MAZDA 6 2002 Workshop Manual Suplement

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

ON-BOARD DIAGNOSTIC
P–9
P
OUTLINEA6E697043000201•The operation of the on-board diagnostic system for ABS (ABS/TCS) or DSC is the same as that of the current
Mazda6 (GG) L8, LF, L3 engine 2WD model, except for the following. (See Mazda6 Training Manual
3359-1*-02C.)
— Due to the addition of the 4WD model, DTCs and PID data monitor has been added.
—Due to the addition of the MZR-CD (RF Turbo) engine model, the DTC C1119 fail-safe function and the
detection condition have been changed.
Fail-safe Function
Fail-safe function table
*1: When engine speed signal through CAN is out of specification, the light illuminates.*2: When engine speed signal through CAN is out of specification, the system is suspended.*3: When engine speed signal value through CAN is invalid, only brake TCS is available.*4: When fuel injection information through CAN is out of specification or invalid, only brake TCS is available.*5: When engine speed signal value through CAN is invalid, only brake DSC is available.*6: When the engine control system has a malfunction, only brake DSC is available.
PID/DATA Monitor Table
End Of Sie
ON-BOARD DIAGNOSTIC
Malfunc-
tion
locationDTC Fail-safe function
WDS
or
equiva-
lentWarning light illumination condition Control condition
ABS
warning
lightBRAKE
system
warning
light
(when
parking
brake is
released)DSC
(TCS)
OFF lightDSC
(TCS)
indicator
light ABS
controlEBD
controlTCS
controlDSC
controlBrake
assist
control
PCM and/
or engine
speed
signal lineC1119Not
Illuminated Not
Illuminated Not
Illuminated
*1Illuminated Available AvailableAvailable*2, *3, *4Available*2, *5, *6Available
Combine
sensor
(forward-
G) lineC1949
Illuminated Not
Illuminated Illuminated IlluminatedNot
availableAvailable—Not
availableNot
available
C1950
CAN line U2511Not
Illuminated Not
Illuminated Not
Illuminated Illuminated Available Available—Available Available
PID name input/output part Operation/unit
ACCLMTR Accelerometer 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.
End Of Sie
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

CONVENTIONAL BRAKE SYSTEM
P–11
P
POWER BRAKE UNIT REMOVAL/INSTALLATIONA6E6912438002011. Remove the master cylinder.
2. Remove the wiper arm.
3. Remove the cowl grille.
4. Remove the wiper motor.
5. Remove the cowl panel.
6. For L.H.D. and R.H.D. (MZR-CD (RF Turbo) only), remove the A/C bracket.
7. For L.H.D., remove the ABS (ABS/TCS) HU/CM or DSC HU/CM.
8. For R.H.D. (except MZR-CD (RF Turbo)), remove the alternator cover.
9. For R.H.D. (except MZR-CD (RF Turbo)), remove the insulator.
10. For R.H.D. (except MZR-CD (RF Turbo)), remove the vacuum pipe bracket.
11. Remove in the order indicated in the table.
12. Install in the reverse order of removal.
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VACUUM SWITCH INSPECTION (MZR-CD (RF TURBO))A6E6912663902011. Remove the vacuum hose from the power brake unit.
2. Set the vacuum pump (any commercially
available model) onto the power brake unit as
shown.
3. Turn the ignition switch to ON.
4. Release the parking brake.
5. Apply vacuum to the power brake unit using the
vacuum pump (any commercially available
model) and verify the operating condition of the
brake warning light. The vacuum switch is
functioning normally if it corresponds to the above
specifications.
•If not as specified, replace the vacuum switch.
End Of Sie
CONVENTIONAL BRAKE SYSTEM
1 Vacuum hose
2 Snap pin
3Clevis pin
4Nut
5Fork
6 Power brake unit
7Gasket
8Nut
GREASEGREASE
R
3
4
8
6
2
7
5
1
18.6—25.5
{1.90—2.60, 13.8—18.8}
N·m {kgf·m, ft·lbf}
15.7—21.6
{1.60—2.20,
11.6—15.9}
A6E6912W044
Vacuum
kPa {mm Hg, inHg}Brake warning light
Below 10.7±2.7
{80±20, 3.1±0.8}ON
Above 10.7±2.7
{80±20, 3.1±0.8}OFFA6E6912W204

