1996 Body Electrical Troubleshooting Manual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 were developed with Mazds-trained technicians in mind. This ‘manual may be useful to non-Mazda trained technicians, but a technician with our service-elated training and experience will be at less risk when performing servicing operations. However, all users of this manual are expected to know general safely procedures. ‘This manual contains "Waings” and “Cautions” applicable to risks not normally encountered in a general technician's experience. They should be followed 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 warn of all the hazardous consequences that might result from failure to follow 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 with 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 ofthe vehicle.VEHICLE IDENTIFICATION NUMBERS (VIN) 626 1YV GE220°TS 500001 - 4YV GE22D°T5 500001 — MX-6 1YV GE31C°TS 500001 — 1YV GE31D°TS 500001 —1996 Mazda 626/MX-6 Body Electrical Troubleshooting Manual FORWARD For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference. All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will 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 without obligation or advance notice. Alllrights reserved. No part of this book may 2e reproduced or used in any form or by any means, electronic or mechanical ~ ncluding photocopying and recording, and ‘he use of any kind of information storage and retrieval system ~ without permission in ‘mrting, WARRANTY The manufacturer's warranty 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 with the Vehicle Identification Numbers (VIN) shown on the following page. CONTENTS. General Information Rear Window Defroster] interior Lamp System Power Window System Power Door Lock System|/[Keyless Entry System [Power Seat} [Cruise Control System) [Power Seat] (Cruise Control System [Theft-deterrent System |{Horn] jommon Connectors) (© 1995 MAZDA MOTOR CORPORATION PRINTED IN THE U.S.A. FORM NO. 1493-10-95F PART NO. 9999-95-084F-96GENERAL INFORMATION GlGl OUTLINE OUTLINE CONTENTS The Body Electrical Troubleshooting Manual is intended as an aid for repairing the body electrical sys- tems ofthe vehicle. The manual is divided into 6 sections: Explains how fo use the manual, uso test G1 | General Information ‘equipment, check hamesses and connectors, and find trouble spots ¥_| Ground Points ‘Shows ground routing to and from the battery W_| Electrical Wiring Schematic | Shows the circuit layout for the entire vehicle Individual system sections | Shows system operation, cout and connector diagrams, component and connector locations, ana| troubleshooting and replacement procedures ‘Common Connectors ‘Shows common connectors throughout system IB_[Woint Box ‘Shows 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 warming 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 will help you to complete a particular procedure. BASIC FLOW OF TROUBLESHOOTING Determine faulty system(s) from customer. t “Turn to appropriate system section —— Work through each flowchart step. ' __t Follow checklist procedures. Reler to appropriate flowchart number Does system work properly? based on symptoms, yes Y END. Gl-2HOW TO READ THE DIAGRAMS. HOW TO READ THE DIAGRAMS ‘SYSTEM OPERATION ‘The system operation description shows how current flows and how the system operates. POWER OUTSIDE MIRROR SWITCH LeFr onwvens sie [Ih Lap] or eassenceres soe 6 POWER OUTSIOE MIRRORS: ‘System Operation 1. Vertical adjustment + When the selector switch is set to the left and the top of the power outside mirror switch is Gl pressed with the ignition switch at ACC, current flows (solid line), the motor turns, and the |_ Explains how the system left miror glass moves upward. (Right mirror operation is sila.) ‘+ When the selector switch is set to the right and the bottom of the power outside mitror switch | pressed with the ignition ewitch at ACC, current flows (broken line), the motor tums, and the right micror glass moves downward. (Left mirror operation is similar.) and its parts operate. Gai-3Gl HOW TO READ THE DIAGRAMS. CIRCUIT DIAGRAM This diagram shows the circuit layout for the system, from the power supply to ground, together with details of the circuit connectors. The power supply side is in the upper part of the diagram; the ground side is in the lower part. The diagram assumes the ignition switch is at OFF. ‘Two-color wires are indicated as colorcolor. ‘The first color is the base; the second is the stripe. | BIW is a black wire with a white stripe, ierin (_)is the connector reference, Current lows in the direction of the arrow. a p—egase Peery Indicates that the circuit Continues on a related diagram, Indicates either a urit or harness ground. A number gives the foca- tion reference shown on ‘Connector Locatiors, Cena Cerny ‘Two dashed ines indicate the same connector ‘Shows conneciors from the hamess side, Unused torminals are indicated by ». Circa diagram ] Connector symbol diagram symbol Gi4HOW TO READ THE DIAGRAMS Gl CONNECTOR LOCATIONS These illustrations show the harness and connector layout of the circuit. Cas Indicates the component that is attached iin harness connector. oR or nO GisGl HOW TO READ THE DIAGRAMS TROUBLESHOOTING FLOWCHARTS The flowcharts outline the steps to be taken once symptoms of the problem have been defined. How to determine Ra pI aaa the symptoms ofthe | FShaeermraeeccrerr 7 problem and where ete erat 2 torelerforthetow ] Hr pmoraaes : Beshooting prove- Smee dure. Ces : Frowchart (Fewcannet [oynpen [Bowerman Dp ernanato ne ‘symptom Possible causes of the problem + Sem we tater ec ‘esi is Troubleshooting able in procedure "HS Toushp an Socen 8) seen ttn erchge mera ea art location and testing method illus- 5 tration fore pea Se REPLACEMENT PROCEDURES These ilustrations show how to remove and install or disassemble and assemble the components of a system, _-Step number in the removal or disas- Tightening torque sembly order specification Tightening torque unit Removalor dsas- ot ane come sembly arder i. GI-6HOW TO READ THE DIAGRAMS Gl GROUND POINTS This section shows the ground points of the vehicle’s main harness. ¥ [FOO PONTE Cemrnn Cetra tres ‘connector locations illustration. Teoweut “The ground connection numbers in the ground points diagram correspond to those in the cicult diagram and Gi-7HOW TO READ THE DIAGRAMS. G1 ELECTRICAL WIRING SCHEMATIC This section details the wiring from the power source to the main fuses and/or other fuses of each sys- tem. Ifa fuse burns, use this diagram to assist in power source diagnosis. Er =a (Nn anos) ABELL Woud INSHENO (Nn. gsHsvo) 251 40 191 wows INauENO (ann NIKD 1S WOW, {__——iNauuno (ann Nayous) ‘20V NOH t___—“INsuuNS ae ane Autovayo eA Sa gg SS OTLWWSHOS ONTBIM WOTHIOST3« | ~~ insuuNOGNY Savi ashs BHYNWaLSAS GI-8HOW TO READ THE DIAGRAMS Gl SYMBOLS Symbol Meaning symbol Meaning Battery | » Generates elecvciy through chemi- || Resistance | Avesitor witha constant valve cal reaction. + Mainly used to protect electrical com- + Supplies iret curent to circuits i ponents in circus by malntlning S rated voltage. 20 Wr : + Reading resistance values. Ground (t) |» Connecting point to vehicle body or other ground wire where current flows clr and from positive to negative terminal of Nozcaer Send battery (eases + Ground (1) indicates a ground point to = body through wie hamess. Ground @) | + Ground (2) indicates point where com- Nano wise Ponent is grounded directly to body. = | Remarks [wor [Noz] Wo [ Wes + Current will not low through a circuit it aor | Resin Isp rowers ground is faulty. eecaniaal . Fuse () |» Metts when curent iow exceeds that peo oT of ae specified for circuit; stopping current ioe o> Ram ‘Orange| 3 [3 | xt0F Precautions Set ++ ck : + Do not replace with fuses exceeding Bee pe pete (blade) specified capacity. = 4 Pepe [77 ator Fuse (2) Grey 6 [6 [xo Wnts | -9-[-3-]-x108 C7e}- God mio | 2a Siver xi | 108% [C= “20% (cartridge)

- | Min fuser Fusibe tink | ess i | Te ro ae we | 3p rte Transistor (1) | + Electrical switching component. ‘Motor T+ Converts electrical energy into ‘ery | + Turns on when voltage fs applied to | mechanical eneray. — thease (8) ge = wo ce : Transistor (@) | + Reading code : Pump ~ Pll in and expels gases ane iquids. 25.6 820 A s— Anennmak [Gs Asighiegvney ne Tenontcor | thoteqrney ne aster ct erninals Slow tequeor RPM ght [> Emits ight and generates heat when || Cigareti lighter | ~ Elecrcal col that ganorates heat current flows through filament, Gl-9Gl HOW TO READ THE DIAGRAMS Symbol Meaning Symbol weaning Hom] > Generates sound when curent ows. || Swich i) |» Alows orbreake curent fow by opening and closing out. exalt 8) Speaker Switch @) CH may ose 0) Tisai | Generates heat when cuentfowe. || Hames | > Unconnectd itesaningharnasa. ‘Veticie speedo [> Movement of magnet in speedometer SS tier aencor” | lume comact wit eensoron and. |] (\ot connected) ih oo Teron ewtoh |» Torin ton Key operas ewich Contacte to complete various out am — Relay (1) |» Current flowing through col produces elecremagnei ce causing coll oopen o cose, Ty Open Soest wekrabra| | mmmvennnoo | [Sgt om) [S]| om Relay (2) 1 AY af vomatysoxearty oc) | [3.f | Few | f Notion [Normally closed (NC) ae = . Sensor (variable) | + Resistor whose resistance changes Diode | > Krow asa eamiconducirretie vith eperaton of ther componcrts tthe dod allows current Now a in one direction ont = See | Catan aa nee Geneon |» Resistor whose eslance changes || Uahiceating | - A code that lghts when curent cnermiston | ith temperature. ‘iode tows, (LED) + Unlike ordinary light bulbs, the GB. dodo doos nl generate heat wen Capacitor | + Component that temporarily stores Cathode(k) 8g — Anodo(a) (condenser) electical charge. Cfpcenteseeo anode} Flow of let eure Soincid | - Curent owing trough col generates || Raterenoe ode | > Alows curent 0 fw in one deo electromagnet fore to operate (Zener dode)” |" fonup tom orain volage: alone far} plungers. current o flow inthe other direction GI-10Gl HOW TO READ THE DIAGRAMS ABBREVIATIONS Mazda Standards A Ampere F Front NO Normally Open AE Acoustic Equilibration FL Front Left Pp Power AS Autostop FR Front Right R Rear AIR Auto Reverse FM Frequency Modulation RH Right Hand ACC_ Accessory HID Heati/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 tilumination SAS Sophisticated Air bag ATX — Automatic Transaxle INT _ Intermittent Sensor 8 Battery JB Joint Box SOL — Solenoid CPU Central Processing Unit LH Left Hand SST Special Service Too! CCT Circuit LCD Liquid Crystal Display ST —_—Start CIGAR Cigarette LO Low SW Switch CONBI Combination M Motor TEMP Temperature CONT Control MAX — Maximum TNS Tail Number Side Lights DEF Defroster MID TR Transistor DRL Daytime Running Light MIN VENT Ventilation ELR — Emergency Locking Mix VOL Volume Retractor MPX ELEC Electric MTX — Manual Transaxle ETR Electronic Tuner Radio NC Normally Closed Gi-11Gl SAE Standards In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents. HOW TO READ THE DIAGRAMS. Previous Standard SAE standard ‘Abbreviation Name | Abbreviation Name Remaric = _| Recaertor Pedal ‘AP __| Accelerator Pedal = [Air Gieaner ‘RCL __| Air Ceaner =| Air Conditioning IC _| Air Gonationing — = Airflow Meter = VAF Volume Air Flow Sensor = _| Aittow Sensor MAF__| Mass Al Flow Sensor = [Aterator GEN | Generator = ATE Thermosensor — | Transmission (Traneane) Fad Tomperature Sensor —__| Rimosshare Pressure BARO__| Barometric Pressure Vo | Battery Votage Bs | Batty Postve Votage ‘OC__| Oxidation Catalytic Convertor Slee TWE | Three-way Catalytic Converter wu-twe | Wamp Tro-way Caahe ro =~ | Creat Opening Relay FPA __| Fuel Pump Relay z = J Gluten Position GPP | Ciuton Pedal Poston =| Crank Angie Sensor GMP Camshatt Postion Sensor Granic Angie Sensor ‘KP | Crankshat Poston Sensor =] Biagnasis Connector DLC | Data Link Connector = Diagnosis/Self-Diagnosis O8D On-Board Diagnostic eae = [oirectigntion LI | Disrbutorass ignition | =P EAT Contr Un Tow [Transmission (Transaxle) Corr Module EGi__| Erecironio Gacoine injection System | CIS | Continuous Fuel Injection Syatom = Electronic Spark Ignition [ Electronic Ignition #8 PCM | Powertrain Control Module [ee | eo ECM__| Engine Control Module i Eg ag | ne Tc i =| Engine RPM Signal — __[ Engine Speed input Sanal — [Evaporative Emission EVA | Evaporative Emission Exhaust Gas Recirculation EGA | Exhaust Gas Reciroulaton = Fan Control __ FC Fan Control = __| Feedback System LS | Closed Loop System =| Flenibie Fuel Floxibio Fuel Fuel Pump _ — FP | Fuel Pum =| Fully Closed CTP | Closed Thrtie Postion = [uly Open WOT | Wide Open Thre =| Ground ‘GNO__| Ground = [ic Regulator VR | Voltago Regulator {41 Diretly connected to exhaust marifols #8: In some models, there is a fuel pump retay that controls pump speed. That relay is now called the fuel pump relay (Speed) Controlled by the ECM (PCM) Device that controls engine and powertrain GI-12HOW TO READ THE DIAGRAMS Gl Previous Standard SAE Standard Teak ‘Name ‘ven Home omark "te Spend Cote TAC | Blair onl = Tia Sich =| Giosed Tote Pasion Sach =a ious Tek [on Gontol ode Tino Poston TR | TranemissonCaneaxe) Fargo intake air Presse WAP [Marios AbocaePressur [neko Ai hemo Tat [ike Ar Tenpaatre Tiers CAC [Chara Ar Coker ia | eh ove S| Knock Sensor = Tne Frssur Stent Vaks = [Pressure Gon Slot = Teas Postion TOE [Torque Corvrior Chic = Fane nist Oak fi ates isto camp =F ais Foe recbon TET [lpr Fuel ction = Opontess OL Opan ap = [overs 7GR | Fouth Gear OBS [Heated Onyoen Sonaar Winner a oe 028 — [Onn Sons =~ [Panerai rane pNP | PaNeutal Poston = Powe Sorin Prose BSP | Power Storing Pressure = [Pate Garrat = epiibine Sheed Sonar =| Fenda BABY | Seaondary A Puls Vaio PAR | Pulsed Saconiryairincion | Fuad = | seconaary Ai jcton System TAR | Secondary Aiton pew [Begun Fearon SFL Sequoia Nip Fol ion | — T Senvice Code(s) DIC | Diagnostic Trouble Code(s) ii ak pao [Dare iion = [Sonia Sich = [rahe Sch r = [ead DIM | Diagrose Tos Woe @ =— Firat ay 16 | Troll 6oay = ti Sonor 1 [rote Postion Sonor | = Turbocharger Tc Turbocharger I = [etic Speed Soser VSS | Vehicle Speed Sear { =~ Weticte Speed Sensor =| Output Speed Sensor T = [Wier Theno ET | Eran Coolant Tempera T= Shi Slo Va ~ ‘Shift A Solenoid Valve ~ oe 23 Shi Slo Vaho — Shift B Solenoid Vaive ~ eee =~ [=i sit Sona Vane [arenas Sm SGA Tre ear 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 switches, including the ignition switch, are at OFF before disconnecting or con- necting the battery cables. If a switch is on, semicon ductor components may be damaged. Replacing Fuses + Replace blown fuses with ones having the same desig- nated capacity. Ifa fuse is replaced with 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 with a vibrating part, the harness insulation may wear or break. + Tape areas of the harness that may rub or bump against sharp edges. Without the tape, the harness 2 insulation may be cut. + When mounting components, make sure the hamess is, not caught. If it is caught, the harness insulation may wear or break. GI-14FUNDAMENTAL TROUBLESHOOTING Gl Handling Components + Do not handle electrical components roughly or drop them. Do not alter the wiring or electrical equipment. Doing so can overload or short a circuit, whch may cause a fire or damage the vehicle or components. + Remove heat-sensitive components, such as relays, when performing maintenance where temperatures can exceed 80°C {176°F}, such as welding. + Make sure connectors are fitted securely when installed. + When disconnecting two connectors, grasp the connec- tors, not the wires. GI-15Gl FUNDAMENTAL TROUBLESHOOTING HANDLING CONNECTORS Removing connectors ‘Checking connector contacts ‘Cheoking for toose torminals Removing terminals Push type When using a matching male terminal, make sure there is no looseness in the female terminal Improperly engaged connectors will cause poor terminal contact Pullup type Spang ‘ype Lightly pull each wire to make sure the terminal does not pull out of the connector. ‘A loose terminal will ‘cause poor terminal contact. “ERS ‘ 1. Open the rear cover. 2. Liftthe tab with a small screwdriver to remove the terminal Rab 4 “=Genaral connectors Lift the tab with a Sp small screwdkiver to remove the terminal “Round connesiors> 41. Open the cover. 2. Liftthe terminal to remove t. 3. Make sure the terminalis securely mounted in the connector when reinstalling ‘ 41. Open the cover. 2, Remove A 3. Liftthe tab with a small screwdriver to remove the terminal. GIM16FUNDAMENTAL TROUBLESHOOTING Gl USING ELECTRICAL TEST EQUIPMENT Equipment Purpose Use Handling Testlignt | Used tofind open or short cir- | + Connect the test light + Use test lights with 12 cuts. between the circu being 1.4W or 3.4W bulbs 2¢ light- measured and ground. ‘emitting diodes (LECS). + The light will turn on ifthe Using large-capacity bulbs circuit is energized to the ‘may damage the CPU. point tested. & 4 21 impor wre | Uae To cate atonporaryci- | = Conect ho jmporwire | » Borel connect he rower oat Setwasn nelarmnas ota | See rety to goura Greuito bypaceswten, | The may bum he moss {ecamage ceo S nets ° Valirter | Used ion opin or shor | » Satine range tothe aacied | - Cornct he valetrin Ca by mossuring creat vote |” vtage poral wth re ert. soe + Sno postive toss | + Use he anes hotowhen feunerevalage stobe. | ” messing vag athe ramuradard’nereomive | —Satinccomater = Chien ground ‘Se Sy + Tie atin wet hepoihe (endo mae nero Src ‘immeise | Used fd spon osha» wake ex tho ent wih | » Heures owing trouoh suis, ig cont contnuy.and |” Wrtfortnenegawe -)bar | ” the cre the cher SSehacksonsorreosiares. "| teyesbetscioomadea | Coudbebume ar] «Sth he obmmetersn the pi seperate menting ange | «SiMe onmmetr ior ee bats sonnet he acs fotnecemecton (LF) ze [eS 2; fmmater | Usastocheckatemator ouput, |» Sette rao othe desred | » Conese mmetria Coren supplog othe stanor” | amperage selene The nddaeurontwihinacret, | » Yauch posites) leadto | _srimatrmaybotuned fit | Sea 7 the power-side terminal and 's connected in paraiel. (oarccurentatmecurent | the hegatie ead tha een 1 flowing through the circuit when | — ground-side terminal Oe isl the ignition switch is at OFF.) GI-17Gl VOLTMETER LEAD N COR CONTACT Checkpoints THIN WIRE OK FUNDAMENTAL TROUBLESHOOTING 0 MEASURING VOLTAGE Connectors When checking for improperly engaged connectors, poor terminal contacts, or loose terminals, wrap a thin Wire around the voltmeter lead. A large voltmeter ead may momentarily contact another terminal when it is inserted into the connector and give an incorrect read- ing. Ground Touch the voltmeter to the ground wire when checking the ground circuil. If there is poor contact belween the ground wire and ground and the voltmeter does not touch the wire, the voltmeter will give an incorrect read- ing. BATTERY (POSITIVE TERMINAL) IGNITION SWITCH VOLTMETER. TESTLUGHT Use a voltmeter or test light to check for voltage at the moasuring points. GROUND 2 GROUND 1 [cooing] Ore operation” 7 |p| Toon SE a Ignition switch: anc a “Thermoswiteh: | Thermoswitch: L = Or ee Sure i ws owe ow ae ae a a TC A a pee cree | ove ores © : Test lamp ON x Testlamp OFF GIsFUNDAMENTAL TROUBLESHOOTING Gl ‘CONTINUITY No CONTINUITY. AB MEASURING CONTINUITY/RESISTANCE Switches Touch the ohmmeter leads to the switch terminals to check for continuity. Diodes Connect the ohmmeter leads as shown in the figure to check for continuity. Ifthe leads are reversed, continuity will not be indicated by the ohmmeter. Note + The negative (-) lead of the ohmmeter is connected to the positive terminal of the internal ohmmeter bat- tery; the positive (+) lead to the negative terminal of the battery. Sensors and Solenoid Valves Touch the ohmmeter leads to the terminals of the sen- sor or solenoid valve to check the resistance. Capacitors 1. Short between the terminals with a jumper wire to dis- charge the capacitor. 2. Set the ohmmeter range to x10 k@ and connect the ‘ohmmeter leads to the capacitor terminals, 3. The capacitor is good if the needle of the ohmmeter swings once and returns to its original position. GI-19Gl FUNDAMENTAL TROUBLESHOOTING FINDING SHORT CIRCUITS Shorts ocour between the power (positive) and ground (negative) sides of a circuit. Therefore, fin short circuit requires determining how the circuit is routed. Circuits Not Connected to Control Module Example ‘Short location Finding short circuits Ignton switch § ruse | Short (A) + Fuse melts + Main fuse melts, ow less of whether the ther- Short (©) mogwitch is on or off when the ignition switch ison, + The fuse Is not melted. Showa) netay| \. & Short (B) shot iby ct FF ~The motor operates regard ‘ + co switch The main fuse melts when Thermo- | ghort (0) the ignition switch and ther- ‘moswitch are on and the relay is operating. 1, Remove the fuse and main fuse ofthe circuit, 2. Disconnect all connec- ‘000 tors of electrical compo- ot ‘ents inthe cect 3, Attach a voltmeter or Test ight test light tothe fuse box ‘and reconnect each con: QO] setts begining near fest the power source. 4. Check for voltage or see ifthe test ght turns on as the connectors are connected. “A short has occured where the volt= meter reads OV or the test light does not turn on. Circuits Connected to Control Module Example Finding short circuits + Fuse melts. im + Solenoid A operates normally ‘when the ignition switch ison, 1 Remove the fuse and main fuse ofthe circuit A) | 2 Disconnect al conmeciors of ot electical components in the eeu 3, Attach a voltmeter or test Testight light the fuse box anc reconnect each connector, “000 | beginning nearest the power source. 