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Mazda 6 2004 All Service Repair Manual

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The 2004 model is a mid-size vehicle celebrated for its engaging driving dynamics and stylish design, embodying a core automotive philosophy. This model was available in sedan, hatchback, and sport...
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Stichworte: 2004 6 Car Cars Mazda Misc
Mazda 6 2004 All Service Repair Manual
The 2004 model is a mid-size vehicle celebrated for its engaging driving dynamics and stylish design, embodying a core automotive philosophy. This model was available in sedan, hatchback, and sport wagon body styles, offering versatility to a wide range of consumers. Notable for its responsive handling and aerodynamic aesthetics, the vehicle competed in a segment populated by established rivals. It offered a choice between a 2.3-liter inline-4 engine, producing 160 horsepower, and a more potent turbocharged version in a performance variant, which delivered 215 horsepower. The vehicle garnered recognition, including being named to a prominent automotive publication's 10Best list for 2003 and 2004, underscoring its blend of performance and practicality. This comprehensive service and repair manual covers all 2004 models, including sedan, hatchback, and wagon variants. With over 1500 pages of detailed information, it serves as an essential resource for owners, mechanics, and technicians. The manual provides in-depth coverage of all major vehicle systems, from engine mechanicals and transmissions (both manual and automatic) to brakes, suspension, steering, and the electrical system. It details routine maintenance procedures, diagnostic troubleshooting, and specific repair instructions for components such as the engine, transmission, brakes, and bodywork. Safety system information and technical specifications are also included, ensuring a complete guide for maintaining and repairing the vehicle.
🏷️ Basic Information
Identification
Make:
Mazda
Model:
6
Year:
2004
Codes
Chassis Code:
GG/GY/GS
Engine Code Primary:
LF-DE
Engine Code Secondary:
L3-VE (MPS)
👋 Introduction
Market Position
Positioning:
The Mazda 6 (2004) represented Mazda's commitment to a more engaging driving experience within the mid-size sedan segment, known for its 'Zoom-Zoom' philosophy.
Competitive Analysis
Competitors 2004:
Competed against vehicles such as the Honda Accord, Toyota Camry, Nissan Altima, and Ford Fusion.
Key Features
Design:
Stylish, aerodynamic design with distinctive 'face' grille and flowing lines.
Handling:
Touted for its sporty handling and responsive chassis, often praised for being more engaging to drive than segment rivals.
Body Styles:
Available as a four-door sedan, five-door hatchback, and five-door sport wagon.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete Service & Repair
Vehicle Variants Covered:
All 2004 Mazda 6 Models (Sedan, Hatchback, Wagon)
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, timing belt/chain, lubrication, cooling, fuel delivery, ignition, emissions
Transmission Manual:
Clutch, gearbox, drive axles, service, repair
Transmission Automatic:
Service, fluid changes, diagnostics, torque converter
Brakes:
Hydraulic system, ABS, EBD, disc/drum components, parking brake
Suspension Steering:
Front/rear suspension, struts, shock absorbers, control arms, steering rack, power steering
Electrical System:
Battery, charging, starting, lighting, fuses, relays, wiring diagrams, ECU diagnostics
HVAC:
Climate control system, A/C refrigerant, heating, ventilation, blower motor
Body Chassis:
Body panels, doors, windows, interior trim, chassis components, collision repair basics
Safety Systems:
Airbags, seat belts, SRS system diagnostics
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotations
Diagnostic Troubleshooting:
Symptom-based diagnosis, fault code interpretation, electrical system troubleshooting
Engine Repair:
Head gasket replacement, piston rings, valve seals, timing belt/chain service
Transmission Repair:
Clutch replacement, internal transmission component service
Brake Repair:
Brake pad/rotor replacement, caliper service, bleeding procedure
Suspension Steering Repair:
Strut/shock replacement, ball joint replacement, tie rod end replacement
Electrical Diagnostics:
Wiring harness repair, sensor testing, module troubleshooting
Bodywork Repair:
Door panel removal, bumper replacement, window regulator repair
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text
Print Quality
Print Readability:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline-4 DOHC
Displacement:
2.3 Liters (2261 cc)
Engine Code Standard:
LF-DE
Horsepower Standard:
160 hp @ 5800 rpm
Torque Standard:
155 lb-ft @ 4000 rpm
Secondary Engine
Engine Type Mps:
Inline-4 DOHC, Turbocharged
Displacement Mps:
2.3 Liters (2261 cc)
Engine Code Mps:
L3-VE
Horsepower Mps:
215 hp @ 5500 rpm (MPS)
Torque Mps:
207 lb-ft @ 3000 rpm (MPS)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Emissions Control:
Catalytic Converter, Secondary Air Injection System (SAIS)
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual
Optional
Transmission Type Opt:
5-Speed Automatic (with Sport Mode)
Features
Automatic Features:
Adaptive Shift Control (ASC), available paddle shifters on some higher trims.
