2002 MAZDA 6 suspension

F1–64
TROUBLESHOOTING
NO.22 VIBRATION CONCERNS (ENGINE)A6E398018881204
Diagnostic procedure
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22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION•Vibration from under hood or driveline
POSSIBLE CAUSE•Loose attaching bolts or worn parts
•Components malfunction such as worn parts
STEP INSPECTION RESULTS ACTION
1 Inspect following components for loose attaching
bolts or worn parts:
•Cooling fan
•Condenser fan
•Drive belt and pulleys
•Engine mounts
All items okay?Yes Inspect following systems:
•Wheels
•ATX
•Driveline
•Suspension
•Electrically controlled 4WD system
No Readjust or retighten engine mount installation
position.
Service if necessary for other parts.
2 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM.

F2–172
TROUBLESHOOTING
×: Applicable
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Troubleshooting item
1 Melting of main or other fuses
2 MIL illuminates
3 Will not crank×
4 Hard start/long crank/erratic start/erratic crank
5 Engine stalls After start/at idle×× ×
6 Cranks normally but will not start×
7 Slow return to idle
8 Engine runs rough/rolling idle×××
9 Fast idle/runs on
10 Low idle/stalls during deceleration××
11Engine stalls/quits Acceleration/cruise××××
Engine runs rough Acceleration/cruise××××
Misses Acceleration/cruise××××
Buck/jerk Acceleration/cruise/ deceleration××××
Hesitation/stumble Acceleration××××
Surges Acceleration/cruise××××
12 Lack/loss of power Acceleration/cruise×× × ×
13 Knocking/pinging
14 Poor fuel economy××××× ×
15 Emissions compliance×
16 High oil consumption/leakage
17 Cooling system concerns Overheating××× ×
18 Cooling system concerns Runs cold××
19 Excessive black smoke
20 Fuel odor (in engine compartment)
21 Engine noise××
22 Vibration concerns (engine)××××
23 A/C does not work sufficiently××
24 A/C always on or A/C compressor runs continuously××
25 A/C does not cut off under wide open throttle conditions
26 Constant voltage
A/C relay (A/C control siganl) circuit malfunctionA/C magnetic clutch or related circuit malfunctionCooling fan No.1 system malfunctionClutch slippageAir in power steering fuluid lineVSS or related circuit malfunctionBrake draggingLoose partsImproper balance of wheel or tiresDriveline malfunctionSuspension malfunctionImmobilizer system and/or circuit malfunctionCoolant heater system malfunction

F2–220
TROUBLESHOOTING
NO.22 VIBRATION CONCERNS (ENGINE)A6E408018881224
Diagnostic Procedure
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION•Vibration from under hood or driveline.
POSSIBLE
CAUSE•Loose attaching bolts or worn parts
•Cooling fan No.1 or cooling fan No.2 seat are improper
•Engine or transaxle mounts are improperly installed
•Components malfunction such as worn parts
•Erratic signal from CMP sensor
•ECT sensor or related circuit malfunction
•Accelerator position sensor or related circuit malfunction
•MAF/IAT sensor or related circuit malfunction
•Idle switch or related circuit malfunction
•Incorrect adjustment of accelerator position sensor and/or idle switch
•Fuel injector malfunction
•Vacuum leakage
•Improper tension or damaged drive belts
•Improper balance of wheels or tires
•Driveline malfunction
•Suspension malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
•Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injury or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete “BEFORE
REPAIR PROCEDURE” and “AFTER REPAIR PROCEDURE” described in this manual.
STEP INSPECTION RESULTS ACTION
1 Inspect following components for loose attaching
bolts or worn parts:
•Cooling fan No.1
•Cooling fan No.2
•Cooling fan No.1 and cooling fan No.2 seat
•Drive belt and pulley
•Engine mounts
•Exhaust system
Are all items okay?Yes Go to next step.
No Readjust or retighten engine mount installation
position.
Service as necessary for other parts.
2 Inspect vacuum leakage.
Are vacuum hoses okay?Yes Go to next step.
No Service as necessary.
Repeat Step 2.

