Mazda 6 Facelift 2005 Training Manual
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Mazda 6 Facelift 2005 Training Manual

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TRAINING MANUAL
Mazda6 Facelift

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Summary of Contents for Mazda 6 Facelift 2005

  • Page 1 TRAINING MANUAL Mazda6 Facelift...
  • Page 2 No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print.
  • Page 3 Contents Title Section General Information Engine Suspension Brakes Transmission / Transaxle Restraints Body & Accessories Service Training Mazda6 Facelift...
  • Page 4 Service Training Mazda6 Facelift...

  • Page 5: General Information

    General Information...

  • Page 6: Table Of Contents

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

  • Page 7: Vehicle Identification Number (Vin) Code

    General Information Vehicle Identification Number (VIN) Code JMZ GG 1 2 3 2 0 1 2 3 4 5 6 Serial No. 0= Hiroshima Plant 1= Hofu Dummy 0, 6 to 9, A to Z 2= 5MTX 6= 6MTX 7= 5ATX Transmission 3= 2.3L (L3) 8= 1.8L (L8)

  • Page 8: Engine / Transaxle Combinations

    General Information Engine / Transaxle Combinations • All engines have been revised. New transaxles have been added to the range. The following engine/transaxle combinations are available: JA5AX-EL FS5A-EL G35M-R G66M-R A26M-R 5-speed 5-speed automatic 5-speed 6-speed 6-speed automatic transaxle manual manual manual transaxle...

  • Page 9: Scheduled Maintenance

    General Information Scheduled Maintenance Europe Maintenance interval (number of momths or km (miles) which ever comes first) Months Maintenance items X1000 km X1000 miles 12,5 37,5 62,5 87,5 112,5 PETROL ENGINE Engine valve clearance Audible inspect every 120,000km (75,000 miles), if noisy adjust Spark plugs Replace every 100,000km (62,500miles) Air cleaner element...

  • Page 10: Brakes

    General Information Remarks: *1 If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air filter more often than the recommended intervals. *2 Replacement of the timing belt is required at every 120,000 km (75,000 miles). Failure to replace the timing belt may result in damage to the engine.
  • Page 11 Engines...
  • Page 12 01 Engine Table of Contents Petrol Engines Mechanics ......................1 Cylinder Head Cover..................1 Valve Mechanism....................2 Lubrication ......................3 Intake-Air System ....................4 Electronic Throttle Control................5 Exhaust System....................6 Charging System....................7 Generator Design....................7 Generator Electrical Diagram ..............8 Ignition System....................9 Engine Control System ..................10 Structural View....................10 Powertrain Control Module (PCM) ..............11 PCM Connector (Harness Side Shown) ..........11 Overview .......................12...
  • Page 13 01 Engine Table of Contents (continued) Oil Dipstick ....................35 Oil Dilution Calculation ..................36 Oil Cooler and Oil Filter.................37 Cooling System ....................39 Specifications....................39 Parts Location ....................40 Intake-air System....................41 Parts Location ....................41 Turbocharger ....................42 Manifold Absolute Pressure Sensor..............43 Fuel System .......................44 Parts Location ....................44 Common Rail ....................45 Injectors ......................46 Injector Correction Factors ..............48...
  • Page 14 01 Engine Table of Contents (continued) Charging System....................77 Specifications....................77 Parts Location ....................77 Smart Charging System ................78 Control System....................79 Parts Location ....................79 Wiring Diagram .....................82 Powertrain Control Module................86 Crankshaft Position Sensor................87 Camshaft Position Sensor................88 Accelerator Pedal Position Sensor..............89 Power Steering Pressure Switch..............92 Service And Repair ..................93 Replacing the Engine Oil ................93 Manual Regeneration ................93...

  • Page 15: Petrol Engines

    Engine Petrol Engines Mechanics M6FL_01057 Cylinder Head Cover • The cylinder head cover is made of plastic. On LF and L3 engines a hole is provided for installation of the OCV (Oil Control Valve). • A dipstick insertion hole has been equipped to the cylinder head cover. M6FL_01001 CMP (Camshaft Position) sensor OCV attachment hole (LF, L3)

  • Page 16: Valve Mechanism

    Petrol Engines Engine Valve Mechanism • For the LF engine the variable valve timing system has been carried over from the L3 engine. • All engines use a sensor ring with 6 reference cams for the CMP Sensor on the intake camshaft.

  • Page 17: Lubrication

    Engine Petrol Engines Lubrication • The lubrication system has been carried over from the previous engines. Depending on specification, both spin-on and cartridge type oil filters are available. • The oil cooler is now installed on both the L3 and the LF engine. M6FL_01003 Oil pump chain tensioner Oil jet valve...

  • Page 18: Intake-Air System

    Petrol Engines Engine Intake-Air System • The intake-air system has been basically carried over from the previous engines. It comprises: – VTCS (Variable Tumble Control System) (L8, LF, L3) – VIS (Variable Intake-air System) (LF, L3) – VAD (Variable Air Duct) (L3) •...

  • Page 19: Electronic Throttle Control

    Engine Petrol Engines Electronic Throttle Control • All engines are using an electronically controlled throttle body, which is quite similar to the one on RX-8. This supersedes the IAC (Idle Air Control) valve. • To keep moisture from freezing inside the throttle body, and thus to prevent the throttle valve from getting stuck, engine coolant is circulated through the throttle body.

  • Page 20: Exhaust System

    Petrol Engines Engine Exhaust System • The exhaust system has been carried over from the previous Mazda6. • Vehicles specified with LF engine are now using the exhaust system with two main silencers (previously used on L3 engines only). M6FL_01006 Main silencer HO2S (front) Middle pipe...

  • Page 21: Charging System

    Engine Petrol Engines Charging System Generator Design • Generator control is carried out by the PCM (Powertrain Control Module). Excitation current in the field coil is increased or decreased by the power transistor built into the generator. The power transistor is controlled by a duty signal from the PCM. •...

  • Page 22: Generator Electrical Diagram

    Petrol Engines Engine Generator Electrical Diagram • Two delta connection type stator coils have been introduced. Due to this, the generator operation noise (electrical noise) is reduced and pulsation occurring through voltage rectifying in the stator coil is minimized, as a result, stable voltage output is supplied. •...

  • Page 23: Ignition System

    Engine Petrol Engines Ignition System • The petrol engines use direct ignition coils which are installed directly to each spark plug. 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 24: Engine Control System

    Petrol Engines Engine Engine Control System Structural View M6FL_01010 Purge valve PCM (LHD) HO2S (front, rear) VAD solenoid valve (L3) ECT (Engine Coolant Temperature) Neutral switch (MTX (Manual sensor Transaxle)) APP (Accelerator Pedal Position) sensor TR (Transmission Range) switch (ATX ( Automatic Transaxle)) Brake switch TP sensor, throttle actuator...

  • Page 25: Powertrain Control Module (Pcm)

    Engine Petrol Engines Powertrain Control Module (PCM) • A PCM with integral BARO (Barometric Pressure) sensor has been introduced. It is installed on the left-hand side under the dashboard. • Right-hand-drive vehicles have two additional PCM covers secured with set bolts. M6FL_01011 PCM connectors PCM Connector (Harness Side Shown)

  • Page 26: Overview

    Petrol Engines Engine Overview M6FL_01013 01-12 Service Training Mazda6 Facelift...
  • Page 27 Engine Petrol Engines ECT sensor APP sensor HO2S (front) VAD shutter valve (L3) Knock sensor Air cleaner EGR valve MAF sensor Fuel injector VAD shutter valve actuator (L3) OCV (LF, L3) VAD solenoid valve (L3) CMP sensor Vacuum chamber Charcoal canister VAD check valve (one-way) (L3) Fuel pump (transfer) TP sensor...

  • Page 28: Wiring Diagram

    Petrol Engines Engine Wiring Diagram M6FL_01014 01-14 Service Training Mazda6 Facelift...
  • Page 29 Engine Petrol Engines IAT sensor Rear HO2S heater MAF sensor A/C (Air Conditioning) relay Fuel pump APP sensor Main relay Cruise control switch Coil antenna Refrigerant pressure switch (medium) Security light Refrigerant pressure switch (high and low) Drive-by-wire relay Brake switch No.1 Ignition switch Brake switch No.2 Battery...
  • Page 30 Petrol Engines Engine Wiring Diagram (Continued) M6FL_01015 01-16 Service Training Mazda6 Facelift...
  • Page 31 Engine Petrol Engines EGR valve PSP (Power Steering Pressure) switch VTCS solenoid valve CKP sensor VIS solenoid valve CMP sensor Throttle actuator Generator Ignition coil No.1 Front HO2S Ignition coil No.2 MAP sensor Ignition coil No.3 ECT sensor Ignition coil No.4 TP sensor Fuel injector No.1 Front HO2S heater...

  • Page 32: Accelerator Pedal Position (App) Sensor

    Petrol Engines Engine Accelerator Pedal Position (APP) Sensor • The APP sensor uses Hall elements to detect accelerator pedal movement. This non- contact sensor type improves durability. • The APP sensor is composed of a main sensor and a sub sensor, and detects the accelerator actuating angle with these two sensors (main and sub).
  • Page 33 Engine Petrol Engines • The main sensor outputs a duty signal, and the sub sensor outputs a voltage signal. • Even if a malfunction occurs in either one of the sensors, the detection is performed and drive-by-wire control is maintained. •...

  • Page 34: Throttle Valve Actuator

    Petrol Engines Engine Throttle Valve Actuator • By controlling the throttle actuator, the PCM sets an optimal throttle valve opening angle according to the engine conditions. • The PCM calculates a target throttle valve opening angle based on the accelerator pedal depression amount.

  • Page 35: Throttle Position (Tp) Sensor

    Engine Petrol Engines Throttle Position (TP) Sensor • The TP sensor is built into the throttle body and detects the throttle valve opening angle. • The TP sensor uses Hall elements to detect throttle valve movement. This non-contact sensor type improves durability. •...

  • Page 36: Tp Sensor Voltage Characteristics

    Petrol Engines Engine TP Sensor Voltage Characteristics M6FL_01019 TP sensor No.1 Throttle opening angle TP sensor No.2 Output voltage Large High 01-22 Service Training Mazda6 Facelift...

  • Page 37: Heated Oxygen Sensors (Ho2S)

    Engine Petrol Engines Heated Oxygen Sensors (HO2S) • Heated oxygen sensors are installed on the front and back of the TWC (Three-Way Catalyst). • The front HO2S is a wide-range air/fuel ratio sensor, which can linearly detect the oxygen concentration in the exhaust gas in all ranges, from lean to rich (air/fuel mixture). •...

