Mazda 1996 626 User manual

I v l c i Z C I c i
y C O
I w l # ^ 1 1 1 ^ ^ : ...

WARNING
Servicing a vehicle can be dangerous. If you have not received service-
related training, the risks of injury and property damage increase. The
recommended servicing procedures for the vehicle in this troubleshooting
manual ere developed ith Mazda-trained technicians in mind. This
manual may be useful to non-Mazda trained technicians, but a technician
ith our service-related training and experience ill be at less risk hen
performing servicing operations. Ho ever, all users of this manual are
expected to kno general safety procedures.
This manual contains “Warnings” and “Cautions” applicable to risks not
normally encountered in a general technician’s experience. They should
be follo ed to reduce the risk of injury and the risk that improper service or
repair may damage the vehicle or render it unsafe. It is also important to
understand that the “Warnings” and “Cautions” are not exhaustive. It is
impossible to arn of all the hazardous consequences that might result
from failure to follo the procedures.
The procedures recommended and described in this manual are effective
methods of performing troubleshooting and repair. Some require tools
specifically designed for a specific purpose. Nonrecommended
procedures and tools should include consideration for safety of the
technician and continued safe operation of the vehicle.
Parts should be replaced ith genuine Mazda replacements parts, not
parts of lesser quality. Use of a nonrecommended replacement part
should include consideration for safety of the technician and continued
safe operation of the vehicle.

VEHICLE IDENTIFICATION NUMBERS (VIN)
6 6
1YV GE22C*T5 500001 -
1YV GE22D*T5 500001 -
MX-6
1YV GE31CTT5 500001 -
1 YV GE31 D*T5 500001 -

1996
Mazda
6 6/MX-6
Body Electrical
Troubleshooting
Manual
FORWARD
For proper repair and maintenance, a
thorough familiarization ith this manual is
important, and it should al ays be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
dra ings and specifications, are the latest
available at the time of printing. As
modifications affecting repair or maintenance
occur, relevant information supplementary to
this volume ill be made available at Mazda
dealers. This manual should be kept up-to-
date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual ithout obligation or advance
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by
any means, electronic or mechanical -
including photocopying and recording, and
the use of any kind of information storage
and retrieval system - ithout permission in
riting.
WARRANTY
The manufacturer’s arranty on Mazda
vehicles and engines can be voided if
improper service or repairs are performed by
persons other than those at an Authorized
Mazda Dealer.
Mazda Motor Corporation
Hiroshima, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning ith the Vehicle Identification
Numbers (VIN) sho n on the follo ing page.
CONTENTS
Title Section
General Information Gl
Ground
Electrical Wiring Schematic W
Fuse / Relay / CPU / Switches Z1—4
Instrument Cluster / Warning System C1,
Windshield Wiper and Washer D
Exterior Lighting System E
Signal Lighting System F
Heater and Air Conditioner Systems G
Rear Window Defroster /
Interior Lamp System 11,
Audio J
Power Window System /
Power Door Lock System / Keyless Entry System K1^3
Outer
Sliding Sunroof M1,
Power Seat P1
Cruise Control System Q
Air Bag System S
Theft-deterrent System / Horn T3, 4
Common Connectors x
Joint Box H R J I
© 1995 MAZDA MOTOR CORPORATION
PRINTED IN THE U.S.A.
FORM NO. 1493-10-95F
PART NO. 9999-95-084F-96

GENERAL INFORMATION
OUTLINE .................................. . .................. . Gl- 2
CONTENTS .................................................. Gl- 2
ADVISORY MESSAGES .............................. Gl- 2
BASIC FLOW OF TROUBLESHOOTING .... Gl- 2
HOW TO READ THE DIAGRAMS .................. Gl- 3
SYSTEM OPERATION ................................. Gl- 3
CIRCUIT DIAGRAM ..................................... Gl- 4
CONNECTOR LOCATIONS ......................... Gl- 5
TROUBLESHOOTING FLOWCHARTS ....... Gl- 6
REPLACEMENT PROCEDURES ................ Gl- 6
GROUND POINTS ....................................... Gl- 7
ELECTRICAL WIRING SCHEMATIC ............ Gl- 8
SYMBOLS .................................................... Gl- 9
ABBREVIATIONS ......................................... GI-11
FUNDAMENTAL TROUBLESHOOTING ......... GI-14
PRECAUTIONS ........................................... GI-14
HANDLING CONNECTORS.........................GI-16
USING ELECTRICAL TEST EQUIPMENT... GI-17
MEASURING VOLTAGE .......................... GI-18
MEASURING CONTINUITY /
RESISTANCE ............................................. GI-19
FINDING SHORT CIRCUITS ....................... GI-20

