warning MAZDA 6 2002 Workshop Manual Suplement

S–16
WINDOW GLASS
7. Set the side window glass in place and insert the
pins and fastener into the body. Install the side
window glass.
8. Allow the sealant to harden completely.
Sealant hardening time: 24 hours
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REAR WINDOW GLASS REMOVALA6E773863931201WGN
1. Remove the rear wiper motor.
2. Apply protective tape along the edge of the body to protect it from damage.
3. Cut the lip of the rear window molding using a
razor.
Warning
•Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.
Note
•The rear window molding is a replacement
part.
Not Reusing Glass
Note
•For the areas of the sealant that are difficult to cut, use a SST (piano wire) and follow the procedure under
“Reusing Glass.”
1. Use a SST, and insert the blade into the sealant.
2. Pull through the sealant around the edge of the
glass.
3. Remove the glass.
PIN
PIN
FASTENER
A6A7738W102
A
B A
B
SEC. A—ASEC. B—B LIP
LIP
REAR WINDOW
GLASS MOLDING
A6E77381107
49 G050 1A0
A6E7738W022

WINDOW GLASS
S–17
S
Reusing Glass
Note
•Before removing the rear window glass from the body, mark the position of the glass by affixing tape to
the glass and body panel.
1. Make a hole through the sealant, avoiding pins,
from the inside of the vehicle using an awl.
2. Pass the SST (piano wire) through the hole.
Warning
•Using a SST (piano wire) with bare hands
can cause injury. Always wear gloves
when using a SST (piano wire).
3. Wind each end of the SST (piano wire) around a
bar.
Note
•Use a long sawing action to spread the work
over the whole length of the SST (piano
wire) to prevent it from breaking.
4. Working with another person, saw through the
sealant around the edge of the glass.
5. Remove the rear window glass.
6. Remove the pins from the glass.
7. Remove the rear window molding from the glass.
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REAR WINDOW GLASS INSTALLATIONA6E773863931202
Caution
•To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door
is closed, open all of the windows and leave them open until the sealant has hardened.
1. Cut away the old sealant using a razor so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around
the circumference of the frame.
Warning
•Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approximately 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
3. Clean and degrease an approximately 50.0 mm {1.97 in} wide strip around the circumference of the glass
and the bonding area on the body.
PIN
PIN
A6E77381108
49 0305 870A
PROTECTIVE
TAPE SEALANT
REAR WINDOW
GLASS MOLDING
A6E77381109
49 0305 870A
A6E7738W021

