Mazda 626 1999 User Manual

mazda :: Mazda 626 LX L4-2.0L DOHC (1999)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Technical Service Bulletins > Accessories - Keyless Entry Service Information

Keyless Entry Module: Technical Service BulletinsAccessories - Keyless Entry Service Information

Bulletin No: 09-018/01
Last Issued: 12/21/2001

Subject:SERVICE INFORMATION FOR KEYLESS ENTRY SYSTEM

APPLICABLE MODEL(S)/VINs1999-2002 Millenia1999-2002 Protege1999-2002 6261999-2002 Miata2000-2002 MPV
DESCRIPTION

It is not necessary to replace BOTH the keyless entry unit and the transmitter when repairing the keyless entry systems.
If there are any concerns with the keyless entry system, then first determine which of the parts is inoperative, and replace only the failed part.
REPAIR PROCEDURE

For troubleshooting the keyless entry system, refer to the appropriate Workshop Manual (section 09) for Symptom Troubleshooting the Keyless EntrySystem.

DISCLAIMER

> Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Technical Service Bulletins > Accessories - Keyless Entry Service Information

Keyless Entry Module: Technical Service BulletinsAccessories - Keyless Entry Service Information

Bulletin No: 09-018/01
Last Issued: 12/21/2001

Subject:SERVICE INFORMATION FOR KEYLESS ENTRY SYSTEM

APPLICABLE MODEL(S)/VINs1999-2002 Millenia1999-2002 Protege1999-2002 6261999-2002 Miata2000-2002 MPV
DESCRIPTION

It is not necessary to replace BOTH the keyless entry unit and the transmitter when repairing the keyless entry systems.
If there are any concerns with the keyless entry system, then first determine which of the parts is inoperative, and replace only the failed part.
REPAIR PROCEDURE

For troubleshooting the keyless entry system, refer to the appropriate Workshop Manual (section 09) for Symptom Troubleshooting the Keyless EntrySystem.

DISCLAIMER

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Testing and Inspection

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications

Electronic Brake Control Module: Specifications

Mounting Bolt ....................................................................................................................................................................... 2.4 - 2.8 Nm (21 - 24 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 20

Electronic Brake Control Module: Service and Repair

ABS HYDRAULIC UNIT AND CONTROL MODULE REMOVAL/INSTALLATION

Note:

The ABS hydraulic unit is not purchased as one part. Replace the ABS hydraulic unit and control module component as one assembly partif the ABS hydraulic unit is malfunctioning.

ABS Hydraulic Unit And ABS Control Module Removal/installation Note

-

When removing/installing the ABS hydraulic unit and ABS control module from/to the vehicle, attach protective tape on the HU connector toprevent brake fluid from entering.

ABS Control Module Removal Note

1. Install the screw plugs (supplied in the service part kit) onto the brake pipe holes of the HU.2. Disconnect the motor connector as follows.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 21

626 LX L4-2.0L DOHC (1999)

1. Remove the charcoal canister.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

Do not apply force on the looking tab when disconnecting the connector.Caution:

1) Lift up the tab to unlock the connector by hand.2) Pull the connector from the ABS CM by grasping the side of the motor connector.

3. Carefully pull the wiring of the pump motor out of the cable guides.

4. Secure the HU as shown. 5. Remove the bolts.6. Protect the HU from damage to the valve body and keep the sealing surface free from foreign materials.

ABS Control Module Installation Note

1. Verify that the sealing surface of the HU is clean. If there are scratches, grooves or dirt, do not mechanically rework. Carefully remove any dirt or
seal residue with plastic tools only. The use of chemical solvents is not permitted.

2. Install the spring plate properly. When re-installing, insert the spring plate over the valve bodies in the correct position to preload the spring and to
center the solenoid coils.

3. Carefully fit the coils of the ABS CM over the valve bodies.4. Locate the ABS CM by placing the new bolts evenly against the housing and tightening them slightly by hands. To aid alignment, the housing may
be pressed onto the contact surface by hand while tightening the bolts.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 22

626 LX L4-2.0L DOHC (1999)

5. Tighten the bolts to the specified torque in the order shown.

Tightening torque: 2.4-2.8 Nm (24-28 kgf-cm, 21-24 inch lbs.)

