The 2004 Mazda6 represents a significant entry into the mid-size sedan and sport wagon market, built on the GG/GY platform. Known for its engaging handling, stylish design, and spacious interior, particularly in the wagon variant, the Mazda6 offers reliable powertrains and a driving experience often associated with Mazda's "Zoom-Zoom" philosophy. This model was recognized with Car and Driver's 10Best List in 2004 and was a contender for MotorTrend's Car of the Year, highlighting its blend of sportiness and practicality. Available with a 2.3L MZR engine producing 160 horsepower and 155 lb-ft of torque, paired with either a 5-speed manual or a 5-speed automatic transmission featuring Sequential Sport Shift, the Mazda6 provides a dynamic and enjoyable driving experience for its class.
This comprehensive factory service and repair manual, written in English, provides detailed guidance for the complete service and repair of the 2004 Mazda6. Spanning approximately 3000+ pages, it covers all essential vehicle systems, including engine mechanicals, fuel, ignition, cooling, exhaust, lubrication, transmissions (automatic and manual), drivetrain, suspension, steering, braking systems (including ABS and EBD), and extensive electrical system diagnostics with wiring diagrams. It also details HVAC, body, interior, and safety systems. The manual includes maintenance schedules, repair procedures, diagnostic troubleshooting, and technical specifications such as torque values, fluid capacities, and component data, making it an indispensable resource for owners and technicians alike.
Market Segment:
Mid-size Sedan/Wagon
Key Competitors 2004:
• Toyota Camry
• Honda Accord
• Nissan Altima
• Ford Fusion
• Volkswagen Passat
Vehicle Strengths 2004 Mazda6:
• Engaging Handling (Zoom-Zoom)
• Stylish Design
• Spacious Interior (especially wagon)
• Reliable Powertrains
Coverage Scope:
Complete Service and Repair
Estimated Page Count:
Approximately 3000+ pages
Manual Type:
Factory Service Manual / Repair Manual
Engine Systems:
• Engine Mechanical
• Engine Control System (ECU)
• Fuel System
• Ignition System
• Cooling System
• Exhaust System
• Lubrication System
Transmission Systems:
• Automatic Transmission (FS5A-EL)
• Manual Transmission (G25M-R)
Drivetrain Systems:
• Front Wheel Drive (FWD)
• All Wheel Drive (AWD) - if applicable
• Axles and Driveshafts
• Differential
Suspension And Steering:
• Front Suspension
• Rear Suspension
• Steering System
• Power Steering System
Braking Systems:
• Brake System (Front and Rear)
• Anti-lock Braking System (ABS)
• Electronic Brake-force Distribution (EBD)
• Brake Components Diagnosis and Repair
Electrical Systems:
• Battery
• Charging System
• Starting System
• Lighting System
• Ignition System
• Instrument Cluster
• Power Accessories
• Body Control Module (BCM)
• Wiring Diagrams
• Fuses and Relays
HVAC Systems:
• Heating System
• Ventilation System
• Air Conditioning (A/C) System
• Climate Control System
Body And Interior:
• Body Panels
• Doors
• Windows
• Seats
• Interior Trim
• Bumpers
• Hood
• Trunk/Liftgate
Safety Systems:
• Airbag System (SRS)
• Seat Belts
• Passive Safety Components
Maintenance Procedures:
• Oil Change
• Filter Replacement (Oil, Air, Cabin)
• Fluid Checks and Replenishments
• Spark Plug Replacement
• Brake Pad and Rotor Replacement
• Tire Rotation and Balancing
• Belts and Hoses Inspection/Replacement
Repair Procedures:
• Engine Component Overhaul
• Transmission Overhaul and Repair
• Suspension Component Replacement
• Brake System Component Repair
• Electrical Component Diagnosis and Replacement
• Body Panel Repair and Replacement
• HVAC System Repair
Diagnostics And Troubleshooting:
• Diagnostic Trouble Codes (DTCs)
• Symptom-Based Troubleshooting Guides
• Wiring Diagram Interpretation
• Component Testing Procedures
Technical Specifications And Data:
• Torque Specifications
• Component Clearances
• Electrical Resistance Values
• Fluid Capacities
• Engine and Transmission Specifications
Depth Of Coverage:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and bodywork.
File Format Details:
Searchable PDF, allowing quick access to information. High resolution for clear diagrams and text.
Print Quality Suitability:
Suitable for professional printing. Includes all original diagrams, illustrations, and schematics.
