tires MAZDA 6 2002 Suplement User Guide

TROUBLESHOOTING
K2–189
K2
Diagnostic procedure
End Of SieNO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED
A6E578001030206
End Of SieNO.4 EXCESSIVE CREEPA6E578001030207
End Of SieNO.5 NO CREEP AT ALLA6E578001030208
STEP INSPECTION ACTION
1•Does vehicle creep when selector lever
moved slightly in N position?Yes•Overhaul control valve body and repair or replace any
defective parts.
(See ATX Workshop Manual.)
—If problem remains, replace or overhaul transaxle and
repair or replace any defective parts.
(See K2–99 AUTOMATIC TRANSAXLE AND
TRANSFER REMOVAL/INSTALLATION.)
(See ATX Workshop Manual.)
No Inspect and adjust selector lever.
(See K2–117 SELECTOR LEVER INSPECTION.)
(See K2–118 SELECTOR CABLE ADJUSTMENT.)
2•Verify test results.
—If okay, return to diagnostic index to service any additional symptoms.
—If malfunction remains, inspect related Service Informations and perform repair or diagnosis.
—If vehicle repaired, troubleshooting completed.
—If vehicle not repaired or additional diagnostic information not available, replace TCM.
3 Vehicle moves in P position, or parking gear does not disengage when P is disengaged
DESCRIPTION•Vehicle rolls when on a downward slope and tires do not lock in P position.
•Tires locked when P disengaged, vehicle does not move in D range, and R position when accelerator
pedal depressed, and engine remains in stall condition.
POSSIBLE
CAUSE•Malfunction of parking mechanism (May have effect on noise or shock from transaxle)
•Improper adjustment of selector lever
•If vehicle moves in N position, perform symptom troubleshooting No.2 “Vehicle moves in N position”
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
4 Excessive creep
DESCRIPTION•Vehicle accelerates in D range, and R position without depressing accelerator pedal.
POSSIBLE
CAUSE•Engine idle speed high (transaxle system is not cause of problem)
•Go to symptom troubleshooting No.9 “Fast idle/runs on”
(See Section F.)
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
5 No creep at all
DESCRIPTION•Vehicle does not move in D range, or R position when idling on flat paved road.
POSSIBLE
CAUSE•Either engine output low or there is clutch circuit slippage.
—Clutch burned
•Line pressure low
•Malfunction of shift solenoid A, B, or C
•Malfunction of body ground
•Malfunction of control valve body
—Transaxle fixed in 4GR (Operation of fail-safe function)
•Short or open circuit in wiring
•Poor connection of connector
•Electronic parts of output and input system malfunctioning
—Engine torque is not start
•Malfunction of torque converter
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.

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.
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GENERAL PROCEDURES

M–82
TROUBLESHOOTING
FOREWORDA6E638027100202
End Of Sie
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.

P–8
DYNAMIC STABILITY CONTROL
End Of SieCOMBINE SENSOR (FORWARD-G SENSOR)A6E692067650202Function
•The forward-G sensor is integrated with the combine sensor to detect and calculate the vehicle forward-G force
and change in voltage to the DSC HU/CM.
Structure/Operation
•The drive train of 4WD vehicles delivers driving force to all four wheels, and due to this interlocking, the speed
of all wheels during braking is the same. When driving on road surfaces with especially low m (friction
coefficient), it is difficult to estimate the vehicle speed based on the wheel speed, and DSC braking becomes
unreliable. (For 2WD vehicles, the front and rear wheels are independent, so it is possible to accurately
estimate the vehicle speed by measuring the difference between the rotation speeds of the front and rear tires.)
A forward-G sensor has been installed to overcome this situation. When braking, the change in G-force is
detected, and the road surface m is judged (low m, high m), enabling a correction of the vehicle speed
estimation.
•The output voltage characteristic for the combine sensor is 2.5 V when the vehicle is standing still, and
changes accordingly as forward-G is formed.
•Forward-G is formed when the sensor detects an inertial force created by, and in proportion to, a G- force
acting on a silicon detection component.
.
End Of Sie
CONTROLLER AREA NETWORK (CAN)A6E692067650203•ABS (ABS/TCS) or DSC HU/CM transmit/receive information through CAN. Due to the addition of TCM, 4WD
CM, and the MZR-CD (RF Turbo) engine model, the following information has been changed. For detailed
information on CAN, see the “CONTROLLER AREA NETWORK.” (See T–3 OUTLINE.)
Transmitted Information
•Coupling torque request (to 4WD CM)
•DSC operating condition (to 4WD CM)
Received Information
•Coupling torque (from 4WD CM)
•Shift position (from TCM)
•Fuel injection information (only MZR-CD (RF Turbo), from PCM)
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(V)
2.5
-14.70
+14.7(m/s
2)
45
3
6
2
1
A6E6920W201
1 External view
2 Front of vehicle
3 Output voltage characteristic4 Deceleration
5 Forward-G
6 Acceleration

