Temperature control MAZDA 6 2002 Suplement Service Manual

F2–230
TROUBLESHOOTING
Cooling Fan No.1/Cooling Fan No.2 Control System Inspection
Cooling fan No.1/cooling fan No.2 system operation
Cooling fan relay No.2
1. Connect the WDS or equivalent to DLC-2.
2. Verify that ECT PID is below main fan operating temperature.
3. Verify that A/C switch and fan switch are off.
4. Turn the engine switch to ON.
5. Verify that the cooling fan No.2 is not operating.
•If the cooling fan No.2 is operating:
(1) Select FAN PID.
(2) Send OFF and verify the cooling fan No.2 is off.
•If the cooling fan No.2 is on, inspect the following.
—Cooling fan relay No.2 stuck in closed position
—Short to GND circuit between cooling fan relay No.2 and PCM terminal 76
—Short to power in circuit at cooling fan relay No.2
—DTC for ECT sensor (P0117, P0118)
•If the cooling fan relay No.2 is off, inspect the following.
—Short to GND circuit between refrigerant pressure switch and PCM terminal 84
—DTC for ECT sensor (P0117, P0118)
6. Start the engine.
7. Verify that the cooling fan No.2 is operating when engine is hot.
•If the cooling fan No.2 does not operate, perform the following.
1. Connect WDS or equivalent to the DLC-2.
2. Select FAN PID.
3. Operate cooling fan No.2 by sending ON command.
4. Inspect if the operation sound is heard from the cooling fan relay No.2.
•If the operation sound is heard, inspect the wiring harness, connectors and cooling fan motor No.2.
•If the operation sound is not heard, inspect cooling fan relay No.2 and open circuit wiring harness
and connectors.
8. Turn the A/C switch and fan switch on.
9. Verify that cooling fan No.2 is operating.
•If fan does not operate, inspect A/C system.
Cooling fan relay No.1
1. Verify that A/C switch and fan switch are off.
2. Start the engine and let it idle.
3. Verify that the cooling fan No.1 is not operating.
•If cooling fan No.1 is operating, inspect for the following.
—Cooling fan relay No.1 is stuck in closed position.
—Short to power in circuit between cooling fan relay No.1 and cooling fan No.1
—Short to GND in circuit between refrigerant pressure switch and PCM terminal 84
—Short to GND circuit between cooling fan relay No.1 and PCM terminal 102
4. Turn the A/C switch and fan switch on.
5. Verify that the cooling fan No.1 is operating and operation sound of A/C compressor magnetic clutch is heard.
Engine conditionCooling fan
relay No.2Cooling fan
relay No.1
ECT below 100°C
{212°F}OFF OFF
ECT above 100°C
{212°F} (until below
97°C {207°F})ON OFF
ECT above 108°C
{228°F} (until below
105°C {230°F})ON ON
A/C and fan switches
are on.ON ON
ECT sensor
malfunctionON ON

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

K2–12
AUTOMATIC TRANSAXLE
Electronic Control Item and Control
Component Description (Electronic Control)
Control item Contents
Shift control•Detects engine load condition and vehicle speed. Shifts to the best gear
position according to the programmed automatic shift diagram.
Line pressure control•Generates line pressure matching the engine load condition and driving
conditions. Optimizes line pressure for each shift. When the ATF
temperature is low, automatically optimizes line pressure for quick clutch
engagement.
Revers inhibition control•When the shift lever is shifted to R position while the vehicle is running
forward at approx. 30 km/h{19 mph} or more, the TCM turns the neutral
shift solenoid valve on and drains the low and reverse brake hydraulic
pressure. Due to this, the transaxle shifts to neutral.
Shift transient control•Adjusts transient hydraulic pressure according to engine load and
vehicle driving conditions when shifting using the pressure control
solenoid, 2-4 brake solenoid valve, the high clutch solenoid valve, and
each accumulator control valve.
•Temporarily lowers engine torque during shift (up and down) to improve
shift feel
•The lock timing for the reduction brake band is controlled by the control
of the reduction timing solenoid valve ON/OFF timing.
•The lock timing for the clutch brake is controlled by the control of shift
solenoid A, B, and C ON/OFF timing.
Feedback control•Corrects clutch engagement pressure and timing on drain side to
compensate for changes in engine performance and changes in
transaxle
TCC control•Controls TCC according to the programmed TCC points
N-D select control•When a driving range is selected from P/N, the fuel injection amount is
controlled to prevent fluctuation in engine speed.
Slope mode control•Changes the shift point to prevent frequent shifting up/down when
climbing hills
OBD system•Detects and/or memorizes failure of input/output part and transaxle
condition
Part name Function
Input system TR switch•Detects selector lever ranges/positions
Input/turbine speed sensor•Detects reverse clutch drum revolution speed
Intermediate sensor•Detects output gear revolution speed
Vehicle speedometer sensor•Detects parking gear revolution speed
TFT sensor•Detects the ATF temperature
Brake switch•Detects the brake pedal depressed
Cruise control module (in cruise actuator)•When the cruise control is in use, the signal detects when the
difference between the target speed and actual speed
exceeds specification
M range switch•Detects selector lever shifted M range
Up switch•Detects up shift in M range
Down switch•Detects down shift in M range
CAN signal Throttle position signal•Input throttle opening angle from PCM
Engine torque signal
(without torque down)•Input engine torque from PCM
Engine torque signal (with
torque down)•Input engine torque from PCM
Engine torque signal (loss
torque)•Input engine loss torque from PCM
Torque reduced signal•Detects signals indicating torque down availability
Engine coolant
temperature signal•Input engine coolant temperature from PCM
Engine speed signal•Input engine speed from PCM
Battery OFF signal•Detect negative battery cable disconnected
4 wheel speed signal•Input wheel speed from ABS HU/CM or DSC HU/CM

