2002 MAZDA 6 engine oil

AUTOMATIC TRANSAXLE
K2–105
K2
4. Coat the oil seal with transfer oil and grease as
shown in the figure.
Caution
•The oil seal is easily damaged by the
sharp edges of the drive shaft splines. Do
not let the splines contact the oil seal.
5. Install the drive shaft and joint shaft. (See Section
M.)
End Of SieCONTROL VALVE BODY REMOVAL/INSTALLATIONA6E571421100202On-Vehicle Removal
Warning
•Hot transaxle and ATF can cause severe burns. Turn off the engine and wait until it ATF have
cooled before removing the control valve body.
•Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes.
Wear protective eyes whenever using compressed air.
Caution
•Clean the transaxle exterior throughly with a stream cleaner or cleaning solvents before removal.
•If any old sealant gets into the transaxle during installation of the oil pan, trouble may occur in the
transaxle case and oil pan. Clean with cleaning fluids.
1. Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents.
2. Disconnect the negative battery cable.
3. Remove the front bumper. (See Section S.)
4. Remove the shroud panel. (See Section S.)
5. Drain the ATF into separate containers.
6. Remove the radiator. (See Section E.)
7. Remove the oil hose. (See K2–108 OIL COOLER REMOVAL/INSTALLATION.)
8. Remove the control valve body cover.
9. Disconnect the solenoid valve connectors, then
remove harness clips.
10. Remove the control valve body.
On-Vehicle Installation
1. Position the manual valve so that it protrudes from
the control valve body end by 3.0 mm.
2. Install the control valve body while holding the
manual valve in the position.
Tightening torque
6.9—8.8 N·m
{0.70—0.90 kgf·m, 5.1—6.5 ft·lbf}
3. Connect the solenoid connectors, then install
harness clips.
4. Apply a light coat of silicon sealant to the contact
surfaces of the control valve body cover and
transaxle case.
OILOIL
0.5—1.5 mm {0.0197—0.0591 in}
GREASEGREASE
A6E5714W130
CONTROL
VALVE BODY
COVER
A6E5714W143
3.0 mm
MANUAL VALVECONTROL
VALVE BODY
A6E5714W144

K2–142
ON-BOARD DIAGNOSTIC
End Of SieDTC P0740A6E577018901212
Diagnostic procedure
12VERIFY TROUBLESHOOTING OF DTC P0720
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from memory using WDS or
equivalent.
•Drive vehicle with vehicle speed 40 km/h {25
mph} or above for 2 second or more
•Is same DTC present?Yes Replace TCM, then go to next step.
(See K2–96 TCM REMOVAL/INSTALLATION.)
No Go to next step.
13VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See K2–124 AFTER REPAIR PROCEDURE.)
•Is there any DTC present?Yes Go to applicable DTC inspection.
No Troubleshooting completed. STEP INSPECTION ACTION
DTC P0740 TCC system malfunction
DETECTION
CONDITION•RPM difference between crankshaft (engine speed signal) and reverse clutch drum (input/turbine speed
sensor signal) exceeds the pre-programmed value.
Diagnostic support note:
•This is continuous monitor (CCM).
•MIL illuminates if TCM detects the above malfunction conditions in two consecutive drive cycles.
•PENDING CODE is available.
•FREEZE FRAME DATA is available.
•AT warning light does not indication.
•DTC is stored in TCM memory.
POSSIBLE
CAUSE•ATF level low.
•Deteriorated ATF.
•TCC solenoid valve and pressure control solenoid stuck.
•Line pressure low.
•Oil pump malfunction.
•Control valve stuck
•Torque convert clutch malfunction
•TCM malfunction.
STEP INSPECTION ACTION
1VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
•Has FREEZE FRAME PID DATA been
recorded?Yes Go to next step.
No Record FREEZE FRAME PID DATA on repair order, then
go to next step.
2VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
•Check for related Service Bulletins and/or on-
line repair information availability.
•Is any related repair information available?Yes Perform repair or diagnosis according to available repair
information.
•If vehicle is not repaired, go to next step.
No Go to next step.
3CHECK ATF CONDITION
•Turn ignition key to OFF.
•Check ATF condition.
