2002 MAZDA 6 service

ON-BOARD DIAGNOSTIC
K2–173
K2
Diagnostic procedure
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.
3INSPECT TERMINAL COMPONENT NO.2 (8-
PIN) CONNECTOR FOR POOR CONNECTION
•Turn ignition key to OFF.
•Disconnect terminal component No.2 (8-pin)
connector.
•Check for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair or replace terminals, then go to Step 12.
4INSPECT INTERMEDIATE SENSOR
RESISTANCE
•Measure resistance between terminal
component No.2 (8-pin) (transaxle case side).
•Is resistance within 513—627 ohms between
terminal component No.2 (8-pin) terminal C
and D (transaxle case side)?Yes Go to next step.
No Go to Step 8
5INSPECT TCM CONNECTOR FOR POOR
CONNECTION
•Disconnect TCM connector.
•Check for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair terminals, then go to Step 12.
6INSPECT TERMINAL COMPONENT NO.2 (8-
PIN) CIRCUIT FOR OPEN
•Check terminal component No.2 (8-pin)
terminals (harness-side) and TCM terminals
(harness-side).
—C and 1K
—D and 1X
•Is there continuity?Yes Go to next step.
No Repair or replace harness, then go to Step 12.
7INSPECT TERMINAL COMPONENT NO.2 (8-
PIN) CIRCUIT FOR SHORT TO GROUND
•Check terminal component No.2 (8-pin)
terminal (harness-side) and body ground.
—C and body ground
—D and body ground
•Is there any continuity?Yes Repair or replace harness, then go to Step 12.
No Go to Step 12.
8INSPECT COUPLER COMPONENT (8-PIN)
CONNECTOR FOR POOR CONNECTION
•Disassemble the control valve body cover.
•Disconnect coupler component (8-pin)
connector.
•Check for poor connection (damaged, pulled-
out terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair terminals, then go to Step 12.
9INSPECT INTERMEDIATE SENSOR
RESISTANCE
•Measure resistance between coupler
component (8-pin).
•Is resistance within 513—627 ohms between
coupler component (8-pin) terminal D and C
(part side)?Yes Repair or replace coupler component, then go to Step 12.
No Go to next step.

K2–176
ON-BOARD DIAGNOSTIC
Diagnostic procedure
STEP INSPECTION ACTION
1VERIFY 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.
2INSPECT TERMINAL COMPONENT NO.1 (12-
PIN) FOR POOR CONNECTION
•Turn ignition key to OFF.
•Disconnect terminal componentNo.1 (12-pin).
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair or replace terminals, then go to Step 12.
3INSPECT RESISTANCE
•Check resistance between terminal component
No.1 (12-pin) terminal C (transaxle case side)
and body ground.
•Is resistance within 2.6—3.2 ohms?
(See K2–88 SOLENOID VALVE INSPECTION.)Yes Go to Step 8.
No Go to next step.
4INSPECT COUPLER COMPONENT (10-PIN)
FOR POOR CONNECTION
•Disconnect coupler component (10-pin)
connector.
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Is terminal okay?Yes Go to next step.
No Repair or replace terminal, then go to Step 12.
5INSPECT RESISTANCE
•Check resistance between coupler component
(10-pin) terminal F (part side) and body
ground.
•Is resistance within 2.6—3.2 ohms?
(See K2–88 SOLENOID VALVE INSPECTION.)Yes Repair or replace coupler component No.1 (12-pin), then
go to Step 12.
No Go to next step.
6INSPECT HIGH CLUTCH SOLENOID VALVE
CONNECTOR FOR POOR CONNECTION
•Disconnect high clutch solenoid valve
connector.
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Is terminal okay?Yes Go to next step.
No Repair or replace terminal, then go to Step 12.
7INSPECT RESISTANCE
•Check resistance between high clutch solenoid
valve connector terminal A (part side) and body
ground.
•Is resistance within 2.6—3.2 ohms?
(See K2–88 SOLENOID VALVE INSPECTION.)Yes Repair or replace coupler component (10-pin), then go to
Step 12.
No Verify high clutch solenoid valve installation.
•If high clutch solenoid valve is installed correctly,
replace high clutch solenoid, then go to Step 13
(See K2–90 SOLENOID VALVE REMOVAL/
INSTALLATION.)
8INSPECT TCM CONNECTOR FOR POOR
CONNECTION
•Disconnect TCM connector.
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair terminals, then go to Step 12.
9INSPECT TERMINAL COMPONENT NO.1 (12-
PIN) CIRCUIT FOR OPEN CIRCUIT
•Check continuity between TCM terminal 2U
(harness-side) and terminal component No.1
(12-pin) terminal C (harness-side).
•Is there continuity between terminals?Yes Go to next step.
No Repair or replace harness, then go to Step 12.
10INSPECT TERMINAL COMPONENT NO.1 (12-
PIN) CIRCUIT FOR SHORT TO POWER
•Turn ignition key to ON (engine OFF).
•Check voltage at terminal component No.1 (12-
pin) terminal C (harness-side).
•Is voltage 0 V?Yes Go to next step.
No Repair or replace harness, then go to Step 12.