4 “The OM thinks the switch is ‘on because the same condi tions exist when the switch is * “The OM thinks the sensor has Short (€) fons eri a8 ven rei ro + Ifthe CM is equipped with a ‘on-board diagnostic function, 2 diagnostic trouble code will be output. ‘Shar location Short (A) ‘anton sen Fuse Fsroniay | Short @) but owich Ais of sigod a] Selena : 8 > The OM transistorbums out shot Sho () wien the ignition switch ts Ot EPO | sro tumed on [Ar sien Short (0) Shor (&) oc on t Check for vattage or see it the test ight tums on as the Connectors are connected ‘A short has occurred where the volimeter | reads OV or the test ight does not turn on. 1. Attach the test light or volt meter tothe CM connector M_y __ and switch/sensor connector. 2. Check for vottage or see if the test ight tums on. ‘A short has occurred where the voltmeter reads OV or the test ight does not turn on GI-20GROUND POINTSoA FS ® GROUND POINTS o@f |jeo@eu EOE aT COREE EET] Clete) oo CHEE BCRoE oer oO o@h ST ET eo een —in—o@ SLNIOd GNNOYD ‘SLNIOd GNNOWDGROUND POINTS Y Y-3tA Y-2) KL ™ GROUND POINTS oS jo@o |ertm| thm oem |i! on or mg © oem jo@en Tre ijeom eer orm SLNIOd GNNOHDA SLNIOd GNNOYWDELECTRICAL WIRING SCHEMATICcM Fs " ELECTRICAL WIRING SCHEMATIC oo BBO. Foner gear 304 cu 004 208 Tea OILLVW3HOS ONIMIM 1VOINLOA TS OLLWW3HOS DNIYIM 1V9I.10413eM KL © ELECTRICAL WIRING SCHEMATIC = ERTS Senelcnenicieciy Loe, we inGanenel Scr | eet es 7 Ta ees oo anoaie Tea gle Hate fea r= sin eet pees = oc Eo oes 8 BP PY anaes ove ee rea] prenen ce 58 @ meee EO eo cee noire roe 100 eer feelin cn cseael oe 960 ese pen te | MBO yt ae afererer seo aye Scomere Comer fa] ee ‘ EOWA ano * sree ose fra OILWWAHOS DNIMIM TWOIWL0373Before beginning any service procedure, refer to section S of this manual for air bag system service warning: FUSE AND JOINT BOX 21Z1 FUSE AND JOINT BOX FUSE AND JOINT BOX ‘STRUCTURAL VIEW 1. MAIN fuse 2. ROOM fuse Z1-2FUSE AND JOINT BOX Z1 FUSES Caution + If one or more fuses are burnt, check for a shorted harness. Determine and correct the cause of burnt fuses before replacing the fuses with the specified type. + If the fuse is replaced before doing this, it may burn again. MAIN Fuse Removal / Installation 1. Disconnect the negative battery cable. 2. Remove the main fuse block cover. 3. Remove the main fuse block mounting nuts. 4, Remove the main fuse mounting bolts. 5. Remove the MAIN fuse. 6. Install in the reverse order of removal. ROOM Fuse Installation Note Uh ‘+ When the ROOM fuse is burnt or removed, the mal- function indicator lamp illuminates. if the ROOM fuse is replaced or installed with the ignition switch at ON, YJ the malfunction indicator lamp will continue to illumi- nate. 1. Turn the ignition switch to LOCK. 2. Install the ROOM fuse. 21-3Z1 FUSE AND JOINT BOX JOINT BOX Removal / Installation 1. Disconnect the negative battery cable. 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal. 4. Scuff plate 2. Front side trim 3. Joint box zi4Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. Z222 RELAY RELAY STRUCTURAL VIEW 1. Headlight rela 4, Horn relay Linspection .... page Z2=3) [inspection page Z2=a1 2. Rear window det 5. DAL relay (Canadal spaction pags 22-3) [Inspection ssc ~ubaG9 22-7] 3. TNS rela 6. Flasher unit Linspection =page Z2=3) (Inspection... Seton F] 22-2RELAY 22 HORN RELAY Inspection 1. Check for continuity between the terminals of the horn relay. 0-0 : Continuity _ Be: Battery positive voltage Terminal Step B D A c [4 oe - 2 Be GND 2 o 2. If not as specified, replace the horn relay. TNS RELAY Inspection 1.Check for continuity betwoon the terminal of the TNS relay. ©-0 : Continuity _ Bs: Batory postive voltage Terminal B ¢ D = 2 Be GND 2. If not as specified, replace the TNS relay. HEADLIGHT RELAY Inspection 1. Check for continuity between the terminals of the head- light relay. 0-0 : Continuity _ Be: Battery positive voltage a erminal Stop aA [oe |e -[ 3 i oo 2 Be GND o—f—o 2. If not as specified, replace the headlight relay. REAR WINDOW DEFROSTER RELAY Inspection 1. Check for continuity between the terminals of the rear window defroster relay. -O : Continuity Be: Battery positive votage ——= Terminal Step B c D 1 < Oo | 2 Be S o 2.1 not as specified, replace the rear window defroster relay. 22-3RELAY DRL RELAY [CANADA] Inspection 1. Check for continuity between the terminals of the DRL relay. 22-4 +0 :Conthuly Bs: Battery postive vdtge [ete Terminal Le Te Step ayTelTelelr i oo ozo as ‘GND. Br oe 2. If not as specified, replace the DRL relay.Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. Z323 cPU CPU STRUCTURAL VIEW iG oO 1. CPU. OUTLINE * The CPU is attached to the joint box near the driver's feet. ‘+ A microcomputer s used by the CPU to control all electrical component functions, thus increasing reliability. QUICK REFERENCE Function Relerence page ‘Seat belt warning system [aecton C2] oar window detrostar = [ Power door loc system Warning alarm Key remi ‘Seat belt reminder Keyless entry system [seotion KS] Thel-deterrent system ~ ‘section TS Lights-on reminder section C2 Z3-2cpu Z3 cpu Removal / Installation 1. Disconnect the negative battery cable. 2. Remove the scuff plate and front side trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal 1. Screw 2. Bolt 3. Joint box Inspection Connector A 1. Remove the CPU from the joint box. 2. Measure the voltage at the CPU terminals from the joint box side, referring to the terminal voltage list on 3.If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 4. If the parts and wiring hamesses are OK but the system still does not work properly, replace the CPU. Connector B 1. Follow the appropriate procedure, referring to the ter hal voltage fst onlpaga 73-8] Terminals 2H, 2N, and 2T (1) Disconnect the CPU connector. (2) Check for continuity between the terminals of the CPU connector and ground. 23-3CPU Terminal voltage list Terminals except 2H, 2N, and 2T (1) Install the CPU onto the joint box. (2) Measure the voltage at the CPU terminals. 2.If not as specified, inspect the parts listed under “Inspection area” and the related wiring hamesses. 3. Ifthe parts and wiring harnesses are OK but the system stil does not work properly, replace the CPU. Bs: Battery positive voltage CONNECTOR A ee sahrefrefo] verse] iH] vi] 9] ] HU] am] aN] 10] 19| Terminal] Signal ‘Connection Test condition tage! | inspection area TA_[iGt METER 158 fuse [Ignition switch at ON B+ [METER 16A fuse 8 = = = = = 1c |B ROOM 15A fuse _| Constant B__ [ROOM 6A fuse 1D _[CPU ground [GND ‘Constant: check for continuity to ground [Yes = TE | Door openiclosed | Door switch “Any door open: check for continuity to [Yes [Door switch ‘ground . ‘Al doors closed: check for continuity to] No ground TF [Courtesy light | Courtesylight | Constant Bs | ROOM 16A fuse + Courtesy light 16 = —_ = = ae 1H = = = = 11 [Keyinseted _|Keyreminder | Key incerted into steering lock Be__|- ROOM 16A fuse ‘switch removed from steering lock * Key reminder Key 3d from steering lock ov |" keys W = = = = 1K [Seatbettwaming [+ Seatbelt warn- | Ignition switch [Seat belt fastened B+ [+ METER 15A fuse Ing light atON + Seat belt warning + Buckle switch Tae light Seat bettunfastened) ov |, tom i 1c = = 7 = = 1M = = = = iN = = = = 10. = = = = 1 | TNS TNS relay Headlight switch at first position Bs | TAIL 15A fuse “INS relay Z3-4cpu Z3 Br: Baty poste votage connector 8 i m1 tL PaO EEN EES CESS erLenloe [awtx fail er Lso 8 sign: jon ‘condition Voltage! | inspection area Se = Test cont SeiB8e | naps tt OV | STOP IA me Hams oy: Som BB Hosa opt | Headigh lay | Headlight ach on Ov | HEAD mA i oy eae 3 atoroat | aor ea ray — [itor i TOW co 3D” | Securly ight | Seourty ght] Socuriy gt ituriaiod OW] ROOM IEA ose Sone ae TE | Powe dorioa | Doorioak mer |For socond ar averatankink | GW | BOOR TSC Sam Coal a Swi rood foe ae B+ BS ter F ] . = = = 26 Powe dooriok | Doriock mer |For. soon tar avaraockak | OV |» BOOR TSO SOR Peres = Serato peo sw Se B58 tector nt oA [eas . ] = = ROE | Ten | Tanck ond [Unio Shea ar canny > Yes | Trai tay andor wee | soe pron mh Ce | Other: check for continuity to ground No. A] Bemer door lode Baar Teak er |For 0.4 seconds ator anamiar OV |» BOR TSO SOR | ime GREK baton reseed fuse te + 88S cme unt 20 | Frank peat] Tank camparmont| Tun opon Ov |= ROOW ih tose Sones Toone + He cnpaten — ise eee = + Trunk compartment! igesmee | Dope saad Bopsaeion [Laat S| ROOM Ehime unlocked ‘switch (driver) ‘Unlocked OV + Door lock assembly a = = = = = Oe TW HAZARD gee Sieae Sasa ot No TR ood opened | Hood ewch | Hood pen daa or cornalyio | — Ro | Hood ach gourd Hood sod choo crirayto | Yes gourd 70 Tk kayase [ond opener | For Ot second for wane OW [rank over vay TRUNK baton reed van |. Ober & ® = = = = = 30 | Rear window [Raa window Jlanlion ach Roar window SW] METER BA haw estes Gevestor nestor | TON stele schon Macarena Hight Other By Z3-5Z3 CPU Be: Battery positive voltage ing nection in Voltage! | inspection area Terminal] signal connect Test conto olage’ | nspecon a aA |Renews otststsCs aN |= ROOM TEA Toso LOCK butions pressed + Keyless unt For 0.8 seconds afer angmitor av UNLOGK btn pressed For 0 seconds afer anomie ov [TRUNK bitoni pressed other av 7S | Roarwindow [Rear window ignition ich Rear window OV] > ENGINE TEA Tice Soroster Gerosterrety [ON arostr stich on * Re weston cots a aarese Sly | Rear wedow | Rar whew | Rar wow dehoster ch or Yes | Rear window Seto Esreserawen [esac or contnuy te gourd Sores tench Fear window defoster swich of Wo hoc or coniuly to grune 23-6Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. —_ SWITCHES STRUCTURAL VIEW 4 IGNITION SWITCH. sss 4 Z4Z4 SWITCHES STRUCTURAL VIEW SWITCHES 626 Mx6 6. Cruise control switch [Removal / Installation .. page 24-8 Inspection... page 24-6 7. Front fog fight [inspection [Removal / Installation page 74-3 3. Combination switch [Inspection page 24-9 | [Removal Installation a. 8. Rear window defroster switch Adjustment. 4, Hazard warning switch [Removal / Installation inspection ‘9. Panel light control switch 79 [Removal / installation Removal / Installation ... page 24-9 5. Cruise control main switchIGNITION swiTcH SWITCHES Z4 IGNITION SWITCH Removal / Installation 1. Disconnect the negative battery cable. 2, Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 3. Disconnect the ignition switch connector. 4, Remove the screw and the ignition switch 5. Install in the reverse order of removal. Inspection 1, Remove the column cover. {Refer to the 1996 626/MX 6 Workshop Manual, section S.) 2. Disconnect the ignition switch connect 3. Check for continuity between the ter tion switch. inals of the igni- (0 :Dontinuity Terminal c}o}/rlejale ‘Switch position Look ‘AGG o-f+—fo ‘ON o START ° Io 4. If not as specified, replace the ignition switch. KEY REMINDER SWITCH Inspection 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the key reminder switch connector. 3. Check for continuity between the terminals of the key reminder switch. 0-0 : Continuity Terminal Switch condition = . Keyinserted Key removed 4. If not as specified, replace the steering lock. (Refer to the 1996 626/MX-6 Workshop Manual, section N.) Z4-3Z4 SWITCHES COMBINATION SWITCH Removal / Installation 1. Disconnect the negative battery cable. 2. Remove the driver-side side panel and lower panel. 3. Disconnect the clock spring connector. Warning + Handling the air bag module improperly can acci- dentally deploy the air bag, which may seriously injure you. Read SERVICE WARNINGS, section S, before handling the air bag module. 4, Remove in the order shown in the figure. 5. Install in the reverse order of removal. 1. Airbag module 4, Combination switch Removal /Installation. section S. [Inspection page 24-5] 2. Steering wheel \GJUSEMENE eee eessese .... page 24—% 3. Column cover 5. Clock spring Removal / Installation Tspection as 1996 Mazda 626/MX-6 Workshop Manual, section S Z4-4Z4 SWITCHES Inspection 1. Remove the combination switch. 2.Check for continuity between the terminals of each switch, Headlight switch 0 : Continuity Terminal Pangan ze [ec [a] 1a] te | 10 | OFF Fashiopass o ms «| oo Fashiopees | O-f-0 oto HI obese Te tor [to o-oo | ope Fasriogess | O S oI Turn swith 2-0 : Continuity Terminal ‘Switch position — a 1G 1H Lett OFF Right Windshield wiper and washer switch O-O : Contiaulty suiten ponent 2k [oan | at | 2s | oom OFF oe ‘One-touch offs INT oto [0 Lo =F 5 HL ale Washer Poo Z4-524-6 SWITCHES Adjustment Clock spring Before installing the steering wheel, adjust the clock spring connector as follows: 1. Set the front wheels straight ahead. 2. Tum the clock spring connector clockwise unti it stops. (Do not force it) 3. Retum the connector 2.75 tums. 4.Align the marks on the clock spring connector to the marks on the outer housing,SWITCHES Z4 HAZARD WARNING SWITCH Removal / Installation 1. Remove the switch panel. (Refer to the 1996 626 MX-6 Workshop Manual, section S.) 2. Remove the hazard waming switch. 3. Install in the reverse order of removal. Inspection 1, Remove the hazard warning switch. 2.Check for continuity between the terminals of the haz- ard warning switch, 2-0 : Continuity O-8-0 : Bulb ferminal switch psi . . 2 2 OFF ON 3 o. o 3. If not as specified, replace the hazard warning switch, Z4-7SWITCHES CRUISE CONTROL MAIN SWITCH Removal / installation 1. Remove the switch panel. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the cruise control main switch connector. 3. Remove the cruise control main switch. 4. Install in the reverse order of removal. Inspection 1. Remove the cruise control main switch. 2. Check for continuity between the terminals of the cruise ‘main switch. 2-0 : Continuity _-@-0 : Bulb rennin] eles ee Switch position — Push ot Others o 3. If not as specified, replace the cruise control main switch. CRUISE CONTROL SWITCH Removal / Installation Warning + Handling the air bag module improperly can acci- dentally deploy the air bag, which may seriously injure you. Read SERVICE WARNINGS, section S, before handling the air bag module. 1. Remove the air bag module. 2. Disconnect the cruise control switch connector. 3. Remove the screws and the cruise control switch. 4. Install in the reverse order of removal. Inspection 1. Disconnect the cruise control switch connector. 2. Measure the resistance between the terminals of the cruise control switch. Ai:2d0n _R2:9100 Terminal ale ‘Switch position—— A 5 [Norma SETICOAST RESUME/ACGEL ce 24-8 3. If not as specified, replace the cruise control switet,SWITCHES Z4 FRONT FOG LIGHT SWITCH Removal / Installation 1. Remove the switch panel. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the front fog light switch connector. 3. Remove the front fog light switch. 4. Install in the reverse order of removal. Inspection 1. Remove the front fog light switch. 2. Check for continuily between the ter fog light switch. Is of the front 0 : Continuity OBO : Bulb Terminal |switen post & ei 2 OFF o a ‘ON S o 2 3. If not as specified, replace the front fog light switch, REAR WINDOW DEFROSTER SWITCH Removal / Installation 1. Remove the switch panel. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the rear window defroster switch connector. 3. Remove the rear window defroster switch, 4 Install in the reverse order of removal. Inspection 1. Remove the rear window defroster switch, 2. Check for continuity between the terminals of the rear window defroster switch. 0 : Continuity O-8-0 : Bulb Terminal] a E F OFF o ON. = o c J 3. If not as specified, replace the rear window defroster switch. PANEL LIGHT CONTROL SWITCH Removal / installation 1, Remove the switch panel. (Reter to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the panel light control switch connector. 3. Remove the panel light control switch. 4, Install in the reverse order of removal. Z4-9Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. INSTRUMENT CLUSTER WATER TEMPERATURE SENDER UNIT. [EUEL GAUGE SENDER UNI ests C1=19 | C1C1 INSTRUMENT CLUSTER INSTRUMENT CLUSTER PREPARATION Sst 49.0839 285 For 49 TO88 OAO For inspection of ingpection of Cheoker, fuel fuel and water | NGS set tachometer thermometer ‘temperature gauges: 49 T088 002 For 49 TO88 0108 For inspection of inspection of Vehicle interface tachometer Program Card tachometer Module (Part of 49 TO88 0A0) 49 T086 001 For 49 T0B8 004 For inspection of inspection of Control Unit tachometer NGS OBD It tachometer Adapter (Part of (art of 48 TO8S 0AO) 49 TOBB OAD) 49 T088 005 For 49 T088 008A For inspection of inspection of Battery Hookup tachometer Instruction tachometer ‘Adapter Manual (Part of 49 TORB 0AO) ci-2INSTRUMENT CLUSTER STRUCTURAL VIEW C1 1. Instrument cluster 4. Water temperature gauge Removal / installation .........page C114 [inspection... age CT—16] [Disassembly / Assembi pageCi=i6] 5. Fuel gauge 2. Speedometer [inspection: page Ci-17] Inspection nan page CT=17] 6. Waming and 3. Tachometer {Inspection. Section C2] (DSPOCHON a nnscennnePAG2CI=IZ] 7. Odometer 8. Tripmeter Cc1-3C1 INSTRUMENT CLUSTER ‘SYSTEM DIAGRAM 11 METER 18A FUSE INSTRUMENT ‘cwsTER t———4 >) ee WARNING WATER nee LOW FUEL LIGHT [SPEEDOMETER] | TEMPERATURE cae INDICATOR TACHOMETER Gauce cncur lveHicLe |SPEEDOMETER SENSOR WATER FUEL GAUGE LEH FTeMPERATURE | SENDER UNIT p SENDER UNIT FSADK IGNITION Col FS MIX, KL: DISTRIBUTOR Description The instrument cluster consists of a tachometer, speedometer/odometer/tripmeter, water temperature gauge, and fuel gauge. These gauges receive signals from the distributor, vehicle speedometer sensor, water temperature sender unit, and fuel gauge sender unit. System Operation + Tachometer When the ignition switch is at ON, battery power is applied to the tachometer. When the engine is running, frequency pulses corresponding to engine speed are sent from the distributor to the tachometer. + Speedometer When the ignition switch is at ON, battery power is applied to the speedometer. When the vehicle is in motion, an AC voltage signal is sent from the vehicle speedometer sensor to the speedometer. The frequeney of this AC voltage signal varies with the vehicle speed. + Fuel Gauge When the ignition switch is at ON, battery power is applied to the fuel gauge. The fuel gauge receives a resistance signal from the fuel gauge sender unit. The resistance of the fuel gauge ‘sender unit varies with the level of fuel in the tank. ‘+ Water Temperature Gauge When the ignition switch is at ON, battery power is applied to the water temperature gauge. The water temperature gauge receives a resistance signal from the water temperature sender unit. The resistance of the water temperature sender unit varies with the engine coolant temperature. C14INSTRUMENT CLUSTER TROUBLESHOOTING Circuit Diagram fa] emeraoven ccusTen G7 Teg east alee [e-b[ + TNsTaUMeNT CLUSTER 273) C1 c1-5INSTRUMENT CLUSTER C1 sate nih a Cc1-6INSTRUMENT CLUSTER C1 Connector Locations ss & a Bu C1-7C1 INSTRUMENT CLUSTER Cc1-8INSTRUMENT CLUSTER C1 Flowchart No.1 ‘Symptom All meters and gauges (speedometer, tachometer, water temperature gauge, and fuel gauge) do not operate | Possible cause Burnt METER 15A fuse Damaged instrument cluster Open or short circuit in wiring hamess Poor connection of connector Step 1 Check the METER 15A fuse in the fuse block, Fuse ‘ction OK Goto Step? Burt place fuse afier checking and repairing wiring harness. Step2 1, Remove the instrument cluster. (Refer to page C1=14Jor[C1-15.)] 2. Check for continuity between terminal 1C (B/R) of the instrument cluster connector and ground. 1. Turn the ignition switch to ON. ment cluster connector. Continuity Action Yes Got Sens No Repair wring harness {instrument cluster—GND) Step 3 2. Measure the voltage at terminal 2G (B/Y) of the instru- B+: Battery positive voltage Voltage ‘ation Be Got Step4 Other Repair wring harness (METER 18A fase—instrument cluster) Step 4 Refer to the flowchart numbers shown, Sympiom Flowchart Wo, | Referto Speedometer 2.3 page O10 Tachometer 4 (pxe=T1] Fuel gauge | [page C=] Water temperature gauge 6 (page 1-13) c1-9C1 INSTRUMENT CLUSTER [Flowchart No.2 ‘Symptom Speedometer does not operate Possible cause + Damaged speedometer + Damaged vehicle speedometer sensor + Open or short circuit in wiring hamess + Poor connection of connector Step 1 1. Remove the instrument cluster. [Refer to page C1—14)or[C1—15)] 2. Measure the voltage between terminals 18 (R/B) and 1F (GY/L) of the instrument cluster connector while tuming the front wheels slowly. Meter need Does not me [ Goto Stop 2 Step 2 1. Remove the vehicle speedometer sensor. gear. . Measure the voltage between terminals A and B of the vehicle speedometer sensor while rotating the driven Meter needle ‘Aetion ‘Moves slightly under 6V | Repair witng harness (instrument cluster—Vehicle speed ‘omoter sensor) ‘Doss nat move Fiaplace vehicle speedometer sensor [Retertopage C18) Flowchart No.3 ‘Symptom Speedometer needle fluctuates or indication incorrect Possible cause + Damaged speedometer + Damaged vehicle speedometer sensor Remedy 1. Remove the vehicle 5 2. Tum the tip of the eedometer sensor. vehicle speedometer sensor and ver- ify that magnetic resistance is felt 3. Verify that there is resistance between the terminals of the vehicle speedometer sensor and that the resistance is not infinite. Resistance Ration ‘ApPrOX. 290. Replace speedometer (Refer to pages C114] or 5nd [16)) ‘Other Fieplaoo vehicle speedometer sensor [eter to page C1-18)INSTRUMENT CLUSTER Flowchart No.4 Possible cause + Damaged distributor (FS MTX, KL) + Damaged ignition coil (FS ATX) + Open or short circuit in wiring harness + Poor connection of connector DATA UN ‘CONNECTOR. [ symptom | Tachometer does not operate normally | Step 1 1. Connect the SST (NGS) to the data link connector-2 and battery, 2. Referring to the NGS instruction manual, select the PID DATA MONITOR function. 