Model Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Generation:
First Generation (1994-1997), Second Generation (1998-2002)
Chassis Codes:
J-Platform
Segment:
Luxury Mid-size Sedan
Brand Statement:
Positioned as Mazda's flagship luxury sedan, aiming to compete with established German and Japanese luxury marques.
Key Competitors:
Acura Legend, Lexus ES, Infiniti J30, BMW 5 Series, Mercedes-Benz E-Class.
Differentiating Technology:
The innovative 'Miller Cycle' engine (especially on the KL-DE and Miller KL-ZE engines) offering improved torque and fuel efficiency.
Design Philosophy:
Sleek, aerodynamic styling with a focus on refinement and a comfortable, quiet interior.
Areas Covered:
All mechanical and electrical systems, bodywork, chassis, interior, exterior, specifications, troubleshooting, diagnostics, repair procedures, maintenance schedules.
Page Count:
Estimated 1000-2000+ pages (typical for comprehensive factory manuals of this era)
Manual Type:
Factory Service Repair Workshop Manual
Engine Systems:
Engine mechanical (including L-Jetronic and Miller Cycle), fuel injection, ignition, lubrication, cooling, exhaust, engine management (ECU).
Transmission Systems:
Automatic transmission (e.g., Mazda 5R55E, 4-speed automatics), clutch, gearbox, differential, driveshafts, axle shafts.
Chassis Systems:
Steering, suspension (front and rear), brakes (hydraulic, ABS), wheels, tires, chassis components, body mounting.
Electrical Systems:
Wiring diagrams, battery, charging system, starting system, lighting, fuses, relays, body electricals, power accessories, instrumentation, diagnostic connectors (OBD-I/OBD-II).
Body And Interior:
Body panels, doors, windows, glass, interior trim, seats, HVAC system, climate control, safety restraints (airbags, seatbelts), body sealing.
Maintenance Procedures:
Oil changes, filter replacements, spark plug service, fluid checks and changes, belt replacements, brake pad replacement, tire rotation.
Repair Procedures:
Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component diagnosis and replacement, body panel repair.
Troubleshooting Guides:
Systematic diagnostic flowcharts and symptom-based troubleshooting for common issues.
Depth:
Comprehensive: Covers everything from basic routine maintenance to complex component overhauls and advanced diagnostic procedures. Includes detailed torque specifications, clearances, and component testing methods.
Engine Code 1:
KL-DE (2.5L V6 DOHC)
Engine Description 1:
Naturally aspirated, 24-valve, DOHC V6 engine.
Engine Displacement 1:
2490 cc (2.5 Liters)
Bore X Stroke 1:
84.5 mm x 74.2 mm
Compression Ratio 1:
9.0:1
Horsepower 1:
170 hp @ 6000 rpm (approximate)
Torque 1:
155 lb-ft @ 5000 rpm (approximate)
Engine Code 2:
KL-ZE (3.0L Miller Cycle V6 DOHC)
Engine Description 2:
Supercharged, 24-valve, DOHC V6 engine utilizing the Miller Cycle for enhanced efficiency and torque.
Engine Displacement 2:
2954 cc (3.0 Liters)
Bore X Stroke 2:
86.7 mm x 83.0 mm
Compression Ratio 2:
8.3:1 (lower due to supercharging)
Horsepower 2:
210 hp @ 5300 rpm (approximate)
Torque 2:
217 lb-ft @ 3500 rpm (approximate)
Fuel Delivery:
Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI).
Recommended Fuel:
Premium Unleaded Gasoline (91 Octane or higher recommended, especially for Miller Cycle engine).
Standard Transmission:
4-speed automatic transmission (FWD)
Optional Transmission:
Available with a 5-speed automatic transmission (e.g., Mazda 5R55E) on certain models/trims.
Transmission Features:
Electronically controlled, adaptive shift logic, Sport mode, manual shift capability on some models.
Transmission Fluid Spec:
Mercon V or equivalent (check specific year/model)
Length:
Approx. 192.7 inches (4895 mm)
Width:
Approx. 71.3 inches (1811 mm)
Height:
Approx. 55.7 inches (1415 mm)
Wheelbase:
Approx. 107.1 inches (2720 mm)
Front Track:
Approx. 60.8 inches (1545 mm)
Rear Track:
Approx. 60.6 inches (1540 mm)
Curb Weight:
Approx. 3500-3700 lbs (1588-1678 kg) depending on configuration
Gross Vehicle Weight Rating:
Varies by model and equipment, typically around 4500-4700 lbs
NHTSA Front Crash Test:
Refer to specific year NHTSA data; generally good for its era.
IIHS Crash Test:
Refer to specific year IIHS data; often rated 'Good' in frontal offset tests for its time.
Anti Lock Brakes:
Standard on most models, providing enhanced braking control.
Traction Control:
Available on some higher trims or later models.
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
Crumple Zones:
Designed with front and rear crumple zones for energy absorption.
Audio System:
Bose premium audio system available on higher trims, cassette player, CD player (later models).
Climate Control:
Automatic climate control with digital display on higher trims.
Cruise Control:
Standard on most models.
Keyless Entry:
Available on select trims.
Diagnostic Interface:
OBD-I (1994-1995) and OBD-II (1996 onwards) compliant for emissions and diagnostics.
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. (Refer to manual for exact specifications).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on spark plug type (copper, platinum, iridium).
Timing Belt Replacement:
If applicable (check specific engine model, some V6s used chains), typically around 60,000-90,000 miles (96,000-144,000 km).
Engine Oil Spec:
5W-30 or 10W-30 API SG/SH/SJ certified (refer to manual for exact viscosity and specification).
Engine Oil Capacity:
Approx. 4.5 US Quarts (4.3 Liters) with filter change.
Coolant Spec:
Mazda Long Life Coolant (Blue) or equivalent, a 50/50 mixture with distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Common Problems 1:
Miller Cycle engine: Potential for supercharger belt issues, intake manifold runner issues, and some specific sensor failures. Regular maintenance is key.
Common Problems 2:
Automatic transmission: Can be sensitive to fluid changes and heat; proper maintenance is crucial for longevity.
Common Problems 3:
Electrical gremlins: Typical for vehicles of this era; check wiring harnesses, grounds, and connectors for corrosion or damage.
Common Problems 4:
HVAC system: Blend door actuators and blower motor issues can occur.
Mazda Philosophy:
Mazda's long history of building engaging and reliable vehicles, often incorporating innovative technologies.
First Generation 1994-1997:
Launched as Mazda's premium sedan, featuring sleek styling and a focus on comfort and performance. Offered with the 2.5L V6.
Second Generation 1998-2002:
Significant redesign with updated styling, improved interior, and the introduction of the innovative 3.0L Miller Cycle supercharged V6 on higher trims (Millenia S). Refined suspension and NVH (Noise, Vibration, Harshness) reduction.
Assembly Location:
Hofheimer Werk, Germany (for the first generation), later models primarily assembled in Japan.
Production Period:
1994-2002
Car And Driver 10Best:
While the Millenia itself didn't make the 10 Best list, Mazda often received recognition for its overall engineering and value in this period.
Consumer Reports:
Consumer Reports ratings varied by year and specific model; the Miller Cycle engine was noted for its innovation but also potential complexity.
Safety Certifications:
Compliant with Federal Motor Vehicle Safety Standards (FMVSS).
