2002 MAZDA 6 lock

WHEEL ALIGNMENT
R–9
R
Total Toe-in Adjustment
1. Center the steering wheel and confirm that the vehicle wheels/tires are pointing straight.
2. Loosen the left and right tie-rod end locknuts and turn the tie-rods equally. Both tie rods are right threaded, so
turning the right tie-rod toward the front of the vehicle and the left toward the rear increases toe-in.
Note
•Turning both tie-rods one complete turn changes toe-in by about 6 mm {0.24 in} (0°36').
3. Tighten the tie-rod end locknuts to the specified torque.
Tightening torque
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
4. Verify that the boot is not twisted, and install the boot clamp.
End Of Sie
REAR WHEEL ALIGNMENT (WGN)A6E741201016201Specification (Unloaded)*1
2WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.*3: Distance between wheel center and fender brim is 407 mm {16.02 in} (reference value).
4WD
*
1: Engine coolant and engine oil are at specified level. Spare tire, jack and tools are in designated position.
*2: Difference between left and right must not exceed 1°30'.
Note
•Adjust the toe-in after adjusting the camber.
Camber Adjustment
1. Loosen the cam nut on the lower arm.
2. Turn the adjusting cam bolt to provide the correct
camber angles as indicated.
3. Tighten the cam nut.
Tightening torque
86.2—116.6 N·m {8.80—11.88 kgf·m, 63.58—
85.99 ft·lbf}
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle
*2 normal–0°59′±1°–1°00′±1°–1°02′±1°–1°04′±1°–1°06′±1°
elevated
*3–0°52′±1°–0°53′±1°–0°55′±1°–0°56′±1°–0°58′±1°
Thrust angle 0°±0°48′
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
Total toe-in(mm {in}) Tire: 2±4 {0.08±0.16}, Rim inner: 1±3 {0.04±0.12}
(degree) 0°11′±0°22′
Camber angle*
2 –0°55′±1°–0°57′±1°–0°59′±1°–1°01′±1°–1°03′±1°
Thrust angle (degree) 0°±0°48′
Left wheel Right wheel
Positive direction ClockwiseCounter-
clockwise
Negative directionCounter-
clockwiseClockwise
LEFT SIDE
(VIEW FROM
FRONT OF THE
VEHICLE)
ADJUSTING
CAM BOLT
A6E7412W003

R–10
WHEEL ALIGNMENT
Total Toe-in Adjustment
1. Loosen the locknut of the lateral link.
2. Adjust the toe-in turning the adjusting link.
Specification
Total Toe-in: 2±4 mm {0.08±0.16 in}
Note
•Toe change amount: 0°43′ / one rotation
3. Tighten the locknut.
Tightening torque
68.6—98.1 N·m {7.0—10.0 kgf·m, 50.6—72.3
ft·lbf}
End Of Sie
A6E7412W004
A6E7412W005
A6E7412W004

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

T–6
MULTIPLEX COMMUNICATION SYSTEM
ON-BOARD DIAGNOSTIC FUNCTIONA6E811155430205Outline
•The on-board diagnostic function is incorporated into the PCM, TCM, ABS (ABS/TCS) HU/CM (with ABS (ABS/
TCS)), DSC HU/CM (with DSC), 4WD control module, and instrument cluster. This function can narrow down
CAN system malfunction locations.
•Due to the adoption of the TCM and the 4WD CM, some DTCs and PID/data monitor items have been added.
Other functions are the same as those of the current Mazda6 (GG) model.
Block Diagram
.
Fail-Safe Function
•When the failure detection function detemines that there is a malfunction, the fail-safe function illuminates a
warning light to advise the driver of the malfunction.
1
3
24
5
6
A6E81111103
1PCM
2 TCM (JA5AX-EL)
3 ABS (ABS/TCS) HU/CM or DSC HU/CM4 4WD control module (4WD)
5 Instrument cluster
6Twist pair
Module Fail-safe function
PCM•MIL illuminated
TCM•AT warning light illuminated
•ABS (ABS/TCS) HU/CM (with ABS (ABS/TCS))
•DSC HU/CM (with DSC)•ABS (ABS/TCS) suspended (with ABS (ABS/TCS))
•DSC suspended (with DSC)
•ABS warning light illuminated
•DSC/TCS indicator light illuminated
•DSC OFF light illuminated
•TCS OFF light illuminated
4WD control module•4WD indicator light illuminated
Instrument cluster•Speedometer, tachometer, water temperature gauge: 0 displayed

