service MAZDA 6 2002 Workshop Manual Suplement

S–1
S
SBODY
OUTLINE................................................................ S-2
OUTLINE OF CONSTRUCTION ......................... S-2
FEATURES .......................................................... S-2
EXTERIOR ATTACHMENT.................................... S-2
OUTLINE ............................................................. S-2
STRUCTURAL VIEW........................................... S-2
TRIM....................................................................... S-3
OUTLINE ............................................................. S-3
STRUCTURAL VIEW........................................... S-3
SEAT....................................................................... S-4
OUTLINE ............................................................. S-4
STRUCTURAL VIEW........................................... S-4
OUTLINE................................................................ S-5
SUPPLEMENTAL SERVICE INFORMATION ..... S-5
LOCATION INDEX................................................. S-6
EXTERIOR........................................................... S-6
INTERIOR ............................................................ S-7
LIFTGATE............................................................... S-8
LIFTGATE REMOVAL/INSTALLATION............... S-8
LIFTGATE DISASSEMBLY/ASSEMBLY ............. S-9
LIFTGATE ADJUSTMENT................................. S-10
EXTERIOR ATTACHMENT.................................. S-11
EXTRACTOR CHAMBER
REMOVAL/INSTALLATION ............................ S-11
REAR SPOILER REMOVAL/INSTALLATION ... S-11
ROOF RAIL REMOVAL/INSTALLATION .......... S-11
MOLDING............................................................. S-12
ROOF MOLDING REMOVAL ............................ S-12
ROOF MOLDING INSTALLATION .................... S-12
WINDOW GLASS................................................. S-14
SIDE WINDOW GLASS REMOVAL .................. S-14
SIDE WINDOW GLASS INSTALLATION .......... S-14
REAR WINDOW GLASS REMOVAL................. S-16
REAR WINDOW GLASS INSTALLATION ......... S-17
SLIDING SUNROOF............................................. S-20
REAR DRAIN HOSE REMOVAL ....................... S-20
TRIM..................................................................... S-21
C-PILLAR TRIM REMOVAL/INSTALLATION .... S-21
D-PILLAR TRIM REMOVAL/INSTALLATION .... S-21
TRUNK SIDE TRIM
REMOVAL/INSTALLATION ............................ S-21
TRUNK SIDE UPPER TRIM
REMOVAL/INSTALLATION ............................ S-22
TRUNK END TRIM
REMOVAL/INSTALLATION ............................ S-23
LIFTGATE UPPER TRIM
REMOVAL/INSTALLATION ............................ S-23
LIFTGATE SIDE TRIM
REMOVAL/INSTALLATION ............................ S-24
LIFTGATE LOWER TRIM
REMOVAL/INSTALLATION ............................ S-24TONNEAU COVER ANCHOR
REMOVAL/INSTALLATION ............................ S-25
HEADLINER......................................................... S-26
HEADLINER REMOVAL/INSTALLATION ......... S-26
FLOOR COVERING............................................. S-27
FRONT FLOOR COVERING
REMOVAL/INSTALLATION ............................ S-27
SEAT BELT.......................................................... S-28
REAR SIDE SEAT BELT
REMOVAL/INSTALLATION ............................ S-28
REAR CENTER SEAT BELT
REMOVAL/INSTALLATION ............................ S-28
SEAT..................................................................... S-29
REAR SEAT REMOVAL/INSTALLATION.......... S-29
REAR SEAT DISASSEMBLY/ASSEMBLY ........ S-29 FEATURES
SERVICE

