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Mazda 6 Service Repair Manual 2002-2007

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🏷️ Basic Information Identification Make: Mazda Model: 6 Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Codes: GG, GY, GH (early production) 👋 Introduction Market Position Segment:...
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Taper: Car
Distributeur:
UGS: 297749
Mazda 6 Service Repair Manual 2002-2007
🏷️ Basic Information
Identification
Make:
Mazda
Model:
6
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007
Codes
Chassis Codes:
GG, GY, GH (early production)
👋 Introduction
Market Position
Segment:
Mid-size Sedan / Hatchback
Target Audience:
DIY enthusiasts, independent repair shops, Mazda owners seeking detailed maintenance and repair information
Competitive Analysis
Competitors During Era:
Honda Accord, Toyota Camry, Nissan Altima, Ford Fusion, Chevrolet Malibu
Key Features
Vehicle Appeal:
Sporty handling, stylish design, reliable powertrains (especially the MazdaSpeed variants)
Manual Value
Benefit To Owner:
Empowers owners to perform maintenance and repairs confidently, saving money and extending vehicle lifespan
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specifications may vary slightly by market, manual generally covers common configurations)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Instant Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, overhaul, timing, lubrication, cooling, emissions
Engine Electrical:
Ignition system, fuel injection, starting system, charging system, engine control module (ECM/PCM) diagnostics
Transmission Manual:
Manual transmission removal, disassembly, repair, clutch system, flywheel
Transmission Automatic:
Automatic transmission removal, disassembly, repair, torque converter, valve body, electronic controls
Drivetrain:
Front-wheel drive (FWD) system, half-shafts, CV joints, differential
Suspension:
Front suspension (struts, control arms, ball joints, bushings), rear suspension (multi-link, shock absorbers, bushings), alignment specifications
Steering:
Power steering system (pump, rack and pinion, fluid), steering column, wheel alignment
Brakes:
Front and rear brake systems (discs, pads, calipers, lines), hydraulic system, parking brake, ABS (Anti-lock Braking System) diagnostics
Electrical System:
Battery, charging system, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams
Body And Interior:
Body panel removal/installation, doors, windows, interior trim, seats, dashboard, climate control system
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, diagnostics
Safety Systems:
Airbag system (SRS), seat belt pre-tensioners, diagnostic procedures
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake pad replacement, tire rotation
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation, symptom-based troubleshooting guides
Repair:
Detailed step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension component replacement
Diagnostics:
OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), using scan tools, sensor testing
Electrical Diagnostics:
Reading wiring diagrams, testing circuits, component testing, troubleshooting electrical faults
Body Repair:
Panel alignment, minor dent repair, glass replacement, weatherstrip installation
Technical Depth
Depth:
Comprehensive (covers everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and schematics)
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Print Quality:
High-resolution, suitable for printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
LF-VE (2.0L DOHC 16-valve Inline-4), L3-VE (2.3L DOHC 16-valve Inline-4), MZR-CD (2.0L Diesel)
Displacement 2.0L:
1999 cc (122 cu in)
Displacement 2.3L:
2261 cc (138 cu in)
Performance
Horsepower 2.0L:
Approx. 140-150 PS (138-148 hp) depending on market and tune
Torque 2.0L:
Approx. 184-194 Nm (136-143 lb-ft) depending on market and tune
Horsepower 2.3L:
Approx. 160-170 PS (158-168 hp) depending on market and tune
Torque 2.3L:
Approx. 205-215 Nm (151-159 lb-ft) depending on market and tune
Mazdaspeed 6 Engine:
MZR DISI Turbo (2.3L Turbocharged Inline-4)
Mazdaspeed 6 Horsepower:
270 PS (266 hp)
Mazdaspeed 6 Torque:
380 Nm (280 lb-ft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded gasoline, 87 octane (minimum) for naturally aspirated engines; higher octane recommended for turbocharged engines
Emission Controls:
