Mazda Millenia 1999 User Manual

mazda :: Mazda Millenia V6-2.5L DOHC (1999)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Testing and Inspection

Audio Control Relay: Testing and Inspection
AUDIO RELAY INSPECTION

1. Remove the audio relay. 2. Apply battery positive voltage and check for continuity between the audio relay terminals.3. If not as specified, replace the audio relay.

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Audio Control Relay > Component Information > Testing and Inspection > Page 7

Audio Control Relay: Service and Repair
AUDIO RELAY REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the rear seat back. 3. Disconnect the audio relay connector.

4. Remove the audio relay.5. Install in the reverse order of removal

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Locations

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information and Instructions

Central 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 - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 13

Millenia V6-2.5L DOHC (1999)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 14

Millenia V6-2.5L 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.

System Circuit Diagram/Connector Diagram

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 15

Millenia V6-2.5L DOHC (1999)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 16

Millenia V6-2.5L DOHC (1999)

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information

and Instructions > Page 17

Millenia V6-2.5L 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.

Wiring Color Code

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

Blue ...................................................................................................................................................................................................................................... LBlack ................................................................................................................................................................................................................................... BBrown ............................................................................................................................................................................................................................... BRDark Blue .......................................................................................................................................................................................................................... DLDark Green ....................................................................................................................................................................................................................... DG

Green ................................................................................................................................................................................................................................... GGray .................................................................................................................................................................................................................................. GYLight Blue ......................................................................................................................................................................................................................... LBLight Green ....................................................................................................................................................................................................................... LGNatural ................................................................................................................................................................................................................................. NOrange ................................................................................................................................................................................................................................. OPink ...................................................................................................................................................................................................................................... PRed ...................................................................................................................................................................................................................................... RPurple ................................................................................................................................................................................................................................ PUSky Blue ............................................................................................................................................................................................................................ SBTan ....................................................................................................................................................................................................................................... TWhite .................................................................................................................................................................................................................................. WYellow ................................................................................................................................................................................................................................. YViolet ................................................................................................................................................................................................................................... V

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 18

> Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Central Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 19

> 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 > Specifications

ABS Main Relay: Specifications

Bracket Mounting Nut ..................................................................................................................................................... 7.9 - 10.7 Nm (70 - 95.4 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 33

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 34

ABS Main Relay: Testing and Inspection

ABS RELAY INSPECTION

Fail-safe Relay Inspection Including Harness to ABS CM

1. Turn the ignition switch to OFF and disconnect the ABS control module connector.2. Turn the ignition switch to ON.

3. Connect terminal 2J [2B for ABS/TCS] of the control module connector to a ground.

4. Check the points.5. If not as specified, inspect the wiring harness and the fail-safe relay.

Fail-safe Relay Inspection

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 35

Millenia V6-2.5L DOHC (1999)

1. Measure resistance between terminals C and D of ABS relay connector.

2. Check for continuity between following terminals.3. If not as specified, replace the ABS relay.

Motor Relay Inspection Including Harness To ABS CM

1. Inspect the fail-safe relay.2. Turn the ignition switch to OFF and disconnect the ABS control module connector.3. Turn the ignition switch to ON.4. Connect terminal 2J [2B for ABS/TCS] to a ground.

5. Connect terminal 2H [2A for ABS/TCS] to a ground.

6. Check the following points: Allowing the motor to operate for more than two seconds will damage the motor.7. If not as specified, inspect the wiring harness and the motor relay.

