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Mazda 6 Facelift 2005, Training Manual

The Mazda 6 Facelift 2005 Training Manual is a comprehensive guide for owners of this sleek and stylish vehicle. Designed to provide step-by-step instructions, troubleshooting tips, and helpful insights, this manual is essential for anyone looking to ensure optimal performance. Download the user manual for free from our website today.

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01 Engine 

Table of Contents (continued) 

Charging System...............................................................................................77 

Specifications................................................................................................77 
Parts Location ...............................................................................................77 
Smart Charging System ................................................................................78 

Control System..................................................................................................79 

Parts Location ...............................................................................................79 
Wiring Diagram .............................................................................................82 
Powertrain Control Module............................................................................86 
Crankshaft Position Sensor...........................................................................87 
Camshaft Position Sensor.............................................................................88 
Accelerator Pedal Position Sensor................................................................89 
Power Steering Pressure Switch...................................................................92 
Service And Repair .......................................................................................93 

Replacing the Engine Oil ........................................................................93 
Manual Regeneration .............................................................................93 
Replacing the MAF Sensor.....................................................................94 
Replacing the High-Pressure Pump........................................................94 
Replacing Injectors .................................................................................94 
Replacing the EGR Valve Or The ISV ....................................................95 
Replacing the DPF..................................................................................95 
Replacing the DPF Differential Pressure Sensor ....................................95 
Replacing the HO2S ...............................................................................96 
Replacing the PCM.................................................................................96 

On-board Diagnostic System ...........................................................................97 

Self Test........................................................................................................97 
PID Monitor ...................................................................................................98 
Simulation Test ...........................................................................................101 

Table of Contents 01 

Service Training Mazda6 Facelift 

Summary of Contents for 6 Facelift 2005

Page 1: ...TRAINING MANUAL Mazda6 Facelift ...

Page 2: ...rmation data and descriptive text in this issue to the best of our knowledge were correct at the time of going to print No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible 2005 Mazda Motor Europe GmbH Training Services ...

Page 3: ...Contents General Information 00 Engine 01 Suspension 02 Brakes 04 Transmission Transaxle 05 Restraints 08 Body Accessories 09 Section Title Service Training Mazda6 Facelift ...

Page 4: ...Service Training Mazda6 Facelift ...

Page 5: ...00 General Information ...

Page 6: ...00 General Information Vehicle Identification Number VIN Code 1 Applicable VIN 1 Engine Transaxle Combinations 2 Scheduled Maintenance 3 Europe 3 Table of Contents 00 Service Training Mazda6 Facelift ...

Page 7: ...T001 Applicable VIN JMZ GG1236 600001 JMZ GG12360 600001 JMZ GG1282 600001 JMZ GG12820 600001 JMZ GG12F6 600001 JMZ GG12F60 600001 JMZ GG12R6 600001 JMZ GG12R60 600001 JMZ GG12T6 600001 JMZ GG12T60 600001 JMZ GG1436 600001 JMZ GG14360 600001 JMZ GG1482 600001 JMZ GG14820 600001 JMZ GG14F6 600001 JMZ GG14F60 600001 JMZ GG14R6 600001 JMZ GG14R60 600001 JMZ GG14T6 600001 JMZ GG14T60 600001 JMZ GY1936...

Page 8: ...saxle FS5A EL 5 speed automatic transaxle front wheel drive JA5AX EL 5 speed automatic transaxle All Wheel Drive AWD M6FL_00T002 L8 1 8L 88 KW 120 HP at 5 500 rpm 165 Nm at 4 300 rpm L3 2 3L 122 KW 166 HP at 6 500 rpm 207 Nm at 4 000 rpm RF Turbo STD 2 0L 89 KW 121 HP at 3 500 rpm 320 Nm at 2 000 rpm X X X X RF Turbo HI 2 0L 105 KW 143 HP at 3 500 rpm 360 Nm at 2 000 rpm LF 2 0L 108 KW 147 HP at 6...

Page 9: ...ESEL ENGINE Drive belt 4 Engine coolant Front and rear suspension and ball joints Drive shaft dus boots Replace every 120 000 km 75 000 miles Replace every 200 000 km 125 000 miles 0r 11 years Tires including spare tire with inflation pressure adjustment Exhaust system and heat shields Battery electrolyte level and specific gravity Brakes lines hoses and connections Steering operation and linkages...

Page 10: ...inspect and adjust the power steering and air conditioner drive belts if installed 5 Use FL22 type coolant in vehicles with the inscription FL22 on the radiator cap itself or the surrounding area Use FL22 when replacing the coolant 6 If the brakes are used extensively for example continuous hard driving or mountain driving or if the vehicle is operated in extremely humid climates change the brake ...

Page 11: ...01 Engines ...

Page 12: ...Module PCM 11 PCM Connector Harness Side Shown 11 Overview 12 Wiring Diagram 14 Accelerator Pedal Position APP Sensor 18 Throttle Valve Actuator 20 Throttle Position TP Sensor 21 TP Sensor Voltage Characteristics 22 Heated Oxygen Sensors HO2S 23 Front HO2S 24 Rear HO2S 25 Crankshaft Position CKP Sensor 26 Camshaft Position CMP Sensor 28 Diesel Engines Mechanics 29 Pistons 30 Cylinder Head 31 Lubri...

Page 13: ...mount Learning Function 49 Emission System 50 Parts Location 50 Exhaust System 51 Parts Location 51 Exhaust Gas Recirculation System 52 EGR Valve 52 EGR Cooler 55 Intake Shutter Valve 56 Diesel Particulate Filter System 59 Diesel Particulates 59 Diesel Particulate Filter 60 DPF Differential Pressure Sensor 63 Diagnostics 66 Exhaust Gas Temperature Sensors 68 Heated Oxygen Sensor 70 DPF Indicator L...

Page 14: ...Sensor 89 Power Steering Pressure Switch 92 Service And Repair 93 Replacing the Engine Oil 93 Manual Regeneration 93 Replacing the MAF Sensor 94 Replacing the High Pressure Pump 94 Replacing Injectors 94 Replacing the EGR Valve Or The ISV 95 Replacing the DPF 95 Replacing the DPF Differential Pressure Sensor 95 Replacing the HO2S 96 Replacing the PCM 96 On board Diagnostic System 97 Self Test 97 P...

Page 15: ... On LF and L3 engines a hole is provided for installation of the OCV Oil Control Valve A dipstick insertion hole has been equipped to the cylinder head cover M6FL_01001 1 CMP Camshaft Position sensor attachment part 3 OCV attachment hole LF L3 2 Dipstick insertion hole Service Training Mazda6 Facelift 01 1 ...

Page 16: ...ne All engines use a sensor ring with 6 reference cams for the CMP Sensor on the intake camshaft M6FL_01002 1 Timing chain 7 Valve assembly 2 Camshaft sprocket 8 Tappet 3 Tensioner arm 9 Camshafts 4 Chain tensioner 10 OCV 5 Crankshaft sprocket 11 Variable valve timing actuator 6 Chain guide 01 2 Service Training Mazda6 Facelift ...

Page 17: ... and the LF engine M6FL_01003 1 Oil pump chain tensioner 11 Oil jet valve 2 Oil pump chain guide 12 Oil cooler LF L3 3 Oil pump chain 13 Gasket 4 Oil pump sprocket 14 Oil pressure switch 5 Oil pump 15 Oil filter adapter 6 O ring 16 Oil filter 7 Oil strainer 17 Oil filter cover 8 Washer 18 Oil filter drain plug 9 Oil pan drain plug 19 Cartridge type oil filter 10 Oil pan 20 Spin on type oil filter ...

Page 18: ...now use an electronic throttle control For the LF engine the VIS has been carried over from the L3 engine M6FL_01004 1 Air cleaner 8 VIS shutter valve actuator LF L3 2 Accelerator pedal 9 Throttle body 3 VAD solenoid valve L3 10 VAD check valve one way L3 4 VAD shutter valve L3 11 Intake manifold 5 Resonance chamber 12 VIS solenoid valve LF L3 6 VAD vacuum chamber L3 13 VTCS solenoid valve 7 VTCS ...

Page 19: ...to prevent the throttle valve from getting stuck engine coolant is circulated through the throttle body The throttle body cannot be disassembled When the throttle actuator is not energized the throttle valve is maintained slightly open by the force of the return spring This allows limited operation of the engine in case of a malfunction M6FL_01005 1 Throttle body 3 TP Throttle Position sensor 2 Th...

Page 20: ... Vehicles specified with LF engine are now using the exhaust system with two main silencers previously used on L3 engines only M6FL_01006 1 Main silencer 5 HO2S front 2 Middle pipe 6 Exhaust manifold 3 HO2S Heated Oxygen Sensor rear 7 LF L3 4 TWC Three Way Catalyst 01 6 Service Training Mazda6 Facelift ...

Page 21: ...r transistor is controlled by a duty signal from the PCM A generator duct made of plastic and a generator heat insulator made of iron have been adopted to protect the generator from the exhaust manifold heat M6FL_01007 1 Pulley 7 Regulator component built in power transistor 2 Front cover 8 Rectifier 3 Front bearing 9 Rear cover 4 Rotor 10 Terminal B connector 5 Rear bearing 11 Heat insulator 6 St...

Page 22: ...mized as a result stable voltage output is supplied The generator warning light in the instrument cluster illuminates under the following conditions Charging system voltage low input Charging system voltage high input IAT sensor circuit low input IAT sensor circuit high input M6FL_01008 1 Stator coil 5 CAN Controller Area Network 2 Terminal not used 6 Instrument cluster warning light 3 PCM 7 Power...

Page 23: ...firing control The direct ignition coil consists of an ignition coil ignition coil connector and boot area which has the same function as the current high tension lead The igniter has been integrated into each ignition coil The firing timing of the coil is controlled by the PCM for optimum ignition timing control M6FL_01009 1 Ignition coil external view 7 Cylinder number No 3 2 Ignition coil 8 Cyl...

Page 24: ...ge switch ATX Automatic Transaxle 5 Brake switch 17 TP sensor throttle actuator 6 Clutch switch MTX 18 MAP Manifold Absolute Pressure sensor 7 OCV LF L3 19 CKP Crankshaft Position sensor 8 Fuel injectors 20 KS Knock Sensor 9 CMP sensor 21 P S Power Steering pressure switch 10 EGR Exhaust Gas Recirculation valve 22 VTCS solenoid valve 11 MAF Mass Air Flow IAT Intake Air Temperature sensor 23 VIS so...

Page 25: ...n introduced It is installed on the left hand side under the dashboard Right hand drive vehicles have two additional PCM covers secured with set bolts M6FL_01011 1 PCM connectors 2 PCM PCM Connector Harness Side Shown The PCM has two connectors with 60 pins each M6FL_01012 Service Training Mazda6 Facelift 01 11 ...

Page 26: ...Petrol Engines Engine Overview M6FL_01013 01 12 Service Training Mazda6 Facelift ...

Page 27: ...wo way 11 Throttle actuator 32 Pressure regulator 12 MAP Manifold Absolute Pressure sensor 33 Fuel filter high pressure 13 VIS control solenoid valve LF L3 34 Fuel pump 14 VTCS solenoid valve 35 Fuel filter low pressure 15 VIS shutter valve actuator LF L3 36 Rollover valve 16 VIS shutter valve LF L3 37 Fuel tank 17 VTCS shutter valve actuator 38 Purge solenoid valve 18 VTCS shutter valve 39 Igniti...

Page 28: ...Petrol Engines Engine Wiring Diagram M6FL_01014 01 14 Service Training Mazda6 Facelift ...

