power steering MAZDA 6 2002 Suplement Owner's Guide

N–12
ENGINE SPEED SENSING POWER STEERING
R.H.D.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, inspect the toe-in.
.
End Of Sie
4
5
4
3
3
6
2
2SST
SST
R
R
R
1
8
74.4—104.8
{7.6—10.6,
54.9—77.2}18.6—26.5
{1.9—2.7,
13.8—19.5}
7.8—10.8
{0.8—1.1,
5.8—7.9}
33.0—44.1
{3.3—4.4,
21.7—32.5}
74.4—104.8
{7.6—10.6,
54.9—77.23} 33.0—44.1
{3.3—4.4,
21.7—32.5}
29.4—44.1
{3.0—4.4,
21.7—32.5}
7
R
R
A6E66142004
1 Bolt (intermediate shaft)
(See N–10 Bolt (intermediate shaft) removal note)
(See N–11 Bolt (intermediate shaft) installation
note)
2 Cotter pin
3Nut
4 Tie-rod end ball joint
(See N–10 Tie-rod end ball joint removal note)5 Pressure pipe
6 Return hose
7 Return pipe
8 Steering gear and linkage
(See N–11 Steering gear and linkage installation
note)

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.

N–14
ENGINE SPEED SENSING POWER STEERING
9
6
88
5
4
4
3
36
22
10
SST
SST7
SST
R
R
R
R
R
R
R
R1
5
B
A
A
B
BC
E
E
DC
C
D
E
10
6
74.4—104.8
{7.6—10.6, 54.9—77.2}
7.8—10.8
{0.8—1.1,
5.8—7.9}
7.8—10.8
{0.8—1.1,
5.8—7.9}
29.4—44.1
{3.0—4.4,
21.7—32.5}74.4—104.8
{7.6—10.6,
54.9—77.2}18.6—26.5
{1.9—2.7,
13.8—19.5}
7.8—10.8
{0.8—1.1,
5.8—7.9}
33.0—44.1
{3.4—4.4,
24.4—32.5}
74.4—104.8
{7.6—10.6,
54.9—77.2} 33.0—44.1
{3.4—4.4,
24.4—32.5}
93.1—116.6
{9.5—11.8,
68.7—85.9}
93.1—131.3
{9.5—13.3,
68.7—96.8}119.6—154.8
{9.5—15.7,
68.7—114.1}119.6—154.8
{9.5—15.7,
68.7—114.1}93.1—131.3
{9.5—13.3,
68.7—96.8} 29.4—44.1
{3.0—4.4,
21.7—32.5}L.H.D
R.H.D
N·m {kgf·m, ft·lbf}
11
A6E66142005

ENGINE SPEED SENSING POWER STEERING
N–15
N
.
No.1 Engine Mount Center Bolt Removal Note
1. Suspend the engine using the SST.
2. Remove the No.1 engine mount center bolt.
End Of Sie
1 Bolt (intermediate shaft)
(See N–10 Bolt (intermediate shaft) removal note)
(See N–11 Bolt (intermediate shaft) installation
note)
2 Cotter pin
3 Nut (tie-rod end ball joint)
4 Tie-rod end ball joint
(See N–10 Tie-rod end ball joint removal note)
5 Pressure pipe
6 Return hose7 No.1 engine mount center bolt
(See N–15 No.1 Engine Mount Center Bolt Removal
Note)
8 Crossmember bracket
(See N–11 Crossmember bracket removal note)
9 Crossmember component, steering gear and
linkage
(See N–11 Crossmember component, steering gear
and linkage removal note)
10 Steering gear and linkage
(See N–11 Steering gear and linkage installation
note)
49 E017 5A0
A6E7414W016

N–16
ENGINE SPEED SENSING POWER STEERING
POWER STEERING OIL PUMP (MZR-CD (RF TURBO)) REMOVAL/INSTALLATIONA6E6614326502011. Remove the air cleaner.
2. Remove the battery and battery tray.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
.
End Of Sie
OILOILR
R
R
4
3
1
229.4—44.1
{3.00—4.49, 21.7—32.5} 18.6—25.5
{1.90—2.60,
13.8—18.8}
N·m {kgf·m, ft·lbf}
A6E66142006
1 Pressure pipe
2 Return hose3 Power steering oil pump
4 O-ring