LOCATION INDEX
T–15
T
POWER SYSTEMA6E810001072201
.
End Of Sie
EXTERIOR LIGHTING SYSTEMA6E810001052201
.
LOCATION INDEX
1
A6E81101124
1 Main fuse block
(See T–19 RELAY LOCATION)
(See T–19 RELAY INSPECTION)
11
2
A6E81121162
1 High-mount brake light
(See T–20 HIGH-MOUNT BRAKE LIGHT
REMOVAL/INSTALLATION)2 Rear auto leveling sensor (4WD)
(See T–20 REAR AUTO LEVELING SENSOR
REMOVAL/INSTALLATION)

AIR BAG SYSTEM
T–33
T
•A live (undeployed) air bag module placed
face down on a surface is dangerous. If the air
bag module deploys, the motion of the
module can cause serious injury. Always face
the front surface up to reduce the motion of
the module in case it accidentally deploys.
Side Air Bag Module Handling
•When the side air bag module deploys due to a collision, the interior of the seat back (pad, frame, etc.)
may become damaged. If the seat back is reused and the side air bag module does not deploy properly,
a serious accident may result. When the side air bag module deploys, always replace both the side air
bag module and the seat back (pad, frame, trim) with new parts. After service, confirm that the seat
operates normally and that the harness is positioned properly.
SAS Unit Handling
•Disconnecting the SAS unit connector or removing the SAS unit with the ignition switch at ON position
can cause the air bag modules to deploy, which may seriously injure you. Before disconnecting the
SAS unit connector or removing the SAS unit, turn the ignition switch to LOCK position, then
disconnect the negative battery cable and wait for more than 1 minute to allow the backup power
supply of the SAS unit to deplete its stored power.
•Connecting the SAS unit connector without firmly installing the SAS unit to the vehicle is dangerous.
The crash sensor inside the control module may send an electrical signal to the air bag modules. This
will deploy the air bag modules, which may result in serious injury. Therefore, before connecting the
connector, firmly mount the control module to the vehicle.
•For vehicles with a single point sensor, once an air bag module is deployed due to an accident or other
causes, the SAS unit must be replaced with a new one even if the used one does not have any external
signs of damage. The used SAS unit may have been damaged internally which may cause improper
operation, resulting in major injuries or even death. The used single point SAS unit cannot be
bench-checked or self-checked.
Crash Zone Sensor Handling
•Disconnecting the crash zone sensor connector or removing the crash zone sensor with the ignition
switch at ON position can cause the crash zone sensor to operate and the air bag modules and pre-
tensioner seat belts to deploy, which may seriously injure you. Before disconnecting the crash zone
sensor connector or removing the crash zone sensor, always turn the ignition switch to LOCK position,
then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power
supply of the SAS control module to deplete its stored power.
•If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bag modules and
pre-tensioner seat belts may operate (deploy) suddenly and cause injury, or it may fail to operate
normally and cause a serious accident. Do not subject the crash zone sensor to shock or disassemble
the sensor.
•Because a sensor is built into the crash zone sensor, when the air bag modules and pre-tensioner seat
belts operates (deploys), there may be a problem, such as an internal malfunction, even if there is not
any external damage or deformation. If the crash zone sensor is reused, the air bag modules and pre-
tensioner seat belts may fail to operate normally and cause a serious injury. Always replace the crash
zone sensor with a new part. The crash zone sensor cannot be bench-checked or self-checked.
A6E8130W021

