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Mazda 6 2002-2008 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Mazda Model: 6 Generation Generation Code: GG/GY Generation Years: 2002-2008 Codes Chassis Codes: GG (Sedan/Hatchback), GY (Wagon) 👋 Introduction Market Position Market Segment: Mid-size Sedan/Wagon...
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Type: Car
Vendor:
Sku: 86536
Mazda 6 2002-2008 WSM Service Manual RepairMazda 6 2002-2008 WSM Service Manual RepairMazda 6 2002-2008 WSM Service Manual RepairMazda 6 2002-2008 WSM Service Manual Repair
🏷️ Basic Information
Identification
Make:
Mazda
Model:
6
Generation
Generation Code:
GG/GY
Generation Years:
2002-2008
Codes
Chassis Codes:
GG (Sedan/Hatchback), GY (Wagon)
👋 Introduction
Market Position
Market Segment:
Mid-size Sedan/Wagon
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Ford Fusion, Nissan Altima, Volkswagen Passat
Key Features
Platform Highlight:
Based on Mazda's 'GJ' platform (shared with Ford Mondeo in early development), known for good handling dynamics and sporty feel.
Design Philosophy:
Emphasized 'Zoom-Zoom' driving experience, stylish design, and a premium feel for its class.
📋 Manual Details
Coverage Areas
Covered Regions:
Global (North America, Europe, Asia specifications likely included)
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Workshop Service Manual (WSM)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System, Automatic Transmission, Manual Transmission
Chassis:
Front Suspension, Rear Suspension, Steering System, Brake System (ABS, DSC), Wheel Alignment
Electrical:
Body Electrical System, Lighting System, Meter and Gauges, Audio System, Navigation System, HVAC Control, Power Windows, Power Locks, SRS (Airbag) System, Immobilizer System
Body And Trim:
Exterior Body Panels, Interior Trim, Doors, Hood, Trunk/Tailgate, Seats, Glass
Procedures Included
Maintenance:
Scheduled Maintenance Intervals, Fluid Changes (Oil, Coolant, Brake Fluid, Transmission Fluid), Filter Replacements (Oil, Air, Fuel, Cabin), Spark Plug Replacement, Belt Inspection and Replacement
Diagnostics:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Component Testing Procedures, PCM/ECU Diagnosis
Repair And Rebuild:
Engine Overhaul, Transmission Overhaul, Brake Component Replacement (Pads, Rotors, Calipers), Suspension Component Replacement (Struts, Bushings, Ball Joints), Steering Gearbox/Rack Replacement, Electrical Component Repair/Replacement
Body And Frame:
Body Panel Repair, Dent Removal, Frame Alignment (if applicable), Glass Replacement, Door Mechanism Adjustment
Technical Depth
Depth Of Coverage:
Comprehensive: Covers basic maintenance, detailed diagnostics, complete repair and overhaul procedures for all major vehicle systems.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, searchable text, clear diagrams and schematics.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Usdm:
L3-VE (2.3L DOHC I4)
Engine Displacement Usdm:
2261 cc (2.3 Liters)
Engine Configuration Usdm:
Inline 4-cylinder, 16-valve, DOHC with S-VT (Variable Valve Timing)
Performance Usdm
Horsepower Usdm:
160 hp @ 6000 rpm (approx.)
Torque Usdm:
155 lb-ft @ 4000 rpm (approx.)
Optional Engine Emea
Engine Code Emea Petrol:
LF-DE (2.0L DOHC I4), LF-VE (2.3L DOHC I4)
Engine Displacement Emea Petrol:
1991 cc (2.0 Liters), 2261 cc (2.3 Liters)
Horsepower Emea Petrol:
120-166 hp (depending on variant)
Engine Code Emea Diesel:
MZR-CD (RF7J) (2.0L DOHC Turbo Diesel I4)
Engine Displacement Emea Diesel:
1998 cc (2.0 Liters)
Horsepower Emea Diesel:
136 hp @ 3500 rpm (approx.)
Torque Emea Diesel:
273 lb-ft @ 2000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI/GDI depending on market and engine variant)
Fuel Type:
Unleaded Gasoline (Regular/Premium), Diesel (for diesel variants)
🔧 Transmission
Standard Usdm
Transmission Type Usdm:
5-Speed Manual (FS5A-EL)
Optional Usdm
Transmission Type Usdm:
5-Speed Automatic (FN4A-EL with Activematic Shifting)
Optional Emea
Transmission Type Emea:
6-Speed Manual, 5-Speed Automatic
Features
Activematic:
Manual shift mode on automatic transmissions allowing driver control.
