4WD MAZDA 6 2002 Suplement Repair Manual

M–16
ELECTRONIC 4WD CONTROL SYSTEM
ON-BOARD DIAGNOSTICA6E632227100208Outline
•The on-board diagnostic function allows for detecting malfunctions in the input/output signals when the ignition
key is at the ON position.
•The DLC-2, which combines the failure detection and detection maintenance connectors, has been adopted to
improve serviceability. By connecting a WDS or equivalent to the DLC-2, malfunction diagnosis can be carried
out.
•Using a WDS or equivalent DTCs can be retrieved or erased, depending on the screen display, thus improving
serviceability.
Block diagram
.
Self-diagnostic function
Failure detection function
•The failure detection function detects malfunctions in the input/output signal systems of the 4WD CM and
displays them when the ignition key is at the ON position.
•When the ignition key is turned to the ON position, the 4WD CM system begins operation, and the 4WD
warning light illuminates for 3 seconds while the function checks for open circuits. At the same time the function
monitors the condition of the power supply voltage and checks for internal malfunctions.
•Then, once the system is running, the function checks the operating conditions of the 4WD solenoid and the
differential oil temperature sensor at regular intervals to determine whether there is any malfunction.
•If any malfunction is detected during these diagnostic tests, the warning light illuminates according to the
malfunction to alert the driver. Also, a DTC is output to DLC-2 via the CAN line. Also, at the same time the
failure detection result is sent to the memory and fail-safe functions.
9
87
5
4
3
10
13
11
12
6
12
A6E63222010
1 Input part
2 Regular control area
3 Output part
4 Fail-safe function
5 Failure detection function
6 Memory function
7 Failure display function8 External tester communication function
9 Failure diagnosis function
10 4WD warning light
11 DLC-2
12 CAN
13 WDS or equivalent

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–18
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E630201018204•The following additions have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
Rear wheel hub bolt
•Replacement procedure has been added.
Wheel hub, knuckle
•Removal/installation procedure has been added.
Joint shaft (MZR-CD (RF Turbo))
•Disassembly/assembly procedure has been added.
Joint shaft (4WD)
•Disassembly/assembly procedure has been added.
Front drive shaft (MZR-CD (RF Turbo))
•Disassembly/assembly procedure has been added.
Front drive shaft (4WD)
•Disassembly/assembly procedure has been added.
Rear drive shaft
•Inspection procedure has been added.
•Removal/installation procedure has been added.
•Disassembly/assembly procedure has been added.
Differential oil
•Inspection procedure has been added.
•Replacement procedure has been added.
Oil seal (side gear)
•Replacement procedure has been added.
Oil seal (companion flange)
•Replacement procedure has been added.
Rear differential
•Removal/installation procedure has been added.
•Disassembly procedure has been added.
•Assembly procedure has been added.
Differential oil temperature sensor
•Inspection procedure has been added.
•Removal/installation procedure has been added.
4WD solenoid
•Inspection procedure has been added.
Coupling component
•Removal/installation procedure has been added.
•Disassembly procedure has been added.
•Assembly procedure has been added.
On-board diagnostic
•Electronic 4WD control system have been added.
Troubleshooting
•Electronic 4WD control system have been added.
End Of Sie
OUTLINE

LOCATION INDEX
M–19
M
AXLE/DRIVE SHAFT LOCATION INDEXA6E630025500201
.
End Of Sie
LOCATION INDEX
5
4
3
1
2
A6J63002001
1 Wheel hub bolt
(See M–22 WHEEL HUB BOLT REPLACEMENT)
2 Wheel hub, knuckle
(See M–22 WHEEL HUB, KNUCKLE REMOVAL/
INSTALLATION)
3 Joint shaft
(See M–29 JOINT SHAFT (MZR-CD (RF Turbo))
DISASSEMBLY/ASSEMBLY)
(See M–31 JOINT SHAFT (4WD) DISASSEMBLY/
ASSEMBLY)4 Front drive shaft
(See M–34 FRONT DRIVE SHAFT (MZR-CD (RF
Turbo)) DISASSEMBLY/ASSEMBLY)
(See M–39 FRONT DRIVE SHAFT (4WD)
DISASSEMBLY/ASSEMBLY)
5 Rear drive shaft
(See M–42 REAR DRIVE SHAFT
PRE-INSPECTION)
(See M–43 REAR DRIVE SHAFT REMOVAL/
INSTALLATION)
(See M–45 REAR DRIVE SHAFT DISASSEMBLY/
ASSEMBLY)

