2002 MAZDA 6 transmission fluid

GI–6
NEW STANDARDS
#1 : Diagnostic trouble codes depend on the diagnostic test mode.
#2 : Controlled by the PCM
#3 : In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
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OL Open Loop—Open Loop
—Output Speed Sensor—Vehicle Speed Sensor 1
OC Oxidation Catalytic Converter—Catalytic Converter
O2S Oxygen Sensor—Oxygen Sensor
PNP Park/Neutral Position—Park/Neutral Range
—PCM Control Relay—Main Relay #6
PSP Power Steering Pressure—Power Steering Pressure
PCM Powertrain Control Module ECU Engine Control Unit #4
—Pressure Control Solenoid—Line Pressure Solenoid Valve
PAIR Pulsed Secondary Air Injection—Secondary Air Injection SystemPulsed
injection
—Pump Speed Sensor—NE Sensor #6
AIR Secondary Air Injection—Secondary Air Injection SystemInjection
with air
pump
SAPV Secondary Air Pulse Valve—Reed Valve
SFI Sequential Multiport Fuel Injection—Sequential Fuel Injection
—Shift Solenoid A—1–2 Shift Solenoid Valve
—Shift A Solenoid Valve
—Shift Solenoid B—2–3 Shift Solenoid Valve
—Shift B Solenoid Valve
—Shift Solenoid C—3–4 Shift Solenoid Valve
3GR Third Gear—3rd Gear
TWC Three Way Catalytic Converter—Catalytic Converter
TB Throttle Body—Throttle Body
TP sensor Throttle Position Sensor—Throttle Sensor
TCV Timer Control Valve TCV Timing Control Valve #6
TCC Torque Converter Clutch—Lockup Position
TCMTransmission (Transaxle) Control
Module—EC-AT Control Unit
—Transmission (Transaxle) Fluid
Temperature Sensor—ATF Thermosensor
TR Transmission (Transaxle) Range—Inhibitor Position
TC Turbocharger—Turbocharger
VSS Vehicle Speed Sensor—Vehicle Speed Sensor
VR Voltage Regulator—IC Regulator
VAF sensor Volume Air Flow Sensor —Airflow Meter
WU-TWCWarm Up Three Way Catalytic
Converter—Catalytic Converter #5
WOT Wide Open Throttle—Fully Open New Standard Previous Standard
Remark
Abbrevi-
ationNameAbbrevi-
ationName

SCHEDULED MAINTENANCE
GI–17
GI
Scheduled Maintenance Service (Specific Work Required)
•The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
For Europe (L.H.D. U.K.)
Bold frames: New item
Maintenance Item Specific Work Required
ENGINE
Engine valve clearance Measure clearance
Drive beltsInspect for wear, cracks and fraying, and check tension.
Replace drive belt.
Engine timing belt Replace engine timing belt.
Engine oil Replace engine oil and inspect for leakage.
Oil filter Replace oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system
(including coolant level adjustment)Check coolant level and quality, and inspect for leakage.
Engine coolant Replace coolant.
FUEL SYSTEM
Air cleaner elementInspect for dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Fuel filter Replace fuel filter.
Fuel lines and hoses Inspect for cracks, leakage and loose connection.
Fuel injection system (for MZR-CD (RF Turbo)) Update to injection amount correction with WDS. (see W/M)
IGNITION SYSTEM (FOR GASOLINE)
Spark plugsInspect for wear, damage, carbon, high-tension lead condition and measure
plug gap.
Replace spark plugs.
EMISSION CONTROL SYSTEM
Evaporative system (for gasoline)Check system operation (see W/M), vapor lines, vacuum fitting hoses and
connection.
E.G.R. system (MZR-CR (RF Turbo))Check system operation (see W/M), vacuum fitting hoses and connection.
Update to MAF correction for E.G.R control with WDS. (see W/M)
ELECTRICAL SYSTEM
Battery electrolyte level and specific gravity Check level and specific gravity.
CHASSIS AND BODY
Brake fluidCheck fluid level and inspect for leakage.
Replace brake fluid.
Brake lines, hoses and connectionsInspect for cracks, damage, chafing, corrosion, scars, swelling and fluid
leakage.
Parking brake Check lever stroke.
Power brake unit and hosesCheck vacuum lines, connections and check valve for improper attachment,
air tightness, cracks chafing and deterioration.
Disc brakesTest for judder and noise. Inspect caliper for correct operation and fluid
leakage, brake pads for wear. Check disc plate condition and thickness.
Power steering fluid and linesCheck fluid level and lines for improper attachment, leakage, cracks,
damage, loose connections, chafing and deterioration.
Power steering fluid Check fluid level.
Power steering system and hosesCheck lines for improper attachment, leakage, cracks, damage, loose
connections, chafing and deterioration.
Steering operation and gear housingCheck that the steering wheel has the specified play. Be sure to check for
changes, such as excessive play, hard steering or strange noises.
Check gear housing and boots for looseness, damage and grease/gear oil
leakage.
Steering linkages tie rod ends and armsCheck ball joint, dust cover and other components for looseness, wear,
damage and grease leakage.
Front and rear suspension and ball joints Inspect for grease leakage, cracks, damage and looseness.
Manual transmission/transaxle oilCheck oil level and inspect for leakage.
Replace manual transmission/transaxle oil.
Automatic transmission/transaxle fluid level Check fluid level.

