2002 MAZDA 6 length

M–42
FRONT DRIVE SHAFT, REAR DRIVE SHAFT
Standard length
mm {in}
4. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Do not let grease leak.
•Do not damage the boot.
5. Verify that the drive shaft length is within the
standard.
•If not, repeat from Step 3.
End Of Sie
REAR DRIVE SHAFT PRE-INSPECTIONA6E6317255002011. Inspect each connecting part for looseness.
•Tighten or replace parts if necessary.
2. Inspect the dust boot on the drive shaft for cracks,
damage, leaking grease, and looseness in the
boot band.
3. Inspect the drive shaft for bends, cracks, and
wear in the joints or splines.
•Repair or replace the drive shaft or boot band
if necessary.
End Of Sie
Left side Right side
667—677
{26.26—26.65}631—641
{24.85—25.23}
A6E6316W007
REAR DRIVE SHAFT
A6J63172101

M–48
REAR DRIVE SHAFT, REAR DIFFERENTIAL
5. Release any trapped air from the boots by
carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
•Do not let grease leak.
•Do not damage the boot.
6. Set the drive shaft to the standard length.
Standard length
mm {in}
7. Verify that the drive shaft length is within the standard.
•If not, repeat from Step 5.
End Of Sie
DIFFERENTIAL OIL INSPECTIONA6E6319271002031. Place the vehicle on level ground.
2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug
hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and
tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7
ft·lbf}
End Of SieDIFFERENTIAL OIL REPLACEMENTA6E6319271002041. Place the vehicle on level ground.
2. Remove the filler plug.
3. Remove the drain plug and drain the differential
oil into a container.
4. Install a new washer and the drain plug, and
tighten.
Tightening torque
39—53 N·m {4.0—5.4 kgf·m, 29—39 ft·lbf}
5. Add the specified differential oil from the filler plug
until the level reaches the brim of the plug hole.
Specified oil
Type (API service GL-5)
Above -18°C {0°F}: SAE 90
Below -18°C {0°F}: SAE 80
Capacity (Approximate quantity):
1.00 L {1.06 US qt, 0.88 Imp qt}
6. After filling with differential oil, perform oil level inspection.
7. Install a new washer and the drain plug, and tighten.
Tightening torque
39.2—53.9 N·m {4.0—5.4 kgf·m, 29.0—39.7 ft·lbf}
Left side Right side
805.4—815.4
{31.71—32.10}852.4—862.4
{33.56—33.95}A6E6316W007
REAR DIFFERENTIAL
FILLER PLUG
A6E63192101
FILLER PLUG
DRAIN PLUG
A6E63192102

R–8
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT (WGN)A6E741201015201Specification (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 405 mm {15.94 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'.
Maximum Steering Angle Adjustment 1. Loosen the tie-rod end locknuts.
2. Remove the steering gear boot clamp.
3. Turn the tie rods to equalize the length L.
Maximum left/right difference3 mm {0.12 in}
4. Turn the tie rods equally to provide the correct maximum steering angle.
5. Tighten the tie-rod end locknuts.
Tightening torque68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
6. Verify that the boot is not twisted, and install the boot clamp.
7. Adjust the toe-in after adjusting the steering angle.
WHEEL ALIGNMENT
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner
18 inch wheel specification vehicles: 36
°±3°
Except for above: 39 °±3°
Outer 18 inch wheel specification vehicles: 30
°±3°
Except for above: 31 °±3°
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 ′
Caster angle
*2
(Reference value) normal 3
°30' ±1 ° 3°32' ±1 ° 3°34' ±1° 3°37' ±1° 3°40' ±1 °
elevated*33 °25' ±1 ° 3°27' ±1 ° 3°29' ±1° 3°32' ±1° 3°35' ±1 °
Camber angle
*2
(Reference value) normal -0
°14' ±1 ° -0°15' ±1°
elevated*3-0 °07' ±1 ° -0°08' ±1°
Steering axis inclination
(Reference value) normal 5
°24'
elevated
*35 °15' 5 °16'
Item Fuel gauge indication
Empty 1/4 1/2 3/4 Full
Maximum steering angle Inner 39
°±3°
Outer 31 °±3°
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 ′
Caster angle*
2 (reference value) 3
°25' ±1 ° 3°27' ±1 ° 3°29' ±1 ° 3°32' ±1 ° 3°35' ±1 °
Camber angle*
2(reference value) -0
°07' ±1 ° -0°08' ±1°
Steering axis inclination (reference value) 5 °15' 5 °16'
LEFT AND RIGHT DIFFERENCE
L
LESS THAN 3 mm {0.12 in}
A6E7412W002

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–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

TD–2
TECHNICAL DATA
ENGINEA6E931001001201
End Of Sie
LUBRICATION SYSTEMA6E931001001202
TECHNICAL DATA
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
MECHANICAL
Valve clearance
[engine cold](mm {in})IN0.12—0.18
{0.005—0.007}
(0.15±0.03 {0.006±0.0011})
EX0.32—0.38
{0.013—0.014}
(0.35±0.03 {0.014±0.0011})
Compression pressure(kPa {kgf/cm
2, psi}) [rpm]Standard3,500
{35.7, 507.7}
[250]
Minimum3,100
{31.6, 449.4}
[250]
Maximum difference
between cylinders196.1 {1.999, 28.44}
Cylinder head bolt length (mm {in})Standard 159.7—160.3 {6.288—6.311}
Maximum 161.0 {6.338}
Pushing distance of the front oil seal
(from the edge of the oil pump body)(mm {in})0—0.5
{0—0.019}
Pushing distance of the rear oil seal
(from the edge of the rear cover)(mm {in})0—0.5
{0—0.019}
Pushing distance of the camshaft oil seal
(from the edge of the cylinder head)(mm {in})0.5—1.5
{0.020—0.059}
Timing belt auto tensioner rod projection (free length) (mm {in})12.9—14.6
{0.508—0.574}
ItemSpecification
Diesel engine
MZR-CD (RF Turbo)
Oil pressure
(approximate quantity)
[oil temperature: 100°C {212°F}](kPa {kgf/cm
2, psi}) min [rpm]147 {1.5, 21} [1,000],
343 {3.5, 50} [3,000]
Oil capacity
(approximate quantity)Total (dry engine)
5.5 {5.8, 4.8}
(L {US qt, Imp qt})
Oil replacement
4.8 {5.1, 4.2}
(L {US qt, Imp qt})
Oil and oil filter replacement
5.0 {5.3, 4.4}
(L {US qt, Imp qt})

TD–6
TECHNICAL DATA
FRONT AND REAR AXLEA6E931001018201
End Of Sie
STEERING SYSTEMA6E931001034201
End Of Sie
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})