Temperature control MAZDA 6 2002 Suplement Manual PDF

M–76
ON-BOARD DIAGNOSTIC
ELECTRONIC 4WD CONTROL SYSTEM ON-BOARD DIAGNOSISA6E637027100202Reading DTCs Procedure
1. Connect WDS or equivalent to the vehicle DLC-2
16-pin connector.
2. Retrieve DTC by WDS or equivalent.
•If a DTC is displayed, proceed with inspection
steps for that DTC.
3. After repair, clear DTCs stored in the 4WD CM by
referring to the Clearing DTCs Procedure.
Clearing DTCs Procedures
1. Connect WDS or equivalent to the vehicle DLC-2
16-pin connector.
2. Clear DTCs by WDS or equivalent.
3. Turn the ignition key to OFF.
4. Perform the DTC inspection again, and verify that
no DTC appears.
5. Disconnect the WDS or equivalent.
DTC Table
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DLC-2
DLC-2
L.H.D.
R.H.D.
A6E63702005
DLC-2
DLC-2
L.H.D.
R.H.D.
A6E63702005
DTC
Diagnosis system component Page
WDS or equivalent
P1887 System wiring (See M–77 DTC P1887)
P1888 Differential oil temperature sensor (See M–79 DTC P1888)
U0100 PCM communication (See M–80 DTC U0100)
U0101 TCM communication (See M–80 DTC U0101)
U0121 ABS/DSC communication (See M–80 DTC U0121)

TROUBLESHOOTING
M–81
M
SYSTEM WIRING DIAGRAMA6E638027100201
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TROUBLESHOOTING
IGNITION SWITCH
BATTERY
DIFFERENTIAL OIL
TEMPERATURE
SENSOR4WD CM4WD SOLENOID ELECTRONIC CONTROL
COUPLING
CAN DRIVERINSTRUMENT CLUSTER
CAN-H
CAN-LPCM DSC HU/CM KO
P I
A
C
NH G
TCM
A6E63702002

N–8
ENGINE SPEED SENSING POWER STEERING
8. Open the gauge valve fully and increase the
engine speed to 1,000—1,500 rpm.
9. Turn the steering wheel fully to the left and right,
then measure the fluid pressure generated at the
gear housing.
•If the pressure is not within the specification,
repair or replace the steering gear
component.
Caution
•If the steering wheel is kept in the fully
turned position for more than 5 seconds,
the fluid temperature will rise excessively
and adversely affect the oil pump.
Gear housing fluid pressure
(MPa {kgf/cm
2, psi})
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
11. Bleed the air from the system.
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STEERING GEAR AND LINKAGE (MZR-CD (RF TURBO)) REMOVAL/INSTALLATIONA6E661432960201
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
L.H.D.
1. Remove the under cover and mud guard. (Left side)
2. Remove the front auto leveling sensor.
3. Separate the stabilizer control link. (shock absorber side)
4. Separate the front lower arm (front and rear) ball joint.
5. Remove the shock absorber bolt. (lower side)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect the toe-in.
9. Adjust the headlight zeroset.
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
THERMOMETER50—60
{122—140 }°
°F
GAUGE
OPEN VALVE
COMPLETELY
A6E0612W080

REAR SUSPENSION
R–13
R
REAR STABILIZER REMOVAL/INSTALLATION (4WD)A6E7416281002011. Remove the rear auto leveling sensor.
(See T–20 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the headlight zeroset.
.
Bolt (Differential Front Side) Removal Note
1. Disconnect differential oil temperature sensor connector and 4WD solenoid connector.
2. Support the differential with a jack as shown in
the figure.
3. Remove the bolt.
5
4
3
1
AA
2
6
GREASEGREASE
43.1—60.8
{4.40—6.19,
31.8—44.8}
74.5—104.9
{7.60—10.69, 54.95—77.37}
43.1—60.8
{4.40—6.19,
31.8—44.8}
RUBBER
GREASE
43.1—60.8
{4.40—6.19,
31.8—44.8}
N·m {kgf·m, ft·lbf} 75.5—94.5
{7.70—9.63, 55.7—69.6}
A6E74162007
1 Stabilizer control link
2 Coil spring component (One side only)
3 Stabilizer bracket
4 Bushing5 Bolt (Differential front side)
(See R–13 Bolt (Differential Front Side) Removal
Note)
(See R–14 Bolt (Differential Front Side) Installation
Note)
6 Rear stabilizer
JACK
A6E74162011

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–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

OUTLINE
U–3
U
Bold frames: New specification
Refrigerant pressure
switchType Dual-pressure: General area
Operating pressure
(MPa {kgf/cm
2, psi})
TypeTriple-pressure: L3 engine,
intensely hot area
– Operating pressure
(MPa {kgf/cm
2, psi})
Thermal protectorType Bimetallic (Indirect sensing type)
Operating temperature
(°C {°F})
Temperature control Reheat full air mix typeItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
ON
OFF0.166—0.226
{1.693—2.304,
24.08—32.77}2.94—3.34
{30.0—34.0,
427—483}
0.02
{0.20, 2.84}
or less0.39—0.79
{3.98—8.05,
56.6—114}
0.195—0.250
{1.989—2.549, 28.30—36.24}
ON
OFF
ON
OFF  HI and LO pressure switch
 Middle pressure switch0.176—0.216
{1.795—2.202,
25.53—31.31}2.94—3.34
{30.0—34.0,
427—483}
0.02 {0.20,
2.84} or less0.39—0.79
{3.98—8.05,
56.6—114}
0.195—0.250 {1.989—2.549,
28.30—36.24}
1.08—1.38
{11.1—14.0, 158—199}
1.39—1.65
{14.2—16.8,
202—238}
ON
OFF145—155
{293—311}:
European
(L.H.D. U.K.)
specs.
150—155
{302—311}:
GCC specs.
123—137 {254—278}
ON
OFF135—145
{275—293}
113—127 {236—260}

