2002 MAZDA 6 battery

K2–108
AUTOMATIC TRANSAXLE
OIL COOLER REMOVAL/INSTALLATIONA6E5714199002031. Disconnect the negative battery cable.
2. Drain the ATF into a container. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.)
3. Remove the radiator. (See Section E.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Add ATF to the specified level. (See K2–80 AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT.)
7. Connect the negative battery cable.
8. Inspect for oil leakage from the oil pipes and oil hoses.
9. Inspect for coolant from the hoses.
10. Inspect the ATF level and condition. (See K2–78 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION.)
11. Carry out the line pressure test. (See K2–72 MECHANICAL SYSTEM TEST.)
12. Carry out the road test. (See K2–75 ROAD TEST.)
.
Radiator (In Tank Oil Cooler) Installation Note
1. The automatic transaxle oil cooler flushing must be performed whenever a transaxle is removed for service
because the existing fluid may be contaminated, and to prevent contamination of new fluid.
Note
• The flushing must be performed after installation of the overhauled or replacing transaxle.
2. Follow the instructions in the manufacturer’s publication for flushing operation.
R
R
1
2
1
3
4
2
R2
R2
R
7.8—10.8 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf} 7.8—10.8 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf}24—35
{2.5—3.5, 18—26}
2
5
AB
A
B
N·m {kgf·m, ft·lbf}
R
A6E5714W146
1Oil hose
(See K2–109 Oil Pipe, Hose Clamp, Oil Hose
Installation Note)
2 Hose clamp
(See K2–109 Oil Pipe, Hose Clamp, Oil Hose
Installation Note)
3Oil cooler4 Oil pipe
(See K2–109 Oil Pipe, Hose Clamp, Oil Hose
Installation Note)
5 Radiator (in tank oil cooler)
(See K2–108 Radiator (In Tank Oil Cooler)
Installation Note)

TRANSFER
K2–115
K2
End Of SieTRANSFER REMOVAL/INSTALLATIONA6E5718170012041. Disconnect the negative battery cable.
2. Remove the propeller shaft. (See L–5 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the TWC. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
4. Remove the front tires and splash shield of right side.
5. Remove the under cover.
6. Remove the drive shaft of right side. (See Section M.)
7. Remove the joint shaft. (See Section M.)
8. Remove the exhaust manifold insulator. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
9. Remove the exhaust manifold. (See F1–30 EXHAUST SYSTEM REMOVAL/INSTALLATION.)
10. Remove in the order shown in the figure.
11. Install in the reverse order of removal.
.
No.1 Engine Mount Installation Bolt Removal Note
1. Support the engine using the SST before
removing the No.1 engine mount.
2. Loosen the bolt A.
3. Remove the bolt B.
4. Remove the bolt C and D.
1 No.1 engine mount installation bolt
(See K2–115 No.1 Engine Mount Installation Bolt
Removal Note)
(See K2–116 No.1 Engine Mount Installation Bolt
Installation Note)
2 PTO heat shield
(See K2–116 PTO Heat Shield Installation Note)
3Transfer
2
3
N·m { kgf·m, ft·lbf} 8—11
{82—112 kgf·cm, 72—96 in·lbf}
64—89
{6.6—9.0, 48—65}
185.3—116.6
{8.70—11.88,
62.91—85.98}
A6E5718W102
49 E017 5A0
A6E5714W132
AC
B
D
A6E5714W138

AUTOMATIC TRANSAXLE SHIFT MECHANISM
K2–117
K2
SELECTOR LEVER INSPECTIONA6E5716461022011. Turn the ignition switch to the ON position (engine off).
2. With the brake pedal depressed, verify that a “click” sound is heard at each range when shifted in the pattern
shown.
3. Verify that the selector lever can only be shifted
as shown.
4. Verify that the position of the selector lever and
the selector indicator light correspond.
•If not as specified, adjust the TR switch. (See
K2–83 TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT.)
5. Verify that the vehicle operates in each selected
range.
End Of SieSELECTOR LEVER COMPONENT INSPECTIONA6E5716461022041. Disconnect the negative battery cable.
2. Remove the console.
3. Remove the dashboard completely. (See section S.)
4. Disconnect the selector lever component connector.
5. Inspect for continuity at the selector lever
component.
•If not as specified, adjust the selector cable.
(See K2–118 SELECTOR CABLE
ADJUSTMENT.)
End Of Sie
AUTOMATIC TRANSAXLE SHIFT MECHANISM
P
R
N
DM
P
R
N
DM
OPERATION WHEN
BRAKE PEDAL IS
DEPRESSED
OPERATION WHEN
BRAKE PEDAL IS
RELEASED
A6E5716W101
SELECTOR LEVER COMPONENT
PART SIDE CONNECTOR
A6A5616W013
A6A5616W012