  • Page 38: Front Ho2S

    Petrol Engines Engine Front HO2S • The front HO2S is a wide-range oxygen sensor, and can detect the oxygen concentration in the exhaust gas in all ranges, from lean to rich (air/fuel mixture). • A heater is built into the sensor to facilitate the activation of the HO2S at engine startup (when the exhaust gas temperature is low).

  • Page 39: Rear Ho2S

    Engine Petrol Engines Rear HO2S • A zirconium element is used on the sensor. When there is a difference between the oxygen concentration inside and outside the element, electromotive force is generated by the movement of oxygen ions (inside of the zirconium element: atmosphere, outside: exhaust gas).

  • Page 40: Crankshaft Position (Ckp) Sensor

    Petrol Engines Engine Crankshaft Position (CKP) Sensor • The CKP sensor is installed near the crankshaft pulley. • The crankshaft position sensor pulse wheel has 30 projections with 10° of crank angle between the rising edge of each projection. M6FL_01023 CKP Sensor Crankshaft Pulley 01-26...
  • Page 41 Engine Petrol Engines • The CKP sensor consists of an IC (Integrated Circuit) with a GMR (Giant Magneto Resistive) element and an integrated signal processing circuit, and a magnet. Signal reliability has been improved with the adoption of the GMR element resulting in the signal amplitude being wider compared to the Hall element.

  • Page 42: Camshaft Position (Cmp) Sensor

    Petrol Engines Engine Camshaft Position (CMP) Sensor • The CMP sensor is installed on the cylinder head cover. • Six pulses per one camshaft rotation are detected. • The CMP sensor uses the same operating principle like the CKP sensor. M6FL_01025 CMP sensor CMP output signal...

  • Page 43: Mechanics

    Engine Diesel Engines Mechanics • The mechanical system of the 2.0 MZR-CD engine basically has been carried over from previous model ranges. M6FL_01030 Service Training Mazda6 Facelift 01-29...

  • Page 44: Pistons

    Diesel Engines Engine Pistons • Pistons with a modified combustion chamber have been introduced to achieve a lower compression ratio of 16.7. This leads to lower pumping losses and optimized thermal efficiency at middle and high engine load, improving the fuel consumption. M6FL_01052 Coating Combustion chamber...

  • Page 45: Cylinder Head

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

  • Page 46: Lubrication

    Oil and oil filter replacement L (US qt, lmp qt) 5.1 (5.4, 4.5) M6FL_01T009 Engine Oil Item Specification Grade ACEA C1 or JASO DL-1 Viscosity SAE 5W-30 Recommended oil e.g. Mazda genuine Dexelia DPF M6FL_01T010 01-32 Service Training Mazda6 Facelift...
  • Page 47 Engine Diesel Engines Parts Location M6FL_01031 Oil filter Oil pan Oil cooler Oil strainer O-ring Gasket Oil jet valve Oil pressure switch Oil drain plug Oil pump Sealing washer Service Training Mazda6 Facelift 01-33...

  • Page 48: Engine Oil

    M5_01058 Service life of DPF Ash amount in the DPF Normal engine oil (ACEA A3/B3/B4) Mazda low SAPS oil (ACEA C1) Conventional low SAPS oil (ACEA C2/C3) DPF blocked with ash 01-34 Service Training Mazda6 Facelift...

  • Page 49: Oil Dipstick

    Engine Diesel Engines Oil Dipstick • Since the fuel post-injections required to regenerate the DPF can lead to an excessively high engine oil dilution, an “X” mark has been added to the oil dipstick to make the customer aware of this condition. If the oil level is close to or exceeds the “X” mark, the engine oil must be replaced.

  • Page 50: Oil Dilution Calculation

    Diesel Engines Engine Oil Dilution Calculation • The PCM calculates the oil dilution amount based on the duration of the regeneration process and the regeneration intervals. • If the engine oil level reaches a certain limit due to oil dilution, DTC P252F is stored in the PCM but no warning light is illuminated.
  • Page 51 Engine Diesel Engines • The different conditions of the oil dilution are shown in the following table. Engine oil dilution Item Engine oil level Flashes every 0.4 s DPF indicator light — — — — — Max. 150 km/h (93 mph) Output restriction —...

  • Page 52: Oil Cooler And Oil Filter

    Diesel Engines Engine Oil Cooler and Oil Filter • The oil cooler and the oil filter are now located at the rear of the engine. M6FL_01032 External view Engine coolant flow direction Cut-view A-A 01-38 Service Training Mazda6 Facelift...

  • Page 53: Cooling System

    Engine Diesel Engines Cooling System Specifications Item Specification Type Water-cooled Coolant capacity (approx. quantity) Water pump Type Centrifugal, Timing belt-driven Type Wax, bottom-bypass Opening temperature °C (°F) 80-84 (176-183) Thermostat Full-open temperature °C (°F) 95 (203) Full-open lift mm (in) 8.5 (0.33) or more Radiator Type...

  • Page 54: Parts Location

    Diesel Engines Engine Parts Location M6FL_01061 Cooling system cap Cooling fan No.2 Radiator Radiator cowling Thermostat Cooling fan motor No.1 Water pump Cooling fan motor No.2 Cooling fan component Coolant reserve tank Cooling fan No.1 01-40 Service Training Mazda6 Facelift...

  • Page 55: Intake-Air System

    Engine Diesel Engines Intake-air System • The intake-air system of the vehicles with 2.0 MZR-CD engine has the following features: – MAF learning function has been cancelled. – Turbocharger with variable geometry turbine and reduced turbine diameter has been introduced. –...

  • Page 56: Turbocharger

    Diesel Engines Engine Turbocharger • A turbocharger with variable geometry turbine and reduced turbine diameter has been introduced. This leads to a lower inertia moment of the turbine, improving the response of the engine during acceleration. M6FL_01064 VBC vacuum actuator Exhaust gas flow Intake air flow 01-42...

  • Page 57: Manifold Absolute Pressure Sensor

    Engine Diesel Engines Manifold Absolute Pressure Sensor • A MAP sensor located above the intake manifold has been introduced. M6FL_01065 Intake manifold MAP sensor Service Training Mazda6 Facelift 01-43...

  • Page 58: Fuel System

    Diesel Engines Engine Fuel System • The fuel system of the vehicles with 2.0 MZR-CD engine has the following features: – Common rail located above the intake manifold has been introduced. – Solenoid valve-type injectors with injector correction factors have been introduced. –...

  • Page 59: Common Rail

    Engine Diesel Engines Common Rail • A common rail located above the intake manifold has been introduced. M6FL_01067 Common rail Fuel pressure sensor Pressure limiter valve Connections (fuel injector-side) Connections (high-pressure pump-side) Service Training Mazda6 Facelift 01-45...

  • Page 60: Injectors

    Diesel Engines Engine Injectors • Solenoid valve-type injectors with lower power consumption and better response have been introduced. M6FL_01068 From common rail To fuel tank Connector NOTE: Since the size of the injector connector is relatively big compared to the diameter of the injector head, there might be an interference between the connector and the injector seal during removal and installation of the cylinder head cover.
  • Page 61 Engine Diesel Engines • The injectors are directly driven by the PCM. The module has a high-voltage generator inside, which amplifies the battery voltage into a high voltage of approx. 90 V and stores it in a capacitor. A control circuit outputs the high voltage to the injectors as a drive signal.

  • Page 62: Injector Correction Factors

    Diesel Engines Engine • When the required injection amount is small, the PCM outputs a short drive signal to the injectors. As a result, the opening time of the injectors is short, resulting in a small injection amount. • When the required injection amount is large, the PCM outputs a long drive signal to the injectors.

  • Page 63: Injection Amount Learning Function

    Engine Diesel Engines NOTE: When re-installing the injectors after a repair, they must be matched to the cylinders they were removed from. Therefore make a note of the injector correction factors and the allocated cylinders before removing the injectors. Failure to follow this instruction may cause irregular idling, increased combustion noise and/or increased black smoke emissions.

  • Page 64: Emission System

    Diesel Engines Engine Emission System Parts Location M6FL_01071 Oxidation catalytic converter and diesel Intake shutter valve particulate filter EGR cooler EGR valve 01-50 Service Training Mazda6 Facelift...

  • Page 65: Exhaust System

    Engine Diesel Engines Exhaust System • The exhaust system of the vehicles with 2.0 MZR-CD engine has the following features: – Warm-up oxidation catalytic converter has been cancelled. – Diesel particulate filter integrated in the housing of the oxidation catalytic converter has been introduced.

  • Page 66: Exhaust Gas Recirculation System

    Diesel Engines Engine Exhaust Gas Recirculation System • The exhaust gas recirculation system of the vehicles with 2.0 MZR-CD engine has the following features: – EGR valve with direct current motor and position sensor has been introduced. – EGR cooler located at the transmission-side of the engine has been introduced. –...
  • Page 67 Engine Diesel Engines • The position of the EGR valve is controlled by the PCM, which activates the DC motor via a duty signal. M6FL_01080 DC motor Current detection circuit • At low engine speeds the PCM controls the DC motor with a large duty cycle, so that the EGR valve opens and exhaust gas is recirculated.
  • Page 68 Diesel Engines Engine • The EGRVP (EGR Valve Position) sensor is integrated in the DC motor and detects its position by a sliding contact potentiometer. When the EGR valve opens the resistance of the potentiometer rises. The sensor supplies the PCM with an analogue voltage signal between 0…5 V.

  • Page 69: Egr Cooler

    Engine Diesel Engines EGR Cooler • An EGR cooler located at the transmission-side of the engine has been introduced. M6FL_01072 EGR valve From exhaust manifold To intake manifold Engine coolant flow EGR cooler Service Training Mazda6 Facelift 01-55...

  • Page 70: Intake Shutter Valve

    Diesel Engines Engine Intake Shutter Valve • An ISV (Intake Shutter Valve) with DC motor and position sensor has been introduced. A reduction gear ensures, that a large rotation angle of the motor results in a small rotation angle of the valve. •...
  • Page 71 Engine Diesel Engines • The position of the ISV is controlled by the PCM, which activates the DC motor via a duty signal. M6FL_01080 DC motor Current detection circuit • When the required EGR rate is high the PCM controls the DC motor with a large duty cycle.
  • Page 72 Diesel Engines Engine • In order to remove any deposits from the ISV a cleaning mode is activated each time the engine is shut off. Therefore, the PCM actuates the ISV so that it is moved from the fully open position to the fully closed position several times. This process takes approx. 10 s. •...

