oil temperature MAZDA 6 2002 Suplement Service Manual

M–76
ON-BOARD DIAGNOSTIC
ELECTRONIC 4WD CONTROL SYSTEM ON-BOARD DIAGNOSISA6E637027100202Reading DTCs Procedure
1. Connect WDS or equivalent to the vehicle DLC-2
16-pin connector.
2. Retrieve DTC by WDS or equivalent.
•If a DTC is displayed, proceed with inspection
steps for that DTC.
3. After repair, clear DTCs stored in the 4WD CM by
referring to the Clearing DTCs Procedure.
Clearing DTCs Procedures
1. Connect WDS or equivalent to the vehicle DLC-2
16-pin connector.
2. Clear DTCs by WDS or equivalent.
3. Turn the ignition key to OFF.
4. Perform the DTC inspection again, and verify that
no DTC appears.
5. Disconnect the WDS or equivalent.
DTC Table
End Of Sie
DLC-2
DLC-2
L.H.D.
R.H.D.
A6E63702005
DLC-2
DLC-2
L.H.D.
R.H.D.
A6E63702005
DTC
Diagnosis system component Page
WDS or equivalent
P1887 System wiring (See M–77 DTC P1887)
P1888 Differential oil temperature sensor (See M–79 DTC P1888)
U0100 PCM communication (See M–80 DTC U0100)
U0101 TCM communication (See M–80 DTC U0101)
U0121 ABS/DSC communication (See M–80 DTC U0121)

ON-BOARD DIAGNOSTIC
M–79
M
DTC P1888A6E637027100204
Diagnostic procedure
DTC P1888 Differential oil temperature sensor
DETECTION
CONDITION•Differential oil temperature sensor voltage monitor circuit detects abnormal input voltage.
POSSIBLE
CAUSE•Open circuit, or short to battery or GND between 4WD CM terminal A and differential oil temperature
sensor terminal A
•Open circuit or short to battery between 4WD CM terminal C and differential oil temperature sensor
terminal B
•Differential oil temperature sensor malfunction
•4WD CM malfunction
•Poor connection of connectors (female terminals)
STEP INSPECTION ACTION
1INSPECT DIFFERENTIAL OIL
TEMPERATURE SENSOR CONDITION
•Turn ignition key to OFF.
•Disconnect differential oil temperature
sensor connector.
•Is it okay?Yes Go to next step.
No Replace differential oil temperature sensor, then go to Step
7.
2INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR OPEN
CIRCUIT
•Disconnect 4WD CM connector.
•Inspect for continuity between 4WD CM
terminal A and differential oil temperature
sensor terminal A.
•Is there continuity?Yes Go to next step.
No Repair or replace harness for open circuit between 4WD CM
and differential oil temperature sensor, then go to Step 7.
3INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
POWER
•Inspect voltage between 4WD CM terminal A
and ground.
•Is voltage B+?Yes Repair or replace harness for short to power between 4WD
CM and differential oil temperature sensor, then go to Step
7.
No Go to next step.
A B A
B C
D E
F G
H I
J K
L M
N O
PA
C A
B
4WD CM CONNECTOR4WD CM
DIFFERENTIAL OIL
TEMPERATURE SENSOR
DIFFERENTIAL OIL TEMPERATURE
SENSOR CONNECTOR

M–80
ON-BOARD DIAGNOSTIC
End Of Sie
DTC U0100A6E637027100205
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
End Of Sie
DTC U0101A6E637027100206
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
End Of Sie
DTC U0121A6E637027100207
Diagnostic Procedure
•Inspect according to the diagnostic procedure in Section T. (See T–39 MULTIPLEX COMMUNICATION
SYSTEM.)
End Of Sie
4INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
GROUND
•Inspect for continuity between 4WD CM
terminal A and ground.
•Is there continuity?Yes Repair or replace harness for short to ground between 4WD
CM and differential oil temperature sensor, then go to Step
7.
No Go to next step.
5INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR OPEN
CIRCUIT
•Inspect for continuity between 4WD CM
terminal C and differential oil temperature
sensor terminal B.
•Is there continuity?Yes Go to next step.
No Repair or replace harness for open circuit between 4WD CM
and differential oil temperature sensor, then go to Step 7.
6INSPECT 4WD CM TO DIFFERENTIAL OIL
TEMPERATURE SENSOR FOR SHORT TO
GROUND
•Inspect for continuity between 4WD CM
terminal C and ground.
•Is there continuity?Yes Repair or replace harness for short to ground between 4WD
CM and differential oil temperature sensor, then go to next
step.
No Replace 4WD CM, then go to next step.
7VERIFY TROUBLESHOOTING COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from memory.
(See M–76 Clearing DTCs Procedures)
•Drive vehicle.
•Is the same DTC present?Yes Replace 4WD CM, then go to next step.
No Go to next step.
8VERIFY AFTER REPAIR PROCEDURE
•Is there any other DTC present?Yes Go to applicable DTC inspection.
No Troubleshooting completed. STEP INSPECTION ACTION
DTC U0100 PCM communication
DETECTION
CONDITION•4WD CM detects that communication signals (throttle opening angle and engine speed signals) from
PCM are abnormal.
POSSIBLE
CAUSE•PCM signals have communication error.
DTC U0101 TCM communication
DETECTION
CONDITION•4WD CM detects that communication signals (selector lever position and gear position signals) from
TCM are abnormal.
POSSIBLE
CAUSE•TCM signals have communication error.
DTC U0121 ABS/DSC communication
DETECTION
CONDITION•4WD CM detects that communication signals (four-wheel speed, ABS/DSC operation condition, and
coupling torque request signals) from DSC HU/CM are abnormal.
POSSIBLE
CAUSE•DSC HU/CM signals have communication error.

