2002 MAZDA 6 oil pressure

TROUBLESHOOTING
K2–187
K2
End Of Sie
Vehicle dose not move in D range, or in R position
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XX X 1
Excessive creep 4
No creep at all 5
Low maximum speed and poor acceleration 6
No shifting 7
Does not shift to fifth gear (5GR) 8
Abnormal shifting 9
Frequent shifting 10
Shift point is high or low 11
Torque converter clutch (TCC) non-operation 12
No kickdown 13
Engine flares up or slips when upshifting or downshifting 14
Engine flares up or slip when accelerating vehicle 15
Judder upon torque converter clutch (TCC) operation 16
Excessive shift shock from N to D or N to R position/range 17
Excessive shift shock on torque converter clutch (TCC) 19
No engine braking in 1GR position of M range 22
Transaxle overheats 23
Engine stalls when shifted to D range, or in R position 24
Engine stalls when driving at slow speeds or stopping 25
Starter does not work 26Excessive shift shock is given when upshifting and
downshifting 18
Noise occurs at idle when vehicle is stopped in all
positions/ranges 20
Noise occurs at idle when vehicle is stopped in D
range, or in R position 21
Gear position indicator light illuminates in D range or P, N,
R positions 28Gear position indicator light does not illuminate in M range
Hydraulic system
components
Control valve bodyPowertrain 27
Does not shift up in M range
29
Does not shift down in M range
Symptom item
Cause of trouble
Reduction accumulator is not operating properly
Clogging
Clogging
Clogging
Clogging
Clogging
Clogging
Clogging Clogging
Clogging
Slipping (clutch, brake) Oil cooler is not operating properly
Torque converter is not operating properly Burned (clutch, brake)
TCC piston is not operating properly TCC piston is cracking or peeling2-4 brake solenoid valve hydraulic circuit Pressure control solenoid hydraulic circuit
TCC solenoid valve hydraulic circuit
High clutch solenoid valve hydraulic circuit
Shift solenoid A hydraulic circuit
Shift solenoid B hydraulic circuit
Shift solenoid C hydraulic circuit
Neutral shift solenoid valve
Reducation timing solenoid valve
30Vehicle moves in N position 2
Vehicle moves in P position, or parking gear does not
disengage when P is disengaged 3
A6E5780W003

K2–192
TROUBLESHOOTING
NO.8 DOES NOT SHIFT TO FIFTH GEAR (5GR)A6E578001030211
Diagnostic procedure
8 Does not shift to fifth gear (5GR)
DESCRIPTION•Vehicle does not upshift from 4GR to 5GR even though vehicle speed increased.
•Vehicle does not shift to 5GR even though accelerator pedal released in D range at 60 km/h {37 mph}.
POSSIBLE
CAUSE•Basically, TCC does not operate when fail-safe is operating. Verify DTC at first. If TCC operates when
driving at high speeds only, malfunction (improper adjustment) is in the D range switch circuit or TR
switch circuit.
Note
•If the TCC or piston is stuck, inspect them. In addition, inspect the oil cooler for foreign particles
which may have mixed in with the ATF.
—TCC piston slipped, burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of ECT sensor
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
—Malfunction of TFT sensor
•Short or open circuit in wiring
•Poor connection of connector
•Malfunction of sensor
—Malfunction of TR switch
•Selector lever adjustment incorrect
•TR switch adjustment incorrect
—Malfunction of TCC solenoid valve
•Short or open circuit in wiring
•Poor connection of connector
•Solenoid valve stuck
—Malfunction of M range switch
—Malfunction of torque converter
—Malfunction of control valve body
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Turn ignition switch to 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 positions”.
2•Drive vehicle in D range and inspect
following:
—1–2 shift up and down
—2–3 shift up and down
—3–4 shift up and down
—4–5 shift up and down
•Are all shift-up and shift-down possible?Yes Go to next step.
NoNo shift at all:
•Go to symptom troubleshooting No.7 “No shifting”.
Abnormal shift:
•Go to symptom troubleshooting No.9 “Abnormal
shifting”.
3•Stop engine.
•Inspect shift solenoid A, B, or C circuit.
•Are they okay?Yes Go to next step.
No•Inspect for shift solenoid mechanical stuck.
(See K2–88 SOLENOID VALVE INSPECTION.)
4•Remove torque converter.
•Inspect torque converter.
(See ATX Workshop.)
•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.

