2002 MAZDA 6 wheel

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

P–8
DYNAMIC STABILITY CONTROL
End Of SieCOMBINE SENSOR (FORWARD-G SENSOR)A6E692067650202Function
•The forward-G sensor is integrated with the combine sensor to detect and calculate the vehicle forward-G force
and change in voltage to the DSC HU/CM.
Structure/Operation
•The drive train of 4WD vehicles delivers driving force to all four wheels, and due to this interlocking, the speed
of all wheels during braking is the same. When driving on road surfaces with especially low m (friction
coefficient), it is difficult to estimate the vehicle speed based on the wheel speed, and DSC braking becomes
unreliable. (For 2WD vehicles, the front and rear wheels are independent, so it is possible to accurately
estimate the vehicle speed by measuring the difference between the rotation speeds of the front and rear tires.)
A forward-G sensor has been installed to overcome this situation. When braking, the change in G-force is
detected, and the road surface m is judged (low m, high m), enabling a correction of the vehicle speed
estimation.
•The output voltage characteristic for the combine sensor is 2.5 V when the vehicle is standing still, and
changes accordingly as forward-G is formed.
•Forward-G is formed when the sensor detects an inertial force created by, and in proportion to, a G- force
acting on a silicon detection component.
.
End Of Sie
CONTROLLER AREA NETWORK (CAN)A6E692067650203•ABS (ABS/TCS) or DSC HU/CM transmit/receive information through CAN. Due to the addition of TCM, 4WD
CM, and the MZR-CD (RF Turbo) engine model, the following information has been changed. For detailed
information on CAN, see the “CONTROLLER AREA NETWORK.” (See T–3 OUTLINE.)
Transmitted Information
•Coupling torque request (to 4WD CM)
•DSC operating condition (to 4WD CM)
Received Information
•Coupling torque (from 4WD CM)
•Shift position (from TCM)
•Fuel injection information (only MZR-CD (RF Turbo), from PCM)
End Of Sie
(V)
2.5
-14.70
+14.7(m/s
2)
45
3
6
2
1
A6E6920W201
1 External view
2 Front of vehicle
3 Output voltage characteristic4 Deceleration
5 Forward-G
6 Acceleration

P–10
OUTLINE , GENERAL PROCEDURES
SUPPLEMENTAL SERVICE INFORMATIONA6E690201020205•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
Power brake unit
•Removal/installation procedure has been modified.
Vacuum switch (MZR-CD (RF Turbo))
•Inspection procedure has been added.
•Removal/installation procedure has been added.
Vacuum pump (MZR-CD (RF Turbo))
•Inspection procedure has been added.
•Removal/installation procedure has been added.
Front brake (disc)
•Inspection procedure has been modified.
•Removal/installation procedure has been modified.
Disc pad (front)
•Replacement procedure has been modified.
Parking brake (lever type)
•Adjustment procedure has been modified.
DSC HU/CM
•Inspection procedure has been modified.
Combine sensor (Forward-G sensor)
•Inspection procedure has been modified.
On-board diagnostic (ABS/TCS)
•4WD and MZR-CD (RF Turbo) have been added.
End Of Sie
PRECAUTION (BRAKES)A6E691001020201Wheels and Tires Removal/Installation
1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a
wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}.
Brake Lines Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
•If any brake line has been disconnected anytime during the procedure, add brake fluid, bleed the brakes,
and inspect for leakage after the procedure has been completed.
Connectors Disconnection
1. Disconnect the negative battery cable before doing any work that requires handling of connectors. Reconnect
the negative battery cable only after the work is completed.
ABS, ABS/TCS, or DSC Components Operations
1. Make sure that there are no DTCs in the ABS, ABS/TCS, or DSC memory after working on ABS, ABS/TCS or
DSC components.
•If there are any DTCs in the memory, clear them.
End Of Sie
OUTLINE
GENERAL PROCEDURES

P–14
CONVENTIONAL BRAKE SYSTEM
FRONT BRAKE (DISC) REMOVAL/INSTALLATIONA6E6912339802021. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
.
9
8
7
5
5
4
3
1
2
6
6
SST
SST
R
RUBBER GREASE 21.6—29.4
{2.21—3.00,
16.0—21.6} 78.4—101.9
{8.00—10.3, 57.9—75.1}
GREASEGREASE
GREASEGREASE
GREASEGREASE
9.8—14.7 N·m
{100—149 kgf·cm,
87—129 in·lbf}7
N·m {kgf·m, ft·lbf} L8, LF (GCC SPECS.):
44.1—49.0 {4.47—4.99, 32.4—36.1}
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO):
49.0—53.9 {5.00—5.49, 36.2—39.7}
L8, LF (GCC SPECS.)
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO)
A6E6912W201
1 Flexible hose
2Cap
3 Guide pin
4 Caliper
5 M-spring 6Disc pad
(See P–15 Disc Pad Installation Note)
7 Guide plate
8 Mounting support
9 Disc plate
(See P–15 Disc Plate Removal Note)
(See P–15 Disc Plate Installation Note)

CONVENTIONAL BRAKE SYSTEM
P–15
P
Disc Plate Removal Note
1. Mark the wheel hub bolt and disc plate before
removal for reference during installation.
Disc Plate Installation Note
1. Remove any rust or grime on the contact face of the disc plate and wheel hub.
2. Install the disc plate and align the marks made before removal.
Disc Pad Installation Note
1. Push the piston fully inward using the SST.
2. Install the disc pad.
End Of Sie
MARK
A6E6912W037
49 0221 600C
A6E6912W038

