2002 MAZDA 6 service

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

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.
.
End Of Sie
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.
End Of Sie
1 Leveling port
2 Low-pressure chamber
3 High-pressure chamber
3
1
2
A6E74162004
OUTLINE

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

T–1
T
TBODY ELECTRICAL SYSTEM
OUTLINE................................................................ T-2
OUTLINE OF CONSTRUCTION ......................... T-2
FEATURES .......................................................... T-2
POWER SYSTEM................................................... T-2
STRUCTURAL VIEW........................................... T-2
MULTIPLEX COMMUNICATION SYSTEM............ T-3
OUTLINE ............................................................. T-3
STRUCTRURAL VIEW ........................................ T-3
SYSTEM WIRING DIAGRAM .............................. T-4
CAN SIGNAL-CHART.......................................... T-4
ON-BOARD DIAGNOSTIC FUNCTION............... T-6
EXTERIOR LIGHTING SYSTEM............................ T-8
OUTLINE ............................................................. T-8
STRUCTURAL VIEW........................................... T-8
INTERIOR LIGHTING SYSTEM............................. T-8
STRUCTURAL VIEW........................................... T-8
WIPER AND WASHER........................................... T-9
OUTLINE ............................................................. T-9
STRUCTURAL VIEW........................................... T-9
WARNING AND INDICATOR SYSTEM............... T-10
OUTLINE ........................................................... T-10
STRUCTURAL VIEW......................................... T-10
SYSTEM WIRING DIAGRAM ............................ T-11
THEFT-DETERRENT SYSTEM............................ T-11
OUTLINE ........................................................... T-11
INTRUDER SENSOR ........................................ T-11
AUDIO AND NAVIGATION SYSTEM.................. T-13
OUTLINE ........................................................... T-13
STRUCTURAL VIEW......................................... T-13
CRUISE CONTROL SYSTEM.............................. T-13
OUTLINE ........................................................... T-13
AIR BAG SYSTEM............................................... T-13
OUTLINE ........................................................... T-13
OUTLINE.............................................................. T-14
SUPPLEMENTAL SERVICE INFORMATION ... T-14
LOCATION INDEX............................................... T-15
POWER SYSTEM.............................................. T-15
EXTERIOR LIGHTING SYSTEM ....................... T-15
INTERIOR LIGHTING SYSTEM ........................ T-16
WIPER AND WASHER SYSTEM ...................... T-16
WARNING AND INDICATOR SYSTEM............. T-17
THEFT-DETERRENT SYSTEM ........................ T-17
AUDIO AND NAVIGATION SYSTEM ................ T-18
AIR BAG SYSTEM............................................. T-18
POWER SYSTEM................................................. T-19
RELAY LOCATION ............................................ T-19
RELAY INSPECTION ........................................ T-19
EXTERIOR LIGHTING SYSTEM.......................... T-20
REAR AUTO LEVELING SENSOR
REMOVAL/INSTALLATION ............................ T-20HIGH-MOUNT BRAKE LIGHT
REMOVAL/INSTALLATION ............................ T-20
INTERIOR LIGHTING SYSTEM........................... T-21
CARGO COMPARTMENT LIGHT
REMOVAL/INSTALLATION ............................ T-21
CARGO COMPARTMENT LIGHT
INSPECTION .................................................. T-22
WIPER AND WASHER......................................... T-22
REAR WIPER MOTOR
REMOVAL/INSTALLATION ............................ T-22
REAR WIPER MOTOR INSPECTION ............... T-22
REAR WIPER ARM AND BLADE
REMOVAL/INSTALLATION ............................ T-23
REAR WIPER ARM AND BLADE
ADJUSTMENT ................................................ T-24
REAR WASHER NOZZLE
REMOVAL/INSTALLATION ............................ T-24
REAR WASHER NOZZLE ADJUSTMENT ........ T-25
REAR WASHER HOSE
REMOVAL/INSTALLATION ............................ T-25
INTERMITTENT REAR WIPER RELAY
REMOVAL/INSTALLATION ............................ T-26
WARNING AND INDICATOR SYSTEM............... T-27
FUEL GAUGE SENDER UNIT
REMOVAL/INSTALLATION ............................ T-27
FUEL GAUGE SENDER UNIT INSPECTION.... T-28
THEFT-DETERRENT SYSTEM............................ T-29
INTRUDER SENSOR
REMOVAL/INSTALLATION ............................ T-29
AUDIO AND NAVIGATION SYSTEM.................. T-30
NOISE FILTER REMOVAL/INSTALLATION ..... T-30
CONDENSER REMOVAL/INSTALLATION ....... T-30
ANTENNA FEEDER LOCATION ....................... T-31
REAR ANTENNA FEEDER INSPECTION ........ T-31
AIR BAG SYSTEM............................................... T-32
SERVICE WARNINGS....................................... T-32
CURTAIN AIR BAG MODULE
REMOVAL/INSTALLATION ............................ T-35
AIR BAG MODULE AND PRE-TENSIONER
SEAT BELT DEPLOYMENT PROCEDURES. T-35
ON-BOARD DIAGNOSTIC
[MULTIPLEX COMMUNICATION SYSTEM].... T-39
MULTIPLEX COMMUNICATION SYSTEM ....... T-39
DTC TABLE ....................................................... T-41
PID/DATA MONITOR TABLE ............................ T-41
PROCEDURES FOR DETERMINING
THE LOCATION OF A MALFUNCTION ......... T-42
DTC U0073, U1900, U2516 ............................... T-45 FEATURES
SERVICE

