brake MAZDA 6 2002 Workshop Manual Suplement

T–28
WARNING AND INDICATOR SYSTEM
Fuel gauge sender cap removal note
1. Using the SST, remove the fuel gauge sender
cap.
Fuel Gauge Sender Cap Installation Note
1. Verify that the fuel tank mark is aligned with the
fuel gauge sender sub-unit mark as shown.
2. Using the SST, tighten the fuel gauge sender cap
without shifting the mark.
Tightening torque
80—90 N·m {8.2—9.1 kgf·m, 60—66 ft·lbf}
Fuel leak inspection after fuel gauge sender sub-unit installation
1. Drive the vehicle.
2. Perform a quick start and a hard brake 5—6 times.
3. Stop the vehicle.
4. Verify that there is no fuel leakage near the fuel pump unit in the vehicle interior.
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FUEL GAUGE SENDER UNIT INSPECTIONA6E8118609602021. Move the float to the topmost and bottommost positions, and verify that the resistance between terminals A and
B of the unit and the position of the float are as indicated in the figure.
•If they are not as indicated, replace the fuel gauge sender unit.
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49 T042 001A
A6J81182105
FUEL GAUGE
SENDER
SUB-UNIT MARK
MARK
A6E81182002
4WD
44.4—58.4
{1.75—2.29}
TOPMOST
POSITION
BOTTOMMOST
POSITION BASIC
POSITION
ARM
FULCRUM
72.9—86.9
{2.88—3.42}AB
*
53.9—60.9
{2.13—2.39}
TOPMOST
POSITION
BOTTOMMOST
POSITION BASIC
POSITION
ARM
FULCRUM
89.7—96.7
{3.54—3.80}
mm {in}
FUEL GAUGE SENDER UNIT
FUEL GAUGE SENDER SUB-UNIT
6.1—8.1 ohms
57.6—59.6 ohms7.2—9.2 ohms
66.5—68.5 ohms
A6E81181103

T–30
AUDIO AND NAVIGATION SYSTEM
NOISE FILTER REMOVAL/INSTALLATIONA6E812466869201Brake Light Noise Filter
1. Remove the noise filter according to the NOISE FILTER REMOVAL/INSTALLATION procedure for the 4SD.
2. Install in the reverse order of removal.
Rear Window Defroster Noise Filter
1. Disconnect the negative battery cable.
2. Remove the liftgate lower trim.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
End Of SieCONDENSER REMOVAL/INSTALLATIONA6E8124668692021. Disconnect the negative battery cable.
2. Remove the liftgate lower trim.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
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AUDIO AND NAVIGATION SYSTEM
1Bolt
2Screw
3 Connector
4 Noise filter
2
3
4
8.9—12.7 N·m
{90—130 kgf·cm,
79—11 2 in·lbf}
1
A6E81241109
1Bolt
2 Connector
3 Condenser
1
3
2
1
2
3
3
2
1
N·m {kgf·cm, in·lbf} 8.9—12.7
{90—130, 79—112}
8.9—12.7
{90—130, 79—112} 8.9—12.7
{90—130, 79—112}
A6E81241122

TECHNICAL DATA
TD–5
TD
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PROPELLER SHAFTA6E931001024204
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Item Specification
Transaxle typeJA5AX-EL
Line pressure
(kPa {kgf/cm
2, psi})D range, M range (2GR)Idle 290—490 {3.0—5.0, 42—71}
Stall 1,550—1,750 {15.8—17.8, 225—254}
M range (1GR), R positionIdle 550—750 {5.6—7.6, 80—109}
Stall 1,550—1,750 {15.8—17.8, 225—254}
Engine stall speed
D, M (1GR, 2GR), R 2,200—2,600
(rpm)
Time lag (second)N-D Approx. 0.5—1.0
N-R Approx. 0.6—1.0
Transaxle fluid
temperature (TFT)
sensor-20 °C {−4 °F} 15.87—17.54
0 °C {32 °F} 5.73—6.33
20 °C {68 °F} 2.38—2.63
40 °C {104 °F} 1.10—1.22
60 °C {140 °F} 0.56—0.62
80 °C {176 °F} 0.31—0.34
(kilohm) 100 °C {212 °F} 0.18—0.20
120 °C {248 °F} 0.11—0.12
130 °C {266 °F} 0.09—0.10
Input/turbine
speed sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Intermediate
sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Vehicle
speedometer
sensor(ohm) ATF temperature: 20 °C {68 °F} 513—627
Solenoid valves (ohm)Shift solenoid A 14—18
Shift solenoid B 14—18
Shift solenoid C 14—18
Neutral shift solenoid valve 14—18
Reduction timing solenoid valve 14—18
TCC solenoid valve 12.0—13.2
2-4 brake solenoid valve 2.6—3.2
High clutch solenoid valve 2.6—3.2
Pressure control solenoid 2.6—3.2
Automatic transaxle fluid
(ATF)Type
M-
III or equivalent (e.g. Dexron ® III )
Capacity (Approximate quantity) (L {US qt, Imp qt}) 8.3 {8.8, 7.3}
Transfer oilGrade API service GL-5
Viscosity SAE 80W-90
Capacity (Approximate quantity) (L {US qt, Imp qt}) 0.62 {0.65, 0.54}
Item Specification
Runout limit mm {in} 0.3 {0.01}
Starting torqueN·m
{kgf·cm}0.29—0.78 {3.0—7.9}