K2–194
TROUBLESHOOTING
NO.11 SHIFT POINT IS HIGH OR LOWA6E578001030214
End Of SieNO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATIONA6E578001030215
Diagnostic procedure
11 Shift point is high or low
DESCRIPTION•Shift point considerably different from automatic shift diagram.
•Shift delays when accelerating.
•Shift occurs quickly when accelerating and engine speed does not increase.
POSSIBLE
CAUSE•If the transaxle does not shift abnormally, there is a malfunction of input signal to TP sensor, input/
turbine speed sensor, or VSS.
•If engine speed is high or low regardless that shifting is normal, inspect tachometer.
•Verify that output signal of TP sensor changes linearly.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
12 Torque converter clutch (TCC) non-operation
DESCRIPTION•TCC does not operate when vehicle reaches TCC operation range.
POSSIBLE
CAUSE•Basically, TCC does not operate when fail-safe is operating. Verify DTC at first. If TCC operates when
driving at high speeds only, the malfunction (improper adjustment) is in D and/or M ranges switch circuit
or TR switch circuit.
Note
•If the TCC or piston is stuck, inspect them. In addition, inspect the oil cooler for foreign particles
which may have mixed in with the ATF.
•TCC piston slipped, burned
—Line pressure low
•Incorrect throttle position signal
•Input/turbine speed sensor malfunction
•TFT sensor malfunction
•Sensor ground malfunction
•VSS malfunction
•Malfunction of output solenoid valve system (Sticking)
•TCC solenoid valve malfunction
•Malfunction of control valve body system (Poor operation, sticking)
•TCC piston hydraulic pressure system malfunction
•Malfunction of TP sensor (Not operating linearly)
•Malfunction of input/turbine speed sensor or VSS
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Turn ignition switch to ON.
•Does gear position lamp 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 positions”.
2•Disconnect TCM.
•Is resistance between ground terminals 1C,
1Y at TCM connector and body ground less
than 5.0 ohm?Yes Go to next step.
No Repair open ground circuit.
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 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.

K2–196
TROUBLESHOOTING
NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLEA6E578001030218
End Of SieNO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATIONA6E578001030219
End Of SieNO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGEA6E578001030220
Diagnostic procedure
15 Engine flares up or slips when accelerating vehicle
DESCRIPTION•Engine flares up when accelerator pedal depressed for upshifting.
•Engine flares up suddenly when accelerator pedal depressed for downshifting.
POSSIBLE
CAUSE•Malfunction is basically the same as for No.14 “Engine flares up or slips when upshifting or
downshifting”.
—If conditions for No.14 worsen, malfunction will develop into No.15.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
16 Judder upon torque converter clutch (TCC) operation
DESCRIPTION•Vehicle jolts when TCC engaged.
POSSIBLE
CAUSE•Poor TCC engagement due to either slippage because TCC piston is stuck or line pressure is low.
Caution
•If the TCC or piston are stuck, inspect them. In addition, inspect the oil cooler for foreign
particles which may have mixed in with the ATF.
—Torque converter clutch piston slipped, burned
•Line pressure low
•Incorrect throttle position signal
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of TCC solenoid valve
•Malfunction of control valve body
—Malfunction of torque converter
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
17 Excessive shift shock from N to D or N to R position/range
DESCRIPTION•Strong shock felt when shifting from N to D or N to R position/range at idle.
POSSIBLE
CAUSE•Shift shock may worsen when fail-safe is operating. If no DTC is output, shift shock may worsen due to
poor operation of control valve body or sticking of clutch.
—Clutch burned (N→D: Low clutch, N→R: Reverse clutch or low and reverse brake)
•Line pressure low
•Incorrect throttle position signal
•Malfunction of TFT sensor
•Malfunction of sensor ground
•Misadjustment of throttle cable
•Malfunction of control valve body
—Poor hydraulic operation (Malfunction in range change)
—Idle speed high
—Poor tightening torque of engine mount, exhaust mount
—Line pressure high
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Does shift shock occur only when engine
cold?Yes Go to next step.
No Go to Step 3.
2•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.