PARKING BRAKE SYSTEM, DYNAMIC STABILITY CONTROL
P–17
P
PARKING BRAKE (LEVER TYPE) ADJUSTMENTA6E6914440002011. Start the engine and depress the brake pedal several times.
2. Stop the engine.
3. For the 2WD model, remove the rear ashtray case behind the center console
4. For the 4WD model, remove the 4 screws (back side) and pull up the rear of the center console, then remove
the rear ashtray case.
5. Turn the adjusting nut as shown in the figure.
6. After adjustment, inspect the following points:
(1) Turn the ignition switch to ON, pull the parking
brake lever one notch, and verify that the
parking brake warning light illuminates.
(2) Verify that the rear brakes do not drag.
End Of Sie
DSC HU/CM INSPECTIONA6E6920676502041. Remove the battery and battery bracket.
2. Disconnect the DSC HU/CM connector.
3. Connect the SST (49 G066 004) to the DSC HU/CM connector and harness side connector.
4. Inspect voltage referring the table below.
Terminal Voltage Table (reference value)
(Ignition switch is at ON, and connector is connected unless indicated otherwise)
PARKING BRAKE SYSTEM
A6E6914W002
DYNAMIC STABILITY CONTROL
Terminal Signal Connected to Test condition Voltage (V) Action
A Ground (1) Ground part 1—Below 1.0•Inspect related harness
B Ground (2) Ground part 2—Below 1.0•Inspect related harness
CSolenoid valve
(power supply)Battery—B+•Inspect DSC HU/CM
•Inspect related harness
DPump motor
(power supply)Battery—B+•Inspect DSC HU/CM
•Inspect related harness
E
*—Check
connector—No need to
check•Inspect related harness
F
JLF wheel-speedLF wheel-speed
sensorVehicle is stopped 0 (AC)
•Inspect related harness
•Inspect wheel-speed
sensor •Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))
SST (49 G066 004)
AQ
B
CDE
FG
HI
J DSC HU/CM HARNESS SIDE CONNECTOR
A
C E
H
K N Q
T
W Z AC AF
F I L O R U X
AA AD AG
G
J
M P S
V
Y AB AE AHB
DKN
T
WZ
AC
AFLO
RU
XAA
ADAGMP
SV
YAB
AEAH
A6E6920W009

P–18
DYNAMIC STABILITY CONTROL
K
HRR wheel-speedRR wheel-
speed sensorVehicle is stopped 0 (AC)
•Inspect related harness
•Inspect wheel-speed
sensor •Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))
M
IRF wheel-speedRF wheel-
speed sensorVehicle is stopped 0 (AC)
•Inspect related harness
•Inspect wheel-speed
sensor •Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))
Q
NLR wheel-speedLR wheel-speed
sensorVehicle is stopped 0 (AC)
•Inspect related harness
•Inspect wheel-speed
sensor •Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))
G Battery (IG) Ignition switch Ignition switch ON B+•Inspect related harness
•Inspect ignition switch
L Brake switch Brake switchWhen brake pedal is
depressed10—14•Inspect related harness
•Inspect brake switch
OLateral-G
(lateral-G signal)Combine
sensorVehicle is stopped 2.2—2.8
•Inspect related harness
•Inspect combine sensor Left corneringFluctuation
between
2.5—4.0 V
Right corneringFluctuation
between
1.0—2.5 V
PCombine sensor
power outputCombine
sensorIgnition switch ON 4.75—5.25•Inspect related harness
•Inspect combine sensor
RSteering angle
(ground)Steering angle
sensor—Below 1.0•Inspect related harness
•Inspect steering angle
sensor
S Combine sensorCombine
sensor—3.5—5.0•Inspect related harness
•Inspect combine sensor
TYaw rate
(yaw rate signal)Combine
sensorVehicle is stopped 2.2—2.8
•Inspect related harness
•Inspect yaw rate sensor Right corneringFluctuation
between
2.5—4.62 V
Left corneringFluctuation
between
2.5—0.33 V
USteering angle
(neutral signal)Steering angle
sensorSteering position:
center position 25°—29°Below 1.0•Inspect related harness
•Inspect steering angle
sensor
Except above condition Approx. 4
VForward-G
(forward-G signal)Combine
sensorVehicle is stopped 2.2—2.8
•Inspect related harness
•Inspect combine sensor AccelerationFluctuation
between
2.5—4.0 V
Deceleration Fluctuation
between
1.0—2.5 V
WSteering angle
(steering angle
signal 2)Steering angle
sensor•Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))•Inspect related harness
•Inspect steering angle
sensor
XSteering angle
(steering angle
signal 1)Steering angle
sensor•Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))•Inspect related harness
•Inspect steering angle
sensor
YCombine sensor
(ground)Combine
sensor—Below 1.0•Inspect related harness
•Inspect combine sensor
AA DSC OFF switchDSC OFF
switchWhen switch is pressed Below 1.0
•Inspect related harness
•Inspect DSC OFF switch
When switch is not pressed B+
AB OBDKLN terminal of
DLC-2It cannot be determined with terminal
voltage whether the condition is good or bad
because advanced function diagnostic
output is performed with serial
communication. Inspect with service codes.•Inspect related harness
•Inspect DSC HU/CM Terminal Signal Connected to Test condition Voltage (V) Action