oil temperature MAZDA 6 2002 Suplement Owner's Guide

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

M–20
LOCATION INDEX
REAR DIFFERENTIAL/ELECTRONIC 4WD CONTROL SYSTEM LOCATION INDEXA6E630027100201
.
End Of Sie
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)

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

REAR DIFFERENTIAL
M–53
M
Rear Cover Disassembly Note
1. Install the SSTs to the engine stand.
2. Install the rear differential to the SSTs.
3. Remove the rear cover using an oil seal cutter.
Bearing Cap Disassembly Note
1. Place alignment marks on the bearing cap and
carrier.
1 Differential oil temperature sensor
2 Rear cover
(See M–53 Rear Cover Disassembly Note)
3 Bearing cap
(See M–53 Bearing Cap Disassembly Note)
4 Rear differential component
(See M–54 Rear Differential Component
Disassembly Note)
5 Side bearing outer race
6 Adjusting shim
7Spacer
8 Locknut
(See M–54 Locknut Disassembly Note)
9 Drive pinion
(See M–54 Drive Pinion Disassembly Note)
10 Collapsible spacer
11 Bearing inner race (front bearing)12 Bearing inner race (rear bearing)
(See M–54 Bearing Inner Race (Rear Bearing)
Disassembly Note)
13 Spacer
14 Bearing outer race
(See M–55 Bearing Outer Race Disassembly Note)
15 Differential carrier
16 Ring gear
(See M–55 Ring Gear Disassembly Note)
17 Knock pin
18 Pinion shaft
19 Pinion gear
20 Side gear
21 Thrust washer
22 Side bearing inner race
(See M–55 Side Bearing Inner Race Disassembly
Note)
23 Oil seal
24 Gear case
49 L027 0A2
49 0107 680A
A6A63192009
49 L027 0A2
49 0107 680A
A6A63192010
MARK
A6E63192011

REAR DIFFERENTIAL
M–57
M
Side Bearing Inner Race Assembly Note
Caution
•Do not mix up the left and right side bearing inner races.
1. Press the side bearing inner races into the gear
case using the SSTs.
Thrust washer assembly note
1. Assemble the side gears, thrust washers and pinion gears to the gear case, then assemble the knock pin.
2. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.
3. Set a dial gauge to the pinion gear as indicated in
the figure.
4. Secure one of the side gears.
5. Move the pinion gear and measure the backlash
at the end of the pinion gear.
•If the backlash exceeds the standard, use the
thrust washers to adjust.
Standard backlash
0.1 mm {0.004 in} or less
Thrust washer thickness
mm {in}
17 Adjusting shim (L)
(See M–61 Adjusting Shim Assembly Note)
18 Spacer
19 Side bearing outer race
20 Rear differential component
21 Adjusting shim (R)22 Bearing cap
(See M–63 Bearing Cap Assembly Note)
23 Rear cover
(See M–64 Rear Cover Assembly Note)
24 Differential oil temperature sensor
25 Oil seal
(See M–64 Oil Seal Assembly Note)
49 F401 331
49 F401 337A
A6A63192020
Identification mark Thickness
F001 27 252 2.0 {0.079}
F001 27 253 2.1 {0.083}
F001 27 254 2.2 {0.086}
A6A63192021

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

M–66
ELECTRONIC 4WD CONTROL SYSTEM
4WD SOLENOID INSPECTIONA6E6322271002111. Disconnect the negative (-) battery cable.
2. Disconnect the 4WD solenoid connector.
3. Measure resistance between 4WD solenoid
connector terminals A and B.
•If the resistance is not within the specification,
replace the coupling unit.
Resistance
1.5—2.0 ohms
(Rear differential oil temperature at 20°C
{68°F})
4. Connect the 4WD solenoid connector.
5. Connect the negative (-) battery cable.
End Of Sie
4WD CONTROL MODURE INSPECTIONA6E632227100212
Note
•4WD CM terminal voltage can vary depending on measuring conditions and vehicle aging, resulting in
misdiagnosis. Therefore, it is necessary to perform an overall inspection of the input/output systems and
4WD CM to determine which part is malfunctioning.
•With the 4WD CM connector connected, measure voltage by connecting the voltmeter negative (-) lead to
the body ground and positive (+) lead to each 4WD CM terminal.
1. Measure voltage or resistance at each 4WD CM terminal using a voltmeter and an ohmmeter.
•If not as specified, replace the 4WD CM.
Terminal Voltage List (Reference)
A
B
A6J63222103
Terminal SignalInput/
outputConnected
toMeasuring
itemTest conditionVoltage (V)/
ContinuityInspection location
in case of failure
ADifferential oil
temperature
sensor signalInputDifferential oil
temperature
sensorVoltageIgnition
key
ONDifferential oil
temperature
20°C {68°F}3.0•Inspect
differential oil
temperature
sensor
•Inspect related
harness Differential oil
temperature
60°C {140°F}1.4
B——— ——— — —
CDifferential oil
temperature
sensor GND—Differential oil
temperature
sensorContinuity Any condition Yes•Inspect related
harness
D——— ——— — —
E——— ——— — —
F——— ——— — —
GCAN-HInput/
output—Perform measurement during DTC inspection.—
HCAN-LInput/
output—Perform measurement during DTC inspection.—
A
B C
D E
F G
H I
J K
L M
N O
P
A6J63222104

ON-BOARD DIAGNOSTIC
M–75
M
WIRING DIAGRAMA6E637027100201
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ON-BOARD DIAGNOSTIC
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