roof MAZDA 6 2002 Workshop Manual Suplement

OUTLINE
B1–3
B1
SPECIFICATIONSA6E220202000204
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ItemSpecification
New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)New
Mazda6
(GG, GY)Current
Mazda6
(GG)
L8 LF L3
Type Gasoline, 4-cycle
Cylinder arrangement and number In-line, 4-cylinder
Combustion chamber Pentroof
Valve systemDOHC,
Timing chain driven, 16 valves
Displacement (ml {cc, cu in})1,798
{1,798, 109.7}1,999
{1,999, 121.9}2,261
{2,261, 137.9}
Bore × stroke (mm {in})83.0 × 83.1
{3.27 ×3.27}87.5 × 83.1
{3.44 ×3.27}87.5 × 94.0
{3.44 × 3.70}
Compression ratio 10.8:1 10.6:1
Compression pressure(kPa {kgf/cm
2,
psi}) [rpm]1,750
{17.85, 253.8}
[300]1,720
{17.54, 249.5}
[300]1,430
{14.58, 207.4}
[290]
Valve timingINOpenBTDC
(°)40—25
CloseABDC
(°)33 52 62—37
EXOpenBBDC
(°)37 42
CloseATDC
(°)45
Valve
clearance
[engine cold](mm {in})IN 0.22—0.28 {0.0087—0.0110} (0.25±0.03 {0.0098±0.0011})
EX 0.27—0.33 {0.0106 —0.0130} (0.30±0.03 {0.0118±0.0011})

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)
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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)
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OUTLINEA6E772801092201•A rear spoiler with a built in high-mount brake light has been adopted.
•A roof rail has been adopted.
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STRUCTURAL VIEWA6E772801092202
.
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OUTLINE
EXTERIOR ATTACHMENT
1
2
A6E7728T101
1 Roof rail2 Rear spoiler

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.
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OUTLINE

S–6
LOCATION INDEX
EXTERIORA6E770001086201
.
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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)

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.
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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.
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ROOF RAIL REMOVAL/INSTALLATIONA6E7728517202011. Remove the headliner.
2. Remove the nuts.
3. Remove the roof rail.
4. Install in the reverse order of removal.
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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.
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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.
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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–20
SLIDING SUNROOF
REAR DRAIN HOSE REMOVALA6E774069922201WGN
1. Remove the headliner.
2. Remove the trunk side upper trim and trunk side trim.
3. Disconnect the rear drain hose from the sunroof frame.
4. Remove the rear drain hose from the clips.
5. Pull the rear drain hose into the room side.
6. Remove the rear drain hose.
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SLIDING SUNROOF
A
AB
B
C
D
D C
A
A B
B
C E
ECRIGHT SIDE
LEFT SIDE
Sec. A—A
Sec. B
—B
Sec. C—C
Sec. E
—E Sec. D
—D
A6E77401101

S–26
HEADLINER
HEADLINER REMOVAL/INSTALLATIONA6E774668030201WGN
1. Disconnect the negative battery cable.
2. Turn the seaming welt and weatherstrip over.
3. Remove the sunroof seaming welt. (vehicles with sunroof only)
4. Remove the A-pillar trims.
5. Remove the B-pillar upper trims.
6. Remove the C-pillar trims.
7. Remove the D-pillar trims.
8. Remove the front and rear map light.
9. Remove the cargo compartment light. (See T–21 CARGO COMPARTMENT LIGHT REMOVAL/
INSTALLATION.)
10. Remove the sunvisors.
11. Remove the assist handle.
12. Remove the net anchor.
13. Disconnect the roof harness connector, remove the clip, and remove the connector.
14. Disconnect the front and rear drain hose.
15. Disconnect the rear washer hose.
16. Place the rear center seat belt bezel out of the way of the headliner.
17. Remove the fasteners.
18. Remove the hook holding the roof panel and remove the headliner.
19. Take the headliner off from the liftgate opening.
20. Install in the reverse order of removal.
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HEADLINER
HOOK
FASTENER
FASTENER ROOF HARNESS HEADLINERHOOK
ROOF HARNESS HEADLINER WITHOUT SUNROOF
WITH SUNROOF REAR WASHER HOSE
REAR WASHER HOSE
NET ANCHOR NET ANCHOR
A6A7746W101