Motor Relay

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 36

Millenia V6-2.5L DOHC (1999)

1. Measure the resistance between terminals E and H, or between a and h of the ABS relay connector.

2. Check for continuity between terminals B and F.3. If not as specified, replace the ABS relay.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay > Component Information > Specifications > Page 37

ABS Main Relay: Service and Repair

REMOVAL/INSTALLATION

The ABS relay contains the fail-safe relay and the motor relay.Note:

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

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

Electronic Brake Control Module: Specifications

Mounting Nuts .................................................................................................................................................................. 8.9 - 12.7 Nm (79 - 112 inch lbs.)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 41

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 42

Electronic Brake Control Module: Testing and Inspection

INSPECTION

Part 1 Of 2

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 43

Millenia V6-2.5L DOHC (1999)

Part 2 Of 2

Terminal Voltage Chart (Reference Value)

(ignition switch is at ON, and connector is connected unless indicated otherwise)

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications > Page 44

Electronic Brake Control Module: Service and Repair

REMOVAL/INSTALLATION

1. Remove in the order indicated in the table.

2. Install in the reverse order of removal.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams > Page 48

Traction Control Module: Testing and Inspection

1. Warm up the engine to normal operating temperature and let it idle.2. Connect NGS tester to the data link connector-2 and retrieve diagnostic trouble code.

If the following DTC is indicated, follow the appropriate troubleshooting procedure:-

P0100 (Mass air flow sensor circuit malfunction)

- P0105 (Manifold absolute pressure/Barometric pressure sensor circuit malfunction)

- P0110 (Intake air temperature sensor circuit malfunction)

- P0115 (Engine coolant temperature sensor circuit malfunction)

- P0125 (Excessive time to enter closed loop)

- P0120 (Throttle position sensor circuit malfunction)

- P0130, P0134, P0140, P0150, P0154, P0160 (Heated oxygen sensor circuit malfunction no activity detected)

- P0335 (Crankshaft position sensor circuit malfunction)

- P1110 (Intake air temperature sensor (Dynamic chamber) circuit malfunction)

3. Connect the NGS tester to the data link connector. Retrieve the diagnostic trouble code for the ABS system. If any DTC is displayed, follow the
appropriate troubleshooting procedure.

4. With no electrical load operating, check the torque reduction inhibit signal at the ABS/TCS control module 2R terminal using an oscilloscope. If
the torque reduction inhibit signal cannot be detected, check for open or short circuit between ABS/TCS control module 2R terminal andpowertrain control module 1S terminal.

5. Lift up the vehicle.6. Shift the selector lever to D.7. Depress the accelerator pedal, and verify that the engine speed does not exceed .1,500 rpm

8. If the engine speed smoothly increases over , check the torque reduction request signal at the ABS/TCS control module 2S terminal1,500 rpm

using an oscilloscope. If the torque reduction request signal can be detected at the ABS/TCS control module 2S terminal, check for open or shortcircuit between the ABS/TCS 2S terminal and powertrain control module 1Q terminal.

9. Depress the accelerator pedal, and verify that the signal changes as shown in the figure. If there is no change, check the ABS/TCS control module.

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams > Page 49

Traction Control Module: Service and Repair

REMOVAL/INSTALLATION

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

ABS/TCS CONTROL MODULE INSPECTION

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams > Page 50

Millenia V6-2.5L DOHC (1999)

Part 1 Of 3

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams > Page 51

Millenia V6-2.5L DOHC (1999)

Part 2 Of 3

> Relays and Modules > Relays and Modules - Brakes and Traction Control > Traction Control Module > Component Information > Diagrams > Page 52

Millenia V6-2.5L DOHC (1999)

Part 3 Of 3

Terminal Voltage Chart (Reference Value)

(Ignition switch is at ON, and connector is connected unless indicated otherwise)

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

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection

Cruise Control Module: Testing and Inspection
CRUISE CONTROL MODULE INSPECTION

1. Measure the voltage at the cruise control module terminals as indicated below.2. Disconnect the cruise control module connector before inspecting continuity at terminal T.3. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses.4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the cruise control module.

Connector View

Terminal Voltage List (Reference)

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection > Page 61

Millenia V6-2.5L DOHC (1999)

Terminal List (A-M)

Terminal List (N-T)

> Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Testing and Inspection > Page 62

Cruise Control Module: Service and Repair
CRUISE CONTROL MODULE REMOVAL/INSTALLATION

1. Remove the scuff plate and front side trim. 2. Remove in the order indicated in the table.3. Install in the reverse order of removal.

