window MAZDA 6 2002 Suplement User Guide

S–6
LOCATION INDEX
EXTERIORA6E770001086201
.
End Of Sie
LOCATION INDEX
6
52
1
4
7
3
A6E77001102
1 Rear spoiler
(See S–11 REAR SPOILER REMOVAL/
INSTALLATION)
2 Rear window glass
(See S–16 REAR WINDOW GLASS REMOVAL)
(See S–17 REAR WINDOW GLASS
INSTALLATION)
3 Liftgate
(See S–8 LIFTGATE REMOVAL/INSTALLATION)
(See S–9 LIFTGATE DISASSEMBLY/ASSEMBLY)
(See S–10 LIFTGATE ADJUSTMENT)4 Rear drain hose
(See S–20 REAR DRAIN HOSE REMOVAL)
5 Side window glass
(See S–14 SIDE WINDOW GLASS REMOVAL)
(See S–14 SIDE WINDOW GLASS
INSTALLATION)
6 Roof molding
(See S–12 ROOF MOLDING REMOVAL)
(See S–12 ROOF MOLDING INSTALLATION)
7Roof rail
(See S–11 ROOF RAIL REMOVAL/
INSTALLATION)

S–14
WINDOW GLASS
SIDE WINDOW GLASS REMOVALA6E7738625802011. Apply protective tape along the edge of the body to protect it from damage.
2. Make a hole through the sealant, avoiding pins,
from the inside of the vehicle using an awl.
3. Pass the SST (piano wire) through the hole.
Warning
•Using a SST (piano wire) with bare hands
can cause injury. Always wear gloves
when using a SST (piano wire).
4. Wind each end of the SST (piano wire) around a
bar.
Note
•Use a long sawing action to spread the work
over the whole length of the SST (piano
wire) to prevent it from breaking.
5. Working with another person, saw through the
sealant around the edge of the glass.
6. Remove the side window glass.
End Of Sie
SIDE WINDOW GLASS INSTALLATIONA6E773862580202
Caution
•To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door
is closed, open all of the windows and leave them open until the sealant has hardened.
1. Cut away the old sealant using a razor so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around
the circumference of the frame.
Warning
•Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approximately 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
3. Clean and degrease an approximately 50.0 mm {1.97 in} wide strip around the circumference of the glass
and the bonding area on the body.
WINDOW GLASS
PIN
PIN
FASTENER
A6A7738W102
49 0305 870A
PROTECTIVE
TAPE
SEALANT
A6A7738W103
49 0305 870A
A6E7738W021

WINDOW GLASS
S–15
S
4. Insert the spacer into the body.
5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for
approximately 30 minutes.
Caution
•Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly
bond to the surface of the glass and body, which may cause leaks to occur.
6. Apply sealant to the area of the glass surface as
shown in the figure.
A
A
SEC. A
—ASPACER
A6A7738W104
mm {in}
A
C B
A
C
B
*1: PRIMER APPLICATION AREA
*2: POSSIBLE PRIMER APPLICATION AREA SEC. A
—ASEC. C—C
SEC. B—B PRIMER
APPLICATION AREAPRIMER
APPLICATION AREA BODY SIDE
SIDE WINDOW GLASS SIDE
9.5 {0.37}*1
9.5 {0.37}*1
9.5 {0.37}*1
5.0 {0.20}*2
11.5 {0.45}*2
6.0 {0.24}*2
11.0 {0.43}*1
4.0 {0.16}*2
11.0 {0.43}*1
6.0 {0.24}
6.0 {0.24}
11.0 {0.43}
*1
A6A7738W105
90˚ 90˚APPLY SEALANT
TO THIS AREA.
5 {0.20}
11 {0.43}
mm {in}
A6A7738W106

