2002 MAZDA 6 coolant level

F2–202
TROUBLESHOOTING
NO.14 POOR FUEL ECONOMYA6E408018881216
Diagnostic Procedure
14 POOR FUEL ECONOMY
DESCRIPTION•Fuel economy is unsatisfactory.
POSSIBLE
CAUSE•Incorrect idle speed
•A/C system improper operation
•Intake -air system clogging or restriction
•Engine cooling system malfunction
•Poor fuel quality
•Improper coolant level
•Erratic signal from CKP sensor
•Erratic signal from CMP sensor
•Fuel pressure sensor or related circuit malfunction
•ECT sensor or related circuit malfunction
•Boost sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•Incorrect adjustment idle switch
•MAF/IAT sensor or related circuit malfunction
•IAT sensor No .2 or related circuit malfunction
•VSS or related circuit malfunction
•Turbocharger malfunction
•Charge air cooler malfunction
•Low engine compression
•Improper valve timing
•Exhaust system and/or catalyst converter clogging
•Incorrect fuel injection timing
•Fuel injector malfunction
•Supply pump malfunction
•Fuel leakage
•Fuel line clogging or restriction
•Fuel filter clogging or restriction
•Brake dragging
•EGR system malfunction
•Vacuum leakage
•Clutch slippage
•Variable boost control (VBC) system malfunction
•Coolant heater system malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE
REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.
STEP INSPECTION RESULTS ACTION
1 Inspect for following:
•Fuel quality (e.g.: including water
contamination, winter/summer blend)
•Fuel line/fuel filter clogging and/or restriction
•Fuel line leakage
•Intake-air system restriction
•Exhaust system and/or catalyst converter
restriction
•Charge air cooler condition (restriction or
damaged)
•Vacuum leakage
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Is brake system functioning properly? Yes Go to next step.
No Inspect for cause.

F2–210
TROUBLESHOOTING
End Of SieNO.17 COOLING SYSTEM CONCERNS-OVERHEATINGA6E408018881219
Diagnostic Procedure
17
COOLING SYSTEM CONCERNS-OVERHEATING
DESCRIPTION•Engine runs at higher than normal temperature/overheats.
POSSIBLE
CAUSE•Cooling fan No.2 malfunction
•Cooling fan No.1 malfunction
•Low drive belt tension
•Drive belt damage
•Improper coolant level
•Thermostat malfunction
•Radiator clogging
•Improper water/anti-freeze mixture
•Improper or damaged radiator cap
•Radiator hose damage
•Coolant leakage (engine internal, turbocharger, external)
•A/C system malfunction
•EGR system malfunction
•Coolant heater system malfunction
STEP INSPECTION RESULTS ACTION
1 Inspect following:
•Engine coolant level
•Coolant leakage (around heater unit in
passenger compartment, coolant hoses and/
or radiator, and around coolant heater unit.)
•Water and anti-freeze mixture
•Radiator condition
•Collapsed or restricted radiator hoses
•Radiator pressure cap
•Drive belt tension
•Drive belt
•Fan rotational direction
Are all items okay?Yes Go to next step.
No Service as necessary.
Repeat Step 1.
2 Perform self-test function using WDS or
equivalent.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to next step.

K2–72
AUTOMATIC TRANSAXLE
MECHANICAL SYSTEM TESTA6E571401030209Mechanical System Test Preparation
1. Apply the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant. (See Section E.)
3. Inspect the engine oil. (See D–8 ENGINE OIL INSPECTION.)
4. Inspect the ATF levels. (See K2–79 Automatic Transaxle Fluid (ATF) Level Inspection.)
5. Inspect the idle speed and ignition timing in P position. (See F1–22 IDLE SPEED INSPECTION (4WD).)
Line Pressure Test
Note
•Line pressure cannot be measured on the JA5AX-EL automatic transaxle. Measure the low clutch
pressure in place of D and M range line pressures. Measure the reverse clutch pressure in place of R
position line pressure.
1. Engine idling.
(1) Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.)
Warning
•Removing the plug when the ATF is hot can be dangerous. Hot ATF can come out of the opening
and badly burn you. Before removing the square-head plug, allow the ATF to cool.
(2) Remove the plug and O-ring shown in the
figure.
AUTOMATIC TRANSAXLE
LINE PRESSURE INSPECTION PORT
D,M RANGES
FRONT
A6E5714W101
LINE PRESSURE INSPECTION PORT
R POSITION
FRONT
A6E5714W102