AUTOMATIC TRANSAXLE
K2–13
K2
End Of SieAUTOMATIC TRANSAXLE DEVICE RELATIONSHIP CHARTA6E571401030206
Output system ON/OFF
typeShift solenoid A•Switches ON and OFF based on electric signals from the
TCM, changes hydraulic circuit to control shifting
Shift solenoid B•Switches ON and OFF based on electric signals from the
TCM, changes hydraulic circuit to control shifting
Shift solenoid C•Switches ON and OFF based on electric signals from the
TCM, changes hydraulic circuit to control shifting
Reduction timing solenoid
valve•Switches ON and OFF based on electric signals from the
TCM, changes hydraulic circuit to control shifting
Neutral shift solenoid valve•Switches ON and OFF based on electric signals from the
TCM, changes hydraulic circuit to control shifting
Duty type
Pressure control solenoid•Switches ON and OFF based on electric signal (duty signals)
from the TCM adjusts line pressure to match driving
conditions
2-4 brake solenoid valve•Switches ON and OFF based on electric signal (duty signals)
from the TCM adjusts line pressure to match driving
conditions
High clutch solenoid valve•Switch ON and OFF based on electric signal (duty signals)
from the TCM adjusts line pressure to match driving
conditions
TCC solenoid valve•Switch ON and OFF based on electric signal (duty signals)
from the TCM to control TCC
CAN signal Reduce torque signal•Sends signals to the PCM during shifting
Range signal•Output transaxle load condition to PCM
Turbine speed signal•Output turbine speed to PCM
ATF temperature signal•Output ATF high temperature signal to PCM
TCC signal•Output TCC signal to PCM
Racing select signal•Requests fuel cut when selector lever is shifted during racing
MIL indicate request signal•Requests MIL illumination when failure is detected by
diagnosis function
AT warning light request
signal•Requests AT warning light indication when failure is detected
by diagnosis function for ATX Part name Function
ComponentControl item
Shift
controlLine
pressure
controlReverse
inhibition
controlShift
transient
controlFeedbac
k controlTCC
controlN-D
select
controlSlope
mode
controlOBD
system
Input
TR switch XXXXXXX X
Input/turbine
speed sensorX XXXXXX
Intermediate
sensorXXX X
Vehicle
speedometer
sensorXXXXXXXXX
TFT sensor XX XXXX X
Brake switch X X X
Cruise control
module (4GR
inhibit signal)XX
M range switch X X
Up switch X X
Down switch X X

AUTOMATIC TRANSAXLE
K2–45
K2
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR DESCRIPTIONA6E571419010201•The TFT sensor, which is installed in the transaxle case, detects the ATF temperature in the transaxle case,
and sends the control signal to the TCM. The TCM controls the driving pattern and the torque converter clutch
based on the signal from the TFT sensor.
Structure/Operation
•The TFT sensor is a thermistor type and the resistance changes according to the ATF temperature.
•The characteristic of the resistance is as shown in the figure below.
•The TFT sensor is integrated with the connector.
End Of SieINPUT/TURBINE SPEED SENSOR DESCRIPTIONA6E571421550201Function
• A input/turbine speed sensor is located in the transaxle case and detects the rotating speed of the reverse
clutch drum.
Construction/Operation
•The magnetic pickup type of input/turbine speed sensor is mounted in the transaxle case, next to the reverse
clutch drum. It generates a 36-pulse signal for each rotation of the reverse clutch drum, and sends this signal to
the TCM.
End Of Sie
AMU0517S020
AMU0517S021

