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Mazda 6 2002 2003 2004 2005 2006 2007 2008 Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: 6 Codes Chassis Code: GG/GY (First Generation) 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon (introduced as a global car) Competitive Analysis Competitors: Toyota...
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Distributeur:
UGS: 68826
Mazda 6 2002 2003 2004 2005 2006 2007 2008 Service Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
6
Codes
Chassis Code:
GG/GY (First Generation)
👋 Introduction
Market Position
Segment:
Mid-size Sedan/Wagon (introduced as a global car)
Competitive Analysis
Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Volkswagen Passat
Key Features
Design Philosophy:
Jinba Ittai (Horse and Rider as One) driving dynamics, sporty handling, unique styling
📋 Manual Details
Coverage Areas
Years Covered:
2002, 2003, 2004, 2005, 2006, 2007, 2008
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution, searchable text, printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
All engine variants (e.g., MZR 2.0L, MZR 2.3L, MZR 3.0L V6)
Transmission:
Manual (FS5A-EL, GF4A-EL) and Automatic Transmissions
Brakes:
Hydraulic system, ABS, EBD, DSC, components, troubleshooting
Suspension Steering:
Front and rear suspension, power steering system, components, alignment
Electrical:
Wiring diagrams, fuses, relays, charging system, starting system, lighting, instrumentation, comfort systems
Body Chassis:
Body construction, interior trim, exterior panels, doors, windows, seats
HVAC:
Climate control system, AC operation, components, troubleshooting
Fuel Exhaust:
Fuel delivery, injectors, exhaust system, emissions control
Safety Systems:
Airbag system, seatbelt pretensioners, SRS troubleshooting
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks
Repair:
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, DTC (Diagnostic Trouble Code) explanations
Diagnostics:
On-board diagnostics (OBD-II), sensor testing, actuator testing
Engine Mechanical:
Engine assembly, disassembly, timing belt/chain service, piston and bearing replacement, cylinder head service.
Transmission Overhaul:
Complete rebuild procedures for both manual and automatic transmissions, including torque converter service.
Body Repair:
Panel replacement, frame straightening (if applicable), door and window mechanism repair.
Diagnostics Electrical:
Detailed circuit diagrams for all electrical systems, including component testing procedures and connector pinouts.
Suspension Alignment:
Specifications and procedures for wheel alignment, suspension component torquing, and chassis measurements.
Technical Depth
Depth:
Comprehensive, from basic checks to full component disassembly and reassembly
⚙️ Engine Specifications
Primary Engine
Engine Options:
MZR 2.0L I4 (LF-DE, LF-VE), MZR 2.3L I4 (L3-VE), MZR 3.0L V6 (JNB, AJ)
Performance
2.3L I4 Hp:
Approx. 160-170 hp
2.3L I4 Torque:
Approx. 150-155 lb-ft
3.0L V6 Hp:
Approx. 220 hp
3.0L V6 Torque:
Approx. 200 lb-ft
Fuel System
Injection Type:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual (FS5A-EL)
Optional
Optional Transmission:
5-Speed Automatic (GF4A-EL), 6-Speed Manual (MZR CD Diesel - some markets)
Features
Automatic Features:
Steptronic (Tiptronic) Shifting (on some models)
📐 Dimensions
Exterior
Wheelbase:
Approx. 106.4 inches (2700 mm)
Length:
Approx. 186.3 inches (4732 mm)
Width:
Approx. 70.1 inches (1781 mm)
Height:
Approx. 57.5 inches (1460 mm)
Weights
Curb Weight:
Approx. 3100-3500 lbs (1400-1600 kg) depending on engine/options
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (Driver and Passenger)
IIHS Side Impact:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard
Traction Control:
Optional/Standard on higher trims (TCS)
Electronic Stability:
Optional/Standard on higher trims (DSC - Dynamic Stability Control)
Passive Features
Airbags:
Frontal, Side, and Curtain Airbags (depending on trim)
Seatbelts:
3-point front and rear seatbelts, front pretensioners
💡 Technology Features
Infotainment
Audio System:
Optional Bose premium audio system, CD player, AM/FM radio.
Navigation:
Optional DVD-based navigation system on higher trims.
Driver Assistance
Cruise Control:
Standard
Connectivity
Aux Input:
Limited connectivity options, generally no standard AUX or USB inputs on early models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months (whichever comes first) with conventional oil, or 7,500 miles/12 months with synthetic oil (refer to manual for specific recommendations).
Spark Plug Replacement:
Approx. 60,000-100,000 miles (depending on plug type - iridium recommended)
Fluid Specifications
Engine Oil:
API SN/SM or ILSAC GF-5, SAE 5W-20 or 5W-30 (check manual for specific engine and temperature range)
Coolant:
Mazda FL22 Long Life Antifreeze/Coolant (or equivalent HOAT coolant)
Transmission Fluid Automatic:
Mazda ATF-Type M-III or equivalent MERCON V
Transmission Fluid Manual:
API GL-4, SAE 75W-90 gear oil
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Engine Mounts:
Premature wear or failure of engine and transmission mounts, leading to vibration.
Power Steering Pump:
Leaking or noisy power steering pumps are a common complaint.
Exhaust Manifold:
Cracking of the exhaust manifold on some 2.3L engines.
ABS Modulator:
Potential failure of the ABS modulator/pump unit.
Body Rust:
Susceptibility to rust in wheel wells, rocker panels, and subframes, particularly in areas with road salt.
📚 Vehicle History
Brand Heritage
Mazda Focus:
Known for 'Zoom-Zoom' driving dynamics and engaging handling across its model line.
Model Evolution
First Generation Launch:
Launched in 2002 as a successor to the Mazda Capella/626, designed as a 'world car'.
Production
Assembly Locations:
Hofu, Japan; Flat Rock, Michigan, USA (for North American market until 2007)
🏆 Awards & Recognition
Recognitions
Car And Driver Ota:
Car and Driver's 10Best list in 2003 and 2004
Motor Trend Ota:
Nominated for Motor Trend Car of the Year
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