—Clear red: Normal
—Milky: Water mixed in fluid
—Reddish brown: Deteriorated ATF
•Is it okay?
(See K2–78 Automatic Transaxle Fluid (ATF)
Condition Inspection.)Yes Go to next step.
No If ATF color milky or reddish brown, replace ATF, then go to
Step 5.
(See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF)
REPLACEMENT.)
4CHECK ATF LEVEL
•Start engine.
•Warm up ATX.
•Is ATF level within specification?
(See K2–79 Automatic Transaxle Fluid (ATF)
Level Inspection.)Yes Go to next step.
No Adjust ATF level, then go to Step 9.
(See K2–79 Automatic Transaxle Fluid (ATF) Level
Inspection.)

ON-BOARD DIAGNOSTIC
K2–143
K2
End Of Sie
5INSPECT LINE PRESSURE
•Start engine.
•Measure line pressure.
Specification
—D range, M (2GR) range
Idle: 290—490 kPa {3.0—4.9 kgf/cm
2, 43—69
psi}
Stall: 1,550—1,750 kPa {15.8—17.8 kgf/cm
2,
225—254 psi}
—M (1GR) range, R position
Idle:550—750 kPa {5.6—7.6 kgf/cm
2, 80—
109 psi}
Stall: 1,550—1,750 kPa {15.8—17.8 kgf/cm
2,
225—254 psi}
•Is line pressure within specification?
(See K2–72 Line Pressure Test.)Yes Go to next step.
No All ranges: Replace or overhaul oil pump or control valve
body, then go to Step 10.
Any ranges: Replace or overhaul automatic transaxle, then
go to Step 10.
(See K2–99 AUTOMATIC TRANSAXLE AND TRANSFER
REMOVAL/INSTALLATION.)
6CLICK TEST OF SOLENOID VALVES
•Turn ignition key to OFF.
•Disconnect terminal component No.1(12-pin).
•Apply battery voltage to terminal component
No.1 (12-pin) terminals (transaxle case side).
—TCC solenoid vale: B
—Pressure control solenoid: D
•Verify the click sounds of TCC solenoid valve
and pressure control solenoid.
•Are there click sounds?Yes Go to next step.
No Replace TCC solenoid valve or pressure control solenoid,
then go to Step 10.
(See K2–105 CONTROL VALVE BODY REMOVAL/
INSTALLATION.)
7INSPECT DIFFERENCE BETWEEN ENGINE
SPEED AND TURBINE SPEED
•Inspect difference between engine speed and
turbine speed during TCC operation in 5GR
•Drive vehicle under following condition
—TR switch position: D range
—Gear position: 5GR
—TCC solenoid valve: ON
•Is difference between engine speed (RPM PID)
and turbine speed okay?
Difference
Below 99 rpmYes Go to Step
No Go to next step.
8INSPECT OPERATION OF EACH VALVE AND
EACH SPRING
•Remove control valve body.
•Disassemble control valve body.
•Is each valve operation okay and is return
spring okay?Yes Replace torque converter, then go to next step.
No Replace control valve body, then go to next step.
(See K2–105 CONTROL VALVE BODY REMOVAL/
INSTALLATION.)
9VERIFY TROUBLESHOOTING OF DTC P0740
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from memory using WDS or
equivalent.
•Start engine.
•Warm up ATX.
•Drive vehicle under following condition for 10
seconds or more.
—Vehicle speed (VSS PID): Within 10—87
km/h {6—54 mph}
—Gear position: 5GR
—TR switch position: D range
—TCC solenoid valve: ON
•Is there pending code present?Yes Replace TCM, then go to next step.
(See K2–96 TCM REMOVAL/INSTALLATION.)
No Go to next step.
10VERIFY AFTER REPAIR PROCEDURE
•Perform “After Repair Procedure”.
(See K2–124 AFTER REPAIR PROCEDURE.)
•Is there any DTC present?Yes Go to applicable DTC inspection.