Gl OUTLINE
OUTLINE
CONTENTS
The Body Electrical Troubleshooting Manual is intended as an aid for repairing the body electrical sys
tems of the vehicle. The manual is divided into 6 sections:
Gl General Information Explains ho to use the manual, use test
equipment, check harnesses and connectors, and
find trouble spots
Y Ground Points Sho s ground routing to and from the battery
W Electrical Wiring Schematic Sho s the circuit layout for the entire vehicle
O T ,
Z
Individual system sections Sho s system operation, circuit and connector
diagrams, component and connector locations, and
troubleshooting and replacement procedures
XCommon Connectors Sho s common connectors throughout system
JB Joint Box Sho s joint box connections and terminals
ADVISORY MESSAGES
You’ll find several Warnings, Cautions, and Notes in this manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning
is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle could result if the caution is
ignored.
Note
A Note provides additional information that ill help you to complete a particular procedure.
BASIC FLOW OF TROUBLESHOOTING
END
GI-

HOW TO READ THE DIAGRAMS Gl
HOW TO READ THE DIAGRAMS
SYSTEM OPERATION
The system operation description sho s ho current flo s and ho the system operates.
ACC
POWER OUTSIDE MIRROR SWITCH
LEFT (DRIVER’S SIDE)
Sho s current flo
POWER OUTSIDE MIRRORS
System Operation
1. Vertical adjustment
* When the selector s itch is set to the left and the top of the po er outside mirror s itch is
pressed ith the ignition s itch at ACC, current flo s (solid line), the motor turns, and the
left mirror glass moves up ard. (Right mirror operation is similar.)
• When the selector s itch is set to the right and the bottom of the po er outside mirror s itch
is pressed ith the ignition s itch at ACC, current flo s (broken line), the motor turns, and
the right mirror glass moves do n ard. (Left mirror operation is similar.)
Explains ho the system
and its parts operate.
Gl—3

Gl HOW TO READ THE DIAGRAMS
CIRCUIT DIAGRAM
This diagram sho s the circuit layout for the system, from the po er supply to ground, together ith
details of the circuit connectors. The po er supply side is in the upper part of the diagram; the ground
side is in the lo er part. The diagram assumes the ignition s itch is at OFF.
Wire Color
• T o-color ires are indicated as color/color.
The first color is the base; the second is the stripe.
B/W is a black ire ith a hite stripe.
• The letter in ( ) is the connector reference.
Related Diagram
Indicates that the circuit
continues on a related
diagram.
Current Flow
Current flo s in the
direction of the arro .
Ground
Indicates either a unit or
harness ground. A
number gives the loca
tion reference sho n on
“Connector Locations.”
Connector Symbol
T o dashed lines indicate the same connector.
Circuit diagram Connector
symbol diagram symbol
Mata laiMrT-lu n
r * n
Femala CmD
Connector Diagram
Sho s connectors from the harness side.
Unused terminals are indicated by *.
Connector on harness sida
Vie from harness
GI-4

HOW TO READ THE DIAGRAMS Gl
CONNECTOR LOCATIONS
These illustrations show the harness and connector layout of the circuit.
POWER
OUTSIDE '
MIRROR
RH
Component Connector
Indicates the component that is attached
to the main harness connector.
El
Ground
BOX
Gl—5