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Code And Type:
LF-VE 2.3L DOHC 16-valve Inline-4 (MZR)
Engine Displacement:
2261 cc (2.3 Liters)
Bore X Stroke:
87.5 mm x 94.0 mm
Horsepower Peak:
160 hp @ 6,500 rpm
Torque Peak:
155 lb-ft @ 4,000 rpm
Fuel Delivery:
Electronic Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline, 87 Octane Recommended
Timing System:
Timing Chain
Cylinder Head Design:
Aluminum Alloy DOHC
Block Material:
Aluminum Alloy
Standard Transmission:
5-speed Manual Transmission (G25M-R)
Optional Transmission:
5-speed Automatic Transmission (FS5A-EL)
Automatic Transmission Features:
Sequential Sport Shift (manual mode)
Automatic Transmission Fluid:
Mazda ATF-FZ (or equivalent Dexron III/Mercon)
Manual Transmission Fluid:
GL-4 SAE 75W-90 Gear Oil
Sedan Length:
186.8 inches
Sedan Height:
57.1 inches
Wagon Length:
187.6 inches
Wagon Height:
58.5 inches
Wheel Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Wheel Size:
16-inch, 17-inch (optional)
Passenger Volume:
Approximately 97.0 cu ft (Sedan), 100.3 cu ft (Wagon)
Trunk Volume Sedan:
14.2 cu ft
Cargo Volume Wagon Seats Up:
26.1 cu ft
Cargo Volume Wagon Seats Down:
59.4 cu ft
Curb Weight Sedan Manual:
3,241 lbs
Curb Weight Sedan Auto:
3,285 lbs
Curb Weight Wagon Manual:
3,351 lbs
Curb Weight Wagon Auto:
3,395 lbs
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Seat:
5 Stars
NHTSA Side Impact Rear Seat:
4 Stars
IIHS Front Offset Crash Test:
Good
IIHS Side Impact Crash Test:
Good
Active Safety Features:
• Anti-lock Braking System (ABS)
• Electronic Brake-force Distribution (EBD)
• Traction Control System (TCS)
• Dynamic Stability Control (DSC) - often standard or optional
Passive Safety Features:
• Front Airbags
• Side Airbags
• Side Curtain Airbags (optional on some trims)
• Pretensioner seat belts
• Crumple zones
Audio System:
Standard AM/FM/CD player with 4-6 speakers. Bose premium audio optional on higher trims.
Climate Control:
Manual climate control standard, automatic climate control optional on select trims.
Driver Assistance Features:
• Cruise Control
• Tire Pressure Monitoring System (TPMS) - typically optional
Connectivity Options:
Auxiliary input for audio (often added aftermarket or on later models). No standard Bluetooth or USB in this era.
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (under normal driving conditions).
Air Filter Replacement:
Every 30,000 miles or 2 years.
Cabin Air Filter Replacement:
Every 15,000 miles or 1 year.
Spark Plug Replacement:
Every 100,000 miles (platinum or iridium plugs).
Transmission Fluid Change Auto:
Every 60,000 miles (under normal driving conditions).
Brake Fluid Flush:
Every 30,000 miles or 2 years.
Engine Oil Type:
SAE 5W-20 (API SM or ILSAC GF-4 or higher)
Engine Oil Capacity:
4.8 US quarts (with filter)
Coolant Type:
Mazda Super Long Life Coolant (Blue) - or equivalent OAT type
Power Steering Fluid:
Mazda Genuine Power Steering Fluid (or Dexron III/Mercon ATF)
Common Wear Items:
• Front control arm bushings
• Sway bar links
• Brake components (pads, rotors)
• Oxygen sensors
• Mass Air Flow (MAF) sensor
Potential Engine Issues:
• Carbon buildup on intake valves (direct injection engines, though this model is port injection)
• Oil consumption in higher mileage engines
• PCV valve issues can lead to oil sludge
Potential Transmission Issues:
• Occasional rough shifting in automatic transmissions
• Transmission fluid leaks
Mazda Brand Philosophy:
Focus on driving dynamics, sportiness, and innovative design, often encapsulated in the 'Zoom-Zoom' marketing.
Mazda6 First Generation Launch:
Introduced as a replacement for the Mazda Capella/626.
Gg Gy Platform Significance:
Marked a significant shift for Mazda's mid-size offerings, emphasizing European-style driving dynamics and upscale interior appointments.
Production Locations:
• Hofu, Yamaguchi, Japan
• Flat Rock, Michigan, USA (for North American market)
Car And Driver Year:
Car and Driver's 10Best List (2004)
Motor Trend Award:
MotorTrend's Car of the Year contender (2004)