3. Using the PID DATA MONITOR function, measure the engine speed. 4, Compare the values of the vehicle tachometer and the SST (NGS). n ‘SST indication “Tachometer indication co Se tem) ‘tom) 1000 880— 1060) INSTRUMENT CLUSTER CONNECTOR: y 5.1f not as specified, go to Step 2. 6. If correct, check the diagnostic trouble code by using the SST (NGS). (Refer to the 1996 626/MX-6 Workshop Manual section F1, F2 and F3). Step2 Verify that the tachometer operates, Ration = Replace the tachometer aie opeaes CLT Jor[FS ano [FET] Goo Step 3 Tachometer Operates Does not operate: Step 3 1. Check the wiring harness. (FS MTX, KL: distributor—instrument cluster). (FS ATX: ignition coil—instrument cluster) 2, ifthe wiring hamess is correct, replace the tachometer. ((Retertopages C1=14]0r S}andT6)] 3. if the wiring harness is incorrect, repair the wiring harness. Ci-11C1 INSTRUMENT CLUSTER Flowchart No.5 _ | Symptom | Fuel gauge does not operate or is incorrect = Possible cause + Damaged fuel gauge sender unit + Damaged fuel gauge + Open or short + Poor connection of connector it in wiring harness Step 1 1. Disconnect the fuel gauge sender unit connector. 2. Connect the red lead of the SST to terminal C (Y) of the connector and the black lead to ground. 3. Turm the ignition switch to ON. 4. Set the SST to the resistance values shown in the fig- ure. To get an accurate reading, wait 2 minutes after setting each value. ETE a +S a FE C1i-12 oe 4" 2 5. Verify that the fuel gauge indicates the correct values. os) "a The allowable indication error is twice the width of the nw F needle. Gauge display ‘etion Correct Roplace fuel gauge sender unt (Rover to the 1996 626/MK-8 Workshop Manual, section Fi, F2, and F3) es Incorest Goto Step? Step 2 1. Remove the instrument cluster. efer to br 2.Connect battery positive voltage to terminal 2G and ground to terminal 1C of the instrument cluster. 3. Connect the red lead of the SST to terminal 1E of the instrument cluster and the black lead to ground. 4,Set the SST to the resistance values shown in the fig- ure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the fuel gauge indicates the correct values. The allowable indication error is twice the width of the needle. ‘Gauge dispiay Correct Ration Repair wiring hamess ‘cluster—Fuel gauge sender unit IncorrectINSTRUMENT CLUSTER C1 [Flowchart No.6 ‘Symptom | Water temperature gauge does not operate or is incorrect Possible cause + Damaged water temperature sender unit + Damaged instrument cluster + Open or short circuit in wiring hamess + Poor connection of connector Step 1 1. Disconnect the water temperature sender unit connec- tor. 2. Connect the red lead of the SST to the water tempera- ture sender unit connector and the black lead to ground. 3. Tum the ignition switch to ON. 4.Set the SST to the resistance values shown in the fig- ure. To get an accurate reading, wait 2 minutes after setting each value 5. Verify that the water temperature gauge indicates the correct values. The allowable indication error is twice the width of the needle. Gauge display Ration Correct (CANADA, Incorrect Go to Step 2. Step 2 1, Remove the instrument cluster. lor 2. Connect battery positive voltage to terminal 2G and ground to terminal 1C of the instrument oluster. 3. Connect the red lead of the SST to terminal 11 of the instrument cluster and the black lead to ground. 4, Set the SST to the resistance values shown in the fig- ure. To get an accurate reading, wait 2 minutes after setting each value. 5. Verify that the water temperature gauge indicates the correct values. The allowable indication error is twice the width of the needle. OIE 183.40 20.4.(18.24 0) Gauge display ation 7, Gorect Repair wiring harness (Instrument cluster — Water temperature sender unit) ¥ eo Tncorect Replace water temperature gauge cop H (iatertopane Cre) (): CANADA C1-13C1 INSTRUMENT CLUSTER INSTRUMENT CLUSTER Removal / installation 1. Remeve in the order shown in the figure. 2. Install in the reverse order of removal 626 1. Meter hood C1i-14 2. Instrument cluster Disassembly / AssembhINSTRUMENT CLUSTER C1 Warning + Handling the air bag module improperly can accidentally deploy the air bag, which may seri- ously injure you. Read SERVICE WARNINGS, section S, before handling the air bag mod- wx8 1. Airbag module 5. Switch panel 2. Steering wheel 6. Instrument cluster 3. Column cover as 2 4. Combination switch C1-15C1 INSTRUMENT CLUSTER Disassembly / Assembly 1. Disassemble as shown in the figure. 2. Assemble in the reverse order of disassembly. 7. Speedometer 1. Glass front 2. Window plate 8. Fuel and water temperature gauges 3. Socket 9. Sheet warning 4. Bulb 10. Lens warning 8. Screw 11. Print plate 12.Case 6. Tachometer C1-16INSTRUMENT CLUSTER C1 ‘Standard indication ‘Allowable range min) ‘ecmun) 40 36.0—46.0 20 B1.0—1085 ‘Standard indication | — Allowable range {MPH} {MPH 30 27.0345 80 72.0—92.0 SPEEDOMETER Inspection Note + Tire wear and improper inflation will increase speedometer error. 1.Using a speedometer tester, check the speedometer for indication error, and check the operation of the odome- ter. 2. Replace the speedometer, it necessary. (Refer to pages C1-14,Jor tel 297088 001 Au San giontorns OE 3.If the speedometer indication is not as specified or the odometer does not operate properly, replace the speedometer. Tachometer Inspection 1.Connect the SST (NGS) to the data link connector-2 and battery. 2.Referring to the NGS operational manual, select the PID DATA MONITOR function. 3.Using the PID DATA MONITOR function, measure the engine speed. 4.Compare the values of the vehicle tachometer and the SST (NGS). ‘Standard indication ‘Allowable indication {tem} {rpm} 1,000 '880— 1,060 2,000 1,970—2,160 3,000 3,000—3,180 4000 4,004,240 5,000 5,000—5,300 6,000 6,000—6,360 7,000 7,000—7,420 8,000 8,000—8,480 5.If not as specified, inspect the wiring harness. (FS MTX, KL: distributor—instrument cluster) (FS ATX: ignition coit—instrument cluster) 6.lf the wiring harness is normal, replace the tachometer. jorltSlandi6.)) FUEL GAUGE Inspection 1.Remove the instrument cluster. (Refer to page C114 )or[CT-15.)) 2.Connect battery positive voltage to terminal 2G and ground to terminal 1€ of the instrument cluster. 8.Connect the red lead of the SST to terminal 1E of the instrument cluster and the black lead to ground. C1-17INSTRUMENT CLUSTER me 20.40 (18.28 0) wag HY ar {CANADA VEHICLE SPEEDOMETER SENSOR 4, Set the SST to the resistance values shown in the fi ure. 5. Verity that the needle indicates the correct range. 6. If not as specified, replace the fuel gauge. WATER TEMPERATURE GAUGE Inspection 4, Flemove the instrument cluster. [Refer to page Ci-14lorfC1—-15] 2. Connect battery positive voltage to terminal 2G and ground to terminal 1C of the instrument cluster. 3. Connect the red lead of the SST to terminal 11 cf the instrument cluster and the black lead to ground. 4, Set the SST to the resistance values shown in the fig- ure. 5. Verify that the needle indicates the correct range. 6.1f not as specified, replace the water temperature gauge. VEHICLE SPEEDOMETER SENSOR Removal / Installation 1, Disconnect the vehicle speedometer sensor connestor. 2. Remove the bolt and vehicle speedometer sensor. 3. Install in the reverse order of removal. Inspection 1, Remove the vehicle speedometer sensor. 2. Tum the tip of the vehicle speedometer sensor and ver- ify that magnetic resistance is felt. 3. Measure the voltage between the terminals of the vehi- cle speedometer sensor while rotating the driven gear. eter needle ‘Aetion Moves slightly under 6V_[ Normal Does nat move Replace vehicle speedometer sensorINSTRUMENT CLUSTER C1 68mm (0240.21 in} THAD THEE: 3.0 32.5 100 J WATER TEMPERATURE SENDER UNIT Removal / installation 1. Disconnect the water temperature sender unit connec: tor. 2. Remove the water temperature sender unit. 3. Before installing the unit, apply sealant from the third thread to the top thread. 4. Install in the reverse order of removal. Tightening torque: 11.8—17.6 Nm {120—180 kgf-cm, 105—156 in-Ibf} Inspection 1, Remove the water temperature sender unit, 2. Place the sensor in water. 3.Heat the water gradually and measure the resisance of the sensor. Water temperature Resistance [5020 (122 Fh 189.4—259.6 @ 4.|f not as specified, replace the water temperature sender unit FUEL GAUGE SENDER UNIT Inspection 1. Remove the fuel gauge sender unit. (Refer to the 1996 626/MX-6 Workshop Manual, section FA, F2 and F3.) 2, Measure the resistance between terminals D and C of the fuel gauge sender unit while moving the unit arm from point F to point E. 3. If not as specified, replace the fuel gauge sender unit C1-19Before beginning any service procedure, refer to section § of this manual for air bag system service warnings. WARNING SYSTEM c2Cc2 WARNING SYSTEM WARNING SYSTEM ‘STRUCTURAL VIEW 4, Oil pressure switch inspection page C2-32] 5. Buckle switch 1. Warning and indicator lights (ia instrument cluster) [Replacement (Bulb). 2. Parking brake switch INSPECTION on 8. Brake fluid level sensor. Inspection 2-2 page C2=35 = page C2=32] 6. Washer fluid-level sensor (Canada) [inspection... ~paga C233WARNING SYSTEM C2 WARNING AND INDICATOR LIGHTS: Structural View . Air bag system warning light (1.4 W) . Seat belt warning light (1.4 W) . Boor ajar warning light (1.4 W) Brake system warning light (1.4 W) Generator warning light (2 W) Gil pressure warning light (1.4 W) MIL (maifunetion indicator amp) (1.4 W) Figh beam indicator light (1.4 W) 9. Turn indicator light (3.4 W x 2) eNoosens 10. Fuel-level warning light (3.4 W) 11. Washer fluid-level warning light (1.4 W) (Canada) 12. ABS warning light (1.4 W) 13. Cruise set indicator light (1.4 W) 14, Rear window defroster indicator light (1.4 W) 18. Scourity light (1.4 W) 16. O/D OFF indicator light (1.4 W) C2-3c2 ‘SYSTEM DIAGRAM WARNING SYSTEM ges WARNING LIGHT x esr tern Kiser \nsrauwent cuisreR 4) ol eressure Door Alan, WARNING Lich WANING LIGHT on. PRESSURE | sumcx| ert oor Sarren C24WARNING SYSTEM ‘COMBINATION SWITCH. ste it c2 INSTRUMENT OUISTER. cae Ste oe Eee ay racer one ne. Saabs ooh, one ist 2 Te + THs fea GOR AJAR REAR, ee JHEADLIGHT WARNING. WINDOW. uGHT, TNS: Z Sirens ten wee tas | [2, were 4 cea a t unr 008 on Tank PANE [Zion 2 leer lee ee ee eon cow ‘SWITCH UGHT | I I [ome C25C2 WARNING SYSTEM. mom . DOOR 3 Lock : oe Qeounresy — in a = a i a rea es RELAY WINDOW dnt DEFROSTER a 8 WINDOW * + * a . 8 Process set — we we a > SwitcH uae C2-6WARNING SYSTEM c2 Description The warning lights and indicators are located in the instrument cluster and are controlled by their respective switches and/or control modules. Most, but not all, of these warning lights and indicators are grounded directly by their respective switch or control module. System Operation n The cruise set indicator illuminates when the cruise control module applies ground to the cruise set indicator light, alerting the driver that the cruise control is engaged. ig The ABS warning light illuminates when there may be a problem with the antilock brake system. This warning light is controlled by the ABS control module. Brake system warning light The brake system warning light illuminates when the ignition switch is at START, the parking orake is set, or the brake fluid level is low. When the ignition switch is at START, battery positive voltage is apolied to a transistor in the instrument cluster. This transistor is turned on by applying ground to the brake system warning light, forcing the warning light to illuminate. When the parking brake is set, the parking brake switch applies ground directly to the brake system warning light. When the brake fluid level is low, the brake fluid level sensor closes and applies ground directly to the brake system warn- ing light, causing the brake system warning light to illuminate. 9 The generator warning light illuminates to warn the driver that the generator is not producing electrici- ty. If the generator stops producing sufficient power, it grounds the generator warning light bulb via a dicde. Seat belt warning light and alarm The seat belt warning light illuminates after the ignition switch is turned to ON with the driver's seat bet unbuckled. The seat belt warning alarm sounds for 4 to 8 seconds after the ignition switch is tumed to ON with the driver's seat belt unbuckled. The seat belt waming alarm is controlled by the CPU Washer Fluid-level Warning Light (Canada) The washer fluid-level warning light illuminates to warn the driver that the washer fluid level is low. When the washer fluid level drops below a certain level, the float switch closes, applying ground to the washer fluid-level warning light. Oil pressure warning light The oil pressure warning light illuminates to alert the driver of a low oil pressure condition. When the oil pressure drops below a certain level, the oil pressure switch closes, applying ground to the oil pressure warning light Door ajar warning light The door ajar warning light illuminates to alert the driver that one or more of the vehicle doors is open. When a door is opened, its door switch closes, grounding the door ajar warning light. C2-7c2 WARNING SYSTEM Fuel-level warning light The fuel-level warning light illuminates to alert the driver of a low fuel condition. As the fuel level drops, the resistance of the fuel sender decreases. The sender is tied to the fuel-evel warning light and the fuel gauge within the instrument cluster. When the sender resistance drops below a cartain resistance, the fueHlevel waming light applies power to the fuel-level warning light. Ignition key reminder alarm The ignition key reminder alarm sounds to alert the driver that the ignition key is in the ignition key cylinder when one of the doors is opened. When the ignition switch is at LOCK or ACC, battery posi- tive voltage is applied to the CPU via the key in the ignition switch. When one of the doors is opened, ground is applied to the CPU via the door switch. When the CPU receives these signals, it sounds the ignition key reminder alarm. Lights-on reminder alarm The Iights-on reminder alarm sounds to alert the driver that the vehicle lights are on when one of the doors is opened. When the ignition switch is at LOCK or ACC, battery positive voltage is removed from the CPU ignition input. When the light switch is left in the headlight position, battery positive volt- age is applied to the CPU via the light switch. When the CPU receives these signals, it sounds the lights-on reminder alarm. C2-8TROUBLESHOOTING Circuit Diagram WARNING SYSTEM c2 fe-g | fea TINGTAMENT CLUSTER (2/3) c2-9c2 WARNING SYSTEM [C-c[ + INSTRUMENT CLUSTER (3/3) CENTRAL PRESSING UNIT EFT "DETERRENT SYSTEM (1 2-10WARNING SYSTEM C2 RAL PROSESSTYG_UNET [GPU (2721 [sols Sier be TPonen System lay C2-11C2 WARNING SYSTEM Connector Locations C2412WARNING SYSTEM c2 C2-13c2 WARNING SYSTEM C2-14WARNING SYSTEM Checklist Check the bulb of each warning light before troubleshooting. If the bulbs are OK, refer and inspect each warning system. C2 to the flowcharts. ignition switch at ON (engine stopped) Procedure / Proper operation ‘Symptom Flowchart No. 7. Turn the ignition switch to ON. ‘Warning fights do not iluminate with ignition switch at 1 2. Verify that all warning lights illuminate | ON (engine stopped) (brake, ABS, MIL, fuel, oll, generator. Generator warning light does not illuminate with igni- 2 tion switch at ON (engine stopped) 'ABS warning light dos not illuminate with ignition 3 switch at ON (engine stopped) Brake eystem warning light does not ilumninate with a parking brake lever set ll pressure warning light does not llurrinate with 5 Ar bag system warning light Goes not Mluminale for 4—8 seconds after ignition switch is tumed to ON (engine stopped) Warning System Check Refer to section S for air bag system warning light symptoms. Refer to section T2 for security light symptoms. Waring | procedure Proper operation Symptom Flowchart No. Start engine ‘Washer id-level waming ight remains é 2.Verily that washer fhidtTovel warning_ | iuminated (engine running) ‘Washer | _ iat goes out (Carada) | 8. Verity that washer fuicHlevel warning Washer fudttevel warning ight doos not 7 light tuminates (when washer uid” jiyminate wih washer fd eve low level low) (engine running) {Stat engine Fuetevel warning light remains ilaminated 8 2.Very that fueHlevel warning ight | (engine running) Fuet |, tus oft Fustovel warning ight does not iuminate wih 3 3. Veily that tueHovel warning ight lumi | FUettevel wa Sora nates when ful tank's almost empy. | ‘We! tank almost empty (engine running) {Stan engine. ‘ABS warning ight remains iuminated (engine | 1096 e26mnx 2. mat ABS warring ght tums running) Workshop of Manual a ei sing ight itumi- 355 qarning ght doe not Nuninate when ABS | 8S | 8. Verity that ABS warring Ha a ‘ABS warning light does not illuminate when ABS | Sectior P nates when ABS system malunc- | majunctions (engine running) tions, 2 ? {Start engine Malfunction indicator lamp remains uminated | 1986 2.Vexiy that malfunction indicator lamp | (engine running) s26ns a |, tums ot Workshop 3.verify that malfunction indicator lam | yfaliunction indicator lamp does not aminate Manuel, iluminates when PCM malfunctions. | wren PCM maltunctions (engine running) sector F C2-15C2 WARNING SYSTEM Warning | procedure Proper operation Symptom Flowchart No. 1.Start engine. ‘Oil pressure warning light remains illuminated | 10 ot | B8am CSS prosewe waning tnt | Quetencmia wat 7-Turnpn seh 6 ON wi sat | Sea ba waraig Toh and alarm do al epaaio [i at tatones a ee a ory ha set bot warning ight and | S28,b5 dam sounds, warning a does nt 2 sere opaeta ‘Seat | 3.Turn ignition switch to LOCK. ‘Sea belt warning light Hluminates; alarm does 13 ani 4.Tum ignition switch to ON and fasten | not sound ‘seat belt within 4—8 seconds. ‘Seat belt alarm sounds for 4 to 8 seconds 5. Verify that seat belt alarm stops. after ignition switch Is turned to ON esters Tam gnen sock BO Da alr waring Hg os vo arate 7 Bogen any coor inar ar pan Sey deri warn i Door ajar minates, | Doo ajar wami remains on with al rs. 1S 1 Sosval door. Boo sar waringhioht ha oo ’ Ey dt dee jar wasnt wef 7 Sian go, ais aston warning Tg dos va tains 7 eee witparing ako tosor at Satta tem waring ot trots Tia aan waning 1g ronaine tuinaed | 16 4 Rolo paring brake Bie aa wang ht rans Waki Brake | ENony hale opto wasng ight | hing rake lased and rake hove ref ety at brake stom waring ght [| iumates when Brake Nuld mn tesee, | Brake system warning ight does not Muminate 7 vorisbuow sit eee eins meee ee a Gram] Tun iion aio COCK or AGG. | Von Ray oat ar esr oon = atlon | > Open any doe i sere oun “een ight wich on Tigo oinor alarm dows rl sound 3 Eta ition sehn LOCK or A, Lighten Toninder | 8:Open any door. 4.Vesify that lights-on reminder alarm sounds. C2-16WARNING SYSTEM C2 Warning lights do not illuminate with ignition switch at ON [rowcnar No.1 | Symptom | (ori topped) Possible cause + Bumnt METER 15A fuse + Open or short circuit in wiring harness + Poor connection of connector Step 1 Check the METER 15A fuse in the fuse block. Fuse Retion OK Goto Step? Burnt Replace fuse afler checking and repairing wing hamess. Step 2 1. Remove the instrument cluster. (Refer to section C1.) 2. Turn the ignition switch to ON. 3, Measure the voltage at terminal 2G (B/Y) of instrument cluster connector. Be: Battery postive voltage Voltage ‘ction Goto Sens Repair wiring hamess (METER 154 fuse—instrument cluster) Step 3 Refer to the flowchart numbers shown. ‘Symptom Flowchart No. Page Generator warning ight 2 Tan] "ABS warning light 3 =a] Brake system warming ight 4 Tee] Oi pressure warning light 5 =F C2-17c2 WARNING SYSTEM| Flowchart No.2 | Symptom Generator waming light does 1 ON (engine stopped) Possible cause + Damaged generator + Damaged instrument cluster + Open or short circuit in wiring hamess + Poorconnection of connector Step 1 1. Disconnect the generator connector and connect ground to terminal B (W/B), 2. Tum the ignition switch to ON and verify that the wamn- ing light illuminates. Light ‘Ration Tiominates Tnspact ganerator (Refer to 1996 626/MX-6Workshop Manual, section G) Daas notiluminale | Goto Step? Step 2 1. Tum the ignition switch to LOCK and connect the gen- erator connector. 2. Remove the instrument cluster. C2-18 3. Disconnect instrument cluster connector. 4. Check for continuity between terminal 3G (W/B) of instrument cluster connector and ground. lo Teton Yes Ropar wing Famess (rumen Star Generator We Goto Slop Step 3 Remove and check the bulb of the warning light. Bulb Feton OK Faglaasnsument str Sant Replace bubWARNING SYSTEM c2 [Fowenar No. 3 ‘Symptom ‘ABS warning light does not illuminate with ignition switch at ON (engine stopped) Possible cause + Burnt ABS warning light bulb + Damaged instrument cluster + Damaged ABS control module + Open or short circuit in wiring harness + Poor conneetion of connector Step 1 1, Disconnect the ABS control module connecto: and tu the ignition switch to ON. 2.Ground terminal 21. (L/Y) of the ABS control module connector and verify that the warning light illuminates. Tight Tiuminates Ration Tnspect ABS control module (Reter to the 1996 626/MX-8 Workshop Manual, section P) “Turn ignition switch to LOGK, and go to Step 2 ‘Does not iluminate Step 2 1, Remove the instrument cluster. 