H–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E490216003201•The construction and operation of the clutch is essentially carried over from that of the current MPV (LW)
models, except for the following features. (See Mazda MPV Training Manual 3340-1*-99F.)
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FEATURESA6E490216003202Adoption of the A65M-R manual transaxle models
•The specifications for the A65M-R manual transaxle models have been added.
Increased torque transmission capacity
•Increased clutch cover set load.
Reduced noise
•The flywheel with a damper has been adopted for the A65M-R manual transaxle model.
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SPECIFICATIONSA6E490216003203
Bold frames:New specifications
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SUPPLEMENTAL SERVICE INFORMATIONA6E490216003204•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
CLUTCH RELEASE CYLINDER
•Removal/installation procedure has been modified.
•Disassembly/assembly procedure has been modified.
CLUTCH UNIT
•Removal/installation procedure has been modified.
•Clutch cover inspection procedure has been modified.
FLYWHEEL
•Flywheel inspection procedure has been modified.
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OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
EngineMZR-CD (RF Turbo)
Manual transaxle type A65M-R
Clutch control Hydraulic
Clutch coverSpring type Diaphragm
Set load (N {kgf, lbf}) 6,550 {668, 1,472}
Clutch discOuter diameter (mm {in}) 239 {9.41}
Inner diameter (mm {in}) 160 {6.30}
Clutch pedalType Suspended
Pedal ratio 5.9 6.41
Full stroke (mm {in}) 140 {5.51} 148 {5.83}
Clutch master cylinder inner diameter (mm {in}) 15.87 {0.625}
Clutch release cylinder inner diameter (mm {in}) 19.05 {0.750}
Clutch fluid type SAE J1703, FMVSS116 DOT-3 or DOT-4
OUTLINE

K2–74
AUTOMATIC TRANSAXLE
Evaluation of line pressure test
Stall Speed Test
1. Perform mechanical system test preparation. (See K2–72 Mechanical System Test Preparation.)
2. Connect a tachometer.
3. Start the engine.
4. Shift the selector lever to D range.
Caution
•Do not maintain WOT in any gear range for more than 5 seconds or transaxle damage will occur.
•If engine speed recorded by the tachometer exceeds maximum specified rpm, release the
accelerator pedal immediately. Clutch or band slippage is indicator.
5. Firmly depress the brake pedal with the left foot, and gently depress the accelerator pedal to the floor (WOT)
with the right.
6. When the engine speed no longer increases, quickly read the engine speed and release the accelerator pedal.
7. Shift the selector the to N position and let the engine idle for 1 minute or more to cool the ATF.
8. Perform stall tests for the remaining ranges and position in the same manner.
•R position
•Mrange (1GR, 2GR)
Engine stall speed
ATF temperature : 60—70 °C {140—158 °F}
Turn off all electrical loads
2,200—2,600 rpm
9. Turn off the engine.
Evaluation of stall test
Condition Possible cause
IdleBelow specificationLow pressure in all rangesWorn oil pump
Poor operation of each solenoid
Fluid leaking from oil strainer, oil pump, pressure regulator
valve, torque converter relief valve, and/or pressure relief valve
Pressure regulator valve or pilot valve sticking
Damaged pressure regulator valve spring or pilot valve spring
Low pressure in D and M
rangeFluid leaking from hydraulic circuit of low clutch
Low pressure in R position
onlyFluid leaking from hydraulic circuit of reverse clutch
Fluid leaking from hydraulic circuit of low and reverse brake
clutch
Above specification High pressure in all rangesThrottle position sensor out of adjustment
TFT sensor malfunction
Poor operation of shift solenoid
Pilot valve sticking
Pressure reducing valve or plug sticking
Stall Below specification Low pressure in all rangesThrottle position sensor out of adjustment
Pressure control solenoid malfunction
Poor operation of shift solenoid
Pilot valve sticking
Pressure reducing valve or plug sticking
Condition Possible cause
Above specificationIn all forward ranges and R
positionInsufficient line pressure
Worm oil pump
Poor operation of low clutch
Poor adjustment or malfunction of TR switch
Oil leaking from oil pump, control valve, and/or transmission
case
Pressure regulator valve or pilot valve sticking
In all forward ranges Low clutch slippage
Low one-way clutch slippage
Reduction one-way clutch slippage
In R positionLow and reverse brake slippage
Reverse clutch slippage
Reduction brake slippage
Below specificationIn all forward ranges and R
positionEngine out of tune
One-way clutch slippage within torque converter