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 ′

TD–8
TECHNICAL DATA
Wheel and Tires
*
1: Total weight exceeds 160 g {5.65 oz}.
*2: One balance weight: 60 g {2.12 oz} max. If the total weight exceeds 100 g {3.53 oz} on one side, rebalance after moving the tire around on the rim. Do not use 3 or more balance weights.
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BODY ELECTRICAL SYSTEMA6E931001047201
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Item Specification
Standard tire and wheel
Wheel Size 15
× 6JJ 16 × 7JJ 17 × 7JJ 18 × 7J
Offset (mm {in}) 50 {1.97} 55 {2.17} 55 {2.17}
Pitch circle diameter (mm {in}) 114.3 {4.50} 114.3 {4.50}
Material Steel Aluminum alloy Aluminum alloy
Tire Size 195/65R15 91V 205/55R16 91V
215/45R17
87W 215/45R17
91W
(reinforced) 215/45R18 89W
Air pressure
(kPa {kgf/
cm
2, psi}) Front
Up to 4
persons
220 {2.2, 32} 2WD: 230
{2.3, 33}
4WD: 250 {2.5, 36} 220 {2.2, 32}
Full load 240 {2.4, 35} 2WD: 240
{2.4, 35}
4WD: 250 {2.5, 36} 240 {2.4, 35}
Rear Up to 4
persons
220 {2.2, 32} 2WD: 230
{2.3, 33}
4WD: 250 {2.5, 36} 220 {2.2, 32}
Full load 300 {3.1, 44} 270 {2.8, 39} 270 {2.8, 39}
Remaining tread (mm {in}) 1.6 {0.06} 1.6 {0.06}
Wheel
and
tire Wheel and tire
runout
Radial
direction
1.5 {0.06} max. 1.5 {0.06} max.
(mm {in}) Lateral direction 2.5 {0.10} max. 2.0 {0.08} max. 2.0 {0.08} max.
Wheel imbalance (g {oz}) Knock-type*
2:
9 {0.32} max. Adhesive-type*
1:
13 {0.46} max.
Knock-type*
2:
8 {0.28} max. Adhesive-type*
1:
11 {0.39} max.
Knock-type*
2:
7 {0.25} max. Adhesive-type*
1:
10 {0.35} max.
Knock-type*
2:
6 {0.21} max.
Temporary spare tire
Wheel Size 15
×4T
Offset (mm {in}) 40 {1.57}
Pitch circle diameter (mm {in}) 114.3 {4.50}
Material Steel
Tire Size T115/70 D15 T135/90 D15
Air pressure
(kPa {kgf/cm
2,
psi}) 420 {4.2, 60}
Wheel
and
tire Wheel and tire
runout
Radial
direction
2.0 {0.08} max.
(mm {in}) Lateral direction 2.5 {0.10} max.
Item Specifications
Exterior light bulb capacity (W) High-mount brake
lightWGNIn-vehicle-type 18.4
× 1
Rear spoiler
type 4
× 1 (LED)
Interior light bulb capacity (W) Cargo compartment light 10 × 1

SPECIAL TOOLS
ST–3
ST
FUEL AND EMISSION CONTROL SYSTEMA6E941001001204
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CLUTCHA6E941001024201
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MANUAL TRANSAXLEA6E941001024202
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AUTOMATIC TRANSAXLEA6E941001024203
WDS 49 T042 001A
Union wrench49 L018 001
O
2 sensor
wrench
49 D015 001
Box wrench
--
49 0259 770B
Flare Nut
Wrench49 SE01 310A
Clutch Disc
Centering Tool49 E011 1A0
Ring Gear
Brake Set
49 U027 003
Oil Seal Installer49 G030 797
Handle49 E017 5A0
Engine Support
Set
49 0378 400C
Oil pressure
gauge set49 B019 901B
Oil pressure
gauge49 L019 014
Adapter
49 L019 016
Installer49 G030 797
Handle49 B010 001
Oil Seal Installer

ST–4
SPECIAL TOOLS
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PROPELLER SHFTA6E941001024204
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FRONT AND REAR AXLEA6E941001018201
49 L019 013
Adapter49 E017 5A0
Engine Support
Set49 E011 1A0
Ring gear brake
set
WDS
——
49 0839 425C
Bearing puller
set49 H027 002
Bearing
Remover49 G030 370
Removing Plate
49 F015 002
Water seal
installer49 0636 145
Water pump
pulley boss
puller49 G030 797
Handle
49 H033 101
Bearing
remover49 U027 005
Bearing installer49 F401 331
Body
49 B034 201
Support block49 F401 335A
Attachment A
—
49 T028 3A0
Ball joint puller
set49 G033 102
Handle49 G033 105
Attachment

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
—