Page 29: ... 21 Security light 7 Refrigerant pressure switch high and low 22 Drive by wire relay 8 Brake switch No 1 23 Ignition switch 9 Brake switch No 2 24 Battery 10 Rear HO2S 25 VAD solenoid valve 11 Clutch pedal position switch 26 Starter relay 12 Neutral switch 27 Starter interlock switch 13 VSS Vehicle Speed Sensor 28 VSS output signal 14 PCM 29 MTX without ABS DSC 15 FAN relay 30 MTX Service Training...

Page 30: ...Petrol Engines Engine Wiring Diagram Continued M6FL_01015 01 16 Service Training Mazda6 Facelift ...

Page 31: ...or 47 Throttle actuator 35 Generator 48 Ignition coil No 1 36 Front HO2S 49 Ignition coil No 2 37 MAP sensor 50 Ignition coil No 3 38 ECT sensor 51 Ignition coil No 4 39 TP sensor 52 Fuel injector No 1 40 Front HO2S heater 53 Fuel injector No 2 41 Generator 54 Fuel injector No 3 42 Purge solenoid valve 55 Fuel injector No 4 Service Training Mazda6 Facelift 01 17 ...

Page 32: ...ct accelerator pedal movement This non contact sensor type improves durability The APP sensor is composed of a main sensor and a sub sensor and detects the accelerator actuating angle with these two sensors main and sub M6FL_01016 1 Accelerator pedal 2 APP Sensor 01 18 Service Training Mazda6 Facelift ...

Page 33: ...he APP sensor fail the signals necessary for the drive by wire control are not input to the PCM and the drive by wire control is disabled However even though the drive by wire control is disabled the throttle valve opening angle necessary for minimum driving is maintained mechanically M6FL_01017 1 Main sensor duty 6 Large 2 Sub sensor voltage 7 Accelerator pedal depression amount 3 High 8 Small 4 ...

Page 34: ...this the previous IAC valve has been eliminated After the ignition switch is turned off the PCM opens and closes the throttle valve At this time the input voltage of the TP sensor at the fully closed position and the fully open position is stored This learned voltage measurement at the fully closed and open position is used when correcting the throttle opening angle If the PCM detects any of the f...

Page 35: ...opening angle with these two sensors main and sub Even if a malfunction occurs in either one of the sensors the detection is performed and drive by wire control is maintained If both the main and the sub sensor for the TP sensor fail the signals necessary for the drive by wire control are not input to the PCM and the drive by wire control is disabled However even though the drive by wire control i...

Page 36: ...Petrol Engines Engine TP Sensor Voltage Characteristics M6FL_01019 1 TP sensor No 1 4 Throttle opening angle 2 TP sensor No 2 5 Output voltage 3 Large 6 High 01 22 Service Training Mazda6 Facelift ...

Page 37: ...tect the oxygen concentration in the exhaust gas in all ranges from lean to rich air fuel mixture The rear HO2S detects the oxygen concentration in the exhaust gas behind the TWC Integral heating elements allow stable detection of the oxygen concentration even when the exhaust gas temperature is low M6FL_01020 A 2WD B 4WD 1 Exhaust manifold 3 HO2S rear 2 HO2S front 4 TWC Service Training Mazda6 Fa...

Page 38: ...to facilitate the activation of the HO2S at engine startup when the exhaust gas temperature is low The wide range oxygen sensor converts the oxygen concentration in the exhaust gas into a current value and sends the value to the PCM The PCM calculates the λ lambda value of the air fuel mixture based on the received current value M6FL_01021 1 Current mA 3 Air fuel ratio 2 λ Lambda 01 24 Service Tra...

Page 39: ...s the voltage generated from the HO2S directly and increases or decreases the fuel injection amount by the fuel injection control so that it is close to the stoichiometric air fuel ratio When the temperature of the zirconium element is low electromotive force is not generated Therefore the HO2S is heated by a built in heater facilitating the oxygen sensor activation Due to this the sensor is effic...

Page 40: ...KP sensor is installed near the crankshaft pulley The crankshaft position sensor pulse wheel has 30 projections with 10 of crank angle between the rising edge of each projection M6FL_01023 1 CKP Sensor 2 Crankshaft Pulley 01 26 Service Training Mazda6 Facelift ...

Page 41: ... magnetic field The size of the magnetic field detected by the GMR element is changed into square waves at the signal processing circuit and then sent to the PCM NOTE If the crankshaft position sensor is removed installed or replaced magnetized objects such as metal shavings adhering to the sensor could cause fluctuation in the magnetic flux causing abnormal sensor output which could adversely aff...

Page 42: ...on the cylinder head cover Six pulses per one camshaft rotation are detected The CMP sensor uses the same operating principle like the CKP sensor M6FL_01025 1 CMP sensor 5 CMP output signal 2 Rotation 6 PCM 3 Camshaft 7 CPU 4 From main relay 01 28 Service Training Mazda6 Facelift ...

Page 43: ...Engine Diesel Engines Mechanics The mechanical system of the 2 0 MZR CD engine basically has been carried over from previous model ranges M6FL_01030 Service Training Mazda6 Facelift 01 29 ...

Page 44: ...ave been introduced to achieve a lower compression ratio of 16 7 This leads to lower pumping losses and optimized thermal efficiency at middle and high engine load improving the fuel consumption M6FL_01052 1 Coating 2 Combustion chamber 01 30 Service Training Mazda6 Facelift ...

Page 45: ...Engine Diesel Engines Cylinder Head A cylinder head with integrated leak off lines for the injectors has been introduced M6FL_01058 Service Training Mazda6 Facelift 01 31 ...

Page 46: ... pressure kPa kgf cm psi 78 118 0 8 1 2 11 3 17 1 Total dry engine L US qt lmp qt 5 5 5 8 4 8 Oil replacement L US qt lmp qt 4 9 5 2 4 3 Oil and oil filter replacement L US qt lmp qt 5 1 5 4 4 5 Oil pressure reference value oil temperature 100 C 212 F Type Item Oil capacity approx quantity Oil filter Type Type Type Oil pump M6FL_01T009 Engine Oil Item Specification Grade ACEA C1 or JASO DL 1 Visco...

Page 47: ...es Parts Location M6FL_01031 1 Oil filter 7 Oil pan 2 Oil cooler 8 Oil strainer 3 O ring 9 Gasket 4 Oil jet valve 10 Oil pressure switch 5 Oil drain plug 11 Oil pump 6 Sealing washer Service Training Mazda6 Facelift 01 33 ...

Page 48: ...ed proportion of these components NOTE The use of engine oil with a higher ash formation is strictly forbidden as this can lead to blockage of the DPF Diesel Particulate Filter The usable filter volume would be reduced significantly due to the higher ash amount deposited in the DPF As a result the regeneration intervals are shortened so that the fuel consumption and hence the oil dilution are incr...

Page 49: ...stick to make the customer aware of this condition If the oil level is close to or exceeds the X mark the engine oil must be replaced NOTE Every time the engine oil is replaced the parameter Calculated oil dilution in the PCM must be reset refer to the section Control System Service and Repair M6FL_01060 1 L mark Low 3 X mark Excessive 2 F mark Full Service Training Mazda6 Facelift 01 35 ...

Page 50: ...In addition the customer must be informed to change the driving method such as driving the vehicle at middle or high engine speeds for a longer distance so that regeneration of the DPF is enabled If the engine oil performance and engine oil level is approaching the limit due to oil dilution the DPF indicator light flashes and DTC P253F is stored in the PCM In addition the PCM reduces the fuel inje...

Page 51: ...action If DTC 253F is stored in the PCM replace the engine oil even if the engine oil level is lower than the X mark on the oil dipstick After inspecting engine oil level replace the engine oil Bring the vehicle to a dealer Disabled Engine oil dilution Enabled P252F Flashes every 0 4 s Max 150 km h 93 mph P253F M6FL_01T011 1 F mark 4 Oil level okay 2 X mark 5 Oil level excessive 3 Oil dipstick Ser...

Page 52: ...gine Oil Cooler and Oil Filter The oil cooler and the oil filter are now located at the rear of the engine M6FL_01032 1 External view 3 Engine coolant flow direction 2 Cut view A A 01 38 Service Training Mazda6 Facelift ...

Page 53: ...ntity L Centrifugal Timing belt driven Cooling fan Type Type Full open temperature Full open lift Type Thermostat Cap valve opening pressure Cooling system cap Type kPa kgf cm psi C F C F mm in 93 2 122 6 0 95 1 25 13 5 17 8 Electric 8 5 0 33 or more 95 203 9 0 Corrugated fin 80 84 176 183 Wax bottom bypass M6_01T012 Service Training Mazda6 Facelift 01 39 ...

Page 54: ... Cooling system cap 7 Cooling fan No 2 2 Radiator 8 Radiator cowling 3 Thermostat 9 Cooling fan motor No 1 4 Water pump 10 Cooling fan motor No 2 5 Cooling fan component 11 Coolant reserve tank 6 Cooling fan No 1 01 40 Service Training Mazda6 Facelift ...

Page 55: ...d reduced turbine diameter has been introduced Manifold absolute pressure sensor located above the intake manifold has been introduced Variable swirl control valves have been cancelled Parts Location M6FL_01063 1 Glow plug lead 5 Charge air cooler 2 VBC Variable Boost Control vacuum actuator 6 Charge air cooler duct 3 Turbocharger 7 Intake manifold 4 Air cleaner 8 Glow plugs Service Training Mazda...

Page 56: ...turbine and reduced turbine diameter has been introduced This leads to a lower inertia moment of the turbine improving the response of the engine during acceleration M6FL_01064 1 VBC vacuum actuator 3 Exhaust gas flow 2 Intake air flow 01 42 Service Training Mazda6 Facelift ...

Page 57: ...ngine Diesel Engines Manifold Absolute Pressure Sensor A MAP sensor located above the intake manifold has been introduced M6FL_01065 1 Intake manifold 2 MAP sensor Service Training Mazda6 Facelift 01 43 ...

Page 58: ...ectors with injector correction factors have been introduced Injector driver module has been cancelled Injection amount learning function has been modified Parts Location M6FL_01066 A LHD Left Hand Drive B RHD Right Hand Drive 1 Fuel warmer 5 Pressure limiter valve 2 Priming pump 6 Common rail 3 Fuel filter 7 Fuel metering valve 4 Fuel injectors 8 High pressure pump 01 44 Service Training Mazda6 F...

Page 59: ...n rail located above the intake manifold has been introduced M6FL_01067 1 Common rail 4 Fuel pressure sensor 2 Pressure limiter valve 5 Connections fuel injector side 3 Connections high pressure pump side Service Training Mazda6 Facelift 01 45 ...

Page 60: ... damage to the seal wrap vinyl tape around the injector connector covering the connector edges In addition the leak off lines of the injectors are located under the cylinder head cover As a result the total leak off amount of the injectors must be measured and compared to the values of a known good vehicle in order to detect a leaking solenoid valve NOTE Always replace the gaskets of the injector ...

Page 61: ...jectors as a drive signal M6FL_01069 1 From PCM control relay 5 Injector No 2 2 High voltage generator 6 Injector No 3 3 PCM 7 Injector No 4 4 Injector No 1 8 Control circuit All injectors are connected in parallel i e they feature the same PCM terminal for the positive voltage supply In case of an open circuit on one injector the PCM cuts off the power supply for this injector so that the engine ...

Page 62: ...factors The correction factors are determined during injector production and are labeled as hexadecimal numbers seven four digit blocks and one two digit block on top of the injector connector At the end of the vehicle production line the injector correction factors of the installed injectors are programmed into the PCM Hereby the PCM equalizes the injection amount of the individual injectors in o...

Page 63: ...0 km h Engine coolant temperature is between 65 95 C A C is not operating Accelerator pedal is not depressed DPF regeneration is not performed If any of these conditions change while carrying out the injection amount learning function the process will be suspended until the conditions are once again met In addition the injection amount learning function has to be carried out at specified service i...

