steering MAZDA 6 2002 Suplement Repair Manual

R–8
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT (WGN)A6E741201015201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1 °30'.*3: Distance between wheel center and fender brim is 405 mm {15.94 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1 °30'.
Maximum Steering Angle Adjustment 1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods to equalize the length L.
Maximum left/right difference3 mm {0.12 in}
4. Turn the tie rods equally to provide the correct maximum steering angle.
5. Tighten the tie-rod end locknuts.
Tightening torque68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
6. Verify that the boot is not twisted, and install the boot clamp.
7. Adjust the toe-in after adjusting the steering angle.
WHEEL ALIGNMENT
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
Outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle
*2
(Reference value) normal 3
°30' ±1 ° 3°32' ±1 ° 3°34' ±1° 3°37' ±1° 3°40' ±1 °
elevated*33 °25' ±1 ° 3°27' ±1 ° 3°29' ±1° 3°32' ±1° 3°35' ±1 °
Camber angle
*2
(Reference value) normal -0
°14' ±1 ° -0°15' ±1°
elevated*3-0 °07' ±1 ° -0°08' ±1°
Steering axis inclination
(Reference value) normal 5
°24'
elevated
*35 °15' 5 °16'
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 39
°±3°
Outer 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle*
2 (reference value) 3
°25' ±1 ° 3°27' ±1 ° 3°29' ±1 ° 3°32' ±1 ° 3°35' ±1 °
Camber angle*
2(reference value) -0
°07' ±1 ° -0°08' ±1°
Steering axis inclination (reference value) 5 °15' 5 °16'
LEFT AND RIGHT DIFFERENCE
L
LESS THAN 3 mm {0.12 in}
A6E7412W002

WHEEL ALIGNMENT
R–9
R
Total Toe-in Adjustment
1. Center the steering wheel and confirm that the vehicle wheels/tires are pointing straight.
2. Loosen the left and right tie-rod end locknuts and turn the tie-rods equally. Both tie rods are right threaded, so
turning the right tie-rod toward the front of the vehicle and the left toward the rear increases toe-in.
Note
•Turning both tie-rods one complete turn changes toe-in by about 6 mm {0.24 in} (0°36').
3. Tighten the tie-rod end locknuts to the specified torque.
Tightening torque
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
4. Verify that the boot is not twisted, and install the boot clamp.
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REAR WHEEL ALIGNMENT (WGN)A6E741201016201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.*3: Distance between wheel center and fender brim is 407 mm {16.02 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.
Note
•Adjust the toe-in after adjusting the camber.
Camber Adjustment
1. Loosen the cam nut on the lower arm.
2. Turn the adjusting cam bolt to provide the correct
camber angles as indicated.
3. Tighten the cam nut.
Tightening torque
86.2—116.6 N·m {8.80—11.88 kgf·m, 63.58—
85.99 ft·lbf}
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle
*2 normal–0°59′±1°–1°00′±1°–1°02′±1°–1°04′±1°–1°06′±1°
elevated
*3–0°52′±1°–0°53′±1°–0°55′±1°–0°56′±1°–0°58′±1°
Thrust angle 0°±0°48′
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle*
2 –0°55′±1°–0°57′±1°–0°59′±1°–1°01′±1°–1°03′±1°
Thrust angle (degree) 0°±0°48′
Left wheel Right wheel
Positive direction ClockwiseCounter-
clockwise
Negative directionCounter-
clockwiseClockwise
LEFT SIDE
(VIEW FROM
FRONT OF THE
VEHICLE)
ADJUSTING
CAM BOLT
A6E7412W003