Manual Features:
Close-ratio gearing for sporty feel, hydraulic clutch actuation.
Fluid Specs
Automatic Transmission Fluid:
Mazda ATF-MV or equivalent DEXRON-III/VI compatible fluid. Capacity: Approx. 7.7 US quarts (7.3 Liters) for complete fill.
Manual Transmission Fluid:
API GL-4 SAE 75W-90 Gear Oil. Capacity: Approx. 1.9 US quarts (1.8 Liters).
📐 Dimensions
Exterior
Wheelbase:
105.3 inches (2675 mm)
Length:
189.5 inches (4813 mm) - Sedan
Width:
70.1 inches (1781 mm)
Height:
57.4 inches (1458 mm) - Sedan
Front Track:
60.7 inches (1541 mm)
Rear Track:
60.4 inches (1534 mm)
Cargo
Trunk Volume Sedan:
Approx. 14.4 cu ft (408 Liters)
Weights
Curb Weight Est Min:
3150 lbs (1430 kg)
Curb Weight Est Max:
3550 lbs (1610 kg) - including MPS
Wheels Tires
Wheel Size Standard:
16-inch alloy
Tire Size Standard:
205/55R16
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size Optional:
17-inch alloy, 18-inch alloy (MPS)
Tire Size Optional:
215/45R17, 215/40R18 (MPS)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
IIHS Front Crash Test:
Good
Active Features
ABS:
Standard (4-wheel disc brakes)
Traction Control:
Optional (TCS)
Stability Control:
Optional (DSC - Dynamic Stability Control)
Passive Features
Airbags Front:
Standard Dual-Stage Frontal Airbags
Airbags Side:
Optional Front Side-Impact Airbags, Optional Side-Curtain Airbags (Roof in some trims)
Seatbelts:
3-point front and rear seat belts, pretensioners and load limiters for front seats.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player with 4-6 speakers. Bose premium audio system available on higher trims with subwoofer.
Navigation:
Optional factory navigation system available on select trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Keyless Entry:
Standard keyless entry, optional remote keyless entry/alarm system.
Connectivity
Aux Input:
Rarely equipped with standard AUX input; aftermarket solutions or early iPod integration available on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions.
Engine Oil Filter:
Replace with every oil change.
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed. Recommended replacement around 30,000 miles (48,000 km).
Cabin Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed. Recommended replacement around 15,000-30,000 miles (24,000-48,000 km).
Spark Plugs:
Replace every 60,000-100,000 miles (96,000-160,000 km) depending on plug type (standard vs. long-life iridium).
Timing Belt Replacement:
This model utilizes a timing chain, not a belt, which generally does not require scheduled replacement but should be inspected for wear.
Fluid Specifications
Engine Oil Type:
API SJ or SL, ILSAC GF-3, SAE 5W-20 or 5W-30 (check owner's manual for specific recommendation based on climate).
Coolant Type:
Mazda Super Long Life Coolant (SLLC) - Blue or equivalent HOAT coolant. Capacity: Approx. 7.7 US quarts (7.3 Liters).
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid Type:
Mazda Genuine Power Steering Fluid or equivalent ATF Dexron III compatible fluid.
Known Issues
Engine Oil Consumption:
Some 2.3L engines, particularly early models, may exhibit higher than normal oil consumption. Regular checks are recommended. PCV valve issues can sometimes contribute.
Suspension Noise:
Front strut mounts and sway bar links can wear out and cause clunking or rattling noises, especially over bumps.
Power Window Motors:
Infrequent reports of power window motor or regulator failures.
PCM Issues:
Rare instances of Powertrain Control Module (PCM) failure or software glitches, often addressed by dealership updates.
Rust:
As with many vehicles of this era, rust can be a concern on wheel wells, rocker panels, and subframes, especially in rust-belt regions. Regular inspection and rust prevention are advised.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda's heritage is built on a spirit of innovation, engineering excellence, and a passion for driving, encapsulated in their 'Zoom-Zoom' marketing and product design.
Model Evolution
First Generation:
The Mazda 6 replaced the Mazda Capella/626. This first generation (2002-2008) marked a significant shift in Mazda's design and driving dynamics.
2004 Updates:
The 2004 model year saw the introduction of the Mazdaspeed6 (MPS), a performance-oriented variant with a turbocharged engine and all-wheel drive (or advanced AWD system).
Production
Manufacturing Location:
Primary manufacturing in Hofu, Yamaguchi Prefecture, Japan. Also assembled in other global locations depending on market.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Mazda 6 was recognized on Car and Driver's 10Best list for 2003 and 2004.
Motor Trend Car Of The Year:
Was a finalist for MotorTrend Car of the Year in 2003.
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