Page 64: ...l Engines Engine Emission System Parts Location M6FL_01071 1 Oxidation catalytic converter and diesel particulate filter 3 Intake shutter valve 2 EGR cooler 4 EGR valve 01 50 Service Training Mazda6 Facelift ...

Page 65: ...on catalytic converter has been cancelled Diesel particulate filter integrated in the housing of the oxidation catalytic converter has been introduced Parts Location M6FL_01040 1 Exhaust manifold 4 Middle pipe 2 Front pipe 5 Main silencer 3 Oxidation catalytic converter and diesel particulate filter Service Training Mazda6 Facelift 01 51 ...

Page 66: ...ion side of the engine has been introduced Intake shutter valve with direct current motor and position sensor has been introduced EGR Valve An EGR valve with DC Direct Current motor and position sensor has been introduced A threaded spindle transforms the rotational movement of the motor into an axial movement of the EGR valve M6FL_01027 1 EGR valve position sensor 4 Return spring 2 Valve 5 DC mot...

Page 67: ...h a small duty cycle so that the EGR valve closes and no exhaust gas is recirculated In order to remove any carbon deposits from the EGR valve seat a cleaning mode is activated each time the engine is shut off Therefore the PCM actuates the EGR valve so that it is moved from the fully open to the fully closed position several times This process takes approx 10 s The PCM controls the DC motor by a ...

Page 68: ...e opens the resistance of the potentiometer rises The sensor supplies the PCM with an analogue voltage signal between 0 5 V NOTE After the EGR valve is replaced its adaptation values in the PCM must be reset and the EGRVP sensor initialized refer to the section Control System Service and Repair M6FL_01081 1 EGRVP sensor 2 PCM 01 54 Service Training Mazda6 Facelift ...

Page 69: ...ooler An EGR cooler located at the transmission side of the engine has been introduced M6FL_01072 1 EGR valve 4 From exhaust manifold 2 To intake manifold 5 Engine coolant flow 3 EGR cooler Service Training Mazda6 Facelift 01 55 ...

Page 70: ...gle of the motor results in a small rotation angle of the valve The valve body is connected to the engine coolant circuit to prevent icing of the ISV at low ambient temperatures M5_01035 1 Valve 6 Drive circuit 2 ISV 7 Intermediate gear 3 Return spring 8 Drive gear 4 Stator with Hall element 9 DC motor 5 Driven gear with magnetic rotor 01 56 Service Training Mazda6 Facelift ...

Page 71: ... exhaust gas can be recirculated When the required EGR rate is low the PCM controls the DC motor with a small duty cycle As a result the ISV opens making the complete cross section of the intake pipe available Thus atmosphere or boost pressure is generated in the intake manifold depending on the operating conditions and only a small amount of exhaust gas can be recirculated When the engine is swit...

Page 72: ...roduced The ISV position sensor is integrated in the cover of the valve body and detects the ISV position by a Hall type sensor The sensor consists of a stator with Hall element and a magnetic rotor joint to the driven gear M6FL_01082 1 ISV position sensor 2 PCM When the magnetic rotor rotates a voltage is generated in the Hall element As the Hall voltage is very low it is amplified in the sensor ...

Page 73: ...hemselves to these granulates increasing their size to 0 09 µm In this way the harmful soot particles are formed The human nose and bronchial tubes are not able to filter out particles smaller than 2 5 µm for comparison a hair is about 70 µm thick As a result the particles can then penetrate through the airways deep into the lungs and pose a health threat especially to children and adults with cer...

Page 74: ...ion catalytic converter and the DPF are located one behind another in a combined housing M5_01037 1 Oxidation catalytic converter and DPF 5 Exhaust gas temperature sensor upper 2 Heated oxygen sensor 6 Connection for reference pressure 3 Exhaust gas temperature sensor lower 7 Connection for high pressure 4 Exhaust gas temperature sensor middle NOTE To ensure proper function of the DPF system only ...

Page 75: ...rter To avoid the DPF from becoming blocked with soot particles it must be regenerated at regular intervals i e the soot particles collected in the filter are burnt off In addition the regeneration process reduces the exhaust gas back pressure caused by the soot amount accumulated preventing an increase in fuel consumption NOTE On vehicles with a higher mileage soot residues can often form on the ...

Page 76: ...le filter volume shortening the regeneration intervals Since the filter pores are clogged by the ash residues the exhaust gas back pressure and hence the fuel consumption are increased Due to the use of engine oil with low ash formation these effects can be reduced to a minimum For this reason there is no replacement interval given for the filter However depending on the operating conditions the u...

Page 77: ...ompartment at the bulkhead and is connected to the upstream and downstream measuring point of the DPF by means of pressure lines The differential pressure sensor consists of a pressure chamber with integrated semi conductor element The electrical resistance of the element varies when its shape changes due to exposure to pressure M6FL_01047 1 Temperature correction sensor 4 Connection for high pres...

Page 78: ...l pressure sensor is used to determine whether the soot amount requires regeneration of the filter In addition the signal serves to monitor the regeneration process The DPF differential pressure sensor supplies the PCM with an analogue voltage signal between 0 5 V M6FL_01082 1 DPF differential pressure sensor 2 PCM 01 64 Service Training Mazda6 Facelift ...

Page 79: ...e PCM with an analogue voltage signal between 0 5 V The signal of the temperature correction sensor is used to compensate the thermal characteristics of the DPF differential pressure sensor NOTE Since the output characteristics of the DPF differential pressure sensor is adjusted while it is installed to the bracket always replace the sensor and the bracket as a unit NOTE After replacing the DPF di...

Page 80: ...ermediate condition of filter If the value measured by the DPF differential pressure sensor is above a certain limit the DPF is recognized as being blocked Then the PCM stores a corresponding DTC illuminates the MIL Malfunction Indicator Light and activates the limp home mode The blocking of the DPF is often as a result of excessive soot emission by the engine e g due to EGR valve stuck open leak ...

Page 81: ... DPF differential pressure sensor should be checked first Call up the Datalogger of the PCM and select the PID EXHPRESS_DIF Press Then connect a hand operated pressure vacuum pump to the upstream pressure line at the DPF apply a pressure of 30 kPa and monitor the PID Parameter Identification If the PID indicates 30 kPa replace the DPF Otherwise check the upstream pressure line and the DPF differen...

Page 82: ...ream of the DPF Each sensor is a temperature resistive resistor with NTC i e its resistance becomes smaller when the temperature rises The exhaust gas temperature sensor supplies the PCM with an analogue voltage signal between 0 5 V M6FL_01045 1 Exhaust gas temperature sensor upper 5 Exhaust gas temperature sensor 2 Oxidation catalytic converter and DPF 6 Thermistor element 3 Exhaust gas temperatu...

Page 83: ...sed to determine whether the exhaust gas temperature required for regeneration of the filter is reached The signal of the lower exhaust gas temperature sensor serves to monitor the exhaust gas temperature during the regeneration process In addition the information from the exhaust gas temperature sensors is used for the calculation of the soot amount burnt off in the DPF M6FL_01084 1 Exhaust gas t...

Page 84: ...petrol engines It generates a clear electrical signal in a wide range from λ 0 7 air with 21 oxygen As a result the sensor is also capable of detecting the oxygen concentration in the exhaust gas of a diesel engine which generally works with an excess air factor of λ 1 4 at full load to λ 3 4 at idle The information of the HO2S is used for the calculation of the soot amount burnt off in the DPF M6...

Page 85: ...rent Since the HO2S only generates a usable signal above a certain temperature it features an integral heater element The temperature of the HO2S is controlled by the PCM which activates the heater element via a duty signal M6FL_01085 1 From PCM control relay 3 PCM 2 Heater element Service Training Mazda6 Facelift 01 71 ...

Page 86: ... 12 V NOTE After replacing the HO2S its adaptation values in the PCM must be reset refer to the section Control System Service and Repair DPF Indicator Light The DPF indicator light is located in the instrument cluster and serves to alert the driver to a malfunction in the DPF system During normal operation the DPF indicator light illuminates when the ignition is on and is extinguished after a few...

Page 87: ...n and optimum engine performance If the soot accumulation rate in the DPF is 80 or more the DPF indicator light illuminates In this case an automatic regeneration of the DPF must be performed by driving the vehicle at an engine speed of 2000 min 1 or more and a vehicle speed of 40 km h or more for approx 10 15 min As soon as the automatic regeneration process starts the DPF indicator light turns o...

Page 88: ... cannot be regenerated anymore and must therefore be replaced The different conditions of the soot accumulation in the DPF are shown in the following table Illuminates Perform manual regeneration long mode Max 150 km h 93 mph P2458 Perform auto regeneration by driving the vehicle at an engine speed of 2 000 rpm or more and a vehicle speed of 40 km h 22 mph or more for 10 15 min Max 70 km h 43 mph ...

Page 89: ...ase the intake air temperature by throttling Performing an early post injection to increase the combustion temperature by burning an additional fuel amount Performing two late post injections to increase the exhaust gas temperature by burning fuel in the oxidation catalytic converter By these measures the minimum exhaust gas temperature of 150 C at low engine load and engine speed is increased to ...

Page 90: ...the usable filter volume is reduced Since the ash amount accumulated in the DPF increases with every regeneration process the regeneration intervals become shorter with rising mileage NOTE High fuel consumption low fuel quality high sulphur content and high engine oil consumption accelerate the accumulation of ash in the DPF shortening the regeneration intervals more quickly 01 76 Service Training...

Page 91: ... charging system has been introduced Specifications V V A Item Specification Ah 12 95D31L 64 115D31L 70 Voltage Type and capacity 5 hour rate Battery Generator Controlled by PCM Output 12 90 Regulated voltage Self diagnosis function M6FL_01T014 Parts Location M5_01050 1 Generator 2 Battery Service Training Mazda6 Facelift 01 77 ...

Page 92: ...oad The PCM determines the duty ratio output to the generator according to the battery voltage battery electrolyte temperature derived from the intake air temperature engine coolant temperature and vehicle speed signal and generator load In addition the PCM transmits information about the generator warning light status via the high speed CAN bus to the instrument cluster which activates the genera...

Page 93: ... a large duty cycle As a result a high exciting current flows through the field coil and the generator outputs a high charging voltage Control System The control system of the vehicles with 2 0 MZR CD engine has the following features Powertrain control module with FEEPROM Flash Electronically Erasable Programmable Read Only Memory has been introduced Magneto resistive type crankshaft and camshaft...

Page 94: ...Diesel Engines Engine Parts Location M6FL_01079 01 80 Service Training Mazda6 Facelift ...

Page 95: ...ection sensor 8 Exhaust gas temperature sensors 26 DPF differential pressure sensor 9 HO2S 27 PSP switch 10 Neutral switch 28 CMP sensor 11 IAT No 2 sensor 29 VBC solenoid valve 12 CKP sensor 30 Cruise control switch 13 MAF IAT sensor 31 APP sensor 14 Intake shutter valve position sensor 32 Brake switch 15 EGR valve position sensor 33 Clutch switch 16 ECT sensor 34 PCM with built in BARO sensor 17...

Page 96: ...Diesel Engines Engine Wiring Diagram M6FL_01076 01 82 Service Training Mazda6 Facelift ...

Page 97: ... fan relay No 2 5 Exhaust gas temperature sensor lower 18 Cooling fan relay No 1 6 CKP sensor 19 Generator 7 CMP sensor 20 Intake shutter valve 8 APP sensor 21 Intake shutter valve position sensor 9 MAP sensor 22 Intake shutter valve actuator 10 Fuel pressure sensor 23 EGR valve 11 ECT sensor 24 EGR valve position sensor 12 Fuel temperature sensor 25 DC motor 13 Security light 26 PCM Service Train...

Page 98: ...Diesel Engines Engine Wiring Diagram Continued M6FL_01077 01 84 Service Training Mazda6 Facelift ...