TROUBLESHOOTING
M–81
M
SYSTEM WIRING DIAGRAMA6E638027100201
End Of Sie
TROUBLESHOOTING
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

M–82
TROUBLESHOOTING
FOREWORDA6E638027100202
End Of Sie
SYMPTOM TROUBLESHOOTINGA6E638027100203•Verify the symptoms, and perform troubleshooting according to the appropriate number.
End Of Sie
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

N–6
ENGINE SPEED SENSING POWER STEERING
POWER STEERING FLUID INSPECTIONA6E661432040201Fluid Level Inspection
1. Inspect the power steering fluid level.
•Add fluid to the specified level as necessary.
Fluid specification
ATF M-III or equivalent (e.g. Dexron
®II)
Fluid Leakage Inspection
Caution
•If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid
temperature will rise excessively and adversely affect the oil pump.
1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.
Note
•The points where fluid leakage may occur are indicated in the figure.
3. Inspect for fluid leakage.
•If fluid leakage is found, replace the related pipe or hose.
ENGINE SPEED SENSING POWER STEERING
L.H.D.
ATX
MTX
R.H.D.
ATX
MTX MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)L.H.D
R.H.D
A6E66142001

ENGINE SPEED SENSING POWER STEERING
N–7
N
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
2. Disconnect the pressure pipe from the oil pump,
and connect the SSTs.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
3. Bleed the air from the system.
4. Open the gauge valve fully.
5. Start the engine and turn the steering wheel fully
left and right to raise the fluid temperature to 50—
60 °C {122—140 °F}.
6. Close the gauge valve completely.
7. Increase the engine speed to 1,000—1,500 rpm
and measure the fluid pressure generated by the
oil pump.
•If the pressure is not within the specification,
repair or replace the oil pump component.
Caution
•If the valve is left closed for more than 5
seconds, the fluid temperature will rise
excessively and adversely affect the oil
pump.
Oil pump fluid pressure
(MPa {kgf/cm
2, psi})
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
49 1232 670B
49 H002 671
A6E0612W101
49 G032 351
49 G032 353
49 G032 352
49 G032 352
49 G032 351
49 G032 353
MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)
A6E66142002
THERMOMETER50—60
{122—140 }°
°F
GAUGE
CLOSE VALVE
COMPLETELY
A6E0612W081

N–8
ENGINE SPEED SENSING POWER STEERING
8. Open the gauge valve fully and increase the
engine speed to 1,000—1,500 rpm.
9. Turn the steering wheel fully to the left and right,
then measure the fluid pressure generated at the
gear housing.
•If the pressure is not within the specification,
repair or replace the steering gear
component.
Caution
•If the steering wheel is kept in the fully
turned position for more than 5 seconds,
the fluid temperature will rise excessively
and adversely affect the oil pump.
Gear housing fluid pressure
(MPa {kgf/cm
2, psi})
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.
Tightening torque
29.4—44.1 N·m {3.0—4.4 kgf·m, 22—32 ft·lbf}
11. Bleed the air from the system.
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STEERING GEAR AND LINKAGE (MZR-CD (RF TURBO)) REMOVAL/INSTALLATIONA6E661432960201
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.
L.H.D.
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.
Type Oil pump fluid pressure
2WD
(Except MZR-CD
(RF Turbo))10.80—11.29
{110.2—115.1, 1,567—1637}
MZR-CD
(RF Turbo)11.31—11.80
{115.4—120.3, 1,641—1,711}
4WD10.30—10.79
{105.1—110.0, 1,490—1,564}
THERMOMETER50—60
{122—140 }°
°F
GAUGE
OPEN VALVE
COMPLETELY
A6E0612W080

REAR SUSPENSION
R–13
R
REAR STABILIZER REMOVAL/INSTALLATION (4WD)A6E7416281002011. Remove the rear auto leveling sensor.
(See T–20 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the headlight zeroset.
.
Bolt (Differential Front Side) Removal Note
1. Disconnect differential oil temperature sensor connector and 4WD solenoid connector.
2. Support the differential with a jack as shown in
the figure.
3. Remove the bolt.
5
4
3
1
AA
2
6
GREASEGREASE
43.1—60.8
{4.40—6.19,
31.8—44.8}
74.5—104.9
{7.60—10.69, 54.95—77.37}
43.1—60.8
{4.40—6.19,
31.8—44.8}
RUBBER
GREASE
43.1—60.8
{4.40—6.19,
31.8—44.8}
N·m {kgf·m, ft·lbf} 75.5—94.5
{7.70—9.63, 55.7—69.6}
A6E74162007
1 Stabilizer control link
2 Coil spring component (One side only)
3 Stabilizer bracket
4 Bushing5 Bolt (Differential front side)
(See R–13 Bolt (Differential Front Side) Removal
Note)
(See R–14 Bolt (Differential Front Side) Installation
Note)
6 Rear stabilizer
JACK
A6E74162011

R–14
REAR SUSPENSION
Bolt (Differential Front Side) Installation Note
1. Support the differential with a jack, and then
install the bolt.
2. Connect differential oil temperature sensor
connector and 4WD solenoid connector.
End Of SieTRAILING LINK REMOVAL/INSTALLATION (4WD)A6E741628200201
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 in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the rear wheel alignment.
(See R–9 REAR WHEEL ALIGNMENT (WGN).)
JACK
A6E74162011