K2–50
AUTOMATIC TRANSAXLE
CONTROLLER AREA NETWORK (CAN) DESCRIPTIONA6E571418901201Outline
•The TCM transmits/receives information using the CAN system. See Section T for detailed information
regarding the CAN system.
Structure/Operation
•The PCM inputs throttle opening angle, engine speed, engine torque, engine coolant temperature. to the TCM.
•The TCM operates shift and TCC controls based on the throttle opening angle, and controls line pressure and
other based on the throttle opening angle and the engine torque.
•The TCM outputs reduce torque signal, range signal, turbine speed, ATF temperature signal, and TCC signal to
the PCM.
•If there is an open or short circuit in the CAN wiring, the system determines that the CAN is abnormal and
switches to fail-safe mode.
Input
•Throttle position
•Engine torque (without torque down)
•Engine torque (with torque down)
•Engine torque (loss torque)
•Torque reduction request
•ECT
•Engine speed
•Buttery reconnection
Output
•Range position
•Turbine speed
•ATF temperature
•TCC
•Racing select
•Gear position
•Desired torque
•Desired gear position
•Upper torque limit
•Traveled distance
•MIL indicate request
•AT warning light indicate request
End Of Sie

AUTOMATIC TRANSAXLE
K2–53
K2
Operation
Manual mode shift
•When the selector lever is shifted over from the D to M range position, the M range switch in the selector lever
component turns on, sending a manual mode command signal to the PCM which activates the manual mode
shift control.
•When in manual mode and the selector lever is operated in the back (+) direction, the up switch in the selector
lever component is turned on and an up-shift command signal is inputted to the PCM.
—The PCM, triggered by the up-shift command signal, carries out shifting by outputting an operation signal to
the shift solenoid if the ATF temperature is not low (for 3GR only), vehicle speed is higher than the set
speed and the gear position is 3GR or lower.
•Conversely, when the selector lever is operated in the forward (-) direction, the down switch in the selector lever
component turns on, and a down-shift command signal is inputted to the PCM.
—The PCM, triggered by the down-shift command signal, carries out shifting by outputting an operation
signal to the shift solenoid if the vehicle speed is less than the set speed and the gear position is 2GR or
above.
•The PCM utilizes a specialized M range automatic shift diagram when down shifting. This restriction of manual
downshifting is carried out to reduce load on the ATX and prevent engine over-revving.
13 Instrument cluster
14 Input15 Selector lever component
-M range switch
-Up switch
-Down switch
16 TR switch
17 ABS HU/CM or DSC HU/CM
18 TFT sensor
Condition Shift control Note
2GR→3GR up-shift command
at low speed•To reduce load on the ATX, upshifting is
inhibited until vehicle reaches speed
possible for upshifting
— 3GR→4GR up-shift command
at low speed
3GR→4GR up-shift command,
low ATF temperature•To reduce load on the ATX, upshifting to
4GR is inhibited
4GR→3GR down-shift
command, above set speed•To prevent engine over-rev, downshifting is
inhibited until vehicle reaches speed
possible for downshifting•Selector indicator “M” light and gear
position indicator light flash to alert
driver
3GR→2GR down-shift
command, above set speed
2GR→1GR down-shift
command, above set speed
In 4GR deceleration, speed
goes below coast-down set
speed (deceleration down-
shift)•To assure drive stability, automatically
downshifts from 4GR to 3GR
— In 3GR deceleration, speed
goes below coast-down set
speed (deceleration down-
shift)•To assure drive stability, automatically
downshifts from 3GR to 1GR
In 2GR deceleration, speed
goes below coast-down set
speed (deceleration down-
shift)•To assure driving stability, automatically
downshifts from 2GR to 1GR

AUTOMATIC TRANSAXLE
K2–57
K2
Line Pressure Control at Extremely Low Temperatures
•When the ATF temperature is approximately –30 °C {–22 °F} or below, the period when the pressure control
solenoid is ON (duty ratio) is set at 3 % to maintain line pressure at maximum regardless of the throttle opening
angle. Thus delay in clutch or brake operation due to high viscosity of ATF is prevented when the ATF
temperature is extremely low.
Pressure Control Solenoid Stop Control
•When the vehicle is stopped and the accelerator pedal is released, the operation (duty ratio) of the pressure
control solenoid is set at 3 %, regardless of the driving range. Due to this, AT noise is reduced when the vehicle
is stopped.
End Of Sie
FEEDBACK CONTROL DESCRIPTIONA6E571418901206Outline
Features
•During shift up with the accelerator pedal depressed, feedback control regulates the clutch pressure on the
engagement and release sides, according to the throttle opening angle and vehicle speed. It also uses past
gearshifts to optimize clutch pressure.
Note
•If the battery terminal is disconnected, feedback memory in the TCM will be erased, and thus gearshift
shock may increase. The shock, however, will decrease gradually as the vehicle is driven.
AMU0517S034

