2002 MAZDA 6 brake

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

TROUBLESHOOTING
M–83
M
Diagnostic procedure
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NO.2 TIGHT CORNER BRAKINGA6E638027100205
Diagnostic procedure
STEP INSPECTION ACTION
1VERIFY DSC, PCM, TCM, AND 4WD SYSTEM
DTCs
•Verify DSC, PCM, TCM, and 4WD system
DTCs using WDS or equivalent.
•Are there any DTCs present?Yes Go to applicable DTC inspection.
No Go to next step.
2VERIFY TIRE AIR PRESSURE
•Inspect tire air pressure.
•Is it within specification?Yes Go to next step.
No Adjust tire air pressure, then go to next step.
3COMPARE WITH SAME MODEL TIRES
•Install tires of the same model.
•Perform simulation driving.
•Does malfunction recur?Yes Go to next step.
No 4WD system is okay.
4COMPARE WITH SAME MODEL VEHICLE
•Install tires of malfunctioning vehicle to
another same model vehicle.
•Perform simulation driving.
•Does malfunction recur?Yes 4WD system is okay.
No Go to next step.
5INSPECT 4WD SOLENOID
•Inspect 4WD solenoid.
(See M–66 4WD SOLENOID INSPECTION)
•Is coupling component solenoid okay?Yes Inspect harness between 4WD solenoid and 4WD CM, then
go to next step.
No Replace coupling component.
6INSPECT WHEEL ALIGNMENT
•Inspect wheel alignment.
•Is it okay?Yes Replace coupling component.
No Inspect wheel alignment, and adjust it if necessary.
2 Tight corner braking
[TROUBLESHOOTING HINTS]
•Because the coupling component locks up easily (similar to direct 4WD), rotational difference between the front
and rear wheels cannot be absorbed and brake-like phenomenon occurs.
•Due to the coupling component construction, slight tight corner braking effect occurs during tight cornering on a
paved road. (4WD system is okay. Compare with another same model vehicle to determine malfunction.)
•Coupling component malfunction
•4WD solenoid malfunction
STEP INSPECTION ACTION
1VERIFY DSC, PCM, TCM, AND 4WD SYSTEM
DTCS
•Verify DSC, PCM, TCM, and 4WD system
DTCs using WDS or equivalent.
•Are there any DTCs present?Yes Go to applicable DTC inspection.
No Go to next step.
2VERIFY TIRE AIR PRESSURE
•Inspect tire air pressure.
•Is it within specification?Yes Go to next step.
No Adjust tire air pressure, then go to next step.
3INSPECT ABS WHEEL-SPEED SENSOR
•Inspect ABS wheel-speed sensor.
•Is it okay?Yes Go to next step.
No Repair or replace malfunctioning part.
4COMPARE WITH SAME MODEL VEHICLE
•Perform simulation driving with another
same model vehicle.
•Does malfunction recur on the same model
vehicle?Yes 4WD system is okay.
No Go to next step.
5PERFORM SIMULATION DRIVING WITH 4WD
SOLENOID CONNECTOR DISCONNECTED
•Turn ignition key OFF.
•Disconnect 4WD solenoid connector.
•Perform simulation driving. (Clear DTC after
simulation driving.)
•Does malfunction recur?Yes Replace coupling component.
No Go to next step.

P–1
P
PBRAKING SYSTEM
OUTLINE................................................................ P-2
OUTLINE OF CONSTRUCTION.......................... P-2
FEATURES .......................................................... P-2
SPECIFICATIONS ............................................... P-2
STRUCTURAL VIEW ........................................... P-3
ABS/TCS................................................................ P-4
OUTLINE.............................................................. P-4
DYNAMIC STABILITY CONTROL......................... P-6
OUTLINE.............................................................. P-6
COMBINE SENSOR
(FORWARD-G SENSOR) ................................. P-8
CONTROLLER AREA NETWORK (CAN) ........... P-8
ON-BOARD DIAGNOSTIC..................................... P-9
OUTLINE.............................................................. P-9
OUTLINE.............................................................. P-10
SUPPLEMENTAL SERVICE INFORMATION ... P-10
GENERAL PROCEDURES.................................. P-10
PRECAUTION (BRAKES).................................. P-10
CONVENTIONAL BRAKE SYSTEM.................... P-11
POWER BRAKE UNIT
REMOVAL/INSTALLATION ............................ P-11
VACUUM SWITCH INSPECTION
(MZR-CD (RF TURBO)) .................................. P-11
VACUUM SWITCH
REMOVAL/INSTALLATION
(MZR-CD (RF TURBO)) .................................. P-12
VACUUM PUMP INSPECTION
(MZR-CD (RF TURBO)) .................................. P-12
VACUUM PUMP REMOVAL/INSTALLATION
(MZR-CD (RF TURBO)) .................................. P-13
FRONT BRAKE (DISC) INSPECTION............... P-13
FRONT BRAKE (DISC)
REMOVAL/INSTALLATION ............................ P-14
DISC PAD (FRONT) REPLACEMENT .............. P-16
PARKING BRAKE SYSTEM................................ P-17
PARKING BRAKE (LEVER TYPE)
ADJUSTMENT ................................................ P-17
DYNAMIC STABILITY CONTROL....................... P-17
DSC HU/CM INSPECTION ................................ P-17
COMBINE SENSOR
(FORWARD-G SENSOR) INSPECTION ........ P-20
ON-BOARD DIAGNOSTIC................................... P-21
DSC ON-BOARD DIAGNOSIS .......................... P-21
DTC C1119 ........................................................ P-26
DTC C1949, C1950............................................ P-27
DTC U2511 ........................................................ P-29 FEATURES
SERVICE

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.)
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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.
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SPECIFICATIONSA6E690201020203
Bold frames: New specifications
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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
.
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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