lock MAZDA 6 2002 Suplement Service Manual

H–6
CLUTCH UNIT
Clutch Cover and Disc Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
Flywheel Removal Note
1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in a crisscross pattern.
3. Remove the flywheel.
Flywheel Installation Note
1. Install the flywheel to the crankshaft.
2. When reusing the bolts, clean threads and hole, then apply locking compound to the threads.
Note
•No locking compound is needed when using new bolts.
3. Hand-tighten the flywheel lock bolts.
4. Install the SST to the flywheel.
5. Gradually tighten the flywheel lock bolts in a
crisscross pattern.
Tightning torque
151.3—161.1 N·m
{15.43—16.42 kgf·m, 111.6—118.8 ft·lbf}
49 SE01 310A
49 E011 1A0
A6E4920W011
49 E011 1A0
5
4
3
61
2
8
7
A6E4920W012
49 E011 1A0
5
4
3
61
2
8
7
A6E4920W013

CLUTCH UNIT
H–7
H
Clutch Disc Installation Note
1. Hold the clutch disc position using the SST.
Clutch Cover Installation Note
1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a
crisscross pattern.
Tightening torque
25—33 N·m {2.6—3.3 kgf·m, 19—24 ft·lbf}
End Of SieCLUTCH COVER INSPECTION (A65M-R MANUAL TRANSAXLE MODELS)A6E4920164102011. Measure the wear of the diaphragm spring
fingers.
•If not as specified, replace the clutch cover.
Depth
0.6 mm {0.024 in} max.
2. Measure the flatness of the pressure plate with a
straight edge and a feeler gauge.
•If not as specified, replace the clutch cover.
Maximum clearance
0.3 mm {0.012 in}
3. When checking the diaphragm spring fingers,
mount a dial indicator on the cylinder block.
49 SE01 310A
A6E4920W014
5
4
3
49 SE01 310A
49 E011 1A06
1
2
A6E4920W015
XME4920W010
XME4920W011

H–8
CLUTCH UNIT, FLYWHEEL
4. Rotate the flywheel and check for misaligned
diaphragm spring fingers.
•If not as specified, replace the clutch cover.
Misalignment
0.6 mm {0.024 in} max.
End Of Sie
FLYWHEEL INSPECTION (A65M-R MANUAL TRANSAXLE MODELS)A6E4922115002011. Install a dial gauge on the cylinder block.
2. Measure the flywheel runout using a dial
indicator.
•If the runout is excessive, replace the
flywheel.
Runout
0.3 mm {0.012 in} max.
End Of Sie
A6E4920W016
FLYWHEEL
A6E4922W001

SHIFT MECHANISM
J2–13
J2
Select Cable Installation Note
1. Remove the center console.
2. Make sure that the shift lever (transaxle side) is in neutral.
3. Unlock the lock pice of the select cable (shift lever
side) in the order shown in the figure.
4. Shift the sift lever to neutral.
5. Lock the lock pice of the selector cable (shift
cable side) in the order shown in the figure.
6. Install the center console.
7. Shift the shift lever from neutral to other position,
and make sure that there are no other
components in that area to interfere with the
lever.
End Of Sie
LOCK PIECE SAFETY
LOCK
1
2
A6E5214W002
LOCK PIECE SAFETY
LOCK
2
1
A6E5214W003

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

AUTOMATIC TRANSAXLE
K2–11
K2
End Of SieAUTOMATIC TRANSAXLE BLOCK DIAGRAMA6E571401030205
.
17 2-4 brake solenoid valve
18 High clutch solenoid valve
19 TCC solenoid valve
20 Shift solenoid A
21 Shift solenoid B
22 Shift solenoid C
23 Reduction timing solenoid valve24 Neutral shift solenoid valve
25 CAN_L
26 CAN_H
27 Instrument cluster
28 PCM
29 ABS HU/CM or DSC HU/CM
543
12
A6E5714W012
1 Input
2Output
3TCM
4PCM
ABS HU/CM or DSC HU/CM
TFT sensor
Input/turbine speed sensor
Intermediate sensor
VSS
TR switch
M range switch
Up switch
Down switch
Brake switch
Cruise control module5 Pressure control solenoid
2-4 brake solenoid valve
High clutch solenoid valve
TCC solenoid valve
Shift solenoid A
Shift solenoid B
Shift solenoid C
Reduction timing solenoid valve
Neutral shift solenoid valve
AT warning light

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
K2–17
K2
Operation
Note
•All rotation are viewed from the side cover.
Component description
Gear Position and Operation of Featured Parts
Component Function
Low clutch•Transmits rotation of low clutch drum to rear internal gear
•Operates in 1GR, 2GR, or 3GR position
2-4 brake•Prevents rotation of front sun gear
•Operates in 2GR, 4GR, or 5GR position
High clutch•Transmits rotation of high clutch drum to front planetary carrier
•Operates in 3GR, 4GR, or 5GR position
Reverse clutch•Transmits rotation of reverse clutch drum to front sun gear
•Operates when vehicle is reversing
Reduction brake•Prevents rotation of direct clutch drum and prevents rotation of reduction sun gear
Low and reverse brake•Prevents rotation of low and reverse brake hub
Direct clutch•Transmits rotation of reduction planetary carrier to reduction sun gear
•Operates in 5GR position
Low one-way clutch•Locks clockwise rotation of front planetary carrier
Reduction one-way clutch•Locks counter clockwise rotation of reduction sun gear
Range
P
R
N
D1GR
2GR
3GR
4GR
5GR
1GR
2GR
3GR
4GR
5GR
: TCC or engine braking is availableMGear positionGear ratioTCC operation
Engine brake Shift
2.970
3.801
2.131
1.364
0.935
0.685
3.801
2.131
1.364
0.935
0.685
A6E5714W013

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

K2–64
AUTOMATIC TRANSAXLE
ON-BOARD DIAGNOSTIC (OBD) SYSTEM DESCRIPTIONA6E571418901210•The OBD system has the following functions:
—Failure detection function: detects failure of the input/output devices and system components of the ATX.
—Memory function: stores the DTC when a failure is detected.
—Fail-safe function: fixes the output device function and input value of the sensors/switches to ensure
minimum vehicle drivability when a failure is detected.
—PID data monitoring function: monitors the input/output signal and calculated value of the TCM and sends
the monitoring data to the scan tool.
Block Diagram
.
Failure Detection Function
•In the failure detection function, the TCM detects malfunctions in the automatic transaxle while driving.
•When vehicle driving conditions correspond with a preset failure detection condition, the TCM determines that
the automatic transaxle has a malfunction and stores the corresponding DTC.
•When a malfunction is detected, stored DTCs can be retrieved using the WDS connected to the DLC-2.
9
87
5
4
3
1
2
10
17
15
1614
13
1112
6
A6E5714W023
1TCM
2 OBD system
3 Memory function
4 Failure indication function
5 Serial communication
6 Failure detection function
7 PID data monitoring function
8 Simulation function
9 Fail-safe function10 Transaxle control system
11 Input devices
12 Output devices
13 Instrument cluster
14 PCM
15 AT warning light
16 DLC-2
17 WDS or equivalent