P–12
CONVENTIONAL BRAKE SYSTEM
VACUUM SWITCH REMOVAL/INSTALLATION (MZR-CD (RF TURBO))A6E6912663902021. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Vacuum Switch Installation Note Caution• Do not apply sealant to the lip of the vacuum switch as it may cause a malfunction to occur.
1. Apply sealant to the new vacuum switch in the area shown in the figure.
End Of Sie
VACUUM PUMP INSPECTION (MZR-CD (RF TURBO))A6E6912187772011. Warn up the engine.
2. Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in
the figure, then check the vacuum.• If the pressure is less than the specification,
inspect for the following.
— Malfunction of the vacuum pump
— Shortage of the lubrication oil pressure
Vacuum specification (In 8 seconds) Engine speed 1,270 rpm: 66.6 kPa {500 mmHg, 19.7 inHg} or more
Engine speed 2,450 rpm: 93.3 kPa {700 mmHg, 27.6 inHg} or more
End Of Sie
1 Connector
2 Vacuum switch (See P –12 Vacu um S w itch Ins tal lat ion Note )
SEALANT
1
219.6—24.5
{2.00—2.49,
14.5—18.0}
N·m {kgf·m, ft·lbf}
A6E6912W205
SEALANT
DO NOT APPLY
SEALANT ON
THIS AREA
A6E6912W206
AME6912W006

CONVENTIONAL BRAKE SYSTEM
P–13
P
VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF TURBO))A6E6912187772021. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Vacuum Pump Installation Note
1. Be careful the O-ring is not pinched when installing the vacuum pump.
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FRONT BRAKE (DISC) INSPECTIONA6E691233980201Disc Plate Thickness Inspection
Caution
•Excessive runout may result if the disc plate is removed from the vehicle then machined. Machine
the disc plate while installed on the vehicle.
1. Measure the thickness of the disc plate.
•If the thickness is not within the specification, replace the disc plate.
Minimum
L8, LF (GCC specs.):
22 mm {0.87 in}
LF (European (L.H.D. U.K.) specs.),
L3, MZR-CD (RF Turbo):
23 mm {0.91 in}
Minimum thickness after machining using a brake lathe on-vehicle
L8, LF (GCC specs.):
22.8 mm {0.90 in}
LF (European (L.H.D. U.K.) specs.),
L3, MZR-CD (RF Turbo):
23.8 mm {0.94 in}
End Of Sie
1 Vacuum hose
2Bolt
3 Vacuum pump
(See P–13 Vacuum Pump Installation Note)
4 O-ring
4
3
1
B
B
A
A
2
N·m {kgf·cm, in·lbf} 18.6—25.5
{1.90—2.60,
13.8—18.8}
R
A6E6912W207

P–14
CONVENTIONAL BRAKE SYSTEM
FRONT BRAKE (DISC) REMOVAL/INSTALLATIONA6E6912339802021. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
.
9
8
7
5
5
4
3
1
2
6
6
SST
SST
R
RUBBER GREASE 21.6—29.4
{2.21—3.00,
16.0—21.6} 78.4—101.9
{8.00—10.3, 57.9—75.1}
GREASEGREASE
GREASEGREASE
GREASEGREASE
9.8—14.7 N·m
{100—149 kgf·cm,
87—129 in·lbf}7
N·m {kgf·m, ft·lbf} L8, LF (GCC SPECS.):
44.1—49.0 {4.47—4.99, 32.4—36.1}
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO):
49.0—53.9 {5.00—5.49, 36.2—39.7}
L8, LF (GCC SPECS.)
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO)
A6E6912W201
1 Flexible hose
2Cap
3 Guide pin
4 Caliper
5 M-spring 6Disc pad
(See P–15 Disc Pad Installation Note)
7 Guide plate
8 Mounting support
9 Disc plate
(See P–15 Disc Plate Removal Note)
(See P–15 Disc Plate Installation Note)