2. Remove and check the ABS warning light bulb. oa Ton Sees Step 3 ‘Check for continuity between terminal 21 (L/Y) of instru- ment cluster connector and ground. Continuity Ration Yes place instrument cluster fsceraeeomTor No Repair wiring harness (Instrumon|cluster— ABS control module) C2-19c2 WARNING SYSTEM Flowchart No.4 | Symptom Brake system warning light does not illuminate with parking brake lever set Possible cause + Damaged parking brake switch + Burnt brake system warning light bulb + Damaged instrument cluster + Open or short circuit in wiring harness + Poor connection of connector Step 1 1. Remove the instrument cluster. 2.Remove and check the brake system warning light bulb. Bulb ‘Ration OK Install the bulb and go to Step 2 Burt Replace bulb Step 2 1. Disconnect instrument cluster connector. 2. Check for continuity between terminals 2G and 3H of ‘the instrument cluster connector. 2-20 Continuity ‘Retion Yes Goto Step 3 No FRplace print pate (Refer to section C7] Step 3 1. Disconnect the parking brake switch connector. 2. Check for continuity between the switch terminal and ground. Parking brake Continuity ‘Sat Yes Released No. 3. If correct, repair the wiring harness (instrument clus- ter—parking brake switch). 4.If not as specified, adjust or replace the parking brake switch, (Refer to the 1996 626/MX-6 Workshop Manual, section P.)WARNING SYSTEM C2 Oil pressure warning light does not illuminate with ignition switch at Flowchart No.5 | Symptom | On! Cnaine stopped) Possible cause + Bumt oil pressure warning light bulb + Damage oil pressure switch + Open or short circu ing harness. + Pcor connection of connector Step 1 1. Disconnect the oil pressure switch connector. 2. Start the engine and check for continuity between the switch terminal and ground Engine condition Continuity Running No. ‘Stopped Yes. 3. If correct, go to Step 2. 4, If not as specified, replace the oil pressure switch. (Refer to the 1996 626/MX-6 Workshop Manual, section D.) Step 2 1. Turn the ignition switch to LOCK. 2. Remove the instrument cluster. 3, Remove and check the oil pressure warning ligt bulb. Bulb ‘Ration OK Repair wiring harness (instrument cluster—Ol pressure switch) Burnt Replace buib 02-21C2 WARNING SYSTEM Flowchart No.6 | Symptom Washer flui (engine running) Jevel warning light remains illuminated Possible cause + Shortage of washer fluid + Damaged washer fluid-level sensor + Shortcircuit of wiring harness Step 1 Check for the washer fluid level Washer fluid level Between LandF | Goto Step2 Below L Supply washer fuid Step 2 4. Disconnect the washer fluid-level sensor connector. 2. Check for continuity between terminals A and B of the washer fluid-level sensor. Washer fluid level Continuity Below MIN Yes: ‘Above MIN. No. 3. If not as specified, replace the washer fluid-level sen- sor. 4. If correct, repair the wiring harness (instrument clus- ter—washer fluid-level sensor). Flowchart No.7 | Symptom Washer fluid-level warning light does not illuminate with washer fluid level low (engine running) Possible cause + Damaged washer fluid-level sensor + Open circuit in wiring hamess + Poor connection of connector Step 1 1. Disconnect the washer fluid-level sensor connector. 2. Check for continuity between terminal B (B/Y) of the washer fluid-level sensor connector and ground. Continuity Retion Yes Goto Step? No Repair wiring hamess (Washer fluid-level sensor—Ground)c2 WARNING SYSTEM Step 2 1. Check for continuity between terminals A and B of the washer fluid-level sensor. ‘Washer fluid level Continuity ay Below MIN Yes ‘Above MIN No. sor. 2.If not as specified, replace the washer fluid-level sen- 3. If correct, repair the wiring harness (instrument clus- ter—washer fluid level sensor). Flowchart No.8 | Symptom Fuel-level warning light remains illuminated (engine running) Possible cause + Shortage of fuel + Damaged fuel gauge sender unit + Open or short circuit in wiring harness Step 1 1. Tum the ignition switch to ON. 2. Verify that the fuel gauge indicates the correct values. ‘Gauge display ‘Ration Moves Gow Spe (Does not move “Troubleshoot fuel gauge [Refer to section Cry] Step 2 ‘Check the fuel level. Fuel level ‘Ration OK ____| Replace instrument cluster = Empiy Ad fuel C2-23c2 WARNING SYSTEM Flowchart No. 9 ‘Symptom Fuel-level warning light does not illuminate with fuel tank almost ‘empty (engine running) Possible cause + Burt fue-level warning light bulb + Damaged instrument cluster Step 2 1. Remove the instrument cluster. 2. Remove and check the fuel-level warning light bulb. Bulb ‘Action OK Replace instrument cluster Burnt Replace fuel-/evel warning light bulb Flowchart No. 10 ‘Symptom Oil pressure warning light remains illuminated (engine running) Possible cause + Low oll pressure + Damaged oil pressure switch + Open or short circuit in wiring harness Step 1 1. Measure the engine oil pressure. (Refer to the 1996 626/MX-6 Workshop Manual, section D.) Oil pressure: '340—490 kPa {3.45.0 kgficm’, 49—71 psi} ‘at 3,000 rpm (KL) 400—490 kPa {4.0—5.0 kgflom?, 51—71 psi} at 3,000 rpm (FS) 2. If correct, go to Step 2. 3. If not as specified, inspect the lubrication system. (Refer to the 1996 626/MX-6 Workshop Manual, section D.) Step 2 1. Disconnect the oil pressure switch connector. 2. Start the engine and check for continuity between the oil pressure switch terminal and ground. Engine condition Continuity Running No. Stopped Yes. 3.If correct, repair the wiring harness (instrument clus- ter—oil pressure switch). 4, If not as specified, replace the oil pressure switch. (Refer to the 1996 626/MX-6 Workshop Manual, section D.)WARNING SYSTEM Flowchart No. 11 Symptom ‘Seat belt warning light and alarm do not operate Possible cause + Damaged CPU + Damaged buckle switch + Open or short circuit in wiring harness + Poor connection of connector Step 1 1. Disconnect the buckle switch connector. 2. Check for continuity between terminals C and F of the switch. 0 : Continuity Terminal Seat belt 2 = Fastened Unfastened oO 3.1f correet, go to Step 2. 4. Ifnot as specified, replace the buckle. Step 2 ‘Check for continuity between terminal F (B) of the buck- le switch connector and ground. Continuty Retion Yes Reconnect buckle switch connector and go = (| No Repair waming harness {Buckle suitchGND) Step 3 1. Remove the CPU from the joint box. 2. With the driver's seat belt unfastened, check for conti- nuity between terminal 1K of the CPU connector on the joint box and ground. Continuity Ration Yes 159 OPU to secon Z3) a No Repair wiring harness (CPU—Buckle switch)C2 WARNING SYSTEM Flowchart No.12 | Symptom | Seat belt warning alarm sounds; warning light does not illuminate Possible cause + Bumt seat belt warning light bulb + Open or short circuit in wiring hamess Remedy 1. Remove the instrument cluster. 2. Remove and check the seat belt warning light bulb. Bulb Ration OK Repair wiring hamess (Instument cluster—OPU) Burt Replace seat belt warning light bulb Seat belt warning light illuminates; waming alarm does not sourd Flowchart No.13_ | Symptom | Seat belt warning alarm sounds for 4 to 8 seconds after ignition switch is turned to ON (belt fastened) Possible cause + Damaged CPU Remedy + Replace the CPI [Refer to section 23.) Flowchart No.14_ | Symptom | Door ajar warning light does not illuminate with any door open Possible cause + Burt door ajar warning light bulb + Damaged CPU + Damaged door switch + Open or short circuit in wiring harness + Poor connection of connector Step 1 1. Remove the instrument cluster. (Refer to section C1.}} 2. Remove and check the door ajar warning light bulb. Bulb Ration OK Goto Step 2 Burnt Replace bulb 2-26WARNING SYSTEM C2 Step 2 1. Remove the CPU from the joint box. ‘[Refer to section Z: 2. Ground terminal 1E of the CPU on the joint box and verify that the door ajar waming light illuminates, Tight ‘Aetion laminates Does not laminate Goto Step S| Repair wiring harness {instrument cluster—CPU) Step 3 1. Remove the door switches. 2. Check for continuity between the terminals of each switch. ‘Switch Continuity Prossed No. Released Yes 3. f correct, repair the wiring hamess (CPU—door switch). 4. if not as specified, replace the door switch. Flowchart No.1 ‘Symptom Door ajar waming light remains on with all doors closed Possible cause + Damaged door switch + Damaged CPU + Open or short circuit in wiring harness Step 1 1. Remove the door switches. 2. Check for continuity between the terminals of each switch ‘Switch Continuity Pressed No Roloased Yes 3. Install door switches and go to Step 2. 4.lf not as specified, replace the door switch Step 2 1. Close all doors. 2. Remove the CPU from the joint box. 8.Check for continuity between terminal 1E of the CPU ‘connector on the joint box and ground. Continuity ation Ves Repair wiring harness (CPU—Dovr switch) No Replace CPU (Rater to socton 23] 02-27C2 WARNING SYSTEM Flowchart No.16_| Symptom Brake system warning light remains illuminated with parking brake released and brake fluid level above MIN Possible cause + Damaged parking brake switch + Short circuit of wiring harness Remedy 1. Disconnect the parking brake switch connector. 2. Check for continuity between the switch terminal and ground. Parking brake Continuity Sat Yes Roiease No. 3.1f correct, repair the wiring harness (instrument clus- ter—parking brake switch). 4. If not as specified, replace the parking brake switch. (Refer to the 1996 626/MX-6 Workshop Manual, section P.) Brake system warning light does not illuminate with brake fluid in reservoir below MIN Flowchart No.17_ | Symptom Possible cause + Damaged brake fluid level sensor + Open or short circuit in wiring harness + Poor connection of connector ‘Step 1 1. Disconnect the brake fluid level sensor connector. 2. Check for continuity between terminal A (B) of the brake fluid level sensor connector and ground. Continuity, ‘Ration Yes Go to Step 2 No Repair wiring harness (Brake fluid level sensor—GND} = Siena 1. Check for continuity between the terminals of the brake fluid level sensor. Fluid level ‘Continuity ‘Below MIN Nese ‘Above MIN, No 2.If correct, repair the wiring harness (instrument clus- ter—brake fluid level sensor). 3. If not as specified, replace the brake fluid level sensor. (Refer to the 1996 626/MX-6 Workshop Manual, section P.)WARNING SYSTEM c2 [ Flowchart No.18 | Symptom | Ignition key reminder alarm does not sound Possible cause + Bumt ROOM 15A fuse Damaged key reminder switch + Damaged door switch + Damaged CPU Open or short circuit in wiring harness Poor connection of connector Step 1 ‘Check the ROOM 15A fuse in the fuse block. Fase Ration OK Goto Step? Burt Replace fuse ater checking and repairing wiring hamess Step 2 1. Remove the column cover. 2. Measure the voltage at terminal B (L/R) of the key reminder switch connector. Be: Battery positive voltage Voltage __ ation Be Goto Step 3 Other Repair wiring harness (ROOM 154 fuse—Key reminder switch) Step 3 1. Measure the voltage at terminal A (P) of the key reminder switch. Bs: Battery positive voltage Ignition key Voltage Inserted Be Removed Other 2. If correct, go to Step 4. 3. If not as specified, replace the key reminder switch. Step 4 Verify that the door ajar warning light illuminates when any door is opened. Light ___Aetion Mluminates Gowsien7 Does notilluminate | Goto Step 5 2-29WARNING SYSTEM Step 5 1. Remove the door switches. 2.Check for continuity between the terminals of each switch. ‘Switch Continuity Pressed No Released Yes 3. If correct, go to Step 6. 4. If not as specified, replace the door switch. Step 6 1. Open each door. 2.Check for continuity between terminal 1E of the CPU connector on the joint box and ground. Continuity Yes Roplace CPU No. Repair wiring harness (Door switch—CPU) Ration Step7 1. Remove the CPU from the joint box. 2. Insert the ignition key into the ignition switch. 3. Measure the voltage at terminal 11 of the GPU connec- tor on the joint box. Bs: Battary postive voltage ‘Switch ‘ation’ a Replace GPU (fear Seaton 7 Other Repair wiring hamess (Key reminder switch—CPU) Flowchart No.19 ‘Symptom Lights-on reminder alarm does not sound Possible cause + Damaged CPU + Damaged door switch + Open or short circuit in wiring harness + Poor connection of connector 2-30 Step 1 1. Remove the door switches. 2.Check for continuity between the terminals of each switch. __ Switch Continuity Pressed No Released Yes, 3. Install door switch and go to Step 2. 4. not as specified, replace the door switch.WARNING SYSTEM. Step 2 3. Measure the volt C2 1, Remove the CPU from the joint box. (Refer to section 23. 2. Tum the ignition switch to LOCK. {age at terminal 1A of the CPU connec- tor on the joint box. Be: Battery positive voltage Voltage ‘Action Be Repair wiring hamess (ROOM 154 fuse—CPU) Other Goto step 3 Step 3 1. Turn the headlight switch on. 2, Measure the voltage at terminal 1P of the CPU connec- tor on the joint box. Be: Battory positive voltage +. Open each door. 2. Check for contin connector on the Voltage ‘Action Br Goto Step 4 Other Repair wiring harness {TAIL 15A fuse—CPU) Step 4 ity between terminal 1 of the CPU joint box and ground, Continuity Ration Yes Foplace CPU [(Retarto secton Za] No Repair wiring hasness (Door switch—CPU) C2-31C2 WARNING SYSTEM WARNING LIGHT BULBS Replacement move the instrument cluster. BUCKLE SWITCH Inspection 1. Disconnect the buckle switch connector. 2.Check for continuity between terminals C and F of the switch. -O : Continuity Terminal ‘Seatbeit . : Fasioned Untastened of —— 3. If rot as specified, replace the buckle. PARKING BRAKE SWITCH Inspection 1. Disconnect the parking brake switch connector. 2. Check for continuity between the switch terminal and ground, Brake lever Continuity Pulled one notch Yes: Released No 3. If rot as specified, replace the parking brake switch. (Refer to the 1996 626/MX-6 Workshop Manual, section P.) C2-32WARNING SYSTEM c2 BRAKE FLUID LEVEL SENSOR Inspection 1. Disconnect the brake fluid level sensor connector. 2. Check for continuity between the sensor terminals. Fluid evel Continuity Below MIN Yes Above MIN No 3. If not as specified, replace the brake fluid level sensor. (Refer to the 1996 626/MX-6 Workshop Manual, saction P.) OIL PRESSURE SWITCH Inspection 1. Disconnect the oil pressure switch connector. 2.Check for continuity between the oil pressure switch terminal and ground. Engine condition Continuity ‘Stopped Yes Running No. 3.If not as specified, replace the oil pressure switch. (Refer to the 1996 626/MX-6 Workshop Manual, ssction D.) WASHER FLUID-LEVEL SENSOR Inspection 1. Disconnect the washer fluid-level sensor connector. 2.Check for continuity between terminals C and D of the sensor as shown. Fluid fevel Continuity Below MIN Yes ‘Above MIN No 3.If not as specified, replace the washer flui sor. level sen- 2-33Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. WINDSHIELD WIPER AND WASHER [STRUCTURAL VIEW. [TROUBLESHOOTING WINDSHIELD WIPER AND WASHER SWITCH .. WINDSHIELD WIPER. [WINDS HID WINDSHIELD WIPER AND WASHER WINDSHIELD WIPER AND WASHER STRUCTURAL VIEW 1. Windshield wiper and washer switch 3. Windshield washer motor i auWINDSHIELD WIPER AND WASHER D ‘SYSTEM DIAGRAM tee wireR 20K Fuse WinosiieLo WIPER AND WASHER switcH a Washer ad i = Siro ig SWITCH INTERMITTENT 2 WIPER RELAY jwanosHieLD /winosiietD WIPER. WASHER MOTOR MOTOR Description The windshield wiper and washer system consists of the windshield wiper and washer switch, wind- ‘shield wiper motor, and windshield washer motor. ‘System Operation 1. Low speed and high speed + When the windshield wiper switch is moved to LO, current flows through the windshield wipe’ switch, to the windshiold wiper motor, and then to ground.’ Tho wipers operate at low speed. + When the windshield wiper switch is moved to HI, current flows through the windshield wiper switch, tothe windshield wiper motor, and then to ground. The wipers operate at high speed. D-3D WINDSHIELD WIPER AND WASHER 2. Autostop While the windshield wiper motor is operating, the aulostop switch is on. If the wiper switch is moved to OFF, current continues to flow through the autostop switch, to the intermittent wiper relay, to the ‘one-touch switch, to the windshield wiper motor, and then to ground. Thus, the wipers keep moving until they reach the park position. When the wipers reach the park position, the autostop switch turns off and the wipers stop. 3. One-touch wiper + When the windshield wiper and washer switch is pushed, the one-touch switch turns on and current flows through the one-touch switch, to the windshield wiper motor, and then to ground. The wipers operate at high speed for one cycle. + When the windshield wiper and washer switch is pushed and held, the wipers cycle at high speed. When the switch is released, the autostop function is activated and the wipers stop at the park posi- tion, 4, Intermittent wiper + When the wiper switch is moved to INT, the intermittent wiper relay is activated, and current flows through the wiper switch, to the intermittent wiper relay, to the one-touch switch, to the windshield wiper motor, and then to ground. The wipers operate at low speed. When the intermittent wiper relay internal circuit turns off the relay, the autostop function is activated, and the wipers stop at the park position. + After the wipers stop, discharge from the capacitor inside the relay turns the intermittent wiper relay ‘on again, and current flows to operate the wipers again. 5. Washer + When the windshield wiper and washer switch is pulled, the washer switch is tuned on. Current flows through the washer switch, to the windshield washer motor, and then to ground. The wind- shield washer motor is activated. + Current also flows to the intermittent wiper relay, turning it on, and continues through the one-touch ‘switch, to the windshield wiper motor, and then to ground. The wipers operate at low speed. + When the washer switch is ON for more than 1.5 Séc., power is stored in the condenser inside of the intermittent wiper relay and so the windshield wiper motor continues to operate for 2.6 sec. after the switch is turned OFF. Then the windshield wiper motor returns to the park position due to the autostop function. D4WINDSHIELD WIPER AND WASHER TROUBLESHOOTING Circuit Diagram D | #WINDSHIELD WIPER AND WASHER paren MarN FUSE BLOCK oo MAIN ey 39 © oo OR ean 108 ar waren —.¢ 2/A¢) — Bae zen) EOI @: 20 ce WINDSMIELO WIPER AND WASHER SWITCH To NER STO Hiaie 3 Tia Sw? int | sien shire ¥ a 5 Lt ge % wa ju > € te te li i wmosure.o ase soraR 0-03 af WIRDSFTELO WIPER VOTO ) to c al AWINDSHIELD WIPER AND WASHER D Step 2 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2.Measure the voltage at the terminals of the windshield wiper and washer switch connector with the wiper switch in the following positions. Br: Battery positive voltage ‘Switch position Terminal Voltage to Be HI U Be 3.1f correct, repair the wiring harness (windshield wiper and washer switch—windshield wiper motor). 4.If not as specified, inspect the windshield wiper and > Flowchart No.3 | Symptom Wipers continue operation after windshield wiper and washer switch | is turned to OFF : Possible cause + Damaged windshield wiper and washer switer Remedy Inspect the windshield wiper and washer switsh. Refer to page D-12. Flowchart No.4 Intermittent wiper operation is not possible Symptom | (iow/nigh oparation is possible) Possible cause + Damaged windshield wiper and washer switch Remedy Inspect the windshield wiper and washer switch. Flowchart No.5_| Symptom Possible cause + Damaged intermittent wiper relay (in combination switch) Interval adjustment of intermittent wiper operation is not possible Remedy Replace the combination switch, Refer to section 24.) Flowchart No.6 Symptom | Wipers continue intermittent operation Possible cause + Damaged windshield wiper and washer switch + Damaged intermittent wiper relay (in combination switch) Remedy Inspect the windshield wiper and washer switch. [Refer to page i] D-9D WINDSHIELD WIPER AND WASHER Flowchart No.7_| Symptom One-touch wiper operation is not possible Possible cause + Damaged windshield wiper and Remedy Inspect the windshield wiper an¢ Refer to page D12. washer switch \d washer switch. Flowchart No.8 | Symptom ‘Autostop operation does not work (wipers immediately stop when windshield wiper and washer switch is turned to OFF) + Damaged windshield wiper mot + Damaged windshield wiper and + Open or short circuit in + Poor connection of connector (or washer switch ing hamess Step 1 wiper motor conn 1. Turn the ignition switch to ON. 2. Measure the voltage at terminal D (L) of the windshield iector. +: Battery positive voltage (Refer to the 1996 2. Measure the vol wiper switch at the Toray Tetion & Goro Stop? Other Repel wing Ramess (WIPER 20A fuse—Windshield wiper motor) Step 2 Measure the voltage at terminal B (L/B) of the wind- shield wiper motor connector with the wiper switch at the low position. Be: Bator postve voltage vorage Faton a Tum windshietwpor and washer ewicho OFF and go tosh 3 Ofer Tnopct windshield wiper clo Step 3 1. Remove the column cover. shield wiper and washer switch connector with the 626/MX-6 Workshop Manual, section S.) tage at terminal K (L/B) of the wind- 1e low position. Be: Battery postive voltage Voltage ‘ation cs noc winter acd washer vich Giro Repair wiring hamess {Windshield wiper motor—Windshield wiper ‘and washer switch)WINDSHIELD WIPER AND WASHER D [Flowchart No.9 ‘Symptom | Washer does nat operate ( ers operate) Possible cause + Damaged windshield wiper and washer switch + Damaged windshield washer motor + Open or short circuit in wiring harness + Poor connection of connector Step 1 1, Remove the column cover. (Refer to the 1986 62G/MX-6 Workshop Manual, section 8.) 