Catalytic converter, EGR (Exhaust Gas Recirculation), O2 sensors, EVAP (Evaporative Emission Control)
🔧 Transmission
Standard
Transmission Options:
5-speed manual, 4-speed automatic, 6-speed manual (MazdaSpeed6)
Optional
Transmission Options Continued:
5-speed automatic (some early models/markets)
Features
Clutch Type:
Single dry plate (manual transmissions)
Drivetrain Layout:
Front-Wheel Drive (FWD) standard; All-Wheel Drive (AWD) available on some models (e.g., MazdaSpeed6)
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Hatchback (Wagon/Hatchback variant)
Length Sedan:
Approx. 4690 mm (184.6 in)
Width:
Approx. 1780 mm (70.1 in)
Height:
Approx. 1435 mm (56.5 in) for Sedan
Wheelbase:
Approx. 2725 mm (107.3 in)
Weights
Curb Weight:
Varies by trim and powertrain, typically 1350-1550 kg (2976-3417 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star (typically for driver and passenger side depending on year and specific test protocols)
IIHS Front Crash Test:
Good (typically for frontal offset crash tests)
Active Features
ABS:
Standard
Traction Control:
Available on higher trims and select models
Electronic Stability Control:
Available on later models and higher trims
Passive Features
Airbags:
Frontal airbags (driver and passenger), front side-impact airbags, available side curtain airbags
Seatbelts:
3-point front and rear seatbelts, pre-tensioners and load limiters for front seats
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional Bose premium sound system, auxiliary input
Display:
Optional navigation system with touchscreen display (later models/higher trims)
Driver Assistance
Cruise Control:
Standard on most trims
Keyless Entry Start:
Available on higher trims (e.g., Smart Entry System)
Connectivity
Phone Integration:
Bluetooth hands-free calling available on select models/trim levels
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first (under normal driving conditions)
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed
Spark Plug Replacement 2.0L:
Every 60,000 miles (96,000 km) with platinum-tipped plugs
Spark Plug Replacement 2.3L:
Every 60,000 miles (96,000 km) with platinum-tipped plugs
Coolant Flush Interval:
Every 60,000 miles (96,000 km) or 4 years
Brake Fluid Flush:
Every 24 months (regardless of mileage)
Fluid Specifications
Engine Oil Type 2.0L 2.3L:
API SN or higher, SAE 5W-30 (check owner's manual for specific viscosity recommendations based on temperature)
Engine Oil Capacity 2.0L:
Approx. 4.0 liters (4.2 US quarts)
Engine Oil Capacity 2.3L:
Approx. 4.0 liters (4.2 US quarts)
Coolant Type:
Mazda FL22 or equivalent Long Life Antifreeze/Coolant (Blue)
Transmission Fluid Manual:
API GL-4 SAE 75W-90 (or GL-5 equivalent, verify specific fill)
Transmission Fluid Automatic:
Mazda Genuine ATF JWS3309 or equivalent (e.g., Mobil 3309)
Power Steering Fluid:
Dexron III/Mercon ATF or Mazda Genuine Power Steering Fluid
Known Issues
Common Electrical Issues:
Corrosion on wiring harnesses, faulty power window motors, intermittent HVAC blower issues
Common Suspension Issues:
Worn front control arm bushings, premature strut failure, rear suspension creaks
Common Engine Issues:
Oil consumption (especially early 2.3L), carbon buildup on intake valves, timing chain stretch (rare but possible)
Common Transmission Issues:
Automatic transmission hard shifting, manual transmission clutch wear
Common Body Issues:
Rust formation in wheel wells and rocker panels, especially in colder climates
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Jinba Ittai (horse and rider as one) - focus on driving dynamics and connection between driver and car
Model Evolution
First Generation Launch:
Introduced in late 2001 (for the 2002 model year) as a successor to the Mazda Capella/626
Styling Influence:
Designed by Tom Mazany, with styling cues from the Mazda MX-Crossport concept
Mazdaspeed Version:
MazdaSpeed6 (Atenza MS) launched in 2005, featuring a turbocharged engine, AWD, and sportier suspension/aesthetics
Production
Production Plants:
Hofu Plant, Yamaguchi Prefecture, Japan; Flat Rock, Michigan, USA (for North American market under Ford ownership)
🏆 Awards & Recognition
Recognitions
Car Of The Year Nominations:
Nominated for North American Car of the Year (2003)
Consumers Reports Reliability:
Generally good reliability scores for the platform, with some model year variations
Ratings
IIHS Side Impact Test:
Good (for models equipped with side airbags)
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