ENGINE SPEED SENSING POWER STEERING
N–17
N
POWER STEERING OIL PUMP (MZR-CD (RF TURBO)) DISASSEMBLY/ASSEMBLYA6E661432650202
Note
•The following procedure is for replacement of the O-ring and oil seal only. Replace the pump component if
other repairs are necessary.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
9
8
7
5
4
3
10
6
1
2
15
16
14
13
11
12
SST
R
ATFTF
22—26
{2.3—2.6, 17—19}
N·m {kgf·m, ft·lbf}
R
ATFTF
R
R
ATFTF
ATFTF
ATFTF
R
31.1—47.0
{3.18—4.79, 23.0—34.6}
31.1—47.0
{3.18—4.79, 23.0—34.6}
A6E66142007
1 Power steering oil pump component
(See N–18 Power Steering Oil Pump Component
Disassembly Note)
2Clip
(See N–18 Clip Disassembly Note)
(See N–19 Clip Assembly Note)
3 Reservoir tank4 O-ring
5Joint
6 Connector
7 O-ring
8 Control valve
9Spring

N–18
ENGINE SPEED SENSING POWER STEERING
Power Steering Oil Pump Component Disassembly Note
1. Secure the power pressure oil pump using the SST.
Caution
•Use the SST to prevent damage to the
pump when securing it in a vise.
Clip Disassembly Note
1. Lift up the clip tab using a flathead screwdriver.
2. Remove the clip by pushing it with a flathead
screwdriver and a hammer as shown in the figure.
Vane Assembly Note
1. Place the vanes in the rotor with the rounded
edges contacting the cam.
10 Rear pump body
(See N–19 Rear Pump Body Assembly Note)
11 Gasket
12 Cam ring
(See N–19 Cam Ring Assembly Note)13 Rotor
14 Vane
(See N–18 Vane Assembly Note)
15 Side plate
16 Power steering oil pump
49 F032 301
A6E66142010
CLIP
R
A6E66142008
A6E6316W013

ENGINE SPEED SENSING POWER STEERING
N–19
N
Cam Ring Assembly Note
1. Install the cam ring in the front pump body with
the mark facing upward.
Rear Pump Body Assembly Note
1. After installing the rear body, manually turn the shaft to verify that it rotates smoothly.
Clip Assembly Note
1. Push the clip slowly in the direction shown in the
figure.
2. Confirm that the clip tab is securely fastened.
End Of Sie
A6E6316W014
CLIP
R
A6E66142009

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

TD–6
TECHNICAL DATA
FRONT AND REAR AXLEA6E931001018201
End Of Sie
STEERING SYSTEMA6E931001034201
End Of Sie
Item Specification
FRONT DRIVE SHAFT
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left sideMZR-CD (RF Turbo): 666.1—676.1 {26.23—26.61}
4WD: 667—677 {26.26—26.65}
Right sideMZR-CD (RF Turbo): 615.9—625.9 {24.25—24.64}
4WD: 631—641 {24.85—25.23}
REAR DRIVE SHAFT (4WD)
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left side 805.4—815.4 {31.71—32.10}
Right side 852.4—862.4 {33.56—33.95}
REAR DIFFERENTIAL (4WD)
Pinion height (mm {in})–0.025—0.025 {–0.001—0.001}
Backlash of side gear and differential pinion (mm {in}) 0.1 {0.004} or less
Drive pinion preload (N·m kgf·cm, in·lbf) 1.3—1.8 {13.3—18.3, 11.5—15.9}
Backlash of drive pinion and
ring gear(mm {in})Standard 0.09—0.11 {0.0036—0.0043}
Minimum 0.05 {0.002}
Differential oilGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Capacity
(Approximate quantity)(L {US qt, lmp qt}) 1.00 {1.06, 0.88}
ELECTRONIC 4WD CONTROL SYSTEM
Differential oil temperature
sensor(kilohm)0°C {32°F} 91—100
10°C {50°F} 56—61
20°C {68°F} 35—39
30°C {86°F} 23—25
40°C {104°F} 14—17
50°C {122°F} 10—11
60°C {140°F} 7.1—7.9
70°C {158°F} 5.0—5.6
80°C {176°F} 3.6—4.0
4WD solenoid
(Rear differential oil temperature
at 20°C {68°F})(ohm) 1.5—2.0
Item Specification
ENGINE SPEED SENSING POWER STEERING
Power
steering oil
pumpOil pump fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Gear housing fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Power
steering
systemFluid type
ATF M-
III or equivalent (e.g. Dexron®II)
Capacity (Approximate quantity) MTX (Except MZR-CD (RF Turbo)): 0.80 {0.85, 0.70}
ATX (Except 4WD): 0.87 {0.92, 0.77}
MZR-CD (RF Turbo): 0.86 {0.91, 0.76}
4WD: 0.89 {0.94, 0.78} (L {US qt, Imp qt})