MAZDA 6 2002 Workshop Manual Suplement

REAR SUSPENSION
R–19
R
2. Tap the bushing onto the rear crossmember using
the SSTs.
End Of Sie
49 G033 102
49 G033 106
A6E7416W002

S–1
S
SBODY
OUTLINE................................................................ S-2
OUTLINE OF CONSTRUCTION ......................... S-2
FEATURES .......................................................... S-2
EXTERIOR ATTACHMENT.................................... S-2
OUTLINE ............................................................. S-2
STRUCTURAL VIEW........................................... S-2
TRIM....................................................................... S-3
OUTLINE ............................................................. S-3
STRUCTURAL VIEW........................................... S-3
SEAT....................................................................... S-4
OUTLINE ............................................................. S-4
STRUCTURAL VIEW........................................... S-4
OUTLINE................................................................ S-5
SUPPLEMENTAL SERVICE INFORMATION ..... S-5
LOCATION INDEX................................................. S-6
EXTERIOR........................................................... S-6
INTERIOR ............................................................ S-7
LIFTGATE............................................................... S-8
LIFTGATE REMOVAL/INSTALLATION............... S-8
LIFTGATE DISASSEMBLY/ASSEMBLY ............. S-9
LIFTGATE ADJUSTMENT................................. S-10
EXTERIOR ATTACHMENT.................................. S-11
EXTRACTOR CHAMBER
REMOVAL/INSTALLATION ............................ S-11
REAR SPOILER REMOVAL/INSTALLATION ... S-11
ROOF RAIL REMOVAL/INSTALLATION .......... S-11
MOLDING............................................................. S-12
ROOF MOLDING REMOVAL ............................ S-12
ROOF MOLDING INSTALLATION .................... S-12
WINDOW GLASS................................................. S-14
SIDE WINDOW GLASS REMOVAL .................. S-14
SIDE WINDOW GLASS INSTALLATION .......... S-14
REAR WINDOW GLASS REMOVAL................. S-16
REAR WINDOW GLASS INSTALLATION ......... S-17
SLIDING SUNROOF............................................. S-20
REAR DRAIN HOSE REMOVAL ....................... S-20
TRIM..................................................................... S-21
C-PILLAR TRIM REMOVAL/INSTALLATION .... S-21
D-PILLAR TRIM REMOVAL/INSTALLATION .... S-21
TRUNK SIDE TRIM
REMOVAL/INSTALLATION ............................ S-21
TRUNK SIDE UPPER TRIM
REMOVAL/INSTALLATION ............................ S-22
TRUNK END TRIM
REMOVAL/INSTALLATION ............................ S-23
LIFTGATE UPPER TRIM
REMOVAL/INSTALLATION ............................ S-23
LIFTGATE SIDE TRIM
REMOVAL/INSTALLATION ............................ S-24
LIFTGATE LOWER TRIM
REMOVAL/INSTALLATION ............................ S-24TONNEAU COVER ANCHOR
REMOVAL/INSTALLATION ............................ S-25
HEADLINER......................................................... S-26
HEADLINER REMOVAL/INSTALLATION ......... S-26
FLOOR COVERING............................................. S-27
FRONT FLOOR COVERING
REMOVAL/INSTALLATION ............................ S-27
SEAT BELT.......................................................... S-28
REAR SIDE SEAT BELT
REMOVAL/INSTALLATION ............................ S-28
REAR CENTER SEAT BELT
REMOVAL/INSTALLATION ............................ S-28
SEAT..................................................................... S-29
REAR SEAT REMOVAL/INSTALLATION.......... S-29
REAR SEAT DISASSEMBLY/ASSEMBLY ........ S-29 FEATURES
SERVICE