2. Tur the ignition switch to ON. 3. Measure the voltage at terminal M (L/O) of the wind- shield wiper and washer switch connector while operat- ing the washer. Bu: Battery positive voltage Voltage ‘Action Be Goto Step? orner Inspect windshield wiper and washer switch eter To page Step 2 1, Remove the mud guard. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Measure the voltage at terminal B (L/O) of the wind- shield washer motor connector while operating the washer. Be: Battory postive votage Voltage ‘etion Be Goi Steps 4 Other Repair wiring harness (Windshield wiper and washer switch— Windshield washer motor) Step 3 1. Tum the ignition switch to OFF. 2. Disconnect the windshield washer motor connector. 3. Check for continuity between A (B/Y) of the windshield washer motor connector and ground. Continuity ‘etion Yes Tnepect windshield washer motor (Gsterto paqo 0-12] No Repair wiring harness (Windshield washer motor—GND) Flowchart No.10 Symptom Washer operates with winds! id washer switch turned OFF Possible cause + Damaged windshield wiper and washer switch Remady Inspect the windshield wiper and washer switch. [Refer fo page D-12,J] D-11D WINDSHIELD WIPER AND WASHER — | WINDSHIELD WIPER AND WASHER SWITCH Inspection 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, secticn S.) 2. Disconnect the windshield wiper and washer switch connector. 3. Check for continuity between the terminals of the wind- shield wiper and washer switch. OO : Continuity Terminal sosition sik etmin ‘Switch position ore | setuch OFF of = Windshiot ‘One-touch ON = wiper [INT i 7 switch [To eS = HL o Windshield washer switch ON o —Fo 4, If not as specified, replace the combination switch. WINDSHIELD WIPER MOTOR Inspection 1. Disconnect the windshield wiper motor connector. 2. Check for continuity between the motor terminals as indicated below. 0-0 : Continutly = Terminal —— Wiper position ees ee Parked o-oo Not parked oF rs 3. Connect battery positive voltage to the terminals of the windshield wiper motor connector and ground to a bare metal part of the vehicle. Verify that the windshield wiper motor operates as indicated below. c 7 Soanties —] = ae f i 4. if not as specified, replace the windshield wiper motor. WINDSHIELD WASHER MOTOR: Inspection 1. Remove the mud guard. (Refer to the 1996 626/MX-6 Workshop Manual, section S,) 2, Disconnect the windshield washer motor connector. 3, Connect battery positive voltage to terminal & and ground to terminal A of the motor. 4, Verify that the windshield washer motor operates. 5.1f the motor does not operate, replace it.WINDSHIELD WIPER AND WASHER: COMPONENTS Removal / Installation 4, Remove in the order shown in the figure. 2. Insiall in the reverse order of removal. — se say 6.90-9.50(700—100,61.0-26:7, Nm tkgfen in 1. Windshield wiper motor 4. Windshield washer motor [Inspection .. pection seomermmpage D=12]] ishield wiper arm and wiper blade 2. Windshield washer tank 3. Windshield washer pipe 6. Windshield washer nozzle D-13Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. EXTERIOR LIGHTING SYSTEM MARKER LIGHT...E EXTERIOR LIGHTING SYSTEM EXTERIOR LIGHTING SYSTEM STRUCTURAL VIEW Front View M8 ¢ 626 1. Headlight Troubleshooting i pn bane Ogi @-« 49 sti Fo Uri MOF 4, Front side marker light 3.8W (194) Troubleshooting. .. page E=35, Removal / Installation (MX-6) rr au. page E=45) [Aiming Removal Installat page E=53 5. Headlight rela) Inspection 2.2 = Section 6. TNS relay [inspection ection 22 7. DAL relay {Canada} 2. Front combination light inspection’ = Section 22 Removal / installation 8. DAL control module [Canada] 8. Front fog light 35W 9. DAL resistor [Canada] ‘Troubleshooting... page E26 [Removal / Installation . wage E53 jemoval /insfallation. page inspection... E-2EXTERIOR LIGHTING SYSTEM E Rear View 3. Licence plate light (MX-6) 4.9 W (168) (626) 5W Removal / installation Taillight 27/8W (115:E EXTERIOR LIGHTING SYSTEM ‘SPECIFICATIONS 626 pee Bulb Wattage (W) ‘Trade number Figh boam x2 3005 Head ight ‘Low beam 51x2 9006 Front turn and hazard waming light/parking light 27/8 x2 1157 NA Front side marker ight 3ax2 184 Front fo ight 5x2 7 Rear conbinaton sgn [Bate Toa B78 x2 Te Fear turn fight 2x2 Ti86NA roca omtinason vga [ate toa BBx2 1187 Bacup light 2x2 1186 ear side marker ight Boxe 84 ence plate gt x2 7 Hiah-mount brake Fat Text wi MX-6 = Bulb Wattage (W) “Trade number Headlight Fighitow beam Sx? e008 Front turn and hazard warning fantberking Fihit Bex? i167 NA Front side marker ight 3Bx2 108 Front fog ight 3x2 = Brake iahthalight B7Bx4 1187 Fear combination ight [Rear turn ight 27x2 1156 Back-up fh 2x2 1156 Rear ade marker ght 38x2 196 Licence plate fat 49x2 168 Without rear spoler Teaxt ei High-mount brake ight ed “a With rear spoiler Bixt — E4EXTERIOR LIGHTING SYSTEM E HEADLIGHTS: a ‘SYSTEM DIAGRAM Headlights 2 6 2 62 HEAD 08 _—veaoson WIPER 208 Fuse Fuse Fuse HEADLIGHT HEADUGHT | RELAY RELAY | s260my | |< sy wie | HeaouHt] § eaD i [conrrot 7 7h i | east Wd ‘TOPASS i mice a | ms Onuy ORL RELAY ONLY RESISTOR luict-seaw — |Low-Beaw HEADLIGHTS [HEADLIGHTS | pt Hct aan | [ ]AeAotGHTS ~ PARKING WITHOUT DAYTIME RUNNING LIGHT WITH DAYTIME RUNNING LIGHT Operation Headlights When the headlight switch is in the second position, the headlight relay is energized and applies volt- age to the dimmer switch. The dimmer switch directs the applied voltage to the high- or low-beam head- light filament. Daytime running lights (Canada) When the ignition is turned to ON and the parking brake is released, the daytime running lights feature is activated. The daytime running light control module turns on the low-beam headlights by energizing the DAL relay. The daytime running light control module turns off the lights when the parking brake is applied or the ignition is turned to LOCK or ACC. Front fog lights When the low-beam headlights are on, voltage is applied to the front fog light switch. When the fog light switch is turned on, voltage is applied to the front fog lights to illuminate the lights. ESE EXTERIOR LIGHTING SYSTEM a TAL 15a FUSE [F TNs RELAY TO PARKING UGHTS, TAILLIGHTS, SIDE MARKER LIGHTS, HEADLIGHT AND LICENCE PLATE LIGHT wea fewircn TNs, Operation When the headlight switch is in the first or second position, the TNS relay coil is grounded through the light switch. The TNS relay now energizes, allowing voltage from the TAIL 15A fuse to be applied to the parking lights, licence plate light, side marker lights, and taillights. E-6“a E-4] FEDERAL AND CALIFORNIA 626 = HEADLIGHTS one +—virn —ah wesbelp y1NJ19. (9z9) s1u6upeeH elwoyje9 pur je1pad ‘ONILOOHSATSNOwL WALSAS DNILHDI1 HOINSLXA « ae —— r INT EST RT eae | fee eal farm] x [orn] fear detenteE EXTERIOR LIGHTING SYSTEM. Canada ‘= HEADLIGHTS. IE-3] CANADA 626 £8EXTERIOR LIGHTING SYSTEM Connector locations Federal and California E-9E EXTERIOR LIGHTING SYSTEM E-10bi-a IE-2| FEDERAL AND CALIFORNIA MX-6 = HEADLIGHTS: 2 a I ae 4 7 on 961 —- POMS ne war 1 e [| pee sae ues | une | “ot | Bearers" | a | Sares| orm. a clos eluoyye9 pue e1epad ‘weasBelp }n0419. (9-xw) s1u6peeH WALSAS ONILHDIT HOIMSLXAaa epeueg E-4] CANADA MX-6 = HEADLIGHTS: on pORire a se __ na an Bales ca O09 —— oe 1a) $$ POvEEI Tae WALSAS ONILHDIT YOIWSLXSEXTERIOR LIGHTING SYSTEM Connector locations Federal and California venue HAIN FUSE BLOCK E13E EXTERIOR LIGHTING SYSTEM E-14EXTERIOR LIGHTING SYSTEM Checklist Procedure!Proper operation ‘Symptom Flowchart No. {Tum Readight wich on, "TNS and headlights do not iluminate 1 2. arity that headlights and TNS (tilights, a parking lights, front side marker ights, "| Teallghts do not iluminate 2 Fear side marker lights, and licence plate | Low-beam headlights do not iluminate (626) 3 Tight iluminate, igh-beam headlights do not lumina 43.Selcimmor switch to low-beam poston | Hiahbeam headlights do not lumina (628) . ‘and verly that low-beam buibs lluminate.| Low-beam headlights do not illuminate (MX-6) coe 4.52 dimmer switch to high-beam position | High-boam headlights do not illuminate (MX-6) 6 ‘and verify that high-beam and low-beam bulbs illuminate (626). ‘Set dimmer switch to high-beam position ‘and verily that high-beam bulbs ilumi- rate (MX-6) 5, Verty that lash-to-pass function oper= ‘ates normally (high-beam bulbs) with light switch at any position. E15E EXTERIOR LIGHTING SYSTEM Flowchart No.1 | Symptom TNS and headlights do not illuminate Possible cause + Open or short circuit in wi + Poor connection of connector hamess E-16 Step 1 Check for continuity between terminal E (B) of the com- bination switch connector and ground. Continuity Tetion ves Goto Step? a No Repair wiring harness (Combination switch—GND) Step 2 Refer to the appropriate flowchart. ‘Symptom Headlights do nat illuminate "TNS do not luminateEXTERIOR LIGHTING SYSTEM E Flowchart No.2 _| Symptom | Headlights do not illuminate Possible cause + Burnt HEAD 30A fuse + Damaged headlight relay + Damaged combination switch + Cpen or short circuit in wiring harness + Poor connection of connector Step 1 Check HEAD 30A fuse in the main fuse block. Fuse ~ Aetion OK Go to Step 2 ‘Burnt Replace fuse alter checking and repairing wiring harness Step 2 1. Remove the headlight relay. 2. Measure the voltage at terr ls A (R) and C (R) of the co headlight relay connector. ola Br: Battery positve voltage Voltage Ret ofa Be Goto Step 3 ‘Other Repair wiring hamess (HEAD 30A fuso—Headlight relay) Step 3 1. Apply battery positive voltage and check for continuity between the terminals of the headlight relay. -O : Continuity _ Bs: Battary positive voltage Terminal = a 8 c > Oo +—0 | 2 By GND of —9 2. If correct, install the headlight relay and go to Step 4. 3. If not as specified, replace the headlight relay. Step 4 1, Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2, Measure the voltage at terminal D (W/R) of the combi- = [wT efeT* nation switch connector. *int eho lafe lol Be: Battory positve voltage Voltage ‘ation a Goro Stop = Other Repair wiring hamess (Headlight rélay—Combination switch) EA7E EXTERIOR LIGHTING SYSTEM Step 5 1. Disconnect the combination switch connector. 2. Turn the headlight switch on (second position) 3. Check for continuity between terminals D (W/R) and E (8) of the combination switch. Continuity ‘Ration Yes Goto Step 6 No Replace combination switch Step 6 Refer to the appropriate flowchart. ‘Symptom Refer to page Low-beam headlights do not illuminate (626) Tee] High-beam headlights do not illuminate (626) Ceo] LLow-beam headlights do not illuminate (MX-6)_| [E21] _ High-beam headlights do not ilaminate (wx-6) | EE=23] E-18[Flowchart No.3 [ Symptom Possible cause + Burnt headlight bulbs + Damaged DRL relay + Open or short circuit in wiring harness + Poor connection of connector EXTERIOR LIGHTING SYSTEM Low-beam headlights do not illuminate (626) _ Step 1 Remove and check the low-beam headlight buts. Refer to pag E-47. Bulb Ration Goto Step 4 [USAT oK Goto Step 2 (Canada}_ Burt Replace bulb Step 2 1. Remove the front side trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the DRL relay connector. 3. Tum the headlight switch on (second position). 4, Measure the voltage at terminal F (W [626] or F/B [MX- 6)) of the DAL relay connector. Be: Battery postive voltage =) Votage ‘Action Ce Goto Steps Other Repair wiring hamess (Headlight relay-—DRL relay) Step 3 Check for continuity between terminal C (L) and F (W (626] or F/B [MX-6)) of the DRL relay connector. Continuity Retion Yes Goto Step 4_ No Roplace ORL relay Step 4 1. Disconnect the headlight connector. 2. Turn the headlight switch on (second position). 3. Measure the voltage at terminal C (W) of the headlight ‘connector. Br: Battery positive voltage Ration Vonage a Fopair wing hamess (Headight—GND) Repair wining harness (Headight relay—Headtight [USA)) (DRL rolay—Headlight (Canada) Other E-19E EXTERIOR LIGHTING SYSTEM Flowchart No.4 ‘Symptom High-beam headlights do not illuminate (626) Possible cause Damaged combination switch Burnt headlight bulbs ‘Open or short circuit in wiring harness Poor connection of connector Step 1 Remove and check the high-beam headlight bulbs. Bub ation OK Goto Step 2 Bur Replace bulb Step 2 4. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2.Turn the headlight switch on (second position, high- beam). 3. Measure the voltage at terminal F (W) of the combina- tion switch connector. B+: Battory postive votage Voltage ‘etion Goro Steps Other Ropair wiring harness (Headight relay-—Combination switch) Step 3 1. Disconnect the combination switch connector. 2. Check for continuity between terminals F (W) and B (RAW) of the combination switch. 6 A cal alesie Continuity Ration Yer Fecomnedl coansolor and goto Stop No Replace combination switch (Geter santo 28) Step 4 Measure the voltage at terminal A (R/W) of the head- light connector. Be: Battery positive voltage Vartage Ration ajeTe Br Repair wiring hamoss BpolF _ ____| tHeadiightGno) | Other Repair wiring hamess E-20 (Conintion smiEXTERIOR LIGHTING SYSTEM E Flowchart No.5 ‘Symptom Low-beam headlights do not illuminate (MX-6) Possible cause ‘Damaged combination switch Damaged DRL relay Burnt headlight bulbs (Open or short circuit in wiring harness Pcor connection of connector Step 1 Remove and check the headlight bulbs. Bulb ‘Retion OK Goto Step? Burt Replace bulb Step 2 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Turn the headlight switch on (second position, low- beam). 3. Measure the voltage at terminal F (W) of the combina- tion switch connector. Be: Battery positive voltage Voltage Be Goto Step S| ‘Other Repair wiring hanness ‘(Headlight relay—Combination switch) ‘Aetion Step 3 1. Disconnect the combination switch connector. 2. Check for continuity between terminals F (Wi and A (RIB) of the combination switch. Continuity Yes Ration Reconnect connector and goto Step 6 [USA] or Step 4 (Canada) No Replace combination switch (eerosecton 7a) Step 4 1. Remove the front side trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the DRL relay connector. 3. Turn the headlight switch on (second positicn, low- beam). == 4, Measure the voltage at terminal F (W [626] or RIB [MX- FE cls 6) of the DRL relay connector. Flals Bt: Battery positive voltage Voltage a Gow Sips Other Repair wiring harness (Combination switch—DRL relay) ‘Action E-21E EXTERIOR LIGHTING SYSTEM Step 5 Check for continuity between terminal C (L) and F (W) of the DRL relay connector. Be: Battery positive voltage Continuity ‘Retion Yes Goto Stop 6 No Replace DAL relay Step 6 1. Disconnect the headlight connector. 2. Turn the headlight switch on (second position, low- beam). 3.Measure the voltage at terminal A (R/B [USA] or L [Canada)) of the headlight connector. Be: Battery positive voltage Vertage ‘Aetion Be Repair wiring harness _(Headlight—GND) : Other Repair wiring harness (Combination switch—Headlight (USA) {ORL relay—Headlight (Canada) E-22EXTERIOR LIGHTING SYSTEM E [Flowchart No.6 | Symptom | High-beam headlights do not il te (MX-6) Possible cause + Damaged combination switch + Burnt headlight bulbs + Oven or short circuit in wiring harness + Poor connection of connector Step 1 Remove and check the headlight bulbs. Bulb ‘ation Replace bulb Step 2 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Turn the headlight switch on (second position, high- beam). 3.Measure the voltage at terminal F (W) of the combina- tion switch connector. eas Be: Battery positive voltage Voltage __| Action’ Be Goto Steps ‘Other Repair wiring hamess (Headlight relay—Combination switch) Step 3 1. Disconnect the combination switch connector. 2. Check for continuity between terminals F and B of the combination switch. 6 A Continuity Ration meelen (ea Yes Reconnect connactor and ga to Step 4 No Replace combination switch [Reterto section Z4) Step 4 Measure the voltage at terminal B (R/W) of the head- light connector. B+: Battery postive votlage Voltage ‘Retion Be Ropar wiring hares (Headlight GND) iepair wiring harness (Combination switch—Headlight) Other E-23ve-3 CANADA, = DAYTIME RUNNING LIGHT (ORL) go - . ms ~ | aang See l 7 + ee # pee! 2B loans foe te OR... 9 1 SF NET EE fe wesBelp ynoi9, (epeueo) s1y617 Buyuuny ewnkeg WALSAS ONILHDIT HOIMALXSSc-4 soir 80x A At ‘et ‘suojevo} s0y00UU0D WALSAS DNILHDIT HOIMALXSE EXTERIOR LIGHTING SYSTEM Front Fog Lights Circuit diagram E-26 IE-5) KL = FRONT FOG LIGHTS Eos Eo gaan exceer Seis ERGO 6e6 "ection Ge a Ee ea sesouro1 BEchiow c-a1 “nn roo 154 MAIN FUSE aLocK oe T FRONT Foo LEGIT SurtON TULUMINATION 7 FeeEn TB Set rio Tats 5-05 cor coc, Eat Sarre E-08 E08 Feo Fos Fronr Eos. Cietr C8 EST BR Seri EOF FRONT FORE CGE [EOS FRONT FOS LIGHT te El = ery eaConnector locations EXTERIOR LIGHTING SYSTEME EXTERIOR LIGHTING SYSTEM Checklist Procedure/Proper operation ‘Symptom Daytime running lights (Canada) 1. Turn switch on, 2.Nertty hat low-beam headlights, talight, and licence plate ight iluminate. Daytime running lights do not lluminate (Canada) —_| Daytime running lights do not turn off when parking brake lever is set (Canada) Daytime running lights do not tum off when ignition ‘switch Is tumed to LOCK or ACC (Canada) | Front fog hts 1. Turn switch to second position and front {og light switch on 2.Nerty shat both front fog lights illuminate. 8.Turn dimmer switch to high and verity that front fog lights turn off Front fog lights do not illuminate Front fog lights do nat turn off E-28EXTERIOR LIGHTING SYSTEM E Symptom [Flowchart No.1 Daytime running lights do not illuminate (Canada) Possible cause + Bumt WIPER 20A fuse + Damaged DRL resistor + Damaged DRL relay + Damaged DRL control module + Open or short circuit in wiring harness + Poor connection of connector oo OFFm Step 1 Check WIPER 20A fuss the fuse block and the DRL resistor 10A fuse. Fuse ation : OK Goto Step | (nam) Bunt Ropar is tar Sis and opaog wring harness USE THE DESIGNATED FUSES ONLY DAL RESISTOR 104 FUSE Step 2 Measure the resistance between the terminals of the DRL resistor. oon Resistance ation ee | [aaa [Goto Steps Other Roplace DAL resistor Step 3 1.Remove the front side trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the DRL relay connector. 3.Measure the voltage at terminal E (R/Y) of the DRL relay connector. Be: Battory postive voltage Woage ae | TActon Be | ‘omer Repair wiring harness (HEAD 30A tuse—DRL relay) E-29E EXTERIOR LIGHTING SYSTEM Step 4 1. Turn the ignition switch to ON. 2. Measure the voltage at terminal A (L) of the DRL relay connector, Be: Battery postive voltage ‘AB | Voltage ‘Aetion 8 Be Goto Steps ‘Omer Repair wing harness (WIPER 204 fuse—DAL relay) | Sipe 4. Turn the ignition switch to LOCK. 2. Remove the ORL relay. ©O-G 3. Apply battery positive voltage and check for continuity between the relay terminals. ‘O-O : Continuity B+: Battery positive voltage A Fle}s Terminal | = oo A B E c F ()}-——(6) © 7 7 © o of 2 Guo | Be 4.1 correct, install the DRL relay and go to Step 6. 5. If not as specified, replace the DAL relay. Step 6 1. Turn the ignition switch to ON. 7 cla | 2.Measure the voltage at terminal C (L) of the DRL con- trol module connector. Be: Battery postive voltage | Voltage Betion | [ee Goto Step 7 Other Repair wiring hamess ee (WIPER 208 tuse—DRL contro! module) =| 1. Turn the ignition switch to LOCK. aTeln 2. Disconnect the ORL control module connector. 3 TA eB x 8. Check for continuity between terminal D (G) of the DRL teL* control module connector and terminal B (G) of the DRL relay connector. Continuity Ration DALCONTROL MODULE ORL RELAY CONNECTOR ‘CONNEGTOR: Yes Goto Step 8 No Repair wiring hamess (OAL contol module—DRL relay) 9 Stop 8 Check for continuity between terminal F (B) of the DRL Control module connector and ground. Retion ‘Goto Sop 9 Repair wiring harness (DRL contzol module—GND} E-30EXTERIOR LIGHTING SYSTEM E = Step 9 1. Release the parking brake. 2. Check for continuity between terminal A (Y/R) of the DRL control module connector and ground. + cla | it [ + ae Yes Repair wiring harness (DRL control L— mediule—Parking brake switch) Ne Go to Step 10 (628) Replace DAL control module (NDC6) Step 10 1. Tum the ignition switch to ON. 2. Turn the headlight switch on (second position). 3.Measure the voltage at terminal J (W) of the DRL con- trol module connector. Be: Battery positive voltage Voltage __ “Action Be Replace DAL control module ‘Other Repair wiring harness (Combination switch—ORL resistor) E-31E EXTERIOR LIGHTING SYSTEM Daytime running lights do not tum off when parking brake lever is, Flowchart No.2 | Symptom | 53? Canada) Possible cause Damaged DRL control module + Damaged parking brake switch + Open or short circuit in wiring hamess + Poor connection of connector Step 1 1. Set the parking brake lever. 2. Check for continuity between terminal A (Y/R) of the DRL control module connector and ground. Continuity [Aeon — a * cla Yes Replace DRL control module lee aile No Goto Stop2 Step 2 1. Remove the rear console. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the parking brake switch connector. 3. Check for continuity between the terminal of the parking brake switch and ground. Continuity Ration Yes Repair wiring harness (Parking brake switch—DRL control module) No (Check parking brake switch and ground Daytime running lights do not turn off when ignition switch is turned Flowchart No.3 | Symptom | 19 LOCK or ACC (Canada) Possible cause + Damaged DRL relay + Open or short circuit in wiring harness 2. Apply battery positive voltage and check for continuity between the relay terminals. OO : Continuity _ Be: Battery positive voltage Terminal | = . e . 