TROUBLESHOOTING
F2–221
F2
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3 Connect WDS or equivalent to DLC-2.
Turn engine switch to ON.
Retrieve any DTC.
Is DTC displayed?YesDTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect following:
•Open circuit between PCM control relay and PCM
terminal 53 or 79
•Open circuit PCM control relay and PCM terminal
69
•PCM control relay stuck open
•Open or poor GND circuit (PCM terminal 65, 85,
103 or 104)
•Poor connection vehicle body GND
NoNo DTC is displayed:
Go to next step.
4 Inspect adjustment of accelerator position
sensor and idle switch.
(See F2–72 ACCELERATOR POSITION
SENSOR INSPECTION)
(See F2–70 IDLE SWITCH INSPECTION)
Are accelerator position sensor and idle switch
adjusted correctly?Yes Go to next step.
No Adjust accelerator position sensor and idle switch
correctly.
(See F2–73 ACCELERATOR POSITION SENSOR
ADJUSTMENT)
(See F2–71 IDLE SWITCH ADJUSTMENT)
5 Inspect adjustment of neutral switch.
(See F2–69 NEUTRAL SWITCH INSPECTION)
Is neutral switch adjusted correctly?Yes Go to next step.
No Adjust neutral switch correctly.
6 Visually inspect CMP sensor and teeth of pulse
wheel.
Are CMP sensor and teeth of pulse wheel okay?Yes Inspect following PIDs:
(See F2–65 PCM INSPECTION)
•ECT
•IAT
•MAF
•RPM
If PID value is not as specified, repair or replace
malfunctioning parts.
If PID value is okay, go to next step.
No Replace malfunctioning parts.
7 Inspect fuel injector.
(See F2–56 FUEL INJECTOR INSPECTION)
Is fuel injector okay?Yes Inspect following systems:
•Wheels
•Transaxle and mounts
•Driveline
•Suspension
Service as necessary.
No Repair or replace as necessary.
8 Verify test results.
•If okay, return to diagnostic index to service any additional symptoms.
•If malfunction remains, replace PCM. (See F2–64 PCM REMOVAL/INSTALLATION) STEP INSPECTION RESULTS ACTION

GENERAL PROCEDURES
M–21
M
PRECAUTION (FRONT AND REAR AXLE)A6E631001018201Wheel and Tire Removal/Installation
1. The removal and installation procedures for the wheels and tires are not mentioned in this section. When a
wheel is removed, tighten it to 88—118 N·m {9.0—12.0 kgf·m, 65.0—87.0 ft·lbf}
Brake Line Disconnection/Connection
Caution
•Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut
tightening torque to allow for use of a torque wrench-SST combination.
2. If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
Suspension Arm Removal/Installation
1. Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and
unloaded.
Note
•Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools
are in designated position.
Connector Disconnection
1. Disconnect the negative (-) battery cable before disconnecting connectors.
Electronic Control 4WD System Parts
1. After servicing the electronic control 4WD system parts, verify that no DTC has been stored. Clear any DTCs
remaining in the memory.
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GENERAL PROCEDURES

R–1
R
RSUSPENSION
OUTLINE................................................................ R-2
OUTLINE OF CONSTRUCTION.......................... R-2
FEATURES .......................................................... R-2
SPECIFICATIONS ............................................... R-3
STRUCTURAL VIEW ...........................................R-4
REAR SUSPENSION............................................. R-5
SUSPENSION CONTROL SYSTEM ................... R-5
OUTLINE................................................................ R-7
SUPPLEMENTAL SERVICE INFORMATION .....R-7
WHEEL ALIGNMENT............................................. R-8
FRONT WHEEL ALIGNMENT (WGN).................R-8
REAR WHEEL ALIGNMENT (WGN) ................... R-9
REAR SUSPENSION........................................... R-11
SUSPENSION CONTROL SYSTEM
ON-VEHICLE INSPECTION (WGN) ...............R-11
REAR SHOCK ABSORBER
REMOVAL/INSTALLATION (WGN) ................ R-11
REAR SHOCK ABSORBER DISPOSAL
(WGN) .............................................................R-12
REAR STABILIZER
REMOVAL/INSTALLATION (4WD)................. R-13
TRAILING LINK REMOVAL/INSTALLATION
(4WD) .............................................................. R-14
REAR CROSSMEMBER
REMOVAL/INSTALLATION (4WD)................. R-16 FEATURES
SERVICE

