Front Suspension System: Removal & Installation Mazda 6 GJ

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION

Scheme 2

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal. (Scheme 2): Front Shock Absorber And Coil Spring Components With Torque Specification

Scheme 3

Scheme 4

Scheme 5

1. Check the identification mark to verify if the part is for the left or right side (Scheme 3): Identifying Damper Fork Identification Mark
2. Set the front shock absorber bracket against the damper fork. (Scheme 4): Front Shock Absorber Bracket
3. Install the bolt aligned with the front shock absorber notch. (Scheme 5): Bolt And Front Shock Absorber Notch
4. Tighten the bolt to the specified torque and install the damper fork.

Scheme 6

1. Remove the front shock absorber and coil spring. (See «FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION»(ref-581673-S02190797892013101400000).)
2. Disassemble in the order indicated in the table.
3. Assemble in the reverse order of removal.
4. Inspect the wheel alignment and adjust it if necessary. (See «FRONT WHEEL ALIGNMENT»(ref-581692-S13766259402013101400000).) (Scheme 6): Front Shock Absorber And Coil Spring With Torque Specifications

FRONT UPPER CONTROL ARM REMOVAL/INSTALLATION

Scheme 7

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-581692-S13766259402013101400000).) (Scheme 7): Front Upper Arm Related Components With Torque Specification

Scheme 8

1. Support the knuckle using the jack.
2. Separate the ball joint from the knuckle using the SST. (Scheme 8): Separating Ball Joint From Knuckle Using SST

Front Upper Arm Removal Note

Note. Pull the front shock absorber and coil spring outward of the vehicle when doing the procedure so as to assure a space for the front upper arm bolt removal.

Scheme 9

1. Remove the nuts from the upper part of the front shock absorber.
2. Pull the front shock absorber and coil spring out of the way, towards the outer side of the vehicle. (Scheme 9): Pulling Front Shock Absorber And Coil Spring
3. Remove the bolts.
4. Remove the front upper arm.

Scheme 10

1. Remove the upper arm from the vehicle.
2. Inspect for damage, cracks, and bending.
3. Inspect the ball joint rotational torque. Rotate the ball joint five times. Measure the rotational torque using a suitable allen socket and a torque wrench. (Scheme 10): Measuring Ball Joint Rotational Torque Using Suitable Allen Socket And Torque Wrench If not within the specification, replace the lower arm component. Front upper arm ball joint rotation torque 1.5 N.m {15 kgf.cm, 13 in.lbf} max.

FRONT LOWER CONTROL ARM REMOVAL/INSTALLATION

Scheme 11

1. Remove the aerodynamic under cover No.2. (MZR 2.5) (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-581657-S19487724012013101400000).)
2. For the vehicle with MZI 3.7 V6, working on the right side of the vehicle, remove the front pipe. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581685-S29941466862013101400000).)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect for front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-581692-S13766259402013101400000).) (Scheme 11): Front Lower Arm Components With Torque Specification

Front Lower Arm Outer Side Nut Removal Note

Front Lower Arm Inner Side Bolt (Front) Removal Note [MZR 2.5]

Note. When working on the left side of the vehicle, lower the front crossmember component slightly so that the oil pan does not interfere with the removal of the front lower arm front side bolt.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Slightly bend back the mudguard. (See «FRONT MUDGUARD REMOVAL/INSTALLATION»(ref-581657-S04390956372013101400000).)
2. Remove the radiator hose bracket bolt. (Scheme 12): Radiator Hose Bracket Bolt
3. Disconnect the steering pipe from the front crossmember. (Scheme 13): Locating Steering Pipe Clamp Of Front Crossmember
4. Remove the crossmember bracket bolts A and loosen the crossmember nut B. (Scheme 14): Locating Crossmember Bracket Bolts A And Crossmember Nut B
5. Support the crossmember component with a jack. (Scheme 15): Supporting Crossmember Component With Jack
6. Remove the nuts at the front of the crossmember.
7. Lower the jack gradually and tilt the crossmember towards the front.
8. Remove the front lower arm inner side bolt (front).

Front Lower Arm Inner Side Bolt (Front) Removal Note [MZI 3.7 V6]

Note. When working on the right side of vehicles, move the engine and transaxle slightly towards the front side of the vehicle so that the engine does not interfere with the removal of the lower arm rear side bolt. Disconnect the No.1 engine mount (engine side). (See ENGINE REMOVAL/INSTALLATION [MZI 3.7 V6] .) Move the engine and transaxle slightly towards the front side of the vehicle. Remove the front lower arm inner side bolt (front).