CONVENTIONAL BRAKE SYSTEM
P–15
P
Disc Plate Removal Note
1. Mark the wheel hub bolt and disc plate before
removal for reference during installation.
Disc Plate Installation Note
1. Remove any rust or grime on the contact face of the disc plate and wheel hub.
2. Install the disc plate and align the marks made before removal.
Disc Pad Installation Note
1. Push the piston fully inward using the SST.
2. Install the disc pad.
End Of Sie
MARK
A6E6912W037
49 0221 600C
A6E6912W038

P–16
CONVENTIONAL BRAKE SYSTEM
DISC PAD (FRONT) REPLACEMENTA6E6912336302011. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
.
End Of Sie
7
7
5
54
3
1
2
6
SST
6
SST
GREASEGREASE
18.5—25.5
{1.89—2.60,
13.7—18.8}
L8, LF (GCC SPECS.)
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO) L8, LF (GCC SPECS.):
44.1—49.0 {4.47—4.99, 32.4—36.1}
LF (EUROPEAN (L.H.D. U.K.) SPECS.),
L3, MZR-CD (RF TURBO)):
49.0—53.9 {5.00—5.49, 36.2—39.7}
RUBBER GREASE18.5—25.5
{1.89—2.60,
13.7—18.8}
N·m {kgf·m, ft·lbf}
A6E6912W203
1Bolt
2Bolt
3Cap
4 Guide pin5M-spring
6Disc pad
(See P–15 Disc Pad Installation Note)
7 Guide plate

PARKING BRAKE SYSTEM, DYNAMIC STABILITY CONTROL
P–17
P
PARKING BRAKE (LEVER TYPE) ADJUSTMENTA6E6914440002011. Start the engine and depress the brake pedal several times.
2. Stop the engine.
3. For the 2WD model, remove the rear ashtray case behind the center console
4. For the 4WD model, remove the 4 screws (back side) and pull up the rear of the center console, then remove
the rear ashtray case.
5. Turn the adjusting nut as shown in the figure.
6. After adjustment, inspect the following points:
(1) Turn the ignition switch to ON, pull the parking
brake lever one notch, and verify that the
parking brake warning light illuminates.
(2) Verify that the rear brakes do not drag.
End Of Sie
DSC HU/CM INSPECTIONA6E6920676502041. Remove the battery and battery bracket.
2. Disconnect the DSC HU/CM connector.
3. Connect the SST (49 G066 004) to the DSC HU/CM connector and harness side connector.
4. Inspect voltage referring the table below.
Terminal Voltage Table (reference value)
(Ignition switch is at ON, and connector is connected unless indicated otherwise)
PARKING BRAKE SYSTEM
A6E6914W002
DYNAMIC STABILITY CONTROL
Terminal Signal Connected to Test condition Voltage (V) Action
A Ground (1) Ground part 1—Below 1.0•Inspect related harness
B Ground (2) Ground part 2—Below 1.0•Inspect related harness
CSolenoid valve
(power supply)Battery—B+•Inspect DSC HU/CM
•Inspect related harness
DPump motor
(power supply)Battery—B+•Inspect DSC HU/CM
•Inspect related harness
E
*—Check
connector—No need to
check•Inspect related harness
F
JLF wheel-speedLF 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))
SST (49 G066 004)
AQ
B
CDE
FG
HI
J DSC HU/CM HARNESS SIDE CONNECTOR
A
C E
H
K N Q
T
W Z AC AF
F I L O R U X
AA AD AG
G
J
M P S
V
Y AB AE AHB
DKN
T
WZ
AC
AFLO
RU
XAA
ADAGMP
SV
YAB
AEAH
A6E6920W009