steering MAZDA 6 2002 Suplement Service Manual

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–6
DYNAMIC STABILITY CONTROL
OUTLINEA6E692067650201•The construction and operation of DSC is the same as that of the current Mazada6 2WD model, except for the
following:
— Due to the addition the 4WD model, DSC HU/CM uses the foward-G signal from the combine sensor to
control DSC.
—Due to adoption of the 4WD CM, DSC HU/CM sends a coupling torque request, a 4-wheel speed, and DSC
operation condition signal to the 4WD CM through CAN.
—Due to the adoption of TCM, DSC HU/CM sends a 4-wheel speed signal to the TCM through CAN.
Structural view
.
DYNAMIC STABILITY CONTROL
7
5
4
3
1
2
14
13
6
13
12
5
4
3
7
6
1011
9
14
8
8
15
A6E6920T004
1 L.H.D.
2 R.H.D.
3 DSC HU/CM
4 Wheel-speed sensor (front)
5 Sensor rotor (front)
6 Wheel-speed sensor (rear)
7 Sensor rotor (rear)
8 DSC OFF switch9 Instrument cluster
10 ABS warning light
11 DSC indicator light
12 DSC OFF light
13 Steering angle sensor
14 Combine sensor
15 Brake system warning light

DYNAMIC STABILITY CONTROL
P–7
P
Wiring Diagram
.
9
RF
FL
RR
RL
PCM
G
E
M
I
F
K
H
Q
NJ
P
S
T
V
O
Y
X
W
U
R
L
Z
AC
D
B
AG
AF
AE
AC
AA
AB
C
F
D
A
B
EDSC HU/CM
A
B
C
D
F
1
3
2
8
7
5
4
6
9
9
9
10
11
13
12
15
14
18
17
16
1920
2122
24
23
A6E6921W203
1 IG switch
2SUS 15A fuse
3 ABS 60 A fuse
4 Meter
5 ABS warning light
6 Brake system warning light
7 DSC OFF light
8 DSC indicator light
9CAN driver
10 Battery
11 Cruise actuator
12 DSC OFF switch13 DLC-2
14 CAN-H
15 CAN-L
16 Wheel-speed sensor
17 Combine sensor
18 Steering angle sensor
19 Brake switch
20 Brake light
21 Back-up light switch (MTX only)
22 Back-up light (MTX only)
23 Audio unit, Wiper and washer switch, Car-navigation
unit, Auto leveling control unit
24 TCM, 4WD CM

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

DYNAMIC STABILITY CONTROL
P–19
P
*: Used for vehicle manufacturing, not used for DSC.
Inspection Using An Oscilloscope (Reference)
Steering angle (steering angle signal 1 and 2)
•DSC HU/CM terminal:
Steering angle signal 2: W (+) — R (-)
Steering angle signal 1: X (+) — R (-)
•Oscilloscope setting:
1 V/DIV (Y), 25 ms/DIV (X), DC range
•Vehicle condition: Rotating steering wheel at one
revolution per second
Note
•As steering wheel rotation speed increases,
period of wave shortens.
•As for shape of steering angle signals 1 and
2, the phase is different.
Wheel speed
•DSC HU/CM terminal:
RF: M (+) — I (-)
RR: K (+) — H (-)
LF: F (+) — J (-)
LR: Q (+) — N (-)
•Oscilloscope setting:
1 V/DIV (Y), 2 ms/DIV (X), AC range
•Vehicle condition: Driving 30 km/h (18.6 mph)
Note
•As vehicle speed increases, period of wave
shortens.
•If there is malfunctioning in the sensor rotor,
wave profile warps.
ACAuto cruise set
signal outputAuto cruise unitWhen auto cruise is ON Below 1.0
•Inspect related harness
•Inspect DSC HU/CM
When auto cruise is OFF B+
AD—— — — —
AEVehicle speed
output•Audio unit
•Wiper and
washer
switch
•Car-navigatio
n unit
•Auto
leveling
control unit
•Cruise
actuatorVehicle is stopped 0
•Inspect related harness
•Inspect front wheel-speed
sensor •Inspect using the wave profile.
(See P–19 Inspection Using An
Oscilloscope (Reference))
AF CAN-L——No need to
check—
AG CAN-H——No need to
check—
AH—— — — — Terminal Signal Connected to Test condition Voltage (V) Action
0 V
A6E6921W014
0 V
A6E6921W013