S–2
OUTLINE, EXTERIOR ATTACHMENT
OUTLINE OF CONSTRUCTIONA6E770201086201•The construction and operation of the body system is essentially carried over from that of the current Mazda6
(GG) model, except for the following features. (See Mazda6 Training Manual 3359-1*-02C)
End Of Sie
FEATURESA6E770201086202Improved Marketability
•A rear spoiler with a built in high-mount brake light has been adopted. (WGN)
•A roof rail has been adopted. (WGN)
•A tonneau cover with an attached net has been adopted. (WGN)
•A fixed rear seat cushion has been adopted. (4WD WGN)
End Of Sie
OUTLINEA6E772801092201•A rear spoiler with a built in high-mount brake light has been adopted.
•A roof rail has been adopted.
End Of Sie
STRUCTURAL VIEWA6E772801092202
.
End Of Sie
OUTLINE
EXTERIOR ATTACHMENT
1
2
A6E7728T101
1 Roof rail2 Rear spoiler

TRIM
S–3
S
OUTLINEA6E774468320202•A tonneau cover with an attached net has been adopted. By extending this cover and net, the privacy of the
cargo compartment can be maintained, the cargo and passenger compartments can be partioned, and cargo
or luggage can be kept from falling into the passenger compartment.
•Fixing the net to the trunk side upper trim allows for partitioning of the rear seat and cargo compartment, and
fixing the net to the rear seat back (folded down) allows for partitioning of the front seat and the cargo
compartment.
End Of Sie
STRUCTURAL VIEWA6E774468320203
.
TRIM
4
2
1
2
2
1
1
4
5
1
6
3
7
8
A6E7744T101
1 Tonneau cover
2Net
3 Rear seat fixing bracket
4Hook5 Tonneau cover anchor
6 Rear seat
7 When fixed to the trunk side upper trim
8 When fixed to the rear seat

S–4
SEAT
End Of Sie
OUTLINEA6E775257100201•A fixed rear seat cushion has been adopted. (4WD WGN)
End Of Sie
STRUCTURAL VIEWA6E775257100202
.
End Of Sie
SEAT
12
44
33
A6E77521101
1 Full flat fold down function (except 4WD WGN)
2 Fold down function (4WD WGN)3 Rear seat back
4 Rear seat cushion

OUTLINE
S–5
S
SUPPLEMENTAL SERVICE INFORMATIONA6E770201086203•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Liftgate
•Removal/Installation procedure has been modified.
•Disassembly/Assembly procedure has been modified.
•Adjustment procedure has been modified.
Extractor chamber
•Removal/Installation procedure has been modified.
Roof rail
•Removal/Installation procedure has been added.
Rear spoiler
•Removal/Installation procedure has been modified.
Roof molding
•Removal procedure has been modified.
•Installation procedure has been modified.
Side window glass
•Removal procedure has been added.
•Installation procedure has been added.
Rear window glass
•Removal procedure has been modified.
•Installation procedure has been modified.
Rear drain hose
•Removal procedure has been modified.
C-pillar trim
•Removal/Installation procedure has been modified.
D-pillar trim
•Removal/Installation procedure has been added.
Trunk side trim
•Removal/Installation procedure has been modified.
Trunk side upper trim
•Removal/Installation procedure has been modified.
Trunk end trim
•Removal/Installation procedure has been modified.
Liftgate upper trim
•Removal/Installation procedure has been modified.
Liftgate side trim
•Removal/Installation procedure has been modified.
Liftgate lower trim
•Removal/Installation procedure has been modified.
Tonneau cover anchor
•Removal/Installation procedure has been added.
Headliner
•Removal/Installation procedure has been modified.
Front floor covering
•Removal/Installation procedure has been modified.
Rear side seat belt
•Removal/Installation procedure has been modified.
Rear center seat belt
•Removal/Installation procedure has been modified.
Rear seat
•Removal/Installation procedure has been modified.
•Disassembly/Assembly procedure has been modified.
End Of Sie
OUTLINE

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)

