2002 MAZDA 6 sensor

M–80
ON-BOARD DIAGNOSTIC
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DTC U0100A6E637027100205
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
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DTC U0101A6E637027100206
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
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DTC U0121A6E637027100207
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
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4INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
GROUND
•Inspect for continuity between 4WD CM
terminal A and ground.
•Is there continuity?Yes Repair or replace harness for short to ground between 4WD
CM and differential oil temperature sensor, then go to Step
7.
No Go to next step.
5INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR OPEN
CIRCUIT
•Inspect for continuity between 4WD CM
terminal C and differential oil temperature
sensor terminal B.
•Is there continuity?Yes Go to next step.
No Repair or replace harness for open circuit between 4WD CM
and differential oil temperature sensor, then go to Step 7.
6INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
GROUND
•Inspect for continuity between 4WD CM
terminal C and ground.
•Is there continuity?Yes Repair or replace harness for short to ground between 4WD
CM and differential oil temperature sensor, then go to next
step.
No Replace 4WD CM, then go to next step.
7VERIFY TROUBLESHOOTING COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from memory.
(See M–76 Clearing DTCs Procedures)
•Drive vehicle.
•Is the same DTC present?Yes Replace 4WD CM, then go to next step.
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Is there any other DTC present?Yes Go to applicable DTC inspection.
No Troubleshooting completed. STEP INSPECTION ACTION
DTC U0100 PCM communication
DETECTION
CONDITION•4WD CM detects that communication signals (throttle opening angle and engine speed signals) from
PCM are abnormal.
POSSIBLE
CAUSE•PCM signals have communication error.
DTC U0101 TCM communication
DETECTION
CONDITION•4WD CM detects that communication signals (selector lever position and gear position signals) from
TCM are abnormal.
POSSIBLE
CAUSE•TCM signals have communication error.
DTC U0121 ABS/DSC communication
DETECTION
CONDITION•4WD CM detects that communication signals (four-wheel speed, ABS/DSC operation condition, and
coupling torque request signals) from DSC HU/CM are abnormal.
POSSIBLE
CAUSE•DSC HU/CM signals have communication error.

TROUBLESHOOTING
M–81
M
SYSTEM WIRING DIAGRAMA6E638027100201
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TROUBLESHOOTING
IGNITION SWITCH
BATTERY
DIFFERENTIAL OIL
TEMPERATURE
SENSOR4WD CM4WD SOLENOID ELECTRONIC CONTROL
COUPLING
CAN DRIVERINSTRUMENT CLUSTER
CAN-H
CAN-LPCM DSC HU/CM KO
P I
A
C
NH G
TCM
A6E63702002

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.

M–84
TROUBLESHOOTING
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NO.3 ABNORMAL NOISE AND/OR VIBRATION FROM COUPLING COMPONENTA6E638027100206
Diagnostic procedure
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6INSPECT 4WD SOLENOID
•Inspect 4WD solenoid.
(See M–66 4WD SOLENOID INSPECTION)
•Is it okay?Yes Inspect harness between 4WD solenoid and 4WD CM, then
go to next step.
No Replace coupling component. STEP INSPECTION ACTION
3 Abnormal noise and/or vibration from coupling component
[TROUBLESHOOTING HINTS]
•Abnormal noise and/or vibration from coupling component during driving
•Propeller shaft is malfunctioning or attached improperly.
•Engine mount or differential mount malfunction
•Resonance of rotating parts on vehicle (engine, propeller shaft, rear differential, tire, etc.)
•Resonance with engine vibration (mainly with exhaust system parts)
•Rear differential malfunction
•Coupling component 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 INSTALLATION CONDITION OF
VEHICLE PARTS
•Verify installation condition for following:
—Propeller shaft (including bending and
joint operation)
—Center bearing
—Engine mount
—Differential mount
—Hub bearing
—Exhaust system parts
—ABS wheel-speed sensor
•Are they properly installed?Yes Go to next step.
No Repair or replace malfunctioning part.
3DETERMINE IF MALFUNCTION IS CAUSED
BY REAR DIFFERENTIAL
•Install tires of another brand.
Note
•When tires of another brand are
installed, the same malfunction can
occur due to conditions different from
customer explanation. Be careful not
to confuse it with customer complaint.
•Perform simulation driving at the same
engine speed, gear position, and vehicle
speed that customer vehicle had
malfunction.
•Does the same malfunction occur?Yes Reinstall customer’s vehicle tire. Go to next step.
No 4WD system is okay.
Reinstall customer’s vehicle tire.
4INSPECT REAR DIFFERENTIAL
•Inspect rear differential for following:
—Backlash
—Teeth contact
(See M–56 REAR DIFFERENTIAL
ASSEMBLY)
•Are they okay?Yes Replace coupling component.
No Inspect malfunctioning part and adjust it if necessary.

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.
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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–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