ON-BOARD DIAGNOSTIC
K2–179
K2
Diagnostic procedure
STEP INSPECTION ACTION
1VERIFY 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.
2INSPECT TCM CONNECTOR FOR POOR
CONNECTION
•Turn ignition key to OFF.
•Disconnect TCM connector.
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair or replace terminals, then go to Step 9.
3INSPECT TCM CIRCUIT FOR SHORT TO
GROUND
•Verify that TCM connector is disconnected.
•Check continuity between TCM harness
connector terminal 2P and ground.
•Is there continuity?Yes Go to next step.
No Go to Step 5.
4INSPECT TCM INTERNAL CIRCUIT FOR OPEN
•Verify that TCM connector is disconnected.
•Check continuity between TCM terminal 2P
and TCM body.
•Is there any continuity?Yes Go to Step 9.
No Replace TCM, then go to Step 9.
5INSPECT TERMINAL COMPONENT NO.1 (12-
PIN) CONNECTOR FOR POOR CONNECTION
•Disconnect terminal component No.1 (12-pin)
connector.
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair or replace terminals, then go to Step 9.
6INSPECT TERMINAL COMPONENT NO.1 (12-
PIN) CIRCUIT FOR SHORT TO GROUND
•Verify that terminal component No.1 (12-pin)
connector is disconnected.
•Check continuity between terminal component
No.1 (12-pin) connector terminal J (transaxle
case side) and ground.
•Is there continuity?Yes Repair or replace TCM harness, then go to Step 9.
No Go to next step.
7INSPECT COUPLER COMPONENT (10-PIN)
CONNECTOR FOR POOR CONNECTION
•Disconnect coupler component (10-pin)
connector.
•Check for poor connection (damaged, pulled-
out, terminals, corrosion, etc.).
•Are terminals okay?Yes Go to next step.
No Repair or replace terminals, then go to Step 9.
8INSPECT COUPLER COMPONENT (10-PIN)
CIRCUIT FOR SHORT TO GROUND
•Verify that coupler component (10-pin)
connector is disconnected.
•Check continuity between coupler component
(10-pin) connector terminal A (part side) and
ground.
•Is there continuity?Yes Repair or replace terminal component, then go to next step.
No Repair or replace coupler component, then go to next step.
9VERIFY TROUBLESHOOTING OF DTC P0763
COMPLETED
•Make sure to reconnect all disconnected
connectors.
•Clear DTC from memory using WDS or
equivalent.
•Drive vehicle in D range and make sure that
gears shift smoothly from 1GR to 5GR.
•Is same DTC present?Yes Replace TCM, then go to next step.
(See K2–96 TCM REMOVAL/INSTALLATION.)
No Go to next step.