LOCATION INDEX
S–7
S
INTERIORA6E770001086202
.
End Of Sie
1
10
12
13
11 14
2
3
4
5
6
7
89
A6E77001104
1 Liftgate side trim
(See S–24 LIFTGATE SIDE TRIM REMOVAL/
INSTALLATION)
2 C-pillar trim
(See S–21 C-PILLAR TRIM REMOVAL/
INSTALLATION)
3 D-pillar trim
(See S–21 D-PILLAR TRIM REMOVAL/
INSTALLATION)
4 Trunk side upper trim
(See S–22 TRUNK SIDE UPPER TRIM REMOVAL/
INSTALLATION)
5 Trunk side trim
(See S–21 TRUNK SIDE TRIM REMOVAL/
INSTALLATION)
6 Extractor chamber
(See S–11 EXTRACTOR CHAMBER REMOVAL/
INSTALLATION)
7 Trunk end trim
(See S–23 TRUNK END TRIM REMOVAL/
INSTALLATION)8 Rear seat
(See S–29 REAR SEAT REMOVAL/
INSTALLATION)
(See S–30 REAR SEAT DISASSEMBLY/
ASSEMBLY)
9 Floor covering
(See S–27 FRONT FLOOR COVERING
REMOVAL/INSTALLATION)
10 Tonneau cover anchor
(See S–25 TONNEAU COVER ANCHOR
REMOVAL/INSTALLATION)
11 Headliner
(See S–26 HEADLINER REMOVAL/
INSTALLATION)
12 Rear center seat belt
(See S–28 REAR CENTER SEAT BELT
REMOVAL/INSTALLATION)
13 Liftgate upper trim
(See S–23 LIFTGATE UPPER TRIM REMOVAL/
INSTALLATION)
14 Liftgate lower trim
(See S–24 LIFTGATE LOWER TRIM REMOVAL/
INSTALLATION)

S–8
LIFTGATE
LIFTGATE REMOVAL/INSTALLATIONA6E772262010201WGN
Warning
•Removing the stay damper without supporting the liftgate can be dangerous. The liftgate may fall
and injure you. Open the liftgate fully and support it before removing the stay damper.
1. Disconnect the negative battery cable.
2. Remove the liftgate upper trim. (SeeS–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION)
3. Disconnect the rear washer hose.
4. Disconnect the vehicle harness and the vehicle
harness connector, attached to the liftgate, from
the liftgate harness connector.
5. Pry away the stay damper's band with a
screwdriver.
6. Pry out the connecting part of the stay damper
and the hinge with a screwdriver to disconnect
them. Then remove the stay damper.
7. Remove the bolts A, then remove the liftgate.
8. To remove the hinge, remove the headliner and
the nut.
LIFTGATE
GROMMET
VEHICLE HARNESS
CONNECTOR LIFTGATE HARNESS
CONNECTORVEHICLE HARNESS
VEHICLE HARNESS
A6E77221101
BAND
STAY
DAMPER
A6E7722W005

LIFTGATE
S–9
S
9. To remove the stay damper, remove the bolt B.
10. Install in the reverse order of removal.
End Of Sie
LIFTGATE DISASSEMBLY/ASSEMBLYA6E772262010202WGN
1. Disconnect the negative battery cable.
2. Remove the liftgate lower trim.
3. To remove the liftgate outer handle and liftgate key cylinder, remove the rear finisher.
4. To remove the stud ball, separate the stud ball and the stay damper.
5. Disassemble in the order indicated in the table.
6. Assemble in the reverse order of disassembly.
.
BOLT B
HINGE
STAY DAMPER
BOLT A
NUT
LIFTGATE
N·m {kgf·cm, in·lbf} 8.8—12.7
{90—130,
78—112}
32.4—48.5 N·m
{3.3—4.9 kgf·m,
24—35 ft·lbf} 7.8—10.8
{80—110, 70—95}
A6E77221102
A
2
N·m {kgf·cm, in·lbf}
A
31
B
6.90—9.80
{70—100,
60.8—86.7}
4.0—5.8
{39.8—60.1,
34.6—52.2}
4
B
16—23 N·m
{1.6—2.4 kgf·m,
12—17 ft·lbf}3.9—5.9
{39.8—60.1,
34.6—52.2}
5
7
6
A6A7722W103
1 Liftgate latch and lock actuator
2 Liftgate outer handle
3 Liftgate key cylinder
4Clip5Stud ball
6 Liftgate
7 Stopper