2 % | o 1 oo o- fo 3. If not as specified, replace the DAL relay. 4. If correct, repair wiring harness. (ignition switch—DRL. relay)EXTERIOR LIGHTING SYSTEM E Flowchart No.4 | Symptom | Front fog lights do not illuminate Possible cause + Burnt FOG 15A fuse + Burnt light bulbs + Damaged front fog light switch + Open or short circuit in wiring harness + Poor connection of connector Step 1 Check FOG 154 fuse in the main fuse block. Fuse ation OK Goto Step 2 Burnt Replace fuse afer checking repairing wing harness Step 2 Remove and check the front fog light bulbs. Bunt Replace bulb Step 3 1. Remove the switch panel. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2.Turn the headlight switch on (second position, low beam). 3. Measure the voltage at terminal B (G/B) of the front fog light switeh connector . Bu: Battery positive voltage Voltage ‘Retion Be “Tura headlight switch off and go to Step 4 ‘Oher Repair wiring harness (FOG 15A fuse—Front fog light switoh) Step 4 + Remove the font og ight switch 2. Check for continuity between the switch terminals. O-0 consnly "Og: Bub Terminal | switch posit JOFF [on 3. If correct, go lo Step 5. 4. not as specified, replace the front fog light switch. E-33 A c B D oE EXTERIOR LIGHTING SYSTEM Step 5 1. Disconnect the front fog light connector. 2.Check for continuity between terminal B (B/Y) of the connector and ground. Continuity ‘Ration Yes Repair wiring hamess (Front fog light switch—Frontfoa light No Repair wiring hamess (Front fog light—GND) Flowchart No.5 _| Symptom | Front fog lights do not tum off Possible cause + Damaged front fog light switch Remedy + Inspect the front fog light switch. (Refer to section 24.)) E-34se-3 *FRONT SIDE MARKER LIGHTS #REAR STOE MABKER LIGHTS: *PARKING LIGHTS #LICENCE PLATE LIGHTS = TAILLIGHTS ea Even Pon on eam tT a wesBelp yno410, 1617 e1e1q eouedry ‘siy617 Buped W31SAS ONILHDIT HOMSLXa {9z9) siuSmes ‘S146! 4ey2e~ ep!E EXTERIOR LIGHTING SYSTEM Connector locations E-36ie-4 E-e] wx-6 *FAONT_SIDE MARKER LIGHTS *PARKING LIGHTS —* TAILLIGHTS "REAR SIOE MARKER LIGHTS LICENCE PLATE LIGHTS: 2 8 ic 5. 2 S & 3 3 z z z 2 = & < 3 = 8 3 2 3 g c : g g 8 = : g ce & z a ©.9 ,, —«Q)r2 aie pon 4 ae + & — = WALSAS ONLLHDIT HOIWSLXSE EXTERIOR LIGHTING SYSTEM Conneetor locations E-38EXTERIOR LIGHTING SYSTEM Checklist Procedure/Proper operation ‘Symptom Flowchart No. {Turn he headight switch to frst poston. | TNS do not iuminate i 2.Veriy that TNS (tllights, parking lights, ' olin front side marker ights, rear side marker |Lcence plate ight does not ituminate 2 lights, and licence plate light) illuminate. | Taillights do not illuminate a Parking ights do not iluminate 4 Front and rear side marker lights do notiluminate 3 E-39E EXTERIOR LIGHTING SYSTEM [Flowchart No.1__[ Symptom | TNS do not illuminate Possible cause Burnt TAIL 15A fuse Damaged TNS relay Damaged combination switch Open or short circuit in wiring harness Poor connection of connector Step 1 {Es Check TAIL 15A fuse in the main fuse block. Ir Fuse ‘Action | iz mooo || fee aa = UI TAIL 5A Burnt Replace iso ator checking and repaing Step 2 1. Remove the TNS relay. 2. Measure the voltage at terminals A (W/L) and C (W/L) cml | of the TNS relay connector. aan B+: Battery positive voltage Voltage ‘Retion o|s Be Goto Step 3 Other ~~] Repair wiring harness {TAIL 15A fuse—TNS relay) Step 3 1. Apply battery positive voltage and check for continuity between the TNS relay terminals. ¢ 4 (OO : Continuity Bs: Battery postive voltage aj eee step LI 5 Sees : 2.{f correct, install the TNS relay and go to Step 4. 3. If not as specified, replace the TNS relay. Step 4 1. Remove the column cover. (Reter to the 1996 626/MX-6 Workshop Manual, section S.) 2.Measure the voltage at terminal C (LG) of the combina- [myiK Eley tion switch connector. sin[efuleie lol Be: Batiry postive vollage = Voltage ‘ction Be Goro Step 5 ‘Other Repair wiring harness (TNS rolay-~Combination switch) E40EXTERIOR LIGHTING SYSTEM E ‘Step 5 1. Disconnect the combination switch connector. 2. Tum the headlight switch on (first position). 3. Check for continuity between terminals C (L/G) and E (B) of the combination switch. Continuity Raton Yes Turn headignt atch of, reconnect connector and goto Sip 8 i Ne Fale cambiagen wi (eer ston 2a Step 6 Refer to the appropriate flowchart. Symptom Refer to page Ticence plat ight doesnot aminale =] [Talighs do netiuminaie =e Parking lights do not illuminate Front orrear side marker Ea Fights So nt iuminate Flowchart No.2 _| Symptom | Licence plate light does not illuminate Possible cause + Burt light bulb + Open or short circuit in wiring harness + Poor connection of connector se ee eee | Step 1 Remove and check the licence plate light bulb. | _IReter to panes E-52E-53.)] [Bulbs = ‘ation OK Go to Step 2 7 Burt Replace bulb Step 2 4. Turn the headlight switch on (frst position). 2. Measure the voltage at terminal A (O) of the licence plate light connector. Be: Battery postive voltage feta Wotlage ‘ation J m opal wing harness {Licence plate light GND) Other Repair wiring namoos (TNS relay—Licence plate light) E41E EXTERIOR LIGHTING SYSTEM Flowchart No.3 ‘Symptom Taillights do not illuminate a Possible cause + Bumt light bulb + Open or short circuit in wiring harness + Poor connection of connector Step 1 Remove and check the tailight bulbs. Refer to pages E-50, E42 Bub i @ OK wae S But Replace bub ey Step 2 4. Turn the headlight switch on (frst position), 2. Measure the voltage at terminal B (O) [626] or D (O) [MX-6] of the rear combination light connector. Ba: Battery postive witage Vortage ation oo Repair wing hamess {ear combination ightGND) find go to Step 2 628) Other Repair wing hamess (TNS ralay—Rear combination ght) and go to Step 3 (628) we6 626 Step 3 Measure the voltage at terminal C (O) of the inboard combination light connector. 64: Battery postive wltage = = joltage ion Be son \e62 ex = a 1 Be Repair wiring hamess (iboara combination ight-—GND) iher Repair wiring hamoss (INS eayhoard combination Hoh —_|EXTERIOR LIGHTING SYSTEM E [Flowchart No.4 | Symptom | Parking lights do not illuminate + Burnt light bulb + Open or short circuit in wiring hamess + Poor connection of connector Step 1 Remove and check the parking light bulbs. Bulb Action OK Go to Step 2 (626) or 3 (MX-6) Burnt Replace bulb Step 2 1. Disconnect the headlight connector. 2. Turn the headlight switch on (first position). nan 3. Measure the voltage at terminal F (O) of the headlight connector. aTeye Be: Battery positive otage elolr Voltage Aetion Be par wring hamess (Headlight GND) Giher Repair wiring hamess — CNS relay“Heactight xe Step 3 1. Disconnect the front combination light connector. 2. Turn the headlight switch on (first position). 3. Measure the voltage at terminal A (O) of the front com- bination light connector. ra Bs: Battry postive voltage iB iA Voltage Retion | Be pair wring hamess (Front combination ight GND) omer pair wring hamess (TNS relay—Front combination light) E43E EXTERIOR LIGHTING SYSTEM Flowchart No.5 ‘Symptom Front and rear side marker lights do not illuminate Possible cause + Burnt light bulb + Open or short circuit in wiring hamess + Poor connector of connector Step 1 Remove and check the side marker light bulbs. ((Refer to page E-53.)] BA REAR Bulb ‘Action OK Goto Step? Burnt eeplace bulb Step 2 1. Disconnect the front side marker light or rear side mark- er light connector. 2. Tum the headlight switch on (frst position). 3. Measure the voltage at terminals A (O) and (0) of the E44 ‘side marker light connector. Be: Battery postive votage Terminal | Vohage ation _ B+ | Repair wiring hamess ron | A (Frontside marker hghtGNO) ‘Other | Repair wiring hamess (TNS relay—Front side marker light) a B+ | Repairwirnghamess «| Rear} © (Pear side maker light—GND) = Other Repair wiring harness: (INS rolay-Rear side marker ligt)EXTERIOR LIGHTING SYSTEM E AIMING Use the vertical-horizontal aiming method for normal headlight aim adjustment. If the vehicle has been damaged in a collision, restore the headlights to their correct position before aiming them. Refer to the 1993 626/MX-6 Bodyshop Manual (No.3212-10-92A) for repair specifications. = a AG I 76m@5A} “ay | centeR oF Low & = BEAM HEADLIGHT UPIDOWN DIRECTION, Wy as ab \ \ Vertical-horizontal Aiming Method 626 4, Measure the tire air pressure when the tire is cold. Adjust the pressure to specification, if necessary. Air pressure Front: 216 kPa {2.2 kgficm’, 31 psi} Rear: 177 kPa {1.8 kgf/cm’, 26 psi} 2. Fill the fuel tank and remove excess cargo. 3. Position the unloaded vehicle on a fit level surface. 4. Position the vehicle straight ahead to the headlight tester. Set the distance between the headlight and the tester to 7.6 m {25 ff). 5. Disconnest the connector of the other headlight. 6. Adjust the up/down position of the headlight by using the vertical aiming gauge. Make sure the bubbe in the ‘gauge is within two lines on either side of the center “0”. E45EXTERIOR LIGHTING SYSTEM ae AMIN POINTS ZA ° oo or LEFTIRIGHT AIMING E-~46 7. Pull up the clip. 8. Push gear A toward the front of the vehicle until gears A and B disengage. 9. Tum the headlights on at low beam. 10. By using a screwdriver, turn gear B to carry out horizon- tal aiming. The left edge of the figure projected on the tester screen must be aligned with the vertical axis as shown. 11. Turn gear A to align the aiming points. 12. Push the clip down until gears A and B engage 18. Do this procedure for both RH and LH headlights. Note + When the headlights are correctly adjusted by follow- ing the above steps, simplified aiming by just turning gear B to align aiming points MX-6 1, Measure the tire air pressure when the tire is cold ‘Adjust the pressure to specification, if necessary. Air pressure Front: 216 kPa {2.2 kgf/cm’, 31 psi} Rear: 177 kPa {1.8 kgf/cm’, 26 psi} 2. Position the unloaded vehicle on a flat, level surface. 3. Turn the adjusting screws as shown in the figure to adjust the headlights. Use a “HOPPY" brand aimer or equivalent to aim the headlights to specification 1um- bers 16H-26V (found on the headlight lens).EXTERIOR LIGHTING SYSTEM E HEADLIGHT AND FRONT COMBINATION LIGHT Removal / Installation 4. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 626 1, Radiator grille 3. Bulb (high beam) 6OW (9005) Removal / Installatior 1996 626/MX-6 4, Bulb (high/low beam) 51W (9006) Workshop Manual, section S 5. Bulb (front tum and hazard warning lightpark- 2. Headlight ing light) 27/8W (1157NA) Clea age) Warning a * If the glass surface of a halogen bulb is touched with bare hands, natural body oil could cause the bulb to overheat when it is lit. Because a halogen Pr , bulb contains pressurized gas, this overheating will cause the bulb to burst. The flying glass may seriously injure you. Hold the metal flange, not, the glass, when replacing the bulb. E-47EXTERIOR LIGHTING SYSTEM Mx-6 FRONT HARNESS (LH ONLY) 1. Front combination light 2. Bulb (front turn and hazard warning light/park- ing light) 27/8W (1157NA) 4, Bulb (high/low beam) 65/45W (9004) Warning if the glass surface of a halogen bulb is touched with bare hands, natural body oil could cause the bulb to overheat when itis lit, Because a halogen bulb contains pressurized gas, this overheating will cause the bulb to burst. The flying glass may seriously injure you. Hold the metal flange, not the glass, when replacing the bulb.EXTERIOR LIGHTING SYSTEM FRONT FOG LIGHT Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 1. Front bumper Removal/installation..... 2..Nut 3. Front fog light ...1996 626/MK-6 4. Cover 5. Bulb 35W Workshop Manual, section S E49E EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 1. Screw 5. Bulb (brake lighttaillight) 2. Rear combination light (1157) 27/8W ( 6. Bulb (rear turn and hazard warning light) 50) 27W (11 7. Bulb (back-up light) 3. Grommet ‘27W (1156) 4. Socket E-50EXTERIOR LIGHTING SYSTEM E Disassembly 1. Use a hot-air blower to soften the “hot melt" (bonding agent) around the lens. 2. Remove the lens from the light housing by pushing the rear of the lens with a hammer handle or round bar. 3. Remove the old hot melt from the light housing. Assembly 1. If new hot meft is used, put Uni-sealer (8531 77 739) adhesive in the light housing groove. 2. Fit the new lens onto the light housing. Press tne lens firmly so that it will adhere. 3. Allow the sealer to dry for about one hour. 4, Immerse the combination light in water to check for leaks. E-51E EXTERIOR LIGHTING SYSTEM INBOARD COMBINATION LIGHT Removal / Installation 1. Remove the trunk lid trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal. _ a @ 8 GF YA 4 A © “Ne ~ D—o 1. Inboard combination light connector 5. Bulb (back-up light) 2. Screw 27W (1156) 3. Cover 6. Nut 4. Bulb (brake light/taillight) 7. Inboard combination light 27/8W (1157) LICENCE PLATE LIGHT Remove / Installation (628) 1. Remove the screws. 2. Remove the licence plate light. 3. Remove the bulb. 4. Install in the reverse order of removal. Bulb: 5W E52EXTERIOR LIGHTING SYSTEM (Wx-6) a 1.Remove the screws. 3.Remove the bulb. Bulb: 4.9W (168) Removal / Installation 2.Remove the screws. 4, Remove the bulb. Bulb: 3.8W (194) Removal / Installation DAL RESISTOR 10.4 FUSE 1. Remove the bolt. 3. Instal Inspection replace it. Resistance: 0.30 2.Remove the licence plate light. 4. Install in the reverse order of removal. FRONT SIDE MARKER LIGHT/ REAR SIDE MARKER LIGHT 1. Remove the mud guard. 3. Remove the marker light. 5. Install in the reverse order of removal. DRL RESISTOR [CANADA] 2. Remove the DRL resistor. the reverse order of removal 3.|f not as specified, replace the DRL resistor. 1. Check the DRL resistor 10 fuse. If the fuse is burnt, 2. Measure the resistance between the resistor terminals. E-53Before beginning any service procedure, refer to section § of this manual for air bag system service warnings. SIGNAL LIGHTING SYSTEMF SIGNAL LIGHTING SYSTEM SIGNAL LIGHTING SYSTEM STRUCTURAL VIEW Front View 626 Mx-6 1. Front combination light Turn and hazard warning light 27/8W (1157 NA) 4, Flasher unit [Troubleshooting sass, PaGe FB] inspection uuu. page F=33] 2. Tuin switch (combination switch) kup light Romoval / Installation ja... 000tion 24 Inspection . inspection jae F=32 F-2SIGNAL LIGHTING SYSTEM F Mx-6 1, Rear combination light 3. High-mount brake light 18.4W (921) [Removal / Installation... = Section E] [Removal / Installation. pai (1) Turn and hazard warning light (Troubleshooting... page F-17 4, High-mount brake light 8.1W Troubleshooting. page F= 5 MX-6 with rear spoiler) (2) Brake light taillight 27/8W (1157) Removal / installation Troubleshooting . a. P4Q@ F=17 {Troubleshootina.... 2. Inboard combination lig page F=34 page F=17 F-3F SIGNAL LIGHTING SYSTEM SYSTEM DIAGRAM Turn and Hazard Warning Light 191 be TURN 16 A FUSE HAzanO 15 FUSE ur wtaw— omren “La | ruswen ot Ten ano neLay Conroe nevav ney me ben | 2 ah reer cuusten ruacano Front aan can ont anes a © i $-*} switch | = . + + + ‘ Description The signal lighting system consists of the following components: + Turn and hazard warning lights in the front combination light + Turn and hazard warning lights in the rear combination light + Tum switch in the combination switch + Hazard warming switch + Flasher unit Operation 4. Turn signal lights When the turn switch is set to the lef (right) position with the ignition switch at ON, relay 1 (relay 2) in the flasher unit closes, turning on the left (right) turn signal lights. 2. Hazard lights When the hazard warning switch is turned on with the ignition switch at any position, relays 1 and 2 in the flasher unit close, tuming an the hazard lights F4v4 |F—4] # TURN AND HAZARD WARNING LIGHTS: 5 Pa... San ser § BY3 & p44, gs vaone on ee rao a e | 2 I dew et net a ona @-2 o—= weaBeIp yn9419 ‘siy617 Bujwem puezeH pue wnt 2. fete) o NLLOOHSaTENOwL WALSAS DONILHDI TWNOIS4 woned0} 10;22NU09 WALSAS DNILHDIT IVNDISSIGNAL LIGHTING SYSTEM Checklist Procedure / Proper operation Symptom Fiowehart Ne, “Tum nionawch to ON. Tum and hazard warning Tnctons do not i 2.Set turn switch to right turn and verify, operate that igh tar gna Tigh tah ee a uandion sa 4. Selum wich ef im and erty that | Tun Sigal uncon does nel operate 2 tft turn signa ight Tas, {Rien rast watt satan on and vert. | Hazard ght fnaion does not operate 3 fy that all tum signal lights flash simulta |_(turn signal function operates) neously. Left or right turn signal function does not operate 4 (hasard fh tuncton operate) Left or right turn signal function and hazard light 5 function do nat operate F-7F SIGNAL LIGHTING SYSTEM Flowchart No.1_| Symptom | Turn and hazard warning functions do not operate Possible cause Burnt HAZARD 15A or TURN 15A fuse Damaged flasher unit Damaged combination switch Damaged hazard warning switch Burnt light bulbs Open or short circuit in wiring harness Poor connection of connector Step 1 Check the HAZARD 15A and TURN 15A fuses in tl fuse block. Fuse ‘Action OK Goto Step Burt Roplace fuse after necking and repairing wiring harness, Step 2 Measure the voltage at terminal H (BR/W) of the flash unit connector, Be: Battery positive volta ‘Aetion Goto Steps ‘Other Repair wiring hares (HAZARD 154 fuse—Flasher unt) Step 3 1. Disconnest the flasher unit connector. 2. Check for continuity between terminal A (B) of the flas er unit connector and ground. Continuity —____ Retion Yes Reconnect connector and go to Step 4 No Repair wiring ames (Flasher unitGND) F-8SIGNAL LIGHTING SYSTEM F Step 4 1, Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Turn the ignition switch to ON. 3. Turn the turn switch on (left or right). 18 1A 4, Measure the voltage at terminal 1G (GY) or 1H (B/R) of wn] iF] 10 | a8 the combination switch connector. Ba: Battory positive voltage [Terminal | Voltag Action 16 Be “Turn ignition switch to LOCK, tum switch off and go to Step 5 ‘Other | Inspect tuen switch (Combinatior switch (tartans Faz) 1H Be “Turn ignition switch to LOGK, tum switch off and go to Step 6 ‘Other | Inspect umn switch (Gombinatior switch) (fartopago t=) Step 5 Set the tun switch to the left position and measure the voltage at terminal F (G/Y) of the flasher unit connector. Br: Battery positive voltage Voltage Ration Be “Tum ignition switch to LOCK and gc to Step 7 Other Repair wiring harness (Combination switch—Flasher unit) Step 6 Set the tum switch to the right position and measure the voltage at terminal E (B/R) of the flasher unit connector. Be: Battery postive voltage Voltage ‘Retion’ Be “Turn ignition switch to LOGK and ge to Step 7 Other Repair wiring harness (Combination switch—Flashor unit) Step7 1, Remove the hazard warning switch. [Refer to section 24,)) ly between terminal B (B) of the haz- ard warning switch connector and ground. Continuity ‘ction Yes Goto Step 8 No Repair wiring harness (Hazard warning switch—GND) F-9F SIGNAL LIGHTING SYSTEM Step 8 1.Check for continuity between the terminals of the haz- | ard warning switch. 0-0 :Continvty O-8-O : Bulb Termin oTejola sen postin = pj ¢ |? ‘OFF o ON == 9 2 2.{f correct, reconnect the connector and go to Step 9. 3. If not as specified, replace the hazard warning switch. Step 9 4. Turn the hazard warning switch on. 2. Check for continuity between terminal C (G/R) of the flasher unit connector and ground, Continuity ‘Aetion Yes Turn hazard warning switch off and 00 Step 10 No Repair wiring harness (Flasher unit—Hazard warning switch) Step 10 1. Reconnect the connector and turn the ignition switch to ‘ON. 2. Set the turn switch to the right position and measure the voltage at terminal G (G/M) of the flasher unit connec- tor. Be: Battery postive voltage Voltage ‘Action ‘Alternates OV and B+ | Turn ignition switch LOCK and tur switch aff, goto Step 11 ° ‘Other Replace ilasher unit 3. Set the tum switch to the lett position and measure the voltage at terminal D (G/B) of the flasher unit connector. Be: Battery postive voltage Veitage ‘Retion ‘Alternates OV and B+ | Turn ignition switch LOCK and tur switch off, goto Step 11 Other Replace flasher unitSIGNAL LIGHTING SYSTEM F Step 11 1, Remove the front combination light. 2. Tum the turn switch on (left or right) 3, Measure the voltage at terminal A (G/B) [626] or C (GIB) [MX-6} of the front combination light connector. Br: Battory postive voltage Voltage ‘ation ‘Alternates OV and B+ | Turn switch off and go to Step 12 Other Repair wiring harness (Flasher unit—Front combination ight) 626 Step 12 1. Remove the trunk end upper trim and lower trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Turn the turn switch on (left or right). 3. Measure the voltage at terminal D (G/B) (626] or G (GIB) [MX-6] of the rear combination light connector. Br: Battery positive voltage Voltage ‘Ration ‘Alternates OV and Be “Turn switch off and go to Step 18 Other Repair wiring harness (Flasher unit—Rear combination ligh) Mx-8 Step 13 1. Turn the ignition switch to LOCK. 2, Remove and check the bulbs. [Refer to section E.}] Tum signalight] Bulb Retion Front OK Ropair wiring harness (Front combination light GND) Burnt Replace bulb Rear ‘OK Repair wiring harness (Rear combination light GND) Burnt Replace bulb F-11FE SIGNAL LIGHTING SYSTEM Flowchart No.2 ‘Symptom Tum signal function does not operate (hazard light function operates) Possible cause Burnt TURN 15A fuse Damaged turn switch Damaged flasher unit Open or short circuit in wiring harness Poor connection of connector Step 1 Check the TURN 15A fuse in the fuse block, Fuse ‘Retion OK Burnt wiring hasness Step 2 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Tum the ignition switch to ON. 3. Measure the voltage at terminal 2F (B/G) of the com! nation switch connector. B+: Battery positive voltage Votiage ‘ation Be Goi Ses Other Repair wiring harmese (TURN 158 fuse—Combination switch) Step 3 1. Turn the turn switch on (left or right). 