2002 MAZDA 6 Workshop Manual Suplement

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

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

WHEEL ALIGNMENT
R–9
R
Total Toe-in Adjustment
1. Center the steering wheel and confirm that the vehicle wheels/tires are pointing straight.
2. Loosen the left and right tie-rod end locknuts and turn the tie-rods equally. Both tie rods are right threaded, so
turning the right tie-rod toward the front of the vehicle and the left toward the rear increases toe-in.
Note
•Turning both tie-rods one complete turn changes toe-in by about 6 mm {0.24 in} (0°36').
3. Tighten the tie-rod end locknuts to the specified torque.
Tightening torque
68.6—98.0 N·m {7.00—9.99 kgf·m, 50.6—72.2 ft·lbf}
4. Verify that the boot is not twisted, and install the boot clamp.
End Of Sie
REAR WHEEL ALIGNMENT (WGN)A6E741201016201Specification (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 407 mm {16.02 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'.
Note
•Adjust the toe-in after adjusting the camber.
Camber Adjustment
1. Loosen the cam nut on the lower arm.
2. Turn the adjusting cam bolt to provide the correct
camber angles as indicated.
3. Tighten the cam nut.
Tightening torque
86.2—116.6 N·m {8.80—11.88 kgf·m, 63.58—
85.99 ft·lbf}
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
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–0°59′±1°–1°00′±1°–1°02′±1°–1°04′±1°–1°06′±1°
elevated
*3–0°52′±1°–0°53′±1°–0°55′±1°–0°56′±1°–0°58′±1°
Thrust angle 0°±0°48′
ItemFuel gauge indication
Empty 1/4 1/2 3/4 Full
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 –0°55′±1°–0°57′±1°–0°59′±1°–1°01′±1°–1°03′±1°
Thrust angle (degree) 0°±0°48′
Left wheel Right wheel
Positive direction ClockwiseCounter-
clockwise
Negative directionCounter-
clockwiseClockwise
LEFT SIDE
(VIEW FROM
FRONT OF THE
VEHICLE)
ADJUSTING
CAM BOLT
A6E7412W003

R–10
WHEEL ALIGNMENT
Total Toe-in Adjustment
1. Loosen the locknut of the lateral link.
2. Adjust the toe-in turning the adjusting link.
Specification
Total Toe-in: 2±4 mm {0.08±0.16 in}
Note
•Toe change amount: 0°43′ / one rotation
3. Tighten the locknut.
Tightening torque
68.6—98.1 N·m {7.0—10.0 kgf·m, 50.6—72.3
ft·lbf}
End Of Sie
A6E7412W004
A6E7412W005
A6E7412W004

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