2002 MAZDA 6 ESP

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.
End Of Sie
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.
End Of Sie
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

T–2
OUTLINE, POWER SYSTEM
OUTLINE OF CONSTRUCTIONA6E810201088201•The construction and operation of the body electrical system is essentially carried over from that of the current
Mazda6 (GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C)
End Of Sie
FEATURESA6E810201088202Improved Safety
•There are two types of high-mount brake lights. (WGN)
Improved Marketability
•A cargo compartment light has been adopted. (WGN)
•The installation positions of the rear wiper and washer components have been changed. (WGN)
•A fuel gauge sender sub-unit has been adopted. (4WD)
•A 4WD indicator light, glow indicator light and sedimentor warning light have been adopted.
•The installation positions of the condenser and the noise filter have been changed. (WGN)
•An antenna feeder has been adopted. (WGN)
•A rear auto leveling sensor especially for the 4WD has been adopted. (4WD)
Improved Security
•A rear intruder sensor has been adopted. (WGN)
End Of Sie
STRUCTURAL VIEWA6E811067730201
.
End Of Sie
OUTLINE
POWER SYSTEM
2
1
A6E81101102
1 Seat warmer relay (with seat warmer)2 Glow relay (MZR-CD (RF Turbo) only)

T–40
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM]
Flowchart
•Use the following flowchart to verify the cause of the trouble.
End Of Sie
Repair the malfunctioning part by
following the DTC inspection.A
Inspect the power supply and the ground circuits for any units
that do not respond.
Are they normal?
Repair the malfunctioning part.A
A
B START
Using the SST (WDS or equivalent), verify if DTCs are displayed for PCM, TCM, ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS)),
DSC HU/CM (with DSC), 4WD control module and instrument cluster.
Are any DTCs displayed?
Ye s
Are any DTCs other than the following displayed?
PCM: U0073, U0101, U0121, U0155
TCM: U0073, U0100
ABS (ABS/TCS) HU/CM, DSC HU/CM,
Instrument cluster: U1900, U2516
4WD control module: U0100, U0101, U0121
NoEND No
No Ye s
Are any of the following DTCs displayed?
PCM: U0073, U0101, U0121, U0155
TCM: U0073, U0100
ABS (ABS/TCS) HU/CM, DSC HU/CM,
Instrument cluster: U1900, U2516
4WD control module: U0100, U0101, U0121
Ye s
Ye s Narrow down CAN system malfunction location.
Using the SST (WDS or equivalent), verify if DTCs are displayed
for PCM, TCM, ABS (ABS/TCS) HU/CM, DSC HU/CM, 4WD
control module and instrument cluster.
Are any DTCs displayed?
No
Using the SST (WDS or equivalent), clear DTCs stored in
each module.
END
Ye s
No
Turn the ignition switch to the LOCK position.
Inspect the wiring harness and connector between
any unit that does not respond and the DLC-2.
PCM
—DLC-2 (except MZR-CD (RF Turbo))
2R—CAN_L
2U—CAN_H
PCM—DLC-2 (MZR-CD (RF Turbo))
39—CAN_L
13—CAN_H
TCM—DLC-2
2J—CAN_L
2M—CAN_H
ABS (ABS/TCS) HU/CM—DLC-2
X—KLN
DSC HU/CM—DLC-2
AB—KLN
4WD control module—DLC-2
H—CAN_L
G—CAN_H
Instrument cluster—DLC-2
2W—CAN_L
2X—CAN_H
Are the wiring harnesses and connectors normal? Is there a response from the PCM, TCM, ABS (ABS/TCS) HU/CM,
DSC HU/CM, 4WD control module and/or instrument cluster?
No Ye s
No
Ye s Repair the malfunctioning part by following the DTC inspection.
Repair the malfunctioning part.
A6E8162L101

ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM]
T–40–1
T
T–40BODY ELECTRICAL SYSTEM
End Of Sie
ON-BOARD DIAGNOSTIC [MULTIPLEX COMMUNICATION SYSTEM]
Connect each unit connector.
Turn the ignition switch to the ON position.
Measure the voltage between DLC-2 terminals CAN_L and CAN_H.
Is the voltage 2.0—3.0 V?
Turn the ignition switch to the LOCK position.
Measure the resistance between DLC-2 terminals CAN_L and
CAN_H.
Is the resistance 59—65 ohms?
Replace any units that
do not respond.Disconnect the PCM connector.
Measure the resistance between PCM
connector terminals 2R and 2U
(except MZR-CD (RF Turbo)) or 13 and
39 (MZR-CD (RF Turbo)).
Is the resistance 118—130 ohms?
Replace the PCM.
Disconnect the instrument cluster connector.
Measure the resistance between instrument cluster connector
terminals 2W and 2X.
Is the resistance 118—130 ohms?
Replace the instrument
cluster.Turn the ignition switch to the LOCK position.
Disconnect the connector of any unit that does not respond.
(If there are two or more units that do not respond,
disconnect only one of the units.)
Turn the ignition switch to the ON position.
Measure the voltage between DLC-2 terminals CAN_L and
CAN_H.
Is the voltage 2.0—3.0 V?
The disconnected unit or the
related wiring harness may
have a malfunction.
Replace the disconnected unit. Replace the related wiring harness.The disconnected
unit is normal.
Are all units that do not respond disconnected?
Inspect if the related wiring harnesses (CAN_L
and/or CAN_H) have been shorted (to power
supply or ground).
If a short is found, replace the related wiring
harness. Ye sNo B
A A A AA
A
Turn the ignition switch to the LOCK position.
Verify the continuity between the following connector terminals of any disconnected unit.
PCM connector (except MZR-CD (RF Turbo)): 2R (CAN_L)—other terminals,
2U (CAN_H)—other terminals
PCM connector (MZR-CD (RF Turbo)): 39 (CAN_L)—other terminals,
13 (CAN_H)—other terminals
TCM connector: 2J (CAN_L)—other terminals, 2M (CAN_H)—other terminals
ABS (ABS/TCS) HU/CM connector: R (CAN_L)—other terminals,
O (CAN_H)—other terminals
DSC HU/CM connector: AF (CAN_L)—other terminals, AG (CAN_H)—other terminals
4WD control module connector: H (CAN_L)—other terminals, G (CAN_H)—other terminals
Instrument cluster connector: 2W (CAN_L)—other terminals, 2X (CAN_H)—other terminals
Is there continuity?
Ye s
No
Ye s
No
Ye sNo
Ye sNo
Ye sNo
Ye sNo
A6E8162L102