Page 1 2006 Mazda MX-5 Service Highlights (3404–1U–05F) 2006 CONTENTS Mazda MX-5 Title Section Service GENERAL INFORMATION Highlights ENGINE SUSPENSION FOREWORD DRIVELINE/AXLE This manual explains each component or system operation and function for the Mazda MX-5. BRAKES For proper repair and maintenance, a...
Page 2 2006 Mazda MX-5 Service Highlights (3404–1U–05F) VEHICLE IDENTIFICATION NUMBERS (VIN) JM1 NC15F✻6# 100001— JM1 NC25F✻6# 100001— RELATED MATERIALS Material Name MNAO Part No. Mazda Material No. 2006 Mazda MX-5 Workshop Manual 9999–95–042B–06 1846–1U–05F Engine Workshop Manual LF L3 9999–95–LFL3–05 1866–1U–05H Manual Transmission Workshop Manual M15M-D 9999–95–421H–06...
Page 3: Table Of Contents
GENERAL INFORMATION SECTION 00–00 Toc of SCT GENERAL INFORMATION ..00-00 Toc of SCT 00–00 GENERAL INFORMATION AIM OF DEVELOPMENT ... . . 00–00–1 UNITS......00–00–11 Product Concept .
Page 4: Vehicle Outline
— A two-fold type soft top has been adopted for improved ease of opening/closing. Interior design • A comfortable interior and sporty design incorporating Mazda’s inherited DNA — A simple, clean-cut dashboard with a spacious feel has been adopted. — A center panel that integrates module audio and air conditioning controls has been adopted.
Page 5 GENERAL INFORMATION Suspension and steering • Front suspension — A newly developed in-wheel-type double-wishbone suspension has been adopted to take full advantage of the low bonnet line enabled by the optimized engine layout. — The front upper arm and the front lower arm have been lengthened and attached to the highly rigid front 00–00 crossmember to allow for linear alignment changes during jounce and rebound of the front wheels.
Page 6 GENERAL INFORMATION • Rear suspension — A multi-link suspension composed of five links has been adopted. — The links have been lengthened and optimally positioned. Due to this, they constantly provide ideal geometry to respond to external forces applied during driving, improving handling stability and riding comfort, and reducing road noise.
Page 7 GENERAL INFORMATION • Power steering — With the adoption of an integrated mount for the steering gear, handling stability has been improved. — With the adoption, for all vehicles, of a steering column with a tilt mechanism, operability has been improved.
Page 8 GENERAL INFORMATION Brakes • The ABS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted, resulting in size and weight reduction. • A semi-conductor element type front ABS wheel-speed sensor has been adopted, improving reliability and reducing size and weight.
Page 9 GENERAL INFORMATION Transmission • Manual transmission [M15M-D] — A linked, triple-cone synchronizer mechanism has been adopted for 1st and 2nd gears. — A linked, double-cone synchronizer mechanism has been adopted for 3rd gears. — A linked, carbon-cone synchronizer mechanism has been adopted for 4th gears. 00–00 —...
Page 10 GENERAL INFORMATION • Manual transmission [P66M-D] — A linked, triple-cone synchronizer mechanism has been adopted for 1st, 2nd, 3rd and 4th gears. — A guide plate type reverse lockout mechanism has been adopted. SHIFT PATTERN 6TH GEAR 4TH GEAR 1ST GEAR 2ND GEAR 3RD GEAR MAINSHAFT...
Page 11 GENERAL INFORMATION — 00–00 E5U513ZS5001 00–00–9...
Page 12: Vehicle Identification Number (Vin) Code
• World-class collision protection is provided due to the lightweight and highly rigid Mazda Advanced Impact- energy Distribution and Absorption System body.
Page 13: Units
GENERAL INFORMATION UNITS E5U000000000N04 Electrical current A (ampere) Electric power W (watt) Electric resistance ohm 00–00 Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm (kilogram force per square Positive pressure...
Page 14: Sae Standard
• In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents. SAE Standard...
Page 15 ENGINE SECTION 01–00 Toc of SCT OUTLINE ....01-00 EMISSION SYSTEM..01-16 ON-BOARD DIAGNOSTIC ..01-02 CHARGING SYSTEM.
Page 16: Outline
OUTLINE ENGINE FEATURES [LF] E5U010002000N02 Mechanical • Variable valve timing mechanism adopted Improved power performance • Aluminum alloy cylinder head and cylinder block adopted Reduced weight • Aluminium alloy cylinder block adopted • Silent timing chain adopted • Crankshaft pulley with torsional damper adopted Reduced engine noise and •...
Page 17: Engine Specification [Lf]
OUTLINE ENGINE SPECIFICATION [LF] E5U010002000N03 Specification Specification Item LF (2.0L) MECHANICAL Type DOHC-16V in-line, 4-cylinder 01–00 Combustion chamber Pentroof 1,999 Displacement (ml {cc, cu in}) {1,999, 122.0} 87.5 × 83.1 Bore × stroke (mm {in}) {3.44 ×3.27} Compression ratio 10:8 1,720 Compression pressure (kPa {kgf/cm...
Page 18 OUTLINE Specification Item LF (2.0L) FUEL SYSTEM Type Hi-ohmic Injector Type of fuel delivery Top-feed Type of drive Voltage Pressure regulator control pressure Approx. 390 {3.98, 56.6} (kPa {kgf/cm , psi}) Fuel pump type Electric Fuel tank capacity (L {US gal, lmp gal}) 48 {12, 10} Fuel type (Anti-knock index) Premium unleaded fuel (96 RON or more)
Page 19 OUTLINE Engine oil specification Item U.S.A. and CANADA Except U.S.A. and CANADA 01–00 Engine oil grade (ILSAC) (ILSAC) API SL or ILSAC Engine oil viscosity 5W–20 End Of Sie 01–00–5...
Page 21 ON-BOARD DIAGNOSTIC 01–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC OUTLINE Sending Continuous Monitoring [LF] ......01–02–1 System Test Results .
Page 22: On-Board Diagnostic
ON-BOARD DIAGNOSTIC DIAGNOSTIC SYSTEM WIRING DIAGRAM [LF] E5U010200000N07 COOLING FAN RELAY NO.1 (BUILT INTO BARO COOLING FAN RELAY NO.2 SENSOR) COOLING FAN RELAY NO.3 REAR HO2S HEATER FRONT HO2S HEATER REAR HO2S A/C RELAY FRONT HO2S FUEL INJECTOR NO.1 FUEL INJECTOR NO.2 FUEL INJECTOR NO.3 MAP SENSOR FUEL INJECTOR NO.4...
Page 23 ON-BOARD DIAGNOSTIC IAT SENSOR (BUILT INTO BARO SENSOR) GENERATOR TERMINAL D 01–02 MAF SENSOR PURGE SOLENOID VALVE EGR VALVE TP SENSOR VARIABLE INTAKE AIR SOLENOID VALVE EVAP SYSTEM LEAK DETECTION PUMP RELATED MODULE GENERATOR TERMINAL P CRUISE CONTROL SWITCH TO TR SWITCH THROTTLE VALVE ACTUATOR NEUTRAL SWITCH CPP SWITCH...
Page 24: Diagnostic Test Mode [Lf]
ON-BOARD DIAGNOSTIC DIAGNOSTIC TEST MODE [LF] E5U010200000N02 • To meet OBD-II regulations, the following diagnostic test modes have been adopted. Diagnostic test mode Item Mode 01 Sending diagnostic data (PID data monitor/On-board system readiness test) Mode 02 Sending freeze frame data Mode 03 Sending emission-related malfunction code (DTC) Mode 04...
Page 25 ON-BOARD DIAGNOSTIC Meaning of fuel system loop status • The following information is displayed on the tester. — Feedback stops: ECT is lower than the determined feedback zone. — Feedback operating: HO2S being used for feedback is normal. — Feedback stops: Open loop due to driving condition —...
Page 26: Sending Freeze Frame Data
ON-BOARD DIAGNOSTIC Sending Freeze Frame Data • The Freeze Frame Data monitor items are shown below. Freeze frame data monitor table Full names Unit DTC that caused required Freeze Frame Data storage No unit Fuel system loop status Refer to list below. LOAD °C °F...
Page 27 ON-BOARD DIAGNOSTIC Self-test Memory DTC No. Condition Monitor item function type* Manifold absolute pressure/atmospheric × P0069 pressure correlation × P0101 MAF sensor circuit range/performance problem × P0102 MAF sensor circuit low input C, O, R × P0103 MAF sensor circuit high input C, O, R 01–02 ×...
Page 28 ON-BOARD DIAGNOSTIC Self-test Memory DTC No. Condition Monitor item function type* Evaporative emission control system leak Evaporative × P0442 C, R detected (small leak) system × P0443 Purge solenoid valve circuit problem C, O, R Change over valve (COV) (EVAP system leak ×...
Page 29 ON-BOARD DIAGNOSTIC Self-test Memory DTC No. Condition Monitor item function type* Throttle actuator control throttle body range/ × P2119 C, R performance problem × P2122 APP sensor No.1 circuit low input C, O, R × P2123 APP sensor No.1 circuit high input C, O, R ×...
Page 30: Sending Intermittent Monitoring System Test Results
ON-BOARD DIAGNOSTIC Sending Intermittent Monitoring System Test Results • The items supported by the sending intermittent monitoring system are shown below. TEST ID Description Related system 10:01:84 HO2S (Front) period (calculated) 10:02:03 Low HO2S (Rear) voltage for switch time calculation (constant) HO2S 10:02:04 High HO2S (Rear) voltage for switch time calculation (constant)
Page 31: Dtc Detection Logic And Conditions [Lf]
ON-BOARD DIAGNOSTIC DTC DETECTION LOGIC AND CONDITIONS [LF] E5U010200000N03 B1342 PCM malfunction • Malfunction in the PCM internal circuit. P0011 CMP Timing over-advanced • The actual valve timing is over-advanced by 15 ° from the target valve timing for specified period when the oil control valve (OCV) is controlled in the maximum valve timing retard condition.
Page 32 ON-BOARD DIAGNOSTIC P0108 MAP sensor circuit high input • The PCM monitors the input voltage from the MAP sensor when intake air temperature is above –10 °C {14 °F}. If input the voltage is above 4.92 V, the PCM determines that the MAP sensor circuit has a malfunction. MONITORING CONDITIONS —...
Page 33 ON-BOARD DIAGNOSTIC P0133 Front HO2S circuit problem • Front HO2S malfunction is detected by measuring of the average frequency of front HO2S signal, time required to pass from rich to lean, time required to pass from lean to rich. If the average frequency of front HO2S signal is more than the threshold value, the PCM determines that there is the front HO2S circuit problem.
Page 34 ON-BOARD DIAGNOSTIC P0140 Rear HO2S no activity detected • The PCM monitors the input voltage from the rear HO2S when the following conditions are met. Under the following monitoring conditions, if the input voltage from the rear HO2S does not even exceed 0.55 V though the short term fuel trim is controlled up to 20.5% for 9.6 s, the PCM determines that sensor circuit is not activated.
Page 35 ON-BOARD DIAGNOSTIC P0421 Warm up catalyst system efficiency below threshold • PCM compares number of front HO2S and rear HO2S inversions for a predetermined time. PCM monitors number of inversions rear side performs while front side inverts for a specified number of times when the following monitoring conditions are met, PCM detects inversion ratio.
Page 36 ON-BOARD DIAGNOSTIC P0456 Evaporative emission control system leak detected (very small leak) • PCM measure the pump load current (EVAP line pressure) when a specified period has passed after EVAP system is sealed when monitoring conditions are met. If the load does not reach the reference load value or rate of the load increase lower than the specified within a specified period, PCM determines that the EVAP system has very small leak.
Page 37 ON-BOARD DIAGNOSTIC P0506 Idle speed control system RPM lower than expected • Actual idle speed is lower than expected by 100 rpm for 14 s, when brake pedal is depressed (brake switch is on) and steering wheel is held straight ahead (power steering pressure (PSP) switch is off). P0507 Idle speed control system RPM higher than expected •...
Page 38 ON-BOARD DIAGNOSTIC P2096 Target A/F feedback system too lean • The PCM monitors the target A/F fuel trim when under the target A/F feedback control. If the fuel trim is more than the specification, the PCM determines that the target A/F feedback system is too lean. MONITORING CONDITION —...
Page 39 ON-BOARD DIAGNOSTIC P2188 Fuel system too rich at idle • PCM monitors short term fuel trim (SHRTFT), long term fuel trim (LONGFT) during closed loop fuel control at idle. If the LONGFT and the sum total of these fuel trims exceed preprogrammed criteria. PCM determines that fuel system is too rich at idle.
Page 40: Koeo/Koer Self-Test [Lf]
ON-BOARD DIAGNOSTIC KOEO/KOER SELF-TEST [LF] E5U010200000N04 • The self-test function consists of the KOEO (Key On Engine Off) self-test, performed when the ignition switch is turned to the ON position and the engine is stopped; and the KOER (Key On Engine Running) self-test, performed when idling.
Page 41 ON-BOARD DIAGNOSTIC Test condition DTC No. Condition KOEO KOER P0139 Rear HO2S circuit problem — — × P0140 Rear HO2S no activity detected — × × P0222 TP sensor No.2 circuit low input × × P0223 TP sensor No.2 circuit high input ×...
Page 42 ON-BOARD DIAGNOSTIC Test condition DTC No. Condition KOEO KOER × P2107 Throttle actuator control module processor error — × P2108 Throttle actuator control module performance error — × P2109 TP sensor minimum stop range/performance problem — × P2112 Throttle actuator control system range/performance problem —...
Page 43 ON-BOARD DIAGNOSTIC PID/DATA MONITOR AND RECORD [LF] E5U010200000N05 • The PID/DATA monitor items are shown below. PID/DATA monitor table (reference) Item Definition Unit/Condition terminal °C Ambient air temperature — AC_REQ Refrigerant pressure switch (high, low) On/Off 01–02 ACCS A/C relay On/Off Air/fuel ratio —...
Page 44 ON-BOARD DIAGNOSTIC Item Definition Unit/Condition terminal EVAP system leak detection pump detect incorrect purge LDP_EVAPCP — flow LDP_IDL EVAP system leak detection pump idle current — LDP_MON EVAP system leak detection pump monitoring current — LDP_REF EVAP system leak detection pump reference current —...
Page 45 ON-BOARD DIAGNOSTIC End Of Sie SIMULATION TEST [LF] E5U010200000N06 • The simulation items are shown below. Simulation item table ×: Applicable —: Not applicable Test condition Item Applicable component Unit/condition PCM terminal KOEO KOER 01–02 × × ACCS A/C relay Off/On ×...
Page 47 MECHANICAL 01–10 MECHANICAL ENGINE STRUCTURAL VIEW [LF] ..01–10–1 VALVE, VALVE SPRING, CYLINDER HEAD COVER VALVE SEAL, VALVE GUIDE CONSTRUCTION [LF] ... . . 01–10–2 CONSTRUCTION [LF] ....01–10–10 CYLINDER HEAD CONSTRUCTION CAMSHAFT CONSTRUCTION [LF] .
Page 48: Mechanical
MECHANICAL CYLINDER HEAD COVER CONSTRUCTION [LF] E5U011010100N01 • The cylinder head cover is made of integrated OIL CONTROL VALVE (OCV) plastic, which is lightweight and sound absorbent. ATTACHMENT HOLE • The oil filler cap is a bayonet type. DIPSTICK INSERTION HOLE •...
Page 49: Cylinder Block Construction
MECHANICAL CYLINDER BLOCK CONSTRUCTION [LF] E5U011010300N01 • The cylinder block is made of aluminum alloy, which is cast with the cast iron liner, improving heat radiation and decreasing weight. • The cylinder block is a deep skirt type and forms the ladder frame structure with the integrated main bearing cap.
Page 50: Crankshaft, Main Bearing Construction [Lf]
MECHANICAL CRANKSHAFT, MAIN BEARING CONSTRUCTION [LF] E5U011011301N01 • A five axle-hole, 4 counter weight cast iron crankshafts have been adopted. • There is no positioning key where the crankshaft sprocket and crankshaft pulley are installed. The crankshaft sprocket must be installed using the SST with the No.1 cylinder aligned with TDC position.
Page 51: Crankshaft Pulley Construction [Lf]
MECHANICAL CRANKSHAFT PULLEY CONSTRUCTION [LF] E5U011011371N01 • The crankshaft position (CKP) signal detecting blade has been adopted for the crankshaft pulley. The torsional damper, which prevents the crankshaft from wobbling, has also been adopted for the crankshaft. • There is no positioning key slot on the crankshaft pulley. Instead, the positioning hole on the crankshaft pulley and the engine front cover are used for aligning the crankshaft pulley with the crankshaft.
Page 52: Piston, Piston Ring, Piston Pin Construction [Lf]
MECHANICAL PISTON, PISTON RING, PISTON PIN CONSTRUCTION [LF] E5U011011010N01 • The pistons are made of aluminium alloy, which withstands heat and is highly conductive. • The piston skirt is coated with graphite to reduce friction. • The offset pistons are used to reduce piston-slapping noise. •...
Page 53: Connecting Rod, Connecting Rod Bearing Construction [Lf]
MECHANICAL CONNECTING ROD, CONNECTING ROD BEARING CONSTRUCTION [LF] E5U011011211N01 • Connecting rod is made of structural sintered alloy to improve rigidity. • The connecting rod, the piston, and the piston pin are interference fit, so that they cannot be disassembled. •...
Page 54: Drive Belt Construction [Lf]
MECHANICAL DRIVE BELT CONSTRUCTION [LF] E5U011015800N01 • A V-ribbed drive belt is employed. • A single, serpentine type drive belt drives auxiliary parts, resulting in a shortened overall belt length and improved serviceability. • A front drive belt auto tensioner with an embedded coil spring has been adopted to automatically maintain the optimal drive belt tension.
Page 55: Valve Mechanism Outline [Lf]
MECHANICAL VALVE MECHANISM OUTLINE [LF] E5U011012111N01 • There are two intake ports and two exhaust ports each cylinder. Totally 16 valves are directly driven by two camshafts. • The variable valve timing mechanism, which insures the best valve timing depending on the drive condition by constantly changing the phase of the intake port side camshaft, has been adopted.
Page 56: Valve, Valve Spring, Valve Seal, Valve Guide Construction [Lf]
MECHANICAL VALVE, VALVE SPRING, VALVE SEAL, VALVE GUIDE CONSTRUCTION [LF] E5U011012111N03 • The valves are heat-resistant steel. There are two intake valves, two exhaust valves per cylinder. Valve specification item Specification Intake valve: About 103.4 {4.070} valve full length (mm {in}) Exhaust valve: About 104.7 {4.122} Intake valve umbrella diameter (mm {in})
Page 57 MECHANICAL • The detection unit (trigger plate) for the camshaft position (CMP) sensor is at the intake port side VARIABLE DOMAIN 0˚ camshaft. • The groove for securing the No.1 cylinder TDC for 5˚ 30˚ the camshaft, is provided at the rear of the intake and exhaust camshaft.
Page 58: Camshaft Sprocket Construction [Lf]
MECHANICAL CAMSHAFT SPROCKET CONSTRUCTION [LF] E5U011012420N02 • The sintered alloy, which has high rigidity, has been adopted for the camshaft sprocket and is quenched to improve the abrasion resistance at the contact point with the timing chain. • The intake camshaft sprocket is integrated (cannot be disassembled) with the variable valve timing actuator. CAMSHAFT SPROCKET VARIABLE VALVE TIMING ACTUATOR...
Page 59: Timing Chain, Chain Tensioner Construction [Lf]
MECHANICAL TIMING CHAIN, CHAIN TENSIONER CONSTRUCTION [LF] E5U011012040N01 • A silent chain (link grounding type) type has been adopted for the timing chain to reduce tapping noise caused by matching each sprocket. • Engine oil inside the engine front cover lubricates the timing chain and each sprocket. The pin part of the timing chain is nitrite-treated to improve abrasion resistance.
Page 60: Tappet Construction [Lf]
MECHANICAL TAPPET CONSTRUCTION [LF] E5U011012431N01 • The tappet is a shimless tappet which is integrated with the shim. • The tappet surface is phosphate-coated to smooth the attaching surface to the cam and improve abrasion resistance. • The valve clearance can be adjusted by replacing the tappet. There are 35 kinds of tappets depending on the thickness.
Page 61: Variable Valve Timing Mechanism
MECHANICAL Variable Valve Timing Mechanism Function • The variable valve timing mechanism continuously modifies the phases of the variable valve timing actuator and the intake camshaft using hydraulic pressure controlled by the oil control valve (OCV) so that optimal valve timing is obtained according to engine operation conditions.