K2–188
TROUBLESHOOTING
NO.1 VEHICLE DOES NOT MOVE IN D RANGE, OR IN R POSITIONA6E578001030204
Diagnostic procedure
End Of SieNO.2 VEHICLE MOVES IN N POSITIONA6E578001030205
1 Vehicle does not move in D range, or in R position
DESCRIPTION•Vehicle does not move when accelerator pedal depressed.
POSSIBLE
CAUSE•If vehicle does not move in D range or R position, basically, malfunction is in ATX. (Vehicle will move
even with a malfunction in TCM.) Since a malfunction in sensor circuit or output circuit is cause of
malfunction in ATX, inspect sensors, output circuit, and related harnesses.
—Clutch slipped, worn (D range-Low clutch, Low one-way clutch, Reduction one-way clutch, R
position-Reverse clutch, Low and reverse brake, Reduction brake)
•Line pressure low
•Malfunction of shift solenoid A, B, or C
•Malfunction of sensor ground
•Malfunction of body ground
•Malfunction of control valve body
—Malfunction of selector lever
—Parking mechanism not properly operated
—Malfunction of torque converter
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•With vehicle stopped on a flat, paved road
and engine off, does vehicle move when
pushed? (in D ranges or N, R positions and
brake released)Yes Go to next step.
No Inspect for parking mechanism.
(See ATX Workshop Manual.)
2•Start engine.
•Does vehicle move when selector lever in
between N position and D range?Yes Inspect or adjust selector lever.
(See K2–117 SELECTOR LEVER INSPECTION.)
(See K2–118 SELECTOR CABLE ADJUSTMENT.)
No Go to next step.
3•Stop engine.
•Inspect pressure control solenoid circuit.
•Is it 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•Inspect for pressure control solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
—If pressure control solenoid okay, inspect for open or
short circuit between TCM connector terminal 2Y and
pressure control solenoid connector terminal D.
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.
2 Vehicle moves in N position
DESCRIPTION•Vehicle creeps in N position.
•Vehicle creeps if brake pedal not depressed in N position.
POSSIBLE
CAUSE•If vehicle moves in N position, basically, malfunction is in ATX. Since a malfunction in sensor circuit or
output circuit is cause of malfunction in ATX, inspect sensors, output circuit, and related harnesses.
—Clutch burned (Low clutch, Low one-way clutch, Low and reverse brake)
•Line pressure low
•Malfunction of control valve body
—Selector lever position disparity (Although the selector indicator shows N position, hydraulic circuit
shows D range or R position)
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.

TROUBLESHOOTING
K2–189
K2
Diagnostic procedure
End Of SieNO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED
A6E578001030206
End Of SieNO.4 EXCESSIVE CREEPA6E578001030207
End Of SieNO.5 NO CREEP AT ALLA6E578001030208
STEP INSPECTION ACTION
1•Does vehicle creep when selector lever
moved slightly in N position?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 Inspect and adjust selector lever.
(See K2–117 SELECTOR LEVER INSPECTION.)
(See K2–118 SELECTOR CABLE ADJUSTMENT.)
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.
3 Vehicle moves in P position, or parking gear does not disengage when P is disengaged
DESCRIPTION•Vehicle rolls when on a downward slope and tires do not lock in P position.
•Tires locked when P disengaged, vehicle does not move in D range, and R position when accelerator
pedal depressed, and engine remains in stall condition.
POSSIBLE
CAUSE•Malfunction of parking mechanism (May have effect on noise or shock from transaxle)
•Improper adjustment of selector lever
•If vehicle moves in N position, perform symptom troubleshooting No.2 “Vehicle moves in N position”
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
4 Excessive creep
DESCRIPTION•Vehicle accelerates in D range, and R position without depressing accelerator pedal.
POSSIBLE
CAUSE•Engine idle speed high (transaxle system is not cause of problem)
•Go to symptom troubleshooting No.9 “Fast idle/runs on”
(See Section F.)
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
5 No creep at all
DESCRIPTION•Vehicle does not move in D range, or R position when idling on flat paved road.
POSSIBLE
CAUSE•Either engine output low or there is clutch circuit slippage.
—Clutch burned
•Line pressure low
•Malfunction of shift solenoid A, B, or C
•Malfunction of body ground
•Malfunction of control valve body
—Transaxle fixed in 4GR (Operation of fail-safe function)
•Short or open circuit in wiring
•Poor connection of connector
•Electronic parts of output and input system malfunctioning
—Engine torque is not start
•Malfunction of torque converter
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.

