service MAZDA 6 2002 Workshop Manual Suplement

F2–224
TROUBLESHOOTING
NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONSA6E408018881227
Diagnostic Procedure
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25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS
DESCRIPTION•A/C compressor magnetic clutch does not disengage under wide open throttle.
POSSIBLE
CAUSE•Accelerator position sensor malfunction
•Accelerator position sensor misadjustment
•Loosely installed accelerator position sensor
STEP INSPECTION RESULTS ACTION
1 Does A/C compressor disengage when A/C
switch is turned off?Yes Go to next step.
No Go to symptom troubleshooting “NO.24 A/C ALWAYS
ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY”.
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:
Inspect adjustment of accelerator position sensor.
If accelerator position sensor adjustment is not
correct, adjust accelerator position sensor.
3 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION)

F2–226
TROUBLESHOOTING
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8Note
•Purpose of this step is to determine if
WDS or equivalent is communicating with
PCM.
Reconnect appropriate sensor connector.
Turn engine switch to ON.
Attempt to access ECT PID.
Can ECT PID be accessed?Yes Go to next step.
No Go to Step 11.
9 Are DTCs present for two or more sensors
connected to PCM terminal 91?
Sensor connected to PCM terminal 91:
•Accelerator position sensor. (P0122, P0123,
P0222, P0223).
•ECT sensor (P0117, P0118)
•Fuel pressure sensor (P0192, P0193)
•Fuel temperature sensor (P0182, P0183)
•MAF/IAT sensor (P0102, P0103, P0112,
P0113)
•IAT sensor No.2 (P0097, P0098)Yes Go to next step.
No Repair open GND circuit to sensor where constant
voltage circuit inspection failed.
10 Turn engine switch to OFF.
Disconnect WDS or equivalent from DLC-2.
Disconnect PCM connector.
Measure resistance between GND circuit at
appropriate sensor connector and PCM
connector terminal 91.
Is resistance less than 5.0 ohms?Yes Reconnect sensor connector.
Go to appropriate DTC test.
No Repair open GND circuit.
11 Turn engine switch OFF.
Disconnect PCM connector.
Measure resistance between battery negative
terminal and PCM terminals 65, 85, 103 and
104.
Is each resistance less than 5.0 ohms?Yes Go to next step.
No Repair open GND circuit.
12 Turn engine switch to OFF.
Measure resistance between GND circuit at
following sensor connector and GND:
•Accelerator position sensor
•ECT sensor
•BARO sensor
•Fuel pressure sensor
•Fuel temperature sensor
•MAF/IAT sensor
•IAT sensor No.2
Is resistance below 5.0 ohms?Yes GND circuits are okay.
Inspect sensor connector for constant voltage again.
No Inspect for open GND circuit.
13 Turn engine switch to OFF.
Disconnect accelerator position sensor.
Turn engine switch to ON.
Measure voltage between constant voltage
circuit at accelerator position sensor and battery
negative terminal.
Is voltage less than 0.5V?Yes Inspect sensor connector for constant voltage again.
No Repair constant voltage circuit shorted power in
harness.
14 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

G–1
G
GENGINE ELECTRICAL SYSTEM
OUTLINE............................................................... G-2
OUTLINE OF CONSTRUCTION......................... G-2
SPECIFICATIONS .............................................. G-2
STRUCTURAl VIEW ........................................... G-3
OUTLINE............................................................... G-4
SUPPLEMENTAL SERVICE INFORMATION .... G-4
LOCATION INDEX .............................................. G-4
CHARGING SYSTEM............................................ G-5
BATTERY REMOVAL/INSTALLATION .............. G-5
BATTERY INSPECTION..................................... G-6
BATTERY RECHARGING .................................. G-6
GENERATOR REMOVAL/INSTALLATION ........ G-7
GENERATOR INSPECTION .............................. G-7
STARTING SYSTEM............................................. G-9
STARTER REMOVAL/INSTALLATION .............. G-9
STARTER INSPECTION .................................. G-11 FEATURES
SERVICE

