4WD MAZDA 6 2002 Workshop Manual Suplement

T–2
OUTLINE, POWER SYSTEM
OUTLINE OF CONSTRUCTIONA6E810201088201•The construction and operation of the body electrical system is essentially carried over from that of the current
Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C)
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FEATURESA6E810201088202Improved Safety
•There are two types of high-mount brake lights. (WGN)
Improved Marketability
•A cargo compartment light has been adopted. (WGN)
•The installation positions of the rear wiper and washer components have been changed. (WGN)
•A fuel gauge sender sub-unit has been adopted. (4WD)
•A 4WD indicator light, glow indicator light and sedimentor warning light have been adopted.
•The installation positions of the condenser and the noise filter have been changed. (WGN)
•An antenna feeder has been adopted. (WGN)
•A rear auto leveling sensor especially for the 4WD has been adopted. (4WD)
Improved Security
•A rear intruder sensor has been adopted. (WGN)
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OUTLINE
POWER SYSTEM
2
1
A6E81101102
1 Seat warmer relay (with seat warmer)2 Glow relay (MZR-CD (RF Turbo) only)

MULTIPLEX COMMUNICATION SYSTEM
T–3
T
OUTLINEA6E811155430201•A TCM and a 4WD control module have been adopted for the CAN system-related module.
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MULTIPLEX COMMUNICATION SYSTEM
4
1
3
2
5
A6E81111101
1 ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS))
DSC HU/CM (with DSC)
2 Instrument cluster3TCM
4PCM
5 4WD control module

T–4
MULTIPLEX COMMUNICATION SYSTEM
SYSTEM WIRING DIAGRAMA6E811155430203
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End Of SieCAN SIGNAL-CHARTA6E811155430204
OUT: Output (sends signal)
IN: Input (receives signal)
1
2
67
3
8
4
5
ROAF AG
HG
2M2J2W
2X
9
10
CAN_L
CAN_H
A6E81111102
1PCM
2 DSC HU/CM (with DSC)
3 ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS))
4 Data link connector-2
5 Instrument cluster
6 TCM (JA5AX-EL)7 4WD control module (4WD)
8Twist pair
9 2R (except MZR-CD (RF Turbo))
39 (MZR-CD (RF Turbo))
10 2U (except MZR-CD (RF Turbo))
13 (MZR-CD (RF Turbo))
SignalMultiplex module
PCM TCMABS (ABS/TCS)
HU/CM or
DSC HU/CM4WD control
moduleInstrument
cluster
Accelerator pedal position
(MZR-CD (RF Turbo))OUT IN IN–IN
Air induction type OUT–IN––
ATF temperature IN OUT–––
AT warning light conditions
(JA5AX-EL)IN OUT––IN
Battery reconnection
(except MZR-CD (RF
Turbo))OUT IN–––
Brake system configuration
(EBD/ABS/TCS/DSC)IN–OUT–IN
Brake system
statusABS IN–OUT––
EBD/ABS/
TCS/DSC––OUT IN IN
Brake system warning light
conditions (brake fluid level
sensor)––IN–OUT
Country OUT–IN––
Coupling torque (with
DSC)––IN OUT–
Coupling torque request
(with DSC)––OUT IN–

