2002 MAZDA 6 torque

K2–200
TROUBLESHOOTING
Diagnostic procedure
End Of SieNO.25 ENGINE STALLS WHEN DRIVING AT SLOW SPEED OR STOPPINGA6E578001030228
Diagnostic procedure
End Of SieNO.26 STARTER DOES NOT WORKA6E578001030229
End Of SieNO.27 GEAR POSITION INDICATOR LIGHT DOES NOT ILLUMINATE IN M RANGEA6E578001030230
Diagnostic procedure
STEP INSPECTION ACTION
1•Go to symptom troubleshooting No.4
“Engine stalls-after start/at idle”.
(See Section F.)
•Is engine control system okay?Yes Go to next step.
No Repair or replace any defective parts according to
inspection results.
2•Remove torque converter.
•Inspect torque converter.
(See ATX Workshop Manual.)
•Is torque converter okay?Yes•Inspect for bend, damage or kinks of oil cooler line
pipes. If okay, 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.
3•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.
25 Engine stalls when driving at slow speeds or stopping
DESCRIPTION•Engine stalls when brake pedal depressed while driving at low speed or stopping.
POSSIBLE
CAUSE•Malfunction is on engine control side (e.g. Fuel injection control, IAC system)
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Go to symptom troubleshooting No.10 “Low
idle/stalls during deceleration”.
(See Section F.)
•Is engine control system okay?Yes Go to symptom troubleshooting No.24 “Engine stalls when
shifted to D range, or in R position”.
No Repair or replace any defective parts according to
inspection results.
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.
26Starter does not work
DESCRIPTION•Starter does not work even when P or N position.
POSSIBLE
CAUSE•Selector lever misadjustment.
•TR switch misadjustment.
•Open or short circuit in TR switch.
27 Gear position indicator light does not illuminate in M range
DESCRIPTION•Gear position indicator light in instrument cluster does not illuminate in M range and ignition switch at
on.
POSSIBLE
CAUSE•M range switch, gear position indicator light or related wiring harness malfunction.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Are other indicator lights illuminated with
ignition switch on? Yes Go to next step.
No Inspect meter fuse.

L–12
PROPELLER SHAFT
Locknut Assembly Note
1. Align the mark on the center yoke and shaft, and
install the center yoke.
Tightening torque
137—177 N·m
{16.1—18.0 kgf·m, 116—130 ft·lbf}
Bearing Cup and Snap Ring Assembly Note
1. Apply the grease to the bearing rollers inside the
bearing cups.
2. Set the new spider to the yoke, and assemble the
new bearing cup as the snap ring groove comes
out.
3. Assemble the opposite bearing cup in the same.
4. Insert the bearing cup to the yoke as the snap
ring groove width of bearing cup widens most and
both grooves width are same.
Caution
•Use a snap ring that thickness is same
for both sides.
MARK
A6E6110W005
GREASEGREASE
GREASEGREASE
A6J6110W016
A6E6110W010
BEARING CUPSPIDER
YOKE
A6E6110W011

L–14
PROPELLER SHAFT
PROPELLER SHAFT INSPECTIONA6E6110250022031. Disassemble the propeller shaft.
2. Measure the propeller shaft runout with a dial
indicator.
•If the runout is excessive, replace the
propeller shaft.
Runout limit
0.3 mm {0.01 in}
3. Move the universal joint in the direction shown,
and inspect joint play.
•If the joint play is not within the specification,
adjust the universal joint using snap rings.
Starting torque
0.29—0.78 N·m {3.0—7.9 kgf·cm}
End Of Sie
A6E6110W015
YTA6110W120