M–20
LOCATION INDEX
REAR DIFFERENTIAL/ELECTRONIC 4WD CONTROL SYSTEM LOCATION INDEXA6E630027100201
.
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8
7
5
4
3
6
1
2
8
7
5
4
3
6
1
2
L.H.D.
R.H.D.
A6J63002002
1 Differential oil
(See M–48 DIFFERENTIAL OIL INSPECTION)
(See M–48 DIFFERENTIAL OIL REPLACEMENT)
2 Oil seal (side gear)
(See M–49 OIL SEAL (SIDE GEAR)
REPLACEMENT)
3 Oil seal (companion flange)
(See M–49 OIL SEAL (COMPANION FLANGE)
REPLACEMENT)
4 Rear differential
(See M–51 REAR DIFFERENTIAL REMOVAL/
INSTALLATION)
(See M–52 REAR DIFFERENTIAL DISASSEMBLY)
(See M–56 REAR DIFFERENTIAL ASSEMBLY)5 Differential oil temperature sensor
(See M–65 DIFFERENTIAL OIL TEMPERATURE
SENSOR INSPECTION)
(See M–65 DIFFERENTIAL OIL TEMPERATURE
SENSOR REMOVAL/INSTALLATION)
6 4WD solenoid
(See M–66 4WD SOLENOID INSPECTION)
7 4WD control module
(See M–66 4WD CONTROL MODURE
INSPECTION)
(See M–67 4WD CONTROL MODURE REMOVAL/
INSTALLATION)
8 Coupling component
(See M–68 COUPLING COMPONENT REMOVAL/
INSTALLATION)
(See M–69 COUPLING COMPONENT
DISASSEMBLY)
(See M–72 COUPLING COMPONENT
ASSEMBLY)

GENERAL PROCEDURES
M–21
M
PRECAUTION (FRONT AND REAR AXLE)A6E631001018201Wheel and Tire 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 Line Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid gets 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.
2. If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
Suspension Arm Removal/Installation
1. Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and
unloaded.
Note
•Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools
are in designated position.
Connector Disconnection
1. Disconnect the negative (-) battery cable before disconnecting connectors.
Electronic Control 4WD System Parts
1. After servicing the electronic control 4WD system parts, verify that no DTC has been stored. Clear any DTCs
remaining in the memory.
End Of Sie
GENERAL PROCEDURES

FRONT DRIVE SHAFT
M–31
M
JOINT SHAFT (4WD) DISASSEMBLY/ASSEMBLYA6E6315257002021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Joint Shaft Disassembly Note
1. Disassemble the joint shaft using the SST.
Bearing Disassembly Note
When the bearing remains on the bracket
1. Remove the bearing and the dust seals (both
differential side and wheel side) using the SSTs.
SST
SST
R
SST
RSST
R
GREASEGREASE
GREASEGREASE
4
1
3
52
A6J63152001
1 Joint shaft
(See M–31 Joint Shaft Disassembly Note)
(See M–33 Joint Shaft Assembly Note)
2 Bearing
(See M–31 Bearing Disassembly Note)
(See M–32 Bearing Assembly Note)3 Dust seal (Differential side)
(See M–32 Dust Seal (Differential Side) Assembly
Note)
4 Dust seal (Wheel side)
(See M–32 Dust Seal (Wheel Side) Assembly Note)
5Bracket
BAR
49 G030 370
A6E63152102
49 B014 001
49 W034 301
STEEL PLATE
A6E63152101