Page 99: ...31 Refrigerant pressure switch 46 PCM control relay main relay 32 Neutral switch 47 Engine switch IG1 33 Clutch switch 48 Engine switch IG2 34 PSP switch 49 Engine switch START 35 Starter relay 50 Battery 36 Starter 51 Fuel injector No 3 37 Brake switch 52 Fuel injector No 2 38 Cruise control switch 53 Fuel injector No 4 39 HO2S 54 Fuel injector No 1 40 Oxygen sensor Service Training Mazda6 Faceli...

Page 100: ...ed calibration data As a result the strategy program and the calibration data logged in the FEEPROM can be updated without replacing the PCM If the PCM should be updated with a later software calibration the module has to be reprogrammed with the aid of the WDS Therefore select the option ToolboxÆ Module ProgrammingÆModule ReprogrammingÆPCM and follow the instructions of the WDS NOTE As later soft...

Page 101: ... the clutch housing The sensor consists of two GMR elements and a magnet which scan a rotor with 56 teeth missing five teeth in one location The rotor is integrated in the flywheel M6FL_01074 1 Clutch housing 5 0 5 V 2 CKP sensor 6 Ground 3 Output signal 7 Crank angle 4 5 V 8 Toothed rotor Service Training Mazda6 Facelift 01 87 ...

Page 102: ...ecognized by the increased engine noise Diesel knocking In order to identify cylinder No 1 during engine start the PCM injects metered quantities of fuel into the individual cylinders and monitors the engine speed via the CKP sensor The cylinder in question is the one where the engine speed increases after fuel has been injected As a result the starting process takes longer than normal M6FL_01073 ...

Page 103: ...d a magnetic rotor joint to the accelerator pedal NOTE If one Hall type sensor fails the PCM uses the signal from the other sensor to detect the driver s acceleration demand As a result the engine speed is limited to approx 2500 min 1 If the APP sensor fails completely the engine speed is limited to 1500 min 1 M5_01056 1 Accelerator pedal 2 APP sensor Service Training Mazda6 Facelift 01 89 ...

Page 104: ...otates a voltage is generated in the Hall elements As the Hall voltage is very low it is amplified in the sensor and input to the PCM M5_01057 1 Sensor body 3 Magnetic rotor 2 Stator with Hall elements 4 Shaft 01 90 Service Training Mazda6 Facelift ...

Page 105: ...e sensor supplies the PCM with an analogue voltage signal between 0 5 V In order to facilitate failure detection there is a voltage offset of 0 5 V between both signals M6FL_01088 1 APP sensor 2 PCM Service Training Mazda6 Facelift 01 91 ...

Page 106: ... been introduced to detect the load condition of the power steering If the power steering oil pressure exceeds a given value the switch closes and supplies the PCM with a voltage signal of 0 V M5_01065 1 PSP switch 2 Power steering oil pump M6FL_01050 1 PSP switch 2 PCM 01 92 Service Training Mazda6 Facelift ...

Page 107: ... over accumulation of soot is prevented In order to cancel the manual regeneration process perform the following procedure 1 Depress the clutch pedal shift to 1st gear and verify that the engine speed decreases to idle speed manual regeneration is cancelled 2 Shift to Neutral and increase the engine speed to 3000 min 1 for 1 min DPF is cooled 3 If the manual regeneration must be performed again wa...

Page 108: ...fore select the option ToolboxÆPowertrainÆData ResetÆ MAF Sensor Replacing the High Pressure Pump After replacing the high pressure pump its adaptation values in the PCM must be reset with the aid of the WDS Therefore select the option ToolboxÆPowertrainÆ Data ResetÆFuel Pump Replacing Injectors After replacing one or more injectors the following steps must be performed 1 The injector adaptation v...

Page 109: ...rtrainÆDPFÆDPF Reset 3 The injection amount learning function must be performed using the option ToolboxÆPowertrainÆEngine ChecksÆLearningÆInjection Amount Correction 4 The DPF must be regenerated manually via the option ToolboxÆPowertrainÆ DPFÆDPF Regeneration 5 The pressure difference of the DPF must be assessed using the option ToolboxÆ PowertrainÆDPFÆDPF Assessment Replacing the DPF Differenti...

Page 110: ... position sensor must be initialized via the option ToolboxÆPowertrainÆETB EGR Initialization 5 The regeneration control in the PCM must be reset using the option ToolboxÆ PowertrainÆDPFÆDPF Reset 6 The injection amount learning function must be performed via the options ToolboxÆ PowertrainÆEngine ChecksÆLearningÆCorrection after Parts Installation Injection Amount Correction 7 The DPF must be reg...

Page 111: ...s to read out the CMDTCs Continous Mode DTC of the PCM with the aid of WDS Therefore select the option ToolboxÆSelf TestÆModulesÆPCMÆRetrieve CMDTCs In addition the KOEO self test can be performed using the option ToolboxÆSelf TestÆ ModulesÆPCMÆKOEO On demand Self Test In order to conduct the KOER self test select the option ToolboxÆSelf TestÆ ModulesÆPCMÆKOER On demand Self Test Service Training ...

Page 112: ...SD Catalyst temperature desired lower C CHRGLP Generator warning light On Off CPP CPP switch On Off DEC_CMP Fuel correction for deceleration No unit DTCCNT DTC count No unit C V EGR_LRN EGR valve learning value closed mm V mm EQ_RAT11 Equivalence ratio lambda No unit ETC_ACT ISV position actual C EXHPRESS_DIF DPF differential pressure sensor Pa EXHPRESS_LRN DPF differential pressure sensor learnin...

Page 113: ...RN_31 Fuel injection learning value injector 1 at 140 MPa ms FI_LRN_32 Fuel injection learning value injector 2 at 140 MPa ms FI_LRN_33 Fuel injection learning value injector 3 at 140 MPa ms FI_LRN_34 Fuel injection learning value injector 4 at 140 MPa ms FIA_DSD Fuel injection amount desired mm3 stroke No unit FIP_FL High pressure pump flow A FIP_FL_DSD High pressure pump flow desired No unit FIP...

Page 114: ...M SC_CANCEL Cruise control cancel switch Active Inactive SC_COAST Cruise control coast switch Active Inactive SC_MAIN Cruise control main switch Active Inactive SC_MODE Cruise control operation mode Off Standby Active Tap up Set Tap down Coast SC_ON Cruise control actuator switch on On Off SC_RES Cruise control resume switch Active Inactive SC_SET Cruise control set indicator light On Off SC_SET A...

Page 115: ...or voltage desired V ___ X GP_LMP Glow plug indicator light On Off X X GPC Glow plug relay On Off X X INJ_1 Fuel injector no 1 On Off ___ X INJ_2 Fuel injector no 2 On Off ___ X INJ_3 Fuel injector no 3 On Off ___ X INJ_4 Fuel injector no 4 On Off ___ X VBCV VBC solenoid valve duty cycle X X FAN1 Cooling fan relay No 1 On Off X X FAN3 Cooling fan relay No 2 On Off X X M6FL_01T017 x Applicable Not ...

Page 116: ...Diesel Engines Engine NOTES 01 102 Service Training Mazda6 Facelift ...

Page 117: ...02 Suspension ...

Page 118: ...02 Suspension Table of Contents Features 1 Tire Dimensions 1 Wheel Dimensions 1 Temporary Spare Tire 1 Winter Tires 2 Tire Chains 2 Table of Contents 02 Service Training Mazda6 Facelift ...

Page 119: ...nsions Tire Size 195 65R 15 91V 205 55R16 91V 215 45R17 87W 215 45R17 91W 215 45R18 89W M6FL_02T001 Item Specifications Wheel Dimensions 15 X 6J 16 X 7J 17 X 7J 18 x 7J Steel Offset mm in 50 1 97 Pitch circle diameter mm in Wheel Item M6FL_02T002 Size Material Specification Alluminium alloy 55 2 17 114 3 4 50 Temporary Spare Tire Tire T115 70D15 2WD T115 70D15 4WD T135 90D15 T125 70D17 17 X 4 T Of...

Page 120: ...er tires is Q only Tire Chains Mazda recommends hexagon type steel ring chains for the following tire sizes 195 65R15 215 45R17 215 45R18 Although Mazda recommends hexagon type steel ring chains all chains within the installation specifications may be used Use of tire chains on a vehicle equipped with 205 55R16 specification tires could cause interference with the vehicle body and scratching If ti...

Page 121: ...04 Brakes ...

Page 122: ...04 Brakes Table of Contents Features 1 Front Disc Brakes 2 Rear Disc Brakes 2 Table of Contents 04 Service Training Mazda6 Facelift ...

Page 123: ...FMVSS 116 DOT 3 or DOT 4 M6FL_04T001 Disc plate dimensions outer diameter thickness Pedal lever ratio Type Disc plate dimensions outer diameter thickness mm in mm in mm 2 in 2 mm in Pad dimensions area thickness Type Type Type L8 4SD 5HB 4 220 6 75 10 0 0 39 L8 WGN LF L3 except 18 inch wheel MZR CD RF Turbo 4 010 6 42 12 0 0 47 L3 18 inch wheel 3 918 6 27 12 5 0 49 L8 4SD 5HB 274 10 8 24 0 0 945 L...

Page 124: ... are equipped with front brake discs of 320 mm diameter and 25 mm thickness M6FL_04001 Rear Disc Brakes Vehicles with L3 engine and 18 inch wheels are equipped with rear brake discs of 314 mm diameter and 11 mm thickness M6FL_04002 04 2 Service Training Mazda6 Facelift ...

Page 125: ...05 Transmission Transaxle ...

Page 126: ... Sectional View 8 Internal Shift Mechanism 9 Power Flow 10 First to Fourth Gear 10 Fifth Sixth and Reverse Gear 11 Shift Interlock Mechanism 12 Neutral Condition 12 Select Condition 13 Shift Condition 14 Shift Mechanism 15 Reverse Lockout Mechanism 16 Transaxle Oil 17 Drain Plug and Oil Level Plug Location 17 Drive Shaft Removal Note 18 Select Cable Adjustment 19 Table of Contents 05 Service Train...

Page 127: ... 27 Shift Interlock Mechanism 28 Shift Mechanism 30 Transaxle Oil 31 Drain Plug Location 31 JA5AX EL Features 33 FS5A EL Features 35 Transmission Control System 36 Structural View 36 Operation Diagram 38 Cross Sectional View 40 Electronic Control 42 Wiring Diagram 42 Hydraulic Control 44 Control Valve Body 44 Secondary Control Valve Body 45 Service Training Mazda6 Facelift Table of Contents 05 ...

Page 128: ...05 Transmission Transaxle Table of Contents 05 Service Training Mazda6 Facelift ...

Page 129: ... R manual transaxle for 2 0L LF and 2 3L L3 petrol engine models new 6 speed A26M R manual transaxle for diesel engine models new Dual mass flywheel A26M R Self adjusting clutch cover A26M R The automatic transaxles have the following features 5 speed JA5AX EL automatic transaxle for AWD carried over from previous Mazda6 5 speed FS5A EL automatic transaxle for 2 0L LF and 2 3L L3 petrol engine mod...

Page 130: ...Transmission Transaxle Notes 05 2 Service Training Mazda6 Facelift ...

Page 131: ... Floor shift Synchromesh Selective sliding and synchromesh 3 666 2 059 1 392 0 970 0 755 3 166 4 388 API service GL 4 or GL 5 All season SAE 75W 90 Above 10 C 50 F SAE 80W 90 Capacity approx quantity L US qt Imp qt 2 87 3 03 2 53 M6FL_05T001 5GR Reverse Final gear ratio Grade Gear ratio Oil Viscosity 1GR 2GR 3GR 4GR Transaxle control Shift assist Forward Reverse Item Engine type Manual transaxle t...