Page 62 MECHANICAL Construction • The variable valve timing mechanism consists of a variable valve timing actuator, oil control valve (OCV), CKP sensor, CMP sensor, and the PCM. ELECTRIC SIGNAL HYDRAULIC PRESSURE CMP SENSOR OIL CONTROL VALVE (OCV) VARIABLE VALVE TIMING ACTUATOR CKP SENSOR E5U110ZT5030 01–10–16...
Page 63: Hydraulic Pressure Flow Diagram
MECHANICAL Hydraulic Pressure Flow Diagram CONTROL VALVE (OCV) 01–10 OIL CONTROL VALVE (OCV) ADAPTER VARIABLE VALVE TIMING CAMSHAFT ACTUATOR CYLINDER BLOCK OIL PUMP OIL PAN E5U110ZT5031 End Of Sie 01–10–17...
Page 64: Variable Valve Timing Mechanism Construction/Operation
MECHANICAL VARIABLE VALVE TIMING MECHANISM CONSTRUCTION/OPERATION [LF] E5U011012111N05 Component and Function • Continuously modifies the phases of the intake camshaft and crankshaft at the forward Variable valve timing actuator end of the intake camshaft using hydraulic pressure from the oil control valve (OCV). •...
Page 65 MECHANICAL Retarding valve timing • When the spool valve in the oil control valve (OCV) moves to the right according to the PCM signal, hydraulic pressure, from the oil pump, feeds into the valve timing retard passage and finally to the valve timing retard chamber in the variable valve timing actuator.
Page 66: Variable Valve Timing Actuator Construction [Lf]
MECHANICAL VARIABLE VALVE TIMING ACTUATOR CONSTRUCTION [LF] E5U011012490N01 • The variable valve timing actuator consists of the following: a housing case integrated to the camshaft sprocket, a cover, a camshaft integrated rotor, and a stopper pin that retains the rotor and case when the engine stops.
Page 67 LUBRICATION 01–11 LUBRICATION LUBRICATION SYSTEM OUTLINE OIL STRAINER CONSTRUCTION [LF] ......01–11–1 [LF] ......01–11–3 Features .
Page 68 LUBRICATION LUBRICATION SYSTEM FLOW DIAGRAM [LF] E5U011100000N03 VARIABLE VALVE TIMING ACTUATOR CAMSHAFT TO OIL PAN TAPPET OIL PRESSURE SWITCH ORIFICE TIMING CHAIN CHAIN TENSIONER OIL FILTER MAIN BEARING CRANKSHAFT PISTON CONNECTING ROD OIL JET VALVE BEARING OIL PUMP OIL PASSAGE OIL RELIEF PASSAGE OIL BYPASS PASSAGE OIL PAN...
Page 69 LUBRICATION OIL PAN CONSTRUCTION [LF] E5U011110040N01 • An aluminum alloy oil pan has been adopted for noise reduction. EXTERNAL VIEW • An oil pan baffle plate has been adopted inside the oil pan to stabilize engine oil diffusion by OIL PAN BAFFLE PLATE crankshaft rotation and oil level when the vehicle rolls.
Page 70 LUBRICATION OIL PUMP CONSTRUCTION [LF] E5U011114100N01 • The oil pump is installed inside the engine front cover. The crankshaft drives the inner rotor through the oil pump chain and oil pump sprocket. • The oil pump component consists of the oil pump body, oil pump sprocket, oil pump chain, oil pump chain guide, and oil pump chain tensioner.
Page 71 LUBRICATION Oil pump driven chain, oil pump sprocket specification Item Specification [mm {in}] Oil pump driven chain Pitch size 8 {0.3} Outer diameter 60.78 {2.392} Oil pump sprocket Driven tooth width 6.15 {0.242} End Of Sie 01–11 OIL JET VALVE CONSTRUCTION/OPERATION [LF] E5U011110730N01 Construction •...
Page 73: Cooling System
COOLING SYSTEM 01–12 COOLING SYSTEM COOLING SYSTEM OUTLINE [LF] ..01–12–1 Construction ..... 01–12–3 Features ......01–12–1 Operation .
Page 74 COOLING SYSTEM COOLING SYSTEM FLOW DIAGRAM [LF] E5U011200000N03 THERMOSTAT CYLINDER HEAD THROTTLE COOLANT BODY VALVE RESERVE TANK CYLINDER BLOCK WATER RADIATOR PUMP HEATER COOLANT FLOW DIRECTION E5U112ZS5002 End Of Sie COOLING SYSTEM CAP, COOLANT RESERVE TANK CONSTRUCTION [LF] E5U011215201N02 • A low-pressure type cap has been adopted for the cooling system. It is installed on the coolant reserve tank to improve serviceability when adding engine coolant and bleeding air.
Page 75 COOLING SYSTEM RADIATOR CONSTRUCTION [LF] E5U011215200N01 • A cross-flow radiator with corrugated fins is used to improve cooling performance. • The radiator tanks are made of plastic and the core is made of aluminum for weight reduction. • Four rubber-insulated mounting brackets are utilized to decrease vibration.
Page 76 COOLING SYSTEM WATER PUMP CONSTRUCTION/OPERATION [LF] E5U011215010N01 Construction • The aluminum alloy water pump with the impeller built into the cylinder block has been adopted for size reduction. • The water pump is not serviceable and must be replaced as a unit if it has a malfunction. Operation •...
Page 77 INTAKE-AIR SYSTEM 01–13 INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM OUTLINE VARIABLE INTAKE AIR SYSTEM [LF] ......01–13–1 OPERATION [LF] .
Page 78: Intake-Air System
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM STRUCTURAL VIEW [LF] E5U011300000N02 VARIABLE INTAKE AIR SOLENOID VALVE DYNAMIC CHAMBER ACCELERATOR PEDAL INTAKE MANIFOLD VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR THROTTLE BODY FRESH-AIR DUCT AIR CLEANER E5U113ZS5010 End Of Sie 01–13–2...
Page 79: Intake-Air System Diagram
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM DIAGRAM [LF] E5U011300000N04 THROTTLE VALVE THROTTLE BODY INTAKE MANIFOLD ACTUATOR DYNAMIC CHAMBER 01–13 FRESH-AIR CHECK VALVE DUCT AIR CLEANER VACUUM CHAMBER VARIABLE INTAKE AIR SOLENOID VALVE VARIABLE INTAKE AIR VARIABLE INTAKE AIR SHUTTER VALVE SHUTTER VALVE ACTUATOR : TO PCM E5U113ZS5001 End Of Sie...
Page 80: Air Cleaner Construction
INTAKE-AIR SYSTEM AIR CLEANER CONSTRUCTION [LF] E5U011313300N01 • Composed of the air cleaner case, air cleaner AIR CLEANER cover, and air cleaner element. COVER • Non-woven fabric (dry type) element has been AIR CLEANER adopted. ELEMENT End Of Sie AIR CLEANER CASE E5U113ZS5012 THROTTLE BODY FUNCTION [LF]...
Page 81: Intake Manifold/Dynamic Chamber Construction
INTAKE-AIR SYSTEM INTAKE MANIFOLD/DYNAMIC CHAMBER CONSTRUCTION [LF] E5U011313100N01 • The intake manifold composed of the variable intake air shutter valve actuator. DYNAMIC CHAMBER INTAKE MANIFOLD 01–13 VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR E5U113ZS5015 End Of Sie VARIABLE INTAKE AIR SYSTEM FUNCTION [LF] E5U011300020N01 •...
Page 82: Variable Intake Air System Structure [Lf]
INTAKE-AIR SYSTEM VARIABLE INTAKE AIR SYSTEM STRUCTURE [LF] E5U011300020N03 • Mainly consists of the variable intake air solenoid valve, variable intake air shutter valve, variable intake air shutter valve actuator and vacuum chamber. DYNAMIC CHAMBER CHECK VALVE VACUUM CHAMBER VARIABLE INTAKE AIR SOLENOID VALVE VARIABLE INTAKE AIR...
Page 83: When Operation Conditions Are Met
INTAKE-AIR SYSTEM When Operation Conditions Are Met. (Variable Intake Air Shutter Valve Is Open) • The variable intake air shutter valve is open. • Under this condition, the effective intake manifold length is from the intake valve to the dynamic chamber (B—C).
Page 84: Variable Intake Air Shutter
INTAKE-AIR SYSTEM VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR FUNCTION [LF] E5U011320132N01 • Opens and closes the variable intake air shutter valve. End Of Sie VARIABLE INTAKE AIR SHUTTER VALVE ACTUATOR CONSTRUCTION/OPERATION [LF] E5U011320132N02 Construction • Mainly consists of the body, rod, diaphragm chamber and spring. Operation •...
Page 85: Specification
FUEL SYSTEM 01–14 FUEL SYSTEM FUEL SYSTEM OUTLINE [LF] ..01–14–1 FUEL PUMP UNIT FUNCTION [LF]..01–14–5 Features ......01–14–1 FUEL PUMP UNIT Specification.
Page 86: Fuel System Structural View
FUEL SYSTEM FUEL SYSTEM STRUCTURAL VIEW [LF] E5U011400000N02 Engine Compartment Side FUEL INJECTOR MAIN FUSE BLOCK (UPPER BLOCK) QUICK RELEASE CONNECTOR (TYPE A) FUEL PUMP RELAY CHECK CONNECTOR E5U114ZS5020 01–14–2...
Page 87 FUEL SYSTEM Fuel Tank Side NONRETURN VALVE 01–14 QUICK RELEASE CONNECTOR (TYPE B) FUEL PUMP UNIT FUEL TANK E5U114ZS5030 End Of Sie FUEL SYSTEM FLOW DIAGRAM [LF] E5U011400000N03 Fuel Flow FUEL FILTER (HIGH-PRESSURE) PRESSURE REGULATOR FUEL INJECTOR FUEL TANK FUEL FILTER FUEL PUMP UNIT (LOW-PRESSURE) FUEL PUMP...
Page 88: Fuel Tank Side
FUEL SYSTEM RETURNEES FUEL SYSTEM OUTLINE [LF] E5U011400000N04 • The returnees fuel system reduces fuel evaporation in the fuel tank. • The pressure regulator located in the fuel tank prevents fuel return from the engine compartment side, thereby maintaining a low fuel temperature in the fuel tank. Due to this, formation of evaporative gas produced by a rise in fuel temperature is suppressed.
Page 89: Fuel Pump Unit Function [Lf]
FUEL SYSTEM FUEL PUMP UNIT FUNCTION [LF] E5U011413350N01 • The fuel pump siphons fuel from the fuel tank and pumps it to the fuel injectors. End Of Sie FUEL PUMP UNIT CONSTRUCTION/OPERATION [LF] E5U011413350N02 Fuel Pump Unit FUEL PUMP UNIT •...
Page 90: Quick Release Connector (Fuel System) Function [Lf]
FUEL SYSTEM QUICK RELEASE CONNECTOR (FUEL SYSTEM) FUNCTION [LF] E5U011442692N01 • Quick release connectors that can be easily connected/disconnected have been adopted to improve serviceability. End Of Sie QUICK RELEASE CONNECTOR (FUEL SYSTEM) CONSTRUCTION/OPERATION [LF] E5U011442692N02 • There are two types of quick release connectors. Quick release connector locations ENGINE COMPARTMENT SIDE TYPE B...
Page 91: Type B
FUEL SYSTEM Type B • The connector can be disconnected by pinching the retainer tab with the SST and pulling the connector. • To connect the quick release connector properly, push it into the fuel pipe until a locking click sound is heard.
Page 92: Fuel Injector Function [Lf]
FUEL SYSTEM FUEL INJECTOR FUNCTION [LF] E5U011413250N01 • Injects fuel according to fuel injector control signals from the PCM. End Of Sie FUEL INJECTOR CONSTRUCTION/OPERATION [LF] E5U011413250N02 • Installed on the cylinder head. • Mainly consists of a coil, spring, needle valve and ball. •...
Page 93 EXHAUST SYSTEM 01–15 EXHAUST SYSTEM EXHAUST SYSTEM OUTLINE [LF] ..01–15–1 EXHAUST SYSTEM Features ......01–15–1 STRUCTURAL VIEW [LF] .
Page 95 EMISSION SYSTEM 01–16 EMISSION SYSTEM EMISSION SYSTEM OUTLINE [LF] ..01–16–2 QUICK RELEASE CONNECTOR Feature......01–16–2 (EMISSION SYSTEM) Specification.
Page 96: Emission System
EMISSION SYSTEM EMISSION SYSTEM OUTLINE [LF] E5U011600000N01 Feature • EGR system adopted Improved exhaust gas purification • Catalytic converter system adopted Specification Item Specification EGR type Stepping motor Catalyst form WU-TWC (monolith), TWC (monolith) Evaporative emission (EVAP) control system Charcoal canister type Positive crankcase ventilation (PCV) system Closed type End Of Sie...
Page 97: Exhaust System
EMISSION SYSTEM Exhaust System 01–16 WU-TWC E5U116ZS5008 Fuel Tank Side FUEL-FILLER CAP EVAP SYSTEM LEAK DETECTION PUMP AIR FILTER QUICK RELEASE CONNECTOR (TYPE C) EVAPORATIVE CHAMBER CHARCOAL CANISTER ROLLOVER VALVE FUEL SHUT-OFF VALVE E5U116ZS5030 End Of Sie EXHAUST PURIFICATION SYSTEM OUTLINE [LF] E5U011600010N01 Feature •...
Page 98: Egr System Outline [Lf]
EMISSION SYSTEM EGR SYSTEM OUTLINE [LF] E5U011600020N01 Features • An EGR valve with a stepping motor has been adopted for optimum control according to engine operation conditions. • For control of EGR system, refer to CONTROL SYSTEM, EGR CONTROL. (See 01–40–30 EGR CONTROL OUTLINE [LF], 01–40–30 EGR CONTROL BLOCK DIAGRAM [LF], 01–40–30 EGR CONTROL OPERATION [LF].) End Of Sie...
Page 99: Catalytic Converter System Outline [Lf]
EMISSION SYSTEM CATALYTIC CONVERTER SYSTEM OUTLINE [LF] E5U011600050N01 Feature • Purifies contaminants in the exhaust gas by utilizing a chemical reaction in a three way catalytic converter. End Of Sie CATALYTIC CONVERTER SYSTEM STRUCTURE [LF] E5U011600050N02 • Consists of a three way catalytic converter and insulator. •...
Page 100: Positive Crankcase Ventilation (Pcv) System Outline [Lf]
EMISSION SYSTEM POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM OUTLINE [LF] E5U011600040N01 Feature • A closed type PCV system has been adopted. End Of Sie POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM STRUCTURE [LF] E5U011600040N02 • Consists of a PCV valve and ventilation hose. •...
Page 101: Evaporative Emission (Evap) Control System Outline [Lf]
EMISSION SYSTEM EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM OUTLINE [LF] E5U011600030N01 Features • With the adoption of the charcoal canister, release of evaporative gas into the atmosphere has been prevented. • A duty solenoid valve (purge control valve) has been adopted for optimum control according to engine operation conditions.
Page 102: Quick Release Connector
EMISSION SYSTEM QUICK RELEASE CONNECTOR (EMISSION SYSTEM) FUNCTION [LF] E5U011642692N01 • Quick release connectors that can be easily connected/disconnected have been adopted to improve serviceability. End Of Sie QUICK RELEASE CONNECTOR (EMISSION SYSTEM) CONSTRUCTION/OPERATION [LF] E5U011642692N02 • There are four types of quick release connectors. Quick release connector locations TYPE A EVAP SYSTEM LEAK...
Page 103: Type B
EMISSION SYSTEM • New quick release connectors are fitted with a checker tab that prevents improper fit. This CHECKER TAB checker tab cannot normally be removed. When the quick release connector is properly connected to the joint port, the lock is released and the checker tab comes off.
Page 104: Type C
EMISSION SYSTEM Type C • The connector can be disconnected by pinching the retainer tab with the SST and pulling the connector. • To connect the quick release connector properly, push it into the joint port until a locking click sound is heard.
Page 105: Purge Solenoid Valve Function
EMISSION SYSTEM • New quick release connectors are fitted with a checker tab that prevents improper fit. This checker tab cannot normally be removed. When the quick release connector is properly connected CONNECTION POINT to the connection point, the lock is released and the checker tab comes off.
Page 106: Fuel-Filler Cap Function [Lf]
EMISSION SYSTEM FUEL-FILLER CAP FUNCTION [LF] E5U011642250N01 • If the evaporative gas passage is closed for some reason, the fuel filler cap prevents the generation of positive or negative pressure in the fuel tank, protecting it from deformation. End Of Sie FUEL-FILLER CAP CONSTRUCTION/OPERATION [LF] E5U011642250N02 •...
Page 107: Fuel Shut-Off Valve Function
EMISSION SYSTEM FUEL SHUT-OFF VALVE FUNCTION [LF] E5U011642990N01 • The fuel shut-off valve prevents fuel from flowing to the charcoal canister during tight turns or vehicle rollover. • The fuel shut-off valve releases evaporative gas to the charcoal canister. • During refueling, the fuel shut-off valve closes to prevent a fuel overflow. End Of Sie FUEL SHUT-OFF VALVE CONSTRUCTION/OPERATION [LF] E5U011642990N02...
Page 108: Evaporative Emission (Evap) System Leak Detection Pump Function [Lf]
EMISSION SYSTEM EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP FUNCTION [LF] E5U011618581N01 • The internal pump pressurizes the emission system by pumping air to check clogging and leakage in the emission system. End Of Sie EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK DETECTION PUMP CONSTRUCTION/OPERATION [LF] E5U011618581N02 Structure •...
Page 109: Air Filter Function [Lf]
EMISSION SYSTEM Evaporative system monitor is operated When obtaining the reference current value • Air is sent from the pump to the orifice. SOLENOID IS OFF AND PUMP IS OPERATED CHANGE OVER VALVE (CLOSED) ORIFICE 01–16 EVAP SYSTEM LEAK DETECTION PUMP : AIR FLOW B6U0116S018 Small leak and very small leak determination...
Page 110: Evaporative Chamber Function
EMISSION SYSTEM EVAPORATIVE CHAMBER FUNCTION [LF] E5U011642590N01 • The evaporative chamber prevents penetration of water and dust in the charcoal canister. End Of Sie EVAPORATIVE CHAMBER CONSTRUCTION/OPERATION [LF] E5U011642590N02 • A small section with partitions is located in the evaporative chamber. These partitions protect the TO CHARCOAL CANISTER charcoal canister by preventing flooding as atmospheric air enters from the airflow holes.
Page 111 CHARGING SYSTEM 01–17 CHARGING SYSTEM CHARGING SYSTEM OUTLINE [LF] . . . 01–17–1 BATTERY CONSTRUCTION [LF] ..01–17–2 Features ......01–17–1 GENERATOR CONSTRUCTION CHARGING SYSTEM [LF] .
Page 112 CHARGING SYSTEM BATTERY CONSTRUCTION [LF] E5U011718520N01 • Air that passes through the battery duct when the vehicle is moving is used to cool the battery, BATTERY preventing battery degradation from the heat COVER created through chemical reaction, improving reliability. End Of Sie BATTERY BATTERY TRAY BATTERY DUCT...
Page 113 CHARGING SYSTEM STATOR COIL 01–17 BATTERY DUMMY POWER TRANSISTOR INSTRUMENT CLUSTER (WARNING LIGHT) E6U117ZNB003 • The phase difference in the circuit of the two stator coils causes the electromagnetic pull between the rotor and the stator to be eliminated logically. Due to this, electromagnetic vibration and generator operation noise (electromagnetic noise) have been reduced.
Page 115 IGNITION SYSTEM 01–18 IGNITION SYSTEM IGNITION SYSTEM OUTLINE [LF]..01–18–1 Construction ..... 01–18–2 Features ......01–18–1 Operation .
Page 116 IGNITION SYSTEM IGNITION COIL CONSTRUCTION/OPERATION [LF] E5U011818100N01 Construction • Direct ignition coils installed directly to each spark plug have been adopted. By adopting direct ignition coils, high-tension leads have been eliminated in order to simplify the parts of the ignition system, preventing voltage reduction, and improving the firing efficiency.
Page 117 IGNITION SYSTEM SPARK PLUG CONSTRUCTION [LF] E5U011818110N01 • An iridium spark plug with excellent durability and firing performance has been adopted. • The extremely thin, center electrode has a diameter of 0.6 mm {0.024 in} and is made of iridium alloy. •...
Page 119 STARTING SYSTEM 01–19 STARTING SYSTEM STARTING SYSTEM OUTLINE [LF]..01–19–1 STARTER INTERLOCK SWITCH Features ......01–19–1 CONSTRUCTION/OPERATION STARTING SYSTEM [MT].
Page 120 STARTING SYSTEM STARTER INTERLOCK SWITCH CONSTRUCTION/OPERATION [MT] E5U011943440N01 Construction • The starter interlock switch mechanism prevents vehicle surge when the engine is started, enhancing the safety. The engine cannot be started unless the clutch is depressed. • The mechanism is provided with a starter interlock switch on the circuit between the ignition switch and the starter.
Page 121: Cruise Control System
CRUISE CONTROL SYSTEM 01–20 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM OUTLINE CRUISE CONTROL SYSTEM [LF] ......01–20–1 STRUCTURAL VIEW [LF] .
Page 122 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM STRUCTURAL VIEW [LF] E5U012000000N02 BRAKE CRUISE CONTROL SWITCH BRAKE SWITCH CRUISE SET INDICATOR LIGHT/ CPP SWITCH (MT) CRUISE MAIN INDICATOR LIGHT APP SENSOR NEUTRAL THROTTLE BODY SWITCH (THROTTLE VALVE ACTUATOR) E5U120ZN5001 End Of Sie 01–20–2...
Page 123 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM BLOCK DIAGRAM [LF] E5U012000000N03 CRUISE CONTROL SWITCH THROTTLE VALVE ACTUATOR BRAKE SWITCH 01–20 VEHICLE SPEED SIGNAL CRUISE SET INDICATOR LIGHT CPP SWITCH (MT) CRUISE MAIN INDICATOR LIGHT NEUTRAL SWITCH (MT) E5U120ZN5002 End Of Sie 01–20–3...
Page 125 CONTROL SYSTEM 01–40 CONTROL SYSTEM ENGINE CONTROL SYSTEM OUTLINE Fuel Cut......01–40–23 [LF] ......01–40–3 FUEL PUMP CONTROL OUTLINE Features .
Page 126 CONTROL SYSTEM STARTER CUT-OFF CONTROL CAMSHAFT POSITION (CMP) SENSOR OPERATION [LF] ....01–40–36 FUNCTION [LF] ....01–40–44 GENERATOR CONTROL OUTLINE CAMSHAFT POSITION (CMP) SENSOR [LF] .
Page 127: Control System
CONTROL SYSTEM ENGINE CONTROL SYSTEM OUTLINE [LF] E5U014000000N01 Features • Drive-by-wire control adopted • Variable intake air control adopted Improved driveability • Variable valve timing control adopted • Wide-range air/fuel ratio sensor has been adopted for the front HO2S Improved exhaust emission •...