OUTLINE
M–3
M
4WD
Bold frames:New specifications
End Of Sie
ItemSpecification
New Mazda6 (GY)(Wagon 4WD)
EngineL3
TransaxleATX
Front axle Bearing type Angular ball bearing
Rear axle Bearing type Angular ball bearing
Front drive shaftJoint typeWheel side Bell joint
Differential side Tripod joint (With free ring)
Shaft diameter (mm {in}) 24.0 {0.94}
Joint shaft Shaft diameter (mm {in}) 29.0 {1.14}
Rear drive shaftJoint typeWheel side Bell joint
Differential side Double offset joint
Shaft diameter (mm {in}) 22.0 {0.87}
Rear and front wheel torque distribution unit Electronic control coupling
Rear differentialReduction gear Hypoid gear
Differential gear Straight bevel gear
Ring gear size (Inches) 6.5
Final gear ratio 2.928
Gears:
Number of teethDrive pinion 14
Ring gear 41
Differential oilTypeGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Amount
(Approximate quantity)(L {US qt, lmp qt}) 1.0 {1.1, 0.9}

ELECTRONIC 4WD CONTROL SYSTEM
M–7
M
OUTLINEA6E632227100201Features
Improved off-road mobility, handling stability, operability, fuel economy and marketability
•An electronic 4WD control system, which automatically optimizes traction distribution to the front and rear
wheels, has been adopted.
Improved serviceability
•A self-diagnostic function has been adopted for the electronic 4WD control system.
Electronic 4WD control system outline
•The newly adopted electronic 4WD control system automatically and optimally controls drive torque distribution
for the front and rear wheels. Due to this off-road mobility, driving stability and fuel economy are improved.
•Based on the input signals from each sensor, the 4WD control modure (4WD CM) determines vehicle driving
and road conditions, and controls output current to the electronic control coupling (4WD solenoid) inside the
rear differential. This control allows for optimal distribution of the drive torque from the engine to the rear
wheels.
•Also, the 4WD CM automatically controls the 4WD, greatly reducing the load on the driver and improving
operability.
Structural view
.
ELECTRONIC 4WD CONTROL SYSTEM
87
5
4
3
6
9
8
7
5
4
3
10
6
1
2
9
10
A6E63222001
1L.H.D.
2 R.H.D.
3 4WD warning light
4 4WD control modure
5 DSC HU/CM6PCM
7TCM
8 Electronic control coupling (4WD solenoid)
9 Differential oil temperature sensor
10 Rear differential

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

ELECTRONIC 4WD CONTROL SYSTEM
M–9
M
End Of SieELECTRONIC CONTROL COUPLINGA6E632227100202Outline
Features
•An electromagnetic clutch, which operates smoothly due to the lack influence from the front and rear wheel
traction force, has been adopted for the electronic control coupling system.
•The construction of the coupling enables the torque formed by the pilot clutch to be amplified by the cam
mechanism, thus allowing the main clutch to obtain a high degree of torque. Due to this, size and weight
reduction of the component parts has been achieved.
Construction
•The electronic control coupling basically consists of an electromagnetic clutch, a cam mechanism and a torque
transmission system.
•The electromagnetic clutch consists of a 4WD solenoid (electromagnetic coil), rear-housing that forms a
magnetic path, pilot clutch, and armature. The cam mechanism consists of a pilot cam, balls, and main cam.
The torque transmission system consists of a main clutch and hydraulic oil (ATF).
.
9
8
7
5
43
10
13
1112
6
12
A6E63222003
1 Front wheel side
2 Rear wheel side
3 Torque transmission system
4 Electromagnetic clutch
5 Rear housing
6 4WD solenoid (Electromagnetic coil)
7 Cam mechanism8Ball
9 Main clutch
10 Main cam
11 Armature
12 Pilot clutch
13 Pilot cam

M–10
ELECTRONIC 4WD CONTROL SYSTEM
Operation
4WD solenoid control current is OFF
•When the 4WD solenoid control current is OFF, no torque is generated in the pilot clutch because there is no
current flowing to the 4WD solenoid. At the same time, the pilot cam and the main cam rotate in the same
direction via the balls, and the main cam does not exert any push force on the main clutch side. Therefore, the
traction from the front wheels is not transmitted to the rear wheels.
.
8
7
5
4
3
6
12
56
7
A6E63222004
1 Main clutch
2 Pilot clutch
3 4WD solenoid (Electromagnetic coil)
4 4WD control modure (4WD CM)5Main cam
6Pilot cam
7Ball
8 Armature