2. Measure the voltage at terminal 1G (G/Y) or 1H (B/R) of the combination switch connector. Be: Battery positive voltage wi ie fio [18 F-12 ‘Terminal | Voltage ‘Action 16 Be Goo Stop 4 ‘Other | Inspect turn switch = | eter topsas r=) WB Go to Step 5 Omer | aac anSIGNAL LIGHTING SYSTEM F Step 4 Set the turn switch to the right position and measure the voltage at terminal E (B/R) of the flasher unit connector. Be: Battery postive voltage Voltage ‘tion Be Replace flasher nit Other opal wing harness (Combination switch=-Flasher unit) Step 5 Set the turn switch to the left position and measure the voltage at terminal F (G/Y) of the flasher unit connector. Be: Battery postive voltage Voltage Ration & Feplace flasher unit ‘Other Repair wiring hamess (Combination switch—Flasher unit) Flowchart No.3 Symptom Hazard light function does not operate (turn signal function operates) Possible cause Damaged hazard warning switch Damaged fiasher unit Open or short circuit in wiring harness Poor connection of connector Step 1 1,Remove the hazard warning switch. Refer to section 24. 2.Check for continuity between terminal 8 (B) of the haz~ ard warning switch connector and ground. Continuity Retion Yes Goto Step No Repair wiring harness (Hazard warning switeh—GND) F-13F SIGNAL LIGHTING SYSTEM Step 2 1. Check for continuity between the terminals of the haz- ard warning switch, 2-0 : Continuity 0-8-0 : Bulb Terminal Switch posi B c D OFF e : ON o o oe 5 2. If correct, reconnect the connector and go to Step 3. 3. Itnot as specified, replace the hazard warning switch, ((Refer to section 24. Step 3 1. Turn the hazard warning switch on. 2. Check for continuity between terminal C (G/R) of the flasher unit connector and ground. Continuity ‘Action Yes Replace flasher unit No Repair wiring harness (Flasher unit—Hazard warning switch) Left or right turn signal function does not operate Flowchart No.4 | Symptom | (.27ard ight function operates) Possible cause + Damaged combination switch + Damaged flasher unit + Open or short circuit in wiring hamess + Poor connection of connector Step 1 1. Remove the column cover. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Turn the ignition switch to ON. 3. Tum the turn switch on (left or right). “ 4, Measure the voltage at terminal G (G/Y) or H (B/R) of u{r[ofe the combination switch connector. Be: Battery positive voltage Voltage ‘etion a Goto Step 2 Other Ingpect turn switch (Reter to page F-32) Step 2 1. Turn the turn switch on (left or right). 2. Measure the voltage at terminal F (G/Y) or E (B/R) of the flasher unit connector. Be: Battery positive voltage Voltage = ‘Aetion By Replace flasher unit ‘Other Repair wiring harness (Combination suiteh—Flashar unit) F-14SIGNAL LIGHTING SYSTEM F Flowchart No.5 | Symptom operate Left or right turn signal function and hazard light function do not Possible cause + Damaged flasher unit + Burnt light bulbs + Open or short circuit in wiring harness + Poor connestion of connector Step 1 1. Tum the ignition switch to ON. 2.Turn the turn switch on (left or right) 3. Measure the voltage at terminal D (G/B) or G (G/W) of the flasher unit connector. = Be: Battery positive voltage Voltage, ‘Action ‘Alternates OV and B+ | Go to Step 2 Other Replace flasher unit Step 2 1. Remove the front combination light and disconnect the connector. 2. Turn the turn switch on (left or right). 3, Measure the voltage at terminal A (G/B or GW) [626] or C (G/B or G/W) [MX-6] of the front combination light connector. Be: Battery positive voltage Voltage ‘Action ‘Aiternates OV and B+ | Goto Step Other Repair wiring harness WX-6 (Flasher unit—Front combination light) F-15F SIGNAL LIGHTING SYSTEM Ss Step 3 1. Remove the trunk end upper trim and trunk end lower trim. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Tum the turn switch on (left or right). 3. Measure the voltage at terminal D (G/B or G/W) (626) otclela or G (G/B or GW) [MX-6] of the rear combination light connector. Br: Battery postive voltage Vortage ‘Retion ‘Atemates OV and B+ | Goto Step 4 Other Repair wiring hamvese Mx6 (asher unit Rear combination ight) Step 4 4. Turn the ignition switch to LOCK, 2. Remove and check the bulbs. (Refer to section E. Tun sigaligh] Bulb ‘Ration Front OK Repair wiring harness (Front combination ight GND) Bumt Replace bulb FRONTTUAN REAR TURN | Rear OK Repair wiring hares | (Rear combination ight~GND) Bumt Replace bulb F-16dba IF—4| sHORNS — SHIGH-MOUNT BRAKE LIGHT = BRAKE LIGHTS fon ei SF Py + garrtace “ers t04 ys wi dw ant Ei eee Dan cot BH Odor (iegee @a || Gets | Bese sii] | bitte) | obs wesBeIp yno119 1461] eyerg junow-yBIH ‘s1yBr7 ayeIg W3LSAS ONILHDIT 1VNDIS8-4 ‘suopea0} 10;90UU0D W3LSAS ONILHDIT TWNDISSIGNAL LIGHTING SYSTEM F Checklist Procedure Proper operation aynpton Flowchart No. Deprse bake pedal and very ht | Bak Ts o nl uiaio 7 Brake igs andhigh-mount take IM Sraeighton on do dos re nialo 2 Figh-mourd brake ight doesnot [ wiht ear apole 3 iluminate with rear spoiler 4 F-19F [Flowchart No.1 Symptom Brake lights do not illuminate SIGNAL LIGHTING SYSTEM Possible cause + Burnt STOP 20A fuse Damaged brake switch Bumt light bulbs Open or short circuit in wiring harness Poor connection of connector Step 1 ‘Check STOP 20A fuse in the fuse block. Fuse ation OK Goto Step? Burnt Replace fuse after checking and repating __| wiring names USE THE DESIGNAT=0 FUSES ONLY Step 2 HiGH-MOUNT BAAKE LIGHT (WiSHOUT REAR SPOILER BRAKE LIGHT Remove and check the brake lights bulbs. (Refer to section E)] Bulb Ration = OK Goo Stop 3 Burnt Replace bulb Step 3 ‘Measure the voltage at terminal A (Y/R) of the brake switch connector. Be: Battery positive voltage switch connector (ee Vo lnge ste | eee Action = Bi Goto Step 4 eee Other Flepair wiring hamness (STOP 208 fuse—Brake switch) Step 4 Measure the voltage at terminal C (W/G) of the brake with the brake pedal depressed. Br: Battery positive voltage —__Woltage Retion _] Goto Step 5 Inspect brake switch (Refer to 1996 626/MX-6 Workshop Manual ‘section P)SIGNAL LIGHTING SYSTEM F Ta sancowanaTionucnt cle | A HiGH.MouNT Det sla BRAKE LIGHT INBOARO COMBINATION LIGHT Step 5 Measure the voltage at the power-side terminals of the brake lights with the brake pedal depressed. Rear combination light: terminal C (W/G) [626] or H (WIG) [MX-6] Inboard combination light: terminal B (W/G) High-mount brake light: terminal A (B/G) [without rear spoiler] or terminal A (W/G) {with rear spoiler) Bs: Battery positive voltage xs ni leterore} = fete L Vortage ‘Reion By Repair wiring hamess (Brake ight—GND) Other Repair wiring hamess (Brake switch—Brake light) FEARCOMBINATION LIGHT —_HIGH-MOUNT BRAKE UIGHT Flowchart No.2 _| Symptom | Brake light on one side does not illuminate Possible cause + Burnt light bulb + Open or short circuit in wiring harness + Pcor connection of connector 626 feteletal REAR COMBINATION LIGHT Step 1 Remove and check the brake light bulb. Bulb OK Goto Stop? Burt Replace bulb ‘ation Step 2 Measure the voltage at the power-side termina of the brake light with the brake pedal depressed Rear combination light: terminal C (W/G) [626] or H (WIG) (Mx-6] Inboard combination light: terminal B (WIG) Be: Battery postive voltage vatage ation ofe[sla = Ropar wang haress (Grake IghGND) !NBOARO COMBINATION Lick Other ona vig barns F-21F SIGNAL LIGHTING SYSTEM M6 REAR COMBINATION LIGHT High-mount brake light does not illuminate Flowchart No.3 | Symptom | (without rear spoiler) Possible cause + Burnt light bulb + Open or short circuit in wiring hamess Step 1 Check the high-mount brake light bulb. Bub ation OK ~ | Goto Step any Burnt Replace bulb bee HioHMoUNT BRAKE LIGHT Step 2 Measure the voltage at terminal A (W/G) of the high- mount brake light connector with the brake pedal depressed. Ps B+: Battery postive voltage aa Toage ation oe Repair wiring harness (tigh-mount brake ight—GND) ‘Other Repair wiring harmese (Brake switch—High-mount brake light) F-22SIGNAL LIGHTING SYSTEM. Flowchart No.4 ‘Symptom Possible cause High-mount brake light does not illuminate (with rear spoiler) + Damaged high-mount brake light + Open or short circuit in wiring harness Step 1 Measure the voltage at terminal A (B/G) of the high- mount brake I ight connector with the brake pedal depressed. Br: Bator postive voltage Wotage Teton ne By Go to Step 2 oer Penal wring Rares (Beaks SutehSigh mount beak ht Step 2 ‘Check for continuity between terminal B (B) of the high- mount brake light connector and ground. Cents “Tats a Yeo place Rgh-nant brake Fgh dele [(Pefertopage t=34)) Ne Repai wing harnese Chignmeun ate igt-GND) F-23ve-d F-2] 626 "BACK-UP LIGHTS Exh) efepelea] a fete wesBerp yng, (9z9) s1u6r7 dn-yoeg WALSAS ONILHDIT IVNDISSIGNAL LIGHTING SYSTEM F Connector locations F-2592-4 Poy ge oe Bar | & A ‘ weiBeIp yno119 (9-xw) Siy617 dn-yorg W3LSAS ONILHDM IVNOISSIGNAL LIGHTING SYSTEM F Connector locations F-27F SIGNAL LIGHTING SYSTEM Checklist Procedure | Proper operation ‘Symptom Flowchart Ne. 1. Tum ignition switch to ON. do nat illuminate 2 Set stitselector lever fo reverse posl- One backcup ight dos not laminate tion and verify that back-up lights ilu nate F-28SIGNAL LIGHTING SYSTEM F [Flowchart No.1 | Symptom | Back-up lights do not iluminate Possible cause + Bumt METER 15A fuse + Damaged back-up light switch (MTX) + Damaged transaxle range switch (ATX) + Burnt iight bulbs ‘© Open or short circuit in wiring hamess * Poor connection of connector Step 1 Check METER 15A fuse in the fuse block. (lees eae) Fuse Retion Step 2 ‘Check the back-up light bulb. Bulb ‘Ration OK Goto Step 3 Burnt Replace bulb Step 3 ae 4. Turn the ignition switch to ON. 2. Measure the voltage at terminal B (BY) of the back-up light switch [terminal | (B/Y) of the transaxle range switch Be: Battory positive voltage Bla Voltage | i a Be Goto Siep4 Other Repair wiring harness (METER 184 fuse—Back-up light switch fe e| Iansaxle range switch) CEA F-29F SIGNAL LIGHTING SYSTEM = Step 4 1. Shift the shift [selector] lever to the reverse position. 2. Measure the voltage at terminal A (R/Y) of the back-up light switch [terminal C (R/Y) of the transaxle range switch]. Be: Battery postive voltage ela Vonage: ‘Retion- ee : Other [iransaxle range switch} = (eter to 1996 626/MX-6 Workshop Menual, oa section Kt) CEA TIelelola Tel To Tey} a Step 5 Measure the voltage at terminal A (R/Y) (626] of the inboard combination light or F (R/Y) [MX-6] of the rear combination light. Be: Battery positive voltage be) cr | Vottage ‘Retion: Be Repair wiring hamess (Back-up ightGND) INBOARD COMBINATION LIGHT Other Repair wiring hamess (Back-up light switch (transaxle range switchl—Back-up light) C EAT MX-6 REAR COMBINATION LIGHT F-30SIGNAL LIGHTING SYSTEM F Flowchart No.2 _| Symptom | One back-up light does not illuminate Possible cause + Bumt light bulb + Open or short circuit in wiring hamess + Poor connection of connector Step 1 Check the back-up light bulb. Bulb ‘etion’ OK Goto Step? Burnt Replace bulb rr Step 2 1. Turn the ignition switch to ON. 2. Shift the shift [selector] lever to the reverse position. 3, Measure the voltage at terminal A (R/Y) [626] of the inboard combination light or F (R/Y) [MX-6] of the rear ‘combination light. Bs: Battery positive voltage Voltage ‘Aetion INBOARO COMBINATION LIGHT Be Repair wiring harness (Back-up light GND) Other Repair wiring harness (Backup light switch [transaxle range Mx6 ssitch}—Back-up light) Cram Eslesyiesle REAR COMBINATION LIGHT F-31F SIGNAL LIGHTING SYSTEM TURN SWITCH (COMBINATION SWITCH) Inspection 1. Check for continuity between the switch terminals. ©-0 : Continuity a ro 7% 1" Ss Lott ° OFF ight ° 7 ry 2.if not as specified, replace the combination switch. [Refer to section Z4.)] HAZARD WARNING SWITCH Inepection 1. Remove the hazard warning switch. (Refer to section 24.) olelela 2. Check for continuity between the switch terminals. 0 : Continuity O-~G-O : Bulb Switch positon 2 e S 2 ‘OFF ‘ON, ot —o 3. If not as specified, replace the hazard warning switch. Refer to section 24) F-32SIGNAL LIGHTING SYSTEM F FLASHER UNIT Inspection 1. Measure the voltage at the flasher unit terminals as indicated below. 2. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harness. 3. If the parts and wiring hamess are OK but the system still dose not work properly, replace the flasher unit. Terminal voltage list B+: Battery positive voltage m eTele| apepele in na nection ondltion Votiage! | in Terminal] Signal Connectior Test conditio continuity, Inspection area Flasher uni Consiani:check for continu eg | Wiig Ramos round oo ground Yes _ | (Flasher unit—GNO} Hazard warning | Hazard warring switch-on OV Hazard warning © | Hazard waring on 9°] switch Hazard warring switch off Be [sth ‘oration o [umstral —Tursgnat_—_ [Tur sna ot LH tastes er | sum eqn none ner flr be x Tum owitch [Combination [lien swich and tum swish (RH) son] Bo ae io ie e+ — Combination ovtch Turvawitch | Combination [loner swich and tum switch (A):on| Be Ce oe oe "+ — 5+ 1 combination svtch ‘Allornaios g_[Tumsignal | Turmsignal ight | Turn signal ight (RK lashes ree flasher (RH) | (BH) oats Ohher ov H Be HAZARD 15A fuse | Constant 8+ [HAZARD T8A ose BACK-UP LIGHT SWITCH (MTX) Inspection 1. Disconnect the back-up light switch connector. 2 Shift the shift lever to the reverse position, 3.Check for continuity between terminals A and 8 of the back-up light switch. 4.|f there is no continuity, replace the back-up light switch. F-33EF SIGNAL LIGHTING SYSTEM HIGH-MOUNT BRAKE LIGHT Removal / Installation 1. Remove in the order shown in the figure. 2. Install in the reverse order of removal. 626 MX-6 (WITHOUT REAR SPOILER) 4. Cover 4. Housing 2. Socket assembly 5. Lens 3. Bulb 18.4W (921) (MX-6 (WITH REAR SPOILER) 09-12Nm {ezigtem, 62—10.4in Bg 1. Rear spoiler 3.LED 2. Screw F-34Before beginning any service procedure, refer to section S of this manual for air bag system service warnings. HEATER AND AIR CONDITIONER SYSTEMS 4 REFRIGERANT-134a (R-134a) G- 4 SERVICE WARNINGS, G5 SERVICE CAUTIONS vases G6 |LESHOOTIN IE Z FUNDAMENTAL PROCEDURES OF TROUBLESHOOTING... Zz 8 CHECKLIST. RCUIT DIAG INDEX INDEX HEATER 1. Heater unit [Removal / installation Disassembly / Assemt F unit 3, Heater control unit [Removal ‘installa ing; yage G-36]INDEX G AIR CONDITIONER 1. A‘ compressor moval installation. eGo 2. Magnetic clutch [Disassembly [Assembh page G=57] linspection.. page G-57 | [Removal installation: page G-65] 3. Condenser fai Inspection. pace G-65 (Removal/insiallafiOn..a.....pageG=58] 8. Relays Gnspection eee Page G-58 | 4, Condenser 9. Refrigerant pressure switch lation. = Re 5 Receiver / drier [Removal / Installation Tpage G60]G Outline CAUTIONARY POINTS FOR MAINTENANCE CAUTIONARY POINTS FOR MAINTENANCE REFRIGERANT-134a (R-134a) * R-12 and other fluorocarbons now used in air conditioners can destroy the ozone layer in the strato- sphere. The result is an increase in hazardous ultraviolet rays which over time can adversely affect both human health and the biosphere. Because of this concern, Mazda has chosen to use R=134a, (HFC-134a), a hydrofluorocarbon-based refrigerant that does not deplete the ozone layer, in this vehice. + R-12 and R-134a are not interchangeable; system parts and system service tools also differ. The table below compares the two systems. Refrigerant systems Part R12 system R-194a system Remarks Rofigerant” | Chlorollvorocarbon=12 | Hydroflorocarbon=T@4a | W the relfigeranis are mixed or one religarento (CFo~12) (HFC-134a) used in a systom that requires the other, the (coer) [chor CFS} ‘ompressor ol wll separate feom the refrigerant ‘and not circulate within the system. This can ‘damage the AIC comprassor and cause abnor- mal compressor vane noise. In addition, mixing R-134a with R12 or using R-1G4a instead of R—12 in an R-12 system” can lower the durability of the NBR O-ring and cis ‘solve the fluorine O-rings. Ifthe fluorine O-rings are dissolved, reigerant may leak. Mineral ot Polyalkylene glycol ol (PAG ol) ‘Special compressor oils for R—14a air condition | ing systems are developed by each air candition- ing vendor. Therefore, use only the specified of for each model vehicié. Ifa PAG oil other than specified type is used, the AIC compressor and ‘eigerant system can be damaged. Ifthe ols are mixed or one ol is used ina sys- tem that requires the other, the refrigerant vill separate from the compressor oil and not crou- late within the system. This can damage the A/C ‘compressor and cause abnormal compressor vane noise. ‘Mixing PAG oil with mineral oil or using PAG oil Instead of mineral ol in an R12 system can Tower the durability of he NBR and fluorine rub- ber O-rings. Oxing Nitrile butadiene rubber (NBR) Fluorine rubber High-circulated nitrile butadiene rubber (HNBR) Ian NBR O-ring is used in an R1Séa sysiom, the PAG oil and R134 will ower the durability of the O-ring. Ifa fluorine rubber O-ring is used in an R~194a systom, tho R1S4a will dissclvo the Oving and cause the refrigerant to leak. Joint nuts Inch threads Matis treads Thread standards for joint nuts connecting pipes ‘and hoses have been changed to avoid cor- necting R12 system parts with R-134a system parts “aint Blocks “The bolt sizes and part measurements for joint blocks connecting cooler pipes and cooler hoses have been changed to avoid connecting R=12 system parts with R-134a aystem parts, Charging valve ‘Sorow-on type Hi: 918-24 UNF Lo: 7/16-20 UNF ‘Quick-connect ype Hi: 16mm {0.6 i) dia, Lo: 13mm {0.5 in} cia. “The shape of the charging valve differs for each system to avoid contusion. The quick-connect type charging valve prevents refrigerant trom leaking when the charging hose is connected to the valve. G4CAUTIONARY POINTS FOR MAINTENANCE G Service tools Part R+12 system R-194a system Remarks | Toot joints Toh threads ‘Matric threads Thread standards for too! joints have been ‘changed to avoid connecting R12 system tools with R-134a system tools, Charging valve | Sorew-on type ‘Quick-connect The shape of the charging valve joints differ for joints Hi: 3/824 UNF ‘ype ‘2ach system to avoid confusion. Lo: 7/1620 UNF Hi: 16 mm {0.6 in} dia. _| The quick-connect type charging valve joint pre- Lo: 13 mm {0.5 in} dia. | vents refrigerant from leaking when the charging hase is connected to the valve. Manifold gauge | High-pressure-side maxi- | Highproscure-side maxi- | R-1a requires a higher pressure to condense mum reading mum reading than B12 2EMPa(sOkgiom, | 34 MPa 35 kl 420 psi 500 psi leaktesior | Gas type lect type ‘Rgas leak Testor acts with chlorine In RH12 10 Eleote type indicate the lation of leak. This Kind of tester does not work with an R-134a system, hawev- ff, beoause R-134a has no chlorine Two kinds of electric tester are available those that work exclusively with one system or the cther and those that work with both. A tester built only for R12 systems can not be used with an R-134a system ‘SERVICE WARNINGS Using/Handling Unapproved Refrigerant + Using a flammable refrigerant, such as OZ-12, in this vehicle is dangerous. In an accident, the refrigerant may catch fire, resulting in serious injury or death. When servicing this vehi- cle, use only R-134a. + Checking for system leaks on a vehicle that has been serviced with flammable refrigerant, such as 02-12, is dangerous. Conventional leak detectors use an electronically generated arc which can ignite the refrigerant, causing serious injury or death. If a flammable refriger- ant has been used to service the system, or if you suspect a flammable refrigerant may have been used, contact the local fire marshall or EPA office for information on handling the refrig- erant. GsG CAUTIONARY POINTS FOR MAINTENANCE Servicing Refrigerant System * Do not allow the refrigerant to leak near fire or any Se} kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as Sy Zt from cigarettes and heaters. 