2002 MAZDA 6 light

ELECTRONIC 4WD CONTROL SYSTEM
M–17
M
Memory function
•This function stores DTCs for malfunctions of the input/output signal systems as determined by the failure
detection function. Once a DTC is stored, it is not cleared even if the input/output signal system malfunction
returns to normal when the ignition key is turned to the LOCK position (engine OFF).
•Since DTCs are stored in the non-volatile memory inside the 4WD CM, they are not cleared even if the battery
is disconnected. Therefore, it is necessary to clear the memory when maintenance has been completed. For
clearing DTCs, refer to the procedures in the Workshop Manual.
•When inspecting DTCs using a WDS or equivalent, only one memory stored DTC at a time can be displayed.
Therefore, when multiple DTCs have been stored, it is necessary to inspect for DTCs again after repairing and
clearing the present DTC to ensure that there are no more DTCs present in the memory.
Fail-safe function
•When the failure detection function determines that there is a malfunction, the 4WD warning light illuminates to
alert the driver. At this time, the fail-safe function suspends control or takes other measures to ensure that
driving stability is not lost.
X:Available
*1: Does not illuminate when only the coupling torque request signal from the DSC HU/CM cannot be received.*2: Only integrated DSC control is prohibited when only the coupling torque request signal from the DSC HU/CM
cannot be received.
External tester communication function
•This function allows for the storing and clearing of DTCs due to a communication link between the 4WD CM
and an external tester.
End Of Sie
DTC Malfunction location4WD warning
lightconditionDTC stored in
memoryControl condition
P1887 System wiring Illuminated X Stop
P1888 Differential oil temperature sensor Illuminated X Stop
U0100 PCM communication system Illuminated X Stop
U0101 TCM communication system Illuminated X Stop
U0121 DSC communication system
Illuminated
*1X
Stop*2

M–22
REAR AXLE
WHEEL HUB BOLT REPLACEMENTA6E6314050002011. Remove the brake caliper component and the disc plate.
2. Remove the wheel hub bolt using the SST as
shown in the figure.
Note
•If the dust cover interferes with the wheel
hub bolt and the wheel hub bolt cannot be
removed, tap the part shown in the figure
with a chisel lightly and bend the process
back to the knuckle side.
3. Install a new wheel hub bolt into the wheel hub
and install a washer and hub nut on the hub bolt.
4. Tighten the hub nut while holding the wheel hub
using a brass bar.
End Of Sie
WHEEL HUB, KNUCKLE REMOVAL/INSTALLATIONA6E631405000202
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 (wheel side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while the vehicle is being
serviced.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
REAR AXLE
49 T028 3A0
BEND THIS PART
A6E0311W011
HUB BOLT
WHEEL
NUT WHEEL
NUT
WASHER
BRASS
BAR
A6E0311W012

M–54
REAR DIFFERENTIAL
Rear Differential Component Disassembly Note
1. Remove the rear differential component using the
SSTs.
2. Mark or otherwise distinguish between the
removed left and right adjusting shims, spacers
and side bearing outer races so that they are not
mixed up at the time of reassembly.
Locknut Disassembly Note
1. Remove the locknut using the SSTs.
Drive Pinion Disassembly Note
1. Remove the drive pinion by lightly tapping with a
copper hammer.
Bearing Inner Race (Rear Bearing) Disassembly Note
1. Remove the bearing inner races (rear bearing)
using the SST and a press.
49 T032 317
49 T032 316
49 L027 004
A6A63192012
49 L027 006
49 L027 007
A6A63192013
A6A63192014
49 H027 002
A6A63192015

REAR DIFFERENTIAL
M–55
M
Bearing Outer Race Disassembly Note
1. Remove the bearing outer races using the 2
grooves in the carrier and alternately tapping the
sides of the races with a brass bar.
Ring Gear Disassembly Note
1. Secure the gear case in a vice and remove the
bolts.
2. Lightly tap around the ring gear using a plastic
hammer to remove the ring gear from the gear
case.
Side Bearing Inner Race Disassembly Note
Note
•Mark or otherwise distinguish between the left and right side bearings so that they are not mixed up at the
time of reassembly.
1. Remove the side bearing inner races from the
gear case using the SST and a press.
End Of Sie
A6A63192016
A6A63192017
49 B027 003
49 F401 366A
49 G030 797
49 E027 002
A6A63192018

TROUBLESHOOTING
M–83
M
Diagnostic procedure
End Of Sie
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.

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–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