2002 MAZDA 6 suspension

R–4
OUTLINE
STRUCTURAL VIEWA6E740201013204REAR SUSPENSION (4WD)
.
End Of Sie
98
7
5
4
3
1
2
10
116
12
A6E74162013
1 Rear crossmember mounting bushing
2 Rear crossmember
3 Rear shock absorber
4 Rear upper arm
5 Bound stopper (body side)
6 Rear trailing arm7 Rear lateral link
8 Rear stabilizer
9 View from vehicle rear side
10 Rear coil spring
11 Bound stopper (spring side)
12 Rear lower arm

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.
.
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

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

R–12
REAR SUSPENSION
Bracket Installation Note
1. Install the bracket as shown in the figure.
End Of SieREAR SHOCK ABSORBER DISPOSAL (WGN)A6E7416287002021. Lay the shock absorber on a level, horizontal surface.
2. Using a 2—3 mm {0.08—0.12 in} drill bit, drill a
hole in the high-pressure side (area indicated by
A), and allow the gas to escape.
Warning
•The oil in the shock absorber is
pressurized and could spray out. Be sure
to drill slowly and carefully.
3. Using a 2—3 mm {0.08—0.12 in} drill bit, drill a
hole in the low-pressure side (area indicated by
B).
4. Place the shock absorber with the hole drilled in
Step 3 turned downwards. Move the piston rod up
and down several times to drain out the oil.
5. Cut the tube at the end of the shock absorber,
and completely drain the oil out.
6. Properly dispose of the waste oil according to
waste disposal laws.
End Of Sie
106.5—112.5°
A6J74162006
A
A6J74161003
B
A6J74161006

REAR SUSPENSION
R–13
R
REAR STABILIZER REMOVAL/INSTALLATION (4WD)A6E7416281002011. Remove the rear auto leveling sensor.
(See T–20 REAR AUTO LEVELING SENSOR REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the headlight zeroset.
.
Bolt (Differential Front Side) Removal Note
1. Disconnect differential oil temperature sensor connector and 4WD solenoid connector.
2. Support the differential with a jack as shown in
the figure.
3. Remove the bolt.
5
4
3
1
AA
2
6
GREASEGREASE
43.1—60.8
{4.40—6.19,
31.8—44.8}
74.5—104.9
{7.60—10.69, 54.95—77.37}
43.1—60.8
{4.40—6.19,
31.8—44.8}
RUBBER
GREASE
43.1—60.8
{4.40—6.19,
31.8—44.8}
N·m {kgf·m, ft·lbf} 75.5—94.5
{7.70—9.63, 55.7—69.6}
A6E74162007
1 Stabilizer control link
2 Coil spring component (One side only)
3 Stabilizer bracket
4 Bushing5 Bolt (Differential front side)
(See R–13 Bolt (Differential Front Side) Removal
Note)
(See R–14 Bolt (Differential Front Side) Installation
Note)
6 Rear stabilizer
JACK
A6E74162011

R–14
REAR SUSPENSION
Bolt (Differential Front Side) Installation Note
1. Support the differential with a jack, and then
install the bolt.
2. Connect differential oil temperature sensor
connector and 4WD solenoid connector.
End Of SieTRAILING LINK REMOVAL/INSTALLATION (4WD)A6E741628200201
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.
3. Inspect the rear wheel alignment.
(See R–9 REAR WHEEL ALIGNMENT (WGN).)
JACK
A6E74162011