6. Visually inspect for all bolts mode contact. The ABS CM must be flush against the housing with no gap in the area of the bolts.

7. Connect the 2-pin connector of the pump motor to the ABS CM. Verify that the spring clip is engaged securely.8. Clip the wiring back in the cable guide.9. Reinsert the soft mount if it is fallen out.

10. Inspect flats of two side retaining bolts and position flats vertically by turning bolts as necessary.

> Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Testing and Inspection

Radiator Cooling Fan Motor Relay: Testing and Inspection
COOLING FAN RELAY INSPECTION

1. Disconnect the negative battery cable.

2. Remove the cooling fan relay.

- If not as specified, replace the cooling fan relay.

3. Apply battery positive voltage and inspect for continuity between terminals of the cooling fan relay by using an ohmmeter.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection

Blower Motor Relay: Testing and Inspection
A/C, BLOWER, AND CONDENSER FAN RELAY INSPECTION

1. Remove the relay.2. Check for continuity between the relay terminals by using an ohmmeter.
If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Testing and Inspection > Page 31

Blower Motor Relay: Service and Repair
BLOWER RELAY DISASSEMBLY/ASSEMBLY

1. Disconnect the negative battery cable.2. Remove the nuts to move the main fuse block to the side.3. Remove in the order indicated in the table.4. Install in the reverse order of removal.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Compressor Relay

Compressor Clutch Relay: Testing and InspectionCompressor Relay
A/C, BLOWER, AND CONDENSER FAN RELAY INSPECTION

1. Remove the relay.2. Check for continuity between the relay terminals by using an ohmmeter.
If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Compressor Relay > Page 36

Compressor Clutch Relay: Testing and InspectionCompressor Cut-Off Relay

ON

1. Start the engine and let it idle.2. Turn the A/C switch and the fan switch .3. Check if the operation sound of the A/C compressor electromagnetic clutch is heard. (A/C compressor starts to work.)4. Fully open the throttle valve. Check if the operation sound the A/C compressor magnetic clutch is heard. (A/C compressor stops to work.) Then, 3
after, check if the operation sound of the A/C compressor electromagnetic clutch is heard.- 6 seconds

5. Turn the A/C switch and the fan switch .OFF

6. If the operation sound is not heard:

ON

1. Connect a jumper wire between both terminals of A/C pressure switch connector.2. Turn the ignition switch .3. Turn the A/C switch and the fan switch . Verify that operation sound is heard from A/C relay.ON

4. If the operation sound is heard, check the following PID using NGS tester.

- TP V PID.

5. If the operation sound is not heard, check the following.

- A/C relay.

- Open or short to ground circuit in wiring harnesses and connectors (Main relay-A/C relay-PCM terminal 69)

- A/C related parts.

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection

Condenser Fan Motor Relay: Testing and Inspection

OFF

1. Verify that A/C switch and fan switch are .2. Start the engine and let it idle.3. Verify that the condenser fan is not operating.

4. If condenser fan is operating, check:

- Condenser fan relay for stuck in closed position.

- Short to power in circuit between condenser fan relay and condenser fan.

- Short to ground in circuit between A/C pressure switches and PCM.

- Short to ground circuit between condenser fan relay and PCM terminal 17 (short circuit).

ON

5. Turn the A/C switch and fan switch .6. Verify that the condenser fan is operating and operating sound of A/C compressor magnetic clutch is heard.7. Turn the A/C switch and fan switch .OFF

8. If the condenser fan does not operate but operating sound of A/C compressor magnetic clutch is heard, check as follows:

- Open circuit between ignition switch and condenser fan relay.

- Open circuit between battery and condenser fan relay.

- Open circuit between condenser fan relay and PCM.

- Open circuit between condenser fan relay and condenser fan motor or fan motor ground.

- Condenser fan relay stuck to open.

- Condenser fan motor.

