battery MAZDA 6 2002 Suplement Manual Online

STARTING SYSTEM
G–11
G
STARTER INSPECTIONA6E471418400203MZR-CD (RF Turbo)
On-vehicle Inspection
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Crank the engine and verify that the starter rotates smoothly without any noise.
•If not as specified, inspect the following:
—Remove the starter, and inspect the magnetic switch and the starter.
—Inspect the related wiring harness and the engine switch.
No Load Test
1. Verify that the battery is fully charged.
•Charge if necessary. (See G–6 BATTERY RECHARGING.)
2. Connect the starter, battery, voltmeter and
ammeter as shown.
3. Operate the starter and verify that it rotates
smoothly.
4. Measure the voltage and current while the starter
is operating.
•If not as specified, replace the starter.
Specification
End Of Sie
Voltage (V)11
Current (A)Below 130
ENGINE
SWITCH
TERMINAL SB
M
STARTERVA
VOLTMETER
BATTERY
AMMETER
A6E4714W101

MANUAL TRANSAXLE
J2–7
J2
NEUTRAL SWITCH REMOVAL/INSTALLATIONA6E5212190102041. Remove the neutral switch.
2. Apply a light coat of silicone sealant to the screw
of the neutral switch.
Sealant
Three Bond product: TB1215
3. Install the neutral switch to the transaxle case.
Tightening torque
22.5—33.3 N·m
{2.29—3.40 kgf·m, 16.6—24.6 ft·lbf}
End Of Sie
MANUAL TRANSAXLE REMOVAL/INSTALLATIONA6E5212010292011. Remove the battery and battery tray.
2. Remove the air cleaner compornent. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the air hose above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove the air pipe above the transaxle. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
5. Remove the solenoid bracket.
6. Remove the wheels, tires and splash shields.
7. Remove the under cover.
8. Separate the steering hose.
9. Remove the steering gear and linkage, and pipe assembly installation bolts from the front crossmember, then
suspend the steering gear and linkage with a cable. (See N–8 STEERING GEAR AND LINKAGE (MZR-CD
(RF Turbo)) REMOVAL/INSTALLATION.)
Tightening torque
•Pipe assembly: 7.8—10.8 N·m {79.6—110.0 kgf·cm, 69.1—95.5 in·lbf}
10. Remove the front auto leveling sensor. (See Section T.)
11. Drain the transaxle oil into a suitable container.
12. Remove in the order indicated in the table.
13. Install in the reverse order of removal.
14. Adjust the headlight zeroset. (See Section T.)
15. Add the specified amount of specified transaxle oil. (See J2–4 TRANSAXLE OIL REPLACEMENT.)
16. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transaxle operation.
NEUTRAL
SWITCH
A6E5212W015

J2–12
SHIFT MECHANISM
SHIFT MECHANISM REMOVAL/INSTALLATIONA6E5214460102011. Remove the battery and battery tray.
2. Remove the air cleaner component. (See F2–36 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the dashboard compleat. (See Section S.)
4. Remove the SAS control module. (See Section T.)
5. Remove the climate control unit. (See Section U.)
6. Remove the rear heat duct. (See Section U.)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. After installation, verify that the shift lever can be shifted smoothly into each position.
.
SHIFT MECHANISM
7
5
A
A
4
3
3
6
6.86—9.8
{70—99 kgf·cm, 61—85 in·lbf}
15.68—22.54
{1.599—2.298,
11.57—16.62} 7.8—10.8
{80—110 kgf·cm,
69.5—95.4 in·lbf}
1
2
N·m {kgf·m, ft·lbf}
15.68—22.54
{1.599—2.298,
11.57—16.62}
A6E5214W001
1 Shift lever knob
2 Boot panel
3 Clip
4 Seal plate5 Select cable
(See J2–13 Select Cable Installation Note)
6 Shift cable
7 Sift lever component

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

K2–14
AUTOMATIC TRANSAXLE
CAN
signalThrottle
position
signalXX XXXXXX
Engine
torque
signal
(without
torque
down)XXXXXX
Engine
torque
signal
(with
torque
down)XXXXX
Engine
torque
signal
(loss
torque)XXXXXX
Engine
coolant
temperatu
re signalXX
Engine
speed
signalX XXX XX
Torque
reduce
signalXXXXX
Battery
OFF
signalXX
Output
ON/
OFF
typeShift
solenoid
AXX X
Shift
solenoid
BXX X
Shift
solenoid
CXX X
Reduction
timing
solenoid
valveXX X
Neutral
shift
solenoid
valveXXXX X ComponentControl item
Shift
controlLine
pressure
controlReverse
inhibition
controlShift
transient
controlFeedbac
k controlTCC
controlN-D
select
controlSlope
mode
controlOBD
system

