2002 MAZDA 6 Workshop Manual Suplement

K2–170
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 component No.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 A (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 D (part side) and body
ground.
•Is resistance within 2.6—3.2 ohms?
(See K2–88 SOLENOID VALVE INSPECTION.)Yes Repair or replace terminal component No.1 (12-pin), then
go to Step 12.
No Go to next step.
6INSPECT 2-4 BRAKE SOLENOID VALVE
CONNECTOR FOR POOR CONNECTION
•Disconnect 2-4 brake solenoid vale 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 2-4 brake 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 2-4 brake solenoid valve installation.
•If 2-4 brake solenoid valve is installed correctly, replace
2-4 brake solenoid valve, then go to Step 12
(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 2V
(harness-side) and terminal component No.1
(12-pin) terminal A (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 A (harness-side).
•Is voltage 0 V?Yes Go to next step.
No Repair or replace harness, then go to Step 12.

ON-BOARD DIAGNOSTIC
K2–171
K2
End Of Sie
11INSPECT TCM CIRCUIT FOR SHORT TO
GROUND
•Turn ignition key to OFF.
•Check continuity between TCM terminal 2V
(harness-side) and body ground.
•Is there any continuity?Yes Repair or replace harness, then go to next step.
No Go to next step.
12VERIFY TROUBLESHOOTING OF DTC P0778
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.
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

K2–172
ON-BOARD DIAGNOSTIC
DTC P0791A6E577018901227
DTC P0791 Intermediate sensor circuit malfunction (open/short)
DETECTION
CONDITION•Rotation speed of output gear (intermediate sensor) is low when vehicle speed and engine speed exceed
the preprogrammed value.
Diagnostic support note:
•This is continuous monitor (CCM).
•MIL illuminates if TCM detects the above malfunction condition.
•PENDING CODE is not available.
•FREEZE FRAME DATA is available.
•AT warning light indication.
•DTC is stored in TCM memory.
POSSIBLE
CAUSE•Intermediate sensor malfunction.
•Short to ground between intermediate sensor terminal B and TCM terminal 1K
•Short to ground between intermediate sensor terminal A and TCM terminal 1X
•Open circuit between intermediate sensor terminal B and TCM terminal 1K
•Open circuit between intermediate sensor terminal A and TCM terminal 1X
•Damaged connectors between intermediate sensor and TCM.
•TCM malfunction.
D
B
AC
1K
1X CDTCM
AT X
TCM
HARNESS SIDE CONNECTOR
TERMINAL COMPONENT
NO.2(8-PIN)
HARNESS SIDE CONNECTOR
COUPLER COMPONENT
(8-PIN)
PART SIDE CONNECTORINTERMEDIATE SENSOR
HARNESS SIDE CONNECTOR INTERMEDIATE
SENSOR

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.

K2–174
ON-BOARD DIAGNOSTIC
End Of Sie
10INSPECT INTERMEDIATE SENSOR
CONNECTOR FOR POOR CONNECTION
•Disassemble the transaxle.
•Disconnect intermediate sensor 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.
11INSPECT INTERMEDIATE SENSOR
RESISTANCE
•Measure resistance between intermediate
sensor.
•Is resistance within 513—627 ohms between
intermediate sensor connector terminal A and
B (part side)?Yes Repair or replace coupler component, then go to next step.
No Replace intermediate sensor, then go to next step.
12VERIFY TROUBLESHOOTING OF DTC P0715
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 and engine speed 1500 rpm or
above for 2 second or more
•Repeat Step ii two times.
•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

ON-BOARD DIAGNOSTIC
K2–175
K2
DTC P0798A6E577018901228
DTC P0798 High clutch solenoid valve circuit malfunction (open/short)
DETECTION
CONDITION•Open or short is high clutch solenoid signal system (while TCM monitors solenoid output voltage, the
voltage that differs from the ON/OFF signal output by CPU in TCM is detected).
Diagnostic support note:
•This is continuous monitor (CCM).
•MIL does not illuminate.
•PENDING CODE is not available.
•FREEZE FRAME DATA is not available.
•AT warning light indication.
•DTC is stored in TCM memory.
POSSIBLE
CAUSE•Open circuit between high clutch solenoid valve terminal A and TCM terminal 2U
•Short to ground between high clutch solenoid valve terminal A and TCM terminal 2U
•Short to power between high clutch solenoid valve terminal A and TCM terminal 2U
•high clutch solenoid valve malfunction
•Damaged connector between high clutch solenoid valve and TCM
•TCM malfunction
C
F
A
A J 2PB 2U TCM
CPU
CPUAT X
TCM
HARNESS SIDE CONNECTOR
TERMINAL COMPONENT
NO.1(12-PIN)
HARNESS SIDE CONNECTOR
COUPLER COMPONENT
(10-PIN)
PART SIDE CONNECTORHIGH CLUTCH
SOLENOID VALVE
HIGH CLUTCH SOLENOID VALVE
HARNESS SIDE CONNECTOR

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
K2–177
K2
End Of Sie
11INSPECT TCM CIRCUIT FOR SHORT TO
GROUND
•Turn ignition key to OFF.
•Check continuity between TCM terminal 2U
(harness-side) and body ground.
•Is there any continuity?Yes Repair or replace harness, then go to next step.
No Go to next step.
12VERIFY TROUBLESHOOTING OF DTC P0798
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.
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