K2–198
TROUBLESHOOTING
NO.20 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN ALL POSITIONS/RANGESA6E578001030223
Diagnostic procedure
End Of SieNO.21 NOISE OCCURS AT IDLE WHEN VEHICLE IS STOPPED IN D RANGE, OR IN R POSITIONA6E578001030224
End Of SieNO.22 NO ENGINE BRAKING IN 1GR POSITION OF M RANGEA6E578001030225
Diagnostic procedure
20 Noise occurs at idle when vehicle is stopped in all positions/ranges
DESCRIPTION•Transaxle noisy in all positions and ranges when vehicle idling.
POSSIBLE
CAUSE•Malfunction is in pressure solenoid or oil pump which causes a high-pitched noise to be emitted from
transaxle at idle.
Note
•If a noise is emitted during shifting only, malfunction is in shift solenoid A, B, or C.
•If a noise is emitted during shifting at certain gears only or during deceleration only, it is gear noise.
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
STEP INSPECTION ACTION
1•Inspect engine condition.
•Is any engine concern (e.g. Rough idle)?Yes Go to appropriate symptom troubleshooting.
(See F1–57 ENGINE SYMPTOM TROUBLESHOOTING.)
No Replace basic inspection and repair or replace any
defective parts according to inspection result.
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.
21 Noise occurs at idle when vehicle is stopped in D range, or in R position
DESCRIPTION•Transaxle noisy in driving ranges when vehicle idling.
POSSIBLE
CAUSE•Although the malfunction is basically the same as No.20 “Noise occurs at idle when vehicle is stopped
in all positions/ranges”, other causes may be selector lever position disparity or TR switch position
disparity.
Note
•Before following troubleshooting steps, make sure that Automatic Transaxle On-Board Diagnostic
and Automatic Transaxle Basic Inspection are conducted.
22 No engine braking in 1GR position of M range
DESCRIPTION•Engine speed drops to idle but vehicle coasts when accelerator pedal released during cruising at
medium to high speeds.
•Engine speed drops to idle but vehicle coasts when accelerator pedal released when in M range (1GR)
at low vehicle speed.
POSSIBLE
CAUSE•Clutch slipped, burned (Reduction brake)
—Line pressure low
•Malfunction of VSS
•Malfunction of input/turbine speed sensor
•Malfunction of sensor ground
•Malfunction of control valve body
—M range switch on not judged by TCM (short, or open circuit, poor operation)
•Malfunction of M range switch signal
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 TR switch adjustment.
•Does TR switch adjusted properly?
•Select PNP PID.
•Is PNP PID reading okay when selecting
range?Yes Go to next step.
No Adjust TR switch as necessary.
(See K2–83 TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT.)
Inspect TR switch.
Repair or replace any defective parts.

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.

N–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E660201036201•The construction and operation of the steering system is essentially carried over from that of the current
Mazda6 (GG), except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
• Due to the addition of the MZR-CD (RF Turbo) engine, a gear-driven power steering oil pump has been
adopted. The operation of the oil pump is the same as that of the current Mazda6 (GG).
• The disassembly/assembly procedures for the steering gear and linkage of the newly equipped MZR-CD (RF
Turbo) engine, wagon and 4WD models are the same as that of the current Mazda6 (GG).
End Of Sie
FEATURESA6E660201036202Improved Steering Feel
• The fluid pressure characteristics of the power steering system has been optimized (MZR-CD (RF Turbo) and
4WD models).
End Of Sie
SPECIFICATIONSA6E660201036203
* : When reservoir tank is at maximum volume
Bold frame:New specifications
End Of Sie
OUTLINE
Item New Mazda6
(GG) (4SD, 5HB) New Mazda6 (GY) (Wagon) Current Mazda6
(GG) (4SD, 5HB)
Drive train 2WD 4WD 2WD
Steering
wheel Outer diameter
370 {14.6}
(mm {in})
Lock-to-lock 18 inch wheel specification vehicles: 2.65
Except for above: 2.75 2.75
(turns)
Steering gear
and linkage Type Rack-and-pinion
Rack stroke 18 inch wheel specification vehicles:
141.6—143.6 {5.57—5.65}
Except for above:146.8—148.8
{5.78—5.85} 146.8—148.8 {5.78—5.85}
(mm {in})
Steering
column and
shaft Shaft type Collapsible
Joint type 2-cross joint
Amount of tilt
45 {1.8}
(mm {in})
Amount of telescope
(If equipped) 50 {2.0}
(mm {in})
Powe r
steering
system Power assist type Engine speed sensing
Pow er
steering
fluid
Ty p e
M-
III or equivalent (e.g. Dexron®II)
Fluid capacity
*
(approximate
quantity) MTX (except MZR-CD (RF Turbo)):
0.80 {0.85, 0.70}
ATX: 0.87 {0.92, 0.77} MZR-CD (RF Turbo):
0.86 {0.91, 0.76} 0.89 {0.94, 0.78}
MTX:
0.80 {0.85, 0.70}
AT X :
0.87 {0.92, 0.77}
(L {US qt, Imp qt})

N–6
ENGINE SPEED SENSING POWER STEERING
POWER STEERING FLUID INSPECTIONA6E661432040201Fluid Level Inspection
1. Inspect the power steering fluid level.
•Add fluid to the specified level as necessary.
Fluid specification
ATF M-III or equivalent (e.g. Dexron
®II)
Fluid Leakage Inspection
Caution
•If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid
temperature will rise excessively and adversely affect the oil pump.
1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.
Note
•The points where fluid leakage may occur are indicated in the figure.
3. Inspect for fluid leakage.
•If fluid leakage is found, replace the related pipe or hose.
ENGINE SPEED SENSING POWER STEERING
L.H.D.
ATX
MTX
R.H.D.
ATX
MTX MZR-CD (RF Turbo)
EXCEPT MZR-CD (RF Turbo)L.H.D
R.H.D
A6E66142001