4 When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources and maintain ade- quate ventilation. Storing Refrigerant * The refrigerant container is highly pressurized. If it subjected to high heat, it could explode, scatter- ing metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temper- atures below 40 °C {104 °F}. Handling Refrigerant * Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When handling the refrigerant, wear gloves and safety joggles. If refrigerant splashes into the eyes, imme- iately wash them with clean water and consult a doctor. SERVICE CAUTIONS Compressor Oil (ATMOS GU10) * Do not spill compressor oil on the vehicle. A drop ‘of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately. PAG OM + PAG oil (ATMOS GU10) has a higher moisture ATMOS GU10), absorption efficiency than the previously used min- jo eral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. There- fore, install caps immediately after using the com- i pressor oil or removing refrigerant system parts to prevent moisture absorption. MINERAL OW, ! } MOISTURE ABSORPTION TIME GsTROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE FUNDAMENTAL PROCEDURES OF TROUBLESHOOTING Proceed with troubleshooting of the heater and air conditioner by following the steps below. yes END. START y (Check system operation using checklist procedure | system operation normal? y Determine symptoms of problem based on results of checklist procedure, ee Refer to flowchart based on symptoms of problem. Repair or replace components) as necessary G7G CHECKLIST TROUBLESHOOTING GUIDE + When inspecting the heater or air conditioner, warm up the engine before each operational check. The engine coolant temperature must be 40 °C {104 °F} or higher. * The air conditioner is composed of an electrical system as well as a refrigerant system. Because some refrigerant system components require the evacuation of refrigerant gas before replacement, inspeot the electrical system first. MAX HOT and verity that the| airllow temperature changes. Symptom Operational check Waitaneton Flowchart No |... sf ; wie fan suteh turned to | fan och postion Ist, Ey ao and 4th Blower motor does not operate when fan respon swat te poston Blower motor doesnot operate when Tan swith sat a poston : Blower ol does rat opiate Whe Ta wich ata pation Blower motor doesnot porate whoa Tan euch wattopeston Tiftow brat oot | Tum fan oh and A0 | Magnetic cic and cordonwa tan dora |S Sana) GGhatycoo) | Schon Check cpeston | operate of ee ‘lutch and con- [Magnetic clutch does not operate: ‘4 (KL engine) eee {condenser fan operates normally) seared Gordons fan doo not operato SK oni) CLC 7 Sora Tite nade does | Press aon rode ch Aion ide dns ak change netchance Cote eanh move. Vly at ‘ Se ingly. = Take af mode | Press RECIFRESH auth: | Take a ado dose nl change Gtevnel change | 6: Verly hat vecrouaton ° See a ‘ow lonparaure | Move iampeaureconval | Afow temperature des nt change Gteonet change | lover tem Mase COLD - G84a] SHEATER AND AIR CONDITIONER (1/2) + wesBeIg INDI) Jeuonipuog sly pue Je1eeH oe em eames rrr =F =§€===_— Aeusuhe-c “S* 16 5" cork | | Bee] Ly C lace ae waren (Ol, r | = a Se. i Thai oitne't ens Rs os ST ease” Org ore | Ae Tecraicenanr "Siow os) + i i a i Shay \| | Fs arc xe ppm conte | * { See wegggnnl b |) SEER coro, fo Ea He LG ey | eee | Seto ose | tI I or rener carer TT ———_— aE Rn GTA a ane PO + [es] Pen) fuser] OE Riba re) (abe cleitaiettelal Bei Ceska) | Gaiouar) Cie ee RETR TSN eur we mera aE em a er See Calon eafeeicele foal TPA [5-30 FEPRIGEMINT PRESSIRE GATTONT ssieaiay WVHDVIG LINDUID GINS ONILOOHSS1ENowLore | suopes07 s0}0@UU0D 3GIND ONILOOHSS1ENOwL1-5 6-40] *HEATER AND AIR CONDITIONER (2/2) | fe Bl] Ae Th @ wesBeig wind, seuonipuog sly pue 18120H 3dIND ONILOOHSATENOwL 2 G or eR ER ETAL ROT [SF ST RDENT PREC TRIPP EE TET a eal =a rape] wale] pa] + tale er] we feeatfly falere] flere oe relferel AESG TROUBLESHOOTING GUIDE Connector Locations 2 G-1b) G-12ero IG-2| FS #CONDENSER FAN SYSTEM vgs Sane 4 wes6eIg Wno11D (4) weisfs uey sesuepuoD 3dGIND ONILOOHSA1ENOwL oeG TROUBLESHOOTING GUIDE Connector Locations MAIN FUSE BLOCK JOINT BOX:sI-9 s-3] KL = CONDENSER FAN SYSTEM ow on Le ane fp arin rae" wesBbeig ynoJ19 (1) wershg ued Jesuepuog AGIND DNILOOHS31ENOwL FIST [IS BIORET Ne rere Oe ae | fs) | os | 6S | ee ey | aeG Connector Locations TROUBLESHOOTING GUIDE a 4 MAIN FUSE BLOCK JOINT BOXFLOWCHART TROUBLESHOOTING GUIDE G Flowchart No. | Symptom... 1 Related components Blower motor does not operate at any fan switch position . Blower motor, resistor, fan switch, wiring harness 8 181 ew HEATER ENGINE 404, 1A LOWER RELAY VRB ___y stanten {_________ un BLOWER Twp aayC [oy MOTOR. uwtL—__} FAN SWITOH perppiiey | RESISTOR (Coersunx ‘System Operation Blower motor speed is controlled by the fan switch and a resistor in the blower unit. When the fan switch is at OFF, the motor ground circuit is open and the blower motor does not operate. When the ‘switch is in the first position, current flow from the blower motor is restricted by the resistor, and the blower motor turns at low speed. Changing the fan switch to the second, third, or fourth positions causes the circuit resistance to. decrease and the blower motor speed to increase. ENGINE 18. [ as il (nm) Oo CIC Ce root HEATER 40 A 1] | | ae) I eis (7 (om es Step 1 1. Check the following fuses. Fuse “Amperage Location HEATER 408 ‘Main fuse block ENGINE 15 Fuse block 2. Ifthe fuses are OK, go to Step 2. 3. If fuse is burnt, check for a short-circuit in the harness before replacing the fuse. G-17G TROUBLESHOOTING GUIDE Step 2 4. Tum the ignition switch to ON. 2.Set the fan switch to the fourth position. 3. Measure the voltage at the following terminal wires of the blower relay connector. Bs: Battery positive votage Wire | Voltage ‘ction (ew |B _ | Measure voltage at (L) wire Other | Repair wiring hamess (ENGINE 15 A fuso—Biower relay) o By | Measure voltage at (BIL) wire Other | Repair wiring hamess (HEATER 40 A fuso—Blower relay) (Gi)|_Other_| Measure voltage at (UR) wire B+ | Repair wiring harness (Blower relay—Starter) or check starting system (UR) B+ | Repair wiring hamess (lower relay—Blower motor) Otner_| Replace biower relay Step 3 1. Verify that the ignition switch is at ON and that the fan switch is in the fourth position. 2, Measure the voltage at the following terminal wires of the blower motor connector. Ba: Battery positive voltage Wire | Vottage ‘Action (UR) |__Be | Measure voltage at (IW) wire ther | Repair wiring harness Gh suowen unit (Biowor rlay-Biower moto) uta Cay [_& | GotoSien4 Other | Replace blower motor — Step 4 4 1. Verify that the ignition switch is at ON FANSWITCH 2.Tum the fan switch off. CONNECTOR 3. Measure the voltage at the (L/W) terminal wire of the fan switch. Ba: Batty postive wltage Voltage ‘ation | Be | GotoSteps Giher | Repair wing harness METER CONTROL UNIT (Giower motor—Fan switch) G-18TROUBLESHOOTING GUIDE G ett Fan SWTCH ‘CONNECTOR, HEATER CONTROL UNIT | Step 5 1. Disconnect the fan switch connector. 2. Check for continuity between the (B) terminal wire of the fan switch connector and ground. [Continuity Retion Yes Replace fan switch No Replace wiring hamess (Fan switch—GND) Flowchart No. 2 Symptom Related components is at Ist, 2nd, 3rd, or 4th position . Resistor, fan switch, wiring haress Blower motor does not operate when fan switch rom <——} ecm i BLOWER MOTOR lagsistoR FAN ‘SWITCH (yFsmnx Step 1 1. Turn the ignition switch to ON. 2. Verify that the fan switch and A/C switch are off. 3. Measure the voltage at the following terminal wires of the resistor. Be: Battery positive voltage Wire| Voltage ation Mi Replace resistor so voltage at (GIR) wire ‘Measure voltage at (L) wire Other_| Replace resistor © Br___| Measure voltage at (UY) wire ‘Other_| Replace resistor oy Br | Goto Step? Oiner | Replace resistor G-19TROUBLESHOOTING GUIDE FAN SHTTC CONNECTOR HEATER CONTROL UNIT G-20 Step 2 1. Verify that the ignition switch is at ON. 2. Verify that the fan switch and A/C switch are off. 3. Measure the voltage at the following terminal wires of the fan switch connector. By: Battery postive witage Wire| Voltage ‘ction (lw) |_B+ _| Measure voltage at (VIB) wire Other | Repair wiring hamess (Resistor—Fan switch) WB) By | Measure voltage at (L) wire Other | Repair wiring harness (Resistor—Fan switch) o B+ | Measure voltage at (UY) wire Other | Repair wiring hamess (Resistor—Fan switch) om By | Replace fan switch ‘Other | Repair wiring hamess (Resistor—Fan switch)TROUBLESHOOTING GUIDE G Symptom Magnetic cluch and condenser fan do not operate Flowchart No. tte orames Related componenis......... Fuses, A/C amplifier, A/C switch, A/C relay, PCM, 3 (ECM: MTX) refrigerant pressure switch, wiring harness| fee shears WIPER 20.8 |AIF-COND 20 4 ay P |scnca aw TERTER CONTROL UN waar lecures lek AC AMPLIFIER + + Comer System Operation 4. Signals from the fan switch and A/C switch ere sent to the A/C amplifier. 2. The thermoswitch resistance changes as the evaporator’s temperature changes. 3. The A/C amplifier monitors the thermoswitch resistance changes. 4. The A/C amplifier signals the PCM (ECM: MTX) to turn the magnetic clutch on or off based on the evaporator’s temperature. This protects the evaporator from freezing. 5. The PCM (ECM: MTX) controls the magnetic clutch by turning the A/C relay on or off. 6. To help liquefy the refrigerant, the condenser fan rotates to increase airflow through the condenser when the A/C compressor is on. 7.If the refrigerant pressure switch is broken or there is abnormal pressure in the refrigerant system, the refrigerant pressure switch will remain cpen and not allow current to flow to the magnetic clutch and condenser fan. Step 1 1. Check the following fuses. Fuse | __Amperage Location ‘AIR-COND 308 Main fuse block WIPER 208 Fuse block 2. Ifthe fuses are OK, go to Step 2. 3.If a fuse is burnt, check for a short-circuit in the wiring harness before replacing the tuse. ‘AIR-COND 30.4 G-21G TROUBLESHOOTING GUIDE Step 2 1. Remove the A/C relay. 2. Tum the ignition switch to ON. 3. Measure the voltage at the follo the AIC relay connector. 9 terminal wires of Be: Battery positive voltage Wire | Voltage ‘ation o Bi | Measure voltage at (GW) wire ‘Otner | Repair wiring harness (AC relay—WIPER 20 A fuso) (Gm) _| Br | Goto Step? JTerminal Ether Repair wiring harness (NG rlay-~AIR-COND 30 A fuse) Step 3 Geeeien 1.Connect battery positive voltage and check for continu: IL ity between the terminals of the A/C relay. 4 \eteke Sy i pr re se ~_ Connection Terminal & | oo [o>] ATSB [Cc TelF oO a ~_ | ottotro | of +0 | 0 A obo IG RECA _ WANFUSE BLOGR| 2. If correct, reinstall the A/C relay and go to Step 4. 3. If not as specified, replace the AIC relay. Step 4 1. Remove the front console. (Refer to the 1996 626/MX-6 Workshop Manual, section S.) 2. Disconnect the appropriate PCM (ECM: MTX) connector. Transaxle neuay e5NNEe TOR MIX ATK 8. Connect a jumper wire between the terminal wire iG/W) of the A/C relay connector and ground. 4, Turn the ignition switch to ON, and verify that the mag- neti¢ clutch and condenser fan operate. Wagnatic clutch and ‘condenser fan ‘Action Remove jumper wire, reconnect POM (ECM: NITX) connector, and go to Step 5 Repair wiring hamess (NC relay—Magnetic clutch, condenser fan) Step 5 1. Turn the A/C switch on and set the fan switch to the first position. 2. Verity that the A/C switch indicator light illuminates. Indicator ight ‘ction Tominates Goto Siep 6 Does notiluminate | Inspect heater contro unit (iverorass Ca) G-22TROUBLESHOOTING GUIDE G Step 6 Measure the voltage at the following terminal wires of the PCM (ECM: MTX) connector. E33) FS engine (MTX) Wire | Vohage Tain a g| | edie nea ihe] Measure vakage (SE) wis GW | wapec ECM Relero 1006 SDERICS ce + Workshop Manual, section F1) Other | Goto Step 7 FS engine (ATX) Wire | Vottage ‘clone Ov | Repair wiring hamess oe (PCM—AIC relay) ‘Giner | Measure voltage at (GiB) wire (OV | inspect POM (Refer to 1996 626 LS Co Workshop Manual, section F3) Other | Go to Step 7 Step7 Measure the voltage at the following terminal wires of the A/C amplifier. ACAMPLIFIER oe GOWECTOR Bu: Battery positive voltage Wire | Voltage = ‘Ration oO Br | Measure voltage at (UB) wire Otner_| Ropair wiring harness (WIPER 20 A fuse—A/C amplifier) (wey OV | Replace AIC amplifier (Roerbpae 55) Toa i AIC AMPLIFIER | 85 —___! Other | Inspect refrigerant pressure switch (Reter to page G-€0) or check wiring harness (PCM—Refrigerant pressure sswitch—AVG amie) G-23G TROUBLESHOOTING GUIDE Flowchart No. _| Symptom Magnetic clutch does not operate (condenser fan’ ‘operates normally) (KL engine) 4 Related components ......... Magnetic clutch, wiring harness, refrigerant systen wren Aln-cono BOAFUSE SOAFUSE | ln uc retay aw | { nepacnae Pee aren Pom 3 cnere ma anes row + , + ‘System Operation 1. Signels from the fan switch and A/C switch are sent to the A/C amplifier. 2. The evaporator temperature sensor resistance changes as the evaporator’s temperature changes. 3. The A/C amplifier monitors the evaporator temperature sensor's resistance changes. 4. The A/C amplifier signals the PCM to turn the magnetic clutch on or off based on the evaporator’s temperature. This protects the evaporator from freezing. 5. The PCM controls the magnetic clutch by turning the A/C relay on and off. 6. To help liquefy refrigerant, the condenser fan rotates to increase airflow through the condenser when the AIC compressor is on. Step 1 4. Turn the ignition switch to LOCK and disconnect the refrigerant pressure switch connector. 2.Connect a jumper wire between terminals A and B of the refrigerant pressure switch connector. 8, Start the engine. 4. Turn the fan switch and A/C switch on, and check the magnetic clutch operation. Magnetic clutch Retion Operates: Goto Step 2 Does not operate | Remove jumper wire, reconnect refigerant pressure switch connector, and go to Sop 3 G-24TROUBLESHOOTING GUIDE G Step2 " Gonnect a mano gauge sot othe charging valves. 2, Measure the high-pressure-side pressure. Rofrigorant pressure] 210—2,640 kPa (2.1—26.0 kallom?, 30—369 psi) Other Perform leak test [Refartopage G45] | Step 3 1. Verify that the ignition switch, fan switch, and A/C switch are on. 2.Measure the voltage at the (G/B) terminal wire of the refrigerant pressure switch connector. Bx: Battery positive voltage Vortage, ‘Ration. B+ | Goto Step4 Other_| Goto Steps Step4 Measure the voltage at the (Y) terminal wire of the mag- netic clutch connector. Be: Batiery postive votiage MAGNETIC CLUTCH CONNECTOR wy woreay © CONNECTOR AIC RELAY CC SP fe 6, Voltage Ration Br | Goto Steps Other | Repair wiring harness (AIC retay—Magnetic clutch) Step 5 Measure the voltage at following terminal wires of the AIC relay connector. Bu: Battery positive voltage Wire | Voltage ‘ction o Be | Measure voltage at terminal A (GAV) ‘Other | Repair wiring hamess (WIPER 20 A tuse—A/C relay) [Terminal A _OV___| Measure voltage af terminal E (GIW) (GW) |“Siner [Ropar wiring harness (PCM-AIC relay) Terminal E|__B+ | Measure voltage at () wire (GW) |“ Other | Repair wiring harness (AIR-COND 30 A fuse—A/C relay) w ‘OV __| Replace AIG relay Other G-25G TROUBLESHOOTING GUIDE Flowchart No. | Symptom ... Magnetic clutch does not operate (condenser fan operates normally) (FS engine) 5 Related components........ Magnetic clutch, wiring hamess ‘NC RELAY f+ conoensen Fan MAGNETIC, JcuutcH Remedy 4. Turn the ignition switch to ON. 2. Measure the voltage at the (Y) terminal wire of the mag- netic clutch connector. Br: Battery postive voltage Voltage ‘Retion B+ | Replace magnetic clutch [[feterto page G=37)) ‘Other | Repair wiring hamess (Magnetic lutch—A/G relay) MAGNETIC CLUTCH CONNECTOR G-26TROUBLESHOOTING GUIDE G ‘Symptom .. . Condenser fan does not operate (magnetic clutch Flowchart No. operates normally) (KL engine) 6 Related components ......... Condenser fan, wiring harness, condenser fan low relay WIPER. AlR-cOND bon 0A FUSE FUSE | > CONDENSER FAN HIGH RELAY NO [few c_ few We conpensen b T]he mes sly sa [us ‘CONDENSER FAN HIGH RELAY NO Tom wagner fan By |e | | CONDENSER FAN FiGH RELAY NO2 TT Step 1 1. Start the engine. 2. Turn the fan switch and A/C switch on. 3. Measure the voltage at the following terminal wires of the condenser fan low relay connector. Be: Battery postive voltage Wire | Voltage ‘etion o Be __| Measure voltage at ($8) wire Other | Repair wiring hamess (WIPER 20 A fuse—Condensor fan low relay) (88) OV __| Measure voltage at (GiW) wire Oiher | Repair wiring harness (Condenser fan low relay—PCM) (Gi) |__ B+ _ | Measure voltage at (UB) wire (Other | Repair wiring hamess (AIR-COND 30 A fuse—Condenser fan low relay) < Bs | Goto Stop2 Other | Replace condenser fan low relay G-27TROUBLESHOOTING GUIDE ‘CONDENSER FAN GONNECTOR = =e j-ay ‘SER FAN TOR Step 2 Measure the voltage at the following terminal wires of the condenser fan connector. B+: Battery positive voltage: Wire | Voltage ‘etion us) By __| Measure voltage at (BY) wire Other | Repair wiring hamess (Condenser fan low relay—Condenser fan) ey B+ | Repair wiring hamess (Condenser fan—GND) Other_| Replace condenser fan Flowchart No. ‘Symptom 7 Related components Condenser fan does not operate (magnetic clutch ‘operates normally) (FS onginc) Condenser fan, wiring hamess y ET CONDENSER FAN GONNECTOR NC RELAY ‘CONDENSER [e Fav Remedy 1. Start the engine, 2. Tum the fan switch and A/C switch on. 3. Measure the voltage at the following terminal wires of the condenser fan connector. Bs: Battery positive voltage G-28 Wire| Vonage ‘Ration m Measure votage at @/Y) wire Repair wiring harness {AIC relay—Condenser fan) (BY) ov Replace condenser fan. B+ | Repair wiring hamess (Condenser fan—GND)TROUBLESHOOTING GUIDE G Flowchart No. | Symptom Airflow mode does not change Related components Airflow mode actuator, heater control unit, wiring 8 harness AIRFLOW MODE ACTUATOR VENT BLLEVEL _HEAT/DEF OEF HEAT © woe |werfwic|wa fy [vw | |we [ye wa fwnjwalwa fy [vw lw [we [vic HEATER CONTROL UNIT Airflow mode actuator ‘The airflow mode actuator opens and closes the airflow mode doors by means of heater control signals, and the link rod. Itis equipped with sliding contacts to set the stopping position Step 1 4. Disconnect the airflow mode actuator connector. ‘AIBELON MODE 2. Connect battery positive voltage to the terminals | and J CONNECTOR of the airflow mode actuator, and check the actuator operation. BELOW MODE Be: Battery positive voltage 5 ‘Connection Operation B+ | GNO Per J 1 “VENT to DEF eaten unit i z DEF to VENT. 3. If correct, go to Step 2. 4. If not as specified, replace the airflow mode actuator. (Refer to 7. G-29TROUBLESHOOTING GUIDE X_ oR Wh wie welyarlw Sy via, wi ¥ Step 2 1.Check for continuity between the terminals of the air- flow mode actuator for each mode. 2-0: Continuity Airslow mode Teemingt VENT. BLLEVEL HEAT. HEATIOEF DEF 2. If correct, go to Step 3. 3. If not as specified, replace the airflow mode actuator. Step 3 1. Disconnect the airflow mode actuator connector and heater control unit connectors. 2. Check for continuity at the following wires betwee the connectors. G-30 Wire| Action itno continuity | Action if continuity (W)__| Repair W) wire Check (WB) wire (wie}_| Repair (WB) wire Check (WY) wire (WAY) _| Repair WI) wire Check (WIG) wire (WiG)__| Repair (WG) wire Check (Wi) wire (Wit) | Repair WML) wire Check (Y) wire (| Repair (7) wire Check (WAN) wire (ant)_| Repair (70) wire ‘Check (¥7B) wire (YB) | Repair (¥) wire ‘Check (YIS) wire (iG) | Repair (¥16) wire Reeplace heater control unitTROUBLESHOOTING GUIDE G Flowchart No. _| Symptom. . Intake air mode does not change 9 Related components ........ Air intake actuator, heater control unit, wiring hamess {IRLINTAKE ACTUATOR POSITION Switch REC - tom vo or tc |____ wire 2on ruse HEATER CONTROK UNIT System Operation The air intake actuator is powered by the wiper fuse. When fresh air is desired, the heater cortrol unit grounds the air intake actuator through the (LG/R) and (G/L) terminal wires. The actuator stops running ‘when the position switch reaches the fresh position, because the actuator’s ground circuit is interrupted. When recirculated air is desired, the motor is grounded through the (L) terminal wire. TE INTARE: CoNNeCTOr ACTURTOR A ‘Connection can Operation AIR INTAKE Bese aN ACTUATOR wah to Rosiroulati ASTUATOR A B Fresh to Recirculation A c Recirculation to Fresh Step 1 1. Disconnect the air intake actuator connector. 2. Connect battery positive voltage to the following termi- nals of the air intake actuator and check the actuator operation. Bt: Battery posite voltage 3. If correct, go to Step 2. 4.Ifnot as specified, replace the air intake actuator, Refer to page G-40, Step 2 1. Disconnect the air intake actuator connector and heater control unit connectors. 2. Check for continuity at the following wires between the connectors. eaten CONTROL UNIT eLowef moror Wire _] Action ino ‘Aetion if Heater [Intake| _ continuity continuity (D erminal 14)| (UO) | Repair (L)—(W/O) wire] Check (L) wee | [terminal 2i)[ (C) | Repair (L) wire ‘Check (G/L) (LGA) Repair (Gi)—(LGIR) Replace heater (et) control unit Warr) G-31G TROUBLESHOOTING GUIDE Flowchart No._| Symptom Airflow temperature does not change 10 Related components ........ Air mix actuator, heater control unit, wiring harness [AIRMIX ACTUATOR BA Ww sa cou a oe ow ya. oe reaten contaot unit | ee ow on @ ‘System Operation The air mix actuator adjusts the opening of the mix door by using a link and rod mechanism. A poteniometer attached to the link outputs a signal to the heater control unit. This signal changes as the position of the door changes. The door position is adjusted based on the temperature control lever setting on the heater control unit. Step 1 1. Disconnect the air mix actuator connector. 2. Connect battery positive voltage to terminals G and H of the air mix actuator and check the actuator operation. Be: Battery positive voltage Connection ae] oun Operation 6 # Hot to Gold H 6 (Cold t Hot 2. If correct, go to Step 2. 4. \fnot as specified, replace the air mix actuator. [(Refer to 37.TROUBLESHOOTING GUIDE G 0} color AIR Mx DOOR HOT cau AIR MIX 000R-+ Row 68 pay ow a3 5 re fi) ee hee Sh 1 Z 1ek'ER CONTAOL UNIT he HEATER jin Step 2 1. Verify that the air mix actuator connector is disconnect- ed. 2. Connect battery positive voltage to terminals G and H, and measure the resistance of the air mix actuetor. 3. Compare the measurement resistance to the character- istics shown in the figure. Connection TF stance | Actioninot | Action it Br | GND asspecified | _cerrect G_|_H | A-B |Replacear | Goto Step ate Tap] ik actuator Step 3 1. Disconnect the air mix actuator connector and heater ‘control unit connector. 2.Check for continuity at the following terminal wires between the connectors. Wire ‘Retion if no ‘Action if Heater | Mix continuity continuity (6A) | (GMW)_| Repair (BA)—(GIW)_| Check (G)—G) wire wire @ (@) | Repair (GG) ‘Check (G/W}—(YIL) (Gw_ |W) _| Repair GW}-WWIL)_| Check (P)-1GIB) wire wie e (GB) [Repair PIGIB) | Check (GN) wie wite (M_ |_| Repair GMIAIGMY | Rentace heater wire control unit G-33