MULTIPLEX COMMUNICATION SYSTEM
T–5
T
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Cruise main indicator light
conditions (MZR-CD (RF
Turbo))OUT–––IN
Cruise set indicator light
conditions (MZR-CD (RF
Turbo))OUT–––IN
Desired gear/
selector lever
positionFN4A-EL OUT–IN–IN
JA5AX-EL IN OUT IN IN IN
ECT OUT IN–IN
Engine control condition OUT–IN––
Engine displacement OUT–IN––
Engine loss torque (except
MZR-CD (RF Turbo))OUT IN–––
Engine speed OUT IN IN IN IN
Engine torque (except
MZR-CD (RF Turbo))OUT IN–––
Fuel injection information OUT–IN––
Fuel type and delivery OUT–IN––
Gear position IN OUT IN IN IN
Generator warning light
conditions (except MZR-
CD (RF Turbo))OUT–––IN
Glow indicator light
condition (MZR-CD (RF
Turbo))OUT–––IN
HOLD indicator light
conditions (FN4A-EL)OUT–––IN
Idle speed up request IN OUT–––
MIL condition (except
MZR-CD (RF Turbo))OUT–––IN
MIL indicate request IN OUT–––
Number of cylinders OUT–IN––
Racing select
determinationIN OUT–––
TCC condition IN OUT–––
Tire circumference (front/
rear)OUT–IN––
Torque reduction inhibit OUT IN IN––
TP OUTINININ–
Transmission/axle type OUT–IN––
Travelled distanceIN–OUT––
IN OUT––IN
OUT–––IN
Torque
reduction
requestJA5AX-EL IN OUT–––
except
JA5AX-ELIN–OUT––
Turbine speed IN OUT–––
Upper torque limit IN OUT–––
Vehicle speedOUT–––IN
IN OUT–––
Wheel speed (front left/
front right/rear left/rear
right)IN IN OUT IN–
OUT–––IN
4WD system operating
condition (warning light
information)–––OUT IN SignalMultiplex module
PCM TCMABS (ABS/TCS)
HU/CM or
DSC HU/CM4WD control
moduleInstrument
cluster

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

MULTIPLEX COMMUNICATION SYSTEM
T–7
T
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
PID/Data Monitoring Function
•The PID/data monitoring function is used to freely select and read out, in real time, the monitored items for the
input/output signals of the TCM, ABS (ABS/TCS) HU/CM, DSC HU/CM and instrument cluster.
•An SST (WDS or equivalent) is used to read out the PID/data monitor information.
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DTC Malfunction location Related module
U0073 CAN system communication error•PCM
•TCM
U0100 Communication error to PCM•TCM
•4WD control module
U0101 Communication error to TCM
•PCM
•4WD control module
U0121 Communication error to ABS (ABS/TCS) HU/CM or DSC HU/CM
U0155 Communication error to instrument cluster PCM
U1900 CAN system communication error•ABS (ABS/TCS) HU/CM (with ABS (ABS/
TCS))
•DSC HU/CM (with DSC)
•Instrument cluster
U2511 Communication error to 4WD control module•ABS (ABS/TCS) HU/CM (with ABS (ABS/
TCS))
•DSC HU/CM (with DSC)
U2516 CAN system wiring harness open and short circuit•ABS (ABS/TCS) HU/CM (with ABS (ABS/
TCS))
•DSC HU/CM (with DSC)
•Instrument cluster
PID name
(definition)Condition Specification Related module Terminal
PCM_MSG
(Missing message
from the PCM)Present Circuit in the PCM is normal•TCM
•ABS (ABS/TCS)
HU/CM or DSC
HU/CM
•Instrument cluster
•TCM: 2J, 2M
•ABS (ABS/TCS) HU/CM
(with ABS (ABS/TCS)): O,
R
•DSC HU/CM (with DSC):
AF, AG
•Instrument cluster: 2W, 2X Not Present Circuit in the PCM is abnormal
TCM_MSG
(Missing message
from the TCM)Present Circuit in the TCM is normal•ABS (ABS/TCS)
HU/CM or DSC
HU/CM
•Instrument cluster Not Present Circuit in the TCM is abnormal
ABS_MSG
(Missing message
from the ABS
(ABS/TCS) HU/
CM or DSC HU/
CM)PresentCircuit in the ABS (ABS/TCS)
HU/CM or DSC HU/CM is
normal
•TCM
•Instrument cluster
Not PresentCircuit in the ABS (ABS/TCS)
HU/CM or DSC HU/CM is
abnormal
AWD_MSG
(Missing message
from the 4WD
control module)PresentCircuit in the 4WD control
module is normal•TCM
•ABS (ABS/TCS)
HU/CM or DSC
HU/CM
•Instrument cluster Not PresentCircuit in the 4WD control
module is abnormal
IC_MSG
(Missing message
from the
instrument
cluster)PresentCircuit in the instrument cluster
is normal•TCM
•ABS (ABS/TCS)
HU/CM or DSC
HU/CM Not PresentCircuit in the instrument cluster
is abnormal

