2002 MAZDA 6 Workshop Manual Suplement

P–12
CONVENTIONAL BRAKE SYSTEM
VACUUM SWITCH REMOVAL/INSTALLATION (MZR-CD (RF TURBO))A6E6912663902021. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Vacuum Switch Installation Note Caution• Do not apply sealant to the lip of the vacuum switch as it may cause a malfunction to occur.
1. Apply sealant to the new vacuum switch in the area shown in the figure.
End Of Sie
VACUUM PUMP INSPECTION (MZR-CD (RF TURBO))A6E6912187772011. Warn up the engine.
2. Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in
the figure, then check the vacuum.• If the pressure is less than the specification,
inspect for the following.
— Malfunction of the vacuum pump
— Shortage of the lubrication oil pressure
Vacuum specification (In 8 seconds) Engine speed 1,270 rpm: 66.6 kPa {500 mmHg, 19.7 inHg} or more
Engine speed 2,450 rpm: 93.3 kPa {700 mmHg, 27.6 inHg} or more
End Of Sie
1 Connector
2 Vacuum switch (See P –12 Vacu um S w itch Ins tal lat ion Note )
SEALANT
1
219.6—24.5
{2.00—2.49,
14.5—18.0}
N·m {kgf·m, ft·lbf}
A6E6912W205
SEALANT
DO NOT APPLY
SEALANT ON
THIS AREA
A6E6912W206
AME6912W006

CONVENTIONAL BRAKE SYSTEM
P–13
P
VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF TURBO))A6E6912187772021. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Vacuum Pump Installation Note
1. Be careful the O-ring is not pinched when installing the vacuum pump.
End Of Sie
FRONT BRAKE (DISC) INSPECTIONA6E691233980201Disc Plate Thickness Inspection
Caution
•Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.
1. Measure the thickness of the disc plate.
•If the thickness is not within the specification, replace the disc plate.
Minimum
L8, LF (GCC specs.):
22 mm {0.87 in}
LF (European (L.H.D. U.K.) specs.),
L3, MZR-CD (RF Turbo):
23 mm {0.91 in}
Minimum thickness after machining using a brake lathe on-vehicle
L8, LF (GCC specs.):
22.8 mm {0.90 in}
LF (European (L.H.D. U.K.) specs.),
L3, MZR-CD (RF Turbo):
23.8 mm {0.94 in}
End Of Sie
1 Vacuum hose
2Bolt
3 Vacuum pump
(See P–13 Vacuum Pump Installation Note)
4 O-ring
4
3
1
B
B
A
A
2
N·m {kgf·cm, in·lbf} 18.6—25.5
{1.90—2.60,
13.8—18.8}
R
A6E6912W207

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

P–16
CONVENTIONAL BRAKE SYSTEM
DISC PAD (FRONT) REPLACEMENTA6E6912336302011. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
.
End Of Sie
7
7
5
54
3
1
2
6
SST
6
SST
GREASEGREASE
18.5—25.5
{1.89—2.60,
13.7—18.8}
L8, LF (GCC SPECS.)
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO) 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}
RUBBER GREASE18.5—25.5
{1.89—2.60,
13.7—18.8}
N·m {kgf·m, ft·lbf}
A6E6912W203
1Bolt
2Bolt
3Cap
4 Guide pin5M-spring
6Disc pad
(See P–15 Disc Pad Installation Note)
7 Guide plate

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

DYNAMIC STABILITY CONTROL
P–19
P
*: Used for vehicle manufacturing, not used for DSC.
Inspection Using An Oscilloscope (Reference)
Steering angle (steering angle signal 1 and 2)
•DSC HU/CM terminal:
Steering angle signal 2: W (+) — R (-)
Steering angle signal 1: X (+) — R (-)
•Oscilloscope setting:
1 V/DIV (Y), 25 ms/DIV (X), DC range
•Vehicle condition: Rotating steering wheel at one
revolution per second
Note
•As steering wheel rotation speed increases,
period of wave shortens.
•As for shape of steering angle signals 1 and
2, the phase is different.
Wheel speed
•DSC HU/CM terminal:
RF: M (+) — I (-)
RR: K (+) — H (-)
LF: F (+) — J (-)
LR: Q (+) — N (-)
•Oscilloscope setting:
1 V/DIV (Y), 2 ms/DIV (X), AC range
•Vehicle condition: Driving 30 km/h (18.6 mph)
Note
•As vehicle speed increases, period of wave
shortens.
•If there is malfunctioning in the sensor rotor,
wave profile warps.
ACAuto cruise set
signal outputAuto cruise unitWhen auto cruise is ON Below 1.0
•Inspect related harness
•Inspect DSC HU/CM
When auto cruise is OFF B+
AD—— — — —
AEVehicle speed
output•Audio unit
•Wiper and
washer
switch
•Car-navigatio
n unit
•Auto
leveling
control unit
•Cruise
actuatorVehicle is stopped 0
•Inspect related harness
•Inspect front wheel-speed
sensor •Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))
AF CAN-L——No need to
check—
AG CAN-H——No need to
check—
AH—— — — — Terminal Signal Connected to Test condition Voltage (V) Action
0 V
A6E6921W014
0 V
A6E6921W013