Gl HOW TO READ THE DIAGRAMS
TROUBLESHOOTING FLOWCHARTS
The flo charts outline the steps to be taken once symptoms of the problem have been defined.
Ho to determine
the symptoms of the
problem and here
to refer for the trou
bleshooting proce
dure.
Checklist
s , Procedure / Proper operation Symptom Flo chart No.
1Operate rear iper t itch and veri
fy (hat iper operates. Rear iper does not opera!* 1
Rear iper continues operating after rear iper s itch
If turned OFF 2
2Turn OFF r*ar s itch during
rtar iper operation, and verify that
iper stop* at park position.
Autoitop operation does not ork
( iper immediately stops hen rear iper s itch k
turned OFF) 3
3Operate rear asher s itch and
verify that asher operates. Rear asher does not operate 4
Possible causes of
the problem
Flowchart No.1 j Symptom j Rear wiper does not operate
Possible causa
• HEAR WIPER (use burnt
• Damaged rear wiper motor
• Damaged CPU No.1
□
Damaged rear wiper and washer switch
Open circuit in wiring harness
Poor connection of connector
Flo chart
corresponding to the
symptom
Part location and
testing method illus
tration
Step 1
Check the REAR WIPER 10A fuse In the fuse block.
Vt: Btn*ry vofl«g«
Fuse Action
OK Go to Step Z
Bgmt fteplac* lusa iftar checking and repairing
iring harness
Step
1. Remove the rear hatch lower trim.
(Refer to the 1993 RX-7 Workshop Manual, Section S.)
. Turn (he ignition switch ON.
3. Measure the voltage at terminal wire (IVG) of the rear
wiper motor harness connector, V«: Battery voftage
Voltage Action
Vi Go to Step 3
Others Repair iring harness
(Fuse block—R tar iper motor)
Troubleshooting
procedure
REPLACEMENT PROCEDURES
These illustrations sho ho to remove and install or disassemble and assemble the components of a
system.
Tightening torque
specification
Step number in the
removal or disas
sembly order
Tightening torque
unit
Removal or disas
sembly order 1. Inner handle cover
. Door trim
3. Door screen
4. Glass run channel
5. Glass guide A
6. Glass guide B
7. Door glass
8. Power window regulator
Inspection .................... . page K1-13
G I-6

HOW TO READ THE DIAGRAMS Gl
GROUND POINTS
This section sho s the ground points of the vehicle’s main harness.
GROUND POINTS imiq t* jomt cottKC'9* »< CIGARETTE LIGHTER
INTERIOR LAMPS
JC*0t C re# (') X CO*<KC*Wi I')
»l > 1 i 1 >Tn
JC * W J 01 «1 C f tw tf d O * tn (ificFincla/iU x-f>* ot** c&wncia# tn r f t i i . s .
;(T^a . v ■;
*E3Sf
,t I ir , 1
•0* |IH 1
'* 1“ rM I . i l l k
Ground Indication Ground Point Reference Number
The ground connection numbers in the ground points
diagram correspond to those in the circuit diagram and
connector locations illustration.
GI-7

G1 HOW TO READ THE DIAGRAMS
ELECTRICAL WIRING SCHEMATIC
This section details the iring from the po er source to the main fuses and/or other fuses of each sys
tem. If a fuse burns, use this diagram to assist in po er source diagnosis.
GI-8