OUTLINE
S–5
S
SUPPLEMENTAL SERVICE INFORMATIONA6E770201086203•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Liftgate
•Removal/Installation procedure has been modified.
•Disassembly/Assembly procedure has been modified.
•Adjustment procedure has been modified.
Extractor chamber
•Removal/Installation procedure has been modified.
Roof rail
•Removal/Installation procedure has been added.
Rear spoiler
•Removal/Installation procedure has been modified.
Roof molding
•Removal procedure has been modified.
•Installation procedure has been modified.
Side window glass
•Removal procedure has been added.
•Installation procedure has been added.
Rear window glass
•Removal procedure has been modified.
•Installation procedure has been modified.
Rear drain hose
•Removal procedure has been modified.
C-pillar trim
•Removal/Installation procedure has been modified.
D-pillar trim
•Removal/Installation procedure has been added.
Trunk side trim
•Removal/Installation procedure has been modified.
Trunk side upper trim
•Removal/Installation procedure has been modified.
Trunk end trim
•Removal/Installation procedure has been modified.
Liftgate upper trim
•Removal/Installation procedure has been modified.
Liftgate side trim
•Removal/Installation procedure has been modified.
Liftgate lower trim
•Removal/Installation procedure has been modified.
Tonneau cover anchor
•Removal/Installation procedure has been added.
Headliner
•Removal/Installation procedure has been modified.
Front floor covering
•Removal/Installation procedure has been modified.
Rear side seat belt
•Removal/Installation procedure has been modified.
Rear center seat belt
•Removal/Installation procedure has been modified.
Rear seat
•Removal/Installation procedure has been modified.
•Disassembly/Assembly procedure has been modified.
End Of Sie
OUTLINE

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–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

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

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

T–32
AIR BAG SYSTEM
SERVICE WARNINGSA6E813001046202Component Disassembly
•Disassembling and reassembling the
components of the air bag system can render
the system inoperative, which may result in
serious injury or death in the event of an
accident. Do not disassemble any air bag
system components.
Wiring Harness Repair
•Incorrectly repairing an air bag system wiring
harness can accidentally deploy the air bag
module or pre-tensioner seat belt, which can
cause serious injury. If a problem is found in
the system wiring, replace the wiring harness.
Do not try to repair it.
Air Bag Module Inspection
•Inspecting an air bag module using an
ohmmeter can deploy the air bag module,
which may cause serious injury. Do not use an
ohmmeter to inspect an air bag module.
Always use the on-board diagnostic to
diagnose the air bag module for malfunctions.
Air Bag Module Handling
•A live (undeployed) air bag module may
accidentally deploy when it is handled and
cause serious injury. When carrying a live
(undeployed) air bag module, point the front
surface away from your body to lessen the
chance of injury in case it deploys.
AIR BAG SYSTEM
A6E8130W044
A6E8130W045
A6E8130W024
A6E8130W022

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

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

U–1
U
UHEATER AND AIR CONDITIONER SYSTEMS
OUTLINE................................................................ U-2
OUTLINE OF CONSTRUCTION.......................... U-2
FEATURES .......................................................... U-2
SPECIFICATIONS ............................................... U-2
CONTROL SYSTEM............................................... U-6
WATER HEATER SYSTEM................................. U-6
OUTLINE................................................................ U-7
SUPPLEMENTAL SERVICE INFORMATION .....U-7
LOCATION INDEX.................................................U-8
BASIC SYSTEM................................................... U-8
CONTROL SYSTEM ............................................ U-9
BASIC SYSTEM................................................... U-10
A/C UNIT REMOVAL/INSTALLATION...............U-10
A/C COMPRESSOR
REMOVAL/INSTALLATION ............................U-11
CONDENSER REMOVAL/INSTALLATION ....... U-12
REFRIGERANT LINES
REMOVAL/INSTALLATION ............................U-13
CONTROL SYSTEM............................................. U-15
WATER HEATER UNIT
REMOVAL/INSTALLATION ............................U-15
FUEL PUMP (WATER HEATER SYSTEM)
INSPECTION .................................................. U-16
CLIMATE CONTROL UNIT INSPECTION.........U-16
ON-BOARD DIAGNOSTIC...................................U-22
FOREWORD ......................................................U-22
DTC TABLE ................................................... U-22-2
PID/DATA MONITOR AND RECORD ........... U-22-2
DTC B1317 .................................................... U-22-3
DTC B1318 ........................................................ U-23
DTC B1342, B2463, B2537, B2538, B2547 ....... U-23
DTC B2449, B2450 ............................................ U-24
DTC B2451, B2452 ............................................ U-24
DTC B2453, B2454 ............................................ U-25
DTC B2548 ........................................................ U-25
TROUBLESHOOTING.......................................... U-26
FOREWORD ......................................................U-26
TROUBLESHOOTING INDEX ...........................U-26 FEATURES
SERVICE