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

Blower Motor Relay: Testing and Inspection
BLOWER RELAY AND MAX-HI RELAY INSPECTION

1. Remove the relay. 2. Check for no continuity between terminals B and F of the relay connector (male).

3. Connect battery positive voltage to terminal A and ground to terminal E of the relay connector (male).4. Check for continuity between terminals B and F.5. If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Blower Relay

Blower Motor Relay: Service and RepairBlower Relay
BLOWER RELAY REMOVAL/INSTALLATION WITH (KL)2.5L

1. Disconnect the negative battery cable.2. Remove the blower relay.

3. Disconnect the blower relay connector.4. Install in the reverse order of removal.

> Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Blower Relay > Page 69

Blower Motor Relay: Service and RepairMax-Hi Relay
MAX-HI RELAY REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.2. Remove the under cover.3. Remove the MAX-HI relay

4. Disconnect the MAX-HI relay connector.5. Install in the reverse order of removal.

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

Compressor Clutch Relay: Testing and Inspection
A/C RELAY, CONDENSER FAN RELAY No.1 AND No.2 INSPECTION

1. Remove the relay. 2. Check for no continuity between terminals C and D of the relay connector (male).

3. Connect battery positive voltage to terminal A and ground to terminal B of the relay connector (male).4. Check for continuity between terminals C and D.5. If not as specified, replace the relay.

> Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Page 73

Compressor Clutch Relay: Service and Repair
A/C RELAY REMOVAL/INSTALLATION WITH (KL)2.5L

1. Disconnect the negative battery cable.2. Remove the A/C relay.

3. Disconnect the A/C relay connector.4. Install in the reverse order of removal.

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

Condenser Fan Motor Relay: Testing and Inspection
A/C RELAY, CONDENSER FAN RELAY No.1 AND No.2 INSPECTION

1. Remove the relay. 2. Check for no continuity between terminals C and D of the relay connector (male).

3. Connect battery positive voltage to terminal A and ground to terminal B of the relay connector (male).4. Check for continuity between terminals C and D.5. 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 77

Condenser Fan Motor Relay: Service and Repair
A/C RELAY, CONDENSER FAN RELAY No.1 AND No.2 REMOVAL/INSTALLATION WITH (KL)2.5L

1. Disconnect the negative battery cable.2. Remove the relays.

3. Disconnect the relay connectors.4. In stall in the reverse order of removal.

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C Amplifier

Climate Control Unit: Testing and InspectionA/C Amplifier
A/C AMPLIFIER INSPECTION

1. Disassemble the climate control component. 2. Connect the A/C amplifier connectors (26-pin, 22-pin, 20-pin) and information display connector.3. Start the engine.

4. Measure the voltage at each A/C amplifier terminal and refer to the terminal voltage list.5. If not as specified, inspect the parts listed under "Inspection area".6. If the parts are okay but the system still does not work properly, replace the A/C amplifier.

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C Amplifier > Page 82

Climate Control Unit: Testing and InspectionTerminal Voltage List (Reference)

TERMINAL VOLTAGE REFERENCE CHARTS AND FIGURES
Terminal Voltage Charts (Reference)

Connector View

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 83

Millenia V6-2.5L DOHC (1999)

Terminal Values Part (1 Of 7)

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 84

Millenia V6-2.5L DOHC (1999)

Terminal Values Part (2 Of 7)

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 85

Millenia V6-2.5L DOHC (1999)

Terminal Values Part (3 Of 7)

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 86

Millenia V6-2.5L DOHC (1999)

Terminal Values Part (4 Of 7)

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 87

Millenia V6-2.5L DOHC (1999)

Terminal Values Part (5 Of 7)

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 88

Millenia V6-2.5L DOHC (1999)

Terminal Values Part (6 Of 7)

Terminal Values Part (7 Of 7)

Terminal Voltage Figures (Reference)

Figure 1

> Relays and Modules > Relays and Modules - HVAC > Climate Control Unit <--> [Control Module HVAC] > Component Information > Testing and Inspection > A/C

Amplifier > Page 89

Millenia V6-2.5L DOHC (1999)

Figure 2

Figure 3