P–10
OUTLINE , GENERAL PROCEDURES
SUPPLEMENTAL SERVICE INFORMATIONA6E690201020205•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
Power brake unit
•Removal/installation procedure has been modified.
Vacuum switch (MZR-CD (RF Turbo))
•Inspection procedure has been added.
•Removal/installation procedure has been added.
Vacuum pump (MZR-CD (RF Turbo))
•Inspection procedure has been added.
•Removal/installation procedure has been added.
Front brake (disc)
•Inspection procedure has been modified.
•Removal/installation procedure has been modified.
Disc pad (front)
•Replacement procedure has been modified.
Parking brake (lever type)
•Adjustment procedure has been modified.
DSC HU/CM
•Inspection procedure has been modified.
Combine sensor (Forward-G sensor)
•Inspection procedure has been modified.
On-board diagnostic (ABS/TCS)
•4WD and MZR-CD (RF Turbo) have been added.
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PRECAUTION (BRAKES)A6E691001020201Wheels and Tires 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 Lines Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid does get 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.
•If any brake line has been disconnected anytime during the procedure, add brake fluid, bleed the brakes,
and inspect for leakage after the procedure has been completed.
Connectors Disconnection
1. Disconnect the negative battery cable before doing any work that requires handling of connectors. Reconnect
the negative battery cable only after the work is completed.
ABS, ABS/TCS, or DSC Components Operations
1. Make sure that there are no DTCs in the ABS, ABS/TCS, or DSC memory after working on ABS, ABS/TCS or
DSC components.
•If there are any DTCs in the memory, clear them.
End Of Sie
OUTLINE
GENERAL PROCEDURES

WHEEL ALIGNMENT
R–9
R
Total Toe-in Adjustment
1. Center the steering wheel and confirm that the vehicle wheels/tires are pointing straight.
2. Loosen the left and right tie-rod end locknuts and turn the tie-rods equally. Both tie rods are right threaded, so
turning the right tie-rod toward the front of the vehicle and the left toward the rear increases toe-in.
Note
•Turning both tie-rods one complete turn changes toe-in by about 6 mm {0.24 in} (0°36').
3. Tighten the tie-rod end locknuts to the specified torque.
Tightening torque
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
4. Verify that the boot is not twisted, and install the boot clamp.
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REAR WHEEL ALIGNMENT (WGN)A6E741201016201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.*3: Distance between wheel center and fender brim is 407 mm {16.02 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.
Note
•Adjust the toe-in after adjusting the camber.
Camber Adjustment
1. Loosen the cam nut on the lower arm.
2. Turn the adjusting cam bolt to provide the correct
camber angles as indicated.
3. Tighten the cam nut.
Tightening torque
86.2—116.6 N·m {8.80—11.88 kgf·m, 63.58—
85.99 ft·lbf}
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle
*2 normal–0°59′±1°–1°00′±1°–1°02′±1°–1°04′±1°–1°06′±1°
elevated
*3–0°52′±1°–0°53′±1°–0°55′±1°–0°56′±1°–0°58′±1°
Thrust angle 0°±0°48′
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle*
2 –0°55′±1°–0°57′±1°–0°59′±1°–1°01′±1°–1°03′±1°
Thrust angle (degree) 0°±0°48′
Left wheel Right wheel
Positive direction ClockwiseCounter-
clockwise
Negative directionCounter-
clockwiseClockwise
LEFT SIDE
(VIEW FROM
FRONT OF THE
VEHICLE)
ADJUSTING
CAM BOLT
A6E7412W003

AIR BAG SYSTEM
T–37
T
Curtain air bag module (WGN)
1. Remove the curtain air bag module. (See T–35 CURTAIN AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Secure the curtain air bag module in a vise, and
cut off the deployment section, as shown in the
figure.
Warning
•Be sure not to collapse the pipe on the
side where it is cut. If it is collapsed, the
interior pressure of the pipe will build up
and can cause it to explode during air
bag module deployment.
3. Connect the SST (Adapter harness) to the curtain
air bag module as shown in the figure.
4. Tie the side air bag module to the tire with the
module facing the center of the tire. Wrap the wire
harness through the tire and around the bracket
at least four times.
Warning
•If the air bag module is not properly
installed to the tire, serious injury may
occur when the module is deployed.
When installing the air bag module to the
tire, make sure the module is facing the
downward.
5. Stack the tire with the curtain air bag module on
top of two tires. Stack a tire on top of three tires.
Stack another tire that has a wheel on top of the
four tires.
CUT
CURTAIN AIR BAG MODULE400 mm {15.7 in} OR MORE
A6E8130W013
49 L066 002
CURTAIN AIR BAG
MODULE
A6E8130W040
WIRE HARNESS
CURTAIN
AIR BAG
MODULE
TIRE
A6E8130W018
TIRE
WITH
WHEEL
TIRE WITH
CURTAIN AIR
BAG MODULETIRE
A6E8130W020

T–38
AIR BAG SYSTEM
6. Tie all tires together with wire.
7. Connect the SST (Deployment tool) to the SST
(Adapter harness).
8. Connect the red clip of the SST (Deployment tool)
to the positive battery terminal and the black clip
to the negative battery terminal.
9. Verify that the red light on the SST (Deployment
tool) is illuminated.
10. Make sure all persons are standing at least 6 m
{20 ft} from the vehicle.
11. Press the activation switch on the SST
(Deployment tool) to deploy the curtain air bag
module.
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A6E8130W034
49 H066 002
49 L066 002
A6E8130W155
49 H066 002
ACTIVATION
SWITCH
A6E8130W028