G–4
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E470202000204•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Battery
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
•Recharging procedure has been added. (MZR-CD (RF Turbo) engine model)
Generator
•Removal/Installation procedure has been added. (MZR-CD (RF Turbo) engine model)
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
Starter
•Removal/Installation procedure has been added.
•Inspection procedure has been added. (MZR-CD (RF Turbo) engine model)
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LOCATION INDEXA6E470202000206MZR-CD (RF Turbo)
.
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OUTLINE
3
1
2
A6E4702W100
1 Battery
(See G–5 BATTERY REMOVAL/INSTALLATION)
(See G–6 BATTERY INSPECTION)
(See G–6 BATTERY RECHARGING)2 Generator
(See G–7 GENERATOR REMOVAL/
INSTALLATION)
(See G–7 GENERATOR INSPECTION)
3Starter
(See G–9 STARTER REMOVAL/INSTALLATION)
(See G–11 STARTER INSPECTION)

H–1
H
HCLUTCH
OUTLINE................................................................ H-2
OUTLINE OF CONSTRUCTION.......................... H-2
FEATURES .......................................................... H-2
SPECIFICATIONS ............................................... H-2
OUTLINE................................................................ H-2
SUPPLEMENTAL SERVICE INFORMATION .....H-2
CLUTCH RELEASE CYLINDER............................ H-3
CLUTCH RELEASE CYLINDER
REMOVAL/INSTALLATION
(A65M-R MANUAL TRANSAXLE MODELS) ....H-3
CLUTCH RELEASE CYLINDER
DISASSEMBLY/ASSEMBLY (A65M-R
MANUAL TRANSAXLE MODELS) ................... H-4
CLUTCH UNIT........................................................H-5
CLUTCH UNIT REMOVAL/INSTALLATION
(A65M-R MANUAL TRANSAXLE MODELS) ....H-5
CLUTCH COVER INSPECTION (A65M-R
MANUAL TRANSAXLE MODELS) ................... H-7
FLYWHEEL............................................................ H-8
FLYWHEEL INSPECTION (A65M-R MANUAL
TRANSAXLE MODELS) ................................... H-8 FEATURES
SERVICE

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

J2–1
J2
J2MANUAL TRANSAXLE [A65M-R]
OUTLINE.............................................................. J2-2
OUTLINE OF CONSTRUCTION........................ J2-2
FEATURES ........................................................ J2-2
SPECIFICATIONS ............................................. J2-2
LOCATION INDEX............................................... J2-3
MANUAL TRANSAXLE LOCATION INDEX ...... J2-3
MANUAL TRANSAXLE........................................ J2-4
TRANSAXLE OIL INSPECTION ........................ J2-4
TRANSAXLE OIL REPLACEMENT ................... J2-4
OIL SEAL (DIFFERENTIAL) REPLACEMENT .. J2-5
REVERSE SWITCH INSPECTION .................... J2-5
REVERSE SWITCH
REMOVAL/INSTALLATION ............................ J2-6
NEUTRAL SWITCH INSPECTION .................... J2-6
NEUTRAL SWITCH
REMOVAL/INSTALLATION ............................ J2-7
MANUAL TRANSAXLE
REMOVAL/INSTALLATION ............................ J2-7
SHIFT MECHANISM........................................... J2-12
SHIFT MECHANISM
REMOVAL/INSTALLATION .......................... J2-12 FEATURES
SERVICE