TD–1
TD
TDTECHNICAL DATA
TECHNICAL DATA............................................. TD-2
ENGINE ............................................................ TD-2
LUBRICATION SYSTEM .................................. TD-2
COOLING SYSTEM .......................................... TD-3
FUEL AND EMISSION CONTROL
SYSTEM ........................................................ TD-3
ENGINE ELECTRICAL SYSTEM ..................... TD-4
CLUTCH............................................................ TD-4
MANUAL TRANSAXLE ..................................... TD-4
AUTOMATIC TRANSAXLE............................... TD-5
PROPELLER SHAFT ........................................ TD-5
FRONT AND REAR AXLE ................................ TD-6
STEERING SYSTEM ........................................ TD-6
BRAKING SYSTEM .......................................... TD-7
SUSPENSION................................................... TD-7
BODY ELECTRICAL SYSTEM ......................... TD-8
HEATER AND AIR CONDITIONER
SYSTEMS ...................................................... TD-9

TD–6
TECHNICAL DATA
FRONT AND REAR AXLEA6E931001018201
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STEERING SYSTEMA6E931001034201
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Item Specification
FRONT DRIVE SHAFT
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left sideMZR-CD (RF Turbo): 666.1—676.1 {26.23—26.61}
4WD: 667—677 {26.26—26.65}
Right sideMZR-CD (RF Turbo): 615.9—625.9 {24.25—24.64}
4WD: 631—641 {24.85—25.23}
REAR DRIVE SHAFT (4WD)
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left side 805.4—815.4 {31.71—32.10}
Right side 852.4—862.4 {33.56—33.95}
REAR DIFFERENTIAL (4WD)
Pinion height (mm {in})–0.025—0.025 {–0.001—0.001}
Backlash of side gear and differential pinion (mm {in}) 0.1 {0.004} or less
Drive pinion preload (N·m kgf·cm, in·lbf) 1.3—1.8 {13.3—18.3, 11.5—15.9}
Backlash of drive pinion and
ring gear(mm {in})Standard 0.09—0.11 {0.0036—0.0043}
Minimum 0.05 {0.002}
Differential oilGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Capacity
(Approximate quantity)(L {US qt, lmp qt}) 1.00 {1.06, 0.88}
ELECTRONIC 4WD CONTROL SYSTEM
Differential oil temperature
sensor(kilohm)0°C {32°F} 91—100
10°C {50°F} 56—61
20°C {68°F} 35—39
30°C {86°F} 23—25
40°C {104°F} 14—17
50°C {122°F} 10—11
60°C {140°F} 7.1—7.9
70°C {158°F} 5.0—5.6
80°C {176°F} 3.6—4.0
4WD solenoid
(Rear differential oil temperature
at 20°C {68°F})(ohm) 1.5—2.0
Item Specification
ENGINE SPEED SENSING POWER STEERING
Power
steering oil
pumpOil pump fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Gear housing fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Power
steering
systemFluid type
ATF M-
III or equivalent (e.g. Dexron®II)
Capacity (Approximate quantity) MTX (Except MZR-CD (RF Turbo)): 0.80 {0.85, 0.70}
ATX (Except 4WD): 0.87 {0.92, 0.77}
MZR-CD (RF Turbo): 0.86 {0.91, 0.76}
4WD: 0.89 {0.94, 0.78} (L {US qt, Imp qt})