P–22
ON-BOARD DIAGNOSTIC
PID/DATA Monitor Table
Note
•There is no change except for the PID marked with an asterisk *
C1730 Combine sensor (with DSC only)
C1949* Combine sensor (with DSC only)
C1950* Combine sensor (with DSC only)
C1951 Combine sensor (with DSC only)
C1952 Combine sensor (with DSC only)
C1953 Brake fluid pressure sensor (with DSC only)
C1954 Brake fluid pressure sensor (with DSC only)
C1955 Steering angle sensor (with DSC only)
C1956 Steering angle sensor (with DSC only)
C1957 Right front DSC switch solenoid valve (with DSC only)
C1958 Left front DSC switch solenoid valve (with DSC only)
C1959 Combine sensor (with DSC only)
U1900 CAN communication
U2021 Invalid/fault data received
U2511* CAN communication
U2516 CAN communicationDTC
Diagnosis system component
WDS or
equivalent
PID Name
(Definition)Unit/Condition Condition/Specification ActionABS (ABS/
TCS) HU/CM or
DSC HU/CM
terminal
RPM
(Engine speed signal input)RPM•Engine is stopped: 0 RPM
•Engine is running: Indicates
engine speedInspect PCM.—
TRANSGR
*
(with DSC only)
(Transaxle gear position)FN4A-EL:
R/N/D/S/L
JA5AX-EL:
R/N/D•Selector lever position is
displayed
—R: R
—N: N
—D: D
—S: SInspect PCM, TR
switch, or DSC HU/
CM.
—
TRAC_SW
(TCS OFF switch input)ON/OFF•TCS (DSC) OFF switch is
depressed: ON
•TCS (DSC) OFF switch is
released: OFFInspect TCS (DSC)
OFF switch.
AA
TC LVAL (with DSC only)
(Traction switch solenoid valve
(LF-RR))ON/OFF•Solenoid valve is activated:
ON
•Solenoid valve is
deactivated: OFFInternal fault of DSC
HU/CM. Replace DSC
HU/CM.—
TC RVAL (with DSC only)
(Traction switch solenoid valve
(RF-LR))ON/OFF•Solenoid valve is activated:
ON
•Solenoid valve is
deactivated: OFFInternal fault of DSC
HU/CM. Replace DSC
HU/CM.—
L_DSC O (with DSC only)
(Stability control solenoid
valve (LF-RR))ON/OFF•Solenoid valve is activated:
ON
•Solenoid valve is
deactivated: OFFInternal fault of DSC
HU/CM. Replace DSC
HU/CM.—
R_DSC O (with DSC only)
(Stability control solenoid
valve (RF-LR))ON/OFF•Solenoid valve is activated:
ON
•Solenoid valve is
deactivated: OFFInternal fault of DSC
HU/CM. Replace DSC
HU/CM.—
CCNTABS
(Number of continuous codes)—DTC is detected: 1—255
DTC is not detected: 0Perform inspection
using appropriate
DTC.—