  • Page 73: Diesel Particulate Filter System

    Engine Diesel Engines Diesel Particulate Filter System • The diesel particulate filter system of the vehicles with 2.0 MZR-CD engine has the following features: – Diesel particulate filter with differential pressure sensor and three exhaust gas temperature sensors (upper/middle/lower) has been introduced. –...

  • Page 74: Diesel Particulate Filter

    Diesel Engines Engine • In comparison to the particulate matter limit for Euro 3 vehicles (0.05 g/km), the limit for Euro 4 vehicles (0.025 g/km) has been lowered by 50 %. In order to comply with the strict Euro 4 emission legislation, the Mazda6 with 2.0 MZR-CD engine is equipped with a diesel particulate filter system.
  • Page 75 Engine Diesel Engines • The DPF is a monolith made of silicon carbide ceramics, which features a high resistance against temperature fluctuations. The individual channels of the filter have porous dividing walls and are closed at alternative ends. As a result, the exhaust gas is forced to flow through the dividing walls, which retain the soot particles and allow gaseous components to pass.
  • Page 76 Diesel Engines Engine • The channels of the DPF are coated with platinum. This catalytic coating facilitates the regeneration of the filter by significantly lowering the light-off temperature of the soot and by accelerating the combustion of the particles. Without coating the burn-off of the particles takes place above a temperature of approx.

  • Page 77: Dpf Differential Pressure Sensor

    Engine Diesel Engines DPF Differential Pressure Sensor • The DPF differential pressure sensor detects the pressure difference in the exhaust gas flow upstream and downstream of the DPF. The pressure difference is a measure for the soot amount accumulated in the filter (i.e. the higher the pressure difference, the higher the soot amount).
  • Page 78 Diesel Engines Engine M5_01041 Oxidation catalytic converter Pipe connections for differential pressure sensor • The signal of the DPF differential pressure sensor is used to determine, whether the soot amount requires regeneration of the filter. In addition, the signal serves to monitor the regeneration process.
  • Page 79 Engine Diesel Engines • In addition, the DPF differential pressure sensor features a temperature correction sensor, which is located on the bracket of the differential pressure sensor and detects the temperature in the engine compartment. The sensor is a temperature-resistive resistor with NTC (Negative Temperature Coefficient), i.e.

  • Page 80: Diagnostics

    Diesel Engines Engine Diagnostics • Since the filter itself creates a certain resistance in the exhaust gas flow, the signal of the DPF differential pressure sensor is also used to determine the filter condition. M6FL_01062 Exhaust-gas volume flow Differential pressure Blocked condition of filter Regenerated condition of filter Overloaded condition of filter...
  • Page 81 Engine Diesel Engines • If the value measured by the DPF differential pressure sensor is below a certain limit, the DPF is recognized as being damaged. Then the PCM stores a corresponding DTC, illuminates the MIL and activates the limp home mode. •...

  • Page 82: Exhaust Gas Temperature Sensors

    Diesel Engines Engine Exhaust Gas Temperature Sensors • The three exhaust gas temperature sensors (upper/middle/lower) are located in the combined housing of the oxidation catalytic converter/DPF and detect the temperature of the exhaust gas upstream of the oxidation catalytic converter, as well as upstream and downstream of the DPF.
  • Page 83 Engine Diesel Engines • The signal of the upper exhaust gas temperature sensor allows checking, whether the exhaust gas temperature required for operation of the oxidation catalytic converter is reached. • The signal of the middle exhaust gas temperature sensor is used to determine, whether the exhaust gas temperature required for regeneration of the filter is reached.

  • Page 84: Heated Oxygen Sensor

    Diesel Engines Engine Heated Oxygen Sensor • The HO2S is located behind the DPF and detects the oxygen concentration in the exhaust gas. The HO2S is a wide range type oxygen sensor and uses the same operating principle as the wide range oxygen sensors on petrol engines. It generates a clear electrical signal in a wide range from λ...
  • Page 85 Engine Diesel Engines • The HO2S supplies the PCM with a current between -1.8…+1.8 mA. M6FL_01086 Excess-air factor λ Current • Since the HO2S only generates a usable signal above a certain temperature, it features an integral heater element. The temperature of the HO2S is controlled by the PCM, which activates the heater element via a duty signal.

  • Page 86: Dpf Indicator Light

    Diesel Engines Engine • At low exhaust gas temperatures the PCM controls the heater element by a large duty cycle, so that the required operating temperature is reached quickly. • At high exhaust gas temperatures the PCM controls the heater element by a small duty cycle, so that no heating takes place.

  • Page 87: Regeneration Control

    Engine Diesel Engines Regeneration Control • The regeneration control determines the soot amount accumulated in the DPF and subsequently starts the regeneration process. The regeneration control is integrated in the PCM. Soot Amount Calculation • The PCM receives information about the soot amount accumulated in the filter from the DPF differential pressure sensor.
  • Page 88 Diesel Engines Engine NOTE: Do NOT perform automatic regeneration when the soot accumulation rate in the DPF is 100 % or more, since this may cause damage to the filter or the engine. • If the soot accumulation rate in the DPF reaches 140 % or more, the MIL also illuminates and DTC P242F is stored in the PCM.

  • Page 89: Regeneration Process

    Engine Diesel Engines Regeneration Process • Due to the effect of the catalytic coating the diesel particles are burnt off above a temperature of 500 °C. Since the exhaust gas temperature during normal driving is between 150…400 °C (depending on the engine operating conditions), it must be increased artificially by external intervention from the engine management system to start the regeneration process.

  • Page 90: Regeneration Intervals

    Diesel Engines Engine Regeneration Intervals • Depending on the operating conditions of the vehicle the DPF is regenerated every 100…300 km. Due to the ash residues that have formed from the engine oil and diesel fuel the usable filter volume is reduced. Since the ash amount accumulated in the DPF increases with every regeneration process, the regeneration intervals become shorter with rising mileage.

  • Page 91: Charging System

    Engine Diesel Engines Charging System • The charging system of the vehicles with 2.0 MZR-CD engine has the following feature: – Smart charging system has been introduced. Specifications Item Specification Voltage Battery Type and capacity (Ah) 95D31L (64), 115D31L (70) (5-hour rate) Output (V-A)

  • Page 92: Smart Charging System

    Diesel Engines Engine Smart Charging System • A so-called "Smart Charging System” has been introduced to improve battery charging and durability. The exciting current of the field coil and hence the charging voltage is controlled by the PCM, which actuates the generator by a duty signal. In addition, the generator sends a feedback signal to the PCM, which hereby monitors the generator load.

  • Page 93: Control System

    Engine Diesel Engines • When the battery voltage/battery electrolyte temperature is high and/or the generator load is low, the PCM controls the generator with a small duty cycle. As a result, a low exciting current flows through the field coil and the generator outputs a low charging voltage.

  • Page 94: Parts Location

    Diesel Engines Engine Parts Location M6FL_01079 01-80 Service Training Mazda6 Facelift...
  • Page 95 Engine Diesel Engines Main fuse block Generator Starter relay Fuel pressure sensor Cooling fan relay No.1 Glow plug PCM control relay (main relay) MAP sensor Cooling fan relay No.2 Fuel injectors A/C relay Refrigerant pressure switch Glow plug relay Temperature correction sensor Exhaust gas temperature sensors DPF differential pressure sensor HO2S...

  • Page 96: Wiring Diagram

    Diesel Engines Engine Wiring Diagram M6FL_01076 01-82 Service Training Mazda6 Facelift...
  • Page 97 Engine Diesel Engines DPF differential pressure sensor A/C relay Temperature correction sensor Glow plug relay Exhaust gas temperature sensor (upper) Glow plugs Exhaust gas temperature sensor (middle) Cooling fan relay No.2 Exhaust gas temperature sensor (lower) Cooling fan relay No.1 CKP sensor Generator CMP sensor...
  • Page 98 Diesel Engines Engine Wiring Diagram (Continued) M6FL_01077 01-84 Service Training Mazda6 Facelift...
  • Page 99 Engine Diesel Engines Oxygen sensor heater IAT sensor No.2 MAF/IAT sensor Immobilizer-related information IAT sensor VBC solenoid valve MAF sensor Suction control valve Refrigerant pressure switch PCM control relay (main relay) Neutral switch Engine switch (IG1) Clutch switch Engine switch (IG2) PSP switch Engine switch (START) Starter relay...

  • Page 100: Powertrain Control Module

    Diesel Engines Engine Powertrain Control Module • The PCM is located behind a cover in the left-hand-side footwell and features a 121-pin (two-block) connector. NOTE: When replacing the PCM, several steps must be performed to ensure its proper function (refer to the section “Control System, Service and Repair”). M6FL_01075 Wiring harness side-connector of the PCM •...

  • Page 101: Crankshaft Position Sensor

    Engine Diesel Engines Crankshaft Position Sensor • A GMR-type CKP sensor has been introduced, which is located at the rear side of the clutch housing. The sensor consists of two GMR elements and a magnet, which scan a rotor with 56 teeth, missing five teeth in one location. The rotor is integrated in the flywheel.

  • Page 102: Camshaft Position Sensor

    Diesel Engines Engine Camshaft Position Sensor • A GMR-type CMP sensor has been introduced, which is located at the vacuum pump. The sensor consists of two GMR elements and a magnet, which scan a rotor with five teeth. The rotor is attached to the drive gear of the power steering oil pump. NOTE: When the CMP sensor is faulty, this can be recognized by the increased engine noise (Diesel knocking).

  • Page 103: Accelerator Pedal Position Sensor

    Engine Diesel Engines Accelerator Pedal Position Sensor • A Hall-type APP sensor has been introduced. For safety reasons the APP sensor consists of two Hall elements integrated in the stator and a magnetic rotor joint to the accelerator pedal. NOTE: If one Hall-type sensor fails, the PCM uses the signal from the other sensor to detect the driver’s acceleration demand.
  • Page 104 Diesel Engines Engine • When the magnetic rotor rotates, a voltage is generated in the Hall elements. As the Hall voltage is very low, it is amplified in the sensor and input to the PCM. M5_01057 Sensor body Magnetic rotor Stator with Hall elements Shaft 01-90...
  • Page 105 Engine Diesel Engines • Each Hall-type sensor supplies the PCM with an analogue voltage signal between 0…5 V. In order to facilitate failure detection there is a voltage offset of 0.5 V between both signals. M6FL_01088 APP sensor Service Training Mazda6 Facelift 01-91...