R–2
OUTLINE
OUTLINE OF CONSTRUCTIONA6E740201013201•The construction and operation of suspension system is essentially carried over from that of the current
Mazda6 (GG), except for the following features. (See Mazda6 Training Manual 3359-1*-02C.)
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FEATURESA6E740201013202Improved Handling Stability and Riding Comfort
•Wheel alignment has been set for WGN models.
•Rear stabilizer outer diameters are as follows:
WGN (2WD): 18 mm {0.71 in}
WGN (4WD): 21 mm {0.83 in}
•The suspension control system has been adopted as follows:
WGN (2WD): as an option
WGN (4WD): all models
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OUTLINE

OUTLINE
R–3
R
SPECIFICATIONSA6E740201013203
*1: Engine coolant and engine oil are at specified level. Fuel is full. 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 following. 4SD and 5HB front: 402 mm {15.82 in} (reference
value) 4SD and 5HB rear: 401 mm {15.78 in} (reference value), WGN (2WD) front: 405 mm {15.94 in}
(reference value) WGN (2WD) rear: 407 mm {16.02 in} (reference value)
Bold frames: New specifications
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Item Specification
New Mazda6 Current
Mazda6
GG (4SD, 5HB) GY (WGN 2WD) GY (WGN 4WD) GG (4SD, 5HB)
Engine type LF, MZR-CD
(RF Turbo) L8, LF, L3,
MZR-CD (RF Turbo) L3 L8, LF, L3
Fr o nt
suspension Type High-mount double wishbone (with double-pivoted lower arm(s))
Spring type Coil spring
Shock absorber type
Cylindrical, double-acting
(Low-pressure gas charged with rebound spring)
Stabilizer Type Torsion bar
Diameter (mm {in}) 23 {0.91}
Wheel
alignment
(Unloaded)*
1
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 ′
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°
Caster
angle*
2
(reference
value) normal 3
°47 ′±1° 3°40 ′±1° 3°35 ′±1° 3°47 ′±1°
elevated*33 °42' ±1° 3°35 ′±1° —3 °42' ±1 °
Camber
angle*
2
(reference
value) normal –0
°17 ′±1° –0°15 ′±1° –0°08 ′±1° –0°17 ′±1°
elevated*3–0 °10' ±1° –0°08 ′±1° —–0 °10' ±1°
Steering
axis
inclination
(reference
value) normal 5
°28 ′ 5°24 ′ 5°16 ′ 5°28 ′
elevated
*35 °18' 5 °16 ′ —5 °18'
Rear
suspension Type E-type multi-link
Spring type Coil spring
Stabilizer
Type Torsion bar
Diameter (mm {in})
4SD: 19 {0.75}
5HB: 18 {0.71}18 {0.71} 21 {0.83}
4SD: 19 {0.75}
5HB: 18 {0.71}
Shock absorber type Cylindrical,
double-acting
(Low-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)/
(High-pressure
gas charged) Cylindrical,
double-acting
(High-pressure gas charged) Cylindrical,
double-acting
(Low-pressure gas charged)
Wheel
alignment
(Unloaded)*
1
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 –1 °13 ′±1° –1°06 ′±1° –1°03 ′±1° –1°13 ′±1°
elevated
*3–1 °05 ′±1° –0°58 ′±1° —–1 °05 ′±1°
Thrust angle (degree) 0 °±0°48 ′