Page 128: Engine Control System Structural View [Lf]
CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURAL VIEW [LF] E5U014000000N02 BRAKE SWITCH ECT SENSOR CPP SWITCH (MT) FRONT HO2S REAR HO2S EGR VALVE APP SENSOR IGNITION COIL CMP SENSOR GENERATOR BATTERY FUEL INJECTOR VARIABLE INTAKE AIR SOLENOID VALVE MAP SENSOR PSP SWITCH PURGE SOLENOID VALVE CKP SENSOR...
Page 129 CONTROL SYSTEM ENGINE CONTROL SYSTEM DIAGRAM [LF] E5U014000000N03 PURGE SOLENOID VALVE APP SENSOR 01–40 EVAP SYSTEM LEAK DETECTION PUMP (BARO SENSOR) THROTTLE SENSOR VALVE SENSOR FUEL ACTUATOR INJECTOR VALVE MAF/IAT SENSOR SENSOR FUEL PUMP UNIT SENSOR FRONT HO2S SENSOR REAR HO2S VARIABLE INTAKE AIR SOLENOID : TO PCM...
Page 130: Engine Control System Wiring Diagram [Lf]
CONTROL SYSTEM ENGINE CONTROL SYSTEM WIRING DIAGRAM [LF] E5U014000000N04 COOLING FAN RELAY NO.1 (BUILT INTO BARO COOLING FAN RELAY NO.2 SENSOR) COOLING FAN RELAY NO.3 REAR HO2S HEATER FRONT HO2S HEATER REAR HO2S A/C RELAY FRONT HO2S FUEL INJECTOR NO.1 FUEL INJECTOR NO.2 FUEL INJECTOR NO.3 MAP SENSOR...
Page 131 CONTROL SYSTEM IAT SENSOR (BUILT INTO BARO SENSOR) GENERATOR TERMINAL D 01–40 MAF SENSOR PURGE SOLENOID VALVE EGR VALVE TP SENSOR VARIABLE INTAKE AIR SOLENOID VALVE EVAP SYSTEM LEAK DETECTION PUMP RELATED MODULE GENERATOR TERMINAL P CRUISE CONTROL SWITCH TO TR SWITCH THROTTLE VALVE ACTUATOR NEUTRAL SWITCH CPP SWITCH...
Page 132: Engine Control System Block Diagram [Lf]
CONTROL SYSTEM ENGINE CONTROL SYSTEM BLOCK DIAGRAM [LF] E5U014000000N05 MAF SENSOR IAT SENSOR TP SENSOR NO.1, NO.2 THROTTLE VALVE ACTUATOR APP SENSOR NO.1, NO.2 VARIABLE INTAKE AIR SOLENOID VALVE MAP SENSOR CMP SENSOR CKP SENSOR FUEL INJECTOR ECT SENSOR FUEL PUMP RELAY MAIN RELAY CONTROL IGNITION COIL...
Page 133: Engine Control System Relation Chart [Lf]
CONTROL SYSTEM ENGINE CONTROL SYSTEM RELATION CHART [LF] E5U014000000N06 ×: Applicable 01–40 Item Input device × × × × × × Neutral switch (MT) × × × × × CPP switch (MT) × × × × × × × × ×...
Page 134 CONTROL SYSTEM Item Output device × Main relay × Fuel pump relay × A/C relay × Cooling fan relay No.1 × Cooling fan relay No.2 × Cooling fan relay No.3 × Starter relay × Purge solenoid valve × EGR valve ×...
Page 135: Main Relay Control Block Diagram [Lf]
CONTROL SYSTEM MAIN RELAY CONTROL OUTLINE [LF] E5U014000000N56 • When the ignition switch is turned to the ON position, the main relay turns on. • When the ignition switch is turned from on to off, the main relay turns on for a few minutes to activate the fully- closed throttle learning function of the drive-by-wire control, the after-cleaning function of the electrical fan control, and EVAP system leak detection function of the EVAP control system.
Page 136: Drive-By-Wire Control Block Diagram [Lf]
CONTROL SYSTEM DRIVE-BY-WIRE CONTROL BLOCK DIAGRAM [LF] E5U014000000N64 • The PCM calculates the throttle valve opening angle matching the engine operation conditions from the following input signals and sends a duty signal to the throttle valve actuator. MAF SENSOR TROTTLE VALVE ACTUATOR IAT SENSOR TP SENSOR NO.1, NO.2...
Page 137: Drive-By-Wire Control Operation [Lf]
CONTROL SYSTEM DRIVE-BY-WIRE CONTROL OPERATION [LF] E5U014000000N60 Idle Speed Control • Controls the throttle valve opening angle so that it is close to the target idle speed calculated by the PCM. • The PCM calculates the target throttle opening angle by adding each type of correction to the basic duty value which is the basis of the throttle valve opening angle, and then sends a duty signal to the throttle valve actuator.
Page 138: Traction Control
CONTROL SYSTEM Traction Control • The PCM calculates the target throttle valve opening angle by the torque up/down request signal from the DSC HU/CM and TCM and the engine speed. Cruise Control • Calculates the throttle valve opening angle based on the deviation of the actual vehicle speed from the set vehicle speed which was set with the cruise control switch and sends a duty signal to the throttle valve actuator.
Page 139 CONTROL SYSTEM Cruise control function • The cruise control includes accelerating, coasting, resume, tap-down, tap-up and downshift functions (AT). Function List Function Contents • When any of the following conditions are met while driving in cruise control and when the RES/+ Accelerating switch is continuously pressed, the PCM gradually increases the set vehicle speed.
Page 140: Variable Valve Timing Control Block Diagram [Lf]
CONTROL SYSTEM VARIABLE INTAKE AIR CONTROL OPERATION [LF] E5U014000000N18 Operation conditions • If any of the following conditions are met: — Engine speed is approx. 4,750 rpm or more — Engine speed is approx. 3,150 rpm or less and the throttle opening angle is the specified value or more. (heavy load condition) When operation conditions are not met •...
Page 141: Maximum Cam Retard Mode
CONTROL SYSTEM Maximum Cam Retard Mode Mode execution condition • When any of the following conditions are met: — Cranking — Idling after completion of cleaning mode — DTC stored for the following devices: • ECT sensor • CKP sensor 01–40 •...
Page 142: Feedback Mode
CONTROL SYSTEM Feedback Mode Mode execution condition • Except during cleaning, maximum cam retard, or feedback hold modes. Purpose • Feedback mode obtains valve timing suitable for engine operation conditions by performing the feedback operation so that present OCV drive current is set closer to the target current determined by the PCM according to engine operation conditions.
Page 143: Fuel Injection Control Block Diagram [Lf]
CONTROL SYSTEM FUEL INJECTION CONTROL BLOCK DIAGRAM [LF] E5U014000000N26 IAT SENSOR MAF SENSOR 01–40 TP SENSOR NO.1, NO.2 APP SENSOR NO.1, NO.2 SYNCHRONIZED FUEL INJECTION MAP SENSOR CMP SENSOR EFFECTIVE CKP SENSOR INJECTION TIME INJECTION ECT SENSOR TIME AT FUEL INJECTOR ENGINE START BASIC FRONT HO2S...
Page 144: Fuel Injection Control Operation [Lf]
CONTROL SYSTEM FUEL INJECTION CONTROL OPERATION [LF] E5U014000000N27 Operation Injection timing • There is synchronized fuel injection, which performs fuel injection by the setting of the crankshaft position, and non-synchronized fuel injection which performs fuel injection when the condition for fuel injection is met regardless of the crankshaft position.
Page 145: Determination Of Effective Injection Time
CONTROL SYSTEM Determination of Effective Injection Time • The PCM divides the engine operation conditions into control zones according to engine speed and engine load and determines the effective injection time at each control zone to perform optimum air/fuel ratio control in all engine driving ranges.
Page 146 CONTROL SYSTEM Deceleration fuel cut zone Purpose • Improved fuel economy • Prevents overheating of the catalytic converter Control conditions • When the engine conditions are as follows (10 s or longer after engine start): — Fully closed throttle valve —...
Page 147 CONTROL SYSTEM Purpose: Improved engine output, decrease of exhaust gas temperature Correction condition • According to engine speed when the throttle valve opening High load volume increase correction angle is the fixed value or more, otherwise, according to engine speed and charging efficiency Correction amount •...
Page 148: Fuel Pump Control Block Diagram [Lf]
CONTROL SYSTEM Fuel cut during immobilizer system activation Purpose • To prevent vehicle theft Execution conditions • When an engine stop request signal is received from the immobilizer system, the PCM force-stops the fuel injectors. Therefore the engine stops. End Of Sie FUEL PUMP CONTROL OUTLINE [LF] E5U014000000N28 •...
Page 149: Electronic Spark Advance (Esa) Control Block Diagram [Lf]
CONTROL SYSTEM ELECTRONIC SPARK ADVANCE (ESA) CONTROL BLOCK DIAGRAM [LF] E5U014000000N32 IAT SENSOR IGNITION COIL IGNITER OPERATION TIME MAF SENSOR 01–40 TP SENSOR NO.1, NO.2 APP SENSOR NO.1, NO.2 IGNITION TIMING CMP SENSOR CKP SENSOR ECT SENSOR CYCLE ESTIMATED IGNITION IDLE SPARK NEUTRAL SWITCH (MT) FIXED...
Page 150: Electronic Spark Advance (Esa) Control Operation [Lf]
CONTROL SYSTEM ELECTRONIC SPARK ADVANCE (ESA) CONTROL OPERATION [LF] E5U014000000N33 Ignition Method • The PCM excites the ignition coils employing either fixed ignition or cycle estimated ignition according to engine operation conditions. Ignition Ignition timing Ignition coil energization period method Fixed at BTDC 8 °...
Page 151: Determination Of Ignition Timing
CONTROL SYSTEM Determination of Ignition Timing Division of control zones • The PCM divides the engine control operations OPEN into each control zone according to the engine speed and throttle valve opening angle to determine the ignition timing by each of the control zones to perform optimum ignition control START under all engine operation conditions.
Page 152: Ignition Inhibition Condition
CONTROL SYSTEM Engine coolant Purpose: Ensures combustion stability when engine coolant temperature is temperature advance Except during idling correction • High charging efficiency , low engine coolant temperature→large correction Warm-up Purpose: Activates the catalytic converter earlier promotion spark Approx. 50 s after engine start •...
Page 153 CONTROL SYSTEM EVAPORATIVE PURGE CONTROL BLOCK DIAGRAM [LF] E5U014000000N38 MAF SENSOR PURGE SOLENOID VALVE PURGE SOLENOID ENERGIZATION TIME VALVE IAT SENSOR 01–40 TP SENSOR NO.1, NO.2 ECT SENSOR PURGE FLOW AMOUNT MAP SENSOR CKP SENSOR BARO SENSOR BASIC PURGE FLOW AMOUNT FRONT HO2S CORRECTIONS...
Page 154: Egr Control Operation [Lf]
CONTROL SYSTEM EGR CONTROL OUTLINE [LF] E5U014000000N34 • Adjusts the EGR valve to the optimum opening angle according to engine operation conditions. • The valve in the EGR valve allows for more precise control by being driven by the stepping motor. End Of Sie EGR CONTROL BLOCK DIAGRAM [LF] E5U014000000N35...
Page 155 CONTROL SYSTEM Control Outline • The PCM constantly calculates the optimum target EGR valve position according to the engine operation conditions and controls the EGR stepping motor step number so that the current EGR valve position is close to the target. •...
Page 156: Heated Oxygen Sensor (Ho2S) Heater Control Outline [Lf]
CONTROL SYSTEM HEATED OXYGEN SENSOR (HO2S) HEATER CONTROL OUTLINE [LF] E5U014000000N40 • Stabilized oxygen concentrations, even when the exhaust gas temperature is low, are detected by controlling of the HO2S, enabling feedback control of the fuel injection control even during cold-engine starting, improving emission performance when cold.
Page 157: A/C Cut-Off Control Block Diagram [Lf]
CONTROL SYSTEM A/C CUT-OFF CONTROL OUTLINE [LF] E5U014000000N43 • Through energization and non-energization to the A/C relay (magnetic clutch) according to engine operation conditions, acceleration performance and engine reliability have been improved. End Of Sie A/C CUT-OFF CONTROL BLOCK DIAGRAM [LF] E5U014000000N44 01–40 TP SENSOR NO.1, NO.2...
Page 158: Electrical Fan Control Block Diagram [Lf]
CONTROL SYSTEM ELECTRICAL FAN CONTROL OUTLINE [LF] E5U014000000N46 • Through cooling of the radiator and condenser by operation of the cooling fan according to vehicle conditions, engine reliability and cooling performance have been improved. • The electrical fan control includes the regular-driving cooling function and the after-cooling function. •...
Page 159 CONTROL SYSTEM Operation Conditions Operation condition Cooling fan relay Cooling fan Refrigerant Function motor rotation pressure amplifier Vehicle speed No.1 No.2 No.3 speed switch (A/C switch) (high, low) — Stop 01–40 More than 70 km/h {44 mph} Less than 100 °C 45 —70 km/h {212 °F} {28—43 mph}...
Page 160: Starter Cut-Off Control Outline [Lf]
CONTROL SYSTEM STARTER CUT-OFF CONTROL OUTLINE [LF] E5U014000000N49 • Theft deterrence has been improved by controlling energization to the starter relay according to an engine stop request signal from the immobilizer system. End Of Sie STARTER CUT-OFF CONTROL BLOCK DIAGRAM [LF] E5U014000000N50 INSTRUMENT CLUSTER (IMMOBILIZER RELATED...
Page 161: Generator Control Outline [Lf]
CONTROL SYSTEM GENERATOR CONTROL OUTLINE [LF] E5U014000000N52 • Idling stability and the corresponding load performance have been improved by optimum control of generator voltage according to engine operation and electrical load conditions. • The PCM determines the engine operation and electrical load conditions based on the input signals from input devices shown in the figure below and controls the excitation time of the generator field coils.
Page 162: Controller Area Network (Can) Outline [Lf]
CONTROL SYSTEM CONTROLLER AREA NETWORK (CAN) OUTLINE [LF] E5U014000000N55 • The PCM sends and receives data to and from other modules via the CAN system. Refer to Section 09 for a detailed explanation of the CAN. (See 09–40–2 CAN SYSTEM DESCRIPTION.) OUT: Output (sends signal) IN: Input (receives signal) Multiplex module...
Page 163: Pcm Function [Lf]
CONTROL SYSTEM PCM FUNCTION [LF] E5U014018880N01 Function List • The control descriptions are as shown below. Function Description Main relay control When the ignition switch is turned to the ON position, the main relay turns on. Drive-by-wire control The drive-by-wire control calculates the optimum target throttle valve opening angle at all ranges of engine speeds and controls the throttle valve actuator.
Page 164: Neutral Switch Function [Lf]
CONTROL SYSTEM NEUTRAL SWITCH FUNCTION [LF] E5U014017640N01 • The neutral switch detects the neutral position of the gearshift lever. End Of Sie NEUTRAL SWITCH CONSTRUCTION/OPERATION [LF] E5U014017640N02 • When the shift lever is in the neutral position, the contact closes (ON) and the PCM detects a voltage of 0 V. When the shift lever is not in the neutral position, the contact opens (OFF) and the PCM detects a voltage of 12 V.
Page 165: Engine Coolant Temperature (Ect) Sensor Function [Lf]
CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR FUNCTION [LF] E5U014018841N01 • Detects the engine coolant temperature. End Of Sie ENGINE COOLANT TEMPERATURE (ECT) SENSOR CONSTRUCTION/OPERATION [LF] E5U014018841N02 01–40 ECT SENSOR E5U140ZN5201 • Installed on the water outlet. • The ECT is a thermistor type, the resistance changes according to the engine coolant temperature.
Page 166: Intake Air Temperature (Iat) Sensor Function [Lf]
CONTROL SYSTEM INTAKE AIR TEMPERATURE (IAT) SENSOR FUNCTION [LF] E5U014018842N01 • Detects air temperature inducted in the engine. End Of Sie INTAKE AIR TEMPERATURE (IAT) SENSOR CONSTRUCTION/OPERATION [LF] E5U014018842N02 • Built into the MAF sensor. MAF SENSOR IAT SENSOR C3U0140S034 •...
Page 167: Crankshaft Position (Ckp) Sensor Function [Lf]
CONTROL SYSTEM CRANKSHAFT POSITION (CKP) SENSOR FUNCTION [LF] E5U014018220N01 • Detects the pulse wheel rotation pulse as the engine crank angle signal. End Of Sie CRANKSHAFT POSITION (CKP) SENSOR CONSTRUCTION/OPERATION [LF] E5U014018220N02 • The CKP sensor is installed on the engine front cover. •...
Page 168: Camshaft Position (Cmp) Sensor Function [Lf]
CONTROL SYSTEM CAMSHAFT POSITION (CMP) SENSOR FUNCTION [LF] E5U014018230N01 • Detects the rotation angle of the intake-side camshaft. End Of Sie CAMSHAFT POSITION (CMP) SENSOR CONSTRUCTION/OPERATION [LF] E5U014018230N02 • Installed on the engine head cover. • Six pulses per one camshaft rotation are detected by a wide projection and a narrow projection installed on the intake air side camshaft.
Page 169: Throttle Position (Tp) Sensor Function [Lf]
CONTROL SYSTEM THROTTLE POSITION (TP) SENSOR FUNCTION [LF] E5U014018910N01 • Detects the throttle valve opening angle. End Of Sie THROTTLE POSITION (TP) SENSOR CONSTRUCTION/OPERATION [LF] E5U014018910N02 • The sensor is built into the throttle body and detects the throttle valve opening angle. •...
Page 170: Accelerator Pedal Position (App) Sensor Function [Lf]
CONTROL SYSTEM ACCELERATOR PEDAL POSITION (APP) SENSOR FUNCTION [LF] E5U014041609N01 • Detects how much the accelerator pedal is depressed. End Of Sie ACCELERATOR PEDAL POSITION (APP) SENSOR CONSTRUCTION/OPERATION [LF] E5U014041609N02 • The sensor is installed on the accelerator pedal and detects how much the accelerator pedal is depressed. •...
Page 171: Mass Air Flow (Maf) Sensor Function [Lf]
CONTROL SYSTEM MASS AIR FLOW (MAF) SENSOR FUNCTION [LF] E5U014013215N01 • Detects the air amount (mass airflow amount) inducted into the engine. End Of Sie MASS AIR FLOW (MAF) SENSOR CONSTRUCTION/OPERATION [LF] E5U014013215N02 • Built into the intake air temperature sensor. •...
Page 172: Heated Oxygen Sensor (Ho2S) Construction/Operation [Lf]
CONTROL SYSTEM HEATED OXYGEN SENSOR (HO2S) CONSTRUCTION/OPERATION [LF] E5U014018860N02 • Installed on the front of the WU-TWC, and back of the TWC. FTONT HO2S REAR HO2S E5U140ZW5307 Front HO2S • The wide-range air/fuel ratio sensor is a limited current type sensor, and can detect the oxygen concentration (air/fuel ratio of the air-fuel mixture) in the exhaust gas in all ranges, from lean to rich.
Page 173: Manifold Absolute Pressure (Map) Sensor Function [Lf]
CONTROL SYSTEM MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR FUNCTION [LF] E5U014018210N01 • Detects intake air pressure in the intake manifold. End Of Sie MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CONSTRUCTION/OPERATION [LF] E5U014018210N02 • When pressure is applied to the piezoelectric element in the sensor, an electric potential difference occurs.
Page 174: Knock Sensor (Ks) Function [Lf]
CONTROL SYSTEM KNOCK SENSOR (KS) FUNCTION [LF] E5U014018920N01 • Detects abnormal combustion in the engine. End Of Sie KNOCK SENSOR (KS) CONSTRUCTION/OPERATION [LF] E5U014018920N02 • Installed on the cylinder block (intake manifold KNOCK SENSOR side). • Converts vibration from abnormal combustion in the engine to voltage using the piezoelectric effect in the semi-conductor and outputs it to the PCM.
Page 175 SUSPENSION SECTION Toc of SCT OUTLINE ....02-00 FRONT SUSPENSION ..02-13 02–00 ON-BOARD DIAGNOSTIC ..02-02 REAR SUSPENSION .
Page 176 OUTLINE SUSPENSION SPECIFICATIONS E5U020000000N03 Suspension Specification Item Vehicle equipped with 16- Vehicle equipped with 17- inch wheel and tire inch wheel and tire Type Double-wishbone Spring type Coil spring Monotube type: High-pressure gas charged, cylindrical, double- Shock absorber type acting Type Torsion bar Stabilizer...
Page 177 ON-BOARD DIAGNOSTIC 02–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM OUTLINE (TIRE PRESSURE ACTIVE COMMAND MODES MONITORING SYSTEM) ... . 02–02–2 FUNCTION (TIRE PRESSURE Block Diagram ....02–02–2 MONITORING SYSTEM) .
Page 178: On-Board Diagnostic
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM OUTLINE (TIRE PRESSURE MONITORING SYSTEM) E5U020237020N01 • The on-board diagnostic system consists of a malfunction detection system that detects abnormalities in input/ output signals when the ignition switch is at the ON position, a data monitor function that reads out specified input/output signals, and an active command modes function that execuse the wheel unit ID registration.
Page 179: On-Board Diagnostic System Function (Tire Pressure Monitoring System)
ON-BOARD DIAGNOSTIC Without advanced keyless system and keyless entry system DLC-2 INSTRUMENT CLUSTER WHEEL UNITS ON-BOARD DIAGNOSIS FUNCTION MALFUNCTION DETECTION FUNCTION MEMORY FUNCTION 02–02 DRIVER MALFUNCTION KEYLESS MALFUNCTION INFORMATION RECEIVER DETERMINATION MALFUNCTION RF SIGNAL INDICATION TPMS FUNCTION WARNING LIGHT TPMS EXTERNAL WARNING PID/DATA...