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
K2–65
K2
Memory Function
•The memory function stores failure information detected in the failure detection function. Once failure
information is stored, the memory will not be cleared even when the ignition switch is turned off (LOCK
position) or the malfunction is repaired.
•The stored memory (failure information) can be cleared by using the WDS or disconnecting the negative
battery cable.
Failure Indication Function
•The failure indication function illuminates the AT warning lights when the failure detection function determines
there is a malfunction.
DTC Table
X : Available
CCM:Continuous monitor
Fail-safe Function
•In the fail-safe function, minimum vehicle drivability is obtained by changing the signals that are determined as
malfunctions by the failure detection function to the preset values, and limiting the TCM control.
DTC No. On-board diagnostic function MILAT warning
light
indicationDCMonitor
itemMemory
function
P0705 TR switch circuit malfunction (Power short circuit) X X 2 CCM X
P0706 TR switch circuit malfunction (Open/ground short circuit) X X 2 CCM X
P0711 TFT sensor malfunction (Stuck) X–2 CCM X
P0712 TFT sensor circuit malfunction (Short circuit) X X 2 CCM X
P0713 TFT sensor circuit malfunction (Open circuit) X X 2 CCM X
P0715 Input/turbine speed sensor circuit malfunction X X 2 CCM X
P0720 Vehicle speedometer sensor circuit malfunction X X 2 CCM X
P0740 TCC system X–2 CCM X
P0743 TCC solenoid valve malfunction (Open/short) X X 1 CCM X
P0748 Pressure control solenoid malfunction (Open/short)–X–CCM X
P0751 Shift solenoid A malfunction (Stuck off) X–2 CCM X
P0752 Shift solenoid A malfunction (Stuck on) X–2 CCM X
P0753 Shift solenoid A malfunction (Open/short) X X 1 CCM X
P0756 Shift solenoid B malfunction (Stuck off) X–2 CCM X
P0757 Shift solenoid B malfunction (Stuck on) X–2 CCM X
P0758 Shift solenoid B malfunction (Open/short) X X 1 CCM X
P0761 Shift solenoid C malfunction (Stuck off) X–2 CCM X
P0762 Shift solenoid C malfunction (Stuck on) X–2 CCM X
P0763 Shift solenoid C malfunction (Open/short) X X 1 CCM X
P0768 Reduction timing solenoid malfunction (Open/short)–X–CCM X
P0773 Neutral shift solenoid malfunction (Open/short)–X–CCM X
P0778 2-4 brake solenoid malfunction (Open/short)–X–CCM X
P0791 Intermediate sensor malfunction (Open/short) X X 2 CCM X
P0798 High clutch solenoid malfunction (Open/short)–X–CCM X
P1710 GND return malfunction–––Other X
U0073 CAN BUS OFF X X 1 CCM X
U0100 TCM cannot receive any signals from PCM X X 1 CCM X
DTC
No.On-board diagnostic function Detection condition Fail-safe TCC
P0705Transaxle range (TR) switch
circuit malfunction (power short
circuit)•Two or more range signals
are inputted from TR switch
for 5 seconds or more•TR switch priority
D > N > P > R
•Inhibits feedback control,
SLOPE mode, torque
reduction controlAvailable
P0706Transaxle range (TR) switch
circuit malfunction (open/ground
short circuit)•No range signal is inputted
from TR switch for 100
seconds or more•Inhibits feedback control,
SLOPE mode, torque
reduction controlAvailable