J2–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E520201025203•The construction and operation of the manual transaxle is the same as those of the current A65M-R type
manual transaxle, except for the following features. (See MPV Workshop Manual supplement 1737-1*-02D.)
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FEATURESA6E520201025201Improved drivability
•The gear ratio has been changed.
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SPECIFICATIONSA6E520201025202
Bold frames:New specifications
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OUTLINE
Item New Mazda6 (GG, GY) Current MPV (LW)
Transaxle typeA65M-R
Transaxle control Floor-shift
Operation system Cable
Shift assistForward
Synchromesh
Reverse
Gear ratio1st 3.416
2nd 1.944 1.789
3rd 1.258 1.193
4th 0.902
5th 0.659
Reverse 3.252
Final gear ratio 3.588 4.133
OilGrade API service GL-4 or GL-5
Viscosity (All season) SAE 75W-90
Capacity (approximate quantity)
(L {US qt, Imp qt})2.30 {2.40, 2.00}

J2–4
MANUAL TRANSAXLE
TRANSAXLE OIL INSPECTIONA6E5212270012011. Park the vehicle on level ground.
2. Remove the filler plug and gasket.
3. Verify that the oil is near the brim of the plug port.
•If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Specified oil grade
API Service GL-4 or GL-5
Specified oil viscosity
SAE 75W-90
4. Install a new gasket and the filler plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
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TRANSAXLE OIL REPLACEMENTA6E5212270012021. Remove the drain plug with the gasket.
2. Drain the oil into a suitable container.
3. Install a new gasket and the drain plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
4. Remove the filler plug with gasket and add the
specified amount and type of oil through the filler
plug hole until the level reaches the bottom of the
filler plug hole.
Specified oil grade
API Service GL-4 or GL-5
Specified oil viscosity
SAE 75W-90
Capacity (approximate quantity)
2.30 L {2.40 US qt, 2.00 lmp qt}
5. Install a new gasket and the filler plug.
Tightening torque
30.0—39.0 N·m
{3.06—3.98 kgf·m, 22.1—28.8 in·lbf}
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MANUAL TRANSAXLE
DRAIN PLUG FILLER PLUG
A6E5212W010
DRAIN PLUG FILLER PLUG
A6E5212W010

