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Turn the ignition switch to ON position.
7. Verify that the air bag system warning light
illuminates for approximately 6 seconds and
then goes off.
•If the air bag system warning light does not
operate in the manner described above, there
are malfunctions in the system. Inspect the system using the on-board diagnostic.
Connector Removal Note
1. Using a flathead screwdriver, pry out the
connector's stopper plate.
2. Disconnect the connector.
End Of SieAIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURESA6E813057000201
Warning
•A live (undeployed) air bag module and pre-tensioner seat belt may accidentally deploy when it is
disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag module and
pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not available,
consult the nearest Mazda representative for assistance.
Caution
•Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.
•When the vehicle is to be scrapped, deploy the air bag modules and pre-tensioner seat belts inside the vehicle.
(See T–36 Deployment Procedure for Inside of Vehicle (Only When Vehicle Is To Be Scrapped).)
•When the vehicle is not to be scrapped, deploy the air bag modules and pre-tensioner seat belts outside the
vehicle. (See T–36 Deployment Procedure for Outside of Vehicle.)
Note
•When disposing of deployed air bag module and pre-tensioner seat belt, refer to the disposal procedure.
•The deployment procedures are the same as those of the current 4SD and 5HB models, except for the
curtain air bag module.
1 Connector
(See T–35 Connector Removal Note)
2Bolt
3 Curtain air bag module3
1
2
N·m {kgf·cm, in·lbf} 7.9—11.7
{80—120, 70—104}
A6E81301126
A6E8130W002

T–36
AIR BAG SYSTEM
Deployment Procedure for Inside of Vehicle (Only When Vehicle Is To Be Scrapped)
1. Inspect the SST (Deployment tool).
2. Move the vehicle to an open space, away from strong winds, and close all the doors and windows.
3. Turn the ignition switch to LOCK position.
4. Disconnect the negative battery cable and wait for more than 1 minute.
5. Follow the appropriate procedure for deploying the driver-side air bag module, passenger-side air bag module,
side air bag module, curtain air bag module, or pre-tensioner seat belt.
Curtain air bag module (WGN)
1. Remove the headliner.
2. Disconnect the curtain air bag module connector.
3. Connect the SST (Adapter harness) to the curtain
air bag module.
4. Connect the SST (Deployment tool) to the SST
(Adapter harness).
5. Connect the red clip of the SST (Deployment tool)
to the positive battery terminal and the black clip
to the negative battery terminal.
6. Verify that the red light on the SST (Deployment
tool) is illuminated.
7. Make sure all persons are standing at least 6 m
{20 ft} from the vehicle.
8. Press the activation switch on the SST
(Deployment tool) to deploy the curtain air bag
module.
Deployment Procedure for Outside of Vehicle
1. Inspect the SST (Deployment tool).
2. Turn the ignition switch to LOCK position.
3. Disconnect the negative battery cable and wait for more than 1 minute.
4. Follow the appropriate procedure for deploying the driver-side air bag module, passenger-side air bag module,
side air bag module, curtain air bag module, or pre-tensioner seat belt.
49 L066 002
CURTAIN
AIR BAG MODULE
CONNECTOR
A6E81301112
49 L066 002
49 H066 002
A6E8130W151
49 H066 002
ACTIVATION
SWITCH
A6E8130W028

T–40
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM]
Flowchart
•Use the following flowchart to verify the cause of the trouble.
End Of Sie
Repair the malfunctioning part by
following the DTC inspection.A
Inspect the power supply and the ground circuits for any units
that do not respond.
Are they normal?
Repair the malfunctioning part.A
A
B START
Using the SST (WDS or equivalent), verify if DTCs are displayed for PCM, TCM, ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS)),
DSC HU/CM (with DSC), 4WD control module and instrument cluster.
Are any DTCs displayed?
Ye s
Are any DTCs other than the following displayed?
PCM: U0073, U0101, U0121, U0155
TCM: U0073, U0100
ABS (ABS/TCS) HU/CM, DSC HU/CM,
Instrument cluster: U1900, U2516
4WD control module: U0100, U0101, U0121
NoEND No
No Ye s
Are any of the following DTCs displayed?
PCM: U0073, U0101, U0121, U0155
TCM: U0073, U0100
ABS (ABS/TCS) HU/CM, DSC HU/CM,
Instrument cluster: U1900, U2516
4WD control module: U0100, U0101, U0121
Ye s
Ye s Narrow down CAN system malfunction location.
Using the SST (WDS or equivalent), verify if DTCs are displayed
for PCM, TCM, ABS (ABS/TCS) HU/CM, DSC HU/CM, 4WD
control module and instrument cluster.
Are any DTCs displayed?
No
Using the SST (WDS or equivalent), clear DTCs stored in
each module.
END
Ye s
No
Turn the ignition switch to the LOCK position.
Inspect the wiring harness and connector between
any unit that does not respond and the DLC-2.
PCM
—DLC-2 (except MZR-CD (RF Turbo))
2R—CAN_L
2U—CAN_H
PCM—DLC-2 (MZR-CD (RF Turbo))
39—CAN_L
13—CAN_H
TCM—DLC-2
2J—CAN_L
2M—CAN_H
ABS (ABS/TCS) HU/CM—DLC-2
X—KLN
DSC HU/CM—DLC-2
AB—KLN
4WD control module—DLC-2
H—CAN_L
G—CAN_H
Instrument cluster—DLC-2
2W—CAN_L
2X—CAN_H
Are the wiring harnesses and connectors normal? Is there a response from the PCM, TCM, ABS (ABS/TCS) HU/CM,
DSC HU/CM, 4WD control module and/or instrument cluster?
No Ye s
No
Ye s Repair the malfunctioning part by following the DTC inspection.
Repair the malfunctioning part.
A6E8162L101

ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM]
T–40–1
T
T–40BODY ELECTRICAL SYSTEM
End Of Sie
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM]
Connect each unit connector.
Turn the ignition switch to the ON position.
Measure the voltage between DLC-2 terminals CAN_L and CAN_H.
Is the voltage 2.0—3.0 V?
Turn the ignition switch to the LOCK position.
Measure the resistance between DLC-2 terminals CAN_L and
CAN_H.
Is the resistance 59—65 ohms?
Replace any units that
do not respond.Disconnect the PCM connector.
Measure the resistance between PCM
connector terminals 2R and 2U
(except MZR-CD (RF Turbo)) or 13 and
39 (MZR-CD (RF Turbo)).
Is the resistance 118—130 ohms?
Replace the PCM.
Disconnect the instrument cluster connector.
Measure the resistance between instrument cluster connector
terminals 2W and 2X.
Is the resistance 118—130 ohms?
Replace the instrument
cluster.Turn the ignition switch to the LOCK position.
Disconnect the connector of any unit that does not respond.
(If there are two or more units that do not respond,
disconnect only one of the units.)
Turn the ignition switch to the ON position.
Measure the voltage between DLC-2 terminals CAN_L and
CAN_H.
Is the voltage 2.0—3.0 V?
The disconnected unit or the
related wiring harness may
have a malfunction.
Replace the disconnected unit. Replace the related wiring harness.The disconnected
unit is normal.
Are all units that do not respond disconnected?
Inspect if the related wiring harnesses (CAN_L
and/or CAN_H) have been shorted (to power
supply or ground).
If a short is found, replace the related wiring
harness. Ye sNo B
A A A AA
A
Turn the ignition switch to the LOCK position.
Verify the continuity between the following connector terminals of any disconnected unit.
PCM connector (except MZR-CD (RF Turbo)): 2R (CAN_L)—other terminals,
2U (CAN_H)—other terminals
PCM connector (MZR-CD (RF Turbo)): 39 (CAN_L)—other terminals,
13 (CAN_H)—other terminals
TCM connector: 2J (CAN_L)—other terminals, 2M (CAN_H)—other terminals
ABS (ABS/TCS) HU/CM connector: R (CAN_L)—other terminals,
O (CAN_H)—other terminals
DSC HU/CM connector: AF (CAN_L)—other terminals, AG (CAN_H)—other terminals
4WD control module connector: H (CAN_L)—other terminals, G (CAN_H)—other terminals
Instrument cluster connector: 2W (CAN_L)—other terminals, 2X (CAN_H)—other terminals
Is there continuity?
Ye s
No
Ye s
No
Ye sNo
Ye sNo
Ye sNo
Ye sNo
A6E8162L102

U–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E850201038201•The construction and operation of the air conditioner system is essentially carried over from that of the previous
Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E850201038202Improved Comfort
•The water heater system has been adopted. (For MZR-CD (RF Turbo) European (L.H.D.) specs.)
End Of Sie
SPECIFICATIONSA6E850201038203Manual Air Conditioner
OUTLINE
ItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
Heating capacity (kW {kcal/h}) 4.400 {3,784}4.400 {3,784} (L.H.D.)
5.120 {4,403} (R.H.D.)
Airflow volume
(during heater operation)Blower motor
(m
3/h)310 (L.H.D.)
300 (R.H.D.)
Electricity consumption
(during heater operation)Blower motor (W) 184
Cooling capacity (kW {kcal/h}) 4.200 {3,612}
Airflow volume (during air
conditioner operation)Blower motor
(m
3/h)460
Electricity consumption
(during air conditioner
operation)Blower motor (W) 225
Magnetic clutch (W) 46 45
Fan type Blower motor Sirocco fan
RefrigerantType R-134a
Regular amount
(approximate quantity)470 {16.6} (L.H.D.)
430 {15.2} (R.H.D.)
(g {oz})
A/C compressorType Vane-rotary
Discharge capacity
120 {120, 4.06}
(ml {cc, fl oz})
Max. allowable speed
6,400
(rpm)
Lube
oilType ATMOS GU10
Sealed volume
(approximate quantity)
120 {120, 4.06} 150 {150, 5.07}
(ml {cc, fl oz})
Magnetic clutch clearance
0.3—0.5 {0.012—0.019}
(mm {in})
CondenserType Multiflow (sub-cooling type)
Radiated heat (kW {kcal/h})4.69 {4,030}: European (L.H.D.) specs.
5.96 {5,130}: European (U.K.), GCC specs.
Receiver/drier
capacity(ml {cc, fl oz}) 190 {190, 6.42}
Desiccant Synthetic zeolite
Expansion valve Type Block type
Evaporator Type Double-tank drawn cup