Page 180: Dtc Table
ON-BOARD DIAGNOSTIC DTC Table TPMS warning light TPMS warning light Malfunction location (WDS or equivalent) illumination condition illumination pattern 0.2 s Instrument cluster B1342 Illuminated 0.5 s System configuration malfunction B2477 Illuminated 0.5 s Wheel unit 1 internal fault B2868 Illuminated Wheel unit 2 internal fault B2869...
Page 181: On-Board Diagnostic System Pid/Data Monitor Function (Tire Pressure Monitoring System)
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION (TIRE PRESSURE MONITORING SYSTEM) E5U020237020N03 • This function allows access to certain data values, input signal, calculated values, and system status information. PID/DATA monitor table Operation/unit PID name Description (Input/output part) (WDS or equivalent) AI_WU1_ID Candidate wheel unit during registering wheel unit ID –...
Page 182: On-Board Diagnostic System Active Command Modes Function (Tire Pressure Monitoring System)
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM ACTIVE COMMAND MODES FUNCTION (TIRE PRESSURE MONITORING SYSTEM) E5U020237020N06 • The active command modes function is used for executing the wheel unit ID registration Operation Command name Description Operation condition Ignition switch at IDR_MODE Wheel unit ID registration Off/On End Of Sie ON-BOARD DIAGNOSTIC SYSTEM FREEZE FRAME DATA MONITOR FUNCTION (TIRE PRESSURE...
Page 183: Serial Communication
ON-BOARD DIAGNOSTIC Serial Communication • Serial communication (synchronous communication) is a method of communication in which many pieces of information are sent and received instantaneously through a single wire. • By connecting the WDS or equivalent to DLC-2, diagnostic information can be sent and received between the WDS or equivalent and the instrument cluster via the CAN communication line.
Page 185 WHEEL AND TIRES 02–12 WHEEL AND TIRES WHEELS AND TIRES OUTLINE..02–12–1 Operation......02–12–8 WHEELS AND TIRES Sensing Function.
Page 186: Wheel And Tires
WHEEL AND TIRES WHEELS AND TIRES STRUCTURAL VIEW E5U021200000N02 STYLED SIDE OF WHEEL 17-INCH ALUMINUM ALLOY WHEEL 16-INCH ALUMINUM ALLOY WHEEL CROSS-SECTIONAL VIEW ADHESIVE-TYPE BALANCE WEIGHT KNOCK-TYPE BALANCE WEIGHT OUTER INNER E5U212ZS5001 End Of Sie 02–12–2...
Page 187: Run-Flat Tires Outline
WHEEL AND TIRES RUN-FLAT TIRES OUTLINE E5U021200000N03 • Because the run-flat tire sidewalls have been reinforced, vehicles with run-flat tires can be driven for 80 km {49.6 mile} at 89 km/h {55.2 MPH} even with air leakage caused by tire damage. As a result, safety is ensured even when the vehicles has a flat tire.
Page 188: Tire Pressure Monitoring System (Tpms) Outline
WHEEL AND TIRES TIRE PRESSURE MONITORING SYSTEM (TPMS) OUTLINE E5U021237020N01 • The tire pressure monitoring system (TPMS) has been adopted to assist the driver in understanding the tire status. It alerts the driver with the TPMS warning light and buzzer if there is an excessive drop in air pressure or a flat tire is detected.
Page 189: Tire Pressure Monitoring System (Tpms) Wiring Diagram
WHEEL AND TIRES TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM E5U021237020N03 With advanced keyless system or keyless entry system WHEEL UNIT NO.1 NO.2 NO.3 NO.4 KEYLESS RF SIGNAL RECEIVER 02–12 INSTRUMENT CLUSTER ANTENNA KEYLESS CM CAN_H CAN_L DRIVER DLC-2 E5U202ZW5001 Without advanced keyless system and keyless entry system WHEEL UNIT NO.1...
Page 190: Construction
WHEEL AND TIRES TIRE PRESSURE MONITORING SYSTEM (TPMS) CONSTRUCTION/OPERATION E5U021237020N04 Construction • The TPMS consists of wheel units that detect air pressure, temperature and acceleration of each tire, and a TPMS control module that receives data (RF signals) sent from the wheel units to monitor the air pressure of each tire.
Page 191: Operation
WHEEL AND TIRES Operation • The wheel unit installed to each wheel sends data on air pressure, temperature and acceleration of each tire by means of RF signals. The keyless receiver receives these signals with a built-in antenna. • For vehicles with the advanced keyless system or keyless entry system, signals received by the keyless receiver are transmitted tot he instrument cluster via the keyless CM.
Page 192: Wheel Unit
WHEEL AND TIRES WHEEL UNIT CONSTRUCTION/OPERATION E5U021237140N01 Construction • The wheel unit is installed to the rim of each wheel with a nut. It monitors air pressure, temperature and acceleration of the tire, and sends the data as RF signals. •...
Page 193: Identification Code Recognition Function
WHEEL AND TIRES Identification Code Recognition Function • Since the identification codes of wheel units mounted on the vehicle have been configured in the instrument cluster, the instrument cluster can verify the identification codes sent from the wheel units against the configured identification codes.
Page 194 WHEEL AND TIRES Flat tire determination • The instrument cluster determines that there is a flat tire when it receives a signal that the air pressure is lower than the specified low-pressure value, and then it illuminates the flat tire warning light and sounds the flat tire warning buzzer.
Page 195: Flat Tire Warning Light, Flat Tire Warning Buzzer Construction
WHEEL AND TIRES FLAT TIRE WARNING LIGHT, FLAT TIRE WARNING BUZZER CONSTRUCTION E5U021267502N04 • The flat tire warning light and the flat tire warning buzzer are built into the instrument cluster. • If the tire pressure decreases to the level that a FLAT TIRE WARNING LIGHT flat tire is detected, the flat tire warning light illuminates and the flat tire warning buzzer...
Page 197 FRONT SUSPENSION 02–13 FRONT SUSPENSION FRONT SUSPENSION OUTLINE ..02–13–1 FRONT UPPER ARM FRONT SUSPENSION CONSTRUCTION ....02–13–3 STRUCTURAL VIEW.
Page 198: Front Suspension
FRONT SUSPENSION DOUBLE WISHBONE FRONT SUSPENSION CONSTRUCTION E5U021300000N03 Improved roadholding • The heightened damper lever ratio has improved the efficiency of shock absorber operation. — Damper lever ratio: shock absorber stroke (B)/wheel vertical stroke (A) — The heightened damper lever ratio has made it possible to provide a damping force even during minute strokes.
Page 199: Front Shock Absorber Construction
FRONT SUSPENSION FRONT SHOCK ABSORBER CONSTRUCTION E5U021334700N01 • The high-pressure gas-filled monotube shock absorber minimizes cavitation and provides stable damping force even during hard driving. — The large-diameter piston ensures superior response during minute strokes, providing consistent damping force and stroke feeling. —...
Page 200: Front Lower Arm Construction
FRONT SUSPENSION FRONT LOWER ARM CONSTRUCTION E5U021334300N01 • The front lower arm is made of aluminum for rigidity and weight reduction. • As with the front upper arm, the zero-stopper-clearance bushings optimize control over changes in vehicle behavior. VEHICLE FRONT FRONT LOWER ARM LOWER ARM BUSHING ZERO-STOPPER-CLEARANCE...
Page 201: Rear Suspension
REAR SUSPENSION 02–14 REAR SUSPENSION REAR SUSPENSION OUTLINE ..02–14–1 Improved Roadholding ... . . 02–14–2 REAR SUSPENSION REAR SHOCK ABSORBER STRUCTURAL VIEW....02–14–1 CONSTRUCTION .
Page 202 REAR SUSPENSION MULTI-LINK REAR SUSPENSION CONSTRUCTION E5U021400000N03 Optimized Link and Shock Absorber Layout Compliance toe control • The suspension system layout is such that the center axis line of the shock absorber intersects TOE-IN MOMENT to the outside and rear of the virtual kingpin axis. CENTER AXIS OF This layout ensures that the toe-in moment is SHOCK ABSORBER...
Page 203 REAR SUSPENSION REAR CROSSMEMBER CONSTRUCTION E5U021428400N01 • Adoption of a six-point mounting system rear crossmember ensures link support stiffness and isolates vibration improving riding comfort and reducing road noise. 02–14 E5U214ZS5002 End Of Sie 02–14–3...
Page 205 2006 Mazda MX-5 Service Highlights (3404–1U–05F) DRIVELINE/AXLE SECTION Toc of SCT OUTLINE ....03-00 DRIVE SHAFT ... . . 03-13 FRONT AXLE .
Page 206 2006 Mazda MX-5 Service Highlights (3404–1U–05F) OUTLINE DRIVELINE/AXLE SPECIFICATIONS E5U030000000N03 Item Specification Transmission type Front axle Bearing type Angular ball bearing Rear axle Bearing type Angular ball bearing Rear drive shaft Wheel side Bell joint Joint type Differential side Tripod joint 26.6 {1.05} (Minimum diameter)
Page 207: Front Axle
FRONT AXLE 03–11 FRONT AXLE FRONT AXLE OUTLINE ... . . 03–11–1 FRONT AXLE CROSS-SECTIONAL VIEW ......03–11–1 End of Toc FRONT AXLE OUTLINE E5U031104000N01...
Page 209: Rear Axle
REAR AXLE 03–12 REAR AXLE REAR AXLE OUTLINE ....03–12–1 REAR AXLE CROSS-SECTIONAL VIEW ......03–12–1 End of Toc REAR AXLE OUTLINE E5U031205000N01...
Page 211: Drive Shaft
DRIVE SHAFT 03–13 DRIVE SHAFT REAR DRIVE SHAFT OUTLINE ..03–13–1 REAR DRIVE SHAFT CROSS-SECTIONAL VIEW ..03–13–1 End of Toc REAR DRIVE SHAFT OUTLINE E5U031325600N01 •...
Page 213 DIFFERENTIAL 03–14 DIFFERENTIAL REAR DIFFERENTIAL OUTLINE ..03–14–1 SUPER-LSD OPERATION ... . 03–14–3 REAR DIFFERENTIAL Straight ahead driving ....03–14–3 CONSTRUCTION .
Page 214: Differential
DIFFERENTIAL SUPER-LSD OUTLINE E5U031427100N03 • The super-LSD is a torque-sensing type that provides improved driving stability due to the following characteristics: — Low torque bias ratio provides improved controllability (torque bias ratio: 2.0) — Creation of initial torque provides improved starting from a standstill and acceleration/deceleration response, and driving straight-ahead (initial torque: 49 N·m {5.0 kgf·m, 36 ft·lbf}) —...
Page 215: Super-Lsd Operation
DIFFERENTIAL SUPER-LSD OPERATION E5U031427100N05 Straight ahead driving • When driving straight, the right and left side gears rotate at the same speed, and the pinion and side gears rotate together with the differential gear case. Input force from the ring gear is transmitted to the pinion gears via the gear case and to the drive shaft via the side gears.
Page 216: Limited-Slip Operation
DIFFERENTIAL Limited-slip operation • If the differential encounters a condition requiring limited-slip control such as wheel spin, thrust force acts on the side gears due to the reaction force from the meshing of the pinion and side gears. This thrust force presses the side gears against the taper ring, generating friction between the side gear cone and the taper ring and reducing the torque of the slipping wheel.
Page 217: Antilock Brake
BRAKES SECTION Toc of SCT OUTLINE ....04-00 ANTILOCK BRAKE ON-BOARD DIAGNOSTIC ..04-02 SYSTEM....04-13 CONVENTIONAL BRAKE DYNAMIC STABILITY SYSTEM .
Page 218 OUTLINE BRAKE FEATURES E5U040000000N02 • Intrusion minimizing brake pedal adopted Improved safety • Electronic brakeforce distribution (EBD) control adopted • Antilock brake system (ABS) adopted • Dynamic stability control (DSC) adopted • Large diameter front disc brakes adopted Improved braking force •...
Page 219 ON-BOARD DIAGNOSTIC 04–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM PID/DATA Monitor Table OUTLINE (ABS, DYNAMIC STABILITY (Vehicles with DSC) ....04–02–7 CONTROL) ..... . 04–02–2 ON-BOARD DIAGNOSTIC SYSTEM Block Diagram .
Page 220: On-Board Diagnostic System Outline (Abs, Dynamic Stability Control)
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM OUTLINE (ABS, DYNAMIC STABILITY CONTROL) E5U040243750N01 • The on-board diagnostic system consists of a malfunction detection system that detects abnormalities in input/ output signals when the ignition switch is at the ON position, a data monitor function that reads out specified input/output signals and a simulation function that allows for override operation of output parts (such as solenoid valves).
Page 221 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM FUNCTION (ABS, DYNAMIC STABILITY CONTROL) E5U040243750N02 Malfunction Detection Function • The malfunction detection function detects malfunctions in the input/output signal system of the ABS HU/CM (vehicles with ABS) or DSC HU/CM (vehicles with DSC) when the ignition switch is at the ON position. •...
Page 222 ON-BOARD DIAGNOSTIC Fail-safe Function Malfunction Contents (Vehicles With ABS) Fail-safe function DTC number Warning light illumination status Control status Malfunction Brake system WDS or location warning light (when equivalent ABS warning light ABS control EBD control parking brake is display released) B1317 Control...
Page 223 ON-BOARD DIAGNOSTIC Fail-safe Function Malfunction Contents (Vehicles With DSC) Fail-safe function number Warning light illumination status Control status Brake system Malfunction WDS or warning location equivale DSC OFF warning light (when indicator light control Control control control light parking light Display brake is released)
Page 224 ON-BOARD DIAGNOSTIC Fail-safe function number Warning light illumination status Control status Brake system Malfunction WDS or warning location equivale DSC OFF warning light (when indicator light control Control control control light parking light Display brake is released) C1194 C1198 C1210 C1214 C1242 C1246...
Page 225 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION (ABS, DYNAMIC STABILITY CONTROL) E5U040243750N03 • The PID/data monitor function is used for optionally selecting input/output signal monitor items preset in the ABS HU/CM or DSC HU/CM and reading them out in real-time. PID/DATA Monitor Table (Vehicles with ABS) Unit/Condition PID/data monitor item...
Page 226: Control)
ON-BOARD DIAGNOSTIC End Of Sie ON-BOARD DIAGNOSTIC SYSTEM ACTIVE COMMAND MODES FUNCTION (ABS, DYNAMIC STABILITY CONTROL) E5U040243750N04 • The active command modes function is used for optionally selecting active command modes items of input/ output parts preset in the ABS HU/CM or DSC HU/CM, and to operate them regardless of CM control. •...
Page 227: Stability Control)
ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL TESTER COMMUNICATION FUNCTION (ABS, DYNAMIC STABILITY CONTROL) E5U040243750N05 • The external tester communication function enables communication of diagnostic data (DTC read-outs, input/ output signal read-outs, and operation of input/output parts) between the ABS HU/CM or the DSC HU/CM and an external tester.
Page 228 ON-BOARD DIAGNOSTIC DLC-2 CONSTRUCTION E5U040243750N06 • A connector (DLC-2) conforming to International Organization for Standardization (ISO) standards has been added. • Shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has been adopted for this connector. The connector has a 16-pin construction that includes the CAN_H (HS), CAN_L (HS), GND1, GND2 and B+ terminals.
Page 229 CONVENTIONAL BRAKE SYSTEM 04–11 CONVENTIONAL BRAKE SYSTEM CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER OUTLINE ......04–11–1 CONSTRUCTION ....04–11–2 CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT STRUCTURAL VIEW .
Page 230 CONVENTIONAL BRAKE SYSTEM INTRUSION-MINIMIZING BRAKE PEDAL FUNCTION E5U041143300N01 • An intrusion-minimizing brake pedal, which minimizes the amount of rearward pedal thrust in a frontal collision, has been adopted. Due to this, impact force to the lower body of the driver is softened. End Of Sie INTRUSION-MINIMIZING BRAKE PEDAL OPERATION E5U041143300N02...
Page 231 CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT CONSTRUCTION E5U041143800N01 • A 9-inch, large diameter, single diaphragm type power brake unit has been adopted for all models, achieving compatibility between high braking performance and excellent brake feeling. End Of Sie E5U411ZS5004 FRONT BRAKE (DISC) CONSTRUCTION E5U041133980N01 04–11 •...
Page 233: Parking Brake System
PARKING BRAKE SYSTEM 04–12 PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM OUTLINE ......04–12–1 STRUCTURAL VIEW ....04–12–1 End of Toc PARKING BRAKE SYSTEM OUTLINE E5U041200000N01...
Page 235: Abs Outline
ANTILOCK BRAKE SYSTEM 04–13 ANTILOCK BRAKE SYSTEM ABS OUTLINE..... 04–13–1 Features ......04–13–8 ABS STRUCTURAL VIEW .
Page 236: Abs System Wiring Diagram
ANTILOCK BRAKE SYSTEM ABS SYSTEM WIRING DIAGRAM E5U041300000N03 ABS 30A ABS 40A ENGINE 15A IG SW BRAKE SWITCH BATTERY BRAKE LIGHT ABS WARNING BRAKE SYSTEM LIGHT WARNING LIGHT ABS HU/CM DRIVER CAN_H INSTRUMENT CLUSTER DRIVER CAN_L DRIVER ABS WHEEL- TCM (ATX) SPEED SENSOR DRIVER DLC-2...
Page 237: Abs Hu/Cm Construction
ANTILOCK BRAKE SYSTEM ABS HU/CM CONSTRUCTION E5U041343750N01 • A high reliability, reduced size and weight ABS HU/CM, integrating both the ABS HU and ABS CM, has been adopted. End Of Sie E5U413ZS5002 ABS HU PART FUNCTION E5U041343750N02 04–13 • The ABS HU adjusts the fluid pressure to the caliper pistons by controlling (on/off) each solenoid valve and pump motor according to signals from the ABS CM.
Page 238 ANTILOCK BRAKE SYSTEM Hydraulic circuit diagram MASTER CYLINDER DAMPER CHAMBER PUMP MOTOR INLET INLET SOLENOID SOLENOID VALVE VALVE RESERVOIR RESERVOIR PUMP OUTLET OUTLET OUTLET OUTLET SOLENOID SOLENOID SOLENOID SOLENOID VALVE VALVE VALVE VALVE E5U413ZS5003 Operating Normal braking or pressure increase mode •...
Page 239 ANTILOCK BRAKE SYSTEM PRESSURE INCREASE MODE MASTER CYLINDER DAMPER CHAMBER PUMP PUMP MOTOR 04–13 RESERVOIR INLET SOLENOID VALVE OUTLET SOLENOID VALVE CALIPER PISTON E5U413ZS5004 Pressure reduction mode • During pressure reduction mode, when the wheels may possibly lock-up due to emergency braking or similar, the inlet solenoid valve closes and the outlet solenoid valve opens.
Page 240 ANTILOCK BRAKE SYSTEM Pressure maintain mode • During pressure maintain mode, both the inlet and outlet solenoid valves are closed. The path for the brake fluid being applied to the caliper piston is blocked and brake fluid pressure is maintained. (Description for single front wheel only) Solenoid valve operation table Inlet solenoid...
Page 241: Abs Control Outline
ANTILOCK BRAKE SYSTEM ABS CONTROL OUTLINE E5U041343750N05 • ABS control occurs when wheel slip is determined by the ABS CM (based on the four ABS wheel-speed sensors). Then, the ABS HU inlet and outlet solenoid valves are operated and brake fluid pressure is controlled accordingly to prevent wheel lock-up.
Page 242: Abs Control Operation
ANTILOCK BRAKE SYSTEM ABS CONTROL OPERATION E5U041343750N06 • When the ABS CM determines wheel slip conditions based on the signals from the ABS wheel-speed sensors during braking, the ABS CM operates the ABS HU inlet and outlet solenoid valves, reducing and maintaining brake fluid pressure in accordance with the wheel slip factors.
Page 243: Block Diagram
ANTILOCK BRAKE SYSTEM Block Diagram ABS HU/CM ABS WHEEL-SPEED CALIPER PISTON (LF) SENSOR (LF) SOLENOID VALVE ABS WHEEL-SPEED CALIPER PISTON (RF) SENSOR (RF) ABS WHEEL-SPEED CALIPER PISTON (LR) PUMP SENSOR (LR) 04–13 MOTOR ABS WHEEL-SPEED CALIPER PISTON (RR) SENSOR (RR) C3U0413S011 End Of Sie EBD CONTROL OPERATION...
Page 244: Operating Condition Transition Diagram
ANTILOCK BRAKE SYSTEM Operating Condition Transition Diagram HIGH VEHICLE SPEED REAR WHEEL SPEED FRONT SPEED EBD INITIAL CONTROL VALUE WHEEL SPEED ABS INITIAL CONTROL VALUE TIME REAR SOLENOID VALVE CONTROL PRESSURE REDUCTION PRESSURE MAINTAINED PRESSURE INCREASE HIGH FRONT BRAKE FLUID PRESSURE BRAKE FLUID PRESSURE REAR BRAKE...
Page 245: Abs Wheel-Speed Sensor And Abs Sensor Rotor Construction/Operation
ANTILOCK BRAKE SYSTEM ABS WHEEL-SPEED SENSOR AND ABS SENSOR ROTOR CONSTRUCTION/OPERATION E5U041343720N02 Construction Front • The front ABS wheel-speed sensor utilizes a semi-conductor element that contains an active FRONT WHEEL HUB COMPONENT drive circuit (MR element*). The front sensor is FRONT ABS WHEEL- installed on the front wheel hub.
