2002 MAZDA 6 wheel

N–6
ENGINE SPEED SENSING POWER STEERING
POWER STEERING FLUID INSPECTIONA6E661432040201Fluid Level Inspection
1. Inspect the power steering fluid level.
•Add fluid to the specified level as necessary.
Fluid specification
ATF M-III or equivalent (e.g. Dexron
®II)
Fluid Leakage Inspection
Caution
•If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid
temperature will rise excessively and adversely affect the oil pump.
1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.
Note
•The points where fluid leakage may occur are indicated in the figure.
3. Inspect for fluid leakage.
•If fluid leakage is found, replace the related pipe or hose.
ENGINE SPEED SENSING POWER STEERING
L.H.D.
ATX
MTX
R.H.D.
ATX
MTX MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)L.H.D
R.H.D
A6E66142001

ENGINE SPEED SENSING POWER STEERING
N–7
N
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
2. Disconnect the pressure pipe from the oil pump,
and connect the SSTs.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
3. Bleed the air from the system.
4. Open the gauge valve fully.
5. Start the engine and turn the steering wheel fully
left and right to raise the fluid temperature to 50—
60 °C {122—140 °F}.
6. Close the gauge valve completely.
7. Increase the engine speed to 1,000—1,500 rpm
and measure the fluid pressure generated by the
oil pump.
•If the pressure is not within the specification,
repair or replace the oil pump component.
Caution
•If the valve is left closed for more than 5
seconds, the fluid temperature will rise
excessively and adversely affect the oil
pump.
Oil pump fluid pressure
(MPa {kgf/cm
2, psi})
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
49 1232 670B
49 H002 671
A6E0612W101
49 G032 351
49 G032 353
49 G032 352
49 G032 352
49 G032 351
49 G032 353
MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)
A6E66142002
THERMOMETER50—60
{122—140 }°
°F
GAUGE
CLOSE VALVE
COMPLETELY
A6E0612W081

N–8
ENGINE SPEED SENSING POWER STEERING
8. Open the gauge valve fully and increase the
engine speed to 1,000—1,500 rpm.
9. Turn the steering wheel fully to the left and right,
then measure the fluid pressure generated at the
gear housing.
•If the pressure is not within the specification,
repair or replace the steering gear
component.
Caution
•If the steering wheel is kept in the fully
turned position for more than 5 seconds,
the fluid temperature will rise excessively
and adversely affect the oil pump.
Gear housing fluid pressure
(MPa {kgf/cm
2, psi})
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
11. Bleed the air from the system.
End Of Sie
STEERING GEAR AND LINKAGE (MZR-CD (RF TURBO)) REMOVAL/INSTALLATIONA6E661432960201
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
L.H.D.
1. Remove the under cover and mud guard. (Left side)
2. Remove the front auto leveling sensor.
3. Separate the stabilizer control link. (shock absorber side)
4. Separate the front lower arm (front and rear) ball joint.
5. Remove the shock absorber bolt. (lower side)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect the toe-in.
9. Adjust the headlight zeroset.
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
THERMOMETER50—60
{122—140 }°
°F
GAUGE
OPEN VALVE
COMPLETELY
A6E0612W080

ENGINE SPEED SENSING POWER STEERING
N–13
N
STEERING GEAR AND LINKAGE (4WD) REMOVAL/INSTALLATIONA6E661432960202
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the under cover and mud guard. (Left side)
2. Remove the front auto leveling sensor.
3. Separate the stabilizer control link. (shock absorber side)
4. Separate the front lower arm (front and rear) ball joint.
5. Remove the shock absorber bolt. (lower side)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Inspect the toe-in.
9. Adjust the headlight zeroset.

P–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E690201020201•The construction and operation of the braking system is the same as that of the current Mazda6 (GG) L8, LF,
L3 engine 2WD model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
End Of Sie
FEATURESA6E690201020202Modifications to match vehicle characteristics
•Due to the addition of the MZR-CD (RF Turbo) engine, the vacuum pump and vacuum switch have been
added.
•Due to the addition of the 4WD model, DSC HU/CM uses the forward-G signal from combine sensor to control
DSC.
End Of Sie
SPECIFICATIONSA6E690201020203
Bold frames: New specifications
End Of Sie
OUTLINE
ItemSpecification
New Mazda6 (GG, GW) Current Mazda6 (GG)
Brake pedalType Suspended
Pedal lever ratio 2.7
Max. stroke (mm {in}) 128.5 {5.06}
Master
cylinderType Tandem (with level sensor)
Cylinder diameter (mm {in}) 20.64 {0.813}
Front disc
brakeType Ventilated disc
Cylinder bore (mm {in}) 57.15 {2.250}
Pad dimensions (area × thickness) L8, LF (GCC specs.):
4,220 {6.75} × 10.0 {0.39}
LF (European (L.H.D. U.K.)
specs.), L3, MZR-CD (RF Turbo):
4,010 {6.42} × 12.0 {0.47}L8, LF (GCC specs.):
4,220 {6.75} × 10.0 {0.39}
LF (European (L.H.D. U.K.) specs.),
L3: 4,010 {6.42} × 12.0 {0.47} (mm
2 {in2} × mm {in})
Disc plate dimensions
(outer diameter × thickness)L8, LF (GCC specs.):
274 {10.8} × 24.0 {0.945}
LF (European (L.H.D. U.K.)
specs.), L3, MZR-CD (RF Turbo):
283 {11.1} × 25.0 {0.984}L8, LF (GCC specs.):
274 {10.8} × 24.0 {0.945}
LF (European (L.H.D. U.K.) specs.),
L3: 283 {11.1} × 25.0 {0.984} (mm {in} × mm {in})
Rear brake
(disc)Type Solid disc
Cylinder bore (mm {in}) 34.93 {1.375}
Pad dimensions (area × thickness)
2,810 {4.51} × 8.0 {0.31}
(mm
2 {in2} × mm {in})
Disc plate dimensions
(outer diameter × thickness)
280 {11.0} × 10.0 {0.39}
(mm {in})
Power brake
unitType Vacuum multiplier, single diaphragm
Diameter (mm {in}) 279 {10.9}
Braking force
control deviceTypeWith ABS: EBD (Electronic Brakeforce Distribution)
Without ABS: Dual proportioning valve
Parking brakeType Mechanical two-rear-wheel control
Operation system Center lever type
Brake fluid TypeEuropean (L.H.D. U.K.) specs.: SAE J1703, FMVSS116 DOT3 OR DOT4
GCC specs.: SAE J1703, FMVSS116 DOT3

OUTLINE
P–3
P
STRUCTURAL VIEWA6E690201020204
.
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7
53
1
2
6
7
53
6
89
4
4
8
10
15
14
15
14
12
13
13
12
11
11
16
16
A6E6902W201
1L.H.D.
2 R.H.D.
3 Brake pedal
4 Master cylinder
5 Power brake unit
6 Front brake (disc)
7 Rear brake (disc)
8 Vacuum pump9 Without ABS
10 Dual proportioning valve
11 ABS (ABS/TCS) or DSC HU/CM
12 ABS wheel-speed sensor (front)
13 ABS sensor rotor (front)
14 ABS wheel-speed sensor (rear)
15 ABS sensor rotor (rear)
16 Combine sensor

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
.
End Of Sie
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