MAZDA 6 2002 Workshop Manual Suplement

S–10
LIFTGATE
End Of SieLIFTGATE ADJUSTMENTA6E772262010203WGN
1. Measure the gap and height between the liftgate and the body.
2. If not as specified, loosen the liftgate hinge
installation bolts or the liftgate striker installation
screws, and reposition the liftgate.
Clearance
a: 0—2.0 mm {0—0.07 in}
b: 4.8—6.8 mm {0.19—0.26 in}
c: 3.5—7.5 mm {0.14—0.29 in}
d: 1.2—3.2 mm {0.05—0.12 in}
e: 2.8—5.2 mm {0.11—0.20 in}
f: -0.7—1.7 mm {-0.02—0.06 in}
g: 2.3—5.7 mm {0.10—0.22 in}
h: 4.0—8.0 mm {0.16—0.31 in}
3. Tighten the bolts or screws.
End Of Sie
a
f bcd
e
E E B
B
C
C
D
D
g a
h SEC. A A SEC. B B
SEC. C C
SEC. D D
SEC. E E A
A
A6A7722W104

EXTERIOR ATTACHMENT
S–11
S
EXTRACTOR CHAMBER REMOVAL/INSTALLATIONA6E772851920201WGN
1. Remove the rear bumper.
2. Remove the left side trunk side trim.
3. Squeeze the clips with your fingers and remove
the extractor chamber from the vehicle side.
4. Install in the reverse order of removal.
End Of Sie
REAR SPOILER REMOVAL/INSTALLATIONA6E772851920202WGN
1. Disconnect the negative battery cable.
2. Remove the liftgate upper trim. (SeeS–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION)
3. Remove the bolts and nuts.
4. Disconnect the high-mount brake light connector.
5. Disengage the pin A from the body, then remove
the rear spoiler.
6. Install in the reverse order of removal.
End Of Sie
ROOF RAIL REMOVAL/INSTALLATIONA6E7728517202011. Remove the headliner.
2. Remove the nuts.
3. Remove the roof rail.
4. Install in the reverse order of removal.
End Of Sie
EXTERIOR ATTACHMENT
EXTRACTOR
CHAMBER CLIP AA
A
A6E77281103
BOLT REAR SPOILER
HIGH-MOUNT BRAKE
LIGHT CONNECTOR
NUTPIN A
AA
N·m {kgf·cm, in·lbf} 7.8—9.8
{79—100, 68.8—86.7} 8.9—12.7 {90—130, 79—112}
A6A7728W104
ROOF RAIL
6.9—9.8 N·m
{70—100 kgf·cm,
60.8—86.7 in·lbf}NUT
A6A7728W105

S–12
MOLDING
ROOF MOLDING REMOVALA6E773050620201With Roof Rail
1. Remove the roof rail.
2. Detach the clips which secure A section of roof
moldings, using a screwdriver or equivalent tool.
3. Remove the roof molding No.2 and No.3.
4. While pulling the roof molding No.1 up, detach the
fit for the T stud of the B section and the roof
molding No.1 and then remove the roof molding
No.1.
End Of Sie
ROOF MOLDING INSTALLATIONA6E773050620202With Roof Rail
1. Attach the roof molding No.1 to the T stud at the A
section.
2. Hook the roof molding No.1 to clip B at the B
section, press it in, and attach the roof molding
No.1 to clip B.
MOLDING
FRONTb
ba
a B
TOP VIEW
SEC. a—a CLIP
SEC. b—b T STUD
ROOF
MOLDING No.3RROOF
MOLDING No.1R
ROOF
MOLDING No.2R
AAA
AA A
A6A7730W102
FRONTb
b a
aB
A
TOP VIEW
SEC. a—a T STUD
ROOF MOLDING No.1
SEC. b—b CLIP B
A6A7730W104

MOLDING
S–13
S
3. Align the front end-face of roof molding No.2 at a
position 216 mm {8.5 in} from the rear end-face
of roof molding No.1.
4. Press in roof molding No.2 along the direction (1)
shown in the figure and attach it to clips B at the B
section.
5. Align the front end-face of roof molding No.3 at a
position 47 mm {1.9 in} from the rear end-face of
roof molding No.2.
6. Press in roof molding No.3 along the direction (2)
shown in the figure and attach it to clips B at the B
section.
End Of Sie
ROOF MOLDING No.2 FRONTb
b
BB B
TOP VIEW
SEC. b—b ROOF MOLDING No.1
CLIP B
(1)
216 mm
{8.5 in}
A6A7730W105
ROOF MOLDING No.3 FRONTb
b
B
B
TOP VIEW
SEC. b—b
ROOF MOLDING No.2
CLIP B(2)
47 mm
{1.9 in}
A6A7730W106

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