K2–190
TROUBLESHOOTING
Diagnostic procedure
End Of SieNO.6 LOW MAXIMUM SPEED AND POOR ACCELERATIONA6E578001030209
Diagnostic procedure
STEP INSPECTION ACTION
1•Does vehicle creep in P and/or N position? Yes Inspect or adjust the selector lever.
(See K2–117 SELECTOR LEVER INSPECTION.)
(See K2–118 SELECTOR CABLE ADJUSTMENT.)
No Go to next step.
2•Stop engine.
•Inspect pressure control solenoid circuit.
•Is it okay?Yes Go to next step.
No•Inspect for pressure control solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
—If pressure control solenoid okay, inspect for open or
short circuit between TCM connector terminal 2Y and
pressure control solenoid connector terminal D.
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 K2–99 AUTOMATIC TRANSAXLE AND
TRANSFER REMOVAL/INSTALLATION.)
(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.
6 Low maximum speed and poor acceleration
DESCRIPTION•Vehicle acceleration poor at start.
•Delayed acceleration when accelerator pedal depressed while driving.
POSSIBLE
CAUSE•If clutch is stuck or does not stay in 4GR, malfunction is in engine circuit.
—Clutch slipped, burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of shift solenoids A, B, or C
•Malfunction of body ground
•Malfunction of control valve body
—Transaxle fixed in 4GR (Operation of fail-safe function)
•Short or open circuit in wiring
•Poor connection of connector
•Electronic parts of output and input system malfunction are malfunctioning
—Insufficient starting torque (Suspected when in-gear condition, shift control and engine circuit are
normal)
•Malfunction of torque converter (Poor operation, sticking)
—Engagement of TCC operation range (Operation of fail-safe function)
•Malfunction of TFT sensor (Short or open circuit)
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•With ignition switch at 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 position”.
2•Go to symptom troubleshooting No.12 “Lack/
loss of power-acceleration/cruise”.
(See Section F.)
•Does engine control system okay?Yes Go to next step.
No Repair or replace any defective parts according to
inspection results.

TROUBLESHOOTING
K2–191
K2
End Of SieNO.7 NO SHIFTINGA6E578001030210
End Of Sie
3•Stop engine.
•Inspect shift solenoid A, B, or C.
•Are they okay?Yes Go to next step.
No•Inspect for shift solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
—If shift solenoids okay, inspect for open or short circuit
between TCM connector terminals 2W, 2T, 2X and
pressure control solenoid connector terminals I, G, or
F.
4•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 K2–99 AUTOMATIC TRANSAXLE AND
TRANSFER REMOVAL/INSTALLATION.)
(See ATX Workshop Manual.)
No Replace torque converter.
5•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. STEP INSPECTION ACTION
7 No shifting
DESCRIPTION•Single shift range only.
•Sometimes it shifts correctly.
POSSIBLE
CAUSE•When gear position is fixed in 4GR due to the fail-safe operation, malfunction is in the ATX.
•Perform malfunction diagnosis according to No.6 “Low maximum speed and poor acceleration”.
—Clutch burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of shift solenoid A, B or C
•Malfunction of control valve body
—4GR is fixed (Operation in fail-safe function)
•Short or open circuit in wiring
•Poor connection of connector
•Poor ground of shift solenoid
•Electrical parts of output and input system malfunctioning
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.

TROUBLESHOOTING
K2–193
K2
End Of SieNO.9 ABNORMAL SHIFTINGA6E578001030212
Diagnostic procedure
End Of Sie
NO.10 FREQUENT SHIFTINGA6E578001030213
End Of Sie
5•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. STEP INSPECTION ACTION
9 Abnormal shifting
DESCRIPTION•Shift incorrectly (incorrect shift pattern).
POSSIBLE
CAUSE•There is a malfunction in signal circuit which controls shifting (Throttle position signal, input/turbine
speed sensor, VSS), control valve is stuck, or clutch circuit is stuck.
—Clutch slipped, burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of shift solenoid A, B, or C
•Malfunction of TCC solenoid valve
•Malfunction of body ground
•Misadjustment of accelerator cable
•Malfunction of control valve body
•Malfunction or misadjustment of TR switch
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 continuity between TCM connector
terminals C and Y and transaxle case.
•Is there continuity?Yes Go to next step.
No Repair or replace ground circuit.
2•Stop engine.
•Inspect shift solenoid A, B, or C circuit.
•Are they okay?Yes Inspect TCM connector terminal for bend, damage,
corrosion or poor contact.
No•Inspect connection of shift solenoid A, B, or C terminal
on ATX for bend, damage, corrosion or looseness.
•Inspect for shift solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
—If shift solenoids okay, inspect for open or short circuit
between TCM connector terminals 2W, 2T, 2X and
coupler component terminals I, G, or F.
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.
10 Frequent shifting
DESCRIPTION•Downshifting occurs immediately even when accelerator pedal depressed slightly in D range.
POSSIBLE
CAUSE•The circuit which is the cause is basically the same as for No.9 “Abnormal shifting”. However, a
malfunction of input signal to TP sensor, input/turbine speed sensor, VSS (including the sensor ground,
sensor harness and connector), or clutch slippage (clutch stuck, low pressure in line) may also be the
cause.
Note
•Before following troubleshooting steps, make sure that the Automatic Transaxle On-Board
Diagnostic and Automatic Transaxle Basic Inspection are conducted.