  • Page 106: Power Steering Pressure Switch

    Diesel Engines Engine Power Steering Pressure Switch • A PSP switch located at the power steering oil pump has been introduced to detect the load condition of the power steering. If the power steering oil pressure exceeds a given value, the switch closes and supplies the PCM with a voltage signal of 0 V. M5_01065 PSP switch Power steering oil pump...

  • Page 107: Service And Repair

    Engine Diesel Engines Service and Repair Replacing the Engine Oil • Every time the engine oil is replaced, the parameter “Calculated oil dilution” in the PCM must be reset with the aid of WDS. Therefore, select the option Toolbox Powertrain Data Reset Engine Oil. Manual Regeneration •...

  • Page 108: Replacing The Maf Sensor

    Diesel Engines Engine NOTE: If the exhaust gas temperature during manual regeneration exceeds a certain limit, the PCM stops the regeneration process and increases the engine speed to 2500 min to cool the DPF. NOTE: Depending on the amount of soot accumulated the PCM performs normal and long regeneration mode one after another, i.e.

  • Page 109: Replacing The Egr Valve Or The Isv

    Engine Diesel Engines Replacing the EGR Valve Or The ISV • After replacing the EGR valve or the ISV, its adaptation values in the PCM must be reset with the aid of the WDS. Therefore, select the option Toolbox Powertrain Data Reset ETB/EGR.

  • Page 110: Replacing The Ho2S

    Diesel Engines Engine Replacing the HO2S • After replacing the HO2S, its adaptation values in the PCM must be reset with the aid of the WDS. Therefore, select the option Toolbox Powertrain Data Reset O2 Sensor. Replacing the PCM • After replacing the PCM, the following steps must be performed: 1.

  • Page 111: On-Board Diagnostic System

    Engine Diesel Engines On-board Diagnostic System • The On-board diagnostic system consists of the following functions: – Self-test function – PID monitor function – Simulation test function Self Test • The self-test function allows to read out the CMDTCs (Continous Mode DTC) of the PCM with the aid of WDS.

  • Page 112: Pid Monitor

    Diesel Engines Engine PID Monitor • The PID monitor function allows to monitor the PIDs of the PCM with the aid of WDS. Therefore, select the option Toolbox Datalogger Modules PCM. Item Definition Unit/Condition AC_REQ A/C ON request On/Off ACCS A/C compressor cycling switch On/Off ALTF...
  • Page 113 Engine Diesel Engines Item Definition Unit/Condition FAN1 Cooling fan No. 1 control signal On/Off FAN3 Cooling fan No. 2 control signal On/Off FI_LRN_01 Fuel injection learning value (injector 1 at 35 MPa) FI_LRN_02 Fuel injection learning value (injector 2 at 35 MPa) FI_LRN_03 Fuel injection learning value (injector 3 at 35 MPa) FI_LRN_04...
  • Page 114 Diesel Engines Engine PID Monitor (Continued) Item Definition Unit/Condition MAF sensor MAF_C Mass air flow per cylinder MAF_C_DSD Mass air flow per cylinder desired MAP sensor Malfunction indicator light On/Off MIL_DIS Travelled distance since MIL illuminated Oxygen concentration in exhaust gas O2S11 HO2S (sensor) Current...

  • Page 115: Simulation Test

    Engine Diesel Engines Simulation Test • The simulation test function allows to activate certain PIDs of the PCM with the aid of WDS. Therefore, select the option Toolbox Datalogger Modules PCM. x: Applicable —: Not applicable Test condition Item Definition Unit/Condition KOEO KOER...
  • Page 116 Diesel Engines Engine NOTES: 01-102 Service Training Mazda6 Facelift...
  • Page 117 Suspension...
  • Page 118 02 Suspension Table of Contents Features .......................1 Tire Dimensions ....................1 Wheel Dimensions ..................1 Temporary Spare Tire................1 Winter Tires.....................2 Tire Chains ....................2 Table of Contents 02 Service Training Mazda6 Facelift...

  • Page 119: Features

    Suspension Features • The suspension system of the Mazda6 Facelift has been basically carried over from the previous Mazda6. All improvements and changes to the previous Mazda6 suspension system (such as reinforced bushings and improved top strut mounts) have been carried over to the Mazda6 Facelift. •...

  • Page 120: Winter Tires

    195/65R15 or 215/45R17 tires, and use genuine Mazda tire chains. • Use only genuine Mazda tire chains on a vehicle equipped with 215/45 R17 or 215/45R18 specification tires. 02-2 Service Training Mazda6 Facelift...
  • Page 121 Brakes...
  • Page 122 04 Brakes Table of Contents Features .......................1 Front Disc Brakes ...................2 Rear Disc Brakes ....................2 Table of Contents 04 Service Training Mazda6 Facelift...
  • Page 123 Brakes Features • The brake system of the Mazda6 Facelift has been basically carried over from the previous Mazda6. • New brake disc dimensions (for 18 inch wheels) have been added. Item Specification Type Suspended Brake pedal Pedal lever ratio Max.
  • Page 124 Brakes Front Disc Brakes • Vehicles with L3 engine and 18 inch wheels are equipped with front brake discs of 320 mm diameter and 25 mm thickness. M6FL_04001 Rear Disc Brakes • Vehicles with L3 engine and 18 inch wheels are equipped with rear brake discs of 314 mm diameter and 11 mm thickness.
  • Page 125 Transmission/ Transaxle...
  • Page 126 05 Transmission/Transaxle Table of Contents Transaxle ......................1 Features......................1 G35M-R Specifications....................3 Cross-Sectional View ..................4 Triple Cone Synchronizer................5 Structural View....................5 Operation....................5 Shift Mechanism .....................6 G66M-R Specifications....................7 Cross-Sectional View ..................8 Internal Shift Mechanism.................9 Power Flow ....................10 First to Fourth Gear ................10 Fifth, Sixth and Reverse Gear ..............11 Shift Interlock Mechanism ................12 Neutral Condition ..................12 Select Condition..................13...
  • Page 127 05 Transmission/ Transaxle Table of Contents (continued) A26M-R Specifications....................21 Cross-Sectional View ..................22 Construction....................24 Power Flow ....................25 First to Sixth Gear...................25 Reverse Gear ..................26 Synchronizer Clutch Hub ................27 Shift Interlock Mechanism ................28 Shift Mechanism ...................30 Transaxle Oil....................31 Drain Plug Location ................31 JA5AX-EL Features......................33 FS5A-EL...
  • Page 128 05 Transmission/Transaxle Table of Contents 05 Service Training Mazda6 Facelift...

  • Page 129: Transaxle

    Transmission/Transaxle Transaxle Features • The manual transaxles have the following features: – Cable operated shift mechanism – Hydraulically operated clutch – 5-speed G35M-R manual transaxle carried over for 1.8L (L8) petrol engine models – 6-speed G66M-R manual transaxle for 2.0L (LF) and 2.3L (L3) petrol engine models (new) –...
  • Page 130 Transmission/Transaxle Notes: 05-2 Service Training Mazda6 Facelift...

  • Page 131: G35M-R

    Transmission/Transaxle G35M-R G35M-R • The G35M-R manual transaxle is essentially the same as that used on the previous Mazda6, except for the following: – Triple-cone synchronizers are used for first and second gears. Specifications Item Specifications Engine type Manual transaxle type G35M-R Operation system Cable...

  • Page 132: Cross-Sectional View

    G35M-R Transmission/Transaxle Cross-Sectional View M6FL_05001 First gear Secondary fourth gear Reverse idler gear Secondary third gear Reverse gear Secondary second gear Second gear Secondary first gear Third gear Secondary shaft Fourth gear Clutch hub sleeve (reverse gear) Fifth gear Primary shaft Secondary fifth gear Differential gear 05-4...

  • Page 133: Triple Cone Synchronizer

    Transmission/Transaxle G35M-R Triple Cone Synchronizer • A triple cone synchronizer mechanism is used for the first and second gears. • The construction of the triple cone synchronizer is essentially the same as a double cone synchronizer, except that the inner surface of the inner ring is used as a friction surface on the triple cone synchronizer.

  • Page 134: Shift Mechanism

    G35M-R Transmission/Transaxle Shift Mechanism • A cable operated shift mechanism similar to that on the previous Mazda6 is used. • The selector cable is adjusted the same way as on the previous Mazda6. M6FL_05002 Shift cable Select cable 05-6 Service Training Mazda6 Facelift...

  • Page 135: G66M-R

    Transmission/Transaxle G66M-R G66M-R • The G66M-R 6-speed manual transaxle is generally based on the G35M-R 5-speed manual transaxle. • The G66M-R 6-speed manual transaxle uses triple cone synchronizers for first and second gears and double cone synchronizers for third and fourth gears. •...

  • Page 136: Cross-Sectional View

    G66M-R Transmission/Transaxle Cross-Sectional View M6FL_05003 Primary shaft Secondary Sixth gear Reverse idler gear shaft Secondary fifth gear Reverse idler gear Secondary fourth gear Second gear Secondary third gear Third gear Secondary second gear Fourth gear Clutch hub sleeve (reverse gear) Fifth gear First gear Sixth gear...

  • Page 137: Internal Shift Mechanism

    Transmission/Transaxle G66M-R Internal Shift Mechanism • The control rod design of the G66M-R manual transaxle has been carried over from the G35M-R manual transaxle. M6FL_05004 Control rod Crank lever Detent ball Shift rod Control rod end Reverse shift fork Service Training Mazda6 Facelift 05-9...

  • Page 138: Power Flow

    G66M-R Transmission/Transaxle Power Flow First to Fourth Gear M6FL_05005 First gear Third gear Second gear Fourth gear 05-10 Service Training Mazda6 Facelift...

  • Page 139: Fifth, Sixth And Reverse Gear

    Transmission/Transaxle G66M-R Fifth, Sixth and Reverse Gear M6FL_05006 Fifth gear Reverse gear Sixth gear Service Training Mazda6 Facelift 05-11...

  • Page 140: Shift Interlock Mechanism

    G66M-R Transmission/Transaxle Shift Interlock Mechanism • The shift interlock mechanism provides reliable double-engagement prevention. • During shifting, the shift rods, except for the one in operation, are locked in the neutral position by the interlock sleeve. Neutral Condition • The interlock sleeve fits into the notches of the 1st/2nd, 5th/6th and reverse shift forks. •...