AUTOMATIC TRANSAXLE SHIFT MECHANISM
K2–119
K2
SELECTOR LEVER REMOVAL/INSTALLATIONA6E5716461022021. Disconnect the negative battery cable.
2. Remove the battery and battery tray.
3. Remove the air cleaner compornent. (See Section F.)
4. Remove the console.
5. Remove the dashboard compleat. (See Section S.)
6. Remove the SAS control module. (See Section T.)
7. Remove the climate control unit. (See Section U.)
8. Remove the rear heat duct. (See Section U.)
9. Remove in the order shown in the figure.
10. Install in the reverse order of removal.
.
1
2
A
A
B
15.68—22.5
{1.60—2.29, 11.6—16.5}
B6.86—9.8 N·m
{70—99 kgf·cm, 61—86 in·lbf}
N·m {kgf·m, ft·lbf}
A6E5716W104
1 Selector cable
(See K2–120 Selector Cable Removal Note.)
(See K2–120 Selector Cable Installation Note.)2Selector lever

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

K2–180
ON-BOARD DIAGNOSTIC
End Of SiePID/DATA MONITOR INSPECTIONA6E5770189012301. Connect the SSTs (WDS or equivalent) to the DLC-2.
2. Turn the ignition switch to ON.
3. Measure the PID value.
Note
•Perform part inspection for the output device after TCM inspection.
•The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the TCM.
Therefore, if a monitored value of an output device is out of specification, it is necessary to inspect the
monitored value of the input device related to the output device control. Since an output device
malfunction is not directly indicated as a malfunction of the monitored value for the output device, it is
necessary to inspect the output device individually using the simulation function, etc.
PID/DATA MONITOR AND RECORD function table
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
Monitor item
(Definition)Unit/
ConditionCondition/Specification ActionTCM
terminal
2-4 B Duty
(2-4 brake
solenoid vale)ON/OFFN position: ON
M range (1GR) stall: OFFInspect 2-4 brake solenoid valve.
(See K2–88 SOLENOID VALVE
INSPECTION.)2V
BOO
(Brake switch)ON/OFFBrake pedal depressed: ON
Other: OFFInspect brake switch.
1U
DWN_SW
(Down switch)ON/OFFDown sift at M range: ON
Other: OFFInspect selector lever component.
1S
GEAR
(Calculated
gear range in
TCM)1ST/2ND/
3RD/4TH/
5TH1GR: 1ST
2GR: 2ND
3GR: 3RD
4GR: 4TH
5GR: 5THInspect following PIDs: THOP, TSS
–
H/C Duty
(High clutch
solenoid valve)%N position: OFF
D range 1GR to 2GR shifting: ONInspect high clutch solenoid valve.
(See K2–88 SOLENOID VALVE
INSPECTION.)2U
LPS
(Pressure
control
solenoid)%Ignition switch ON: 0%
Idle: 0—100%Inspect pressure control solenoid.
(See K2–88 SOLENOID VALVE
INSPECTION.)2Y
MNL_SW
(M range
switch)ON/OFFM range: ON
Other: OFFInspect selector lever component.
1AA
NSFT TIM
(Neutral shift
solenoid valve)ON/OFFN position: OFF
R position inhibition control: ONInspect main relay.
(See T–19 RELAY INSPECTION.)
Inspect battery.
(See G–6 BATTERY INSPECTION.)2D
OSS
(Intermediate
sensorrpmIgnition switch ON: 0 rpm
Idle: 700—800 rpmInspect intermediate sensor.
(See K2–86 INTERMEDIATE SENSOR
INSPECTION.)1K, 1X
PNP
(TR switch (P/
N position
switch))ON/OFFP or N position: ON
R position and all ranges: OFFInspect TR switch.
(See K2–88 SOLENOID VALVE
INSPECTION.)–
RDCN TIM
(Reduction
timing solenoid
valve)ON/OFFN position: OFF
D range: ONInspect reduction timing solenoid valve.
(See K2–88 SOLENOID VALVE
INSPECTION.)2G
RPM
(Engine speed)rpmIgnition switch ON: 0 rpm
Idle: 700—800 rpmInspect TCM.
(See K2–90 TCM INSPECTION.)–
SSA/SS1
(Shift solenoid
A)ON/OFFN position: ON
D range 3GR: OFFInspect shift solenoid A.
(See K2–88 SOLENOID VALVE
INSPECTION.)–