Page 246 ANTILOCK BRAKE SYSTEM Operation Front • As the front ABS sensor rotor rotates, the magnetic flux between the front ABS wheel-speed sensor and the front ABS sensor rotor change periodically. This periodic change is in proportion to the rotation speed. •...
Page 247 DYNAMIC STABILITY CONTROL 04–15 DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL (DSC) Oversteer Tendency Suppression ..04–15–15 OUTLINE ......04–15–2 Understeer Tendency Suppression .
Page 248: Dynamic Stability Control
DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL (DSC) OUTLINE E5U041500000N01 • The DSC HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted, resulting in a size and weight reduction. • A combined sensor, integrating both the yaw rate sensor and lateral-G sensor, has been adopted, improving serviceability.
Page 249: Dynamic Stability Control (Dsc) Structural View
DYNAMIC STABILITY CONTROL End Of Sie DYNAMIC STABILITY CONTROL (DSC) STRUCTURAL VIEW E5U041500000N02 DSC INDICATOR LIGHT DSC OFF LIGHT BRAKE REAR ABS WHEEL- SPEED SENSOR ABS WARNING BRAKE SYSTEM LIGHT WARNING LIGHT DSC HU/CM COMBINED (BUILT INTO BRAKE FLUID SENSOR PRESSURE SENSOR) 04–15 TCM (AT)
Page 250: Dynamic Stability Control (Dsc) System Wiring Diagram
DYNAMIC STABILITY CONTROL DYNAMIC STABILITY CONTROL (DSC) SYSTEM WIRING DIAGRAM E5U041500000N04 ROOM 15 A ABS 30A IG 1 ABS 40A COMBINED SENSOR ENGINE 15A STEERING IG SW ANGLE SENSOR BATTERY CAN_L BRAKE SYSTEM ABS WARNING CAN_H WARNING LIGHT LIGHT BRAKE SWITCH BRAKE DSC OFF LIGHT LIGHT...
Page 251: Dsc Hu/Cm Construction
DYNAMIC STABILITY CONTROL DSC HU/CM CONSTRUCTION E5U041543750N01 • A high reliability, reduced size and weight DSC HU/CM, integrating both the DSC HU and the DSC CM, has been adopted. End Of Sie E5U415ZS5003 DSC HU PART FUNCTION E5U041543750N02 04–15 • According to DSC CM signals, the DSC HU controls (on/off) each solenoid valve and the pump motor, adjusts fluid pressure in each caliper piston, and actuates each function (ABS, EBD (Electronic Brakeforce Distribution), TCS and DSC) of the DSC system.
Page 252 DYNAMIC STABILITY CONTROL Hydraulic circuit diagram MASTER CYLINDER BRAKE FLUID PRESSURE SENSOR DAMPER CHAMBER TRACTION CONTROL TRACTION SOLENOID CONTROL VALVE SOLENOID VALVE STABILITY PUMP CONTROL STABILITY MOTOR SOLENOID CONTROL VALVE SOLENOID RESERVOIR RESERVOIR VALVE PUMP INLET INLET INLET SOLENOID SOLENOID SOLENOID VALVE INLET...
Page 253 DYNAMIC STABILITY CONTROL Operation During normal braking • During normal braking, the solenoid valves are not energized and all of them are off. When the brake pedal is depressed, brake fluid pressure is transmitted from the master cylinder, through the traction switch and inlet solenoid valves, and then to the caliper piston.
Page 254 DYNAMIC STABILITY CONTROL During ABS and EBD control • During ABS and EBD control, when wheel lock-up is about to occur, the traction switch and stability control solenoid valves are not energized, and the inlet and outlet solenoid valves are energized and controlled in three pressure modes (increase, reduction or maintain), thereby adjusting brake fluid pressure.
Page 255 DYNAMIC STABILITY CONTROL During DSC control (suppress oversteer tendency) • When a large oversteer tendency is determined, the traction switch and the stability control solenoid valves are energized, switching the hydraulic circuits. At the same time, the pump motor is actuated to operate the pump, supplying brake fluid pressure from the reservoir to the outer front wheel cylinder.
Page 256 DYNAMIC STABILITY CONTROL During DSC control (to suppress understeer tendency) and TCS control • When a large understeer tendency is determined, the traction switch and the stability control solenoid valves are energized, switching the hydraulic circuits. At the same time, the pump motor is actuated to operate the pump, thereby increasing pressure by supplying brake fluid pressure to the caliper piston of the inner rear wheel or the slipping driving wheel.
Page 257 DYNAMIC STABILITY CONTROL DSC CM PART FUNCTION E5U041543750N04 • The DSC CM makes calculations using signals input from each sensor, outputs a brake fluid pressure control signal to the DSC HU to actuate DSC system functions and outputs an engine output control signal to the PCM. •...
Page 258: Ebd Control Function
DYNAMIC STABILITY CONTROL Block Diagram INPUT OUTPUT CM INTERNAL CALCULATION WHEEL-SPEED ABS WHEEL- CALCULATION SPEED SENSOR PUMP ESTIMATED VEHICLE MOTOR SPEED CALCULATION CONTROL AMOUNT FRONT SOLENOID VALVE BRAKE OPERATING BRAKE SWITCH CONDITION DETERMINATION REAR ENGINE SPEED SOLENOID ENGINE SPEED CALCULATION VALVE CONTROL AMOUNT...
Page 259: Tcs Control Outline
DYNAMIC STABILITY CONTROL TCS CONTROL OUTLINE E5U041543750N07 • TCS control actuates torque reduction through throttle, fuel cut and ignition timing control, as well as using brake control to control traction. Note • Brake control: Brake fluid pressure from the hydraulic unit to the slipping driving wheel is increased, operating the brake and preventing drive wheel slip.
Page 260: Dsc Control Outline
DYNAMIC STABILITY CONTROL DSC CONTROL OUTLINE E5U041543750N09 • While a vehicle normally turns safely in response to steering operation, there are instances when the limits of tire lateral grip is surpassed due to road surface conditions or vehicle speed, and the influence of evasive steering to avoid an accident or similar situations.
Page 261: Dsc Control Operation
DYNAMIC STABILITY CONTROL DSC CONTROL OPERATION E5U041543750N10 • When the DSC HU/CM determines that the vehicle has a strong oversteer or understeer tendency, engine output is lowered and, at the same time, it suppresses the yaw moment by affecting the braking of the front or rear wheels to inhibit the oversteer or understeer tendency.
Page 262: Controller Area Network (Can) Outline
DYNAMIC STABILITY CONTROL CONTROLLER AREA NETWORK (CAN) OUTLINE E5U041543750N11 • The DSC HU/CM sends and receives data to and from other modules via the CAN system. Refer to Section 09 for a detailed explanation of the CAN system. Data sent •...
Page 263: Brake Fluid Pressure Sensor Function
DYNAMIC STABILITY CONTROL BRAKE FLUID PRESSURE SENSOR FUNCTION E5U041543774N01 • The brake fluid pressure sensor detects the fluid pressure from the master cylinder and transmits it to the DSC HU/CM. End Of Sie BRAKE FLUID PRESSURE SENSOR CONSTRUCTION E5U041543774N02 • The brake fluid pressure sensor is integrated with the DSC HU/CM. Therefore if there is any malfunction of the brake fluid pressure sensor, replace the DSC HU/CM.
Page 264: Dsc Indicator Light Operation
DYNAMIC STABILITY CONTROL DSC INDICATOR LIGHT OPERATION E5U041555430N02 • When the DSC and CAN lines are normal, the DSC indicator light illuminates for approx. 3 s when the ignition switch is turned to the ON position to check the light function. When the system is malfunctioning, the DSC indicator light remains illuminated.
Page 265: Manual Transmission
TRANSMISSION/TRANSAXLE SECTION Toc of SCT OUTLINE ....05-00 MANUAL TRANSMISSION ON-BOARD DIAGNOSTIC [P66M-D] 6-SPEED MT..05-11B [SJ6A-EL] 6-SPEED AT ..05-02 AUTOMATIC TRANSMISSION CLUTCH .
Page 266: [Sj6A-El] 6-Speed At
OUTLINE TRANSMISSION/TRANSAXLE FEATURES E5U050000000N02 CLUTCH • A hydraulic clutch control mechanism is used. Improved operability 5-SPEED MT [M15M-D] • A triple synchronizer mechanism has been adopted for 1GR and 2GR. • A double synchronizer mechanism has been adopted for 3GR. •...
Page 267: Manual Transmission [P66M-D]
2006 Mazda MX-5 Service Highlights (3404–1U–05F) OUTLINE Manual Transmission [M15M-D] Item Specification Transmission type M15M-D Transmission control Floor-shift Shift assist Synchromesh 3.136 1.888 1.330 Gear ratio 1.000 0.814 Reverse 3.758 Grade API Service GL-4 or GL-5 All season SAE 75W-90 Viscosity Above 10°C {50°F}...
Page 268: Automatic Transmission
2006 Mazda MX-5 Service Highlights (3404–1U–05F) OUTLINE Automatic Transmission Item Specification Transmission type SJ6A-EL 3.538 2.060 1.404 Gear ratio 1.000 0.713 0.582 Reverse 3.168 Type JWS3309 Capacity (Approx. quantity) 7.4 {7.8, 6.5} (L {US qt, lmp qt}) Torque converter stall torque ratio 2.00...
Page 269 ON-BOARD DIAGNOSTIC [SJ6A-EL] ON-BOARD DIAGNOSTIC [SJ6A-EL] 6-SPEED AT 05–02 ON-BOARD DIAGNOSTIC (OBD) MALFUNCTION INDICATION FUNCTION SYSTEM OUTLINE [SJ6A-EL] ..05–02–1 [SJ6A-EL] ......05–02–3 ON-BOARD DIAGNOSTIC (OBD) FAIL-SAFE FUNCTION [SJ6A-EL] .
Page 270 ON-BOARD DIAGNOSTIC [SJ6A-EL] MALFUNCTION DETECTION FUNCTION [SJ6A-EL] E5U050200000N03 Malfunction Detection Function • In the malfunction detection function, the TCM detects malfunctions in the automatic transmission while driving. • When vehicle driving conditions correspond with a preset malfunction detection condition, the TCM determines that the automatic transmission has a malfunction and stores the corresponding DTC.
Page 271: Memory Function [Sj6A-El]
ON-BOARD DIAGNOSTIC [SJ6A-EL] Memory DTC No. Condition warning function light P2719 Shift solenoid G range/performance (stuck) P2720 Shift solenoid G circuit malfunction (short to ground/open circuit) P2721 Shift solenoid G circuit malfunction (short to power) P2757 Torque converter clutch (TCC) stuck on P2758 Torque converter clutch (TCC) stuck off P2762...
Page 272 ON-BOARD DIAGNOSTIC [SJ6A-EL] On-board diagnostic Detection condition Fail-safe function • Fixes ATF temperature value at 80 °C Transmission fluid • TCM detects ATF temperature of less {176 °F} temperature (TFT) sensor than -43 °C {-45.4 °F} when engine is P0713 •...
Page 273 ON-BOARD DIAGNOSTIC [SJ6A-EL] On-board diagnostic Detection condition Fail-safe function • Emergency mode • Feedback current corresponding to Line pressure control • Inhibits self learning control P0961 solenoid range/ solenoid current command value is • Inhibits driver adaptive shift control performance (stuck) irregular when engine is running.
Page 274 ON-BOARD DIAGNOSTIC [SJ6A-EL] On-board diagnostic Detection condition Fail-safe function • Open or short circuit in shift solenoid D • Emergency mode Shift solenoid D circuit signal system (while TCM monitors • Inhibits self learning control P0983 malfunction (short to solenoid output voltage, the voltage •...
Page 275: Emergency Mode
ON-BOARD DIAGNOSTIC [SJ6A-EL] Emergency Mode • Emergency mode shifts as follows when in D range or R position. Selector lever position Condition D range position Normal shifting Reverse When there is any malfunction in shift solenoids A, B, C, D, E, F, G, line Reverse pressure, or TCC control solenoid End Of Sie...
Page 276: Simulation Function [Sj6A-El]
ON-BOARD DIAGNOSTIC [SJ6A-EL] SIMULATION FUNCTION [SJ6A-EL] E5U050200000N08 • By using the WDS or equivalent, simulation items for input/output parts preset in the TCM can be optionally selected and operated regardless of TCM control conditions. Simulation Item Table X: Available Operation Simulation Applicable component Unit/Condition...
Page 277 CLUTCH 05–10 CLUTCH CLUTCH OUTLINE ....05–10–1 CLUTCH RELEASE CYLINDER ..05–10–2 CLUTCH STRUCTURAL VIEW..05–10–1 STRUCTURE .
Page 278 CLUTCH CLUTCH MASTER CYLINDER E5U051000000N03 • The clutch master cylinder consists of a primary cup, piston, and a return spring. PRIMARY CUP RETURN SPRING PISTON E5U510ZS5002 End Of Sie CLUTCH RELEASE CYLINDER E5U051000000N04 STRUCTURE • The clutch release cylinder consists of a return spring, piston, push rod and a bleeder screw for bleeding air. BLEEDER SCREW PUSH ROD PISTON...
Page 279 MANUAL TRANSMISSION [M15M-D] 05–11A MANUAL TRANSMISSION [M15M-D] 5-SPEED MT MANUAL TRANSMISSION OUTLINE DOUBLE SYNCHRONIZER MECHANISM [M15M-D] ......05–11A–1 CONSTRUCTION/OPERATION MANUAL TRANSMISSION [M15M-D] .
Page 280 MANUAL TRANSMISSION [M15M-D] MANUAL TRANSMISSION POWER FLOW [M15M-D] E5U051100000N12 REVERSE E5U511AS5002 End Of Sie SHIFT MECHANISM [M15M-D] E5U051100000N13 Detent Spring • Due to the addition of anti-friction material between the detent springs and balls, hiss and rasping feeling have been greatly reduced, thus improving shift feeling. Shift Return Spring •...
Page 281 MANUAL TRANSMISSION [M15M-D] TRIPLE SYNCHRONIZER MECHANISM STRUCTURE [M15M-D] E5U051100000N14 Features • A triple cone synchronizer mechanism is used for the 1st and 2nd gears. • The triple cone synchronizer mechanism is a compact device capable of heavy duty meshing. • The synchro mechanism reduces meshing time and improves operation. •...
Page 282 MANUAL TRANSMISSION [M15M-D] TRIPLE SYNCHRONIZER MECHANISM OPERATION [M15M-D] E5U051100000N15 1. When the hub sleeve moves to the left (in the CLUTCH HUB SLEEVE direction of the arrow), the synchronizer key SYNCHRONIZER RING presses against the synchronizer ring. SYNCHRONIZER KEY DOUBLE CONE INNER CONE E5U511AS5005 2.
Page 283 MANUAL TRANSMISSION [M15M-D] SHIFT INTERLOCK MECHANISM FUNCTION [M15M-D] E5U051100000N16 • This provides reliable double-engagement prevention. End Of Sie SHIFT INTERLOCK MECHANISM OPERATION [M15M-D] E5U051100000N17 Structure • During shifting, the shift rods, except for the one in operation, are locked in the neutral position by the interlock pins.
Page 284 MANUAL TRANSMISSION [M15M-D] REVERSE LOCKOUT MECHANISM FUNCTION [M15M-D] E5U051117570N03 • The reverse lockout mechanism prevents the driver from accidentally shifting into reverse gear when downshifting from 5th to 4th gear. End Of Sie REVERSE LOCKOUT MECHANISM CONSTRUCTION/OPERATION [M15M-D] E5U051117570N04 • A cam-type reverse lockout mechanism is adopted to ensure reliability. •...
Page 285 MANUAL TRANSMISSION [M15M-D] POWER PLANT FRAME (PPF) FUNCTION [M15M-D] E5U051100000N21 Features • The power plant frame (PPF) maintains rigidity with a bracket installed between the transmission and the differential. Due to this the shift feeling is solid and a feeling of direct drive when starting from a standstill or accelerating is created.
Page 287 MANUAL TRANSMISSION [P66M-D] 05–11B MANUAL TRANSMISSION [P66M-D] 6-SPEED MT MANUAL TRANSMISSION OUTLINE SHIFT INTERLOCK MECHANISM [P66M-D] ......05–11B–1 FUNCTION [P66M-D] .
Page 288 MANUAL TRANSMISSION [P66M-D] MANUAL TRANSMISSION POWER FLOW [P66M-D] E5U051100000N03 REVERSE E5U511BS5008 End Of Sie 05–11B–2...
Page 289 MANUAL TRANSMISSION [P66M-D] SHIFT MECHANISM [P66M-D] E5U051100000N04 Shift rod STRUCTURE • The shift lever stroke has been set shorter to provide optimal shift feel. • To realize assured shift feel, the shift link mechanism has been integrated. • Due to the use of metal bushings for the sliding parts of the shift rod, sliding resistance during shifting is greatly reduced, thus improving shift quality.
Page 290 MANUAL TRANSMISSION [P66M-D] TRIPLE SYNCHRONIZER MECHANISM STRUCTURE [P66M-D] E5U051100000N05 Features • A triple cone synchronizer mechanism is used for the 1st, 2nd, 3rd and 4th gears. • The triple cone synchronizer mechanism is a compact device capable of heavy duty meshing. •...
Page 291 MANUAL TRANSMISSION [P66M-D] TRIPLE SYNCHRONIZER MECHANISM OPERATION [P66M-D] E5U051100000N06 1. When the hub sleeve moves to the left (in the CLUTCH HUB SLEEVE direction of the arrow), the synchronizer key SYNCHRONIZER RING presses against the synchronizer ring. SYNCHRONIZER DOUBLE CONE INNER CONE E5U511BS5010 2.
Page 292 MANUAL TRANSMISSION [P66M-D] SHIFT INTERLOCK MECHANISM FUNCTION [P66M-D] E5U051100000N07 • This provides reliable double-engagement prevention. End Of Sie SHIFT INTERLOCK MECHANISM OPERATION [P66M-D] E5U051100000N08 Structure • During shifting, the shift rods, except for the one in operation, are locked in the neutral position by the interlock pins.
Page 293 MANUAL TRANSMISSION [P66M-D] Reverse shifting • Movement of the reverse shift rod forces interlock REVERSE pin A out of the reverse shift rod groove, and the SHIFT ROD 1/2 shift rod is locked. In addition, interlock pin A forces interlock pins C and E out via interlock pins B and D, and the 3rd/4th shift rod and 5th/6th shift rod are locked.
Page 294 MANUAL TRANSMISSION [P66M-D] REVERSE LOCKOUT MECHANISM FUNCTION [P66M-D] E5U051117570N01 • The reverse lockout mechanism prevents the driver from accidentally shifting into reverse gear when shifting from neutral to 1st gear. End Of Sie REVERSE LOCKOUT MECHANISM CONSTRUCTION/OPERATION [P66M-D] E5U051117570N02 • With the adoption of the reverse lockout mechanism, which utilizes a guide plate, reliability has been assured. •...
Page 295 AUTOMATIC TRANSMISSION [SJ6A-EL] 05–13 AUTOMATIC TRANSMISSION [SJ6A-EL] 6-SPEED AT AUTOMATIC TRANSMISSION OUTLINE LINE PRESSURE CONTROL SOLENOID [SJ6A-EL] ..... . . 05–13–1 OUTLINE [SJ6A-EL] .
Page 296 AUTOMATIC TRANSMISSION [SJ6A-EL] AUTOMATIC TRANSMISSION CROSS-SECTIONAL VIEW [SJ6A-EL] E5U051300000N02 E5U513ZS5001 End Of Sie 05–13–2...
Page 297 AUTOMATIC TRANSMISSION [SJ6A-EL] AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [SJ6A-EL] E5U051300000N03 TFT SENSOR N POSITION POWER SUPPLY P POSITION TR SWITCH R RANGE D RANGE 05–13 SHIFT SOLENOID A M RANGE SWITCH SHIFT SOLENOID B SELECTOR UP SWITCH SHIFT SOLENOID C LEVER COMPONENT DOWN SWITCH...
Page 298 AUTOMATIC TRANSMISSION [SJ6A-EL] End Of Sie EC-AT OPERATION CHART [SJ6A-EL] E5U051300000N04 Shift pattern Transmission Solenoid ON/OFF type Linear type Mode Gear position Neutral less than 11km/n {7mph} Reverse 3.168 more than 11km/n {4mph} Neutral 3.538 2.060 1.404 1.000 POWER/ NORMAL 0.713 TCC ON 0.582...
Page 299 AUTOMATIC TRANSMISSION [SJ6A-EL] POWERFLOW STRUCTURE [SJ6A-EL] E5U051300000N05 Description of Components F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE ONE-WAY CLUTCH 05–13 C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH...
Page 300 AUTOMATIC TRANSMISSION [SJ6A-EL] POWERFLOW OPERATION [SJ6A-EL] E5U051300000N06 List of operating components Clutch / Brake Operation • Engages input shaft and intermediate shaft via F4 one-way clutch. C1 clutch • Engages input shaft and middle planetary carrier. C2 clutch • Engages input shaft and front sun gear. C3 clutch •...
Page 301 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C1 CLUTCH OPERATES. INTERMEDIATE SHAFT ROTATES CLOCKWISE. REAR SUN GEAR ROTATES CLOCKWISE. REAR PLANETARY PINION GEAR ROTATE COUNTERCLOCKWISE. REAR RING GEAR TRIES TO ROTATE COUNTERCLOCKWISE. 05–13 F3 ONE-WAY CLUTCH OPERATES (LOCKS COUNTERCLOCKWISE ROTATION OF REAR PLANETARY CARRIER).
Page 302 AUTOMATIC TRANSMISSION [SJ6A-EL] F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH : OPERATING : OPERATING WHEN ENGINE BRAKING E5U513ZS5007...
Page 303 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C1 CLUTCH OPERATES. INTERMEDIATE SHAFT ROTATES CLOCKWISE. MIDDLE SUN GEAR ROTATES CLOCKWISE. REAR SUN GEAR ROTATES CLOCKWISE. MIDDLE PLANETARY PINION GEAR ROTATE COUNTERCLOCKWISE. 05–13 B3 BRAKE, F2 ONE-WAY CLUTCH, AND F1 ONE-WAY CLUTCH OPERATE (LOCKS COUNTERCLOCKWISE ROTATION OF MIDDLE RING GEAR AND FRONT RING GEAR).
Page 304 AUTOMATIC TRANSMISSION [SJ6A-EL] F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH : OPERATING : OPERATING WHEN ENGINE BRAKING : OPERATING BUT NOT CONTRIBUTING TO TRANSMISSION POWER...
Page 305 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C3 CLUTCH OPERATES. C1 CLUTCH OPERATES. FRONT SUN GEAR ROTATES CLOCKWISE. INTERMEDIATE SHAFT ROTATES CLOCKWISE. FRONT INNER PLANETARY PINION GEAR ROTATE COUNTERCLOCKWISE. FRONT OUTER PLANETARY PINION GEAR ROTATES CLOCKWISE. 05–13 F1 ONE-WAY CLUTCH OPERATES (LOCKS COUNTERCLOCKWISE ROTATION OF FRONT PLANETARY CARRIER).