K2–68
AUTOMATIC TRANSAXLE
Parameter Identification (PID) Access
Monitor item table
End Of Sie
Display on the
testerDefinitionUnit/
ConditionTCM
terminal
2-4 B Duty 2-4 brake solenoid valve control signal in TCM ON/OFF 2V
BOO Brake switch ON/OFF 1U
DWN_SW Down switch ON/OFF 1S
GEAR Calculated gear range in TCM1ST/2ND/
3RD/4TH/5TH–
H/C Duty High clutch solenoid valve control signal in TCM % 2U
LPS Pressure control solenoid control signal in TCM % 2Y
MNL_SW M range switch ON/OFF 1AA
NSFT TIM Neutral shift solenoid valve control signal in TCM ON/OFF 2D
OSS Intermediate sensor rpm 1K, 1X
PNP TR switch (P/N position switch) ON/OFF–
RDCN TIM Reduction timing solenoid valve control signal in TCM ON/OFF 2G
RPM Engine speed rpm–
SSA/SS1 Shift solenoid A control signal in TCM ON/OFF–
SSB/SS2 Shift solenoid B control signal in TCM ON/OFF–
SSC/SS3 Shift solenoid C control signal in TCM ON/OFF–
TCCC TCC solenoid valve control signal in TCM % 2S
TCIL AT warning light control signal in TCM ON/OFF 1E
TFT ATF temperature°C1B, 1F
TFTV ATF temperature signal voltage V 1B, 1F
THOP Throttle position %–
TRD Tr switch (D range switch) ON/OFF 1Z
TRR TR switch (R position switch) ON/OFF 1W
TSS Input/turbine speed sensor rpm 1N, 2F
UP_SW Up switch ON/OFF 2C
VPWR Battery voltage V 1P
VSS Vehicle speed km/h 1V, 1M

AUTOMATIC TRANSAXLE
K2–81
K2
3. Connect the TR switch connector.
End Of SieTRANSAXLE RANGE (TR) SWITCH REMOVAL/INSTALLATIONA6E5714194402021. Disconnect the negative battery cable.
2. Remove the air cleaner component. (See Section F.)
Caution
•Water or foreign objects entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign objects on the connector when disconnecting it.
3. Disconnect the TR switch connector.
4. Remove the spring and disconnect the selector
cable.
5. Rotate the manual shaft to the N position.
Caution
•Do not use an impact wrench. Hold the
manual shaft lever when removing the
manual shaft nut, or the transaxle may be
damaged.
6. Set the adjustable wrench as shown to hold the
manual shaft lever.
7. Remove the manual shaft nut and washer.
8. Remove the manual shaft lever.
9. Remove the TR switch.
10. Rotate the manual shaft to the right fully, them
return 2 notches to set the N position.
Caution
•Improper adjustment of the TR switch will
cause abnormal operation of the
automatic transaxle. Be sure to use the
SST to adjust the TR switch correctly.
BC AE
DG
I
FH
A6E5714W109
SPRING
SELECTOR
CABLE
MANUAL
SHAFT
LEVER
A6E5714W110
A6E5714W111
TO VEHICLE FRONT
MANUAL SHAFT
D, MN
R
P
A6E5714W112

K2–82
AUTOMATIC TRANSAXLE
11. Using the SST and by turning the TR switch,
adjust the positions of the manual shaft and the
TR switch neutral hole.
12. Tighten the TR switch mounting bolts.
Tightening torque
4.9—6.9 N·m
{50—70 kgf·cm, 44—61 in·lbf}
13. Inspect for continuity at the TR switch between
terminals C and D.
14. Remove the SST.
15. Install the manual shaft lever and washer.
Caution
•Do not use an impact wrench. Hold the
manual shaft lever when tightening the
manual shaft nut, or the transaxle may be
damaged.
16. Set the adjustable wrench as shown to hold the
manual shaft lever.
17. Tighten the manual shaft nut using a torque
wrench.
Tightening torque
31.36—46.06 N·m
{3.198—4.696 kgf·m, 23.13—33.96 ft·lbf}
18. Install the spring as shown in the figure.
•If it is bend, replace a new spring.
19. Verify that the selector lever range position and
TR switch are aligned, then connect the selector
cable.
20. Inspect for continuity at the TR switch. (See K2–
80 Inspection of Continuity.)
21. Connect the TR switch connector.
22. Install the air cleaner component. (See Section
F.)
23. Connect the negative battery cable.
24. Inspect operation of the TR switch. (See K2–80
Inspection of Operation.)
49 L019 013
A6E5714W113
BC AE
DG
I
FH
A6E5714W109
A6E5714W150
SPRING
SELECTOR CABLE
A6E5714W114
SELECTOR CABLE
MANUAL SHAFT LEVERSPRING
UPWARD
A6E5714W115