HOW TO READ THE DIAGRAMS Gl
SYMBOLS
Symbol
Battery
© ©
Ground (1)
Ground (2)
4 -
Fuse (1)
(blade)
Fuse (2)
(cartridge)
Main fuse/
Fusible link
Transistor (1)
CeU*nor (C)
Emltir (E)
Transistor (2)
Cot.cH* (C)
Meaning
Generates electricity through chemi
cal reaction.
Supplies direct current to circuits.
• Connecting point to vehicle body or
other ground ire here current flo s
from positive to negative terminal of
battery.
• Ground (1) indicates a ground point to
body through ire harness.
• Ground (2) indicates point here com
ponent is grounded directly to body.
Remarks
• Current ill not flo through a circuit if
ground is faulty.
• Melts hen current flo exceeds that
specified for circuit; stopping current
flo .
Precautions
• Do not replace ith fuses exceeding
specified capacity.
<Blade type> cCartridge type>
<Main fuse> <Fusible linlo
Electrical s itching component.
Turns on hen voltage is applied to
the base (B).
Reading code
2 S C 828 A f Revision mark
~c I .
_______________ /A.High-lrequency PNP
Semiconductor I B:Low-lrequency PNP
\ C.Hiflh'Irequency NPN
Number ol terminals \ D:Low-frequency NPN
Symbol
Resistance
Motor
Pump
Meaning
* A resistor ith a constant value.
* Mainly used to protect electrical com
ponents in circuits by maintaining
rated voltage.
* Reading resistance values.
<Colored>
■No.1 color band
■No.2 color band
■No.3 color band
‘ No.4 color band
Narro — n i l <-WkU
No.1 | No.2 No.3 No.4
Color Resistance
values Multiplier Tolerance
Black 0 0 x10°
Bro n 1 1 x101
Red 2 2 x102
Orange 33x103
Yello 4 4 x104
Green 5 5 X105
Blue 6 6 x106
Purple 7 7 xIO^
Grey 8 8 x108
White 9 9 X109
Gold x10-i ±5%
Silver X10-2 ± 10%
-+20%
<Numerical>
Third :x10"
Second! Resistance values
Converts electrical energy into
mechanical energy.
Pulls in and expels gases and liquids.
Light Emits light and generates heat hen
current flo s through filament. Cigarette lighter Electrical coil that generates heat.
G I-9

Gl HOW TO READ THE DIAGRAMS
Symbol
Horn
Speaker
DO
Heater
E .
Vehicle speedo
meter sensor
Ignition s itch
St n - '
£. ^ACC
Meaning
Generates sound hen current flo s.
Generates heat hen current flo s.
Movement of magnet in speedometer
turns contact ithin sensor on and off.
Turning ignition key operates s itch
contacts to complete various circuits.
Symbol
S itch (1)
Normally open (NO)
S itch (2)
Normally closed (NC)
Harness
(Not connected)
(Connected)
Meaning
Allo s or breaks current flo by
opening and closing circuits.
Unconnected intersecting harness.
Connected intersecting harness.
Relay (1)
t — t
Normally open (NO)
Relay (2)
1— r
Normally closed (NC)
Current flo ing through coil produces electromagnetic force causing contact to open or close.
Sensor (variable)
— —
Sensor
(thermistor)
Capacitor
(condenser)
Solenoid
Resistor hose resistance changes
ith operation of other components.
Resistor hose resistance changes
ith temperature.
Component that temporarily stores
electrical charge.
Current flo ing through coil generates
electromagnetic force to operate
plungers.
Diode
Light-emitting
diode
(LED)
-H-
Reference diode
(Zener diode)
Kno n as a semiconductor rectifi
er, the diode allo s current flo
in one direction only.
C n ho d fl(K ) M Ao odo (A )
R o w of elftctflc current
K - m - A K- -A K -G E > A
• A diode that lights hen current
flo s.
• Unlike ordinary light bulbs, the
diode does not generate heat
hen lit.
Cathode(K) — Anode(A)
/ ---- n=>— Calhode(K)
^ -- Lf=;— Anode(A)
Flo of electric current
Allo s current to flo in one direc
tion up to a certain voltage; allo s
current to flo in the other direction
GI-10

HOW TO READ THE DIAGRAMS Gl
ABBREVIATIONS
Mazda Standards
AAmpere pFront NO Normally Open
AE Acoustic Equilibration FL Front Left P Po er
AS Autostop FR Front Right R Rear
A/R Auto Reverse FM Frequency Modulation RH Right Hand
ACC Accessory H/D Heat/Defroster RL Rear Left
ACCEL Accelerator HEAT Heater RPM Revolutions Per Minute
AM Amplitude Modulation HI High RR Rear Right
AMP Amplifier IG Ignition REC Recirculation
ANT Antenna ILLUMI Illumination SAS Sophisticated Air bag
ATX Automatic Transaxle INT Intermittent Sensor
BBattery JB Joint Box SOL Solenoid
CPU Central Processing Unit LH Left Hand SST Special Service Tool
CCT Circuit LCD Liquid Crystal Display ST Start
CIGAR Cigarette LO Lo SW S itch
COMBI Combination M Motor TEMP Temperature
CONT Control MAX Maximum TNS Tail Number Side Lights
DEF Defroster MID Middle TR Transistor
DRL Daytime Running Light MIN Minimum VENT Ventilation
ELR Emergency Locking MIX Mixture VOL Volume
Retractor MPX Multiplex
r— i r" /"*
IZLlZL/ Electric MTX Manual Transaxle
ETR Electronic Tuner Radio NC Normally Closed
Gl—11