  • Page 141: Select Condition

    Transmission/Transaxle G66M-R Select Condition • The shift lever is moved laterally to the 1st/2nd position. • Both the control lever and the interlock sleeve turn in the direction shown by the arrow. • The control lever fits into the notch of the 1st/2nd shift fork. •...

  • Page 142: Shift Condition

    G66M-R Transmission/Transaxle Shift Condition • The shift lever is moved vertically to the 2nd position. • The control lever moves up the 1st/2nd shift fork and the change to 2nd gear is complete. • The interlock sleeve holds the 3rd/4th, 5th/6th and reverse shift forks at the neutral position, preventing double engagement of gears.

  • Page 143: Shift Mechanism

    Transmission/Transaxle G66M-R Shift Mechanism • A cable operated shift mechanism similar to that on the previous Mazda6 is used. • Note the new shift position for the reverse gear. • The selector cable is adjusted the same way as on the previous Mazda6. M6FL_05010 Shift cable Select cable...

  • Page 144: Reverse Lockout Mechanism

    G66M-R Transmission/Transaxle Reverse Lockout Mechanism • The reverse lockout mechanism prevents the driver from accidentally shifting into reverse gear when shifting into 1st gear. • A guide plate, attached to the shift lever assembly, prevents accidental shifting into reverse when shifting into 1st gear by restricting the movement of the shift lever. •...

  • Page 145: Transaxle Oil

    Transmission/Transaxle G66M-R Transaxle Oil • The G66M-R manual transaxle is filled with 2.95 litres of manual transaxle oil which complies with the specification API Service GL-4 or GL-5 (grade) and SAE 75W-90 (viscosity) for all season use and SAE 80W-90 above 10° C. •...

  • Page 146: Drive Shaft Removal Note

    G66M-R Transmission/Transaxle Drive Shaft Removal Note • Install the SST (Special Service Tool) 49 G030 455 into the transaxle to hold the side gears after the joint shaft is removed. (This also applies to the G35M-R transaxle.) M6FL_05029 SST 49 G030 455 05-18 Service Training Mazda6 Facelift...

  • Page 147: Select Cable Adjustment

    Transmission/Transaxle G66M-R Select Cable Adjustment 1. Make sure that the shift lever (transaxle side) is in neutral. 2. Unlock the lock piece of the select cable (shift lever side) in the order as shown in the figure. M6FL_05027 Safety lock Lock piece 3.
  • Page 148 G66M-R Transmission/Transaxle Notes: 05-20 Service Training Mazda6 Facelift...

  • Page 149: A26M-R

    Transmission/Transaxle A26M-R A26M-R • The A26M-R 6-speed manual transaxle is designed for front-wheel-drive vehicles with a transversely mounted powertrain. Specifications Item Specifications Engine type MZR-CD (RF Turbo) Manual transaxle type A26M-R Forward Synchromesh Shift assist Synchromesh (Lever type) Reverse 3.538 1.913 1.218 Gear ratio...

  • Page 150: Cross-Sectional View

    A26M-R Transmission/Transaxle Cross-Sectional View M6FL_05020 05-22 Service Training Mazda6 Facelift...
  • Page 151 Transmission/Transaxle A26M-R Primary shaft Secondary shaft No. 1 Final gear No. 2 Third gear Reverse gear Fourth gear Reverse idler gear Second gear Fifth gear First gear Sixth gear Differential ring gear Secondary shaft No. 2 Final Gear No. 1 Service Training Mazda6 Facelift 05-23...

  • Page 152: Construction

    A26M-R Transmission/Transaxle Construction • The A26M-R manual transaxle is a three-shaft design; one primary (input) shaft and two secondary (output) shafts. • The three-shaft design allows for a more compact construction due to the fact that each output shaft needs only to carry three or four gears, so can thus be made shorter. •...

  • Page 153: Power Flow

    Transmission/Transaxle A26M-R Power Flow First to Sixth Gear M6FL_05021 First gear Fourth gear Second gear Fifth gear Third gear Sixth gear Service Training Mazda6 Facelift 05-25...

  • Page 154: Reverse Gear

    A26M-R Transmission/Transaxle Reverse Gear M6FL_05022 05-26 Service Training Mazda6 Facelift...

  • Page 155: Synchronizer Clutch Hub

    Transmission/Transaxle A26M-R Synchronizer Clutch Hub • A ball-type detent mechanism is used in each clutch hub to reduce the overall dimensions of the hub. • The ball-type detent mechanism consists of a coil-type synchronizer key spring, synchronizer key, and ball. Its function is essentially the same as the radial-type spring found in other transaxles.

  • Page 156: Shift Interlock Mechanism

    A26M-R Transmission/Transaxle Shift Interlock Mechanism • The shift interlock mechanism prevents two gears being engaged at a time. During shifting, the shift forks and control rod, except for the one in operation, are locked in the neutral position by the interlock plate. M6FL_05024 05-28 Service Training Mazda6 Facelift...
  • Page 157 Transmission/Transaxle A26M-R Reverse shift fork First gear Inner lever Second gear Fifth/sixth gear shift fork Third gear Interlock plate Fourth gear First/second gear shift fork Fifth gear Third/fourth gear control rod Sixth gear A-A sectional view Reverse gear Neutral Service Training Mazda6 Facelift 05-29...

  • Page 158: Shift Mechanism

    A26M-R Transmission/Transaxle Shift Mechanism • A cable operated shift mechanism similar to that on the previous Mazda6 is used. • The selector cable is adjusted the same way as on the previous Mazda6. • The reverse lockout mechanism is the same as on Mazda6 with G66M-R transaxle. M6FL_05015 Shift cable Select cable...

  • Page 159: Transaxle Oil

    Transmission/Transaxle A26M-R Transaxle Oil • The A26M-R manual transaxle is filled with 2.55 litres of manual transaxle oil which complies with the specification API Service GL-4 or GL-5 (grade) and SAE 75W-90 (viscosity). • To check the transaxle oil level, verify that the oil level is near the brim of the plug port. M6FL_05025 Oil level check Drain Plug Location...
  • Page 160 A26M-R Transmission/Transaxle Notes: 05-32 Service Training Mazda6 Facelift...

  • Page 161: Ja5Ax-El

    Transmission/Transaxle JA5AX-EL Features • The JA5AX-EL automatic transaxle with AWD has been basically carried over from the previous Mazda6 AWD (comprising the running changes of revised final drive ratio and the deletion of cruise control). • An air cooling type oil cooler has been introduced for improved cooling of the automatic transmission fluid.
  • Page 162 JA5AX-EL Transmission/Transaxle Notes: 05-34 Service Training Mazda6 Facelift...

  • Page 163: Fs5A-El

    Transmission/Transaxle FS5A-EL Features • The new FS5A-EL five-speed automatic transaxle is available as an option for Mazda6 Facelift fitted with LF or with L3 engine. • The FS5A-EL uses one double planetary gear set and one single reduction planetary gear set. Hydraulic control is provided by six shift solenoid valves and two pressure control solenoid valves.

  • Page 164: Transmission Control System

    FS5A-EL Transmission/Transaxle Transmission Control System Structural View M6FL_05035 05-36 Service Training Mazda6 Facelift...
  • Page 165 Transmission/Transaxle FS5A-EL ATX MIL TR sensor Selector lever position indicator Oil pressure switch Actual gear display Turbine shaft speed APP sensor CKP sensor ECT sensor Selector lever unit comprising: - M-range switch, - UP switch, - DOWN switch MAF sensor Output shaft speed sensor Secondary control valve body Intermediate shaft speed sensor...

  • Page 166: Operation Diagram

    FS5A-EL Transmission/Transaxle Operation Diagram M6FL_05032 05-38 Service Training Mazda6 Facelift...
  • Page 167 Transmission/Transaxle FS5A-EL Powertrain mechanism Shift solenoid A, B, C Hydraulic pressure control mechanism Oil pump Electronic control mechanism Torque converter Oil pressure switch signal Brake clutch Output shaft speed Planetary gear Oil temperature Differential Turbine shaft speed Tire Engine speed Secondary control valve body Throttle position signal Shift solenoid D, E...

  • Page 168: Cross-Sectional View

    FS5A-EL Transmission/Transaxle Cross-Sectional View M6FL_05030 05-40 Service Training Mazda6 Facelift...
  • Page 169 Transmission/Transaxle FS5A-EL Band brake Primary gear Reverse clutch Output gear 3-4 clutch Differential Rear planetary gear Secondary gear Front planetary gear Direct clutch Forward clutch Reduction brake Oil pressure switch One-way clutch No. 2 Oil pump Low and reverse brake Torque converter One-way clutch No.

  • Page 170: Electronic Control

    FS5A-EL Transmission/Transaxle Electronic Control Wiring Diagram M6FL_05031 05-42 Service Training Mazda6 Facelift...
  • Page 171 Transmission/Transaxle FS5A-EL Inhibitor switch CAN_H ATF temperature sensor PCM, ABS/DSC, instrument cluster M-range switch Pressure control solenoid A UP switch Pressure control solenoid B Down switch Shift solenoid F Oil pressure switch Shift solenoid E Intermediate shaft speed sensor Shift solenoid D Output shaft speed sensor Shift solenoid C Turbine shaft speed sensor...

  • Page 172: Hydraulic Control

    FS5A-EL Transmission/Transaxle Hydraulic Control Control Valve Body • The main control valve body basically has been carried over from the FN4A-EL automatic transaxle. M6FL_05033 Control valve body - upper part Shift solenoid A Control valve body - lower part Solenoid valve body Oil strainer Pressure control solenoid A Shift solenoid B...

