Mazda Car 2002-04

Removal & Installation 4

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Mazda6 And Mazdaspeed6 Models



  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    Refer the exploded view illustration for component locations and if applicable, their retainer torque specifications.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Discharge the refrigerant from the system.
  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove the dynamic chamber.
  10.  
  11. Remove the glove box as follows:
    1. Remove the damper clip.
    2.  
    3. Bend the stoppers in to disengage them.
    4.  
    5. Lower the glove box door and remove the clips by pulling straight out and remove the glove box.
    6.  

  12.  
  13. Remove the console as follows:
    1. If equipped with a manual transmission, remove the shifter knob.
    2.  
    3. Remove the panels (1 and 2) with a tape wrapped prytool, make sure to disconnect the cigarette lighter and ashtray illumination connections on panel 2.
    4.  
    5. Remove the bolts, disconnect the socket connector and remove the console.

      Click image to see an enlarged view

      Fig. Exploded view of the console assembly-Mazda6 and Mazdaspeed6 models

    6.  

  14.  
  15. Remove the meter hood as follows:
    1. Remove the screws, pull the meter hood outwards and detach the column cover.
    2.  

  16.  
  17. Remove the instrument cluster as follows:
    1. Lower the tilt steering wheel to its lowest point.
    2.  
    3. Pull the steering wheel towards you.
    4.  
    5. Remove the screws, connectors and cluster.
    6.  

  18.  
  19. Remove the column cover.
  20.  
  21. Remove the lower panel as follows:
    1. Pull the hood release lever.
    2.  
    3. While pushing the tab in the direction illustrated, using a tape wrapped small flat prytool to pull the release lever outwards from the lower panel.

      Click image to see an enlarged view

      Fig. Hood release lever removal-Mazda6 and Mazdaspeed6 models



      Click image to see an enlarged view

      Fig. Lower panel mounting-Mazda6 and Mazdaspeed6 models

    4.  
    5. Remove the lower panel screws.
    6.  
    7. Pull the panel out to disengage the clips A from the tabs B and remove the panel.
    8.  

  22.  
  23. Remove the steering shaft as follows:
    WARNING
    Handling the air bag module improperly can accidentally operate (deploy) the air bag module, which may seriously injure you.



    Click image to see an enlarged view

    Fig. Exploded view of the steering column and shaft assembly-Mazda6 and Mazdaspeed6 models

    1. Remove the air bag cover.
    2.  
    3. Remove the bolt.
    4.  
    5. Using a flathead screwdriver, pry out the connector stopper plate and unplug the connector.
    6.  
    7. Remove the drivers side air bag module.
    8.  
    9. Remove the lockbolt.
      WARNING
      Handling the air bag module improperly can accidentally deploy the air bag module, which may seriously injure you.

    10.  
    11. Remove the locknut.
      CAUTION
      Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse.

    12.  
    13. Set the vehicle in the straight-ahead position.
    14.  
    15. Remove the steering wheel using a suitable puller.
    16.  
    17. Remove the column cover.
    18.  
    19. Remove the clock spring connector.
    20.  
    21. Remove the screw.
    22.  
    23. Remove the clock spring.
    24.  
    25. Remove the combination switch.
    26.  
    27. Remove the steering shaft.
    28.  

  24.  
  25. Remove the A-pillar trim as follows:
    1. Partially pull back the seaming welt.
    2.  
    3. Gently pull the trim the disengage the clips A and then B (1).
    4.  
    5. Pull gently upwards on the trim to disengage clip B (2).
    6.  
    7. Disengage the tabs and remove the trim.

      Click image to see an enlarged view

      Fig. Exploded view of the A-trim mounting-Mazda6 and Mazdaspeed6 models



      Click image to see an enlarged view

      Fig. Exploded view of the front scuff plate mounting-Mazda6 and Mazdaspeed6 models

    8.  

  26.  
  27. Remove the front scuff plates as follows:
    1. Pull the scuff plate upwards and disengage clips (B), pins (C and D) and tabs (E).
    2.  
    3. Remove the scuff plate.
    4.  

  28.  
  29. Remove the front side trims as follows:
    1. Partially pull back the seaming welt.
    2.  
    3. Pull the trim outwards to disengage clip (A) and the stud bolt, then remove the trim.
    4.  

  30.  
  31. Remove the side panels using a flat bladed pry tool to disengage the clips.