Page 132: ...se idler gear 10 Secondary third gear 3 Reverse gear 11 Secondary second gear 4 Second gear 12 Secondary first gear 5 Third gear 13 Secondary shaft 6 Fourth gear 14 Clutch hub sleeve reverse gear 7 Fifth gear 15 Primary shaft 8 Secondary fifth gear 16 Differential gear 05 4 Service Training Mazda6 Facelift ...

Page 133: ...e cone synchronizer except that the inner surface of the inner ring is used as a friction surface on the triple cone synchronizer Structural View M6FL_05016 1 Gear 4 Outer synchronizer ring 2 Inner synchronizer ring 5 Synchronizer assembly 3 Synchronizer cone Operation M6FL_05017 1 Synchronizer ring 4 Synchronizer hub sleeve 2 Synchronizer key 5 Friction surface 3 Key groove Service Training Mazda...

Page 134: ...Mechanism A cable operated shift mechanism similar to that on the previous Mazda6 is used The selector cable is adjusted the same way as on the previous Mazda6 M6FL_05002 1 Shift cable 2 Select cable 05 6 Service Training Mazda6 Facelift ...

Page 135: ...been carried over from the G35M R manual transaxle Specifications LF L3 2 059 1 842 0 970 1 030 0 795 0 837 0 680 0 755 All season Above 10 C 50 F Capacity approx quantity L US qt Imp qt M6FL_05T002 Item Specifications G66M R Cable Engine type Manual transaxle type Operation system Floor shift Synchromesh 3 454 1 310 3 166 4 388 API service GL 4 or GL 5 SAE 75W 90 SAE 80W 90 2 95 3 12 2 60 Shift a...

Page 136: ...t 11 Secondary fifth gear 3 Reverse idler gear 12 Secondary fourth gear 4 Second gear 13 Secondary third gear 5 Third gear 14 Secondary second gear 6 Fourth gear 15 Clutch hub sleeve reverse gear 7 Fifth gear 16 First gear 8 Sixth gear 17 Differential gear 9 Secondary shaft 18 Reverse gear 05 8 Service Training Mazda6 Facelift ...

Page 137: ...sm The control rod design of the G66M R manual transaxle has been carried over from the G35M R manual transaxle M6FL_05004 1 Control rod 4 Crank lever 2 Detent ball 5 Shift rod 3 Control rod end 6 Reverse shift fork Service Training Mazda6 Facelift 05 9 ...

Page 138: ...G66M R Transmission Transaxle Power Flow First to Fourth Gear M6FL_05005 1 First gear 3 Third gear 2 Second gear 4 Fourth gear 05 10 Service Training Mazda6 Facelift ...

Page 139: ...Transmission Transaxle G66M R Fifth Sixth and Reverse Gear M6FL_05006 1 Fifth gear 3 Reverse gear 2 Sixth gear Service Training Mazda6 Facelift 05 11 ...

Page 140: ...ds except for the one in operation are locked in the neutral position by the interlock sleeve Neutral Condition The interlock sleeve fits into the notches of the 1st 2nd 5th 6th and reverse shift forks The control lever fits into the notch of the 3rd 4th shift fork M6FL_05007 1 Shift fork 3 Control lever 2 Interlock sleeve 05 12 Service Training Mazda6 Facelift ...

Page 141: ... the control lever and the interlock sleeve turn in the direction shown by the arrow The control lever fits into the notch of the 1st 2nd shift fork The interlock sleeve fits into the notches of the 3rd 4th 5th 6th and reverse shift forks M6FL_05008 1 1 Shift fork 1st 2nd Service Training Mazda6 Facelift 05 13 ...

Page 142: ...ork and the change to 2nd gear is complete The interlock sleeve holds the 3rd 4th 5th 6th and reverse shift forks at the neutral position preventing double engagement of gears The operation procedure is the same for other gear positions M6FL_05009 1 Shift fork 5th 6th 3 Shift fork reverse 2 Shift fork 3rd 4th 05 14 Service Training Mazda6 Facelift ...

Page 143: ...d shift mechanism similar to that on the previous Mazda6 is used Note the new shift position for the reverse gear The selector cable is adjusted the same way as on the previous Mazda6 M6FL_05010 1 Shift cable 2 Select cable Service Training Mazda6 Facelift 05 15 ...

Page 144: ...estricting the movement of the shift lever When shifting into reverse once the shift lever is pressed down and moved towards the reverse position the projection on the lever goes under the guide plate releasing the reverse shift restriction and allowing for shifting into reverse M6FL_05011 Guide plate function A Shifting when the shift lever is not pressed down B Shifting when the shift lever is p...

Page 145: ...rvice GL 4 or GL 5 grade and SAE 75W 90 viscosity for all season use and SAE 80W 90 above 10 C To check the transaxle oil level verify that the oil level is near the brim of the plug port M6FL_05012 1 Oil level 3 Low level 2 High level 4 About 10 mm Drain Plug and Oil Level Plug Location M6FL_05013 1 Oil level plug 2 Drain plug Service Training Mazda6 Facelift 05 17 ...

Page 146: ...emoval Note Install the SST Special Service Tool 49 G030 455 into the transaxle to hold the side gears after the joint shaft is removed This also applies to the G35M R transaxle M6FL_05029 1 SST 49 G030 455 05 18 Service Training Mazda6 Facelift ...

Page 147: ... the figure M6FL_05027 1 Safety lock 2 Lock piece 3 Shift the shift lever to neutral 4 Lock the lock piece of the selector cable shift cable side in the order as shown in the figure M6FL_05028 1 Safety lock 2 Lock piece 5 Shift the shift lever from neutral to other position and make sure that there are no other components in that area to interfere with the lever Service Training Mazda6 Facelift 05...

Page 148: ...G66M R Transmission Transaxle Notes 05 20 Service Training Mazda6 Facelift ...

Page 149: ...sh Lever type 3 538 1 913 1 218 0 880 0 809 0 673 3 831 3 611 3 095 API service GL 4 or GL 5 All season SAE 75W 90 Above 10 C 50 F SAE 75W 90 Capacity approx quantity L US qt Imp qt 2 55 2 69 2 24 M6FL_05T003 Gear ratio 5GR 6GR Reverse Grade Viscosity Oil Final gear ratio 5GR 6GR Reverse 1GR 4GR 1GR 2GR 3GR 4GR Item Engine type Manual transaxle type Shift assist Forward Reverse M6FL_05018 Service ...

Page 150: ...A26M R Transmission Transaxle Cross Sectional View M6FL_05020 05 22 Service Training Mazda6 Facelift ...

Page 151: ...ry shaft No 1 2 Final gear No 2 9 Third gear 3 Reverse gear 10 Fourth gear 4 Reverse idler gear 11 Second gear 5 Fifth gear 12 First gear 6 Sixth gear 13 Differential ring gear 7 Secondary shaft No 2 14 Final Gear No 1 Service Training Mazda6 Facelift 05 23 ...

Page 152: ...r four gears so can thus be made shorter As a result of the three shaft construction there are two different final gear ratios possible one for the first to fourth gears and another one for the fifth sixth and reverse gears A triple synchronizer mechanism has been used for first second and third gears The fourth gear has a double synchronizer mechanism M6FL_05019 1 Differential 3 Primary shaft 2 S...

Page 153: ...Transmission Transaxle A26M R Power Flow First to Sixth Gear M6FL_05021 1 First gear 4 Fourth gear 2 Second gear 5 Fifth gear 3 Third gear 6 Sixth gear Service Training Mazda6 Facelift 05 25 ...

Page 154: ...A26M R Transmission Transaxle Reverse Gear M6FL_05022 05 26 Service Training Mazda6 Facelift ...

Page 155: ...b The ball type detent mechanism consists of a coil type synchronizer key spring synchronizer key and ball Its function is essentially the same as the radial type spring found in other transaxles M6FL_05023 1 Synchronizer ring 5 Ball 2 Middle ring 6 Synchronizer key 3 Inner ring 7 Spring 4 Hub sleeve 8 Clutch hub Service Training Mazda6 Facelift 05 27 ...

Page 156: ...he shift interlock mechanism prevents two gears being engaged at a time During shifting the shift forks and control rod except for the one in operation are locked in the neutral position by the interlock plate M6FL_05024 05 28 Service Training Mazda6 Facelift ...

Page 157: ...lever 10 Second gear 3 Fifth sixth gear shift fork 11 Third gear 4 Interlock plate 12 Fourth gear 5 First second gear shift fork 13 Fifth gear 6 Third fourth gear control rod 14 Sixth gear 7 A A sectional view 15 Reverse gear 8 Neutral Service Training Mazda6 Facelift 05 29 ...

Page 158: ...ism similar to that on the previous Mazda6 is used The selector cable is adjusted the same way as on the previous Mazda6 The reverse lockout mechanism is the same as on Mazda6 with G66M R transaxle M6FL_05015 1 Shift cable 2 Select cable 05 30 Service Training Mazda6 Facelift ...

Page 159: ...ransaxle oil which complies with the specification API Service GL 4 or GL 5 grade and SAE 75W 90 viscosity To check the transaxle oil level verify that the oil level is near the brim of the plug port M6FL_05025 1 Oil level check Drain Plug Location M6FL_05026 1 Drain plug Service Training Mazda6 Facelift 05 31 ...

Page 160: ...A26M R Transmission Transaxle Notes 05 32 Service Training Mazda6 Facelift ...

Page 161: ...unning changes of revised final drive ratio and the deletion of cruise control An air cooling type oil cooler has been introduced for improved cooling of the automatic transmission fluid M6FL_05014 1 Radiator 4 Air cooling type oil cooler 2 Oil pipe from oil cooler 5 Water cooling type oil cooler 3 Oil pipe to oil cooler Service Training Mazda6 Facelift 05 33 ...

Page 162: ...JA5AX EL Transmission Transaxle Notes 05 34 Service Training Mazda6 Facelift ...

Page 163: ...ic transaxle is based on the proven FN4A EL four speed automatic transaxle To upgrade the transaxle to a five speed transaxle the following components have been added reduction planetary gear set one way clutch No 2 reduction brake direct clutch secondary control valve body intermediate shaft speed sensor To facilitate the fifth gear the secondary gear drives the output gear through the reduction ...

Page 164: ...FS5A EL Transmission Transaxle Transmission Control System Structural View M6FL_05035 05 36 Service Training Mazda6 Facelift ...

Page 165: ...13 Turbine shaft speed 4 APP sensor 14 CKP sensor 5 ECT sensor 15 Selector lever unit comprising M range switch UP switch DOWN switch 6 MAF sensor 16 TCM 7 Output shaft speed sensor 17 PCM 8 Secondary control valve body 18 DLC 9 Intermediate shaft speed sensor 19 Brake switch 10 Control valve body Service Training Mazda6 Facelift 05 37 ...

Page 166: ...FS5A EL Transmission Transaxle Operation Diagram M6FL_05032 05 38 Service Training Mazda6 Facelift ...

Page 167: ...ut shaft speed 3 Planetary gear 17 Oil temperature 4 Differential 18 Turbine shaft speed 5 Tire 19 Engine speed 6 Secondary control valve body 20 Throttle position signal 7 Shift solenoid D E 21 Intermediate shaft speed 8 Primary control valve body 22 Power flow 9 Pressure control solenoid B 23 Hydraulic pressure control signal 10 Shift solenoid F 24 Electronic signal 11 Pressure control solenoid ...

Page 168: ...FS5A EL Transmission Transaxle Cross Sectional View M6FL_05030 05 40 Service Training Mazda6 Facelift ...

Page 169: ...clutch 12 Differential 4 Rear planetary gear 13 Secondary gear 5 Front planetary gear 14 Direct clutch 6 Forward clutch 15 Reduction brake 7 Oil pressure switch 16 One way clutch No 2 8 Oil pump 17 Low and reverse brake 9 Torque converter 18 One way clutch No 1 Service Training Mazda6 Facelift 05 41 ...

Page 170: ...FS5A EL Transmission Transaxle Electronic Control Wiring Diagram M6FL_05031 05 42 Service Training Mazda6 Facelift ...