Page 306 AUTOMATIC TRANSMISSION [SJ6A-EL] F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH : OPERATING : OPERATING WHEN ENGINE BRAKING : OPERATING BUT NOT CONTRIBUTING TO TRANSMISSION POWER...
Page 307 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C2 CLUTCH OPERATES. C1 CLUTCH OPERATES. INTERMEDIATE SHAFT ROTATES CLOCKWISE. MIDDLE SUN GEAR ROTATES CLOCKWISE. BECAUSE THE MIDDLE PLANETARY PINION GEARS CANNOT ROTATE, THE MIDDLE PLANETARY GEAR UNIT ROTATES CLOCKWISE AS A SINGLE UNIT. 05–13 REAR RING GEAR ROTATES CLOCKWISE.
Page 308 AUTOMATIC TRANSMISSION [SJ6A-EL] F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH : OPERATING : OPERATING BUT NOT CONTRIBUTING TO TRANSMISSION POWER E5U513ZS5010...
Page 309 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C3 CLUTCH OPERATES. C2 CLUTCH OPERATES. FRONT SUN GEAR ROTATES CLOCKWISE. FRONT INNER PLANETARY PINION GEAR ROTATE COUNTERCLOCKWISE. FRONT OUTER PLANETARY PINION GEAR ROTATES CLOCKWISE. 05–13 B1 BRAKE OPERATES (LOCKS ROTATION OF FRONT PLANETARY CARRIER).
Page 310 AUTOMATIC TRANSMISSION [SJ6A-EL] F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH : OPERATING : OPERATING BUT NOT CONTRIBUTING TO TRANSMISSION POWER E5U513ZS5011...
Page 311 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C2 CLUTCH OPERATES. MIDDLE PLANETARY CARRIER ROTATES CLOCKWISE. MIDDLE PLANETARY PINION GEARS ROTATE COUNTERCLOCKWISE. B2 BRAKE OPERATES (LOCKS ROTATION OF MIDDLE RING GEAR). 05–13 MIDDLE SUN GEAR ROTATES CLOCKWISE. REAR SUN GEAR ROTATES CLOCKWISE. REAR RING GEAR ROTATES CLOCKWISE.
Page 312 AUTOMATIC TRANSMISSION [SJ6A-EL] R position F3 ONE-WAY CLUTCH B2 BRAKE B4 BRAKE B1 BRAKE F1 ONE-WAY CLUTCH OUTPUT B3 BRAKE F2 ONE-WAY CLUTCH C3 CLUTCH C2 CLUTCH C1 CLUTCH REAR PLANETARY GEAR C4 CLUTCH MIDDLE PLANETARY GEAR FRONT PLANETARY GEAR INPUT F4 ONE-WAY CLUTCH : OPERATING...
Page 313 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT SHAFT ROTATES CLOCKWISE. C3 CLUTCH OPERATES. FRONT SUN GEAR ROTATES CLOCKWISE. FRONT INNER PLANETARY PINION GEAR ROTATE COUNTERCLOCKWISE. FRONT OUTER PLANETARY PINION GEAR ROTATES CLOCKWISE. B1 BRAKE AND F1 ONE-WAY CLUTCH OPERATES (LOCKS FRONT PLANETARY CARRIER). 05–13 FRONT RING GEAR ROTATES CLOCKWISE.
Page 314 AUTOMATIC TRANSMISSION [SJ6A-EL] CONTROL VALVE BODY COMPONENT OUTLINE [SJ6A-EL] E5U051321100N01 • The control valve body supplys oil by switching the oil circuit for the hydraulic pressure generated by the oil pump. Based on the control signal from the TCM, the solenoid valves are activated to control the hydraulic pressure to the clutch and brakes, performing gear shift and TCC.
Page 315 AUTOMATIC TRANSMISSION [SJ6A-EL] ELECTRONIC CONTROL SYSTEM CONSTRUCTION [SJ6A-EL] E5U051318901N01 ECT SENSOR BRAKE SWITCH AT WARNING LIGHT GEAR POSITION INDICATOR LIGHT APP SENSOR SELECTOR INDICATOR LIGHT 05–13 SENSOR STEERING SHIFT SWITCH (DOWN SWITCH) MAF/IAT SENSOR TURBINE SENSOR TCC CONTROL SOLENOID STEERING SHIFT SWITCH (UP SWITCH) SHIFT SOLENOID G...
Page 316 AUTOMATIC TRANSMISSION [SJ6A-EL] ELECTRONIC CONTROL SYSTEM BLOCK DIAGRAM [SJ6A-EL] E5U051318901N02 INPUT SIGNALS INPUT SIGNALS TR SWITCH TFT CHECK CONNECTOR TFT SONSOR OTHER MODULE TURBINE SONSOR BRAKE SWITCH M RANGE INPUT SIGNALS SWITCH MAF SENSOR UP SWITCH APP SENSOR DOWN SWITCH CKP SENSOR OUTPUT SIGNALS TRANSMISSION...
Page 317 AUTOMATIC TRANSMISSION [SJ6A-EL] COMPONENT DESCRIPTIONS (ELECTRONIC CONTROL) [SJ6A-EL] E5U051318901N04 Part name Function • Detects parking gear (output) revolution speed. • Detects direct and reverse disc clutch case (input) revolution Turbine sensor speed. • Detects selector lever ranges/positions. TR switch • Selects driving modes (M range) and changes driving M range switch patterns.
Page 318 AUTOMATIC TRANSMISSION [SJ6A-EL] INPUT/OUTPUT SIGNAL AND RELATED CONTROLS [SJ6A-EL] E5U051318901N05 Control item Manual 5-6 shift Torque Line Shift On-board Component Shift mode inhibit reduction pressure learning diagnostic control shift control control control control control function control Input Turbine sensor TR switch M range switch Up switch Down switch...
Page 319 AUTOMATIC TRANSMISSION [SJ6A-EL] TRANSMISSION RANGE (TR) SWITCH FUNCTION [SJ6A-EL] E5U051319200N01 • The TR switch sends information on which range is selected in the automatic transmission using a combination of the position circuit terminals, and its functions are as follows: 1. Enables engine starting only in P or N positions 2.
Page 320 AUTOMATIC TRANSMISSION [SJ6A-EL] TURBINE SENSOR, VEHICLE SPEED SENSOR (VSS) CONSTRUCTION/OPERATION [SJ6A-EL] E5U051319200N02 • The turbine sensor detects the rotation speed of the direct and reverse disc clutch case, and sends it to the TCM as a signal. • The VSS detects the rotation speed of the parking gear and sends it to the TCM as a signal. •...
Page 321 AUTOMATIC TRANSMISSION [SJ6A-EL] TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR OUTLINE [SJ6A-EL] E5U051319200N03 • The TFT sensor and the coupler component are equipped to the control valve body component as a single unit. • A hydraulic pressure sensor for hydraulic control during shifting has been equipped inside the control valve body component.
Page 322 AUTOMATIC TRANSMISSION [SJ6A-EL] SHIFT SOLENOID E OUTLINE [SJ6A-EL] E5U051321101N02 • Shift solenoid E is directly equipped to the control valve body component. • Shift solenoid E turns on and off according to the control signals from the TCM, and switches the C4 clutch and the B1 brake.
Page 323 AUTOMATIC TRANSMISSION [SJ6A-EL] TORQUE CONVERTER CLUTCH (TCC) CONTROL SOLENOID OUTLINE [SJ6A-EL] E5U051321101N04 • Adjusts the pressure of the TCC in the torque converter based on the control signals from the TCM. TCC CONTROL SOLENOID 05–13 INCREASES GENERATED HYDRAULIC PRESSURE CURRENT INCREASES E5U513ZS5030 End Of Sie...
Page 324 AUTOMATIC TRANSMISSION [SJ6A-EL] SHIFT SOLENOID F, G OUTLINE [SJ6A-EL] E5U051321101N05 • By performing linear adjustment of the C3 clutch pressure and the B2 brake pressure based on the control signals from the TCM, the pressure which is applied to the C3 clutch and the B2 brake is directly controlled during shift changes from 5th to 6th gears.
Page 325 AUTOMATIC TRANSMISSION [SJ6A-EL] COUPLER COMPONENT OUTLINE [SJ6A-EL] E5U051321101N06 • The coupler component are installed on the transmission case as the grouped connectors of the TFT sensor and solenoids. TFT SENSOR SHIFT LINE PRESSURE SOLENOID F CONTROL SOLENOID SHIFT SOLENOID G SHIFT SHIFT SOLENOID E...
Page 326 AUTOMATIC TRANSMISSION [SJ6A-EL] MANUAL MODE SHIFT CONTROL STRUCTURE [SJ6A-EL] E5U051318901N07 Features • The manual mode shift control is activated by moving the selector lever from the D to M range position (selector lever is shifted over toward driver side). • Manual mode shift control with a manual shifting system allowing selection of gear positions by manual operation of the selector lever forward (–) and back (+) has been adopted.
Page 327 AUTOMATIC TRANSMISSION [SJ6A-EL] • Conversely, when the selector lever is operated in the forward (–) direction, the down switch in the selector lever component turns on, and a down-shift command signal is input to the TCM. — The TCM, triggered by the down-shift command signal, carries out shifting by outputting an operation signal to the shift control solenoid if the vehicle speed is less than the set speed and the gear position is 2GR or above.
Page 328 AUTOMATIC TRANSMISSION [SJ6A-EL] Shift Diagram TCC OPERATION AVAILABLE TCC OPERATION TCC OPERATION TCC OPERATION TCC OPERATION {6.2} {12} {19} {25} {31} {37} {43} {50} {56} {62} {68} {74} {81} {87} {93} {99} {105} {112} {118} {124} {131} {137} {143} VEHICLE SPEED km/h {mph} DOWNSHIFTING IS INHIBITED UNTIL VEHICLE REACHES SPEED POSSIBLE FOR DOWNSHIFTING WHEN DECELERATING BELOW SET VEHICLE SPEED,...
Page 329 AUTOMATIC TRANSMISSION [SJ6A-EL] AT WARNING LIGHT CONSTRUCTION/OPERATION [SJ6A-EL] E5U051321101N08 • The AT warning light is built into the instrument cluster. • The AT warning light illuminates when the instrument cluster receives a warning signal from the TCM via CAN communication. •...
Page 330 AUTOMATIC TRANSMISSION [SJ6A-EL] SELECTOR INDICATOR LIGHT CONSTRUCTION/OPERATION [SJ6A-EL] E5U051321101N10 Construction • The selector indicator light is built into the instrument cluster. • When in the P, R, N or D range, the TCM detects the selector lever position based on an analog signal from the TR switch.
Page 331 AUTOMATIC TRANSMISSION [SJ6A-EL] SELF-DIAGNOSIS FUNCTION OUTLINE [SJ6A-EL] E5U051318901N12 • The TCM monitors the communication status of each sensor, electronic component and PCM including the PCM. If any malfunction should occur, the TCM functions to warn the driver and stores the malfunction as a diagnosis code.
Page 333: Automatic Transmission Shift Mechanism Outline
AUTOMATIC TRANSMISSION SHIFT MECHANISM 05–14 AUTOMATIC TRANSMISSION SHIFT MECHANISM AUTOMATIC TRANSMISSION SELECTOR LEVER OUTLINE ..05–14–3 SHIFT MECHANISM OUTLINE..05–14–1 SELECTOR LEVER STRUCTURE..05–14–3 AUTOMATIC TRANSMISSION M Range Switch .
Page 334 AUTOMATIC TRANSMISSION SHIFT MECHANISM KEY INTERLOCK SYSTEM OUTLINE E5U051409000N01 • The key interlock system, which is composed of the interlock cable and steering lock, prevents the ignition switch from being removed when the selector lever is in any position other than the P range. (The ignition switch cannot be turned to the LOCK position.) End Of Sie KEY INTERLOCK SYSTEM OPERATION...
Page 335: M Range Switch
AUTOMATIC TRANSMISSION SHIFT MECHANISM 2. When the brake pedal is depressed, the slider pin INTERLOCK CABLE moves freely in direction B. The slider block also SLIDER BLOCK starts to move freely. The interlock cable and SELECTOR LEVER SIDE interlock cam are not locked, thus shifting out of P position becomes possible.
Page 336: Down Switch
AUTOMATIC TRANSMISSION SHIFT MECHANISM Down Switch Outline • The down switch detects a down-shift operation in the M range and sends a down-shift request signal to the TCM. DOWN SWITCH Operation • The down switch is an ON/OFF type switch that turns on when the selector lever is in the M range (–) side position.
Page 337 STEERING SECTION Toc of SCT OUTLINE ....06-00 POWER STEERING ..06-14 Toc of SCT 06–00 OUTLINE STEERING ABBREVIATION .
Page 339: Power Steering
POWER STEERING 06–14 POWER STEERING POWER STEERING OUTLINE ..06–14–1 STEERING SHAFT POWER STEERING STRUCTURAL CONSTRUCTION ....06–14–2 VIEW .
Page 340 POWER STEERING STEERING GEAR AND LINKAGE CONSTRUCTION E5U061432960N01 • A size and weight reduced rack and pinion system steering gear has been adopted. • Heightened support rigidity has been achieved due to the integration of the steering gear mounts (two locations) and gear housing, improving response and steering stability.
Page 341 POWER STEERING ENERGY ABSORBING SYSTEM CONSTRUCTION / OPERATION E5U061432010N01 Construction • Due to impact absorbing mechanisms at two points on the steering shaft, when a collision occurs, the steering shaft effectively absorbs the impact energy that would be transmitted to the driver, thereby reducing injury. Operation •...
Page 343 2006 Mazda MX-5 Service Highlights (3404–1U–05F) HEATER, VENTILATION & AIR CONDITIONING (HVAC) SECTION Toc of SCT OUTLINE ....07-00 CONTROL SYSTEM ..07-40 BASIC SYSTEM .
Page 344 2006 Mazda MX-5 Service Highlights (3404–1U–05F) OUTLINE HVAC SPECIFICATIONS E5U070000000N03 Basic System Item Specification Heating capacity (kW {kcal/h}) 3.700 {3,182} Cooling capacity (kW {kcal/h}) 3.700 {3,182} Type R-134a Refrigerant Regular amount (g {oz}) 450 {15.9} (approx. quantity) Type 5 vane rotaly type...
Page 345 BASIC SYSTEM 07–11 BASIC SYSTEM BASIC SYSTEM STRUCTURAL Construction ..... 07–11–4 VIEW ......07–11–1 Air Mix Damper Operation.
Page 346: Basic System
BASIC SYSTEM BASIC SYSTEM FLOW DIAGRAM E5U071100000N03 VENTILATION SYSTEM SIDE VENT SIDE SIDE CENTER VENT DEFROSTER DEFROSTER DEMISTER DEMISTER FRESH CENTER VENT RECIRCULATE SIDE VENT WAIST LOUVER WAIST LOUVER EVAPORATOR HEATER BLOWER HEAT HEAT MOTOR CORE E5U711ZS5002 REFRIGERANT SYSTEM LOW-PRESSURE CHARGING VALVE EXPANSION VALVE EVAPORATOR A/C COMPRESSOR...
Page 347: Air Dist Unit Construction
BASIC SYSTEM AIR DIST UNIT CONSTRUCTION E5U071161140N01 • Composed of the following parts: — Airflow mode actuator AIRFLOW — Airflow mode main link MODE — Airflow mode door ACTUATOR AIRFLOW MODE DOOR AIRFLOW MODE MAIN LINK E5U711ZS5003 Airflow Mode Door Operation •...
Page 348: Airflow Distribution
BASIC SYSTEM Airflow Distribution AIRFLOW RATE (%) VENT WAIST HEAT DEFROSTER AIRFLOW PASSENGER- PASSENGER- PASSE PASSE MODE DRIVER-SIDE DRIVER-SIDE DRIVE DRIVE SIDE SIDE NGER- NGER- R-SIDE R-SIDE SIDE SIDE SIDE CENTER CENTER SIDE SIDE CENTER CENTER SIDE OPEN-VENT 21.25 21.25 21.25 21.25 –...
Page 349: A/C Compressor Construction
BASIC SYSTEM A/C COMPRESSOR CONSTRUCTION E5U071161450N01 • Composed of the following parts: MAGNETIC CLUTCH — A/C compressor body — Magnetic clutch End Of Sie A/C COMPRESSOR BODY E5U711ZS5007 CONDENSER CONSTRUCTION E5U071161480N01 • A sub cool condenser has been adopted. It is a multi-flow condenser which is equipped with a sub cooling part and integrated with a receiver/drier.
Page 350: Refrigerant Lines Construction
BASIC SYSTEM REFRIGERANT LINES CONSTRUCTION E5U071161460N01 • Aluminum alloy has been adopted for the pipes of the refrigerant lines and rubber (flexible hoses) has been adopted for the hoses. • A high-pressure charging valve is installed on cooler pipe No.2, and a low-pressure charging valve is installed on the cooler pipe No.3.
Page 351 CONTROL SYSTEM 07–40 CONTROL SYSTEM CONTROL SYSTEM STRUCTURAL Function ......07–40–4 VIEW ......07–40–1 Construction/Operation .
Page 352: Control System
CONTROL SYSTEM CONTROL SYSTEM SYSTEM WIRING DIAGRAM E5U074000000N03 A/C RELAY REFRIGERANT PRESSURE EVAPORATOR SWITCH TEMPERATURE SENSOR MAGNETIC CLUTCH BLOWER AIRFLOW RELAY MODE ACTUATOR BLOWER MOTOR CLIMATE CONTROL UNIT POWER ACTUATOR INTAKE ACTUATOR RELAY METER REAR WINDOW DEFROSTER RELAY E5U740ZS5107 End Of Sie AIR INTAKE ACTUATOR CONSTRUCTION E5U074061060N01 •...
Page 353: Air Mix Actuator Construction
CONTROL SYSTEM AIR MIX ACTUATOR CONSTRUCTION E5U074061415N01 • A communication type has been adopted. End Of Sie 280° COLD E5U740ZS5004 AIRFLOW MODE ACTUATOR CONSTRUCTION E5U074061070N01 • A communication type has been adopted. End Of Sie VENT 105° 07–40 DEFROSTER E5U740ZS5005 BLOWER MOTOR CONSTRUCTION E5U074061020N01 •...
Page 354: Power Metal Oxide Semiconductor Field Effect Transistor (Power Mos Fet) Function
CONTROL SYSTEM POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT TRANSISTOR (POWER MOS FET) FUNCTION E5U074000116N01 Function • Controls the supply voltage to the blower motor POWER MOS FET according to the gate voltage sent from the climate control unit and adjusts the rotation speed (airflow volume).
Page 355: Magnetic Clutch Construction
CONTROL SYSTEM MAGNETIC CLUTCH CONSTRUCTION E5U074061010N01 • Consists of the following parts: — Pressure plate SNAP — Shim RING — Snap ring SHIM — A/C compressor pulley PRESSURE — Stator PLATE End Of Sie STATOR SNAP RING A/C COMPRESSOR PULLEY E5U740ZS5104 EVAPORATOR TEMPERATURE SENSOR CONSTRUCTION E5U074061022N01...
Page 356: Climate Control Unit Construction
CONTROL SYSTEM CLIMATE CONTROL UNIT CONSTRUCTION E5U074061190N01 • Composed of the following parts: — Fan switch — Airflow mode control dial — REC switch — A/C switch — Temperature control dial — Rear window defroster switch AIRFLOW MODE TEMPERATURE FAN SWITCH CONTROL DIAL CONTROL DIAL REAR WINDOW...
Page 357: Manual Air Conditioner Function
CONTROL SYSTEM MANUAL AIR CONDITIONER FUNCTION E5U074000005N01 Defroster Control • A/C is on (A/C indicator is the same as before the operation) and the intake mode is automatically switched to FRESH by setting the mode to HEAT, HEAT/DEF, or DEFROSTER. —...
Page 359 RESTRAINTS SECTION Toc of SCT OUTLINE ....08-00 AIR BAG SYSTEM ..08-10 ON-BOARD DIAGNOSTIC ..08-02 SEAT BELT.
Page 361 ON-BOARD DIAGNOSTIC 08–02 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FUNCTION Self-Malfunction Diagnostic OUTLINE ......08–02–1 Function ..... . . 08–02–2 ON-BOARD DIAGNOSTIC PID/Data Monitoring Function .
Page 362 ON-BOARD DIAGNOSTIC ON-BOARD DIAGNOSTIC FUNCTION E5U080200000N02 Self-Malfunction Diagnostic Function Malfunction detection function • Detects overall malfunctions in the air bag system-related parts. Fail-safe function • If the SAS control module performance/function cannot be maintained due to any cause, the fail-safe function stops air bag system control and flashes the air bag system warning light to prevent the air bags from operating (deploying) accidentally.
Page 363 ON-BOARD DIAGNOSTIC Air bag system warning light System malfunction location Priority display Flashing pattern ranking  Continuously illuminated Air bag system warning light circuit open B1869 Air bag system warning light circuit short to body   Does not illuminate ground Driver-side pre-tensioner seat belt circuit B1877...
Page 364 ON-BOARD DIAGNOSTIC Air bag system warning light System malfunction location Priority display Flashing pattern ranking Driver-side side air bag module circuit short to B1992 power supply Driver-side side air bag module circuit short to B1993 body ground Driver-side side air bag module circuit resistance B1994 high Driver-side side air bag module circuit resistance...
Page 365 ON-BOARD DIAGNOSTIC Air bag system warning light System malfunction location Priority display Flashing pattern ranking Driver-side buckle switch circuit short to body B2434 ground Passenger-side buckle switch circuit open or short B2437 to power supply Passenger-side buckle switch circuit short to body B2438 ground B2477...
Page 366 ON-BOARD DIAGNOSTIC PID/data monitor table PID name (definition) Unit/Condition Operation Condition (Reference) Terminal BUCKLE_D • Driver-side buckle switch on: Buckled Buckled/ (Driver-side buckle switch 3A, 3D • Driver-side buckle switch off: Unbuckled Unbuckled status) BUCKLE_P • Passenger-side buckle switch on: Buckled Buckled/ (Passenger-side buckle switch 3J, 3G...
Page 367 ON-BOARD DIAGNOSTIC PID name (definition) Unit/Condition Operation Condition (Reference) Terminal OCSFLT_CAL • Sensor normal: OK (Seat weight sensor • Passenger sensing system calibration error: FAULT FAULT calibration status) OCSFLT_COM • Sensor normal: OK (Seat weight sensor control • Passenger sensing system communication error: FAULT FAULT module communication status) OCSFLT_L...
Page 369: Air Bag System
AIR BAG SYSTEM 08–10 AIR BAG SYSTEM AIR BAG SYSTEM OUTLINE ..08–10–2 PASSENGER AIR BAG DEACTIVATION AIR BAG SYSTEM STRUCTURAL (PAD) SYSTEM FUNCTION ..08–10–11 VIEW .
Page 370 AIR BAG SYSTEM AIR BAG SYSTEM OUTLINE E5U081000000N01 • The air bag system is a device that supplements the passenger restraint function of the seat belts. The air bag system will not have the designed effect if the seat belts are not worn properly. •...
Page 371 AIR BAG SYSTEM AIR BAG SYSTEM STRUCTURAL VIEW E5U081000000N02 SIDE AIR BAG MODULE CRASH ZONE SENSOR SIDE AIR BAG SENSOR PRE-TENSIONER SEAT BELT SEAT BELT WARNING LIGHT INDICATOR AIR BAG SYSTEM WARNING LIGHT 08–10 PASSENGER-SIDE AIR BAG MODULE SAS CONTROL MODULE PAD SWITCH DRIVER-SIDE AIR BAG...
