2002 MAZDA 6 window

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

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.
End Of Sie
OUTLINE

S–6
LOCATION INDEX
EXTERIORA6E770001086201
.
End Of Sie
LOCATION INDEX
6
52
1
4
7
3
A6E77001102
1 Rear spoiler
(See S–11 REAR SPOILER REMOVAL/
INSTALLATION)
2 Rear window glass
(See S–16 REAR WINDOW GLASS REMOVAL)
(See S–17 REAR WINDOW GLASS
INSTALLATION)
3 Liftgate
(See S–8 LIFTGATE REMOVAL/INSTALLATION)
(See S–9 LIFTGATE DISASSEMBLY/ASSEMBLY)
(See S–10 LIFTGATE ADJUSTMENT)4 Rear drain hose
(See S–20 REAR DRAIN HOSE REMOVAL)
5 Side window glass
(See S–14 SIDE WINDOW GLASS REMOVAL)
(See S–14 SIDE WINDOW GLASS
INSTALLATION)
6 Roof molding
(See S–12 ROOF MOLDING REMOVAL)
(See S–12 ROOF MOLDING INSTALLATION)
7Roof rail
(See S–11 ROOF RAIL REMOVAL/
INSTALLATION)

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–15
S
4. Insert the spacer into the body.
5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for
approximately 30 minutes.
Caution
•Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly
bond to the surface of the glass and body, which may cause leaks to occur.
6. Apply sealant to the area of the glass surface as
shown in the figure.
A
A
SEC. A
—ASPACER
A6A7738W104
mm {in}
A
C B
A
C
B
*1: PRIMER APPLICATION AREA
*2: POSSIBLE PRIMER APPLICATION AREA SEC. A
—ASEC. C—C
SEC. B—B PRIMER
APPLICATION AREAPRIMER
APPLICATION AREA BODY SIDE
SIDE WINDOW GLASS SIDE
9.5 {0.37}*1
9.5 {0.37}*1
9.5 {0.37}*1
5.0 {0.20}*2
11.5 {0.45}*2
6.0 {0.24}*2
11.0 {0.43}*1
4.0 {0.16}*2
11.0 {0.43}*1
6.0 {0.24}
6.0 {0.24}
11.0 {0.43}
*1
A6A7738W105
90˚ 90˚APPLY SEALANT
TO THIS AREA.
5 {0.20}
11 {0.43}
mm {in}
A6A7738W106

S–16
WINDOW GLASS
7. Set the side window glass in place and insert the
pins and fastener into the body. Install the side
window glass.
8. Allow the sealant to harden completely.
Sealant hardening time: 24 hours
End Of Sie
REAR WINDOW GLASS REMOVALA6E773863931201WGN
1. Remove the rear wiper motor.
2. Apply protective tape along the edge of the body to protect it from damage.
3. Cut the lip of the rear window molding using a
razor.
Warning
•Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.
Note
•The rear window molding is a replacement
part.
Not Reusing Glass
Note
•For the areas of the sealant that are difficult to cut, use a SST (piano wire) and follow the procedure under
“Reusing Glass.”
1. Use a SST, and insert the blade into the sealant.
2. Pull through the sealant around the edge of the
glass.
3. Remove the glass.
PIN
PIN
FASTENER
A6A7738W102
A
B A
B
SEC. A—ASEC. B—B LIP
LIP
REAR WINDOW
GLASS MOLDING
A6E77381107
49 G050 1A0
A6E7738W022

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

S–18
WINDOW GLASS
4. Install the molding as shown in the figure.
5. Use only glass primer on the glass, and body primer on the body and the molding. Allow it to dry for
approximately 30 minutes.
Caution
•Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly
bond to the surface of the glass and body, which may cause leaks to occur.
-3—3 mm
{-0.12—0.12 in} 45˚
LOWER REAR WINDOW
MOLDING
REAR WINDOW MOLDING
SIDE
A6E77381110
*2
8.0 {0.31}
9.5 {0.37}
*1
11.5
{0.45}*1
4.5 {0.18}*2
28.9 {1.14}
5.0 {0.20} 4.4 {0.17}
*2
5.0 {0.20}*2
17.5
{0.69}
mm {in}
SEC. A—A
SEC. C
—C SEC. B
—B
*1: PRIMER APPLICATION AREA
*2: POSSIBLE PRIMER APPLICATION AREA BODY SIDEREAR WINDOW GLASS SIDE
PRIMER
APPLICATION AREA
PRIMER
APPLICATION AREA
9.5 {0.37}
ALIGN WITH
CERAMIC MARKINGA
AB
B
9.5 {0.37} 9.5 {0.37}
9.5 {0.37}*1
9.5 {0.37}*1
11.5
{0.45}*1
11.5
{0.45}*1
1.7 {0.07}*2
5.8
{0.23}*2C
C
A6E77381112