Mazda 626 Station Wagon 1997-2002 Workshop Service Manual

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Taper: Car

Distributeur:

UGS: 68840

Mots clés: 1997 1998 1999 2000 2001 2002 626 Station Wagon Car Cars Mazda Misc

Variantes de produits

Description

This manual covers the Station Wagon, produced for the model years 1997 through 2002. Known for its reliability, comfortable ride, and practical cargo space, this mid-size station wagon offered families and individuals dependable transportation. The Station Wagon, chassis code GW, is powered by a 2.0L DOHC inline-4 engine and was available with either a 5-speed manual or a 4-speed automatic transmission. Its engineering quality and fuel efficiency for its class made it a competitive option in the automotive market. This comprehensive workshop service and repair manual provides detailed information for all trims of the Station Wagon. It is designed to assist owners, mechanics, and technicians in maintaining and repairing the vehicle. The manual covers a wide range of systems, including engine mechanical and performance, transmissions, drivetrain, suspension, steering, brakes, electrical systems, and HVAC. It includes preventative maintenance schedules, troubleshooting guides, repair and rebuild procedures, diagnostic information, and technical specifications, offering over 1500 pages of in-depth guidance.

🏷️ Basic Information

Identification

Make:

Mazda

Model:

626 Station Wagon

Generation:

GF/GW (1991-2002)

Covered Years:

1997, 1998, 1999, 2000, 2001, 2002

Codes

Chassis Codes:

👋 Introduction

Market Position

Segment:

Mid-size station wagon

Target Audience:

Families, individuals seeking practical and reliable transportation

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Mondeo, Volkswagen Passat

Key Features

Vehicle Strengths:

Reliability, comfortable ride, practical cargo space, fuel efficiency (for its class)

Manual Utility:

Designed for professional technicians, offering the depth required for all repair and maintenance tasks.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop service and repair

Specific Models Covered:

Mazda 626 Station Wagon (all trims)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system

Engine Performance:

Fuel injection, ignition system, emission control systems, engine diagnostics

Transmission Manual:

Manual transmission disassembly, assembly, clutch system, shift linkage

Transmission Automatic:

Automatic transmission (FS-EX, FS-EX5) diagnosis, repair, fluid service, torque converter

Drivetrain:

Front-wheel drive, CV joints, drive axles, differential

Suspension:

Front and rear suspension components, struts, shocks, springs, control arms, alignment specifications

Steering:

Power steering system, steering rack, column, universal joints

Brakes:

Front and rear brake systems (disc and drum), ABS (Anti-lock Braking System), hydraulic components, parking brake

Electrical System:

Battery, charging system, starting system, lighting system, horn, wipers, power accessories

Engine Control Electronics:

ECU (Engine Control Unit), sensors (MAF, O2, TPS, Crankshaft Position), actuators, diagnostic trouble codes (DTCs), wiring diagrams

Body And Frame:

Body panel removal and installation, interior trim, exterior trim, glass, doors, hood, tailgate, chassis structure

HVAC:

Heating, Ventilation, and Air Conditioning system diagnosis and repair

Safety Systems:

Airbag system components and servicing (SRS)

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks and changes, belt inspections, spark plug replacement

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides

Repair And Rebuild:

Step-by-step instructions for component removal, repair, and reinstallation

Diagnostics:

OBD-II (On-Board Diagnostics II) code retrieval and interpretation, sensor testing

Specifications And Tolerances:

Torque specifications, clearances, alignment angles, measurements

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Print Quality

Quality:

High-resolution scans, clear diagrams and text

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

FS-DE (2.0L DOHC)

Engine Type:

Inline-4, Naturally Aspirated, DOHC, 16-valve

Displacement:

1991 cc (2.0 Liters)

Performance

Horsepower:

Approx. 118-130 hp (varies slightly by market and year)

Torque:

Approx. 125-135 lb-ft (varies slightly by market and year)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) / MPI (Multi-Point Injection)

Fuel Type:

Unleaded gasoline

Cooling System

Coolant Type:

Ethylene Glycol-based antifreeze (Mazda's recommended mixture)

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual

Optional

Transmission Type Opt:

4-speed Automatic (FS-EX, FS-EX5)

Features

Automatic Features:

Electronically controlled with lock-up torque converter

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (check manual for specific viscosity)

Automatic Transmission Fluid:

Mazda ATF-MV or equivalent Dexron III/Mercon

📐 Dimensions

Exterior

Length:

Approx. 4715 mm (185.6 inches)

Width:

Approx. 1765 mm (69.5 inches)

Height:

Approx. 1470 mm (57.9 inches)

Wheelbase:

Approx. 2615 mm (103.0 inches)

Cargo

Cargo Volume:

Approx. 35.7 - 58.1 cu ft (rear seats up/down)

Weights

Curb Weight:

Approx. 1400-1500 kg (3086-3307 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not explicitly rated for this generation/specific model year in all markets. Generally considered safe for its era.

Active Features

Optional/Standard on higher trims

Passive Features

Airbags:

Driver and passenger front airbags (standard/optional depending on market and trim)

Seatbelts:

Three-point seatbelts with pretensioners (front)

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player and/or cassette tape. Optional premium sound systems.

Climate Control:

Manual or automatic climate control (depending on trim level).

Driver Assistance

Cruise Control:

Standard or optional depending on trim.

Connectivity

Auxiliary Input:

Not typically standard; aftermarket solutions required for modern device connectivity.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000-7,500 miles or 6-12 months, whichever comes first.

Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Spark Plugs:

Replace approximately every 60,000-100,000 miles (depending on plug type: standard or iridium).

Fluid Specifications

Engine Oil Capacity:

Approx. 4.2 - 4.5 Liters (4.4 - 4.8 Quarts) with filter (for 2.0L engine)

Engine Oil Type:

API SL/SM/SN, SAE 5W-30 or 10W-30 (check manual for climate-specific recommendations)

Coolant Capacity:

Approx. 6.0 - 6.5 Liters (6.3 - 6.9 Quarts)

Known Issues

Common Problems:

Oil leaks (valve cover gasket, oil pan gasket), suspension wear (bushings, ball joints), catalytic converter failure, ABS sensor issues, transmission shift solenoids (automatic transmission).

Preventative Measures:

Regular fluid changes, timely replacement of worn suspension components, diligent inspection for oil leaks.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Known for 'Zoom-Zoom' driving dynamics and reliable, well-engineered vehicles.

Model Evolution

Sixth Generation:

The GW chassis represents the sixth generation (1991-2002), known for its improved styling and refined chassis over predecessors.

Facelift:

This period (1997-2002) likely includes minor updates and possibly a mid-cycle refresh for the GW generation.

Production

Manufacturing Locations:

Japan (primary), possibly some assembly in other regions.

🏆 Awards & Recognition

Recognitions

Consumer Ratings:

Generally received positive reviews for reliability and value during its production run, though specific awards are less documented for this generation.