OUTLINE
U–5
U
Bold frames: New specificationEnd Of Sie
Refrigerant pressure
switchType Dual-pressure: General area
Operating pressure
(MPa {kgf/cm
2, psi})
TypeTriple-pressure: L3 engine,
intensely hot area
– Operating pressure
(MPa {kgf/cm
2, psi})
Thermal protectorType Bimetallic (Indirect sensing type)
Operating temperature
(°C {°F})
SensorSolar radiation sensor Photodiode
Ambient temperature sensor
Thermistor Cabin temperature sensor
Evaporator temperature
sensor
Water temperature sensor
ActuatorAir intake actuator Sliding contact type
Air mix actuator, airflow mode
actuatorPotentiometer type
Temperature control Reheat full air mix typeItemSpecification
L3, L8, LF MZR-CD (RF Turbo)
ON
OFF0.166—0.226
{1.693—2.304,
24.08—32.77}2.94—3.34
{30.0—34.0,
427—483}
0.02
{0.20, 2.84}
or less0.39—0.79
{3.98—8.05,
56.6—114}
0.195—0.250
{1.989—2.549, 28.30—36.24}
ON
OFF
ON
OFF  HI and LO pressure switch
 Middle pressure switch0.176—0.216
{1.795—2.202,
25.53—31.31}2.94—3.34
{30.0—34.0,
427—483}
0.02 {0.20,
2.84} or less0.39—0.79
{3.98—8.05,
56.6—114}
0.195—0.250 {1.989—2.549,
28.30—36.24}
1.08—1.38
{11.1—14.0, 158—199}
1.39—1.65
{14.2—16.8,
202—238}
ON
OFF145—155
{293—311}:
European
(L.H.D. U.K.)
specs.
150—155
{302—311}:
GCC specs.
123—137 {254—278}
ON
OFF135—145
{275—293}
113—127 {236—260}

U–6
CONTROL SYSTEM
WATER HEATER SYSTEMA6E854000169201Outline
•The function, structure and operation of the water heater system is essentially carried over from that of the
current MPV (LW) model, except for following:
—Full/half switching temperature has been changed.
Structural View
.
Operation
Full/half switching
•Depending on the engine coolant temperature, the CPU sets the flame to either full or half strength settings.
.
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CONTROL SYSTEM
1
2
A6E85402002
1 Water heater unit2 Fuel pump (water heater system)
3
1
2
68
{154}74
{165}75
{167}78
{172}˚C
{˚F}
A6E85402003
1 Full mode
2 Half mode3 Idle mode

CONTROL SYSTEM
U–17
U
1B +5 V•Air mix actuator
•Airflow mode
actuator
•Solar radiation
sensorIgnition switch at ON
position
5.0•Inspect for short circuit
(Climate control unit— air
mix actuator, airflow mode
actuator, solar radiation
sensor: 1B—B, B, A)
•Inspect air mix actuator
•Inspect airflow mode
actuator
•Inspect solar radiation
sensor
•Inspect terminal voltage of
climate control unit
connector (2H, 2L)
Ignition switch at LOCK
positionBelow 1.0•Replace climate control unit
1C Blower motor
control signalPower MOS FET Fan switch is OFF Below 1.0•Inspect terminal voltage of
climate control unit (1A)
Fan switch is at manual
LO4.1
Fan switch is at manual
HI7.9
1D—— —— —
1E Rear window
defroster SW
signalRear window
defroster relayRear window defroster
switch is off
12•Inspect for continuity or
short circuit (Climate control
unit—rear window defroster
relay: 1E—E)
•Inspect rear window
defroster relay
Rear window defroster
switch is on Below 1.0•Inspect terminal voltage of
climate control unit (2H, 2L)
•Inspect center panel
1F On-board
diagnostic signalA/C check
connectorTerminal A of A/C check
connector is shorted. Below 1.0•Inspect for continuity
(Climate control unit—A/C
check connector: 1F—A)
Other
5.4•Inspect short circuit (Climate
control unit—A/C check
connector: 1F—A)
•Inspect terminal voltage of
climate control unit (2H, 2L)
1G—— —— —
1H—— —— —
1I GND•Cabin
temperature
sensor
•Evaporator
temperature
sensor
•Ambient
temperature
sensor
•Water
temperature
sensor
•Air mix actuator
•Airflow mode
actuatorUnder any condition
Below 1.0•Inspect terminal voltage of
climate control unit (2L)
1J Water heater
selectGround Under any condition
Below 1.0•Inspect for continuity
(Climate control unit—
ground: 1J—GND)
•Inspect center panel Terminal Signal Connected to Test condition Voltage (V) Action