  • Page 173: Secondary Control Valve Body

    Transmission/Transaxle FS5A-EL Secondary Control Valve Body • The secondary control valve body has been added to accommodate one more shift solenoid and an additional pressure control solenoid. M6FL_05033 Shift solenoid F Secondary control valve body - lower part Secondary control valve body - upper Pressure control solenoid B part Service Training Mazda6 Facelift...
  • Page 174 FS5A-EL Transmission/Transaxle Notes: 05-46 Service Training Mazda6 Facelift...
  • Page 175 Restraint System...
  • Page 176 08 Restraint System Table of Contents Features .......................1 Wiring Diagram ....................2 Table of Contents 08 Service Training Mazda6 Facelift...
  • Page 177 Restraints Features • The restraints system of the Mazda6 Facelift has been basically carried over from the previous Mazda6, except the following: – A PAD (Passenger Airbag Deactivation) switch has been added (supersedes the occupancy sensor for the front passenger seat). –...
  • Page 178 Restraints Wiring Diagram M6FL_08001 PAD switch Clock spring PASS AIRBAG ON Driver-side air bag module PASS AIRBAG OFF Passenger-side air bag module Poor connection detector bar Driver-side pre-tensioner seat belt Data Link Connector (DLC) Driver-side curtain air bag module Instrument cluster Driver-side side air bag module Air bag system warning light Passenger-side pre-tensioner seat belt...
  • Page 179 Body & Accessories...
  • Page 180 09 Body & Accessories Table of Contents Body Body ........................1 Reinforced Body Shell ..................1 Accessories Body Control Module (BCM)................3 BCM Wiring Diagram ..................4 BCM PID Table ....................7 BCM On-Board Diagnostic System..............8 Constant Monitor ..................8 Self Test ....................8 Power Window System ..................9 Power Window Main Switch................10 Power Window Subswitch................11 Exterior Opening/Closing ................12...
  • Page 181 09 Body & Accessories Table of Contents (continued) Card Key Structural View ................32 Programming New Card Keys...............33 With Two or More Card Keys..............33 With WDS ....................33 Erasing Registered Card Keys..............34 Keyless Antennas ..................34 Keyless Antennas Structural View ............35 Request Switches ..................36 Keyless Buzzer .....................36 Steering Lock Unit..................37 Steering Lock Unit Structural View ............37...
  • Page 182 09 Body & Accessories Table of Contents (continued) Entertainment Systems ..................63 Audio System....................63 Audio System Structural View ..............64 Specifications ..................65 Speaker ....................65 Center Panel Module ................66 Center Panel Structural View..............67 Audio On-board Diagnostic System............68 Self Diagnostic Function .................68 Diagnostic Assist Function..............68 Car Navigation System .................69 Features ....................69 Specifications ..................69...

  • Page 183: Body

    This also improves the rigidity of the chassis and raised local body stiffness to match the upgraded powertrain. • The front bumper was revised, the front grille redesigned (now with a larger Mazda badge) and the design of the rear bumper was refined. Reinforced Body Shell...
  • Page 184 Body Body & Accessories Notes: 09-2 Service Training Mazda6 Facelift...

  • Page 185: Body Control Module (Bcm)

    Body & Accessories Accessories Body Control Module (BCM) • The following relays are built into the BCM: – Door lock/unlock relays • The BCM controls the following systems: – Turn/hazard light system – Rear wiper system – Room light control system –...

  • Page 186: Bcm Wiring Diagram

    Accessories Body & Accessories BCM Wiring Diagram M6FL_09003 09-4 Service Training Mazda6 Facelift...
  • Page 187 Body & Accessories Accessories Trunk compartment light switch (4SD (4- Instrument cluster Door Sedan)) Cargo compartment light switch (5HB (5- Door Hatchback), WGN (Wagon)) Driver’s side door key cylinder switch Door switch (passenger's side) Hazard switch Door switch (rear, left) Driver’s side door lock-link switch Door switch (rear, right) Rear left side door lock-link switch...
  • Page 188 Accessories Body & Accessories BCM Wiring Diagram (Continued) M6FL_09004 DSC (Dynamic Stability Control) with DSC Horn switch ABS (Antilock Brake System) CM (Control Module) (with ABS) Fuel gauge sender unit To DLC (Data Link Connector) To brake light switch To back-up light switch To tail light To audio system Rear wiper motor...

  • Page 189: Bcm Pid Table

    Body & Accessories Accessories BCM PID Table PID/data Unit/Condition Input/output part BCM terminal monitor item (Tester display) CCNT_GE — — B_AJAR Open/Closed Bonnet switch TRUNK_AJAR Open/Closed Trunk compartment light switch REAR_AJAR Open/Closed Rear door switch (LH/RH) 7D, 1F RF_AJAR Open/Closed Front door switch (RH) LF_AJAR Open/Closed...

  • Page 190: Bcm On-Board Diagnostic System

    Accessories Body & Accessories BCM On-Board Diagnostic System • The on-board diagnostic system of the BCM consists of the following functions: – Constant monitor – Self test – PID monitor Constant Monitor • The constant monitor is carried out whenever the ignition is ON. If a fault is detected, a DTC will be stored in the BCM.

  • Page 191: Power Window System

    Body & Accessories Accessories Power Window System • The power window system is essentially the same as that on the current Mazda5 and has the following features: – Manual open/close function on all windows. – Auto open/close function on all windows. –...

  • Page 192: Power Window Main Switch

    Accessories Body & Accessories Power Window Main Switch M6FL_09005 Power window main switch Hall effect switch 1 Power window motor (driver’s side) Hall effect switch 2 Close To power mirror switch Open To power window subswitch A Auto To power window subswitch B Power-cut switch Conjunction circuit P/W (Power Window) CM...

  • Page 193: Power Window Subswitch

    Body & Accessories Accessories Power Window Subswitch M6FL_09006 Power window subswitch Open relay Power window motor Hall effect switch 1 Close Hall effect switch 2 Open P/W CM Auto To power window main switch A Close relay To power window main switch B Service Training Mazda6 Facelift 09-11...

  • Page 194: Exterior Opening/Closing

    Accessories Body & Accessories Exterior Opening/Closing • The exterior opening/closing function allows all of the windows to either be opened, or closed simultaneously from outside the vehicle. • By pressing the driver’s door request switch, or the LOCK button on a card key or a retractable type key transmitter for approximately 1.5 seconds, all of the windows can be closed.

  • Page 195: Window Closing Operation With Request Switch

    Body & Accessories Accessories Window Closing Operation with Request Switch M6FL_09007 Request switch (driver's side) P/W subswitch (RF (Right Front)) Keyless receiver P/W subswitch (LR (Left Rear)) Keyless control module P/W subswitch (RR (Right Rear)) Door latch switch P/W motor (LF (Left Front)) Start knob/Key reminder switch P/W motor (RF) Cargo compartment light switch...

  • Page 196: Operation With Transmitter

    Accessories Body & Accessories Operation with Transmitter M6FL_09008 Close operation Close operation signal Open operation Open (unlock button held approx. 1.5 s) Close (lock button held approx. 1.5 s) Unlock signal Lock signal Open request signal Close request signal Open operation signal P/W switch 09-14 Service Training Mazda6 Facelift...

  • Page 197: Power Seat

    Body & Accessories Accessories Power Seat • A power seat with memory function has been adopted. • The memory function slides the seat into a previously stored position according to the used memory switch or according to the transmitter that was used to open the vehicle. Power Seat Structural View M6FL_09009 Position memory switch...

  • Page 198: Power Seat Wiring Diagram

    Accessories Body & Accessories Power Seat Wiring Diagram M6FL_09010 Instrument cluster Memory switch 1 Door ajar warning light Memory switch 2 Door switch (driver’s side) Memory switch 3 ABS / DSC CM Slide motor -Keyless control module (with advanced Front tilt motor Keyless system) -BCM (without advanced Keyless) Power seat switch...

  • Page 199: Seat Position Memory

    Body & Accessories Accessories Seat Position Memory • Three seat positions can be programmed in the position memory control module corresponding to the memory switch. • An additional seat position can be programmed corresponding to each transmitter. • Programming of the seat position is possible according to the following procedures. Seat Position Programming Using the Memory Switches Slide the seat manually to the desired position.

  • Page 200: Security And Locks

    Accessories Body & Accessories Security and Locks • The security and lock system on the Mazda6 Facelift has the following features: – Advanced Keyless Entry and Starting System has been adopted (option). – Power door lock system controlled by the BCM is used. –...

  • Page 201: Advanced Keyless System Structural View

    Body & Accessories Accessories Advanced Keyless System Structural View M6FL_09011 Start knob (ignition switch) Liftgate latch and lock actuator (5HB, WGN) Security light (with immobilizer system) Keyless antenna (exterior, rear) Coil antenna (with immobilizer system) Card key Steering lock unit Transmitter Keyless warning light (green) Auxiliary key...

  • Page 202: Advanced Keyless System Wiring Diagram

    Accessories Body & Accessories Advanced Keyless System Wiring Diagram M6FL_09012 09-20 Service Training Mazda6 Facelift...
  • Page 203 Body & Accessories Accessories With immobilizer system Keyless antenna (exterior, rear) Keyless receiver Keyless antenna (interior, middle) Coil antenna Keyless antenna (interior, rear) (4SD) Keyless antenna (interior, RR) (5HB, Keyless antenna (interior, LR) (5HB, WGN) Steering lock unit Keyless antenna (interior, front) Push switch Security light Key reminder switch...

  • Page 204: Power Door Lock System

    Accessories Body & Accessories Power Door Lock System • When the driver’s door is unlocked or locked with the key, or by pushing the lock knob, the lock link switch in the door lock actuator sends a lock or unlock signal to the BCM, which operates the locks on all doors.

  • Page 205: Vehicle Entry Using The Transmitter

    Body & Accessories Accessories Vehicle Entry Using the Transmitter • When either of the buttons on the transmitter are pushed, the transmitter ID (Identification) and a rolling code are transmitted as radio waves. The signal is detected by the keyless receiver and communicated to the Keyless Control Module. The Keyless Control Module verifies that the ID of the key is valid, and sends a signal to the BCM to operate the door lock actuators.

  • Page 206: Vehicle Entry Using The Request Switches

    Accessories Body & Accessories Vehicle Entry Using the Request Switches • Whenever one of the request switches is pressed, the keyless control module transmits an ID request signal via the keyless antennas to the card key. If the driver’s door request switch is operated, for example, the ID request signal will only be transmitted to the area outside the driver’s door.
  • Page 207 Body & Accessories Accessories • When a request switch is pushed, the doors will only unlock if the following conditions are all met: – Auxiliary key is not in the ignition. – Start knob is in the LOCK position, and also not being pressed. –...

  • Page 208: Auto Re-Lock Function

    Accessories Body & Accessories Auto Re-lock Function • The doors will automatically re-lock 30 seconds after being unlocked unless any of the following conditions are met: – Any of the doors or liftgate are opened. – The auxiliary key is inserted in the ignition. –...

  • Page 209: Advanced Keyless Engine Start Function

    Body & Accessories Accessories Advanced Keyless Engine Start Function • If a card key is with the driver when they enter the car, the engine can be started merely by operating the start knob; without inserting a key in the ignition. •...