9. If both condenser fan and A/C compressor do not operate, check:

- TP V PID.

- A/C system.

A/C, BLOWER, AND CONDENSER FAN RELAY INSPECTION

1. Remove the relay.2. Check for continuity between the relay terminals by using an ohmmeter.
If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Condenser Fan Motor Relay, HVAC > Component Information > Testing and Inspection > Page 40

Condenser Fan Motor Relay: Service and Repair
CONDENSER FAN RELAY REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Headlight High Relay

Headlamp Relay: Testing and InspectionHeadlight High Relay
HEADLIGHT HIGH RELAY INSPECTION

Canada Only

1. Remove the headlight high relay.2. Check for continuity between the headlight high relay terminals by using an ohmmeter.
If not as specified, replace the headlight high relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Headlight High Relay > Page 46

Headlamp Relay: Testing and InspectionHeadlight Relay
HEADLIGHT RELAY INSPECTION

1. Disconnect the negative battery cable.2. Remove the headlight relay.3. Check for continuity between the headlight relay terminals by using an ohmmeter.
If not as specified, replace the headlight relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Testing and Inspection > Page 47

Headlamp Relay: Service and Repair
HEADLIGHT HIGH RELAY REMOVAL/INSTALLATION

Canada Only

1. Disconnect the negative battery cable.2. Remove the nuts to move the main fuse block to the side.3. Disconnect the connector.4. Remove the headlight high relay.5. Install in the reverse order of removal.

> Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Testing and Inspection

Horn Relay: Testing and Inspection
HORN RELAY INSPECTION

1. Remove the horn relay.2. Check for continuity between the horn relay terminals by using an ohmmeter.
If not as specified, replace the horn relay.

> Relays and Modules > Relays and Modules - Lighting and Horns > Tail Lamp Relay > Component Information > Testing and Inspection

Tail Lamp Relay: Testing and Inspection
TNS RELAY INSPECTION

1. Disconnect the negative battery cable.2. Remove the TNS relay.3. Check for continuity between the TNS relay terminals by using an ohmmeter.
If not as specified, replace the TNS relay.

> Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > I-4a

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > I-4a > Page 64

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and

Instructions

Body Control Module: Diagram Information and Instructions

Contents of Wiring Diagrams

^ This document comprises the 7 groups shown.

Ground Points

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 67

626 LX L4-2.0L DOHC (1999)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 68

626 LX L4-2.0L DOHC (1999)

^ This shows ground points of the harness.

Routing Diagram

^ The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector symbols.

Wiring Color Code

............................................................................................................................................................................................................................. Color Code

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 69

626 LX L4-2.0L DOHC (1999)

Blue ...................................................................................................................................................................................................................................... LBlack ................................................................................................................................................................................................................................... BBrown ............................................................................................................................................................................................................................... BRDark Blue .......................................................................................................................................................................................................................... DLDark Green ....................................................................................................................................................................................................................... DGGreen ................................................................................................................................................................................................................................... GGray .................................................................................................................................................................................................................................. GYLight Blue ......................................................................................................................................................................................................................... LBLight Green ....................................................................................................................................................................................................................... LGNatural ................................................................................................................................................................................................................................. NOrange ................................................................................................................................................................................................................................. OPink ...................................................................................................................................................................................................................................... PRed ...................................................................................................................................................................................................................................... RPurple ................................................................................................................................................................................................................................ PUSky Blue ............................................................................................................................................................................................................................ SB

Tan ....................................................................................................................................................................................................................................... TWhite .................................................................................................................................................................................................................................. WYellow ................................................................................................................................................................................................................................. YViolet ................................................................................................................................................................................................................................... V

System Circuit Diagram/Connector Diagram

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 70

626 LX L4-2.0L DOHC (1999)

^

These diagrams show the circuits for each system, from the power supply to the ground. The power supply side is on the upper part, the groundside on the lower part. The diagrams describe circuits with the ignition switch off.Below is an explanation of the various points in the diagram.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and

Instructions > Page 71

Body Control Module: Connector Views

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 72

626 LX L4-2.0L DOHC (1999)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and

Instructions > Page 73

Body Control Module: Electrical Diagrams

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Diagram Information and Instructions > Page 74

626 LX L4-2.0L DOHC (1999)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 75

Body Control Module: Testing and Inspection
CPU INSPECTION

1. Remove the driver's side front shaft plate.2. Remove the driver's side front side trim.3. Remove the nut fixed in the joint box.4. Follow the appropriate procedure, referring to the terminal voltage list.

