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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Type: Car

Vendor:

Sku: 297749

Tags: 2002 2003 2004 2005 2006 2007 6 Car Cars Mazda Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

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

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:

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)