📐 Dimensions
Exterior Sedan
Length Sedan:
4795 mm (188.8 in)
Width Sedan:
1795 mm (70.7 in)
Height Sedan:
1440 mm (56.7 in)
Exterior Wagon
Length Wagon:
4775 mm (188.0 in)
Width Wagon:
1795 mm (70.7 in)
Height Wagon:
1490 mm (58.7 in)
Interior
Wheelbase:
2725 mm (107.3 in)
Cargo
Trunk Volume Sedan:
Approx. 15.1 cu ft
Cargo Volume Wagon:
Approx. 21.2 cu ft (seats up), 56.7 cu ft (seats down)
Weights
Curb Weight Min:
Approx. 3190 lbs (1447 kg)
Curb Weight Max:
Approx. 3500 lbs (1588 kg)
🛡️ Safety Features
Ratings Us Nhtsa
Frontal Driver NHTSA:
★★★★★ (5-star)
Frontal Passenger NHTSA:
★★★★★ (5-star)
Side Driver NHTSA:
★★★★☆ (4-star)
Side Rear Passenger NHTSA:
★★★★☆ (4-star)
Ratings Us Iihs
Front Crash IIHS:
Good
Side Crash IIHS:
Good (for models equipped with side airbags)
Rear Crash IIHS:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available Traction Control System (TCS)
Stability Control:
Available Dynamic Stability Control (DSC)
Passive Features
Airbags:
Front Airbags, Available Side-Curtain Airbags, Available Side Impact Airbags
Seatbelts:
3-point ELR seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, MP3 capability, available premium Bose sound system with subwoofer and amplifier.
Navigation:
Optional factory-installed navigation system (typically DVD-based).
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Input:
Available auxiliary audio input jack on some models.
🔧 Maintenance
Service Intervals Usdm 2.3L
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first. Use synthetic oil.
Air Filter Replacement:
Every 15,000 miles or 12 months. Inspect every 5,000 miles.
Spark Plug Replacement:
Every 100,000 miles (Long-life Iridium plugs).
Transmission Fluid Change:
Every 30,000 miles for automatic transmission under severe service; 60,000 miles for normal service. Inspect fluid condition regularly.
Fluid Specifications
Engine Oil:
SAE 5W-20, API SN or ILSAC GF-5 certified (check owner's manual for specific recommendation). Capacity: Approx. 4.9 US quarts (with filter).
Coolant:
Mazda Genuine Long Life Antifreeze (FL22) or equivalent (Blue/Green, ethylene glycol based). Capacity: Approx. 7.8 US quarts (sedan).
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Auto:
Mazda Genuine ATF-FZ or equivalent. Capacity: Approx. 3.8 US quarts (drain and fill).
Transmission Fluid Manual:
API GL-4 SAE 75W-90 Gear Oil. Capacity: Approx. 2.2 US quarts.
Known Issues
Common Problems:
Rust/corrosion (especially in areas with road salt), oil leaks from valve cover gasket or oil pan, occasional transmission issues (e.g., harsh shifting in automatics), suspension component wear (bushings, ball joints), HVAC blower motor resistor failure.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda's reputation for building reliable and enjoyable-to-drive vehicles, often with a focus on sporty handling.
Model Evolution
First Generation Launch:
Introduced for the 2002 model year, replacing the Mazda Capella/626.
Facelift Timing:
Received a significant facelift for the 2005 model year, with updated styling, interior refinements, and powertrain enhancements.
Production
Production Locations:
Hofu Plant, Yamaguchi Prefecture, Japan; Flat Rock, Michigan, USA (for North American market initially)
Production Years:
2002-2008
🏆 Awards & Recognition
Recognitions
Car Of The Year:
Car of the Year awards in various publications in different markets.
Ratings
IIHS Top Safety Pick:
Many models received 'Good' ratings from IIHS for crashworthiness, contributing to a strong safety image.
Certifications
Desempeño Manejo:
Consistently praised by automotive journalists for its engaging handling and driving dynamics, setting it apart in its class.
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