T–34
AIR BAG SYSTEM
Side Air Bag Sensor Handling
•Disconnecting the side air bag sensor connector or removing the side air bag sensor with the ignition
switch at ON position can cause the side air bag sensor to operate and the side air bag module to
deploy, which may seriously injure you. Before disconnecting the side air bag sensor connector or
removing the side air bag sensor, always turn the ignition switch to LOCK position, then disconnect the
negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS
control module to deplete its stored power.
•If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag module
may operate (deploy) suddenly and cause injury, or it may fail to operate normally and cause a serious
accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
•Because a sensor is built into the side air bag sensor, when the side air bag module operates (deploys),
there may be a problem, such as an internal malfunction, even if there is not any external damage or
deformation. If the side air bag sensor is reused, the side air bag module may fail to operate normally
and cause a serious injury. Always replace the side air bag sensor with a new part. The side air bag
sensor cannot be bench-checked or self-checked.
Pre-tensioner Seat Belt Inspection
•Inspecting a pre-tensioner seat belt using an
ohmmeter can deploy the pre-tensioner seat
belt, which can cause serious injury. Do not
use an ohmmeter to inspect the pre-tensioner
seat belt. Always use the on-board diagnostic
to diagnose the pre-tensioner seat belt for
malfunctions.
Component Handling
•Oil, grease, water, etc on components may cause the air bag modules and pre-tensioner seat belts to
fall to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on
components.
•Inserting a screwdriver, etc., into the
connector of an air bag module or a pre-
tensioner seat belt may damage the connector
and cause the air bag module or the pre-
tensioner seat belt to deploy improperly,
which may cause serious injury. Do not insert
any foreign objects into the connector.
Component Reuse
•Even if an air bag module or a pre-tensioner seat belt does not deploy in a collision and does not have
any external signs of damage, it may have been damaged internally, which may cause improper
operation. Improper operation may cause serious injury. Always self-check the undamaged air bag
module or pre-tensioner seat belt to determine whether it can be reused.
End Of Sie
A6E8130W025
A6E8130W023

AIR BAG SYSTEM
T–35
T
CURTAIN AIR BAG MODULE REMOVAL/INSTALLATIONA6E813000171201
Warning
•Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM SERVICE WARNINGS before handling the air bag
module. (See T–32 SERVICE WARNINGS.)
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable and wait for more than 1 minute.
3. Remove the headliner.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Turn the ignition switch to ON position.
7. Verify that the air bag system warning light
illuminates for approximately 6 seconds and
then goes off.
•If the air bag system warning light does not
operate in the manner described above, there
are malfunctions in the system. Inspect the system using the on-board diagnostic.
Connector Removal Note
1. Using a flathead screwdriver, pry out the
connector's stopper plate.
2. Disconnect the connector.
End Of SieAIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURESA6E813057000201
Warning
•A live (undeployed) air bag module and pre-tensioner seat belt may accidentally deploy when it is
disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag module and
pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not available,
consult the nearest Mazda representative for assistance.
Caution
•Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.
•When the vehicle is to be scrapped, deploy the air bag modules and pre-tensioner seat belts inside the vehicle.
(See T–36 Deployment Procedure for Inside of Vehicle (Only When Vehicle Is To Be Scrapped).)
•When the vehicle is not to be scrapped, deploy the air bag modules and pre-tensioner seat belts outside the
vehicle. (See T–36 Deployment Procedure for Outside of Vehicle.)
Note
•When disposing of deployed air bag module and pre-tensioner seat belt, refer to the disposal procedure.
•The deployment procedures are the same as those of the current 4SD and 5HB models, except for the
curtain air bag module.
1 Connector
(See T–35 Connector Removal Note)
2Bolt
3 Curtain air bag module3
1
2
N·m {kgf·cm, in·lbf} 7.9—11.7
{80—120, 70—104}
A6E81301126
A6E8130W002