brake MAZDA 6 2002 Workshop Manual Suplement

TRIM
S–23
S
TRUNK END TRIM REMOVAL/INSTALLATIONA6E774468890201WGN
1. Pull the trunk end trim upward, then disengage
clips A and pins B from the body.
2. Remove the trunk end trim.
3. Install in the reverse order of removal.
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LIFTGATE UPPER TRIM REMOVAL/INSTALLATIONA6E774468930201WGN
Without rear spoiler
Caution
•Removing the liftgate upper trim by pulling on the middle section of the trim could damage the
high-mount brake light. When removing the trim, be sure to pull on the side edges of the trim only.
1. Pull the liftgate upper trim on the side edges
towards you, then disengage pins A from the
body.
2. Pull the middle section of the trim towards you
and disengage clips B and pin C from the body.
3. Remove the liftgate upper trim.
4. Install in the reverse order of removal.
With rear spoiler
1. Pull the liftgate upper trim toward you, then
disengage the pin A, C and clip B from the body.
2. Remove the liftgate upper trim.
3. Install in the reverse order of removal.
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AB
A
A
B
A
A
A B
TRUNK END TRIM
PIN B
CLIP A
A6A7744W108
AC B
AB
CLIP B
PIN A LIFTGATE UPPER TRIM
PIN C
A6A7744W109
ABAB
C
CLIP BPIN C LIFTGATE UPPER TRIM
PIN A
A6A7744W110

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)
End Of Sie
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–

T–8
EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM
OUTLINEA6E811201052201•In-vehicle-type high-mount brake light and rear spoiler type high-mount brake light have been adopted. (WGN)
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STRUCTURAL VIEWA6E811201052202
.
End Of Sie
STRUCTURAL VIEWA6E811401052201
.
End Of Sie
EXTERIOR LIGHTING SYSTEM
2
1
A6E8112T101
1 High-mount brake light (in-vehicle-type)2 High-mount brake light (rear spoiler type)
INTERIOR LIGHTING SYSTEM
FRONT
1
A6E81141001
1 Cargo compartment light

T–14
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E810201088203•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Relay
•Location has been changed.
•Inspection procedure has been modified.
Rear auto leveling sensor
•Removal/Installation procedure has been modified.
High-mount brake light
•Removal/Installation procedure has been modified.
Cargo compartment light
•Removal/Installation procedure has been modified.
•Inspection procedure has been modified.
Rear wiper motor
•Removal/Installation procedure has been modified.
•Inspection procedure has been modified.
Rear wiper arm and blade
•Removal/Installation procedure has been modified.
•Adjustment procedure has been modified.
Rear washer nozzle
•Removal/Installation procedure has been modified.
•Adjustment procedure has been modified.
Rear washer hose
•Removal/Installation procedure has been modified.
Intermittent rear wiper relay
•Removal/Installation procedure has been modified.
Fuel gauge sender unit
•Removal/Installation procedure has been modified.
•Inspection procedure has been modified.
Intruder sensor
•Removal/Installation procedure has been modified.
Noise filter
•Removal/Installation procedure has been modified.
Condenser
•Removal/Installation procedure has been modified.
Antenna feeder
•Location has been changed.
Rear antenna feeder
•Inspection procedure has been modified.
Curtain air bag module
•Removal/Installation procedure has been added.
Air bag module and pre-tensioner seat belt
•Deployment procedure has been modified.
On-board diagnostic
•Multiplex communication system procedure has been modified.
End Of Sie
OUTLINE

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)

T–20
EXTERIOR LIGHTING SYSTEM
REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATIONA6E8112510302011. Disconnect the negative battery cable.
2. Jack up the vehicle.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Adjust the headlight zeroset.
End Of SieHIGH-MOUNT BRAKE LIGHT REMOVAL/INSTALLATIONA6E811251580201In-vehicle-type
1. Disconnect the negative battery cable.
2. Remove the liftgate upper trim.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
EXTERIOR LIGHTING SYSTEM
1 Connector
2Bolt
3Bracket
4 Rear auto leveling sensor
2
1
3
4
4
6.9—9.8 N·m {70—99 kgf·cm, 61—85 in·lbf}
REAR STABILIZER
3
A6E81121158
1 Connector
2Socket
3 High-mount brake light bulb
4 High-mount brake light
12
3HOOK
LIFTGATE
4
A6A8112W113

EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM
T–21
T
Rear spoiler type
1. Disconnect the negative battery cable.
2. Remove the rear spoiler.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
End Of Sie
CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATIONA6E8114514412011. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Lens Removal Note
1. Insert a tape-wrapped flathead screwdriver into
the service hole.
2. Twist the flathead screwdriver as indicated by the
arrow to remove the lens.
End Of Sie
1Bolt
2 Cover
3 Connector
4 High-mount brake light
4
12
3
A6J81121004
INTERIOR LIGHTING SYSTEM
1Lens
(See T–21 Lens Removal Note)
2 Cargo compartment light bulb
3 Screw (if equipped)
4 Cargo compartment light
5 Connector
12
33
4
5
A6J81141102
SERVICE HOLE
A6A8114W104

T–24
WIPER AND WASHER
Rear Wiper Arm Installation Note
1. Clean the rear wiper arm connector shaft using a
wire brush before installing the rear wiper arm.
End Of SieREAR WIPER ARM AND BLADE ADJUSTMENTA6E8116674202021. Operate the rear wiper motor to set the wiper in the park position.
2. Set the rear wiper arm onto the ceramic end line.
End Of SieREAR WASHER NOZZLE REMOVAL/INSTALLATIONA6E8116675112011. Disconnect the negative battery cable.
2. Remove the liftgate upper trim. (See S–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION)
3. Remove the high-mount brake light (In-vehicle-type).
4. Remove the rear washer hose from the rear washer nozzle.
5. Squeeze the tabs of the rear washer nozzle.
6. Pull the rear washer nozzle out to remove it.
7. Install in the reverse order of removal.
8. Adjust the rear washer nozzle. (See T–25 REAR
WASHER NOZZLE ADJUSTMENT.)
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REAR WIPER ARM
CONNECTOR
SHAFT
A6E81161103
20—23
CERAMIC
END LINE GLASS
END LINE
CERAMIC
END
LINE
GLASS
END LINE {0.8—0.9}
mm {in}
A6E81161129
TA B
A6E81161105