2002 MAZDA 6 height

REAR SUSPENSION
R–5
R
SUSPENSION CONTROL SYSTEMA6E741601013201Outline
•The self-leveling suspension is a system that adjusts the vehicle height according the amount of vehicle load.
This system will raise the rear of a vehicle, lowered due to a load placed on it, to the designated load level
* after
the vehicle has been driven a certain distance.
•The vehicle height adjustment is performed using a gas-pressurized pump function built into the rear shock
absorber.
•For the vehicle height to return to the designated load level, the vehicle must be driven approx. 5—6 km {3.1—
3.7 miles} in city driving conditions. (Distance will vary due to load and road conditions.)
•A load amount of approx. 140—300 kg {308—660 lb} at the rear axle will cause the vehicle height to be raised,
and any weight over that will prevent the vehicle from returning to the designated load level.
*: Designated load level is defined as the level at which the vehicle is with: a full fuel tank; engine coolant and oil at
specified levels; spare tire, jack and tools in designated positions; and four people, weighing 55 kg {121 lb} each,
riding in the vehicle.
Construction
.
REAR SUSPENSION
5
4
3
6
1
2
A6E74162001
1 Outlet check valve
2 Pump chamber
3 Low-pressure chamber4 High-pressure chamber
5Piston
6 Inlet check valve

R–6
REAR SUSPENSION
Operation
During leveling operation
•During shock absorber expansion, the inlet check valve opens due to negative pressure created in the pump
chamber, and oil is drawn into the pump chamber from the low-pressure chamber. During shock absorber
contraction, oil pressure in the pump chamber forces the outlet check valve to open, and oil in the pump
chamber flows through the pump cylinder into the high-pressure chamber. Due to this expansion and
contraction while driving, rod reaction force increases, and the vehicle height returns to the designated load
level. Also, similar to a regular shock absorber, damping is performed while driving with the damping valve.
.
Leveling operation completed
•When the vehicle height returns to the designated
load level, the volume of oil in the high-pressure
chamber increases and the piston rises. This
causes the pump chamber and the high-pressure
chamber to be connected at the pump rod notch,
and the expansion or contraction is completed.
.
87
5
4
3
6
1
2
A6E74162002
1 Pump chamber
2 Outlet check valve
3 Inlet check valve
4 Low-pressure chamber5 Damping valve
6 High-pressure chamber
7 Leveling operation (expansion)
8 Leveling operation (contraction)
1 Pump chamber
2Piston
3 Pump rod notch
4 High-pressure chamber
4
3
1
2
A6E74162003

REAR SUSPENSION, OUTLINE
R–7
R
During unloading of passengers and cargo
•When the vehicle height is higher than the
designated load level, oil flows back into the low-
pressure chamber from the high-pressure
chamber via the pump rod leveling port. As a
result, pressure in the high-pressure chamber
decreases, rod reaction force is reduced, and the
vehicle height returns to the designated load
level.
.
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SUPPLEMENTAL SERVICE INFORMATIONA6E740201013205•The following changes have been made since publication of the Mazda6 Workshop Manual (1730-1*-02C).
Front wheel alignment (WGN)
•Specifications have been added.
Rear wheel alignment (WGN)
•Specifications have been added.
Suspension control system (WGN)
•On-vehicle inspection procedure has been added.
Rear shock absorber (WGN)
•Removal/installation procedure has been added.
•Disposal procedure has been added.
Rear stabilizer (4WD)
•Removal/installation procedure has been added.
Trailing link (4WD)
•Removal/installation procedure has been added.
Rear crossmember (4WD)
•Removal/installation procedure has been added.
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1 Leveling port
2 Low-pressure chamber
3 High-pressure chamber
3
1
2
A6E74162004
OUTLINE

REAR SUSPENSION
R–11
R
SUSPENSION CONTROL SYSTEM ON-VEHICLE INSPECTION (WGN)A6E7416010132021. Pull up the dust boot and visually inspect the piston rod for oil leakage.
2. Remove all cargo and drive the vehicle, with only the driver aboard, for 1 km {0.62 miles} or more. After
driving, verify that the rear vehicle height (distance measured from the fender brim to the center of the wheel) is
360 mm {14.2 in} or more
*. If not as specified, replace the rear shock absorbers.
3. Place a load equivalent to five people riding in
order to make the rear vehicle height to be 330
mm {13.0 in} or less.
4. Immediately after driving the vehicle for 5 km {3.0
miles} or more, under the same load conditions,
verify that the rear vehicle height is 335 mm {13.2
in} or more. If not as specified replace the rear
shock absorbers.
*: Indicates rear vehicle height with fuel tank full.
Height will vary 6—8 mm {0.24—0.31 in} between a
full and empty fuel tank.
End Of SieREAR SHOCK ABSORBER REMOVAL/INSTALLATION (WGN)A6E741628700201
Caution
•Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
REAR SUSPENSION
SECTION
A—AMEASURING POINT
A
A
A6E7412W001
1 Rear shock absorber and bracket
2Bracket
(See R–12 Bracket Installation Note)
3 Rear shock absorber
1
3
37.2—51.9
{3.80—5.29,
27.5—38.2}
286.2—116.6
{8.80—11.88,
63.58—85.99}
86.2—116.6
{8.80—11.88,
63.58—85.99}
N·m {kgf·m, ft·lbf}
A6E74162006

