Mazda Car 2002-04

Strut (MacPherson Strut) Assembly 2

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Overhaul (Coil Spring Removal & Installation)



  1. Compress the coil spring in the compressor tool and install the shock absorber so the lower end of the spring is seated on the step of the lower spring seat.
  2.  
  3. Install the bound stopper.
  4.  
  5. Install the dust boot by hooking the bottom edge over the shock absorber lip as illustrated.
  6.  
  7. Install the bearing by hooking the upper end of the dust boot to the bearing lip and align the projection A on the lower part of the shock absorber with the bearing projection B, as illustrated.
  8.  
  9. Install the mounting rubber.
  10.  
  11. Install the piston rod nut and tighten to 42-56 ft. lbs. (57-76 Nm) and remove the spring compressor.
  12.  
  13. Install the stiffener so the mark LH or RH is facing upwards as shown.
  14.  
  15. Align the piston rod nut with the center part where the shock absorber is installed by placing the piston rod nut with lengths A all the same and tighten the shock absorber upper bolts.
  16.  
  17. Use a jack to raise the lower control arm, attach the shock absorber and tighten the bolts.

    Click image to see an enlarged view

    Fig. Install the dust boot by hooking the bottom edge over the shock absorber lip-Mazda 3



    Click image to see an enlarged view

    Fig. Install the bearing by hooking the upper end of the dust boot to the bearing --.-Mazda 3



    Click image to see an enlarged view

    Fig. -- and align the projection A on the lower part of the shock absorber with the bearing projection B-Mazda 3



    Click image to see an enlarged view

    Fig. The stiffener should be positioned as shown-Mazda 3

  18.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the strut assembly from the vehicle.
  4.  
  5. Install a coil spring compressor and compress the coil spring.
    CAUTION
    Failure to fully compress the spring and hold it securely can be extremely dangerous.

  6.  
  7. Remove the upper strut nut.
  8.  
  9. Slowly release the coil spring tension
  10.  
  11. Remove the mounting rubber, bound stopper, dust boot and coil spring.

    Click image to see an enlarged view

    Fig. Install a coil spring compressor and compress the coil spring-Mazda 6

  12.  

To install:

  1. Temporarily install the spring, dust boot and mounting so the lower end of the coil spring is seated on the step of the lower seat.
  2.  
  3. Mark the spring, dust boot and rubber for correct installation as shown in the accompanying illustration.
  4.  
  5. Align the mark of the coil spring and dust boot, use a piece of cloth to protect the spring and boot and install the compressor.
  6.  
  7. Compress the coil spring in the compressor tool and install the shock absorber so the lower end of the spring is seated on the step of the lower spring seat.
  8.  
  9. Ensure the marks on the shock absorber and dust boot are aligned to the marks made earlier, install the mounting rubber and the rod not and tighten the nut to 29-39 ft. lbs. (39-52 Nm)
  10.  
  11. Install the shock assembly.

    Click image to see an enlarged view

    Fig. Mark the spring, dust boot and rubber for correct installation as shown when assembly the front shock assembly-Mazda 6

  12.  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Support the lower control arm with a jack.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Brake hose and/or ABS sensor harness to the strut Bolts or clips
     
    Actuator from the top of the strut, if equipped with Automatic Adjusting Suspension (AAS)
     

  6.  
  7. Paint alignment marks on the upper strut mounting block and strut tower, and on the lower strut mount-to-steering knuckle so the strut can be reinstalled in the same position.
  8.  
  9. Remove or disconnect the following:

    Upper strut mounting nuts
     
    Strut-to-knuckle bolts
     
    Strut assembly
     

  10.  

To install:

  1. Install or connect the following:

    Strut into the strut tower, aligning the paint marks made during removal
     
    Upper mounting nuts and tighten to specifications
     
    Strut-to-knuckle bolts and tighten to specifications
     
    Actuator and engage the electrical connector, if equipped with AAS
     
    Brake hose and/or ABS sensor harness clips or bolts
     
    Wheel
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Support the lower control arm with a jack.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Stabilizer bar nut
     
    Lower arm ball joint from the knuckle
     
    Lower arm bolts
     
    Lower the lower arm and remove the shock. Be careful not to lower the arms too much or it may cause damage.
     

  6.  

To install:

  1. Installation is the reverse of removal. Tighten the upper shock nuts to 26 ft. lbs. (36 Nm) and the lower shock nut and bolt to 86 ft. lbs. (116 Nm).
  2.  
  3. Check and/or adjust the front end alignment.
  4.  



Click image to see an enlarged view

Fig. Exploded view of the front strut and spring assembly components-Mazda 3

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the ABS sensor connector.
  4.  
  5. Disconnect the brake hose from the bracket on the strut assembly.
  6.  
  7. Remove the stabilizer bar link upper nut and disconnect the bar from the strut assembly.
  8.  
  9. Disconnect the tie rod from the knuckle.
  10.  
  11. Remove the shock absorber lower bolt.
  12.  
  13. Loosen the front lower arm inner bolt, the separate the shock from the hub assembly by tapping the knuckle with a hammer or mallet being careful not to damage any components.
  14.  
  15. Remove the shock absorber assembly.
  16.  

To install:

  1. Align the piston rod nut with the center part where the shock absorber is installed by placing the piston rod nut with lengths (A) all the same and tighten the shock absorber upper bolts. Refer to the accompanying illustration.