S–16
WINDOW GLASS
7. Set the side window glass in place and insert the
pins and fastener into the body. Install the side
window glass.
8. Allow the sealant to harden completely.
Sealant hardening time: 24 hours
End Of Sie
REAR WINDOW GLASS REMOVALA6E773863931201WGN
1. Remove the rear wiper motor.
2. Apply protective tape along the edge of the body to protect it from damage.
3. Cut the lip of the rear window molding using a
razor.
Warning
•Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.
Note
•The rear window molding is a replacement
part.
Not Reusing Glass
Note
•For the areas of the sealant that are difficult to cut, use a SST (piano wire) and follow the procedure under
“Reusing Glass.”
1. Use a SST, and insert the blade into the sealant.
2. Pull through the sealant around the edge of the
glass.
3. Remove the glass.
PIN
PIN
FASTENER
A6A7738W102
A
B A
B
SEC. A—ASEC. B—B LIP
LIP
REAR WINDOW
GLASS MOLDING
A6E77381107
49 G050 1A0
A6E7738W022

WINDOW GLASS
S–17
S
Reusing Glass
Note
•Before removing the rear window glass from the body, mark the position of the glass by affixing tape to
the glass and body panel.
1. Make a hole through the sealant, avoiding pins,
from the inside of the vehicle using an awl.
2. Pass the SST (piano wire) through the hole.
Warning
•Using a SST (piano wire) with bare hands
can cause injury. Always wear gloves
when using a SST (piano wire).
3. Wind each end of the SST (piano wire) around a
bar.
Note
•Use a long sawing action to spread the work
over the whole length of the SST (piano
wire) to prevent it from breaking.
4. Working with another person, saw through the
sealant around the edge of the glass.
5. Remove the rear window glass.
6. Remove the pins from the glass.
7. Remove the rear window molding from the glass.
End Of Sie
REAR WINDOW GLASS INSTALLATIONA6E773863931202
Caution
•To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door
is closed, open all of the windows and leave them open until the sealant has hardened.
1. Cut away the old sealant using a razor so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around
the circumference of the frame.
Warning
•Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approximately 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer.
3. Clean and degrease an approximately 50.0 mm {1.97 in} wide strip around the circumference of the glass
and the bonding area on the body.
PIN
PIN
A6E77381108
49 0305 870A
PROTECTIVE
TAPE SEALANT
REAR WINDOW
GLASS MOLDING
A6E77381109
49 0305 870A
A6E7738W021

S–18
WINDOW GLASS
4. Install the molding as shown in the figure.
5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for
approximately 30 minutes.
Caution
•Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly
bond to the surface of the glass and body, which may cause leaks to occur.
-3—3 mm
{-0.12—0.12 in} 45˚
LOWER REAR WINDOW
MOLDING
REAR WINDOW MOLDING
SIDE
A6E77381110
*2
8.0 {0.31}
9.5 {0.37}
*1
11.5
{0.45}*1
4.5 {0.18}*2
28.9 {1.14}
5.0 {0.20} 4.4 {0.17}
*2
5.0 {0.20}*2
17.5
{0.69}
mm {in}
SEC. A—A
SEC. C
—C SEC. B
—B
*1: PRIMER APPLICATION AREA
*2: POSSIBLE PRIMER APPLICATION AREA BODY SIDEREAR WINDOW GLASS SIDE
PRIMER
APPLICATION AREA
PRIMER
APPLICATION AREA
9.5 {0.37}
ALIGN WITH
CERAMIC MARKINGA
AB
B
9.5 {0.37} 9.5 {0.37}
9.5 {0.37}*1
9.5 {0.37}*1
11.5
{0.45}*1
11.5
{0.45}*1
1.7 {0.07}*2
5.8
{0.23}*2C
C
A6E77381112

WINDOW GLASS
S–19
S
6. Apply sealant to the area of the glass surface as
shown in the figure.
7. Set the position of the front windshield glass and
insert a pin into the body. Install the glass.
8. Keeping the measurement of the molding lip gap
within specification, press completely along the
perimeter of the glass.
9. Install the following points.
(1) Install the rear wiper motor.
(2) Install the liftgate lower trim.
(3) Install the liftgate side trim.
(4) Install the liftgate upper trim.
10. Allow the sealant to harden completely.
Sealant hardening time: 24 hours
End Of Sie
mm {in} 5 {0.20}11
{0.43}
APPLY SEALANT
TO THIS AREA.
A6A7738W113
PIN
PIN
A6E77381114
mm {in}
C
CA
A
B
SEC. A—A
SEC. C
—CSEC. B
—B
17.5 {0.69}
27.7 {1.09} 26.4 {1.04}
B
A6E77381115