Page 171: ... A 4 UP switch 15 Pressure control solenoid B 5 Down switch 16 Shift solenoid F 6 Oil pressure switch 17 Shift solenoid E 7 Intermediate shaft speed sensor 18 Shift solenoid D 8 Output shaft speed sensor 19 Shift solenoid C 9 Turbine shaft speed sensor 20 Shift solenoid B 10 ATX main relay 21 Shift solenoid A 11 CAN_L 22 TCM Service Training Mazda6 Facelift 05 43 ...

Page 172: ...ed over from the FN4A EL automatic transaxle M6FL_05033 1 Control valve body upper part 6 Shift solenoid A 2 Control valve body lower part 7 Solenoid valve body 3 Oil strainer 8 Pressure control solenoid A 4 Shift solenoid B 9 Shift solenoid D 5 Shift solenoid C 10 Shift solenoid E 05 44 Service Training Mazda6 Facelift ...

Page 173: ...e body has been added to accommodate one more shift solenoid and an additional pressure control solenoid M6FL_05033 1 Shift solenoid F 3 Secondary control valve body lower part 2 Secondary control valve body upper part 4 Pressure control solenoid B Service Training Mazda6 Facelift 05 45 ...

Page 174: ...FS5A EL Transmission Transaxle Notes 05 46 Service Training Mazda6 Facelift ...

Page 175: ...08 Restraint System ...

Page 176: ...08 Restraint System Table of Contents Features 1 Wiring Diagram 2 Table of Contents 08 Service Training Mazda6 Facelift ...

Page 177: ...vious Mazda6 except the following A PAD Passenger Airbag Deactivation switch has been added supersedes the occupancy sensor for the front passenger seat The front airbags for driver and front passenger use single stage deployment The crash zone sensor has been discontinued Service Training Mazda6 Facelift 08 1 ...

Page 178: ...nnector DLC 16 Driver side curtain air bag module 6 Instrument cluster 17 Driver side side air bag module 7 Air bag system warning light 18 Passenger side pre tensioner seat belt 8 PAD indicator 19 Passenger side curtain air bag module 9 Driver side side air bag sensor 20 Passenger side side air bag module 10 Passenger side side air bag sensor 21 SAS Sophisticated Airbag Sensor control module 11 T...

Page 179: ...09 Body Accessories ...

Page 180: ... 17 Seat Position Programming Using the Memory Switches 17 Seat Position Programming Using the Transmitter 17 Seat Positioning Using Memory Switch 17 Seat Positioning Using Transmitter 17 Security And Locks 18 Vehicles With Advanced Keyless Entry And Start System 18 Advanced Keyless System Structural View 19 Advanced Keyless System Wiring Diagram 20 Power Door Lock System 22 Vehicle Entry Using th...

Page 181: ...stem Wiring Diagram 43 Vehicles without Advanced Keyless Entry System 44 Keyless Entry System Structural View 44 Keyless Entry System Wiring Diagram 46 Transmitter 48 Immobilizer System on Vehicles without Advanced Keyless System 49 Immobilizer System Structural View 49 Immobilizer System Wiring Diagram 50 Theft Deterrent System 51 Theft Deterrent System Structural View 52 Theft Deterrent System W...

Page 182: ...Unit 69 LCD Unit 69 Speaker 69 Parts Location 70 System Overview 71 Car Navigation Unit 72 LCD Unit 73 Screen Layout 74 Remote Control and Cradle 77 Traffic Message Channel 78 Availability of TMC in Europe 81 How to Enable TMC and DRGS 82 Diagnostics 82 Rear Seat Belt Warning Alarm 83 Operation 83 Rear Seat Belt Warning Alarm Structural View 84 Rear Seat Belt Warning Alarm Wiring Diagram 85 Front ...

Page 183: ...d powertrain The front bumper was revised the front grille redesigned now with a larger Mazda badge and the design of the rear bumper was refined Reinforced Body Shell M6FL_09001 1 Increased thickness of B pillar reinforcement 4 Increased thickness of front frame reinforcement 2 Increased rigidity of door outer panel 5 Optimized rigidity of lower B pillar redesigned outer reinforcement and gussets...

Page 184: ...Body Body Accessories Notes 09 2 Service Training Mazda6 Facelift ...

Page 185: ... light system Rear wiper system Room light control system Power door lock system Keyless entry system without advanced keyless entry system Theft deterrent system The BCM is connected to the CAN Databus and diagnosis can be done using WDS NOTE The BCM does not require any programming or initialization after replacing M6FL_09002 1 BCM Service Training Mazda6 Facelift 09 3 ...

Page 186: ...Accessories Body Accessories BCM Wiring Diagram M6FL_09003 09 4 Service Training Mazda6 Facelift ...

Page 187: ...lock actuators without double locking system 7 Passenger s side door lock link switch 23 Door lock actuators with double locking system 8 Hazard switch 24 Trunk lid opener 4SD Liftgate lock actuator 5HB WGN 9 Bonnet switch 25 Front turn light RH Right Hand 10 Key reminder switch 26 Front turn light LH Left Hand 11 Courtesy light 27 Rear turn light RH 12 Map light 28 Rear turn light LH 13 Turn swit...

Page 188: ...orn switch 2 Fuel gauge sender unit 11 To DLC Data Link Connector 3 To brake light switch 12 To back up light switch 4 To tail light 13 To audio system 5 Rear wiper motor 14 To headlight leveling switch 6 Rear wiper switch 15 Intruder sensor front 7 Theft deterrent siren 16 Intruder sensor rear WGN only 8 Horn relay 17 BCM 9 Horn 09 6 Service Training Mazda6 Facelift ...

Page 189: ...d Rear door switch LH RH 7D 1F RF_AJAR Open Closed Front door switch RH 7F LF_AJAR Open Closed Front door switch LH 7B HAZARD On Off Hazard warning switch 4G WPINT_REAR On Off Rear wiper switch INT position 4J TURN_SW_R On Off Turn switch RH 4E TURN_SW_L On Off Turn switch LH 4C LLSW_D LOCK UNLOCK Driver side door lock link switch 7C 7E LLSW_P_R LOCK UNLOCK Except driver side door lock link switch...

Page 190: ...age BCM IC Integrated Circuit Self Test All systems other than those tested in the constant monitor are monitored during the self test If a fault is detected a DTC will be stored in the BCM The self test function allows BCM DTCs to be displayed on WDS To view these connect WDS to the vehicle and select the option Toolbox Self Test Modules GEM When the ignition is switched off DTCs stored by the se...

Page 191: ...uto open close function on all windows Auto reverse pinch protection function on all windows Two step down function on all windows Ignition off timer function 40 seconds is used Exterior opening closing function available Power window motors with Hall sensors are used Illumination LEDs Light Emitting Diode are used in the power window main switch and subswitches Service Training Mazda6 Facelift 09...

Page 192: ...motor driver s side 11 Hall effect switch 2 3 Close 12 To power mirror switch 4 Open 13 To power window subswitch A 5 Auto 14 To power window subswitch B 6 Power cut switch 15 BCM 7 Conjunction circuit 16 P W Power Window CM 8 Close relay 17 ACC Accessory position ignition switch 9 Open relay 09 10 Service Training Mazda6 Facelift ...

Page 193: ...09006 1 Power window subswitch 7 Open relay 2 Power window motor 8 Hall effect switch 1 3 Close 9 Hall effect switch 2 4 Open 10 P W CM 5 Auto A To power window main switch A 6 Close relay B To power window main switch B Service Training Mazda6 Facelift 09 11 ...

Page 194: ...ased while they are still moving If any button on the transmitter is pressed during the automatic open operation the window will stop opening immediately During IG Ignition OFF timer operation power window system operates approx 40 s after IG OFF the power window switch operation has priority over the exterior open close function Operation Prohibition When the following conditions are met before o...

Page 195: ...receiver 11 P W subswitch LR Left Rear 3 Keyless control module 12 P W subswitch RR Right Rear 4 Door latch switch 13 P W motor LF Left Front 5 Start knob Key reminder switch 14 P W motor RF 6 Cargo compartment light switch 15 P W motor LR 7 Power window main switch 16 P W motor RR 8 Input signal 17 BCM 9 Control signal Service Training Mazda6 Facelift 09 13 ...

Page 196: ...ion 7 Close operation signal 2 Open operation 8 Open unlock button held approx 1 5 s 3 Close lock button held approx 1 5 s 9 Unlock signal 4 Lock signal 10 Open request signal 5 Close request signal 11 Open operation signal 6 P W switch 12 BCM 09 14 Service Training Mazda6 Facelift ...

Page 197: ...ccording to the transmitter that was used to open the vehicle Power Seat Structural View M6FL_09009 1 Position memory switch 7 Recliner motor 2 Set switch 8 Power seat switches 3 Memory switches 9 Position memory control module 4 Slide motor 10 Transmitter with advanced keyless system 5 Rear tilt motor 11 Transmitter with keyless entry system 6 Front tilt motor Service Training Mazda6 Facelift 09 ...

Page 198: ...ith advanced Keyless system BCM without advanced Keyless 17 Front tilt motor 6 Power seat switch 18 Rear tilt motor 7 Slide switch 19 Recliner motor 8 Front tilt switch 20 Position sensor slide motor 9 Rear tilt switch 21 Position sensor front tilt motor 10 Recliner switch 22 Position sensor rear tilt motor 11 Position memory switch 23 Position sensor recliner motor 12 Set switch 24 Position memor...

Page 199: ... seat manually to the desired position 2 Press and hold the set switch Then press the UNLOCK button on the transmitter 3 Buzzer sounds and seat position is programmed NOTE If the vehicle battery is disconnected for more than 5s all of the seat position memory will be erased Seat Positioning Using Memory Switch If all of the following conditions are met the seat position is automatically called up ...

Page 200: ...eir possession operation of the doorlocks and start knob to start the engine can be achieved without actually removing the card key from their pocket or bag Unlocking and locking of doors can be achieved either by using the auxiliary key by pushing the buttons on the remote transmitter card key or simply by pressing the request switches on each door An answer back function provides visual and audi...

Page 201: ...n Keyless warning light red 18 Auxiliary key 6 Keyless buzzer 19 Keyless antenna interior rear 4SD 7 Keyless antenna driver side 20 Keyless antenna interior LR 5HB WGN 8 Request switch 21 Keyless antenna interior RR 5HB WGN 9 Front door key cylinder 22 Keyless control module 10 Keyless antenna passenger side 23 Keyless receiver 11 Front door latch and lock actuator 24 BCM 12 Rear door latch and lo...

Page 202: ...Accessories Body Accessories Advanced Keyless System Wiring Diagram M6FL_09012 09 20 Service Training Mazda6 Facelift ...

Page 203: ... Push switch 22 Security light 7 Key reminder switch 23 Keyless indicator light green 8 Request switch liftgate 24 Keyless warning light red 9 Request switch driver side 25 Instrument cluster 10 Request switch passenger side 26 Keyless buzzer 11 LOCK 27 DLC 12 UNLOCK 28 Keyless control module 13 Door lock actuator 29 BCM 14 Door lock link switch 30 ACC 15 Keyless antenna driver side 31 CAN L Contr...

Page 204: ...g the lock knob the lock link switch in the door lock actuator sends a lock or unlock signal to the BCM which operates the locks on all doors M6FL_09013 1 Driver s door lock knob 4 BCM 2 Driver s door key cylinder 5 Lock actuators 3 Door lock link switch in driver s door lock actuator 09 22 Service Training Mazda6 Facelift ...

Page 205: ... is being pressed the doors will not be locked The auxiliary key is in the ignition The start knob is in any position other than LOCK The start knob is being pressed Any of the doors are open The keyless control module then sends a signal to the keyless buzzer and to the BCM to operate the hazard lights answer back function If any of the conditions below are met while the unlock button is being pr...