    Click image to see an enlarged view

    Fig. Exploded view of the front side trim mounting-Mazda6 and Mazdaspeed6 models

  32.  
  33. If equipped with a wire type climate control unit, disconnect the wires for the front A/C unit as follows:
    1. Remove the illumination bulb.
    2.  
    3. Remove the unit.
    4.  
    5. Remove the fan switch.
    6.  
    7. Disassemble the wire as illustrated.

      Click image to see an enlarged view

      Fig. If equipped with a wire type climate control unit, disconnect the wires for the front A/C unit as shown-Mazda6 and Mazdaspeed6 models

    8.  

  34.  
  35. Disconnect the dashboard wiring harness connectors.
  36.  
  37. Remove the dashboard bolts and pull the dashboard pins out from the body.
    WARNING
    When removing the dashboard, make sure to support the dashboard is properly supported to avoid injury and also to avoid damage to the dashboard.

  38.  
  39. Remove the dashboard through the drivers side door.
  40.  
  41. Remove the theft control module bolt, connector and the module.
  42.  
  43. Disconnect the heater hose at the firewall.
  44.  
  45. Disconnect the block joint type pipes by grasping female side of the block with pliers or similar tool and holding firmly, then remove the connection bolt or nut.

    Click image to see an enlarged view

    Fig. Block type refrigerant joint-Mazda6 and Mazdaspeed6 models

  46.  
  47. Remove the heater core on Mazd6 models by removing or disconnecting the following:

    Duct
     
    Blower motor.
     
    A/C case 3 and case 4
     
    Harness
     
    Air intake actuator
     
    Air intake crank
     
    Air filter cover
     
    Air filter
     
    Resistor if equipped with a manual A/C system
     
    PMW unit if equipped with a fully automated A/C system
     
    Harness if equipped with a fully automated A/C system
     
    Air flow mode actuator
     
    Air flow mode bracket, main link, sub link and crank
     
    Air mix link and crank if equipped with a manual A/C system
     
    Air mix actuator, link and crank if equipped with a fully automated A/C system
     
    Water temperature sensor if equipped with a fully automated A/C system
     
    Heater core cover and the heater core
     

  48.  
  49. Remove the heater core on Mazdspeed6 models by removing or disconnecting the following:

    Duct (1)
     
    Polyurethane protector 1, 2 and 3
     
    Airflow mode actuator, main link, sublink (2) and sub link (3) and mode crank
     
    Power MOS FET
     
    Duct (2)
     
    Air mix actuator, rod, crank (1 and 2) and air mix rod holder
     
    Heater core

    Click image to see an enlarged view

    Fig. Exploded view of the dashboard mounting-Mazda6 and Mazdaspeed6



    Click image to see an enlarged view

    Fig. Exploded view of the A/C unit assembly-Mazda6



    Click image to see an enlarged view

    Fig. Exploded view of the A/C unit assembly-Mazdaspeed6

     

  50.  

To install:

  1. Installation is the reverse of removal, keep in mind the following:
    1. Adjust the clock spring as follows:
      CAUTION
      If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break when the steering wheel is turned. Always adjust the clock spring after installing it.


      CAUTION
      The clock spring will break if over-wound. Do not forcibly turn the clock spring.



      Set the front tires straight-ahead
       



      Turn the clock spring clockwise until it stops

      Click image to see an enlarged view

      Fig. Turn the clock spring clockwise until it stops-Mazda6 and Mazdaspeed6



      Click image to see an enlarged view

      Fig. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns-Mazda6 and Mazdaspeed6



      Click image to see an enlarged view

      Fig. Align the marks on the clock spring-Mazda6 and Mazdaspeed6

       
      From the stopped position, turn the clock spring counterclockwise 2 3 / 4 turns
       
      Align the marks
       
      Verify that the tilt / telescope lever is in the LOCK position
       

    2.  
    3. Tighten the steering shaft bolts A, nut B and nut C in that order.

      Click image to see an enlarged view

      Fig. Tighten the steering shaft bolts A, nut B and nut C in that order-Mazda6 and Mazdaspeed6

    4.  
    5. If equipped with a wire type climate control unit, connect the wires for the front A/C unit as illustrated.

      Click image to see an enlarged view

      Fig. If equipped with a wire type climate control unit, connect the wires for the front A/C unit as shown-Mazda6 and Mazdaspeed6 models

    6.  

  2.  

 
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