K2–1
K2
K2AUTOMATIC TRANSAXLE [JA5AX-EL]
OUTLINE.............................................................. K2-3
FEATURES ........................................................ K2-3
SPECIFICATIONS ............................................. K2-3
AUTOMATIC TRANSAXLE.................................. K2-4
OUTLINE ........................................................... K2-4
CROSS-SECTIONAL VIEW .............................. K2-6
ELECTRONIC CONTROL SYSTEM
STRUCTURAL VIEW...................................... K2-8
AUTOMATIC TRANSAXLE CONTROL SYSTEM
WIRING DIAGRAM ....................................... K2-10
AUTOMATIC TRANSAXLE BLOCK
DIAGRAM ..................................................... K2-11
AUTOMATIC TRANSAXLE DEVICE
RELATIONSHIP CHART .............................. K2-13
POWERTRAIN DESCRIPTION ....................... K2-15
TORQUE CONVERTER DESCRIPTION......... K2-40
OIL PUMP DESCRIPTION .............................. K2-41
CENTRIFUGAL BALANCE CLUTCH
DESCRIPTION ............................................. K2-42
CONTROL VALVE BODY DESCRIPTION ...... K2-43
TRANSAXLE FLUID TEMPERATURE
(TFT) SENSOR DESCRIPTION ................... K2-45
INPUT/TURBINE SPEED SENSOR
DESCRIPTION ............................................. K2-45
INTERMEDIATE SENSOR DESCRIPTION..... K2-46
VEHICLE SPEEDOMETER SENSOR
DESCRIPTION ............................................. K2-46
SOLENOID VALVE DESCRIPTION ................ K2-47
CONTROLLER AREA NETWORK (CAN)
DESCRIPTION ............................................. K2-50
TRANSAXLE CONTROL MODULE
(TCM) DESCRIPTION .................................. K2-51
SHIFT CONTROL DESCRIPTION .................. K2-51
MANUAL MODE SHIFT CONTROL
DESCRIPTION ............................................. K2-52
LINE PRESSURE CONTROL DESCRIPTION K2-54
FEEDBACK CONTROL DESCRIPTION ......... K2-57
N-D SELECT CONTROL DESCRIPTION........ K2-59
TORQUE CONVERTER CLUTCH
(TCC) CONTROL DESCRIPTION ................ K2-59
SLOPE MODE CONTROL DESCRIPTION ..... K2-63
ON-BOARD DIAGNOSTIC (OBD)
SYSTEM DESCRIPTION.............................. K2-64
COOLING SYSTEM DESCRIPTION ............... K2-69
LOCATION INDEX............................................. K2-70
AUTOMATIC TRANSAXLE LOCATION
INDEX ........................................................... K2-70
AUTOMATIC TRANSAXLE................................ K2-72
MECHANICAL SYSTEM TEST ....................... K2-72
ROAD TEST .................................................... K2-75AUTOMATIC TRANSAXLE FLUID
(ATF) INSPECTION ...................................... K2-78
AUTOMATIC TRANSAXLE FLUID
(ATF) REPLACEMENT ................................. K2-80
TRANSAXLE RANGE (TR) SWITCH
INSPECTION ................................................ K2-80
TRANSAXLE RANGE (TR) SWITCH
REMOVAL/INSTALLATION .......................... K2-81
TRANSAXLE RANGE (TR) SWITCH
ADJUSTMENT .............................................. K2-83
TRANSAXLE FLUID TEMPERATURE
(TFT) SENSOR INSPECTION ...................... K2-84
TRANSAXLE FLUID TEMPERATURE
(TFT) SENSOR REMOVAL/INSTALLATION K2-85
INPUT/TURBINE SPEED SENSOR
INSPECTION ................................................ K2-85
INPUT/TURBINE SPEED SENSOR
REMOVAL/INSTALLATION .......................... K2-86
INTERMEDIATE SENSOR INSPECTION ....... K2-86
INTERMEDIATE SENSOR
REMOVAL/INSTALLATION .......................... K2-86
VEHICLE SPEEDOMETER SENSOR
(VSS) INSPECTION...................................... K2-87
VEHICLE SPEEDOMETER SENSOR
(VSS) REMOVAL/INSTALLATION ............... K2-87
SOLENOID VALVE INSPECTION ................... K2-88
SOLENOID VALVE
REMOVAL/INSTALLATION .......................... K2-90
TCM INSPECTION .......................................... K2-90
TCM REMOVAL/INSTALLATION .................... K2-96
AUTOMATIC TRANSAXLE AND
TRANSFER REMOVAL/INSTALLATION...... K2-99
OIL SEAL REMOVAL/INSTALLATION .......... K2-104
CONTROL VALVE BODY
REMOVAL/INSTALLATION ........................ K2-105
OIL COOLER FLUSHING .............................. K2-106
OIL COOLER REMOVAL/INSTALLATION .... K2-108
OIL COOLER DISASSEMBLY/ASSEMBLY .. K2-110
DRIVE PLATE REMOVAL/INSTALLATION... K2-112
TRANSFER....................................................... K2-114
TRANSFER OIL INSPECTION ...................... K2-114
TRANSFER OIL REPLACEMENT ................. K2-114
TRANSFER REMOVAL/INSTALLATION....... K2-115
BREATHER PLUG
REMOVAL/INSTALLATION ........................ K2-116
AUTOMATIC TRANSAXLE SHIFT
MECHANISM................................................. K2-117
SELECTOR LEVER INSPECTION ................ K2-117
SELECTOR LEVER COMPONENT
INSPECTION .............................................. K2-117
SELECTOR CABLE ADJUSTMENT .............. K2-118
SELECTOR LEVER
REMOVAL/INSTALLATION ........................ K2-119
SELECTOR LEVER
DISASSEMBLY/ASSEMBLY ...................... K2-122
ON-BOARD DIAGNOSTIC............................... K2-123
FOREWORD .................................................. K2-123 FEATURES
SERVICE