trunk MAZDA 6 2002 Workshop Manual Suplement

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

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.
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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

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

LOCATION INDEX
S–7
S
INTERIORA6E770001086202
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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)

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–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

TRIM
S–21
S
C-PILLAR TRIM REMOVAL/INSTALLATIONA6E774468240201WGN
1. Remove the trunk side upper trim.
2. Turn the seaming welt over.
3. Remove the fastener.
4. Pull the C-pillar trim forward, then disengage the
clip A and pin B from the body.
5. Remove the hook from the body, then remove the
C-pillar trim.
6. Install in the reverse order of removal.
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D-PILLAR TRIM REMOVAL/INSTALLATIONA6E7744682802011. Remove the trunk side upper trim.
2. Pull the D-pillar trim forward, then disengage the
clips A and pin B from the body.
3. Remove the hook from the body, then remove the
D-pillar trim.
4. Install in the reverse order of removal.
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TRUNK SIDE TRIM REMOVAL/INSTALLATIONA6E774468860201WGN
1. Remove the trunk side upper trim.
2. Remove the trunk side trim cover.
TRIM
A
BC-PILLAR TRIM
SEAMING WELTCLIP A
PIN B HOOK
FRONT
FASTENER
A6A7744W102
A B
AA AD-PILLAR TRIM
CLIP A
PIN B
HOOK FRONT
A6A7744W103
FRONT
TRUNK SIDE TRIM COVER
A6A7744W105

S–22
TRIM
3. Remove the screw, then remove the bracket.
4. Remove the cargo hooks.
5. Remove the fasteners, then remove the trunk
side trim.
6. Install in the reverse order of removal.
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TRUNK SIDE UPPER TRIM REMOVAL/INSTALLATIONA6E774468860202WGN
1. Remove the tire house trim.
2. Remove the rear seat remote lever.
3. Remove the cargo hooks.
4. Remove the screw.
5. Pull the trunk side upper trim toward you, then
remove the hooks A, C, D and clips B, pin E from
the body.
6. Remove the trunk side upper trim.
7. Install in the reverse order of removal.
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FASTENER
TRUNK SIDE TRIM
CARGO HOOK FRONT
SCREW
BRACKET
A6E77441106
B AD C
A B
C
ED
SCREW TRUNK SIDE UPPER TRIM
CARGO HOOK FRONT
HOOK C
HOOK D HOOK A
PIN E CLIP B
A6A7744W107

TRIM
S–23
S
TRUNK END TRIM REMOVAL/INSTALLATIONA6E774468890201WGN
1. Pull the trunk end trim upward, then disengage
clips A and pins B from the body.
2. Remove the trunk end trim.
3. Install in the reverse order of removal.
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LIFTGATE UPPER TRIM REMOVAL/INSTALLATIONA6E774468930201WGN
Without rear spoiler
Caution
•Removing the liftgate upper trim by pulling on the middle section of the trim could damage the
high-mount brake light. When removing the trim, be sure to pull on the side edges of the trim only.
1. Pull the liftgate upper trim on the side edges
towards you, then disengage pins A from the
body.
2. Pull the middle section of the trim towards you
and disengage clips B and pin C from the body.
3. Remove the liftgate upper trim.
4. Install in the reverse order of removal.
With rear spoiler
1. Pull the liftgate upper trim toward you, then
disengage the pin A, C and clip B from the body.
2. Remove the liftgate upper trim.
3. Install in the reverse order of removal.
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AB
A
A
B
A
A
A B
TRUNK END TRIM
PIN B
CLIP A
A6A7744W108
AC B
AB
CLIP B
PIN A LIFTGATE UPPER TRIM
PIN C
A6A7744W109
ABAB
C
CLIP BPIN C LIFTGATE UPPER TRIM
PIN A
A6A7744W110

TRIM
S–25
S
TONNEAU COVER ANCHOR REMOVAL/INSTALLATIONA6E7744683202011. Remove the trunk side upper trim.
2. Remove the screws.
3. Remove the tonneau cover anchor.
4. Install in the reverse order of removal.
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SCREWTONNEAU COVER ANCHOR
A6A7744W114