Page 206: ...ess control module The keyless control module verifies that the ID of the card key is valid and sends a signal to the BCM to operate the door lock actuators The keyless control module then sends a signal to the keyless buzzer and to the BCM to operate the hazard lights answer back function When a request switch is pushed the doors will only lock if the following conditions are all met The card key...

Page 207: ...xterior 4 Request switch 9 Radius approx 80 cm 2 6 ft 5 Keyless antennas Operation in detail a The request button is pressed b The request signal is sent by wire to the keyless control module c The keyless control module sends a signal through the antenna d The antenna sends a signal to the card key e The card key sends its ID to the keyless receiver f The keyless receiver forwards the ID to the k...

Page 208: ...d the doors will automatically be locked this function is set to OFF for new vehicles The keyless buzzer sounds one time and the system enters standby mode but locks are not operated when the following conditions are met All doors and liftgate are closed door switch OFF after one or more having been opened door switch ON The card key is not inside the vehicle The card key is within the reception r...

Page 209: ...passes the information on to the keyless control module The keyless control module verifies that the ID of the card key is valid and unlocks the start knob lock At the same time it illuminates the keyless indicator light green in the instrument cluster NOTE If the ID of the card cannot be identified unregistered card key or flat card key battery the start knob lock will not be unlocked and the key...

Page 210: ...12 5HB WGN Operation in detail a The start knob is pressed b The request signal is sent by wire to the keyless control module c The keyless control module sends a signal through the antenna d The antenna sends a signal to the card key e The card key sends its ID to the keyless receiver f The keyless receiver forwards the ID to the keyless control module The keyless control module checks the ID g I...

Page 211: ...ors and to disable the intrusion sensor when burglar alarm is fitted a button type battery CR2025 an auxiliary key and an indicator light When the LOCK or UNLOCK buttons are operated or a request signal is received from the vehicle the indicator light illuminates If the advanced keyless entry system is malfunctioning the driver s door can be opened and the engine started using the auxiliary key A ...

Page 212: ...nd under any condition other than above Flashes 4 Request switch is pressed from outside vehicle with proper card key inside vehicle and another card key carried Sounds 3 times Request switch is pressed with card key is carried and a door open or start knob not in LOCK position Sounds 3 times Battery voltage low indication Card key battery voltage depleted Flashes Approx 30s after IG OFF Start kno...

Page 213: ... engine cannot be restarted by turning the start knob from the ACC position to the START position even though the start knob has not been turned to the LOCK position 2 When the ignition switch is OFF except for LOCK position Start knob not in LOCK warning buzzer sound overrides 3 Initial setting is OFF 4 Stops flashing and goes out if the card key is detected inside the vehicle Service Training Ma...

Page 214: ...ssories Card Key Structural View M6FL_09017 1 Indicator light 4 Intruder sensor cut off button with theft deterrent system 2 Lock button 5 Auxilliary key 3 Unlock button 6 Transmitter 09 32 Service Training Mazda6 Facelift ...

Page 215: ...s 7 Open and close the driver s door three times The door lock actuators will lock once then unlock to confirm that key programming mode is active 8 Push the UNLOCK button on the card key to be programmed twice The door lock actuators will lock once then unlock to confirm that programming was successful 9 To program additional card keys remove the auxiliary key from the ignition lock and repeat th...

Page 216: ...ss Antennas A total of six to seven depending on the body style antennas send request signals to card keys and relay card key ID s to the keyless control module The keyless antennas built into the front doors can output signals to both inside or outside the vehicle and change the level of radio waves output to inside or outside the vehicle depending on whether a card key is detected inside or outs...

Page 217: ...ear 5 Keyless antenna interior middle 2 Keyless antenna interior RR 5HB WGN 6 Keyless antenna exterior driver side 3 Keyless antenna interior LR 5HB WGN 7 Keyless antenna exterior passenger side 4 Keyless antenna interior rear 4SD 8 Keyless antenna interior front Service Training Mazda6 Facelift 09 35 ...

Page 218: ... signal to the card key The request switch on the driver s door can also be used to open and close the windows see section 9 Power Window System M6FL_09019 1 Request switch 3 4SD 2 Internal circuit diagram 4 5HB WGN Keyless Buzzer The keyless buzzer is installed inside the driver s door To access it the door trim panel and speaker must be removed M6FL_09020 1 Keyless buzzer 09 36 Service Training ...

Page 219: ...Lock Unit Programming If the steering lock unit is replaced the new unit must be programmed using WDS NOTE Do not program the steering lock while WDS or any other computer devices are in the vehicle Make sure all card keys are operational and have good batteries NOTE To program the steering lock unit a registered card key is necessary If there is no programmed card key perform the steering lock un...

Page 220: ... right side kick panel NOTE When replacing the keyless control module the new module has to be configured To do this connect WDS to the vehicle and select the option Toolbox Module Programming Programmable Module Installation RKE Follow instructions on WDS to complete programming M6FL_09022 1 Keyless control module with advanced keyless system 09 38 Service Training Mazda6 Facelift ...

Page 221: ...s of the following functions Self test PID monitor Simulation test function Self Test The self test function allows the Advanced Keyless Entry system DTCs to be displayed To view these connect WDS to the vehicle and select the option Toolbox Self Test Modules RKE Service Training Mazda6 Facelift 09 39 ...

Page 222: ...switch Driver s door OPEN CLOSE 2R DRSW_ALL Door switch All doors and liftgate OPEN CLOSE 2R REQ_SW_D Request switch Driver s door On Off 3H REQ_SW_P Request switch Passenger door On Off 3J REQ_SW_BK Request switch Trunk lid Liftgate On Off 3L LOCK_SW_D Door lock link switch On Off 3E IMMOBI Immobilizer system equipped or not On Off TR LG_SW Trunk liftgate latch switch OPEN CLOSE 2R IG_KEY_IN Key ...

Page 223: ...part name Unit Operation Terminal BZR_OUT Keyless buzzer On Off 3Y BZR_INN Interior buzzer Instrument cluster On Off 3Z 3AA LNP_RED Keyless warning light red On Off 3Z 3AA LNP_GREEN Keyless indicator light green On Off 3Z 3AA HAZARD Hazard flashers On Off 2R DR_LOCK All doors Lock Off Lock Off 2R DR_UNLOCK All doors Unlock Off Unlock Off 2R SUPERLOCK All doors Lock Off Lock Off 2R Active Command M...

Page 224: ...re when resetting the immobilizer system PCM replacement keyless control module replacement or replacement of all programmed keys two or more keys usable with the immobilizer system must be readied before starting the operation A maximum of eight keys can be programmed to one vehicle The PID data monitor function can be used to verify the number of keys programmed to the vehicle A maximum of six c...

Page 225: ... clearing The programmed key ID number can only be cleared using the WDS or equivalent When clearing key ID numbers using the WDS or equivalent all the programmed key ID numbers are cleared PCM replacement The key ID numbers for all keys that were being used must be programmed using the WDS or equivalent Two or more keys must be programmed Keyless control module replacement Card key and steering l...

Page 226: ...Accessories Body Accessories Notes 09 44 Service Training Mazda6 Facelift ...

Page 227: ...d Keyless Entry System Structural View M6FL_09024 1 BCM 6 Door lock actuator rear left 2 Key cylinder 7 Door lock actuator rear right 3 Keyless receiver 8 Trunk lid opener 4SD Liftgate lock actuator 5HB WGN 4 Door lock actuator driver s side door lock link switch key cylinder switch 9 Transmitter 5 Door lock actuator passenger s side key cylinder switch Service Training Mazda6 Facelift 09 45 ...

Page 228: ...Accessories Body Accessories Keyless Entry System Wiring Diagram M6FL_09025 09 46 Service Training Mazda6 Facelift ...

Page 229: ... front door 16 Door switch rear door RH 5 Door lock link switch rear door RH 17 Door switch rear door LH 6 Door lock link switch rear door LH 18 Door switch passenger side front door 7 Front turn light RH 19 Lock actuators without double locking 8 Front turn light LH 20 Lock actuators with double locking 9 Rear turn light RH 21 Trunk lid opener 4SD Liftgate lock actuator 5HB WGN 10 Rear turn light...

Page 230: ...pushing the release button on the transmitter the ignition key will automatically pop out When the key is no longer needed it can be folded back into the transmitter case The key can be separated from the transmitter and the transmitter case opened to allow battery replacement M5_09026 1 Retractable key 4 Unlock button 2 Keyless transmitter 5 Intruder sensor cut off button with theft deterrent sys...

Page 231: ...nd prohibits the engine from being started using any other method such as using an unregistered key or by shorting the starter relay circuit The system is composed of the transponder equipped key the coil antenna and the PCM If there is a malfunction in the system the security light will display the DTC by flashing when the ignition switch is turned to the ON position Also the DTC can be displayed...

Page 232: ...Accessories Body Accessories Immobilizer System Wiring Diagram M6FL_09029 1 Instrument cluster 4 Coil antenna 2 Security light 5 PCM 3 Key transponder 09 50 Service Training Mazda6 Facelift ...

Page 233: ...a successful engine start stops the alarm An intruder sensor has been installed in the forward part of the roof 4SD 5HB without sliding sunroof WGN with sliding sunroof or in the center part of the roof 4SD 5HB with sliding sunroof WGN without sliding sunroof The intruder sensor senses movement in the vehicle based on radio waves and sends an alert signal to the theft deterrent control module A se...

Page 234: ...Accessories Body Accessories Theft Deterrent System Structural View M6FL_09030 09 52 Service Training Mazda6 Facelift ...

Page 235: ...switch 2 Horn relay 11 Door switch 3 Bonnet switch 12 Coil antenna 4 Transmitter 13 BCM 5 Security light 14 Theft deterrent siren 6 Key reminder switch 15 Trunk lid light switch 4SD Cargo compartment light switch 5HB WGN 7 Intruder sensor Vehicles without sliding sunroof 16 ABS or DSC CM 8 Intruder sensor Vehicles with sliding sunroof 17 Intruder sensor WGN 9 Keyless control module 18 WGN Service ...

Page 236: ...Accessories Body Accessories Theft Deterrent System Wiring Diagram M6FL_09031 09 54 Service Training Mazda6 Facelift ...

Page 237: ... Door lock link switch passenger side front door 5 Rear turn light RH 16 Door lock link switch rear door RH 6 Rear turn light LH 17 Door lock link switch rear door LH 7 Door key cylinder switch driver side 18 Bonnet switch 8 Trunk compartment light switch 4SD Liftgate latch switch 5HB WGN 19 Horn relay 9 Theft deterrent siren 20 Horn 10 Door switch driver side front door 21 Intruder sensor front 1...

Page 238: ...n signal to the BCM An intruder sensor cut off switch has been installed on the keyless entry system transmitter as well as on the advanced keyless transmitter If the intruder sensor cut off switch is pressed while the theft deterrent system is pre armed the intruder sensor is switched off M6FL_09032 1 Intruder sensor without sliding sunroof 5 Intruder sensor cut off switch 2 Intruder sensor with ...

Page 239: ...of the headlights has been adopted For vehicles equipped with discharge headlights An auto light wiper control module that automatically illuminates and turns off the headlights and controls the front wipers has been adopted Stepped reflectors have been adopted to the rear combination lights Auto Light System An auto light system that automatically and optimally illuminates and turns off the headl...

Page 240: ...ssories Body Accessories Auto Light System Structural View M6FL_09033 1 Auto light sensor 4 Light switch 2 Sensor diode 5 Auto light wiper control module 3 Windshield 09 58 Service Training Mazda6 Facelift ...