AUTOMATIC TRANSAXLE
K2–63
K2
Determination of Torque Converter Clutch (TCC) Cancellation
The TCC control is canceled when any of the following condition are met:
•Engine coolant temperature is low.
•ATF temperature is low.
•Brake switch is on (when depressing the brake pedal).
•Accelerator depressing speed and accelerator opening angle are above the set value.
•Engine speed signal is below the set value.
•Failure is in the TCC control system detected by diagnosis function.
End Of Sie
SLOPE MODE CONTROL DESCRIPTIONA6E571418901209•Climbing and the appropriate gear is determined by engine load and the vehicle acceleration.
Slope Mode Control Block Diagram
.
When climbing hill
•When the hill is steeper than a certain grade, unnecessary up shift is prevented by holding an appropriate gear.
End Of Sie
2C 2B
2J
2M1AA 1S 1T 1Z1W 1B 1F
2W
1M 1V2T
2X
PN
RD
M
9
8
7
543
1
2
10
18
17
15
16
14
13
11
12
6
A6E5714W022
1Starter
2 TR switch
3 Down switch
4 Up switch
5 M range switch
6 TFT sensor
7PCM
8CAN
9 Input10 Throttle position signal
Engine speed signal
Engine torque signal
11 TCM
12 Throttle opening angle
13 Shift diagram
14 Vehicle speed
15 VSS
16 Shift solenoid A
17 Shift solenoid B
18 Shift solenoid C

K2–66
AUTOMATIC TRANSAXLE
P0711Transaxle fluid temperature (TFT)
sensor malfunction (stuck)•TFT sensor signal stays
outside normal temperature
range for 10 minute or more—Available
P0712Transaxle fluid temperature (TFT)
sensor circuit malfunction (short
circuit)•Signals form TFT sensor are
155 °C {311 °F} or greater
for 10 min.
•Inhibits feedback control
•Engine coolant temperature
signal are used for shifting.Available
P0713Transaxle fluid temperature (TFT)
sensor circuit malfunction (open
circuit)•Vehicle speed is 20 km/h
{12.4 mph} or greater, and
signals from TFT sensor are
–30 °C {–22 °F} or less for
150 seconds or moreAvailable
P0715Input/turbine speed sensor circuit
malfunction•Input/turbine speed sensor
is 600 rpm or less while
engine speed is 1500 rpm or
greater and vehicle speed is
40 km/h {24.8 mph} or
greater in D ranges.•Inhibits shift control Available
P0720Vehicle speedometer sensor
circuit malfunction•Parking gear rotation
detected by VSS is 150 rpm
or less while intermediate
sensor 1400 rpm or greater
in D range for 2 second or
more.•Inhibits SLOPE mode,
feedback control, torque
reduction controlAvailable
P0740Torque converter clutch (TCC)
system•RPM difference between
crankshaft (engine speed
signal) and reverse clutch
drum (input/turbine speed
sensor signal) exceeds the
pre-programmed value—Available
P0743Torque converter clutch (TCC)
solenoid valve malfunction (open/
short)•Open or short in torque
converter clutch solenoid
valve circuit (Voltage
different from on/off signal
relayed by CPU in TCM is
detected while TCM is
monitoring solenoid output
voltage.)•Stops driving of TCC
solenoid valve (OFF)Inhibition
P0748Pressure control solenoid
malfunction (open/short)•Open or short in pressure
control solenoid circuit
(Voltage different from on/off
signal relayed by CPU in
TCM is detected while TCM
is monitoring solenoid
output voltage.)•Stops driving of pressure
control solenoid, 2-4 brake
solenoid valve, and high
clutch solenoid valve (OFF)
•Inhibit feedback control.Available
P0751Shift solenoid A malfunction
(stuck off)•Difference between actual
gear ratio and gear ratio set
in TCM is large—Available
P0752Shift solenoid A malfunction
(stuck on)•Difference between actual
gear ratio and gear ratio set
in TCM is large—Available
P0753Shift solenoid A malfunction
(open/short)•Open or short in shift
solenoid A circuit (Voltage
different from on/off signal
relayed by CPU in TCM is
detected while TCM is
monitoring solenoid output
voltage.)•Stops driving all ON/OFF
type solenoids (OFF) and
TCC solenoid valve (OFF)Inhibition
P0756Shift solenoid B malfunction
(stuck off)•Difference between actual
gear ratio and gear ratio set
in TCM is large—Available
P0757Shift solenoid B malfunction
(stuck on)•Difference between actual
gear ratio and gear ratio set
in TCM is large—Available DTC
No.On-board diagnostic function Detection condition Fail-safe TCC