All terminals of the connector A

-NOTE:

The voltage cannot be measured nor can a continuity to ground check be performed at the terminals of connector A with the connectors connectedto the joint box.

­Remove the CPU from the joint box, then measure the voltage or check for continuity to ground at the CPU terminals from the joint box side withthe joint box connectors connected.

Disconnect the CPU connector before checking for continuity at terminals 4B and 4D as shown in the figure.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Page 76

626 LX L4-2.0L DOHC (1999)

-Terminals 4B and 4D of connector D

-Terminals except 4B and 4D of connector D

Measure the voltage at the CPU connector while it is connected with the CPU as shown in the figure.

5. If not as specified, inspect' the parts listed under Inspection area" and the related wiring harnesses.

6. If the parts and wiring harnesses are okay but system still does not work properly, replace the CPU.

Connector Views A,B,C,D

Terminal Values 1A-1F

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Page 77

626 LX L4-2.0L DOHC (1999)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Page 78

626 LX L4-2.0L DOHC (1999)

Terminal Values 1G-2E

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component

Information > Diagrams > Page 79

626 LX L4-2.0L DOHC (1999)

Terminal Values 2F-4C

Terminal Values 4D-4N

Terminal Voltage List (Reference)

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 80

Body Control Module: Service and Repair
CPU REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the driver's side front shaft plate.3. Remove the driver's side front side trim.4. Remove in the order indicated in the table.5. Install in the reverse order of removal.

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 84

Engine Control Module: Diagrams

B1-01 PCM (EM)

Terminals 1 Thru 9

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Locations > Page 85

626 LX L4-2.0L DOHC (1999)

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Locations > Page 86

626 LX L4-2.0L DOHC (1999)

Terminals 10 Thru 30

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Locations > Page 87

626 LX L4-2.0L DOHC (1999)

Terminals 31 Thru 51

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Locations > Page 88

626 LX L4-2.0L DOHC (1999)

Terminals 52 Thru 66

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Locations > Page 89

626 LX L4-2.0L DOHC (1999)

Terminals 67 Thru 87

Terminals 88 Thru 104

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests

and General Diagnostics

> Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Testing and Inspection > Component Tests

and General Diagnostics > Page 92

Engine Control Module: Pinout Values and Diagnostic Parameters

Terminal Voltage Inspection

CAUTION:

The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of theinput systems, output systems and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.

USING THE SST 104 PIN BREAKOUT BOX

1. Disconnect the negative battery cable.2. Disconnect the PCM connector.

SST

3. Connect the (104 Pin Breakout Box) to the PCM as shown.4. Tighten the connector bolt.

Tightening torque: 7.9 - 10.7 Nm (80 -110 kg.m, 69.5 - 95.4 in.lb.)

5. Connect the negative battery cable.6. Measure the voltage at each terminal.

-

If any incorrect voltage is detected, check related systems, wiring harnesses and connectors referring to the possible malfunction in theterminal voltage list.

Terminals 1 Thru 9

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Testing and Inspection > Component Tests and General Diagnostics > Page 93

626 LX L4-2.0L DOHC (1999)

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Testing and Inspection > Component Tests and General Diagnostics > Page 94

626 LX L4-2.0L DOHC (1999)

Terminals 10 Thru 30

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Testing and Inspection > Component Tests and General Diagnostics > Page 95

626 LX L4-2.0L DOHC (1999)

Terminals 31 Thru 51

> Relays and Modules> Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component

Information > Testing and Inspection > Component Tests and General Diagnostics > Page 96

626 LX L4-2.0L DOHC (1999)

Terminals 52 Thru 66