2002 MAZDA 6 oil

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)

AUTOMATIC TRANSAXLE
K2–109
K2
Oil Pipe, Hose Clamp, Oil Hose Installation Note
1. Apply compressed air to cooler-side opening, and
blow any remaining grime and foreign material
from the cooler pipes. Compressed air should be
applied for no less than one minute.
2. Align the marks, and slide the oil hose onto the oil
pipe until it is fully seated as shown.
Note
•If reusing the hose, install the new hose
clamp exactly on the mark left by the
previous hose camp.Then apply force to the
hose clamp in the direction of the arrow in
order to fit the clamp in the place.
3. Install the new hose clamp onto the hose.
4. Verify that the hose clamp does not interfere with
any other components.
End Of Sie
A6E5614W070
OIL
HOSE OIL
PIPEMARK
A6E5614W071

K2–110
AUTOMATIC TRANSAXLE
OIL COOLER DISASSEMBLY/ASSEMBLYA6E5714199002041. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
.
Radiator Outer Tank (In Tank Oil Cooler) Removal Note
1. Inspect the height of the header tabs.
2. Insert the end of a medium tip screwdriver
between the end of the header tab and the outer
tank.
Note
•Do not open more tabs than necessary for
tank removal.
R
0.78—1.56 N·m
{7.96—15.9 kgf·cm,
7—14 in·lbf}
7
4
3
6
2
5
1
A6E5614W072
1 Mount rubber
2 Radiator outer tank (in tank oil cooler)
(See K2–110 Radiator Outer Tank (In Tank Oil
Cooler) Removal Note.)
(See K2–111 Radiator Outer Tank (In Tank Oil
Cooler) Installation Note.)
3 O-ring
4 Washer5 Drain cock
6 ATF cooler
7Radiator
RADIATOR
LOWER
TANK
HEADER TAB
HEIGHT
O-RING
A6E5614W073

AUTOMATIC TRANSAXLE
K2–111
K2
3. Pivot the screwdriver to pry the tab away from the
tank and repeat the procedure for each tab.
4. Remove the radiator outer tank and O-ring
(gasket) from the core header when all of the tabs
are opened.
Note
•If any header tabs are missing from the core,
replace the radiator.
5. Inspect the gasket surface of the radiator core
header to ensure it is clean and free of foreign
material or damage.
6. Inspect the radiator outer tank for warping. If it is
warped, replace radiator tank.
Radiator Outer Tank (In Tank Oil Cooler) Installation Note
1. Install a new O-ring and ensure it is not twisted.
Note
•The old O-ring must be replaced.
2. Position the radiator tank in the original direction
to the core using care not to scratch the tank
sealing surface with the header tabs.
Note
•Step 3 will set jaw opening to the correct
specification.
3. With the jaws of locking-type pliers (vise grips)
closed and locked, turn the adjusting screw to
position the jaws against the drill bit with the
diameter measured (height) in removal procedure
1. Tighten the lock nut on the adjusting screw
against the handle to lock the adjustment in place.
SCREWDRIVER
A6E5614W074
O-RING
A6E5614W075
LOCKING TYPE PLIERS
(VISE PLIERS)
LOCKNUTADJUSTING
SCREW
DRILL BIT
A6E5614W093

AUTOMATIC TRANSAXLE
K2–113
K2
Drive Plate Mounting Bolts Removal Note
1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate.
Drive Plate Installation Note
Caution
•If the bolts are reused, remove the oil sealant from the bolt threads. Tightening a bolt that has old
sealant on it can cause thread damage.
1. Remove the sealant from the bolts hole in the crankshaft and from the drive plate mounting bolts.
Note
•If all the previous sealant cannot be removed from a bolt, replace the bolts.
•Do not apply sealant if a new bolts is used.
2. Install the drive plate.
3. Install the adapter.
4. Apply sealant to the drive plate mounting bolts and install them.
5. Set the SST or equivalent against the drive plate.
Caution
•When installing sealant covered bolts, tighten them immediately. Leaving these bolts in a half
installed condition could cause them to be stuck that way, due to the natural hardening or the
sealant.
6. Tighten the drive plate mounting bolts in two or
three steps in the order shown.
Tightening torque
108—1116 N·m
{11.0—11.8 kgf·m, 80—85 ft·lbf}
7. Install the transaxle. (See K2–99 AUTOMATIC
TRANSAXLE AND TRANSFER REMOVAL/
INSTALLATION.)
End Of Sie
5
4
361
2
49 E011 1A0
A6E5614W079
49 E011 1A0
5
4
361
2
A6E5614W081

K2–114
TRANSFER
TRANSFER OIL INSPECTIONA6E5718170012011. Park the vehicle on level ground.
2. Remove the PTO heat shield.
3. Remove the filler plug.
4. Verify that the oil is near the brim of the plug port.
•If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Specified oil grade
API Service GL-5
Specified oil viscosity
SAE 80W-90
5. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
6. Install the filler plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
7. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
End Of Sie
TRANSFER OIL REPLACEMENTA6E5718170012021. Remove the drain plug.
2. Drain the oil into a suitable container.
3. Apply a sealant to the thread area of drain plug.
Specified sealant
TB1215
4. Install the drain plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
5. Remove the PTO heat shield.
6. Remove the filler plug and add the specified amount and type of oil through the filler plug hole until the level
reaches the bottom of the filler plug hole.
Specified oil grade
API Service GL-5
Specified oil viscosity
SAE 80W-90
Capacity (approximate quantity)
0.62 L {0.65 US qt, 0.54 lmp qt}
7. Apply a sealant to the thread area of filler plug.
Specified sealant
TB1215
8. Install the filler plug.
Tightening torque
9.8—19.6 N·m
{100—199 kgf·cm, 116—175 in·lbf}
9. Install the PTO heat shield. (See K2–116 PTO Heat Shield Installation Note.)
TRANSFER
TRANSFER
FILLER PLUG
DRAIN PLUG
A6E5718W101
TRANSFER
FILLER PLUG
DRAIN PLUG
A6E5718W101

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