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.
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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

TD–6
TECHNICAL DATA
FRONT AND REAR AXLEA6E931001018201
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STEERING SYSTEMA6E931001034201
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Item Specification
FRONT DRIVE SHAFT
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left sideMZR-CD (RF Turbo): 666.1—676.1 {26.23—26.61}
4WD: 667—677 {26.26—26.65}
Right sideMZR-CD (RF Turbo): 615.9—625.9 {24.25—24.64}
4WD: 631—641 {24.85—25.23}
REAR DRIVE SHAFT (4WD)
Shaft length
(Air in boot at atmospheric
pressure)(mm {in})Left side 805.4—815.4 {31.71—32.10}
Right side 852.4—862.4 {33.56—33.95}
REAR DIFFERENTIAL (4WD)
Pinion height (mm {in})–0.025—0.025 {–0.001—0.001}
Backlash of side gear and differential pinion (mm {in}) 0.1 {0.004} or less
Drive pinion preload (N·m kgf·cm, in·lbf) 1.3—1.8 {13.3—18.3, 11.5—15.9}
Backlash of drive pinion and
ring gear(mm {in})Standard 0.09—0.11 {0.0036—0.0043}
Minimum 0.05 {0.002}
Differential oilGrade API service GL-5
ViscosityAbove –18°C {0°F}: SAE 90
Below –18°C {0°F}: SAE 80
Capacity
(Approximate quantity)(L {US qt, lmp qt}) 1.00 {1.06, 0.88}
ELECTRONIC 4WD CONTROL SYSTEM
Differential oil temperature
sensor(kilohm)0°C {32°F} 91—100
10°C {50°F} 56—61
20°C {68°F} 35—39
30°C {86°F} 23—25
40°C {104°F} 14—17
50°C {122°F} 10—11
60°C {140°F} 7.1—7.9
70°C {158°F} 5.0—5.6
80°C {176°F} 3.6—4.0
4WD solenoid
(Rear differential oil temperature
at 20°C {68°F})(ohm) 1.5—2.0
Item Specification
ENGINE SPEED SENSING POWER STEERING
Power
steering oil
pumpOil pump fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Gear housing fluid pressure 2WD (Except MZR-CD (RF Turbo)):
10.80—11.29 {110.2—115.1, 1,567—1,637}
MZR-CD (RF Turbo):
11.31—11.80 {115.4—120.3, 1,641—1,711}
4WD: 10.30—10.79 {105.1—110.0, 1,490—1,564} (MPa {kgf·cm
2, psi})
Power
steering
systemFluid type
ATF M-
III or equivalent (e.g. Dexron®II)
Capacity (Approximate quantity) MTX (Except MZR-CD (RF Turbo)): 0.80 {0.85, 0.70}
ATX (Except 4WD): 0.87 {0.92, 0.77}
MZR-CD (RF Turbo): 0.86 {0.91, 0.76}
4WD: 0.89 {0.94, 0.78} (L {US qt, Imp qt})

ST–6
SPECIAL TOOLS
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49 0107 680A
Engine stand49 T032 317
Weight49 T032 316
Shaft
49 L027 004
Gear case
remover49 L027 0A0
Locknut
replacer set49 L027 006
Serrate socket
(Part of 49 L027
0A0)
49 L027 007
Hex socket
(Part of 49 L027
0A0)49 F401 366A
Plate49 B027 003
Attachment M
49 F401 331
Body49 F401 337A
Attachment C49 M005 797
Handle
49 F027 007
Attachment
φ 7249 G027 004
Gauge block49 8531 565
Drive pinion
model
49 8531 567
Collar A
(Part of 49 8531
565)49 8531 568
Collar B
(Part of 49 8531
565)49 G032 347
Oil seal installer
49 0727 570
Pinion height
gauge body49 S033 108
Bearing installer49 W010 107A
Installer
49 S032 333
Bearing installer49 E027 002
AttachmentWDS