No Troubleshooting completed. STEP INSPECTION ACTION

TROUBLESHOOTING
K2–187
K2
End Of Sie
Vehicle dose not move in D range, or in R position
X
X
X
XXX X
XX X
XX X
XX X XX
X
X
X X XX
XX
X XXXXXXXXX
XXX
X
X
X X
XX XXX
X
X
XX X
X
X
X X
X
X
X X
XX
X XXX X XXX
XX X 1
Excessive creep 4
No creep at all 5
Low maximum speed and poor acceleration 6
No shifting 7
Does not shift to fifth gear (5GR) 8
Abnormal shifting 9
Frequent shifting 10
Shift point is high or low 11
Torque converter clutch (TCC) non-operation 12
No kickdown 13
Engine flares up or slips when upshifting or downshifting 14
Engine flares up or slip when accelerating vehicle 15
Judder upon torque converter clutch (TCC) operation 16
Excessive shift shock from N to D or N to R position/range 17
Excessive shift shock on torque converter clutch (TCC) 19
No engine braking in 1GR position of M range 22
Transaxle overheats 23
Engine stalls when shifted to D range, or in R position 24
Engine stalls when driving at slow speeds or stopping 25
Starter does not work 26Excessive shift shock is given when upshifting and
downshifting 18
Noise occurs at idle when vehicle is stopped in all
positions/ranges 20
Noise occurs at idle when vehicle is stopped in D
range, or in R position 21
Gear position indicator light illuminates in D range or P, N,
R positions 28Gear position indicator light does not illuminate in M range
Hydraulic system
components
Control valve bodyPowertrain 27
Does not shift up in M range
29
Does not shift down in M range
Symptom item
Cause of trouble
Reduction accumulator is not operating properly
Clogging
Clogging
Clogging
Clogging
Clogging
Clogging
Clogging Clogging
Clogging
Slipping (clutch, brake) Oil cooler is not operating properly
Torque converter is not operating properly Burned (clutch, brake)
TCC piston is not operating properly TCC piston is cracking or peeling2-4 brake solenoid valve hydraulic circuit Pressure control solenoid hydraulic circuit
TCC solenoid valve hydraulic circuit
High clutch solenoid valve hydraulic circuit
Shift solenoid A hydraulic circuit
Shift solenoid B hydraulic circuit
Shift solenoid C hydraulic circuit
Neutral shift solenoid valve
Reducation timing solenoid valve
30Vehicle moves in N position 2
Vehicle moves in P position, or parking gear does not
disengage when P is disengaged 3
A6E5780W003

K2–192
TROUBLESHOOTING
NO.8 DOES NOT SHIFT TO FIFTH GEAR (5GR)A6E578001030211
Diagnostic procedure
8 Does not shift to fifth gear (5GR)
DESCRIPTION•Vehicle does not upshift from 4GR to 5GR even though vehicle speed increased.
•Vehicle does not shift to 5GR even though accelerator pedal released in D range at 60 km/h {37 mph}.
POSSIBLE
CAUSE•Basically, TCC does not operate when fail-safe is operating. Verify DTC at first. If TCC operates when
driving at high speeds only, malfunction (improper adjustment) is in the D range switch circuit or TR
switch circuit.
Note
•If the TCC or piston is stuck, inspect them. In addition, inspect the oil cooler for foreign particles
which may have mixed in with the ATF.
—TCC piston slipped, burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of ECT sensor
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
—Malfunction of TFT sensor
•Short or open circuit in wiring
•Poor connection of connector
•Malfunction of sensor
—Malfunction of TR switch
•Selector lever adjustment incorrect
•TR switch adjustment incorrect
—Malfunction of TCC solenoid valve
•Short or open circuit in wiring
•Poor connection of connector
•Solenoid valve stuck
—Malfunction of M range switch
—Malfunction of torque converter
—Malfunction of control valve body
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Turn ignition switch to ON.
•Does gear position indicator light indication
correspond to selector lever position?Yes Go to next step.
No Go to symptom troubleshooting No.27 “Gear position
indicator light does not illuminate in M range” or No.28
“Gear position indicator light illuminates in D range or P, N,
R positions”.
2•Drive vehicle in D range and inspect
following:
—1–2 shift up and down
—2–3 shift up and down
—3–4 shift up and down
—4–5 shift up and down
•Are all shift-up and shift-down possible?Yes Go to next step.
NoNo shift at all:
•Go to symptom troubleshooting No.7 “No shifting”.
