2002 MAZDA 6 warning

M–82
TROUBLESHOOTING
FOREWORDA6E638027100202
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SYMPTOM TROUBLESHOOTINGA6E638027100203•Verify the symptoms, and perform troubleshooting according to the appropriate number.
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NO.1 FREQUENT FRONT WHEEL SLIPA6E638027100204
Warning
•During simulation driving, vehicle stability may decrease extremely and cause an accident. Be
sure to perform the simulation test driving in a safe area.
Malfunction vehicle delivered
Questionnaire
Verify malfunction symptoms
Symptom troubleshooting
Verify that malfunctions have been repaired
Troubleshooting completedConfirm all customer problems using a questionnaire.
Confirm malfunction on actual vehicle.
DTC inspection
Inspect for DTCs using WDS or equivalent.
Perform applicable troubleshooting inspection according to
diagnostic index.
A6E63802001
No. Symptom Description
1 Frequent front wheel slip Front wheels slip frequently during acceleration on low-friction road.
2
Tight corner braking effectBrakes seem to be applied during tight cornering while driving very
slowly on paved road.
3 Abnormal noise and/or vibration from
coupling unitThere is abnormal noise and/or vibration from coupling unit during
driving.
1 Frequent front wheel slip
[TROUBLESHOOTING HINTS]
•Tire traction performance is extremely poor for given road friction. (4WD system is normal.)
•Improper wheel alignment (4WD system is normal.)
•Rear differential oil temperature is extremely high (Fail-safe condition)
•Differential oil temperature sensor malfunction (Fail-safe condition)
•Compare slip frequency with another vehicle of the same model (under the same road conditions and tire traction
performance).
•Replace tires with others of the same model and perform test under the same road conditions to determine if the
malfunction was caused by tire traction performance.
•Coupling component malfunction
•4WD solenoid malfunction

ENGINE SPEED SENSING POWER STEERING
N–11
N
Crossmember bracket removal note
Warning
•Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the jack securely supports the crossmember component before
removing the crossmember bracket.
1. Support the crossmember component with a jack
and remove the nuts.
2. Remove the crossmember bracket.
Crossmember component, steering gear and linkage removal note
Warning
•Removing the crossmember is dangerous. The crossmember component could fall and cause
serious injury or death. Verify that the jack securely supports the crossmember component before
removing the crossmember bracket.
1. Remove the crossmember component, steering gear and linkage.
Steering gear and linkage installation note
1. Loosely tighten bolts.
2. Tighten the mounting bracket bolts to the
specified torque in the order shown.
Tightening torque
74.4—104.8 N·m
{7.6—10.6 kgf·m, 55—77 ft·lbf}
Bolt (intermediate shaft) installation note
1. Align the marks and install the intermediate shaft and bolt.
JACK
A6E7414W036
3
3
1
1
2
2
L.H.D.
R.H.D.
A6E0612W027

P–4
ABS/TCS
OUTLINEA6E692146444201•The construction and operation of ABS (ABS/TCS) is the same as that of the current Mazda6 (GG) L8, LF, L3
engine 2WD model, except for the following. (See Mazda6 Training Manual 3359-1*-02C.)
—Due to adoption of TCM, ABS (ABS/TCS) HU/CM sends 4-wheel speed signal to the TCM through CAN.
Structural View
.
ABS/TCS
5
3
1
2
6
7
5
3
6
8
4
4
7
9
10TCS
OFF
11
12
A6E6916W201
1 L.H.D.
2 R.H.D.
3 ABS wheel-speed sensor (front)
4 ABS sensor rotor (front)
5 ABS wheel-speed sensor (rear)
6 ABS sensor rotor (rear)7 TCS OFF switch
8 Instrument cluster
9 ABS warning light
10 Brake system warning light
11 TCS indicator light
12 TCS OFF light

ABS/TCS
P–5
P
System Diagram
.
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9
9
8
7
5
43
12
6
18
17
15
16
14
13
11
12
RF
FL
RR
RL
PCMG
E
FI Z
U
D
A
B
C
Y
AC
X
V O
R ADAB AA
ABS/TCS HU/CM
pP
9
10
19
920
A6E6921W201
1 IG switch
2SUS 15 A fuse
3 ABS 60 A fuse
4 Meter
5 ABS warning light
6 Brake system warning light
7 TCS OFF light
8 TCS indicator light
9CAN driver
10 Brake light11 Cruise actuator
12 TCS OFF switch
13 DLC-2
14 CAN-H
15 CAN-L
16 ABS Wheel-speed sensor
17 Battery
18 Brake switch
19 Audio unit, Wiper and washer switch, Car-navigation
unit, Auto leveling control unit
20 TCM, 4WD CM

P–6
DYNAMIC STABILITY CONTROL
OUTLINEA6E692067650201•The construction and operation of DSC is the same as that of the current Mazada6 2WD model, except for the
following:
— Due to the addition the 4WD model, DSC HU/CM uses the foward-G signal from the combine sensor to
control DSC.
—Due to adoption of the 4WD CM, DSC HU/CM sends a coupling torque request, a 4-wheel speed, and DSC
operation condition signal to the 4WD CM through CAN.
—Due to the adoption of TCM, DSC HU/CM sends a 4-wheel speed signal to the TCM through CAN.
Structural view
.
DYNAMIC STABILITY CONTROL
7
5
4
3
1
2
14
13
6
13
12
5
4
3
7
6
1011
9
14
8
8
15
A6E6920T004
1 L.H.D.
2 R.H.D.
3 DSC HU/CM
4 Wheel-speed sensor (front)
5 Sensor rotor (front)
6 Wheel-speed sensor (rear)
7 Sensor rotor (rear)
8 DSC OFF switch9 Instrument cluster
10 ABS warning light
11 DSC indicator light
12 DSC OFF light
13 Steering angle sensor
14 Combine sensor
15 Brake system warning light