TECHNICAL DATA
TD–7
TD
BRAKING SYSTEMA6E931001020201
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SUSPENSIONA6E931001013201Suspension
WGN (2WD)
*1: Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 1 ° 30 ′.*3: Distance between wheel center and fender brim is following. Front: 405 mm {15.94 in} (reference value) Rear:
407 mm {16.02 in} (reference value)
WGN (4WD)
*1: Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 1 ° 30 ′.
Item Specification
CONVENTIONAL BRAKE SYSTEM
Front disc
brake Minimum disc pad
thickness
(mm {in})L8, LF (GCC specs.): 22 mm {0.87 in}
LF (European (L.H.D. U.K.) specs.), L3, MZR-CD (RF Turbo):
23 mm {0.91 in}
Minimum disc plate
thickness (mm {in})L8, LF (GCC specs.): 22.8 mm {0.90 in}
LF (European (L.H.D. U.K.) specs.), L3, MZR-CD (RF Turbo): 23.8 mm {0.94 in}
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Fr o nt wh ee l
alignment
(Unloaded)
*1
Maximum steering
angle Inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
Outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle
*2
(Reference value) normal 3
°30' ±1 ° 3°32' ±1 ° 3°34' ±1 ° 3°37' ±1 ° 3°40' ±1°
elevated*33 °25' ±1 ° 3°27' ±1 ° 3°29' ±1 ° 3°32' ±1 ° 3°35' ±1°
Camber angle
*2
(Reference value) normal –0
°14' ±1 ° –0°15' ±1°
elevated*3–0 °07' ±1 ° –0°08' ±1°
Steering axis inclination
(Reference value) normal 5
°24'
elevated
*35 °15' 5 °16'
Rear wheel
alignment
(Unloaded)
*1
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Camber angle
*2 normal –0 °59 ′±1° –1°00 ′±1° –1°02 ′±1° –1°04 ′±1° –1°06 ′±1°
elevated
*3–0 °52 ′±1° –0°53 ′±1° –0°55 ′±1° –0°56 ′±1° –0°58 ′±1°
Thrust angle 0 °±0°48 ′
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Fr o nt wh ee l
alignment
(Unloaded)
*1
Maximum steering
angle Inner 39
°±3°
Outer 31 °±3°
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Caster angle
*2 (Reference value) 3
°25' ±1 ° 3°27' ±1 ° 3°29' ±1 ° 3°32' ±1 ° 3°35' ±1°
Camber angle
*2 (Reference value) –0
°07' ±1 ° –0°08' ±1°
Steering axis inclination
(Reference value) 5
°15' 5 °16'
Rear wheel
alignment
(Unloaded)
*1
Total toe-in (mm {in}) Tire: 2
±4 {0.08 ±0.16}, Rim inner: 1 ±3 {0.04 ±0.12}
(degree) 0 °11 ′±0°22 ′
Camber angle
*2 –0 °55 ′±1° –0°57 ′±1° –0°59 ′±1° –1°01 ′±1° –1°03 ′±1°
Thrust angle 0 °±0°48 ′

ST–1
ST
STSPECIAL TOOLS
SPECIAL TOOLS................................................. ST-2
ENGINE .............................................................ST-2
LUBRICATION SYSTEM ...................................ST-2
COOLING SYSTEM ........................................... ST-2
FUEL AND EMISSION CONTROL SYSTEM .... ST-3
CLUTCH.............................................................ST-3
MANUAL TRANSAXLE ...................................... ST-3
AUTOMATIC TRANSAXLE................................ ST-3
PROPELLER SHFT ........................................... ST-4
FRONT AND REAR AXLE ................................. ST-4
STEERING SYSTEM .........................................ST-7
BRAKING SYSTEM ........................................... ST-7
SUSPENSION.................................................... ST-7
BODY ................................................................. ST-7
BODY ELECTRICAL SYSTEM .......................... ST-8

SPECIAL TOOLS
ST–7
ST
STEERING SYSTEMA6E941001034201
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BRAKING SYSTEMA6E941001020201
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SUSPENSIONA6E941001013201
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BODYA6E941001047201
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49 1232 670B
Power steering
gauge set49 H002 671
Adapter49 G032 3A4
Power steering
gauge adapter
set
49 T028 3A0
Ball joint puller
set49 F032 301
Power steering
pump hanger49 E017 5A0
Engine support
set
49 0259 770B
Flare nut
wrench49 FA18 602
Disc brake
piston wrench49 0221 600C
Disc brake
expand tool
WDS 49 G066 001
Adapter
harness
(with ABS)49 G066 004
Adapter
harness
(with DSC)
49 G033 102
Handle49 G033 106
Attachment
—
49 0305 870A
Window tool set49 G050 1A0
Sealant
remover
—