ON-BOARD DIAGNOSTIC
K2–181
K2
End Of Sie
SSB/SS2
(Shift solenoid
B)ON/OFFN position: ON
D range 4GR: OFFInspect shift solenoid B.
(See K2–88 SOLENOID VALVE
INSPECTION.)–
SSC/SS3
(Shift solenoid
C)ON/OFFN position: ON
D range 2GR: OFFInspect shift solenoid C.
(See K2–88 SOLENOID VALVE
INSPECTION.)–
TCCC
(TCC solenoid
valve)%TCC operating: ON
TCC non operating: OFFInspect TCC solenoid valve.
(See K2–88 SOLENOID VALVE
INSPECTION.)2S
TFT
(ATF
temperature)°CATF 20 °C {68 °F}: 20 °C {68 °F}
ATF 60 °C {140 °F}: 60 °C {140 °F}Inspect TFT sensor.
(See K2–84 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION.)1B, 1F
TFTV
(ATF
temperature
signal voltage)VATF 20 °C {68 °F}: 1.55 V
ATF 60°C {140 °F}: 0.7 VInspect TFT sensor.
(See K2–84 TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION.)1B, 1F
THOP
(Throttle
position)%CTP:0%
WOT: 100%Inspect TCM.
(See K2–90 TCM INSPECTION.)–
TRD
(TR switch [D
range])ON/OFFD range: ON
Other ranges and all positions: OFFInspect TR switch.
(See K2–80 TRANSAXLE RANGE (TR)
SWITCH INSPECTION.)1Z
TRR
(TR switch [R
position])ON/OFFR position: ON
Other positions and all ranges: OFFInspect TR switch.
(See K2–80 TRANSAXLE RANGE (TR)
SWITCH INSPECTION.)1W
TSS
(Input/turbine
speed sensor)rpmIgnition switch ON: 0 rpm
Idle: 700—800 rpmInspect input/turbine speed sensor.
(See K2–85 INPUT/TURBINE SPEED
SENSOR INSPECTION.)1N, 2F
UP_SW
(Up switch)ON/OFFUp sift at M range: ON
Other: OFFInspect selector lever component.
2C
VPWR
(Battery
voltage)VIG ON: B+
Idle: 13—14 VInspect main relay.
1P
VSS
(Vehicle
speed)km/hVehicle speed 20 km/h {12.5 mph}: 20
km/h {12.5 mph}
Vehicle speed 40 km/h {25 mph}: 40 km/
h {25 mph}Inspect vehicle speedometer sensor.
(See K2–87 VEHICLE SPEEDOMETER
SENSOR (VSS) INSPECTION.)1V, 1M Monitor item
(Definition)Unit/
ConditionCondition/Specification ActionTCM
terminal

M–8
ELECTRONIC 4WD CONTROL SYSTEM
Components and Functions
System Diagram
.
Part name Function
Electronic control coupling
(4WD solenoid)•Based on a signal from the 4WD CM, it operates the electromagnetic clutch and
transmits drive torque to the rear wheels.
Differential oil temperature
sensor•Informs the 4WD CM of the rear differential oil temperature.
4WD CM•Controls operation of the electronic control coupling (4WD solenoid) based on signals
input from the throttle opening angle, speed, differential oil temperature and other
sensors.
•Outputs coupling control condition and 4WD warning control information as a CAN
signal.
•Controls the on-board diagnostic system and the fail-safe system if there is a malfunction
in the 4WD system.
4WD warning light•Illuminates or flashes to alert driver of a malfunction or control failure in the 4WD system.
PCM•Sends the throttle opening angle and engine speed signals, as CAN signals, to the 4WD
CM.
TCM•Sends the selector lever position and gear position signals, as CAN signals, to the 4WD
CM.
DSC HU/CM•Sends the four-wheel speed and DSC operating condition signals, as CAN signals, to the
4WD CM.
•Sends the coupling torque request signal, as a CAN signal, to the 4WD CM.
KO
P I
A
C
NH G
9
8
7
5
4
3
10
13
11
12
6
1
2
A6E63222002
1 Battery
2 Ignition switch
3 Differential oil temperature sensor
4 4WD control modure (4WD CM)
5 Electronic control coupling
6 4WD solenoid
7 Instrument cluster8 DSC HU/CM
9TCM
10 PCM
11 CAN-H
12 CAN-L
13 CAN driver