Page 372 AIR BAG SYSTEM AIR BAG SYSTEM WIRING DIAGRAM E5U081000000N03 TWISTED PAIR INSTRUMENT CLUSTER CLOCK SPRING INFLATOR SEAT BELT NO. 1 DRIVER- WARNING SIDE LIGHT AIR BAG INFLATOR MODULE NO. 2 INSTRUMENT CLUSTER INFLATOR AIR BAG NO. 1 SYSTEM PASSENGER- WARING SIDE AIR BAG LIGHT MODULE...
Page 373 AIR BAG SYSTEM SAS CONTROL MODULE FUNCTION E5U081057030N01 Outline • A two-step air bag deployment control system has been adopted. In case of a frontal or frontal offset collision, an optimal air bag deployment force is matched to the impact force. The inflators for the driver and passenger- side air bag modules have two tiers, and deploy at either a low or high rate, according to the force of the impact.
Page 374 AIR BAG SYSTEM Side air bag system 1. During a lateral collision to the vehicle, the crash sensors in the side air bag sensor and SAS control module detect the collision. 2. The level of impact detected by the crash sensor in the side air bag sensor is converted to an electrical signal and sent to the SAS control module through the signal amplification circuit.
Page 375 AIR BAG SYSTEM Seat Belt Buckled/Unbuckled Condition Matching (Deployment) Control • The SAS control module detects the buckled or unbuckled condition of the driver-side and passenger-side seat belts based on a signal received from the buckle switch. Based on this signal, the necessary air bag system deployment is controlled according to the impact profile (speed) range.
Page 376 AIR BAG SYSTEM SEAT TRACK POSITION SENSOR FUNCTION E5U081057030N03 • The seat track position sensor converts the seat position into an electrical signal and sends it to the SAS control module. End Of Sie SEAT TRACK POSITION SENSOR CONSTRUCTION/OPERATION E5U081057030N04 •...
Page 377 AIR BAG SYSTEM PASSENGER SENSING SYSTEM OPERATION E5U081057031N03 1. The load on the passenger-side seat is converted into an electric signal by the strain gauge built into the seat weight sensor, and this signal is sent to the seat weight sensor control module. 2.
Page 378 AIR BAG SYSTEM ELECTRIC SIGNAL ADULT DETERMINED SEAT WEIGHT SENSOR SEAT (RH) WEIGHT PASSENGER-SIDE SENSOR AIR BAG MODULE CONTROL SEAT MODULE WEIGHT CONTROL SENSOR MODULE PASSENGER-SIDE SIDE (LH) TWISTED AIR BAG MODULE PAIR PASSENGER-SIDE PRE-TENSIONER SEAT BELT ELECTRIC SIGNAL CHILD (INCLUDING A INDICATOR CHILD-RESTRAINT SEAT) SEAT...
Page 379 AIR BAG SYSTEM PASSENGER AIR BAG DEACTIVATION (PAD) SYSTEM FUNCTION E5U081064170N01 • By operation of the PAD switch, vehicle occupants can optionally switch the passenger-side air bag module, passenger-side side air bag module, and the passenger-side pre-tensioner seat belt between operational (deployable) and inoperational (undeployable) conditions.
Page 380 AIR BAG SYSTEM PAD SWITCH IS AT PASS AIRBAG ON POSITION PAD INDICATOR PASSENGER-SIDE AIR BAG MODULE SAS CONTROL PASSENGER-SIDE SIDE PAD SWITCH MODULE AIR BAG MODULE PASS PASS AIRBAG AIRBAG PASSENGER-SIDE PRE- TENSIONER SEAT BELT PAD SWITCH IS AT PASS AIRBAG OFF POSITION INDICATOR PASSENGER-SIDE AIR BAG MODULE...
Page 381 AIR BAG SYSTEM GAS GENERATING INFLAMMATION AGENT AGENT IGNITION OF INFLAMMATION AGENT IGNITER (INFLATOR NO.1) AIR BAG AIR BAG FILTER GAS GENERATING AGENT COMBUSTION 08–10 ADA8130T003 Inflator No.2 1. When the driver-side air bag module receives an operation (deployment) signal from the SAS control module, the igniter built into inflator No.2 builds up heat and ignites the inflammation agent.
Page 382 AIR BAG SYSTEM PASSENGER-SIDE AIR BAG MODULE CONSTRUCTION/OPERATION E5U081057050N02 Inflator Operation Inflator No.1 1. When the passenger-side air bag module receives an operation (deployment) signal from the SAS control module, the igniter built into inflator No.1 builds up heat and ignites the inflammation agent. 2.
Page 383 AIR BAG SYSTEM SIDE AIR BAG MODULE CONSTRUCTION/OPERATION E5U081000147N02 Construction • Side air bag modules are installed on the outboard sides of the seat backs. • The side air bag module is composed of an inflator and air bag. • When the air bag operates (deploys), the seat back trim is spread apart by argon gas generated from the inflator, inflating the air bag.
Page 384 AIR BAG SYSTEM PRE-TENSIONER SEAT BELT CONSTRUCTION/OPERATION E5U081057630N02 Construction SPRING SEAT SPRING SHAFT SPRING SPRING CASE SPINDLE BASE CLUTCH PISTON ROLLER CAP NUT GEAR COVER GAS GENERATOR CYLINDER EPU810ZT3011 Operation Normal (Seat Belt Pretensioners Not Operating) • Normally, the clutch roller installed to the outer circumference of the spindle sits in the recess of the gear and does not interfere with the spindle.
Page 385 AIR BAG SYSTEM GEAR GEAR SPINDLE CLUTCH ROLLER EPU810ZT3012 Seat Belt Pretensioners Operating 1. When an operation signal is received from the SAS control module, the gas generator produces gas. Due to the pressure from the gas, the piston in the cylinder is pressed up. 08–10 2.
Page 387: Seat Belt
SEAT BELT 08–11 SEAT BELT SEAT BELT OUTLINE ....08–11–1 LOAD LIMITER RETRACTOR Features ......08–11–1 CONSTRUCTION/OPERATION .
Page 388 SEAT BELT LOAD LIMITER RETRACTOR CONSTRUCTION/OPERATION E5U081157000N03 1. Initial state CPJ811ZNB004 2. Pre-tensioner and ELR operation When the vehicle has been subjected to an impact, the pre-tensioner or ELR activates, locking the belt and securing the passenger's body. THE VEHICLE IS INVOLVED IN AN IMPACT E5U811ZS5002 3.
Page 389: Security And Locks
BODY & ACCESSORIES SECTION Toc of SCT OUTLINE ....09-00 EXTERIOR TRIM ... 09-16 BODY PANELS .
Page 390 OUTLINE BODY AND ACCESSORIES NEW FEATURES E5U090000000N02 • Power window system adopted • Power door lock system adopted Improved marketability • Advanced keyless entry and start system adopted • A center panel unit, composed of the installed audio unit and the audio switches built into Improved convenience the center panel, has been adopted •...
Page 391: Body Panels
BODY PANELS 09–10 BODY PANELS BODY PANEL OUTLINE ... . . 09–10–1 CABIN CONSTRUCTION ... . . 09–10–2 CRUSH ZONE CONSTRUCTION ..09–10–1 HOOD CONSTRUCTION .
Page 392 BODY PANELS CABIN CONSTRUCTION E5U091056100N03 • The side impact bar inside the front door is positioned to effectively disperse an impact throughout the body. • Body rigidity has been improved due to the highly rigid, closed-section high-mount backbone frame located along the upper part of the transmission tunnel.
Page 393 DOORS AND LIFTGATE 09–11 DOORS AND LIFTGATE DOOR OUTLINE ....09–11–1 DOOR CONSTRUCTION ... . . 09–11–2 Features .
Page 394 DOORS AND LIFTGATE DOOR CONSTRUCTION E5U091158010N02 • The internal parts of the door (door speaker, and door harness) have been integrated into a door unit carrier. • Due to the integrated door unit, weight reduction has been achieved for the whole door. •...
Page 395 2006 Mazda MX-5 Service Highlights (3404–1U–05F) GLASS/WINDOWS/MIRRORS 09–12 GLASS/WINDOWS/MIRRORS REAR WINDOW DEFROSTER SYSTEM POWER WINDOW SYSTEM OUTLINE ......09–12–1 WIRING DIAGRAM .
Page 396 2006 Mazda MX-5 Service Highlights (3404–1U–05F) GLASS/WINDOWS/MIRRORS REAR WINDOW DEFROSTER SYSTEM STRUCTURAL VIEW E5U091263000N02 LOWER BLOCK UPPER BLOCK REAR WINDOW DEFROSTER RELAY HEATED OUTER MIRROR REAR WINDOW DEFROSTER FILAMENT CLIMATE CONTROL UNIT REAR WINDOW DEFROSTER SWITCH E5U912ZS9001 End Of Sie 09–12–2...
Page 397 GLASS/WINDOWS/MIRRORS REAR WINDOW DEFROSTER SYSTEM CONSTRUCTION/OPERATION E5U091263000N03 • Fogging is cleared from the rear window by heating of the filament. REAR WINDOW DEFROSTER RELAY CLIMATE CONTROL UNIT REAR WINDOW DEFROSTER INDICATOR LIGHT REAR WINDOW DEFROSTER FILAMENT MICROCOMPUTER REAR WINDOW DEFROSTER SWITCH E5U912ZS5008 End Of Sie...
Page 398 GLASS/WINDOWS/MIRRORS POWER WINDOW SYSTEM WIRING DIAGRAM E5U091258000N03 POWER WINDOW MAIN SWITCH OPEN AUTO OPEN OPEN CLOSE P/W CM OPEN CLOSE RELAY OPEN OPEN CLOSE CLOSE POWER WINDOW MOTOR POWER WINDOW MOTOR (DRIVER'S SIDE) (PASSENGER'S SIDE) E5U912ZS5004 End Of Sie POWER OUTER MIRROR OUTLINE E5U091269100N01 •...
Page 399 GLASS/WINDOWS/MIRRORS POWER OUTER MIRROR SYSTEM WIRING DIAGRAM E5U091269100N03 POWER OUTER POWER OUTER MIRROR (LH) MIRROR (RH) RIGHT LEFT LEFT RIGHT DOWN DOWN LEFT RIGHT LEFT RIGHT LEFT/ RIGHT/ DOWN SIDE SIDE SIDE SIDE LEFT RIGHT DOWN 09–12 POWER OUTER MIRROR SWITCH E5U912ZS5006 End Of Sie 09–12–5...
Page 400 GLASS/WINDOWS/MIRRORS POWER OUTER MIRROR OPERATION E5U091269100N04 Mirror Glass Adjustment • The left/right selection switch establishes left or right side outer mirror circuit and current is supplied in either one of the four directions according to the position of the mirror glass adjustment switch. Due to this, the motor rotates either up or down, left or right.
Page 401 SEATS 09–13 SEATS SEATS OUTLINE....09–13–1 SEATS SPECIFICATION ... . . 09–13–1 FEATURES .
Page 403 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] 09–14A SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] SECURITY AND LOCKS OUTLINE ..09–14A–1 KEYLESS BEEPER SECURITY AND LOCKS CONSTRUCTION ....09–14A–14 STRUCTURAL VIEW .
Page 404 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] SECURITY AND LOCKS STRUCTURAL VIEW E5U091400001N02 START KNOB (IGNITION SWITCH) SECURITY LIGHT STEERING LOCK UNIT KEYLESS INDICATOR LIGHT (GREEN) KEYLESS WARNING LIGHT COIL ANTENNA (RED) TRUNK LID KEYLESS ANTENNA OPENER (EXTERIOR, LF) REQUEST SWITCH CANCEL SWITCH KEYLESS ANTENNA...
Page 405 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] SECURITY AND LOCKS SYSTEM WIRING DIAGRAM E5U091400001N03 LOCK UNLOCK KEYLESS RECEIVER (FRONT) WITH KEYLESS ANTENNA (EXTERIOR, RF) IMMOBILIZER SYSTEM KEYLESS ANTENNA (EXTERIOR, LF) KEYLESS ANTENNA (EXTERIOR, REAR) COIL ANTENNA KEYLESS ANTENNA (INTERIOR, MIDDLE) KEYLESS ANTENNA (INTERIOR, TRUNK) INSTRUMENT CLUSTER KEYLESS ANTENNA (INTERIOR, REAR)
Page 406 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] POWER DOOR LOCK SYSTEM OUTLINE E5U091466000N01 • A door lock knob interlock function has been adopted where all doors are locked/unlocked when the driver’s door is locked/unlocked with the driver’s door lock knob. • A door key interlock function has been adopted where all doors are locked/unlocked when the driver’s door is locked/unlocked with the driver’s door key cylinder.
Page 407 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] 3. The keyless control module operates the hazard warning lights flash to flash according to lock/unlock signal from the transmitter (card key). — When the LOCK button is pressed, the hazard warning lights flash once. —...
Page 408 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] Trunk lid opening Note • If any of the following conditions are not met, the trunk lid cannot be opened by operating the request switch. — The auxiliary key is not inserted in the ignition key cylinder. —...
Page 409 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] Auto re-lock function • The auto re-lock function automatically locks the doors if any of the following operations are performed within approx. 30 s after the UNLOCK button of the card key is pressed, or after the request switch is pressed to unlock the doors.
Page 410 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] ADVANCED KEYLESS START FUNCTION OPERATION E5U091469000N03 • The advanced start function activates to start the engine by operating the start knob, and not by inserting the key but by the driver carrying the card key while in the vehicle. 1.
Page 411 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] WARNING/GUIDANCE FUNCTION OPERATION E5U091469000N04 • If the system is operated improperly, it warns the driver using the indicator light in the instrument cluster, buzzer sound, and keyless beeper in the trunk compartment. • The operation condition of the advanced keyless system is indicated by the indicator light and beeper sound to guide user’s operation.
Page 412 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] ON-BOARD DIAGNOSYS SYSTEM OUTLINE (ADVANCED KEYLESS ENTRY SYSTEM) E5U091469000N06 Special Features • The keyless entry system has an on-board diagnostic function to facilitate system diagnosis. • The on-board diagnostic function consists of the following functions: a malfunction detection function, which detects overall malfunctions in the keyless entry system-related parts;...
Page 413 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] PID/data monitor table PID name Unit/ Data contents Terminal (definition) Operation − − DTC_CNT Number of continuous DTCs Engine speed 4Z, 4AA Vehicle speed 4Z, 4AA VPWR Supply voltage − − NUMCARD Number of programmed card keys −...
Page 414 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] ACTIVE COMMAND MODE TABLE Command Unit/ Output part name Terminal name Operation BZR_OUT Keyless beeper On/Off BZR_INN Interior buzzer (Instrument cluster) On/Off 4Z, 4AA LNP_RED Keyless warning light (red) On/Off 4Z, 4AA LNP_GREEN Keyless indicator light (green) On/Off 4Z, 4AA HAZARD...
Page 415 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] KEYLESS ANTENNA CONSTRUCTION/OPERATION E5U091469000N09 • Consists of the antennas for request signal output (7 locations). • Operated by the keyless control module, the keyless antennas send request signals to produce the reception areas inside and outside the vehicle. •...
Page 416 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] KEYLESS BEEPER CONSTRUCTION E5U091469000N11 • Installed on the trunk compartment. End Of Sie KEYLESS BEEPER E5U914AS1011 TRUNK LID OPENER SYSTEM CONSTRUCTION/OPERATION E5U091466000N03 • The trunk lid can be opened by following items: — Key —...
Page 417 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] THEFT-DETERRENT SYSTEM STRUCTURAL VIEW E5U091450000N02 DOOR KEY CYLINDER SWITCH HOOD LATCH SWITCH DRIVER'S SIDE DOOR TRUNK LID OPENER LOCK SWITCH ACTUATOR DOOR (DOOR LOCK- SWITCH LINK SWITCH) KEYLESS CONTROL MODULE HORN PASSENGER'S SIDE DOOR LOCK ACTUATOR (DOOR TRUNK LID OPENER LOCK-LINK SWITCH)
Page 418 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] THEFT-DETERRENT SYSTEM WIRING DIAGRAM E5U091450000N03 HORN RELAY HORN STEERING LOCK UNIT PUSH SWITCH FLASHER CONTROL MODULE KEY REMINDER SWITCH HAZARD DOOR SWITCH WARNING DOOR SWITCH (PASSENGER-S SWITCH (DRIVER-S SIDE) SIDE) TRUNK COMPARTMENT LIGHT KEYLESS TRUNK TRUNK DOOR KEY CYLINDER...
Page 419 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] SYSTEM FLOWCHART E5U091450000N04 Dead Hazard warning light: off Horn: off Ignition switch to ON position Ignition switch to LOCK position or key reminder switch on and key reminder switch off Initial Hazard warning light: off Horn: off Under all the following conditions, lock doors or trunk lid Cancel confirmation...
Page 420 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] IMMOBILIZER SYSTEM OUTLINE E5U091467000N01 Note • The construction and operation of the auxiliary key is described. Refer to “ADVANCED KEYLESS START FUNCTION OPERATION” for starting engine with the card key. (See 09–14A–8 ADVANCED KEYLESS START FUNCTION OPERATION.) Special Features •...
Page 421 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] Structural View COIL ANTENNA AUXILIARY KEY SECURITY LIGHT (TRNSPONDER) INSTRUMENT CLUSTER KEYLESS CONTROL MODULE E5U914AS1015 End Of Sie IMMOBILIZER SYSTEM BLOCK DIAGRAM E5U091467000N02 09–14A INSTRUMENT SECURITY CLUSTER LIGHT KEYLESS COIL CONTROL ANENNA MODULE Hs-CAN E5U914AS1016 End Of Sie 09–14A–19...
Page 422 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] IMMOBILIZER SYSTEM CONSTRUCTION/OPERATION E5U091467000N03 • Keys contain a unique ID number that is previously programmed to the keyless control module and PCM. Due to this, if immobilizer system component parts are replaced (such as key addition/clearing or replacement of the keyless control module, instrument cluster or PCM), it is necessary to reset the system.
Page 423 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] Immobilizer System Setting • Some immobilizer system settings can be performed only using the WDS or equivalent. When using the WDS or equivalent, first, security access must be requested. Obtain security access permission according to the WDS or equivalent screen and then perform system procedures.
Page 424 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] COIL ANTENNA CONSTRUCTION E5U091467000N05 • Installed on the steering lock. • Forms a magnetic field near the steering lock and communicate to the key. • Demodulates the received key signal and outputs the signal to the keyless control module. End Of Sie COIL ANTENNA E6U914AS1017...
Page 425 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] ON-BOARD DIAGNOSYS SYSTEM OUTLINE (IMMOBILIZER SYSTEM) E5U091467000N07 • The immobilizer system is provided with a malfunction diagnosis function. • Malfunction diagnosis of the immobilizer system occurs automatically when the start knob is turned from the LOCK (ACC) to the ON (START) position.
Page 426 SECURITY AND LOCKS [ADVANCED KEYLESS SYSTEM] WDS or equivalent display Keyless Detection condition Keyless Security light flashing pattern warning Instrument control light cluster module Unprogrammed key ID number − B1601 P1260 detected Keyless control module B1342 B1601 P1260 malfunction Communication error between −...
Page 427 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] 09–14B SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM (RETRACTABLE KEY TYPE)] SECURITY AND LOCKS OUTLINE ..09–14B–1 IMMOBILIZER SYSTEM SECURITY AND LOCKS WIRING DIAGRAM ....09–14B–6 STRUCTURAL VIEW .
Page 428 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] SECURITY AND LOCKS STRUCTURAL VIEW E5U091400001N05 TRUNK LID OPENER CANCEL SWITCH FRONT DOOR LATCH AND LOCK ACTUATOR TRUNK LID OPENER DOOR LOCK SWITCH TRUNK LID OPENR KEYLESS CONTROL SWITCH MODULE KEYLESS RECEIVER TRANSMITTER E5U914BS1001 End Of Sie 09–14B–2...
Page 429 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] SECURITY AND LOCKS SYSTEM WIRING DIAGRAM E5U091400001N06 LOCK UNLOCK KEYLESS RECEIVER SECURITY LIGHT KEY REMINDER SWITCH INSTRUMENT CLUSTER FLASHER HORN DOOR SWITCH RELAY CONTROL DOOR SWITCH (PASSENGER-S MODULE (DRIVER-S SIDE) SIDE) HORN KEYLESS TRUNK CONTROL MODULE COMPARTMENT HAZARD...
Page 430 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] POWER DOOR LOCK SYSTEM OPERATION E5U091466000N05 • When the driver’s door is locked/unlocked with the driver’s door lock knob or key cylinder, the door lock-link switch in the door lock actuator is locked/unlocked via the rod. •...
Page 431 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] TRANSMITTER (RETRACTABLE KEY TYPE) STRUCTURAL VIEW E5U091469000N14 LOCK BUTTON UNLOCK BUTTON PANIC BUTTON TRUNK LID OPENER BUTTON C5U914ZS5001 End Of Sie IMMOBILIZER SYSTEM OUTLINE E5U091467000N09 • The immobilizer system is a vehicle theft prevention device that only allows keys that have previously been registered to the vehicle to start the engine.
Page 432 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] IMMOBILIZER SYSTEM STRUCTURAL VIEW E5U091467000N10 COIL ANTENNA SECURITY LIGHT KEY (TRNSPONDER) INSTRUMENT CLUSTER E5U914BS1004 End Of Sie IMMOBILIZER SYSTEM WIRING DIAGRAM E5U091467000N11 COIL ANTENNA INSTRUMENT CLUSTER FUEL INJECTOR TX LINE FUEL PUMP RELAY RX LINE IGNITION COIL STARTER RELAY C3U0914S008...
