2002 MAZDA 6 Workshop Manual Suplement

S–4
SEAT
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OUTLINEA6E775257100201•A fixed rear seat cushion has been adopted. (4WD WGN)
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STRUCTURAL VIEWA6E775257100202
.
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SEAT
12
44
33
A6E77521101
1 Full flat fold down function (except 4WD WGN)
2 Fold down function (4WD WGN)3 Rear seat back
4 Rear seat cushion

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.
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OUTLINE

S–6
LOCATION INDEX
EXTERIORA6E770001086201
.
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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)

LOCATION INDEX
S–7
S
INTERIORA6E770001086202
.
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1
10
12
13
11 14
2
3
4
5
6
7
89
A6E77001104
1 Liftgate side trim
(See S–24 LIFTGATE SIDE TRIM REMOVAL/
INSTALLATION)
2 C-pillar trim
(See S–21 C-PILLAR TRIM REMOVAL/
INSTALLATION)
3 D-pillar trim
(See S–21 D-PILLAR TRIM REMOVAL/
INSTALLATION)
4 Trunk side upper trim
(See S–22 TRUNK SIDE UPPER TRIM REMOVAL/
INSTALLATION)
5 Trunk side trim
(See S–21 TRUNK SIDE TRIM REMOVAL/
INSTALLATION)
6 Extractor chamber
(See S–11 EXTRACTOR CHAMBER REMOVAL/
INSTALLATION)
7 Trunk end trim
(See S–23 TRUNK END TRIM REMOVAL/
INSTALLATION)8 Rear seat
(See S–29 REAR SEAT REMOVAL/
INSTALLATION)
(See S–30 REAR SEAT DISASSEMBLY/
ASSEMBLY)
9 Floor covering
(See S–27 FRONT FLOOR COVERING
REMOVAL/INSTALLATION)
10 Tonneau cover anchor
(See S–25 TONNEAU COVER ANCHOR
REMOVAL/INSTALLATION)
11 Headliner
(See S–26 HEADLINER REMOVAL/
INSTALLATION)
12 Rear center seat belt
(See S–28 REAR CENTER SEAT BELT
REMOVAL/INSTALLATION)
13 Liftgate upper trim
(See S–23 LIFTGATE UPPER TRIM REMOVAL/
INSTALLATION)
14 Liftgate lower trim
(See S–24 LIFTGATE LOWER TRIM REMOVAL/
INSTALLATION)

S–8
LIFTGATE
LIFTGATE REMOVAL/INSTALLATIONA6E772262010201WGN
Warning
•Removing the stay damper without supporting the liftgate can be dangerous. The liftgate may fall
and injure you. Open the liftgate fully and support it before removing the stay damper.
1. Disconnect the negative battery cable.
2. Remove the liftgate upper trim. (SeeS–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION)
3. Disconnect the rear washer hose.
4. Disconnect the vehicle harness and the vehicle
harness connector, attached to the liftgate, from
the liftgate harness connector.
5. Pry away the stay damper's band with a
screwdriver.
6. Pry out the connecting part of the stay damper
and the hinge with a screwdriver to disconnect
them. Then remove the stay damper.
7. Remove the bolts A, then remove the liftgate.
8. To remove the hinge, remove the headliner and
the nut.
LIFTGATE
GROMMET
VEHICLE HARNESS
CONNECTOR LIFTGATE HARNESS
CONNECTORVEHICLE HARNESS
VEHICLE HARNESS
A6E77221101
BAND
STAY
DAMPER
A6E7722W005

LIFTGATE
S–9
S
9. To remove the stay damper, remove the bolt B.
10. Install in the reverse order of removal.
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LIFTGATE DISASSEMBLY/ASSEMBLYA6E772262010202WGN
1. Disconnect the negative battery cable.
2. Remove the liftgate lower trim.
3. To remove the liftgate outer handle and liftgate key cylinder, remove the rear finisher.
4. To remove the stud ball, separate the stud ball and the stay damper.
5. Disassemble in the order indicated in the table.
6. Assemble in the reverse order of disassembly.
.
BOLT B
HINGE
STAY DAMPER
BOLT A
NUT
LIFTGATE
N·m {kgf·cm, in·lbf} 8.8—12.7
{90—130,
78—112}
32.4—48.5 N·m
{3.3—4.9 kgf·m,
24—35 ft·lbf} 7.8—10.8
{80—110, 70—95}
A6E77221102
A
2
N·m {kgf·cm, in·lbf}
A
31
B
6.90—9.80
{70—100,
60.8—86.7}
4.0—5.8
{39.8—60.1,
34.6—52.2}
4
B
16—23 N·m
{1.6—2.4 kgf·m,
12—17 ft·lbf}3.9—5.9
{39.8—60.1,
34.6—52.2}
5
7
6
A6A7722W103
1 Liftgate latch and lock actuator
2 Liftgate outer handle
3 Liftgate key cylinder
4Clip5Stud ball
6 Liftgate
7 Stopper

S–10
LIFTGATE
End Of SieLIFTGATE ADJUSTMENTA6E772262010203WGN
1. Measure the gap and height between the liftgate and the body.
2. If not as specified, loosen the liftgate hinge
installation bolts or the liftgate striker installation
screws, and reposition the liftgate.
Clearance
a: 0—2.0 mm {0—0.07 in}
b: 4.8—6.8 mm {0.19—0.26 in}
c: 3.5—7.5 mm {0.14—0.29 in}
d: 1.2—3.2 mm {0.05—0.12 in}
e: 2.8—5.2 mm {0.11—0.20 in}
f: -0.7—1.7 mm {-0.02—0.06 in}
g: 2.3—5.7 mm {0.10—0.22 in}
h: 4.0—8.0 mm {0.16—0.31 in}
3. Tighten the bolts or screws.
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a
f bcd
e
E E B
B
C
C
D
D
g a
h SEC. A A SEC. B B
SEC. C C
SEC. D D
SEC. E E A
A
A6A7722W104

EXTERIOR ATTACHMENT
S–11
S
EXTRACTOR CHAMBER REMOVAL/INSTALLATIONA6E772851920201WGN
1. Remove the rear bumper.
2. Remove the left side trunk side trim.
3. Squeeze the clips with your fingers and remove
the extractor chamber from the vehicle side.
4. Install in the reverse order of removal.
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REAR SPOILER REMOVAL/INSTALLATIONA6E772851920202WGN
1. Disconnect the negative battery cable.
2. Remove the liftgate upper trim. (SeeS–23 LIFTGATE UPPER TRIM REMOVAL/INSTALLATION)
3. Remove the bolts and nuts.
4. Disconnect the high-mount brake light connector.
5. Disengage the pin A from the body, then remove
the rear spoiler.
6. Install in the reverse order of removal.
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ROOF RAIL REMOVAL/INSTALLATIONA6E7728517202011. Remove the headliner.
2. Remove the nuts.
3. Remove the roof rail.
4. Install in the reverse order of removal.
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EXTERIOR ATTACHMENT
EXTRACTOR
CHAMBER CLIP AA
A
A6E77281103
BOLT REAR SPOILER
HIGH-MOUNT BRAKE
LIGHT CONNECTOR
NUTPIN A
AA
N·m {kgf·cm, in·lbf} 7.8—9.8
{79—100, 68.8—86.7} 8.9—12.7 {90—130, 79—112}
A6A7728W104
ROOF RAIL
6.9—9.8 N·m
{70—100 kgf·cm,
60.8—86.7 in·lbf}NUT
A6A7728W105