Scheme 16

Scheme 17

Scheme 18

1. Support the crossmember component with a jack. (Scheme 16): Supporting Crossmember Component With Jack
2. Lower the jack gradually and tilt the crossmember towards the front.
3. Install the front lower arm inner side bolt (front).
4. Install the nuts at the front of the crossmember. Tightening torque 120-154 N.m {13-15 kgf.m, 89-113 ft.lbf}
5. Install the crossmember bracket bolts A, and tighten the crossmember nut B. (Scheme 17): Locating Crossmember Bracket Bolts A And Crossmember Nut B Tightening torque Bolts A: 94-116 N.m {9.6-11 kgf.m, 70-85 ft.lbf} Nut B: 120-154 N.m {13-15 kgf.m, 89-113 ft.lbf}
6. Connect the steering pipe to the front crossmember. Tightening torque 8-10 N.m {82-101 kgf.cm, 71-88 in.lbf}
7. Install the radiator hose bracket to the front crossmember. (Scheme 18): Radiator Hose Bracket Bolt With Torque Specification

Front Lower Arm Inner Side Bolt (Front) Installation Note [MZI 3.7 V6]

1. Move the engine and transaxle slightly towards the front side of the vehicle.
2. Install the front lower arm inner side bolt (front).
3. Install the No. 1 engine mount (engine side). (See «ENGINE REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581682-S09006967352013101400000) .)

Scheme 19

1. Remove the lower arm from the vehicle.
2. Inspect the arm for bending or damage, and the ball joint for excessive looseness. If there is any malfunction, replace the lower arm.
3. Install the torque wrench to the front lower arm ball joint. (Scheme 19): Measuring Front Lower Arm Starting Torque
4. Measure the starting torque. Front lower arm starting torque 18 N.m {1.8 kgf.m, 13 ft.lbf} max.
5. Rotate the ball joint stud 5 times.
6. Measure the rotational torque. If not within the specification, replace the lower arm. Front lower arm rotational torque 1.2-2.2 N.m {13-22 kgf.cm, 11-19 in.lbf} max.

FRONT STABILIZER REMOVAL/INSTALLATION

Scheme 20

1. Drain the power steering fluid.
2. Remove the steering shaft cover. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
3. Disconnect the steering shaft from the steering gear and linkage. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
4. Remove the front mudguard. (See «FRONT MUDGUARD REMOVAL/INSTALLATION»(ref-581657-S04390956372013101400000).)
5. Remove the aerodynamic under cover No.2. (MZR 2.5) (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-581657-S19487724012013101400000).)
6. Remove the front pipe.(MZI 3.7 V6) (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581685-S29941466862013101400000).)
7. Remove the transverse member. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-581673-S38629292282013101400000).)
8. Remove in the order indicated in the table.
9. Install in the reverse order of removal.
10. Add the power steering fluid. (See «AIR BLEEDING»(ref-581622-S34031649532013101400000).)
11. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-581692-S13766259402013101400000).) (Scheme 20): Front Stabilizer Components With Torque Specification

Scheme 21

1. Install the front stabilizer so that the identification mark faces toward the right side of the vehicle. (Scheme 21): Identifying Tag Label On Front Stabilizer

Scheme 22

1. Install the bushing so that the arrow faces toward the front of the vehicle. (Scheme 22): Identifying Bushing Installation Position

Scheme 23

1. Remove the stabilizer control link from the vehicle. (See «FRONT STABILIZER REMOVAL/INSTALLATION»(ref-581673-S28379808502013101400000).)
2. Inspect for bending and damage.
3. Measure the ball joint starting torque. Rock the ball joint stud side to side 10 times. Rotate the ball joint stud 10 times. Measure the starting torque using a suitable allen socket and a torque wrench. (Scheme 23): Measuring Ball Joint Starting Torque Using Suitable Allen Socket And Torque Wrench Front stabilizer control link ball joint starting torque 0.2-0.8 N.m {2.1-8.1 kgf.cm, 1.8-7.0 in.lbf} If not within the specification, replace the stabilizer control link. Even when within the specification, if there is excessive play in the ball joint, replace the stabilizer control link.

FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 2.5]

Scheme 24

1. Drain the power steering fluid.
2. Remove the steering shaft cover. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
3. Disconnect the steering shaft from the steering gear and linkage. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
4. Remove the steering dust cover. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
5. Remove the front mudguard. (See «FRONT MUDGUARD REMOVAL/INSTALLATION»(ref-581657-S04390956372013101400000).)
6. Remove the aerodynamic under cover No. 2. (See «AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION»(ref-581657-S19487724012013101400000).)
7. Remove the transverse member. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-581673-S38629292282013101400000).)
8. Remove in the order indicated in the table.
9. Install in the reverse order of removal.
10. Add the power steering fluid. (See «AIR BLEEDING»(ref-581622-S34031649532013101400000).)
11. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-581692-S13766259402013101400000).) (Scheme 24): View Of Front Crossmember Components With Torque Specifications (MZR 2.5)

Scheme 25

1. Detach the tie-rod end from the steering knuckle using the SST. (Scheme 25): Detaching Tie-Rod End From Steering Knuckle Using SST

Front Crossmember Component Removal Note

Scheme 26

Scheme 27

Scheme 28

Scheme 29

1. Remove the front lower arm bolts shown in the figure. (Scheme 26): Locating Front Lower Arm Bolts
2. Remove the radiator hose bracket bolt. (Scheme 27): Radiator Hose Bracket Bolt
3. Support the crossmember component with a jack. (Scheme 28): Supporting Crossmember Component With Jack
4. Loosen the No.1 engine mount bolts A, and remove the No.1 engine mount bolt B. (Scheme 29): No.1 Engine Mount Bolts A And B
5. Remove the crossmember bracket.
6. Remove the front crossmember component.