AUTOMATIC TRANSAXLE
K2–75
K2
Time Lag Test
1. Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.)
2. Start the engine.
3. Warm up the engine until the ATF temperature reaches 60—70°C {140—158°F}. Shift the selector lever from N
position to D range.
4. Use a stopwatch to measure the time it takes from shifting until engagement is felt. Take three measurements
for each test and average the results using the following formula.
Formula
Average time lag = (Time 1 + Time 2 + Time 3) / 3
5. Perform the test for the following shifts in the same manner.
•N position → P position
Time lag
N → D range ... approx. 0.5—1.0 second
N → R position ... approx. 0.6— 1.0 second
Evaluation of time lag test
End Of SieROAD TESTA6E571401030210Road Test Preparation
1. Inspect the engine coolant. (See Section E.)
2. Inspect the engine oil. (See D–8 ENGINE OIL INSPECTION.)
3. Inspect the ATF levels. (See K2–78 AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION.)
4. Inspect the idle speed and ignition timing in P position. (See F1–22 IDLE SPEED INSPECTION (4WD).)
5. Bring up the engine and transaxle to normal operating temperature.
Shift Diagram
D range (normal mode)
Condition Possible Cause
Above specificationN → D shiftInsufficient line pressure in all forward ranges
Low clutch slippage
Low one-way clutch slippage
Reduction one-way clutch slippage
N → R shiftInsufficient line pressure in R position
Low and reverse brake slippage
Reverse clutch slippage
Reduction brake slippage
0/8 1/8
2/8
3/8
4/8
5/8
6/8
7/8
8/8
TCC OPERATION AVAILABLE
VEHICLE SPEED km/h {mph}
THROTTLE OPENING
SHIFT UP
4GR
TCC
OFF
SHIFT DOWN
0
{0}20
{12}40
{25}60
{37}80
{50}100
{63}120
{75}140
{87}160
{99}180
{112}220
{137} 200
{124} 112 23
2
2 232
34
4534
45
5GR TCC ON
4GR TCC ON
5GR TCC OFF
A6E5714W104

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)

TROUBLESHOOTING
K2–199
K2
End Of SieNO.23 TRANSAXLE OVERHEATSA6E578001030226
Diagnostic procedure
End Of SieNO.24 ENGINE STALLS WHEN SHIFTED TO D RANGE, OR IN R POSITIONA6E578001030227
2•Do following symptoms concurrently occur?
—Engine flares up or slips during
acceleration
—Engine flares up or slips when shiftingYes Go to symptom troubleshooting No.14 “Engine flares up or
slips when upshifting or downshifting” or No.15 “Engine
flares up or slips when accelerating vehicle”.
No Go to next step.
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. STEP INSPECTION ACTION
23 Transaxle Overheat
DESCRIPTION•Burnt smell emitted from transaxle.
•Smoke emitted from transaxle.
POSSIBLE
CAUSE•Malfunction is restricted to hindrance of coolant at oil cooler. In addition, overheating of transaxle may
be caused by a malfunction of TFT sensor.
—Line pressure low
•ATF level low
•Incorrect throttle position signal
•Misadjustment of throttle cable
—Oil cooler malfunction (Foreign material mixed in with ATF)
—TFT sensor malfunction
—Excessive amount of ATF
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Is line pressure okay?
(See K2–72 Line Pressure Test.)Yes Go to next step.
No Repair or replace any defective parts according to
inspection results.
2•Is stall speed okay?
(See K2–74 Stall Speed Test.)Yes Go to next step.
No Repair or replace any defective parts according to
inspection results.
3•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.
4•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.)
5•Inspect for bend, damage, corrosion or kinks
of oil cooler pipes.
•Are oil cooler pipes 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 any defective parts.
6•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.
24 Engine stalls when shifted to D range, or in R position
DESCRIPTION•Engine stalls when shifting from N or P position to D range or R position at idle.
POSSIBLE
CAUSE•Malfunction is on the engine control side (e.g. IAC system). Otherwise, malfunction is in input/turbine
speed sensor (engine sometimes starts) or TCC piston circuit (engine always stalls).
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic and
Automatic Transaxle Basic Inspection are conducted.