P–24
ON-BOARD DIAGNOSTIC
ABSRF_I
(Right front ABS pressure
retention solenoid valve output
state)ON/OFF•During ABS control: ON/
OFF
(solenoid valve is activated/
deactivated)
•Not ABS control: OFF
(solenoid valve is
deactivated)Internal fault of ABS
(ABS/TCS) or DSC
HU/CM. Replace ABS
(ABS/TCS) or DSC
HU/CM.—
ABSLF_I
(Left front ABS pressure
retention solenoid valve output
state)ON/OFF•During ABS control: ON/
OFF
(solenoid valve is activated/
deactivated)
•Not ABS control: OFF
(solenoid valve is
deactivated)Internal fault of ABS
(ABS/TCS) or DSC
HU/CM. Replace ABS
(ABS/TCS) or DSC
HU/CM.—
ABSVLVRLY
(Fail-safe relay output state)ON/OFF•Fail-safe relay is
activated: ON
•Fail-safe relay is
deactivated: OFFInspect ABS (ABS/
TCS) or DSC HU/CM.
—
ABSPMPRLY
(Motor relay output state)ON/OFF•Motor relay is activated: ON
•Motor relay is deactivated:
OFFInspect ABS (ABS/
TCS) or DSC HU/CM.—
SWA POS (with DSC only)
(Steering angle sensor input)ANGLE•Steering wheel is in neutral
position: 0 DEG
•Steering wheel is turned to
left: Changes between
0 DEG and -1,638.40 DEG
•Steering wheel is turned to
right: Changes between
0 DEG and 1,638.35 DEGInspect steering angle
sensor.
R, U, W, X
LF_WSPD
(Left front wheel-speed sensor
input)SPEED•Vehicle is stopped: 0 KPH
{0 MPH}
•Vehicle is driving: Indicates
vehicle speedInspect wheel-speed
sensor/sensor rotor.ABS (ABS/
TCS): E, I
DSC: F, J
RF_WSPD
(Right front wheel-speed
sensor input)SPEED•Vehicle is stopped: 0 KPH
{0 MPH}
•Vehicle is driving: Indicates
vehicle speedInspect wheel-speed
sensor/sensor rotor.ABS (ABS/
TCS): D, G
DSC: I, M
LR_WSPD
(Left rear wheel-speed sensor
input)SPEED•Vehicle is stopped: 0 KPH
{0 MPH}
•Vehicle is driving: Indicates
vehicle speedInspect wheel-speed
sensor/sensor rotor.ABS (ABS/
TCS): C, F
DSC: N, Q
RR_WSPD
(Right rear wheel-speed
sensor input)SPEED•Vehicle is stopped: 0 KPH
{0 MPH}
•Vehicle is driving: Indicates
vehicle speedInspect wheel-speed
sensor/sensor rotor.ABS (ABS/
TCS): A, B
DSC: H, K
LAT ACC (with DSC only)
(Lateral-G sensor input)ACCELERATION•Vehicle is stopped or driving
straight: 0 G
•Cornering to left: Changes
between 0 G and 1.27 G
•Cornering to right: Changes
between 0 G and -1.28 GInspect ABS wheel-
speed sensor/sensor
rotor.
O
YAW_RATE (with DSC only)
(Yaw rate sensor input)ACCELERATION•Vehicle is stopped or driving
straight: 0 DG/S
•Cornering to left: Changes
between 0 DG/S and 127
DG/S
•Cornering to right: Changes
between 0 DG/S and -128
DG/SInspect combine
sensor.
T
MCYLI P (with DSC only)
(Brake fluid pressure sensor
input)PRESSURE•Brake pedal is released:
0 MPa
•Brake pedal is depressed:
Changes between 0 MPa
and 25.5 MPaInspect DSC HU/CM.
— PID Name
(Definition)Unit/Condition Condition/Specification ActionABS (ABS/
TCS) HU/CM or
DSC HU/CM
terminal

OUTLINE
R–3
R
SPECIFICATIONSA6E740201013203
*1: Engine coolant and engine oil are at specified level. Fuel is full. 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 following. 4SD and 5HB front: 402 mm {15.82 in} (reference
value) 4SD and 5HB rear: 401 mm {15.78 in} (reference value), WGN (2WD) front: 405 mm {15.94 in}
(reference value) WGN (2WD) rear: 407 mm {16.02 in} (reference value)
Bold frames: New specifications
End Of Sie
Item Specification
New Mazda6 Current
Mazda6
GG (4SD, 5HB) GY (WGN 2WD) GY (WGN 4WD) GG (4SD, 5HB)
Engine type LF, MZR-CD
(RF Turbo) L8, LF, L3,
MZR-CD (RF Turbo) L3 L8, LF, L3
Fr o nt
suspension Type High-mount double wishbone (with double-pivoted lower arm(s))
Spring type Coil spring
Shock absorber type
Cylindrical, double-acting
(Low-pressure gas charged with rebound spring)
Stabilizer Type Torsion bar
Diameter (mm {in}) 23 {0.91}
Wheel
alignment
(Unloaded)*
1
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 ′
Maximum
steering
angle inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
Caster
angle*
2
(reference
value) normal 3
°47 ′±1° 3°40 ′±1° 3°35 ′±1° 3°47 ′±1°
elevated*33 °42' ±1° 3°35 ′±1° —3 °42' ±1 °
Camber
angle*
2
(reference
value) normal –0
°17 ′±1° –0°15 ′±1° –0°08 ′±1° –0°17 ′±1°
elevated*3–0 °10' ±1° –0°08 ′±1° —–0 °10' ±1°
Steering
axis
inclination
(reference
value) normal 5
°28 ′ 5°24 ′ 5°16 ′ 5°28 ′
elevated
*35 °18' 5 °16 ′ —5 °18'
Rear
suspension Type E-type multi-link
Spring type Coil spring
Stabilizer
Type Torsion bar
Diameter (mm {in})
4SD: 19 {0.75}
5HB: 18 {0.71}18 {0.71} 21 {0.83}
4SD: 19 {0.75}
5HB: 18 {0.71}
Shock absorber type Cylindrical,
double-acting
(Low-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)/
(High-pressure
gas charged) Cylindrical,
double-acting
(High-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)
Wheel
alignment
(Unloaded)*
1
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 –1 °13 ′±1° –1°06 ′±1° –1°03 ′±1° –1°13 ′±1°
elevated
*3–1 °05 ′±1° –0°58 ′±1° —–1 °05 ′±1°
Thrust angle (degree) 0 °±0°48 ′