Abnormal shift:
•Go to symptom troubleshooting No.9 “Abnormal
shifting”.
3•Stop engine.
•Inspect shift solenoid A, B, or C circuit.
•Are they okay?Yes Go to next step.
No•Inspect for shift solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
4•Remove torque converter.
•Inspect torque converter.
(See ATX Workshop.)
•Is torque converter okay?Yes•Overhaul control valve body and repair or replace any
defective parts.
(See ATX Workshop Manual.)
—If problem remains, replace or overhaul transaxle and
repair or replace any defective parts.
(See K2–99 AUTOMATIC TRANSAXLE AND
TRANSFER REMOVAL/INSTALLATION.)
(See ATX Workshop Manual.)
No Replace torque converter.

K2–194
TROUBLESHOOTING
NO.11 SHIFT POINT IS HIGH OR LOWA6E578001030214
End Of SieNO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATIONA6E578001030215
Diagnostic procedure
11 Shift point is high or low
DESCRIPTION•Shift point considerably different from automatic shift diagram.
•Shift delays when accelerating.
•Shift occurs quickly when accelerating and engine speed does not increase.
POSSIBLE
CAUSE•If the transaxle does not shift abnormally, there is a malfunction of input signal to TP sensor, input/
turbine speed sensor, or VSS.
•If engine speed is high or low regardless that shifting is normal, inspect tachometer.
•Verify that output signal of TP sensor changes linearly.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
12 Torque converter clutch (TCC) non-operation
DESCRIPTION•TCC does not operate when vehicle reaches TCC operation range.
POSSIBLE
CAUSE•Basically, TCC does not operate when fail-safe is operating. Verify DTC at first. If TCC operates when
driving at high speeds only, the malfunction (improper adjustment) is in D and/or M ranges switch circuit
or TR switch circuit.
Note
•If the TCC or piston is stuck, inspect them. In addition, inspect the oil cooler for foreign particles
which may have mixed in with the ATF.
•TCC piston slipped, burned
—Line pressure low
•Incorrect throttle position signal
•Input/turbine speed sensor malfunction
•TFT sensor malfunction
•Sensor ground malfunction
•VSS malfunction
•Malfunction of output solenoid valve system (Sticking)
•TCC solenoid valve malfunction
•Malfunction of control valve body system (Poor operation, sticking)
•TCC piston hydraulic pressure system malfunction
•Malfunction of TP sensor (Not operating linearly)
•Malfunction of input/turbine speed sensor or VSS
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Turn ignition switch to ON.
•Does gear position lamp indication
correspond to selector lever position?Yes Go to next step.
No Go to symptom troubleshooting No.27 “Gear position
indicator light does not illuminate in M range”, or No.28
“Gear position indicator light illuminates in D range or P, N,
R positions”.
2•Disconnect TCM.
•Is resistance between ground terminals 1C,
1Y at TCM connector and body ground less
than 5.0 ohm?Yes Go to next step.
No Repair open ground circuit.
3•Remove torque converter.
•Inspect torque converter.
(See ATX Workshop Manual.)
•Is torque converter okay?Yes•Overhaul control valve body and repair or replace any
defective parts.
(See ATX Workshop Manual.)
•If problem remains, replace or overhaul transaxle and
repair or replace any defective parts.
(See ATX Workshop Manual.)
No•Replace torque converter.
4•Verify test results.
—If okay, return to diagnostic index to service any additional symptoms.
—If malfunction remains, inspect related Service Informations and perform repair or diagnosis.
—If vehicle repaired, troubleshooting completed.
—If vehicle not repaired or additional diagnostic information not available, replace TCM.

K2–196
TROUBLESHOOTING
NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLEA6E578001030218
End Of SieNO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATIONA6E578001030219
End Of SieNO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGEA6E578001030220
Diagnostic procedure
15 Engine flares up or slips when accelerating vehicle
DESCRIPTION•Engine flares up when accelerator pedal depressed for upshifting.
•Engine flares up suddenly when accelerator pedal depressed for downshifting.
POSSIBLE
CAUSE•Malfunction is basically the same as for No.14 “Engine flares up or slips when upshifting or
downshifting”.