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.
End Of Sie
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

T–36
AIR BAG SYSTEM
Deployment Procedure for Inside of Vehicle (Only When Vehicle Is To Be Scrapped)
1. Inspect the SST (Deployment tool).
2. Move the vehicle to an open space, away from strong winds, and close all the doors and windows.
3. Turn the ignition switch to LOCK position.
4. Disconnect the negative battery cable and wait for more than 1 minute.
5. Follow the appropriate procedure for deploying the driver-side air bag module, passenger-side air bag module,
side air bag module, curtain air bag module, or pre-tensioner seat belt.
Curtain air bag module (WGN)
1. Remove the headliner.
2. Disconnect the curtain air bag module connector.
3. Connect the SST (Adapter harness) to the curtain
air bag module.
4. Connect the SST (Deployment tool) to the SST
(Adapter harness).
5. Connect the red clip of the SST (Deployment tool)
to the positive battery terminal and the black clip
to the negative battery terminal.
6. Verify that the red light on the SST (Deployment
tool) is illuminated.
7. Make sure all persons are standing at least 6 m
{20 ft} from the vehicle.
8. Press the activation switch on the SST
(Deployment tool) to deploy the curtain air bag
module.
Deployment Procedure for Outside of Vehicle
1. Inspect the SST (Deployment tool).
2. Turn the ignition switch to LOCK position.
3. Disconnect the negative battery cable and wait for more than 1 minute.
4. Follow the appropriate procedure for deploying the driver-side air bag module, passenger-side air bag module,
side air bag module, curtain air bag module, or pre-tensioner seat belt.
49 L066 002
CURTAIN
AIR BAG MODULE
CONNECTOR
A6E81301112
49 L066 002
49 H066 002
A6E8130W151
49 H066 002
ACTIVATION
SWITCH
A6E8130W028

CONTROL SYSTEM
U–17
U
1B +5 V•Air mix actuator
•Airflow mode
actuator
•Solar radiation
sensorIgnition switch at ON
position
5.0•Inspect for short circuit
(Climate control unit— air
mix actuator, airflow mode
actuator, solar radiation
sensor: 1B—B, B, A)
•Inspect air mix actuator
•Inspect airflow mode
actuator
•Inspect solar radiation
sensor
•Inspect terminal voltage of
climate control unit
connector (2H, 2L)
Ignition switch at LOCK
positionBelow 1.0•Replace climate control unit
1C Blower motor
control signalPower MOS FET Fan switch is OFF Below 1.0•Inspect terminal voltage of
climate control unit (1A)
Fan switch is at manual
LO4.1
Fan switch is at manual
HI7.9
1D—— —— —
1E Rear window
defroster SW
signalRear window
defroster relayRear window defroster
switch is off
12•Inspect for continuity or
short circuit (Climate control
unit—rear window defroster
relay: 1E—E)
•Inspect rear window
defroster relay
Rear window defroster
switch is on Below 1.0•Inspect terminal voltage of
climate control unit (2H, 2L)
•Inspect center panel
1F On-board
diagnostic signalA/C check
connectorTerminal A of A/C check
connector is shorted. Below 1.0•Inspect for continuity
(Climate control unit—A/C
check connector: 1F—A)
Other
5.4•Inspect short circuit (Climate
control unit—A/C check
connector: 1F—A)
•Inspect terminal voltage of
climate control unit (2H, 2L)
1G—— —— —
1H—— —— —
1I GND•Cabin
temperature
sensor
•Evaporator
temperature
sensor
•Ambient
temperature
sensor
•Water
temperature
sensor
•Air mix actuator
•Airflow mode
actuatorUnder any condition
Below 1.0•Inspect terminal voltage of
climate control unit (2L)
1J Water heater
selectGround Under any condition
Below 1.0•Inspect for continuity
(Climate control unit—
ground: 1J—GND)
•Inspect center panel Terminal Signal Connected to Test condition Voltage (V) Action