T–10
WARNING AND INDICATOR SYSTEM
OUTLINEA6E811801069201•In accordance with the 4WD setting, the following indicator light has been added:
—4WD indicator light
•In accordance with the MZR-CD (RF Turbo) setting, the following indicator lights have been added:
—Glow indicator light
—Sedimentor warning light
•A fuel gauge sender sub-unit has been adopted. (4WD)
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STRUCTURAL VIEWA6E811801069202
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WARNING AND INDICATOR SYSTEM
3
2
1
4
5
4WD
A6E81181101
1 Sedimentor warning light
2 4WD indicator light
3 Glow indicator light4 Fuel gauge sender unit
5 Fuel gauge sender sub-unit

WARNING AND INDEICATOR SYSTEM, THEFT-DETERRENT SYSTEM
T–11
T
SYSTEM WIRING DIAGRAMA6E811801069203
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OUTLINEA6E812050000201•An intruder sensor has been adopted on the rear part of the roof. (WGN)
•The construction and operation of the theft-deterrent system is the same as that of the current Mazda6 (GG)
model.
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INTRUDER SENSORA6E812050000202Outline
•WGN models are equipped with intruder sensors in two places in the vehicle, due to the necessity of movement
detection in the all around wider vehicle interior. The intruder sensors are located in the roof at the front (with
sliding sunroof), or the center (without sliding sunroof), and the cargo space.
•The structure and operation of the rear intruder sensor is the same as that of the current front and center
intruder sensors.
IG1
B+
1
345
2
6
97
8
2H 2V
1C 2F 2D 2M 2X 2W
A6E81181004
1 Instrument cluster
2Microcomputer
3 Glow indicator light
4 Sedimentor warning light
5 4WD indicator light6 PCM, ABS (ABS/TCS) HU/CM or DSC HU/CM
7 Fuel gauge sender sub-unit (4WD)
8 Fuel gauge sender unit
9 Sedimentor switch
THEFT-DETERRENT SYSTEM

LOCATION INDEX
T–15
T
POWER SYSTEMA6E810001072201
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EXTERIOR LIGHTING SYSTEMA6E810001052201
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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)

WARNING AND INDICATOR SYSTEM
T–27
T
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATIONA6E811860960201Fuel Gauge Sender Unit
2WD
•There are no changes from the current fuel gauge sender unit removal/installation procedure.
4WD
1. Remove the fuel gauge sender unit. (See F1–26 FUEL PUMP UNIT REMOVAL/INSTALLATION.)
2. Install in the reverse order of removal.
Fuel Gauge Sender Sub-Unit
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel gauge sender sub-unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
3. Complete the following in order to the work area.
(1) Loosen the bolt of the fuel tank strap.
(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.
4. Remove the rear seat cushion.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
8. Complete the “Fuel leak inspection after fuel
gauge sender sub-unit installation.“ (See T–28
Fuel leak inspection after fuel gauge sender sub-
unit installation.)
WARNING AND INDICATOR SYSTEM
1 Service hole cover
2 Connector
3 Plastic fuel hose (fuel tank side, transfer hose part)
(See F1–29 FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART) REMOVAL/
INSTALLATION)
4 Fuel gauge sender cap
(See T–28 Fuel gauge sender cap removal note)
(See T–28 Fuel Gauge Sender Cap Installation
Note)
5 Packing
6 Fuel gauge sender sub-unit
3
1
4
5
6
2
80—90 {8.2—9.1, 60—66}
N·m {kgf·m, ft·lbf}
R
SST
A6E81182001