Page 433 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] Immobilizer System Release Operation The ignition switch is turned from the LOCK (ACC) to the ON (START) position. (Security light illuminates.) (1) The instrument cluster sends data A* to the key (transponder) via the coil. (2) The key (transponder) calculates data B from received data A and sends its specific key ID number and data B to the instrument cluster via the coil.
Page 434 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] Immobilizer System Setting • The immobilizer system can be set so that only the WDS or equivalent must be used to perform system procedures. When using the WDS or equivalent, first security access must be requested. Obtain security access permission according the WDS or equivalent screen and then perform system procedures.
Page 435 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] COIL ANTENNA CONSTRUCTION E5U091467000N14 • Installed on the steering lock. • Forms a magnetic field near the steering lock and receives the key signal. • The received key signal is demodulated and input to the instrument cluster. End Of Sie COIL ANTENNA STEERING LOCK...
Page 436 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] ON-BOARD DIAGNOSTIC SYSTEM OUTLINE [IMMOBILIZER SYSTEM] E5U091467000N16 • The immobilizer system is provided with a malfunction diagnosis function. • Malfunction diagnosis of the immobilizer system occurs automatically when the ignition switch is turned from the LOCK (ACC) to the ON (START) position.
Page 437 SECURITY AND LOCKS [KEYLESS ENTRY SYSTEM] WDS or equivalent Detection condition display Security light flashing pattern Instrument cluster The instrument cluster cannot read key ID number B1602 P1260 data normally. The instrument cluster has detected unregistered B1601 P1260 key ID number. Communication error between the instrument U2510 P1260...
Page 439 2006 Mazda MX-5 Service Highlights (3404–1U–05F) EXTERIOR TRIM 09–16 EXTERIOR TRIM EXTERIOR TRIM OUTLINE ..09–16–1 EXTERIOR TRIM STRUCTURAL VIEW ....09–16–1...
Page 441: Interior Trim
INTERIOR TRIM 09–17 INTERIOR TRIM INTERIOR TRIM OUTLINE ... 09–17–1 INTERIOR TRIM STRUCTURAL VIEW ....09–17–1 End of Toc INTERIOR TRIM OUTLINE E5U091755000N01...
Page 443 LIGHTING SYSTEMS 09–18 LIGHTING SYSTEMS LIGHTING SYSTEMS OUTLINE ..09–18–1 DISCHARGE HEADLIGHT LIGHTING SYSTEMS CONTROL MODULE SPECIFICATION ....09–18–1 CONSTRUCTION/OPERATION .
Page 444: Lighting Systems Structural View
LIGHTING SYSTEMS LIGHTING SYSTEMS STRUCTURAL VIEW E5U091800000N03 TRUNK COMPARTMENT LIGHT HIGH-MOUNT BRAKE LIGHT DISCHARGE HEADLIGHT CONTROL MODULE LICENSE PLATE LIGHT FRONT SIDE MARKER LIGHT REAR COMBINATION LIGHT FRONT FOG LIGHT FRONT COMBINATION LIGHT IGNITION KEY ILLUMINATION DRL CONTROL MODULE MAP LIGHT FLASHER CONTROL MODULE E5U918ZS5101 End Of Sie...
Page 445: Front Combination Light Construction
LIGHTING SYSTEMS FRONT COMBINATION LIGHT CONSTRUCTION E5U091851060N01 • A headlight with built-in front turn light and parking light has been adopted for design improvement. • Projector type headlights have been adopted, and these have been incorporated, along with the front turn light and the parking light, into a single unit to reduce size.
Page 446: Discharge Headlight Structural View
LIGHTING SYSTEMS DISCHARGE HEADLIGHT STRUCTURAL VIEW E5U091851030N02 DISCHARGE HEADLIGHT BULB HEADLIGHT DISCHARGE HEADLIGHT CONTROL MODULE SEC. A—A E5U918ZS5103 End Of Sie DISCHARGE HEADLIGHT OPERATION E5U091851030N03 1. A high voltage pulse (alternating current approx. 25,000 V) travelling from the discharge headlight control module is applied between both discharge headlight bulb terminals, energizing the xenon gas in the bulb.
Page 447: Abnormal Output Detection Function
LIGHTING SYSTEMS Abnormal Output Detection Function • If there is an abnormality in the output system (detects an open or GND short circuit in harness), the discharge headlight control module turns off the headlights for protection and to prevent partial operation errors. •...
Page 448: Rear Combination Light Construction
LIGHTING SYSTEMS REAR COMBINATION LIGHT CONSTRUCTION E5U091851150N01 • A step reflector that diffuses and reflects the light of the rear combination light bulbs, has been adopted. A flat, uncut lens has been adopted to control illumination distribution. • A round reflector for the rear combination lights has been adopted to improve design. BRAKE LIGHT/ TAILLIGHT BULB REAR TURN...
Page 449: Drl System Wiring Diagram
LIGHTING SYSTEMS DRL SYSTEM WIRING DIAGRAM E5U091800200N03 HEADLIGHT RELAY HEAD LOW R 15 A FUSE HEAD LOW L 15 A FUSE 15 A FUSE HEADLIGHT FRONT FOG RELAY 15 A FUSE FRONT FOG LIGHT DRL 1 RELAY HEADLIGHT HEADLIGHT (RH) (LH) HIGH-BEAM INDICATOR...
Page 450: Ignition Key Illumination Function
LIGHTING SYSTEMS IGNITION KEY ILLUMINATION FUNCTION E5U091851311N05 • The illumination time of the ignition key illumination is controlled by the microcomputer in IGNITION KEY the instrument cluster. KEY REMINDER ILLUMINATION • The ignition key illumination glows when the SWITCH BULB ignition switch is at the LOCK or ACC position and any door is open.
Page 451 WIPER/WASHER SYSTEM 09–19 WIPER/WASHER SYSTEM WIPER/WASHER SYSTEM Low Speed And High Speed OUTLINE ......09–19–1 Operation ..... . 09–19–2 WIPER/WASHER SYSTEM Autostop Function .
Page 452: Wiper System Wiring Diagram
WIPER/WASHER SYSTEM WIPER SYSTEM OUTLINE E5U091900000N03 • The wiper system has autostop function, one-touch function, and intermittent function with various timings. End Of Sie WIPER SYSTEM WIRING DIAGRAM E5U091900000N04 WIPER SWITCH ONE-TOUCH SWITCH WASHER SWITCH RELAY AUTOSTOP WASHER WIPER SWITCH MOTOR MOTOR E5U919ZS5002...
Page 453: Autostop Function
WIPER/WASHER SYSTEM Autostop Function • While the wipers are operating, the autostop switch remains on except when the wipers are in the park position. Current flows through the INT relay to the wiper switch, wiper motor, then to ground. Thus, the wipers continue to operate until they reach the park position even if the wiper switch moves to the OFF position.
Page 454: Intermittent Wiper Operation
WIPER/WASHER SYSTEM Intermittent Wiper Operation • When the wiper switch moves to the INT position, the intermittent wiper (INT) relay turns on, and current flows through the INT relay to the wiper switch, wiper motor, then to ground. The wipers operate at low speed. •...
Page 455 ENTERTAINMENT 09–20 ENTERTAINMENT ENTERTAINMENT OUTLINE ..09–20–1 ON-BOARD DIAGNOSTIC SYSTEM AUDIO SYSTEM SPECIFICATIONS ..09–20–2 FUNCTION ..... . . 09–20–10 Audio Unit.
Page 456 ENTERTAINMENT AUDIO SYSTEM SPECIFICATIONS E5U092000001N05 Audio Unit Specification Item BOSE Standard Rated voltage (kHz) Type A : 530—1710, Type B : 522—1629 Frequency band (MHz) Type A : 87.7—107.9, Type B : 87.5—108 External type audio amplifier Door speaker : 74 × 2 Audio amplifier maximum 40 ×...
Page 457: Entertainment
ENTERTAINMENT AUDIO SYSTEM STRUCTURAL VIEW E5U092000001N02 CENTER SPEAKER (BOSE) AUDIO CONTROL SWITCH TWEETER (STD) / DOOR UPPER SPEAKER (BOSE) AUDIOPILOT MICROPHONE DOOR (BOSE) SPEAKER ACCESSORY SOCKET CENTER PANEL MANUAL REAR UNIT SPEAKER ANTENNA AUDIO AMPLIFIER (BOSE) CONDENSER 09–20 E5U920ZS5003 End Of Sie 09–20–3...
Page 458: Audio System Block Diagram
ENTERTAINMENT AUDIO SYSTEM BLOCK DIAGRAM E5U092000001N06 Vehicles with BOSE CONVERTIBLE TOP OPEN/CLOSE SIGNAL MANUAL AUDIO ANTENNA UNIT CENTER PANEL UNIT DOOR UPPER (BUILT-IN INFORMATION SPEAKER (RIGHT) AUDIO UNIT) DISPLAY DOOR SPEAKER (RIGHT) AUDIO CENTER CONTROL SPEAKER CIRCUIT AUDIO BASE UNIT DOOR SPEAKER AMPLIFIER (LEFT)
Page 459: Center Panel Unit Outline
ENTERTAINMENT CENTER PANEL UNIT OUTLINE E5U092066900N01 • The center panel unit is composed of the installed audio unit and the audio switches built into the center panel. End Of Sie CENTER PANEL UNIT CONSTRUCTION E5U092066900N02 Structural View 09–20 E5U920ZS5010 Center panel Lower module Base unit Cover...
Page 460: Terminal Layout And Signal
ENTERTAINMENT Terminal Layout and Signal Audio unit Terminal Signal Door speaker LH (+) B+ (Power back up) Door speaker LH (–) Door speaker RH (+) TNS (+) Door speaker RH (–) Illumination (–) Antenna control Vehicle speed signal*2 AMP control*1 UART–1 —...
Page 461: Button And Switch Location
ENTERTAINMENT Button and switch Location E5U920ZW5110 Type A Type B Type A Type B FM/AM button FM 1/2 button Preset button 3 SAT button AM button Preset button 4 CD button Preset button 5 MEDIA button Preset button 6 09–20 POWER/VOLUME AUDIO CONT/TUNE/ SEEK switch...
Page 462: Auto Level Control (Alc) Function [Without Bose]
ENTERTAINMENT AUTO LEVEL CONTROL (ALC) FUNCTION [WITHOUT BOSE] E5U092066900N03 • Adjusts the audio volume so that the sound is balanced against wind and road noise while driving. End Of Sie AUTO LEVEL CONTROL (ALC) OPERATION [WITHOUT BOSE] E5U092066900N08 • The audio unit changes the volume automatically based on the vehicle speed signal sent from the instrument cluster.
Page 463: Audiopilot Outline [With Bose]
ENTERTAINMENT AUDIOPILOT OUTLINE [WITH BOSE] E5U092066900N06 • Measures the driving noise level inside the vehicle with a specialized microphone, and the amplifier adjusts the volume in accordance with the degree of noise masking the music component. Due to this, passengers can enjoy music at a constantly perceived volume level regardless of the noise level.
Page 464: On-Board Diagnostic System Function
ENTERTAINMENT ON-BOARD DIAGNOSTIC SYSTEM FUNCTION E5U092066900N05 Self-diagnostic Function Malfunction detection function • The malfunction detection section detects malfunctions occurring in the system. Memory function • The memory function detects a malfunction, changes it to a DTC, and stores it in the memory. The memory can store a maximum of three DTCs.
Page 465: Diagnostic Assist Function
ENTERTAINMENT Screen display Malfunction location Output signal 03: Er01 — CD player system 03: Er02 CHECK CD CD player system 03: Er07 CHECK CD CD player system 03: Er10 — CD player communication circuit system 05: Er01 — CD changer system 05: Er07 CHECK CD CD changer system...
Page 466 ENTERTAINMENT Button and switch • The diagnostic assist function sounds the buzzer when the buttons and switches are pressed to check their operating condition. E5U920ZS5012 Speaker With BOSE • The diagnostic assist function outputs sound to all the speakers to determine the operating condition of the speakers and wiring harnesses between the base unit and each speaker.
Page 467: Audio Amplifier Construction
ENTERTAINMENT AUDIO AMPLIFIER CONSTRUCTION E5U092066910N01 • Located under the rear package tray. • A digital amplifier has been adopted. • Converts music signals (analog voltage waves) output from an audio unit, into digital pulse signals, and then amplifies and outputs them. Terminal Layout and Signal Signal Terminal...
Page 468: Tweeter Construction
ENTERTAINMENT TWEETER CONSTRUCTION E5U092068966N01 • Tweeters (high-frequency speaker) are installed in the door trim, providing wide-range sound. End Of Sie DOOR UPPER SPEAKER CONSTRUCTION E5U092068966N02 • The door upper speakers (speakers for middle and upper register sound range) have been installed to the upper part of the left and right doors, improving the sound quality and output.
Page 469 POWER SYSTEMS 09–21 POWER SYSTEMS POWER SYSTEMS OUTLINE..09–21–1 POWER SYSTEMS STRUCTURAL VIEW ....09–21–1 End of Toc POWER SYSTEMS OUTLINE E5U092167730N01 •...
Page 471 INSTRUMENTATION/DRIVER INFO. 09–22 INSTRUMENTATION/DRIVER INFO. INSTRUMENT CLUSTER OUTLINE..09–22–1 BURNT OUT BULB CHECK FUNCTION INSTRUMENT CLUSTER OUTLINE ......09–22–11 SPECIFICATIONS .
Page 472 INSTRUMENTATION/DRIVER INFO. INSTRUMENT CLUSTER SPECIFICATIONS E5U092255430N02 Item Specification Meter type Stepping motor type Indication range (mph {km/h}) 0—150 {0—240} Speedometer Input signal communication system CAN system Input signal source Rated voltage DC 12 Meter type Stepping motor type Indication range (rpm) 0—7,500 Red zone...
Page 473: Instrumentation/Driver Info
INSTRUMENTATION/DRIVER INFO. Item Specification Sound frequency (Hz) 1,800—2,600 Output sound pressure level (dB) 54.0—70.0 Sound frequency (Hz) 1,900 CONTINUOUS Lights-on reminder warning alarm Sound cycle Sound frequency (Hz) 2,400 WHEN IGNITION SWITCH TURNED ON t1: approx. 0.7 s t2: approx. 1 s t3: approx.
Page 474: Instrument Cluster Structural View
INSTRUMENTATION/DRIVER INFO. INSTRUMENT CLUSTER STRUCTURAL VIEW E5U092255430N03 Meter And Gauge OIL PRESSURE GAUGE TACHOMETER SPEEDOMETER PANEL LIGHT CONTROL SWITCH TRIPMETER SWITCH FUEL GAUGE ODOMETER/TRIPMETER WATER TEMPERATURE GAUGE E5U922ZS5001 Warning And Indicator Light BRAKE E5U922ZS5014 09–22–4...
Page 475 INSTRUMENTATION/DRIVER INFO. ×: Applicable Warning and indicator Input signal source CAN system Note light × — • DSC HU/CM × ABS warning light — • ABS HU/CM × DSC OFF light DSC HU/CM With DSC × DSC indicator light DSC HU/CM With DSC ×...
Page 476: Instrument Cluster System Wiring Diagram
INSTRUMENTATION/DRIVER INFO. INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM E5U092255430N04 INSTRUMENT CLUSTER ILLUMINATION WATER TEMPERATURE GAUGE TACHOMETER FUEL GAUGE SPEEDOMETER OIL PRESSURE GAUGE CAN SYSTEM- RELATED MODULE ODOMETER/TRIPMETER IGNITION KEY ILLUMINATION TO ILLUMINATION LIGHT BULBS KEY REMINDER SWITCH MICRO- VEHICLE SPEED COMPUTER SIGNAL OUTPUT PANEL LIGHT CONTROL SWITCH KEYLESS...
Page 477 INSTRUMENTATION/DRIVER INFO. BUCKLE SWITCH (DRIVER'S SIDE) BUCKLE SWITCH AIR BAG SYSTEM (PASSENGER'S SIDE) WARNING LIGHT SEAT WEIGHT SENSOR TURN INDICATOR CONTROL LIGHT (LH) MODULE SAS CONTROL MODULE TURN INDICATOR LIGHT (RH) FLASHER CONTROL MODULE KEYLESS CONTROL MODULE SECURITY LIGHT TURN SWITCH KEYLESS TURN LIGHT WARNING LIGHT...
Page 478: Input/Output Check Mode Outline
INPUT/OUTPUT CHECK MODE OPERATION E5U092255430N06 Operation procedure • Refer to Mazda MX-5 Workshop Manual. Input circuit check • When the parts listed in the chart are operated and a signal is output to the instrument cluster, the built-in microcomputer determines the operability of the input circuit based on that signal.
Page 479: Pid/Data Monitor And Record
INSTRUMENTATION/DRIVER INFO. TACHOMETER WATER WARNING AND ILLUMINATION TEMPERATURE SPEEDOMETER BUZZER INDICATOR LIGHT LIGHT BULB FUEL GAUGE OIL PRESSURE GAUGE GAUGE MICROCOMPUTER INSTRUMENT CLUSTER E5U922ZS5005 PID/Data Monitor and Record • The PID/data monitoring items for the instrument cluster is as shown in following the table: Monitor item table —: Not applicable Input-output signal/part...
Page 480: Lights-On Reminder Warning Alarm Outline
INSTRUMENTATION/DRIVER INFO. LIGHTS-ON REMINDER WARNING ALARM OUTLINE E5U092255430N07 • Warns the driver that the headlights or TNS are on when the driver-side door is opened. End Of Sie LIGHTS-ON REMINDER WARNING ALARM CONSTRUCTION/OPERATION E5U092255430N08 System Wiring Diagram Operation • The buzzer in the instrument cluster sounds continuously when all the following three conditions are met: RELAY...
Page 481: Key Reminder Warning Alarm Outline
INSTRUMENTATION/DRIVER INFO. KEY REMINDER WARNING ALARM OUTLINE E5U092255430N11 • Warns the driver that the key is in the steering lock when the driver-side door is opened. End Of Sie KEY REMINDER WARNING ALARM CONSTRUCTION/OPERATION E5U092255430N12 System Wiring Diagram Operation • The buzzer in the instrument cluster sounds when KEY REMINDER SWITCH all the following three conditions are met:...
Page 482: Speedometer Control Outline
INSTRUMENTATION/DRIVER INFO. SPEEDOMETER CONTROL OUTLINE E5U092255430N17 • The vehicle speed signal is output from the PCM to the microcomputer in the instrument cluster. End Of Sie SPEEDOMETER CONTROL CONSTRUCTION/OPERATION E5U092255430N18 System Wiring Diagram IG1 B+ Operation • The vehicle speed signal sent from the PCM via the CAN system is input to the microcomputer in the instrument cluster.
Page 483: Fuel Gauge Control Outline
INSTRUMENTATION/DRIVER INFO. FUEL GAUGE CONTROL OUTLINE E5U092255430N21 • The fuel level signal is output from the fuel gauge sender unit to the microcomputer in the instrument cluster. Fuel gauge variation caused by fluctuating fuel level when cornering or driving on a slope, is reduced by microcomputer control.
Page 484: Oil Pressure Gauge Control Outline
INSTRUMENTATION/DRIVER INFO. OIL PRESSURE GAUGE CONTROL OUTLINE E5U092255430N25 • The engine coolant temperature signal and engine speed signal are output from the PCM to the microcomputer in the instrument cluster. End Of Sie OIL PRESSURE GAUGE CONTROL CONSTRUCTION/OPERATION E5U092255430N26 System Wiring Diagram IG1 B+ Operation •...
Page 485 CONTROL SYSTEM 09–40 CONTROL SYSTEM CONTROLLER AREA NETWORK (CAN) Twisted Pair ..... . 09–40–2 SYSTEM OUTLINE ....09–40–1 Time Division Multiplex .
Page 486 CONTROL SYSTEM CAN SYSTEM DESCRIPTION E5U094055430N04 Mechanism of CAN System-Related Module • A CAN system-related module is composed of an electrical circuit, CPU, and input/output interface. • The size of the module has been reduced due to the elimination of the bulky, superfluous, input/output interface in the conventional type of electrical module.
Page 487 CONTROL SYSTEM Time Division Multiplex • For information exchange between electrical modules in a conventional system, a wire connection was necessary for each information signal. However, by sending the different signal at varying times over one channel, it is possible to send a large amount of information via a small wiring harness. •...
Page 488 CONTROL SYSTEM CAN Signal-Chart OUT: Output (sends signal) IN: Input (receives signal) Multiplex module ABS HU/CM Keyless Steering Signal Instrument or DSC HU/ control angle cluster module sensor Engine speed IN (DSC) – Vehicle speed – – – – Engine coolant temperature –...
Page 489 CONTROL SYSTEM On-Board Diagnostic Function • The on-board diagnostic function is incorporated into the following module: — PCM — TCM — DSC HU/CM (with DSC) — ABS HU/CM (with ABS) — Keyless control module — Steering angle sensor — Instrument cluster •...
Page 490 CONTROL SYSTEM DTC table Malfunction location DTC output module • PCM • TCM • ABS HU/CM U0073 CAN system communication error • DSC HU/CM • Keyless control module • Instrument cluster • TCM • DSC HU/CM U0100 Communication error to PCM •...
Page 491 CONTROL SYSTEM Example (PCM-related communication error) Note • This example is for MT with DSC. 1. DTCs for the PCM, DSC HU/CM, steering angle sensor and instrument cluster can be verified using the WDS or equivalent. Module Displayed DTC Probable malfunction location U0073 PCM-related CAN system malfunction U0121...

Mazda 2006 MX-5 Service Highlights

00 General Information

Aim of Development

Vehicle Identification Number (Vin) Code

Vehicle Identification Numbers

Units

Sae Standard

01 Engine

01-00 Outline

Engine Abbreviations [Lf]

On-Board Diagnostic 01-02 On-Board Diagnostic

On-Board Diagnostic

Diagnostic System Wiring Diagram [Lf]

Diagnostic Test Mode [Lf]

Dtc Detection Logic and Conditions [Lf]

Koeo/Koer Self-Test [Lf]

Mechanical 01-10 Mechanical

Intake-Air System 01-13 Intake-Air System

Fuel System 01-14 Fuel System

Fuel System Outline [Lf]

01-14 Fuel System

Nonreturn Valve Function

Fuel System Flow Diagram

Emission System 01-16 Emission System

Emission System

Rollover Valve

Fuel Shut-Off Valve

Charcoal Canister

Air Filter

Table of Contents

On-Board Diagnostic 02-02 On-Board Diagnostic

Wheel and Tires 02-12 Wheel and Tires

Quick Links

Chapters

Related Manuals for Mazda 2006 MX-5

Summary of Contents for Mazda 2006 MX-5