  • Page 210: Advanced Keyless Engine Start Structural View

    Accessories Body & Accessories Advanced Keyless Engine Start Structural View M6FL_09016 Steering lock unit ID verification Not OK Keyless warning light (red) (flash) Transmitter (card key) ID verification OK Keyless antenna Keyless indicator light (green) Reception range (interior) (illuminated) Keyless receiver Keyless control module 5HB, WGN Operation in detail:...

  • Page 211: Customization

    Body & Accessories Accessories Customization • The following functions can be switched ON or OFF using WDS: – Out of range auto-lock function (set to OFF from factory). – Lock/unlock answer back function (set to OFF from factory). – Low card key battery warning (set to ON from factory). Card Key •...

  • Page 212: Guidance Function

    Accessories Body & Accessories Guidance Function • The user is informed of faults or misuse of the system via the warning light and buzzer in the instrument cluster, or the buzzer in the driver's door. Instrument cluster Keyless buzzer Keyless Keyless Item Operation condition...
  • Page 213 Body & Accessories Accessories If the start knob is turned to the LOCK position with the card key out of the vehicle, the start knob is inoperable (the engine cannot be restarted). For vehicles with immobilizer system, the engine cannot be restarted by turning the start knob from the ACC position to the START position even though the start knob has not been turned to the LOCK position.

  • Page 214: Card Key Structural View

    Accessories Body & Accessories Card Key Structural View M6FL_09017 Indicator light Intruder sensor cut-off button (with theft- deterrent system) Lock button Auxilliary key Unlock button Transmitter 09-32 Service Training Mazda6 Facelift...

  • Page 215: Programming New Card Keys

    Body & Accessories Accessories Programming New Card Keys NOTE: Do not program card keys while WDS or any other computer devices are in the vehicle. Make sure all card keys are operational and have good batteries. NOTE: Auxiliary keys have to be programmed separately as ignition keys. With Two or More Card Keys •...

  • Page 216: Erasing Registered Card Keys

    Accessories Body & Accessories Erasing Registered Card Keys Establish communication between WDS and the vehicle. Select the option Toolbox→Body→Security→PATS Functions. Carry out the security access procedure (read out the WDS outcode, and input the corresponding incode). Select the option Card Key Clearing. Complete procedure by programming at least two new card keys.

  • Page 217: Keyless Antennas Structural View

    Body & Accessories Accessories Keyless Antennas Structural View M6FL_09018 Keyless antenna (exterior, rear) Keyless antenna (interior, middle) Keyless antenna (interior, RR) (5HB, Keyless antenna (exterior, driver side) WGN) Keyless antenna (interior, LR) (5HB, Keyless antenna (exterior, passenger WGN) side) Keyless antenna (interior, rear) (4SD) Keyless antenna (interior, front) Service Training Mazda6 Facelift 09-35...

  • Page 218: Request Switches

    Accessories Body & Accessories Request Switches • Request switches are installed to driver’s door, passenger’s door, and liftgate respectively. When the request switch is pressed, the keyless control module sends a request signal to the card key. The request switch on the driver’s door can also be used to open and close the windows (see section 9, “Power Window System”) M6FL_09019 Request switch...

  • Page 219: Steering Lock Unit

    Body & Accessories Accessories Steering Lock Unit • The steering lock unit consists of the steering lock and the start knob, which is blocked in OFF position. When the start knob is pushed in a request signal is sent by the keyless antennas.

  • Page 220: Keyless Control Module

    Accessories Body & Accessories Keyless Control Module • The keyless control module is only fitted to vehicles with advanced keyless system. • The keyless control module is located behind the right side kick panel. NOTE: When replacing the keyless control module, the new module has to be configured. To do this connect WDS to the vehicle and select the option Toolbox→Module Programming→Programmable Module Installation→RKE.

  • Page 221: Advanced Keyless System Diagnosis

    Body & Accessories Accessories Advanced Keyless System Diagnosis • The on-board diagnostic system consists of the following functions: – Self-test – PID monitor – Simulation test function Self Test • The self-test function allows the Advanced Keyless Entry system DTCs to be displayed. To view these, connect WDS to the vehicle and select the option Toolbox→Self Test→Modules→RKE.

  • Page 222: Pid Monitor

    Accessories Body & Accessories PID Monitor • The PID monitor function allows the PIDs for the Advanced Keyless Entry system to be monitored. To view these connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RKE. PID/Data Monitor Table PID name Unit/ Data contents Terminal...

  • Page 223: Simulation Test

    Body & Accessories Accessories Simulation Test • The simulation test function allows certain PIDs for the Advanced Keyless Entry system to be activated. To do this, connect WDS to the vehicle and select the option Toolbox→Datalogger→Modules→RKE. Active Command Mode Table Command Output part name Unit/ Operation...

  • Page 224: Immobilizer System On Vehicles With Advanced Keyless System

    Accessories Body & Accessories Immobilizer System on Vehicles with Advanced Keyless System • The immobilizer system is a vehicle theft prevention device that only allows keys that have previously been programmed to the vehicle to start the engine. It functions to prevent theft by means such as a forged key or hotwiring.

  • Page 225: Immobilizer System Wiring Diagram

    Body & Accessories Accessories Immobilizer System Wiring Diagram M6FL_09023 Instrument cluster Security light CAN-High CAN-Low Coil antenna Keyless control module • When immobilizer system component parts (key, PCM, steering lock unit and keyless control module) are replaced, the system must be reset as described below. Refer to the Workshop Manual for the detailed reset procedure.
  • Page 226 Accessories Body & Accessories Notes: 09-44 Service Training Mazda6 Facelift...

  • Page 227: Vehicles Without Advanced Keyless Entry System

    Body & Accessories Accessories Vehicles without Advanced Keyless Entry System • A keyless entry system similar to that on the Mazda5 is installed. • A switchblade type retractable key has been adopted. Keyless Entry System Structural View M6FL_09024 Door lock actuator (rear left) Key cylinder Door lock actuator (rear right) Keyless receiver...

  • Page 228: Keyless Entry System Wiring Diagram

    Accessories Body & Accessories Keyless Entry System Wiring Diagram M6FL_09025 09-46 Service Training Mazda6 Facelift...
  • Page 229 Body & Accessories Accessories Trunk compartment light switch (4SD) Door ajar warning light Liftgate latch switch (5HB, WGN) Door key cylinder switch (driver side) Instrument cluster Door lock-link switch (driver-side front Door switch (driver-side front door) door) Door lock-link switch (passenger-side Door switch (rear door RH) front door) Door lock-link switch (rear door RH)

  • Page 230: Transmitter

    Accessories Body & Accessories Transmitter • The keyless transmitter incorporates buttons to lock and unlock the doors and to disable the intruder sensor (when burglar alarm is fitted), a button type battery (CR2025), and a retractable ignition key with integrated transponder. •...

  • Page 231: Immobilizer System On Vehicles Without Advanced Keyless System

    Body & Accessories Accessories Immobilizer System on Vehicles without Advanced Keyless System • A PATS (Passive Anti-Theft System), which incorporates the former immobilizer unit function, has been adopted and is built into the PCM. • The PATS prevents vehicle theft by only allowing keys that have been registered specifically for the vehicle to start the engine and prohibits the engine from being started using any other method (such as using an unregistered key or by shorting the starter relay circuit).

  • Page 232: Immobilizer System Wiring Diagram

    Accessories Body & Accessories Immobilizer System Wiring Diagram M6FL_09029 Instrument cluster Coil antenna Security light Key (transponder) 09-50 Service Training Mazda6 Facelift...

  • Page 233: Theft Deterrent System

    Body & Accessories Accessories Theft Deterrent System • The theft deterrent system is standard equipment in Base and in Touring specification. • The theft-deterrent system includes sound and light alarm. The system will be armed by locking the vehicle with the transmitter. The armed system alarms when the bonnet, the trunk lid (4SD) or liftgate (5HB, WGN), or a door is opened by means other than the transmitter.

  • Page 234: Theft Deterrent System Structural View

    Accessories Body & Accessories Theft Deterrent System Structural View M6FL_09030 09-52 Service Training Mazda6 Facelift...
  • Page 235 Body & Accessories Accessories Horn Front door latch and lock actuator (Driver's side) •Front door latch switch •Door lock-link siwtch •Door key cylinder switch Front door latch and lock actuator (Passenger’s side) •Front door latch switch Horn relay Door switch Bonnet switch Coil antenna Transmitter...

  • Page 236: Theft Deterrent System Wiring Diagram

    Accessories Body & Accessories Theft Deterrent System Wiring Diagram M6FL_09031 09-54 Service Training Mazda6 Facelift...
  • Page 237 Body & Accessories Accessories • Door switch (rear door LH) Keyless control module with Advanced Keyless System • Keyless receiver w/o Advanced Keyless System Door switch (passenger-side front door) Door lock-link switch (driver-side front Front turn light (RH) door) Front turn light (LH) Door lock-link switch (passenger-side front door) Rear turn light (RH)

  • Page 238: Intruder Sensor

    Accessories Body & Accessories Intruder Sensor • The intruder sensor is located in the center part of the roof on sliding sunroof-equipped vehicles or in the forward part of the roof on sliding sunroof non-equipped vehicles. • The intruder sensor detects movement in the vehicle by radio waves and sends the detection signal to the BCM.

  • Page 239: Lighting / Wiper System

    Body & Accessories Accessories Lighting / Wiper System • The lighting system of the Mazda6 Facelift is essentially the same like on the previous Mazda6. It has the following features: – Headlight with built-in front fog light, front turn and parking light has been adopted. –...

  • Page 240: Auto Light System Structural View

    Accessories Body & Accessories Auto Light System Structural View M6FL_09033 Auto light sensor Light switch Sensor diode Auto light / wiper control module Windshield 09-58 Service Training Mazda6 Facelift...

  • Page 241: Auto Light System Wiring Diagram

    Body & Accessories Accessories Auto Light System Wiring Diagram M6FL_09034 Auto light / wiper control module Front and rear fog light switch Headlight relay Front fog light switch Headlight (low-beam) Rear fog light switch Headlight (high-beam) Illumination light TNS (Tail Number Side lights) relay Headlight switch Parking light/taillight/license plate light Headlight...

  • Page 242: Auto Light Sensor

    Accessories Body & Accessories Auto Light Sensor • Installed behind the rearview mirror (windshield center) and integrated with the rain sensor as a single unit. M6FL_09035 Auto-light sensor Lens sensor 09-60 Service Training Mazda6 Facelift...

  • Page 243: Wiper / Washer System

    Body & Accessories Accessories Wiper / Washer System • The wiper / washer system is essentially carried over from the previous Mazda6. • An auto wiper system that detects rainfall on the windshield and automatically controls all operation (stop, interval, low, and high) has been adopted, removing the burden of operating switches from the driver.