—If conditions for No.14 worsen, malfunction will develop into No.15.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
16 Judder upon torque converter clutch (TCC) operation
DESCRIPTION•Vehicle jolts when TCC engaged.
POSSIBLE
CAUSE•Poor TCC engagement due to either slippage because TCC piston is stuck or line pressure is low.
Caution
•If the TCC or piston are stuck, inspect them. In addition, inspect the oil cooler for foreign
particles which may have mixed in with the ATF.
—Torque converter clutch piston slipped, burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of TCC solenoid valve
•Malfunction of control valve body
—Malfunction of torque converter
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
17 Excessive shift shock from N to D or N to R position/range
DESCRIPTION•Strong shock felt when shifting from N to D or N to R position/range at idle.
POSSIBLE
CAUSE•Shift shock may worsen when fail-safe is operating. If no DTC is output, shift shock may worsen due to
poor operation of control valve body or sticking of clutch.
—Clutch burned (N→D: Low clutch, N→R: Reverse clutch or low and reverse brake)
•Line pressure low
•Incorrect throttle position signal
•Malfunction of TFT sensor
•Malfunction of sensor ground
•Misadjustment of throttle cable
•Malfunction of control valve body
—Poor hydraulic operation (Malfunction in range change)
—Idle speed high
—Poor tightening torque of engine mount, exhaust mount
—Line pressure high
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Does shift shock occur only when engine
cold?Yes Go to next step.
No Go to Step 3.
2•Inspect TFT sensor and related harness:
vibration, intermittent open/short circuit.
•Is it okay?Yes Go to next step.
No Repair or replace part if necessary.

K2–198
TROUBLESHOOTING
NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGESA6E578001030223
Diagnostic procedure
End Of SieNO.21 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN D RANGE, OR IN R POSITIONA6E578001030224
End Of SieNO.22 NO ENGINE BRAKING IN 1GR POSITION OF M RANGEA6E578001030225
Diagnostic procedure
20 Noise occurs at idle when vehicle is stopped in all positions/ranges
DESCRIPTION•Transaxle noisy in all positions and ranges when vehicle idling.
POSSIBLE
CAUSE•Malfunction is in pressure solenoid or oil pump which causes a high-pitched noise to be emitted from
transaxle at idle.
Note
•If a noise is emitted during shifting only, malfunction is in shift solenoid A, B, or C.
•If a noise is emitted during shifting at certain gears only or during deceleration only, it is gear noise.
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Inspect engine condition.
•Is any engine concern (e.g. Rough idle)?Yes Go to appropriate symptom troubleshooting.
(See F1–57 ENGINE SYMPTOM TROUBLESHOOTING.)
No Replace basic inspection and repair or replace any
defective parts according to inspection result.
2•Verify test results.
—If okay, return to diagnostic index to service any additional symptoms.
—If malfunction remains, inspect related Service Informations and perform repair or diagnosis.
—If vehicle repaired, troubleshooting completed.
—If vehicle not repaired or additional diagnostic information not available, replace TCM.
21 Noise occurs at idle when vehicle is stopped in D range, or in R position
DESCRIPTION•Transaxle noisy in driving ranges when vehicle idling.
POSSIBLE
CAUSE•Although the malfunction is basically the same as No.20 “Noise occurs at idle when vehicle is stopped
in all positions/ranges”, other causes may be selector lever position disparity or TR switch position
disparity.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
22 No engine braking in 1GR position of M range
DESCRIPTION•Engine speed drops to idle but vehicle coasts when accelerator pedal released during cruising at
medium to high speeds.
•Engine speed drops to idle but vehicle coasts when accelerator pedal released when in M range (1GR)
at low vehicle speed.
POSSIBLE
CAUSE•Clutch slipped, burned (Reduction brake)
—Line pressure low
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of control valve body
—M range switch on not judged by TCM (short, or open circuit, poor operation)
•Malfunction of M range switch signal
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Inspect TR switch adjustment.
•Does TR switch adjusted properly?
•Select PNP PID.
•Is PNP PID reading okay when selecting
range?Yes Go to next step.
No Adjust TR switch as necessary.
(See K2–83 TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT.)
Inspect TR switch.
Repair or replace any defective parts.