GENERAL PROCEDURES
M–21
M
PRECAUTION (FRONT AND REAR AXLE)A6E631001018201Wheel and Tire Removal/Installation
1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a
wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}
Brake Line Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
2. If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
Suspension Arm Removal/Installation
1. Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and
unloaded.
Note
•Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools
are in designated position.
Connector Disconnection
1. Disconnect the negative (-) battery cable before disconnecting connectors.
Electronic Control 4WD System Parts
1. After servicing the electronic control 4WD system parts, verify that no DTC has been stored. Clear any DTCs
remaining in the memory.
End Of Sie
GENERAL PROCEDURES

OUTLINE
R–3
R
SPECIFICATIONSA6E740201013203
*1: Engine coolant and engine oil are at specified level. Fuel is full. Spare tire, jack and tools are in designated position.
*
2: Difference between left and right must not exceed 1 °30'.*3: Distance between wheel center and fender brim is following. 4SD and 5HB front: 402 mm {15.82 in} (reference
value) 4SD and 5HB rear: 401 mm {15.78 in} (reference value), WGN (2WD) front: 405 mm {15.94 in}
(reference value) WGN (2WD) rear: 407 mm {16.02 in} (reference value)
Bold frames: New specifications
End Of Sie
Item Specification
New Mazda6 Current
Mazda6
GG (4SD, 5HB) GY (WGN 2WD) GY (WGN 4WD) GG (4SD, 5HB)
Engine type LF, MZR-CD
(RF Turbo) L8, LF, L3,
MZR-CD (RF Turbo) L3 L8, LF, L3
Fr o nt
suspension Type High-mount double wishbone (with double-pivoted lower arm(s))
Spring type Coil spring
Shock absorber type
Cylindrical, double-acting
(Low-pressure gas charged with rebound spring)
Stabilizer Type Torsion bar
Diameter (mm {in}) 23 {0.91}
Wheel
alignment
(Unloaded)*
1
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Maximum
steering
angle inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
Caster
angle*
2
(reference
value) normal 3
°47 ′±1° 3°40 ′±1° 3°35 ′±1° 3°47 ′±1°
elevated*33 °42' ±1° 3°35 ′±1° —3 °42' ±1 °
Camber
angle*
2
(reference
value) normal –0
°17 ′±1° –0°15 ′±1° –0°08 ′±1° –0°17 ′±1°
elevated*3–0 °10' ±1° –0°08 ′±1° —–0 °10' ±1°
Steering
axis
inclination
(reference
value) normal 5
°28 ′ 5°24 ′ 5°16 ′ 5°28 ′
elevated
*35 °18' 5 °16 ′ —5 °18'
Rear
suspension Type E-type multi-link
Spring type Coil spring
Stabilizer
Type Torsion bar
Diameter (mm {in})
4SD: 19 {0.75}
5HB: 18 {0.71}18 {0.71} 21 {0.83}
4SD: 19 {0.75}
5HB: 18 {0.71}
Shock absorber type Cylindrical,
double-acting
(Low-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)/
(High-pressure
gas charged) Cylindrical,
double-acting
(High-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)
Wheel
alignment
(Unloaded)*
1
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Camber
angle*
2
normal –1 °13 ′±1° –1°06 ′±1° –1°03 ′±1° –1°13 ′±1°
elevated
*3–1 °05 ′±1° –0°58 ′±1° —–1 °05 ′±1°
Thrust angle (degree) 0 °±0°48 ′