T–14
OUTLINE
SUPPLEMENTAL SERVICE INFORMATIONA6E810201088203•The following changes and/or additions have been made since publication of the Mazda6 Workshop Manual
(1730-1*-02C).
Relay
•Location has been changed.
•Inspection procedure has been modified.
Rear auto leveling sensor
•Removal/Installation procedure has been modified.
High-mount brake light
•Removal/Installation procedure has been modified.
Cargo compartment light
•Removal/Installation procedure has been modified.
•Inspection procedure has been modified.
Rear wiper motor
•Removal/Installation procedure has been modified.
•Inspection procedure has been modified.
Rear wiper arm and blade
•Removal/Installation procedure has been modified.
•Adjustment procedure has been modified.
Rear washer nozzle
•Removal/Installation procedure has been modified.
•Adjustment procedure has been modified.
Rear washer hose
•Removal/Installation procedure has been modified.
Intermittent rear wiper relay
•Removal/Installation procedure has been modified.
Fuel gauge sender unit
•Removal/Installation procedure has been modified.
•Inspection procedure has been modified.
Intruder sensor
•Removal/Installation procedure has been modified.
Noise filter
•Removal/Installation procedure has been modified.
Condenser
•Removal/Installation procedure has been modified.
Antenna feeder
•Location has been changed.
Rear antenna feeder
•Inspection procedure has been modified.
Curtain air bag module
•Removal/Installation procedure has been added.
Air bag module and pre-tensioner seat belt
•Deployment procedure has been modified.
On-board diagnostic
•Multiplex communication system procedure has been modified.
End Of Sie
OUTLINE

EXTERIOR LIGHTING SYSTEM, INTERIOR LIGHTING SYSTEM
T–21
T
Rear spoiler type
1. Disconnect the negative battery cable.
2. Remove the rear spoiler.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
End Of Sie
CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATIONA6E8114514412011. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Lens Removal Note
1. Insert a tape-wrapped flathead screwdriver into
the service hole.
2. Twist the flathead screwdriver as indicated by the
arrow to remove the lens.
End Of Sie
1Bolt
2 Cover
3 Connector
4 High-mount brake light
4
12
3
A6J81121004
INTERIOR LIGHTING SYSTEM
1Lens
(See T–21 Lens Removal Note)
2 Cargo compartment light bulb
3 Screw (if equipped)
4 Cargo compartment light
5 Connector
12
33
4
5
A6J81141102
SERVICE HOLE
A6A8114W104

WARNING AND INDICATOR SYSTEM
T–27
T
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATIONA6E811860960201Fuel Gauge Sender Unit
2WD
•There are no changes from the current fuel gauge sender unit removal/installation procedure.
4WD
1. Remove the fuel gauge sender unit. (See F1–26 FUEL PUMP UNIT REMOVAL/INSTALLATION.)
2. Install in the reverse order of removal.
Fuel Gauge Sender Sub-Unit
Warning
•Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel gauge sender sub-unit when removing or installing.
Caution
•Disconnecting/connecting the quick release connector without cleaning it may possibly cause
damage to the fuel pipe and quick release connector. Always clean the quick release connector
joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is
free of foreign material.
1. Complete the “BEFORE REPAIR PROCEDURE”.
2. Disconnect the negative battery cable.
3. Complete the following in order to the work area.
(1) Loosen the bolt of the fuel tank strap.
(2) Lower the fuel tank to a position where the SST can be attached from the service hole cover.
4. Remove the rear seat cushion.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the “AFTER REPAIR PROCEDURE”.
8. Complete the “Fuel leak inspection after fuel
gauge sender sub-unit installation.“ (See T–28
Fuel leak inspection after fuel gauge sender sub-
unit installation.)
WARNING AND INDICATOR SYSTEM
1 Service hole cover
2 Connector
3 Plastic fuel hose (fuel tank side, transfer hose part)
(See F1–29 FUEL HOSE (FUEL TANK SIDE,
TRANSFER HOSE PART) REMOVAL/
INSTALLATION)
4 Fuel gauge sender cap
(See T–28 Fuel gauge sender cap removal note)
(See T–28 Fuel Gauge Sender Cap Installation
Note)
5 Packing
6 Fuel gauge sender sub-unit
3
1
4
5
6
2
80—90 {8.2—9.1, 60—66}
N·m {kgf·m, ft·lbf}
R
SST
A6E81182001