T–1
T
TBODY ELECTRICAL SYSTEM
OUTLINE................................................................ T-2
OUTLINE OF CONSTRUCTION ......................... T-2
FEATURES .......................................................... T-2
POWER SYSTEM................................................... T-2
STRUCTURAL VIEW........................................... T-2
MULTIPLEX COMMUNICATION SYSTEM............ T-3
OUTLINE ............................................................. T-3
STRUCTRURAL VIEW ........................................ T-3
SYSTEM WIRING DIAGRAM .............................. T-4
CAN SIGNAL-CHART.......................................... T-4
ON-BOARD DIAGNOSTIC FUNCTION............... T-6
EXTERIOR LIGHTING SYSTEM............................ T-8
OUTLINE ............................................................. T-8
STRUCTURAL VIEW........................................... T-8
INTERIOR LIGHTING SYSTEM............................. T-8
STRUCTURAL VIEW........................................... T-8
WIPER AND WASHER........................................... T-9
OUTLINE ............................................................. T-9
STRUCTURAL VIEW........................................... T-9
WARNING AND INDICATOR SYSTEM............... T-10
OUTLINE ........................................................... T-10
STRUCTURAL VIEW......................................... T-10
SYSTEM WIRING DIAGRAM ............................ T-11
THEFT-DETERRENT SYSTEM............................ T-11
OUTLINE ........................................................... T-11
INTRUDER SENSOR ........................................ T-11
AUDIO AND NAVIGATION SYSTEM.................. T-13
OUTLINE ........................................................... T-13
STRUCTURAL VIEW......................................... T-13
CRUISE CONTROL SYSTEM.............................. T-13
OUTLINE ........................................................... T-13
AIR BAG SYSTEM............................................... T-13
OUTLINE ........................................................... T-13
OUTLINE.............................................................. T-14
SUPPLEMENTAL SERVICE INFORMATION ... T-14
LOCATION INDEX............................................... T-15
POWER SYSTEM.............................................. T-15
EXTERIOR LIGHTING SYSTEM ....................... T-15
INTERIOR LIGHTING SYSTEM ........................ T-16
WIPER AND WASHER SYSTEM ...................... T-16
WARNING AND INDICATOR SYSTEM............. T-17
THEFT-DETERRENT SYSTEM ........................ T-17
AUDIO AND NAVIGATION SYSTEM ................ T-18
AIR BAG SYSTEM............................................. T-18
POWER SYSTEM................................................. T-19
RELAY LOCATION ............................................ T-19
RELAY INSPECTION ........................................ T-19
EXTERIOR LIGHTING SYSTEM.......................... T-20
REAR AUTO LEVELING SENSOR
REMOVAL/INSTALLATION ............................ T-20HIGH-MOUNT BRAKE LIGHT
REMOVAL/INSTALLATION ............................ T-20
INTERIOR LIGHTING SYSTEM........................... T-21
CARGO COMPARTMENT LIGHT
REMOVAL/INSTALLATION ............................ T-21
CARGO COMPARTMENT LIGHT
INSPECTION .................................................. T-22
WIPER AND WASHER......................................... T-22
REAR WIPER MOTOR
REMOVAL/INSTALLATION ............................ T-22
REAR WIPER MOTOR INSPECTION ............... T-22
REAR WIPER ARM AND BLADE
REMOVAL/INSTALLATION ............................ T-23
REAR WIPER ARM AND BLADE
ADJUSTMENT ................................................ T-24
REAR WASHER NOZZLE
REMOVAL/INSTALLATION ............................ T-24
REAR WASHER NOZZLE ADJUSTMENT ........ T-25
REAR WASHER HOSE
REMOVAL/INSTALLATION ............................ T-25
INTERMITTENT REAR WIPER RELAY
REMOVAL/INSTALLATION ............................ T-26
WARNING AND INDICATOR SYSTEM............... T-27
FUEL GAUGE SENDER UNIT
REMOVAL/INSTALLATION ............................ T-27
FUEL GAUGE SENDER UNIT INSPECTION.... T-28
THEFT-DETERRENT SYSTEM............................ T-29
INTRUDER SENSOR
REMOVAL/INSTALLATION ............................ T-29
AUDIO AND NAVIGATION SYSTEM.................. T-30
NOISE FILTER REMOVAL/INSTALLATION ..... T-30
CONDENSER REMOVAL/INSTALLATION ....... T-30
ANTENNA FEEDER LOCATION ....................... T-31
REAR ANTENNA FEEDER INSPECTION ........ T-31
AIR BAG SYSTEM............................................... T-32
SERVICE WARNINGS....................................... T-32
CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION ............................ T-35
AIR BAG MODULE AND PRE-TENSIONER
SEAT BELT DEPLOYMENT PROCEDURES. T-35
ON-BOARD DIAGNOSTIC
[MULTIPLEX COMMUNICATION SYSTEM].... T-39
MULTIPLEX COMMUNICATION SYSTEM ....... T-39
DTC TABLE ....................................................... T-41
PID/DATA MONITOR TABLE ............................ T-41
PROCEDURES FOR DETERMINING
THE LOCATION OF A MALFUNCTION ......... T-42
DTC U0073, U1900, U2516 ............................... T-45 FEATURES
SERVICE

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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STRUCTURAL VIEWA6E811067730201
.
End Of Sie
OUTLINE
POWER SYSTEM
2
1
A6E81101102
1 Seat warmer relay (with seat warmer)2 Glow relay (MZR-CD (RF Turbo) only)

T–4
MULTIPLEX COMMUNICATION SYSTEM
SYSTEM WIRING DIAGRAMA6E811155430203
.
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
End Of Sie
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

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
.
End Of Sie
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
.
End Of Sie
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–17
T
End Of SieWARNING AND INDICATOR SYSTEMA6E810001067201
.
End Of SieTHEFT-DETERRENT SYSTEMA6E810050000201
.
End Of Sie
2
1
A6E81181112
1 Fuel gauge sender sub-unit
(See T–27 FUEL GAUGE SENDER UNIT
REMOVAL/INSTALLATION)
(See T–28 FUEL GAUGE SENDER UNIT
INSPECTION)2 Fuel gauge sender unit
(See T–27 FUEL GAUGE SENDER UNIT
REMOVAL/INSTALLATION)
(See T–28 FUEL GAUGE SENDER UNIT
INSPECTION)
3
12
A6E81201102
1 Front intruder sensor (with sliding sunroof)
2 Center intruder sensor (without sliding sunroof)3 Rear intruder sensor (WGN)