    Click image to see an enlarged view

    Fig. Align the piston rod nut with the center part where the shock absorber is installed by placing the piston rod nut with lengths (A) all the same-Mazda 3

  2.  
  3. Use a jack to raise the lower control arm, attach the shock absorber and tighten the bolts
  4.  
  5. Tighten the upper shock nuts to 14-20 ft. lbs. (19-28 Nm) and the lower shock nut and bolt to 40-54 ft. lbs. (54-74 Nm).
  6.  
  7. Tighten the tie rod end nut to 27-37 ft. lbs. (37-50 Nm), install a new cotter pin. Tighten the nut, if necessary, to align the ball stud hole with the nut castellation.
  8.  
  9. Install the stabilizer bar link and tighten the upper nut to 30-40 ft. lbs. (40-54 Nm).
  10.  
  11. Install the brake hose and ABS sensor connector.
  12.  
  13. Check and/or adjust the front end alignment.
  14.  



Click image to see an enlarged view

Fig. Exploded view of the front strut and spring assembly components-Mazda 6

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the ABS sensor.
  4.  
  5. Disconnect the brake hose from the bracket on the strut assembly.
  6.  
  7. Remove the stabilizer bar link upper nut and disconnect the bar from the strut assembly.
  8.  
  9. Remove the shock absorber lower bolt, the dynamic damper and the damper fork.
  10.  
  11. Remove the upper shock absorber nuts.
  12.  
  13. Remove the shock absorber assembly.
  14.  

To install:

  1. Install the shock absorber assembly. Position the stud bolts at a 27-33 degree angle from where the stabilizer bar is installed (center line), towards the inner side of the vehicle. Refer to the accompanying illustration.

    Click image to see an enlarged view

    Fig. Position the stud bolts at a 27-33 degree angle from where the stabilizer bar is installed (center line), towards the inner side of the vehicle when installing the front shock assembly-Mazda 6

  2.  
  3. Tighten the upper nuts to 21-29 ft. lbs. (29-39 Nm).
  4.  
  5. Install the damper fork and align the gap of the fork with the projection of the damper as illustrated and install and tighten the bolt to 31-38 ft. lbs. (43-52 Nm)
  6.  
  7. Install the dynamic damper and the lower shock bolt and tighten to 68-93 ft. lbs. (93-126 Nm).
  8.  
  9. Install the stabilizer bar link and tighten the nut to 31-40 ft. lbs. (43-54 Nm).
  10.  
  11. Install the brake hose, tighten the bolt to 13-18 ft. lbs. (18-25 Nm).
  12.  
  13. Install the sensor.
  14.  
  15.  
  16. Check and/or adjust the front end alignment.
  17.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Support the lower control arm with a jack.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Brake hose and/or ABS sensor harness to the strut Bolts or clips
     
    Actuator from the top of the strut, if equipped with Automatic Adjusting Suspension (AAS)
     

  6.  
  7. Paint alignment marks on the upper strut mounting block and strut tower, and on the lower strut mount-to-steering knuckle so the strut can be reinstalled in the same position.
  8.  
  9. Remove or disconnect the following:

    Upper strut mounting nuts
     
    Strut-to-knuckle bolts
     
    Strut assembly
     

  10.  

To install:

  1. Install or connect the following:

    Strut into the strut tower, aligning the paint marks made during removal
     
    Upper mounting nuts and tighten to 34-46 ft. lbs. (47-62 Nm)
     
    Strut-to-knuckle bolts and tighten to 55-61 ft. lbs. (74-83 Nm)
     
    Actuator and engage the electrical connector, if equipped with AAS
     
    Brake hose and/or ABS sensor harness clips or bolts
     
    Wheel
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Support the lower control arm with a jack.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Brake hose and/or ABS sensor harness to the strut Bolts or clips
     
    Stabilizer link nut
     
    Strut-to-knuckle bolt
     
    Upper strut mounting nuts
     
    Stiffener, if equipped
     
    Sheet
     
    Strut assembly
     

  6.  

To install:

  1. Install or connect the following:

    Face the mounting block direction indicator towards the rear outboard position and install the shock assembly.
     
    Sheet
     
    Stiffener, if equipped
     
    Upper mounting nuts and tighten to 34-46 ft. lbs. (47-62 Nm)
     
    Strut-to-knuckle bolts and tighten to 68-93 ft. lbs. (94-126 Nm)
     
    Stabilizer link nut and tighten to 32-44 ft. lbs. (47-60 Nm)
     
    Brake hose and/or ABS sensor harness clips or bolts
     
    Wheel
     

  2.  
  3. Check and/or adjust the front end alignment.
  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Support the lower control arm with a jack.
  4.  
  5. Remove or disconnect the following:

    Front wheel
     
    Brake hose and/or ABS sensor harness to the strut bolts or clips
     

  6.  
  7. Paint alignment marks on the upper strut mounting block and strut tower, and on the lower strut mount-to-steering knuckle so the strut can be reinstalled in the same position.
  8.  
  9. Remove or disconnect the following:

    Upper strut mounting nuts
     
    Stiffener
     
    Strut-to-knuckle bolts
     
    Strut assembly
     

  10.  

To install:

  1. Install or connect the following:

    Stiffener. Make sure the word LH or RH faces up and the parting area faces the inside of the vehicle.
     
    Strut into the strut tower, aligning the paint marks made during removal
     
    Upper mounting nuts and tighten to 38-49 ft. lbs. (51-67 Nm)
     
    Strut-to-knuckle bolts and tighten to 73-101 ft. lbs. (99-137 Nm)
     
    Brake hose and/or ABS sensor harness clips or bolts
     
    Wheel
     

  2.  
  3. Check and/or adjust the front end alignment. .
  4.  

 
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