DYNAMIC STABILITY CONTROL
P–7
P
Wiring Diagram
.
9
RF
FL
RR
RL
PCM
G
E
M
I
F
K
H
Q
NJ
P
S
T
V
O
Y
X
W
U
R
L
Z
AC
D
B
AG
AF
AE
AC
AA
AB
C
F
D
A
B
EDSC HU/CM
A
B
C
D
F
1
3
2
8
7
5
4
6
9
9
9
10
11
13
12
15
14
18
17
16
1920
2122
24
23
A6E6921W203
1 IG switch
2SUS 15A fuse
3 ABS 60 A fuse
4 Meter
5 ABS warning light
6 Brake system warning light
7 DSC OFF light
8 DSC indicator light
9CAN driver
10 Battery
11 Cruise actuator
12 DSC OFF switch13 DLC-2
14 CAN-H
15 CAN-L
16 Wheel-speed sensor
17 Combine sensor
18 Steering angle sensor
19 Brake switch
20 Brake light
21 Back-up light switch (MTX only)
22 Back-up light (MTX only)
23 Audio unit, Wiper and washer switch, Car-navigation
unit, Auto leveling control unit
24 TCM, 4WD CM

ON-BOARD DIAGNOSTIC
P–9
P
OUTLINEA6E697043000201•The operation of the on-board diagnostic system for ABS (ABS/TCS) or DSC is the same as that of the current
Mazda6 (GG) L8, LF, L3 engine 2WD model, except for the following. (See Mazda6 Training Manual
3359-1*-02C.)
— Due to the addition of the 4WD model, DTCs and PID data monitor has been added.
—Due to the addition of the MZR-CD (RF Turbo) engine model, the DTC C1119 fail-safe function and the
detection condition have been changed.
Fail-safe Function
Fail-safe function table
*1: When engine speed signal through CAN is out of specification, the light illuminates.*2: When engine speed signal through CAN is out of specification, the system is suspended.*3: When engine speed signal value through CAN is invalid, only brake TCS is available.*4: When fuel injection information through CAN is out of specification or invalid, only brake TCS is available.*5: When engine speed signal value through CAN is invalid, only brake DSC is available.*6: When the engine control system has a malfunction, only brake DSC is available.
PID/DATA Monitor Table
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ON-BOARD DIAGNOSTIC
Malfunc-
tion
locationDTC Fail-safe function
WDS
or
equiva-
lentWarning light illumination condition Control condition
ABS
warning
lightBRAKE
system
warning
light
(when
parking
brake is
released)DSC
(TCS)
OFF lightDSC
(TCS)
indicator
light ABS
controlEBD
controlTCS
controlDSC
controlBrake
assist
control
PCM and/
or engine
speed
signal lineC1119Not
Illuminated Not
Illuminated Not
Illuminated
*1Illuminated Available AvailableAvailable*2, *3, *4Available*2, *5, *6Available
Combine
sensor
(forward-
G) lineC1949
Illuminated Not
Illuminated Illuminated IlluminatedNot
availableAvailable—Not
availableNot
available
C1950
CAN line U2511Not
Illuminated Not
Illuminated Not
Illuminated Illuminated Available Available—Available Available
PID name input/output part Operation/unit
ACCLMTR Accelerometer ACCELERATION

CONVENTIONAL BRAKE SYSTEM
P–11
P
POWER BRAKE UNIT REMOVAL/INSTALLATIONA6E6912438002011. Remove the master cylinder.
2. Remove the wiper arm.
3. Remove the cowl grille.
4. Remove the wiper motor.
5. Remove the cowl panel.
6. For L.H.D. and R.H.D. (MZR-CD (RF Turbo) only), remove the A/C bracket.
7. For L.H.D., remove the ABS (ABS/TCS) HU/CM or DSC HU/CM.
8. For R.H.D. (except MZR-CD (RF Turbo)), remove the alternator cover.
9. For R.H.D. (except MZR-CD (RF Turbo)), remove the insulator.
10. For R.H.D. (except MZR-CD (RF Turbo)), remove the vacuum pipe bracket.
11. Remove in the order indicated in the table.
12. Install in the reverse order of removal.
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VACUUM SWITCH INSPECTION (MZR-CD (RF TURBO))A6E6912663902011. Remove the vacuum hose from the power brake unit.
2. Set the vacuum pump (any commercially
available model) onto the power brake unit as
shown.
3. Turn the ignition switch to ON.
4. Release the parking brake.
5. Apply vacuum to the power brake unit using the
vacuum pump (any commercially available
model) and verify the operating condition of the
brake warning light. The vacuum switch is
functioning normally if it corresponds to the above
specifications.
•If not as specified, replace the vacuum switch.
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CONVENTIONAL BRAKE SYSTEM
1 Vacuum hose
2 Snap pin
3Clevis pin
4Nut
5Fork
6 Power brake unit
7Gasket
8Nut
GREASEGREASE
R
3
4
8
6
2
7
5
1
18.6—25.5
{1.90—2.60, 13.8—18.8}
N·m {kgf·m, ft·lbf}
15.7—21.6
{1.60—2.20,
11.6—15.9}
A6E6912W044
Vacuum
kPa {mm Hg, inHg}Brake warning light
Below 10.7±2.7
{80±20, 3.1±0.8}ON
Above 10.7±2.7
{80±20, 3.1±0.8}OFFA6E6912W204