  • Page 244: Auto Wiper System Wiring Diagram

    Accessories Body & Accessories Auto Wiper System Wiring Diagram M6FL_09037 Windshield wiper and washer switch Windshield wiper motor Windshield washer switch Windshield washer motor Auto light / wiper control module Rain sensor Microcomputer Rainfall Detection Function • The LED in the rain sensor emits infrared light that is reflected off the windshield via the lens sensor and then received by the photodiode in the rain sensor.

  • Page 245: Entertainment Systems

    Body & Accessories Accessories Entertainment Systems Audio System • The center panel module has been adopted • The center panel module consists of: – the audio unit – the control unit (automatic A/C only) – the audio switch – the A/C switch –...

  • Page 246: Audio System Structural View

    Accessories Body & Accessories Audio System Structural View M6FL_09038 Center panel module (built-in audio unit) Condenser Audio control switch Woofer (BOSE) Tweeter (BOSE) Noise filter (rear window defroster) Woofer relay (BOSE) Center roof antenna Noise filter (brake switch) Glass antenna (not for EU (European Union) market) Antenna feeder Information display...

  • Page 247: Specifications

    Body & Accessories Accessories Specifications Specification Item Bose Standard Type B Type C Rated voltage (KHZ) 153-279 153-279 Frequency (KHZ) 531-1602 531-1602 band (MHZ) 87.5-108.0 87.5-108.0 Information system Audio amplifier maximum 25 x 4 25 x 4 ouput power (External type audio amplifier) Ouput impedance (Ohm) M6FL_09T006...

  • Page 248: Center Panel Module

    Accessories Body & Accessories Centre Panel Module • The center panel module consists of the audio unit, switches and the heater control unit. A lower module (cassette deck or MD player) can be added to the radio/CD (Compact Disc) player base unit. M6FL_09039 Center panel Cover (without upper module)

  • Page 249: Center Panel Structural View

    Body & Accessories Accessories Centre Panel Structural View M6FL_09040 SCAN button Preset button “3” FM1 button Preset button “4” FM2 button Preset button “5” AM button Preset button “6” CD button SEEK button (upper) MEDIA button SEEK button (lower) AUTO-M button POWER/VOLUME button Preset button “1”...

  • Page 250: Audio On-Board Diagnostic System

    Accessories Body & Accessories Audio On-board Diagnostic System • The on-board diagnostic system is similar to the Mazda3 (BK), and consists of the following functions: – Self-diagnostic function – Diagnostic assist function Self Diagnostic Function • The self-diagnostic function allows DTCs in the audio unit to be displayed. It can be entered as follows: Turn the ignition switch to the ACC or ON position.

  • Page 251: Car Navigation System

    Body & Accessories Accessories Car Navigation System • The Mazda6 Facelift is equipped with a new navigation system, manufactured by Denso. It uses the GPS (Global Positioning System), a European map DVD (Digital Versatile Disc), the vehicle speed signal and an incorporated gyro sensor. •...

  • Page 252: Parts Location

    Accessories Body & Accessories Parts Location M6FL_09041 Front door speaker (right) Front door speaker (left) Tweeter (right) (BOSE) Remote control Car-navigation unit Cradle LCD unit Audio amplifier (BOSE) Audio unit ABS or DSC CM GPS antenna TR switch (ATX) Tweeter (left) (BOSE) Backup-light switch (MTX) 09-70 Service Training Mazda6 Facelift...

  • Page 253: System Overview

    Body & Accessories Accessories System Overview M6FL_09042 ABS or DSC CM Information display TR switch (ATX) or back-up light Remote control switch (MTX) Cradle Car-navigation unit Audio unit Power amplifier GPS receiver Speaker output to driver’s side Gyro sensor DVD driver Audio amplifier GPS antenna Tweeter (driver side)

  • Page 254: Car Navigation Unit

    Accessories Body & Accessories Car Navigation Unit • The car navigation unit is located in the glove compartment and incorporates the DVD- ROM drive and the gyro sensor. M6FL_09043 DVD-ROM loading slot Eject button DVD-ROM 09-72 Service Training Mazda6 Facelift...

  • Page 255: Lcd Unit

    Body & Accessories Accessories LCD Unit • The LCD unit of the navigation system is a pop-up type TFT monitor incorporated in the dashboard. • The information display below shows information about the audio, DIS (Driver Information System) and A/C. •...

  • Page 256: Screen Layout

    Accessories Body & Accessories Screen Layout • Different display modes can be selected with the split screen function. Some of the different options are shown below. One-Screen Map Display M5_09058 Dual Screen Map Display with Different Scales M5_09059 09-74 Service Training Mazda6 Facelift...
  • Page 257 Body & Accessories Accessories Map and Turn List M5_09060 Map and Turn Arrows M5_09061 Service Training Mazda6 Facelift 09-75...
  • Page 258 Accessories Body & Accessories Automatically Enlarged Illustration of a nearby Intersection on Main Roads M5_09062 Automatically Enlarged Illustration of a Nearby Intersection on Motorways M5_09063 09-76 Service Training Mazda6 Facelift...

  • Page 259: Remote Control And Cradle

    Body & Accessories Accessories Remote Control and Cradle • A remote control with an appropriate cradle has been adopted. The remote control and cradle are located on the centre console. • An infrared sensor that receives signals from the remote control is located on the cradle. The signals received are sent to the LCD unit.

  • Page 260: Traffic Message Channel

    Accessories Body & Accessories Traffic Message Channel • The TMC function is a specific application of the RDS (Radio Data System), using an FM receiver that is incorporated in the navigation unit. It receives traffic messages and forwards the received information to the CPU. The messages can be displayed and the route can be automatically recalculated when there are traffic jams along the first selected route.
  • Page 261 Body & Accessories Accessories • Traffic events will be considered within a distance of 25 km from the current location of the vehicle and be displayed by a sign on the display in the scale 50m…4km. • The colour and type of the sign depends on the traffic information. The colours which are related to the events are described in the following table: Category Colour...
  • Page 262 Accessories Body & Accessories • Each traffic event is indicated by one sign. M5_09072 Icon for traffic event 09-80 Service Training Mazda6 Facelift...

  • Page 263: Availability Of Tmc In Europe

    Body & Accessories Accessories Availability of TMC in Europe • TMC is generally available in the countries shown on the map below. NOTE: Even when the TMC displays traffic events on other roads, the DRGS recalculates the route only for traffic events on motorways. NOTE: A TMC information about a heavy traffic jam does not necessarily mean that the navigation system will re-route the vehicle.

  • Page 264: How To Enable Tmc And Drgs

    Accessories Body & Accessories How to Enable TMC and DRGS • To switch on the TMC and DRGS first select “RDS-TMC” from the main menu. A new menu will be displayed where the customer can select between some options. M5_09074 Displays traffic events on the guided route Enables TMC Selected country...

  • Page 265: Rear Seat Belt Warning Alarm

    Body & Accessories Accessories Rear Seat Belt Warning Alarm • The rear seat belt warning LEDs are installed on the installation area of the rear view mirror. • The indicator and the buzzer are built-in corresponding to the seat belt for each rear seat.

  • Page 266: Rear Seat Belt Warning Alarm Structural View

    Accessories Body & Accessories Rear Seat Belt Warning Alarm Structural View M6FL_09058 Rear seat belt reminder indicator Rear center seat belt Rear left seat belt Rear right seat belt 09-84 Service Training Mazda6 Facelift...

  • Page 267: Rear Seat Belt Warning Alarm Wiring Diagram

    Body & Accessories Accessories Rear Seat Belt Warning Alarm Wiring diagram M6FL_09059 Instrument cluster Rear right seat belt indicator Generator warning light Red (unfastened) Rear seat belt reminder indicator Green (fastened) Buzzer Buckle switch (rear left) Microcomputer Buckle switch (rear center) Rear left seat belt indicator Buckle switch (rear right) Rear center seat belt indicator...

  • Page 268: Front Seat Belt Warning Alarm

    Accessories Body & Accessories Front Seat Belt Warning Alarm • Driver seat belt warning alarm operates with a single buckle switch like the seat belt warning alarm from the previous Mazda6. • The seat belt warning light in the instrument cluster shows if the driver is not buckled while ignition is on or engine runs.

  • Page 269: Controller Area Network (Can) System

    Body & Accessories Accessories Controller Area Network (CAN) System • Due to the simplification of the wiring harness, a CAN system for transmission of multiplex input/output signals among electrical modules has been adopted. • Twisted-pair wiring is used for connections between the following modules (each electrical module hereafter referred to as a CAN system-related module): –...
  • Page 270 Accessories Body & Accessories • With an on-board diagnostic function included for each multiplex module, display of DTCs using the WDS or equivalent has improved serviceability. M6FL_09061 2R (except MZR-CD (RF Turbo)) 39 (MZR-CD (RF Turbo)) DSC CM (with DSC) 2U (except MZR-CD (RF Turbo)) 13 (MZR-CD (RF Turbo)) ABS CM (with ABS)
  • Page 271 List of Abbreviations 2-Wheel Drive CAN-L Controller Area Network-Low 4-Door Sedan Compact Disc 4-Wheel Drive Crankshaft Position 5-Door Hatchback Control Module Air Conditioning CMDTC Continous Mode DTC Antilock Brake System Camshaft Position Accessory Central Processing Unit (position ignition switch) Direct Current Amplitude Modulation Driver Information System Accelerator Pedal Position...
  • Page 272 List of Abbreviations Electronic Control Unit Knock Sensor Exhaust Gas Recirculation Liquid Crystal Display EGRVP Exhaust Gas Recirculation Light Emitting Diode Valve Position European Union Left Front FEEPROM Flash Electronically Erasable Left Hand Programmable Read Only Memory Left Hand Drive Frequency Modulation Left Rear Gigant Magnetic Resistive...
  • Page 273 List of Abbreviations Power Steering SAPS Sulphate Ash, Phosphor, Sulphur Power Window Sophisticated Airbag Sensor Passenger Airbag Deactivation Special Service Tool PATS Passive Anti Theft System Transaxle Control Module Powertrain Control Module Traction Control System Positive Crankcase Thin Film Transistor Ventilation Traffic Message Channel Parameter Identification...
  • Page 274 List of Abbreviations VTCS Variable Tumble Control System Worldwide Diagnostic System Wagon Service Training Mazda6 Facelift...

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