Gl HOW TO READ THE DIAGRAMS
SAE Standards
In accordance ith ne regulations, SAE (Society of Automotive Engineers) standard names and
abbreviations are no used in this manual. The table belo lists the names and abbreviations that have
been used in Mazda manuals up to no and their SAE equivalents.
Previous Standard SAE standard
Abbreviation Name Abbreviation Name Remark
_Accelerator Pedal AP Accelerator Pedal
— Air Cleaner ACL Air Cleaner
—Air Conditioning A/C Air Conditioning
— Airflo Meter VAF Volume Air Flo Sensor
—Airflo Sensor MAF Mass Air Flo Sensor
—Alternator GEN Generator
—ATF Thermosensor —Transmission (Transaxle) Fluid
Temperature Sensor
—Atmospheric Pressure BARO Barometric Pressure
VbBattery Voltage B+ Battery Positive Voltage
—Catalytic Converter
OC Oxidation Catalytic Converter
TWC Three- ay Catalytic Converter
WU-TWC Warm Up Three- ay Catalytic
Converter #1
—Circuit Opening Relay FPR Fuel Pump Relay #2
__ Clutch Position CPP Clutch Pedal Position
—Crank Angle Sensor CMP Camshaft Position Sensor
—Crank Angle Sensor 2 CKP Crankshaft Position Sensor
—Diagnosis Connector DLC Data Link Connector
—Diagnosis/Self-Diagnosis OBD On-Board Diagnostic
—Direct Ignition DLI Distributorless Ignition
—EC-AT Control Unit TCM Transmission (Transaxle) Control
Module
EGI Electronic Gasoline Injection System CIS Continuous Fuel Injection System
—Electronic Spark Ignition El Electronic Ignition #3
ECU Engine Control Unit PCM Po ertrain Control Module #4
ECM Engine Control Module
—Engine Modification EM Engine Modification
—Engine RPM Signal _Engine Speed Input Signal
—Evaporative Emission EVAP Evaporative Emission
—Exhaust Gas Recirculation EGR Exhaust Gas Recirculation
—Fan Control FC Fan Control
—Feedback System CLS Closed Loop System
—Flexible Fuel FF Flexible Fuel
—Fuel Pump FP Fuel Pump
—Fully Closed CTP Closed Throttle Position
—Fully Open WOT Wide Open Throttle
—Ground/Earth GND Ground
—IC Regulator VR Voltage Regulator
#1: Directly connected to exhaust manifold
#2: In some models, there is a fuel pump relay that controls pump speed.
That relay is no called the fuel pump relay (Speed).
#3: Controlled by the ECM (PCM)
#4: Device that controls engine and po ertrain
GI-1