No.1 Engine Mount Installation Note

1. Install the No.1 engine mount to the front crossmember and temporarily tighten the bolt until approx. three pitches are visible.

Front Crossmember Component Installation Note

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

1. Jack up the front crossmember component slowly. (Scheme 30): Jacking Up Front Crossmember Component
2. Install the front crossmember component, and tighten the nuts and bolts to the specified torque.
3. Temporarily tighten the No.1 engine mount bolts A and B. (Scheme 31): No.1 Engine Mount Bolts A And B
4. Tighten the No.1 engine mount bolts in the order of B and A. Tightening torque 77-103 N.m {7.9-10 kgf.m, 57-75 ft.lbf}
5. Tighten the No.1 engine mount bolt C. (Scheme 32): No.1 Engine Mount Bolt C Tightening torque 77-103 N.m {7.9-10 kgf.m, 57-75 ft.lbf}
6. Tighten the No.1 engine mount bolt D. (Scheme 33): No.1 Engine Mount Bolt D Tightening torque 94-116 N.m {9.6-11 kgf.m, 70-85 ft.lbf}
7. Install the radiator hose bracket to the front crossmember. (Scheme 34): Radiator Hose Bracket Bolt With Torque Specification

FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZI 3.7 V6]

Scheme 35

1. Drain the power steering fluid.
2. Remove the steering shaft cover. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
3. Disconnect the steering shaft from the steering gear and linkage. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
4. Remove the steering dust cover. (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITHOUT ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S34424186902013101400000).) (See «STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION [WITH ADVANCED KEYLESS ENTRY AND PUSH BUTTON START SYSTEM]»(ref-581622-S06798620582013101400000).)
5. Remove the front mudguard. (See «FRONT MUDGUARD REMOVAL/INSTALLATION»(ref-581657-S04390956372013101400000).)
6. Remove the front pipe. (See «EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581685-S29941466862013101400000).)
7. Remove the transverse member. (See «TRANSVERSE MEMBER REMOVAL/INSTALLATION»(ref-581673-S38629292282013101400000).)
8. Remove in the order indicated in the table.
9. Install in the reverse order of removal.
10. Add the power steering fluid. (See «AIR BLEEDING»(ref-581622-S34031649532013101400000).)
11. Inspect the front wheel alignment. (See «FRONT WHEEL ALIGNMENT»(ref-581692-S13766259402013101400000).) (Scheme 35): View Of Front Crossmember Components With Torque Specifications (MZI 3.7 V6)

Scheme 36

1. Detach the tie-rod end from the steering knuckle using the SST. (Scheme 36): Detaching Tie-Rod End From Steering Knuckle Using SST

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Remove the front lower arm bolts shown in the figure. (Scheme 37): Front Lower Arm Bolts
2. Disconnect the power steering fluid line shown in the figure. (See «POWER STEERING FLUID LINE COMPONENT REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581622-S19100028502013101400000).) (Scheme 38): Power Steering Fluid Line
3. Support the crossmember component with a jack. (Scheme 39): Supporting Crossmember Component With Jack
4. Loosen the No.1 engine mount bolts A, and remove the No.1 engine mount bolt B. (Scheme 40): No.1 Engine Mount Bolts A And B
5. Remove the crossmember bracket.
6. Remove the front crossmember component.

1. Install the No.1 engine mount to the front crossmember and temporarily tighten the bolt until approx. three pitches are visible.

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. Jack up the front crossmember component slowly. (Scheme 41): Jacking Up Front Crossmember Component
2. Install the front crossmember component, and tighten the nuts and bolts to the specified torque.
3. Temporarily tighten the No.1 engine mount bolts A and B. (Scheme 42): No.1 Engine Mount Bolts A And B
4. Tighten the No.1 engine mount bolts in the order of B and A. Tightening torque 77-103 N.m {7.9-10 kgf.m, 57-75 ft.lbf}
5. Tighten the No.1 engine mount bolt C. (Scheme 43): No.1 Engine Mount Bolt C Tightening torque 77-103 N.m {7.9-10 kgf.m, 57-75 ft.lbf}
6. Tighten the No.1 engine mount bolt D. (Scheme 44): No.1 Engine Mount Bolt D Tightening torque 94-116 N.m {9.6-11 kgf.m, 70-85 ft.lbf}
7. Connect the power steering fluid line shown in the figure. (See «POWER STEERING FLUID LINE COMPONENT REMOVAL/INSTALLATION [MZI 3.7 V6]»(ref-581622-S19100028502013101400000).) (Scheme 45): Power Steering Fluid Line

Scheme 46

1. Remove the transverse member. (Scheme 46): Transverse Member And Nuts With Torque Specification
2. Install the transverse member.