FRONT DRIVE SHAFT
M–39
M
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.
Clearance A
3.2 mm {0.13 in}
6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
•If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
•If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.
Clearance B
2.4—2.8 mm {0.095—0.110 in}
8. Verify that the boot band does not protrude from the boot band installation area.
•If it does, replace the boot band and repeat Steps 7 and 8.
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FRONT DRIVE SHAFT (4WD) DISASSEMBLY/ASSEMBLYA6E6315255002021. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
A6E0313W043
1 Boot band (wheel side)
(See M–35 Boot Band (Wheel Side) Disassembly
Note)
(See M–38 Boot Band (Wheel Side) Assembly
Note)
2 Boot band (transaxle side)
(See M–35 Boot Band (Transaxle Side)
Disassembly Note)
(See M–38 Boot Band (Transaxle Side) Assembly
Note)
3 Outer ring
(See M–40 Outer Ring Disassembly Note)
(See M–41 Outer Ring Assembly Note)
4 Snap ring
(See M–40 Snap Ring, Tripod Joint Disassembly
Note)
(See M–41 Tripod Joint, Snap Ring Assembly Note)5 Tripod joint
(See M–40 Snap Ring, Tripod Joint Disassembly
Note)
(See M–41 Tripod Joint, Snap Ring Assembly Note)
6 Free ring
7Boot
(See M–40 Boot Disassembly Note)
(See M–41 Boot Assembly Note)
8 ABS sensor rotor (with ABS)
(See M–36 ABS Sensor Rotor (With ABS)
Disassembly Note)
(See M–36 ABS Sensor Rotor (With ABS) Assembly
Note)
9 Shaft and ball joint component
10 Dynamic damper
(See M–41 Dynamic Damper Assembly Note)

REAR DIFFERENTIAL
M–51
M
REAR DIFFERENTIAL REMOVAL/INSTALLATIONA6E6319271002071. Drain the rear differential oil into a container.
2. Remove the after silencer, presilencer, and catalytic converter. (See F1–30 EXHAUST SYSTEM REMOVAL/
INSTALLATION.)
3. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove the rear drive shaft. (See M–43 REAR DRIVE SHAFT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Add the specified rear differential oil.
.
SEALANTSEALANT
5
3
12
6
86.2—116.6
{8.8—11.9,
63.6—85.9}
74.5—104.9
{7.6—10.6, 55.0—77.3}
43.1—60.8
{4.4—6.1,
31.8—44.8}
22.6—26.4
{2.4—2.6,
16.7—19.4}
4
N·m {kgf·m, ft·lbf}
A6E63192201
1 Differential oil temperature sensor connector
2 4WD solenoid connector
3 Coupling component and rear differential
component
(See M–52 Coupling Component and Rear
Differential Component Removal/installation Note)
4 Rear differential bracket 5 Coupling component
(See M–68 COUPLING COMPONENT REMOVAL/
INSTALLATION)
6 Rear differential

ELECTRONIC 4WD CONTROL SYSTEM
M–65
M
DIFFERENTIAL OIL TEMPERATURE SENSOR INSPECTIONA6E632227100209
Warning
•Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.
1. Disconnect the negative (-) battery cable.
2. Disconnect the differential oil temperature sensor connector and remove the differential oil temperature sensor.
3. Wrap the differential oil temperature sensor with
plastic wrap and immerse it into a beaker filled
with water. Gradually raise the water
temperature, and measure resistance between
differential oil temperature sensor terminals A and
B.
•If not as specified, inspect the harness for
continuity. If there is normal continuity
between the terminals, replace the differential
oil temperature sensor.
Specification
4. Install the differential oil temperature sensor and connect the connector.
5. Connect the negative (-) battery cable.
End Of Sie
DIFFERENTIAL OIL TEMPERATURE SENSOR REMOVAL/INSTALLATIONA6E632227100210
Warning
•Hot differential oil may cause severe burns. Do not perform maintenance while differential oil is
hot.
1. Disconnect the negative (-) battery cable.
2. Disconnect the differential oil temperature sensor connector.
3. Remove the differential oil temperature sensor.
4. Apply differential oil to the O-ring.
5. Install the differential oil temperature sensor.
Tightening torque
12.7—17.3 N·m {1.3—1.7 kgf·m, 9.4—12.7
ft·lbf}
6. Connect the differential oil temperature sensor
connector.
7. Connect the negative (-) battery cable.
End Of Sie
ELECTRONIC 4WD CONTROL SYSTEM
Water temperature (°C {°F}) Resistance (kirohm)
0 {32} 91—100
10 {50} 56—61
20 {68} 35—39
30 {86} 23—25
40 {104} 14—17
50 {122} 10—11
60 {140} 7.1—7.9
70 {158} 5.0—5.6
80 {176} 3.6—4.0
A B
A6J63222101
DIFFERENTIAL OIL
TEMPERATURE SENSOR
A6E63222102