Page 241: ...adlight low beam 13 Rear fog light switch 4 Headlight high beam 14 Illumination light 5 TNS Tail Number Side lights relay 15 Headlight switch 6 Parking light taillight license plate light 16 Headlight 7 Front fog light relay 17 Flash to pass 8 Front fog light 18 Auto light switch 9 Rear fog relay 19 Auto light sensor 10 Rear fog light 20 ABS or DSC CM Service Training Mazda6 Facelift 09 59 ...

Page 242: ...ccessories Auto Light Sensor Installed behind the rearview mirror windshield center and integrated with the rain sensor as a single unit M6FL_09035 1 Auto light sensor 2 Lens sensor 09 60 Service Training Mazda6 Facelift ...

Page 243: ...itches from the driver The auto wiper system is essentially carried over from the Mazda3 except that there is now a separate control module which controls the auto wiper operation as well as the auto light operation The rain sensor can be adjusted using WDS This can be necessary after replacing the windscreen for example Auto Wiper System Structural View M6FL_09036 1 Rain sensor 4 Wiper and washer...

Page 244: ...Microcomputer Rainfall Detection Function The LED in the rain sensor emits infrared light that is reflected off the windshield via the lens sensor and then received by the photodiode in the rain sensor If the rate of reflected infrared light is reduced it is determined that rain is contacting the windshield and the intensity of the rainfall is calculated from the amount of reflection rate reductio...

Page 245: ...ocated on the steering wheel for audio operation Four speakers are installed as standard one each to the front and rear doors For BOSE specified systems 7 speakers including the door speakers are installed on the inner garnish of the front doors tweeters and in the rear package 4SD or temporary spare tire 5HB WGN woofer A noise filter has been installed on the brake light and rear window defroster...

Page 246: ...h 11 Woofer BOSE 3 Tweeter BOSE 12 Noise filter rear window defroster 4 Woofer relay BOSE 13 Center roof antenna 5 Noise filter brake switch 14 Glass antenna not for EU European Union market 6 Antenna feeder 15 Information display 7 Front door speaker 16 WGN 8 Rear door speaker 17 5HB 9 Audio amplifier BOSE 09 64 Service Training Mazda6 Facelift ...

Page 247: ...Frequency band Rated voltage Information system The mute function for hands free telephone systems has been discontinued To install a mobile phone hands free device use the accessory wiring harness which contains cut off relays to mute the speakers while the phone is operating Speaker Front Rear 4 SD 5 HB WGN Maximum input W Impedance Ohm 4 3 2 Size in 5 5 x 7 5 6 5 5 25 2 9 5 25 M6FL_09T007 Stand...

Page 248: ...added to the radio CD Compact Disc player base unit M6FL_09039 1 Center panel 7 Cover without upper module 2 Audio unit 8 Cover with upper module 3 Base unit 9 Cover without lower module 4 Lower module 10 Cover with lower module 5 Circuit board manual A C only 11 Climate control unit auto A C only 6 Information display harness 12 Ventilator grille 09 66 Service Training Mazda6 Facelift ...

Page 249: ...FM1 button 11 Preset button 4 3 FM2 button 12 Preset button 5 4 AM button 13 Preset button 6 5 CD button 14 SEEK button upper 6 MEDIA button 15 SEEK button lower 7 AUTO M button 16 POWER VOLUME button 8 Preset button 1 17 AUDIO CONT TUNE TEXT button 9 Preset button 2 Service Training Mazda6 Facelift 09 67 ...

Page 250: ... 2 button and the MEDIA button for 2 seconds or more Diagnostic Assist Function The diagnostic assist function allows the different components of the audio system to be checked The procedures for entering it are shown below Component Tested Procedure Buttons With the audio power on press the POWER button and simultaneously press the MEDIA button for approximately 1 second Speakers With the audio p...

Page 251: ...to automatically select a detour in case of traffic jams The voice guidance and screen display can be set to the following languages English British English American German French Italian Spanish Dutch Portugese Swedish Danish Norwegian and Finnish Specifications Navigation Unit Item Specification Unit type Stand alone Rated voltage 12 V Rom type DVD ROM Read Only Memory Voice guidance ouput power...

Page 252: ...ht 8 Front door speaker left 2 Tweeter right BOSE 9 Remote control 3 Car navigation unit 10 Cradle 4 LCD unit 11 Audio amplifier BOSE 5 Audio unit 12 ABS or DSC CM 6 GPS antenna 13 TR switch ATX 7 Tweeter left BOSE 14 Backup light switch MTX 09 70 Service Training Mazda6 Facelift ...

Page 253: ...on unit 15 Cradle 4 CPU 16 Audio unit 5 GPS receiver 17 Power amplifier 6 Gyro sensor 18 Speaker output to driver s side 7 DVD driver 19 Audio amplifier 8 GPS antenna 20 Tweeter driver side 9 LCD unit 21 Front door speaker driver side 10 LCD 22 BOSE system only 11 Tilt switch 23 RDS TMC tuner 12 OPEN CLOSE switch 24 RDS TMC antenna Service Training Mazda6 Facelift 09 71 ...

Page 254: ...ar Navigation Unit The car navigation unit is located in the glove compartment and incorporates the DVD ROM drive and the gyro sensor M6FL_09043 1 DVD ROM loading slot 3 Eject button 2 DVD ROM 09 72 Service Training Mazda6 Facelift ...

Page 255: ...D unit features a private bi directional serial bus to the navigation unit and the audio unit All necessary video signals are separately sent as a video signal RGB Red Green Blue Video Driver Standard It features different illumination modes for the navigation display The driver can select between automatic day and night mode M6FL_09044 1 LCD unit assembly 4 LCD unit 2 Open 5 Information display 3...

Page 256: ... Different display modes can be selected with the split screen function Some of the different options are shown below One Screen Map Display M5_09058 Dual Screen Map Display with Different Scales M5_09059 09 74 Service Training Mazda6 Facelift ...

Page 257: ...Body Accessories Accessories Map and Turn List M5_09060 Map and Turn Arrows M5_09061 Service Training Mazda6 Facelift 09 75 ...

Page 258: ... Accessories Automatically Enlarged Illustration of a nearby Intersection on Main Roads M5_09062 Automatically Enlarged Illustration of a Nearby Intersection on Motorways M5_09063 09 76 Service Training Mazda6 Facelift ...

Page 259: ...when set in the cradle The batteries are not charged when the remote control is in the cradle M6FL_09051 1 Remote control 2 Cradle 3 Front view 4 Top view 5 Underside view 6 Infrared transmitter 7 Infrared sensor 8 Power supply connector 9 Position button Displays the current position 10 Joystick Selects items by tilting it up down right and left 11 Enter button Executes a selected item 12 Zoom bu...

Page 260: ...ding traffic information provided from a lot of radio stations The quality of the information varies depending on the radio station and on how they receive their information either only by the police and listeners or in addition by companies providing more detailed information Sometimes the verbal information from a radio station is different to the TMC information they provide M6FL_09052 1 Traffi...

Page 261: ... events are described in the following table Category Colour Stationary Traffic Red Traffic Jam Orange Accidents Pink Closed Road Black Road Works Danger Pink Road Conditions Weather Delays Yellow Parking Out of order Grey M6FL_09T011 Inside the vehicle the TMC signals are processed as shown below M6FL_09054 1 Navigation ECU Electronic Control Unit 5 Decoder 2 RDS TMC Receiver 6 CPU Communication ...

Page 262: ...Accessories Body Accessories Each traffic event is indicated by one sign M5_09072 1 Icon for traffic event 09 80 Service Training Mazda6 Facelift ...

Page 263: ...splays traffic events on other roads the DRGS recalculates the route only for traffic events on motorways NOTE A TMC information about a heavy traffic jam does not necessarily mean that the navigation system will re route the vehicle Re routing always depends on local facts M5_09073 1 Covered 2 Under preparation Service Training Mazda6 Facelift 09 81 ...

Page 264: ...ic events on the guided route 6 Enables TMC 2 Selected country 7 Switches between automatic and manual country selection 3 Selected TMC radio station 8 Selects a TMC radio station 4 Enables DRGS 9 Displays all traffic events 5 Enables verbal information regarding traffic events Diagnostics If a malfunction is suspected the navigation system has to be checked according to the Workshop Manual 09 82 ...

Page 265: ...t belt is not fastened buckle switch is off Each indicator turns off if the condition corresponds to any of the following When the ignition switch is in the LOCK position When approx 40 s have elapsed since the generator warning light turned off engine runs If the buckle switch signal changes on to off or off to on with the ignition switch in the ON position and the indicator is not illuminated th...

Page 266: ...ody Accessories Rear Seat Belt Warning Alarm Structural View M6FL_09058 1 Rear seat belt reminder indicator 3 Rear center seat belt 2 Rear left seat belt 4 Rear right seat belt 09 84 Service Training Mazda6 Facelift ...

Page 267: ...belt indicator 2 Generator warning light 9 Red unfastened 3 Rear seat belt reminder indicator 10 Green fastened 4 Buzzer 11 Buckle switch rear left 5 Microcomputer 12 Buckle switch rear center 6 Rear left seat belt indicator 13 Buckle switch rear right 7 Rear center seat belt indicator Service Training Mazda6 Facelift 09 85 ...

Page 268: ... WDS A front passenger seat belt warning alarm was added to Mazda6 Facelift using an occupancy sensor to detect whether the front passenger seat is occupied or not and a buckle switch to indicate the buckle situation The warning light in the instrument cluster shows if the passenger is not buckled when vehicle speed is higher than 20 km h Then also the warning sound occurs Passenger seat belt warn...

Page 269: ... signals among electrical modules has been adopted Twisted pair wiring is used for connections between the following modules each electrical module hereafter referred to as a CAN system related module PCM TCM ATX 4WD CM 4WD DSC CM with DSC ABS CM with ABS Keyless control module with advanced keyless system Instrument cluster BCM Service Training Mazda6 Facelift 09 87 ...

Page 270: ...eability M6FL_09061 1 PCM 9 2R except MZR CD RF Turbo 39 MZR CD RF Turbo 2 DSC CM with DSC 10 2U except MZR CD RF Turbo 13 MZR CD RF Turbo 3 ABS CM with ABS 11 Audio unit 4 Data link connector 12 Twisted pair 5 Instrument cluster 13 BCM 6 TCM ATX 14 CAN L 7 4WD CM 4WD 15 CAN H 8 Keyless control module advanced keyless system 09 88 Service Training Mazda6 Facelift ...

Page 271: ...y Control Module CAN Controller Area Network CAN H Controller Area Network High CAN L Controller Area Network Low CD Compact Disc CKP Crankshaft Position CM Control Module CMDTC Continous Mode DTC CMP Camshaft Position CPU Central Processing Unit DC Direct Current DIS Driver Information System DLC Data Link Connector DPF Diesel Particulate Filter DRGS Dynamic Route Guidance System DSC Dynamic Stab...

Page 272: ...ir Control IAT Intake Air Temperature IC Integrated Circuit ID Identification IG Ignition IG1 Ignition switch position 1 ISV Intake Shutter Valve KS Knock Sensor LCD Liquid Crystal Display LED Light Emitting Diode LF Left Front LH Left Hand LHD Left Hand Drive LR Left Rear LW Long Wave MAF Mass Air Flow MAP Manifold Absolute Pressure MD Mini Disc MIL Malfunction Indicator Light MTX Manual Transaxl...

Page 273: ...te Keyless Entry ROM Read Only Memory RR Right Rear Rx Receive wire Data Bus SAPS Sulphate Ash Phosphor Sulphur SAS Sophisticated Airbag Sensor SST Special Service Tool TCM Transaxle Control Module TCS Traction Control System TFT Thin Film Transistor TMC Traffic Message Channel TNS Tail Number Side lights TP Throttle Position TR Transaxle Range TWC Three Way Catalyst Tx Transmit wire Data Bus VAD ...

Page 274: ...List of Abbreviations VTCS Variable Tumble Control System WDS Worldwide Diagnostic System WGN Wagon Service Training Mazda6 Facelift ...

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