HOW TO READ THE DIAGRAMS Gl
Previous Standard SAE Standard
Abbreviation Name Abbreviation Name Remark
—Idle Speed Control IAC Idle Air Control
—Idle S itch —Closed Throttle Position S itch
Igniter ICM Ignition Control Module
_Inhibitor Position TR Transmission (Transaxle) Range
—Intake Air Pressure MAP Manifold Absolute Pressure
—Intake Air Thermo IAT Intake Air Temperature
—Intercooler CAC Charge Air Cooler
_Knock Sensor KS Knock Sensor
—Line Pressure Solenoid Valve —Pressure Control Solenoid
—Lock-up Position TCC Torque Converter Clutch
—Malfunction Indicator Light MIL Malfunction Indicator Lamp
_Multiport Fuel Injection MFI Multiport Fuel Injection
—Open Loop OL Open Loop
—Overdrive 4GR Fourth Gear
—Oxygen Sensor H02S Heated Oxygen Sensor With heater
02S Oxygen Sensor
—Park/Neutral Range PNP Park/Neutral Position
—Po er Steering Pressure PSP Po er Steering Pressure
—Pulse Generator —Input/Turbine Speed Sensor
—Reed Valve SAPV Secondary Air Pulse Valve
—Secondary Air Injection System PAIR Pulsed Secondary Air Injection Pulsed
injection
AIR Secondary Air Injection Inject ith
compressor
—Sequential Fuel Injection SFI Sequential Multipoint Fuel Injection
_Service Code(s) DTC Diagnostic Trouble Code(s)
—Spark Ignition Dl Distributor Ignition
—Stoplight S itch —Brake S itch
_Test Mode DTM Diagnostic Test Mode #5
—Throttle Body TB Throttle Body
—Throttle Sensor TP Throttle Position Sensor
—Turbocharger TC Turbocharger
_Vehicle Speed Sensor VSS Vehicle Speed Sensor
— Vehicle Speed Sensor 1_Output Speed Sensor
—Water Thermo ECT Engine Coolant Temperature
—1—2 Shift Solenoid Valve —Shift Solenoid A
Shift A Solenoid Valve
—2—3 Shift Solenoid Valve —Shift Solenoid B
Shift B Solenoid Valve
—3—4 shift Solenoid Valve —Shift Solenoid C
—3rd Gear 3GR Third Gear
— — —Incorrect Gear Ratio
#5: Diagnostic trouble codes depend on the diagnostic test mode
GI-13

Gl FUNDAMENTAL TROUBLESHOOTING
FUNDAMENTAL TROUBLESHOOTING
PRECAUTIONS
Disconnecting the Battery
• Disconnect the negative (-) battery cable first and
reconnect it last. Make sure all s itches, including the
ignition s itch, are at OFF before disconnecting or con
necting the battery cables. If a s itch is on, semicon
ductor components may be damaged.
Replacing Fuses
• Replace blo n fuses ith ones having the same desig
nated capacity. If a fuse is replaced ith one of a larger
capacity, components may be damaged or a fire may
result.
Securing Harnesses
• Clamp all harnesses that are near vibrating compo
nents, such as the engine, to remove slack and prevent
contact resulting from vibration. If the harness is in con
tact ith a vibrating part, the harness insulation may
ear or break.
• Tape areas of the harness that may rub or bump
against sharp edges. Without the tape, the harness
insulation may be cut.
• When mounting components, make sure the harness is
not caught. If it is caught, the harness insulation may
ear or break.
GI-14

FUNDAMENTAL TROUBLESHOOTING Gl
Handling Components
• Do not handle electrical components roughly or drop
them. Do not alter the iring or electrical equipment.
Doing so can overload or short a circuit, hich may
cause a fire or damage the vehicle or components.
• Remove heat-sensitive components, such as relays,
hen performing maintenance here temperatures can
exceed 80°C {176°F}, such as elding.
• Make sure connectors are fitted securely hen
installed.
• When disconnecting t o connectors, grasp the connec
tors, not the ires.

Gl FUNDAMENTAL TROUBLESHOOTING
HANDLING CONNECTORS
Removing connectors Checking connector
contacts Checking for loose
terminals Removing terminals
CD
Q.
&
is
CL
03
Q .
Cl
i
"5
CL
O )
C 0 iS'
<CPU connectors>
When using a matching
male terminal, make
sure there is no
looseness in the female
terminal.
Improperly engaged
connectors ill cause
poor terminal contact.
Lightly pull each ire to
make sure the terminal
does not pull out of the
connector.
A loose terminal ill
cause poor terminal
contact.
1. Open the rear
cover.
2. Lift the tab ith a
small scre driver
to remove the
terminal.
<General connectors>
Lift the tab ith a
small scre driver to
remove the terminal.
<Round connectors>
= t^S 3 J
Open the cover.
Lift the terminal
to remove it.
3. Make sure the
terminal is
securely
mounted in the
connector hen
reinstalling.
cCommon ground connectors>
1. Open the cover.
2. Remove A.
3. Lift the tab ith a
small scre driver
to remove the
terminal.
GI-16