🏷️ Basic Information

Make:

Mazda

Model:

6

Year:

2002

Chassis Code:

GG

Engine Code Primary:

FS-DE (2.0L)

Engine Code Optional:

ZY-VE (2.3L)

Transmission Code Primary:

GF4A-EL (4-speed automatic)

Transmission Code Optional:

GZ5 (5-speed manual)

👋 Introduction

Segment:

Mid-size Sedan / Sport Sedan

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance.

Key Competitors 2002:

Toyota Camry, Honda Accord, Nissan Altima, Ford Mondeo, Volkswagen Passat.

Vehicle Highlights:

Sporty handling, stylish design, reliable powertrains, spacious interior for its class.

Manual Value Proposition:

Provides in-depth technical knowledge and procedural guidance for maintaining and repairing the Mazda 6 of this era, empowering owners and technicians alike.

📋 Manual Details

Covered Regions:

Global (primarily North America and Europe)

Estimated Page Count:

1500+

Manual Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing belt/chain, valves, lubrication system, cooling system.

Engine Performance:

Fuel system (injectors, pump, lines), ignition system, exhaust system, emission control systems (catalytic converter, O2 sensors).

Transmission Mechanical:

Manual transmission overhaul, automatic transmission overhaul (including valve body, clutch packs, torque converter), clutch system (for manual).

Transmission Electronic:

Transmission control module (TCM) diagnostics and operation, shift solenoid testing.

Brakes:

Hydraulic system, ABS system (including sensors, control module, hydraulic unit), brake pad replacement, rotor replacement, caliper service, brake fluid bleeding.

Steering:

Power steering system (pump, rack, lines), steering column, wheel alignment specifications.

Suspension:

Front and rear suspension components (struts, shocks, control arms, bushings), wheel bearings, sway bars.

Electrical System:

Battery, charging system (alternator, starter), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM) basics.

HVAC:

Air conditioning system (compressor, refrigerant, condenser, evaporator), heating system, climate control module, cabin air filter replacement.

Body And Interior:

Body panel removal and installation, door mechanisms, seat removal, trim panel replacement, glass replacement.

Diagnostics:

On-Board Diagnostics (OBD-II) procedures, diagnostic trouble codes (DTCs) with descriptions and troubleshooting steps.

Preventative Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotations, spark plug replacement, belt inspection/replacement.

Troubleshooting:

Diagnostic flowcharts for common drivability issues, electrical problems, and system failures.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all systems.

Special Tools:

Identification and usage of specialized tools required for specific repair procedures.

Torque Specifications:

Detailed torque values for all fasteners throughout the vehicle.

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics).

📊 Manual Specifications

Format Details:

Searchable PDF with high-resolution diagrams and text.

Printability:

Printable pages for easy workshop use.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Displacement Primary:

2.0 Liters (1991 cc)

Engine Type Primary:

Inline-4 Cylinder, DOHC, 16-valve

Engine Code Primary Details:

FS-DE (Naturally Aspirated)

Horsepower Primary:

134 hp @ 6000 rpm (US spec)

Torque Primary:

135 lb-ft @ 4000 rpm (US spec)

Engine Displacement Optional:

2.3 Liters (2261 cc)

Engine Type Optional:

Inline-4 Cylinder, DOHC, 16-valve

Engine Code Optional Details:

ZY-VE (Naturally Aspirated)

Horsepower Optional:

160 hp @ 6000 rpm (US spec)

Torque Optional:

155 lb-ft @ 4000 rpm (US spec)

Fuel Type:

Unleaded Gasoline

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Octane Rating:

87 Octane (Recommended for 2.0L), 87 Octane (Recommended for 2.3L)

🔧 Transmission

Standard Transmission:

5-speed Manual (GZ5)

Optional Transmission:

4-speed Automatic (GF4A-EL)

Automatic Transmission Features:

Electronically controlled, lock-up torque converter.

Manual Transmission Clutch:

Hydraulically actuated, single dry plate clutch.

Automatic Transmission Fluid Type:

Mazda ATF-MV or equivalent (e.g., Dexron III compatible)

Manual Transmission Fluid Type:

API GL-4, SAE 75W-90 Gear Oil

📐 Dimensions

Length:

186.8 inches (4745 mm)

Width:

70.1 inches (1780 mm)

Height:

57.1 inches (1450 mm)

Wheelbase:

105.3 inches (2675 mm)

Front Track:

60.6 inches (1540 mm)

Rear Track:

60.0 inches (1525 mm)

Front Headroom:

38.5 inches (978 mm)

Rear Headroom:

37.0 inches (940 mm)

Front Legroom:

42.3 inches (1074 mm)

Rear Legroom:

35.3 inches (897 mm)

Trunk Volume:

14.7 cu ft (416 L)

Curb Weight Base Model:

3148 lbs (1428 kg)

Gross Vehicle Weight Rating:

4410 lbs (2000 kg) (approximate)

🛡️ Safety Features

NHTSA Front Impact Driver 2002:

5-Star

NHTSA Front Impact Passenger 2002:

5-Star

IIHS Frontal Offset Score:

Good (for original models tested)

ABS:

Standard on all models

Traction Control:

Optional on some trims

Airbags Front:

Driver and Passenger Frontal Airbags (Standard)

Airbags Side:

Optional Front Side-Impact Airbags

Seatbelts:

3-point front and rear seatbelts with pretensioners and load limiters.

💡 Technology Features

Audio System:

AM/FM stereo with CD player, optional premium audio with subwoofer and amplifier. Up to 6 speakers.

Climate Control:

Manual or automatic climate control depending on trim level.

Cruise Control:

Standard on most trims.

Keyless Entry:

Available on most trims.

Usb Aux Input:

Not standard, aftermarket solutions common.

🔧 Maintenance

Engine Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first.

Oil Filter Replacement Interval:

Replace with every oil change.

Engine Air Filter Replacement Interval:

Every 15,000 miles (24,000 km) or 12 months.

Cabin Air Filter Replacement Interval:

Every 15,000 miles (24,000 km) or 12 months (if equipped).

Coolant Replacement Interval:

Initial flush at 105,000 miles (168,000 km), then every 52,500 miles (84,000 km).

Brake Fluid Replacement Interval:

Every 2 years or 45,000 miles (72,000 km).

Engine Oil Viscosity:

5W-30

Engine Oil Capacity:

4.2 US quarts (4.0 L) with filter for 2.0L; 4.8 US quarts (4.5 L) with filter for 2.3L.

Coolant Type:

Mazda Super Long Life Coolant (Blue) or equivalent HOAT

Power Steering Fluid Type:

Mazda Genuine Power Steering Fluid or Dexron II/III

Common Issues Engine:

Premature oil consumption in some 2.3L engines (ZY-VE), timing belt tensioner noise (2.0L FS-DE), coil-on-plug failure.

Common Issues Transmission:

Automatic transmission hesitation or harsh shifting (GF4A-EL), clutch wear (manual).

Common Issues Suspension:

Worn control arm bushings, premature front strut failure, wheel bearing noise.

Common Issues Electrical:

Power window motor failure, HVAC blower motor resistor failure, dashboard warning light illumination (e.g., ABS, SRS).

Common Issues Body:

Rust formation on rocker panels and rear wheel arches, interior trim rattles.

📚 Vehicle History

Mazda Heritage:

Founded in 1920, Mazda has a long history of innovation and producing distinctive vehicles, known for their focus on driving dynamics ('Jinba Ittai' - horse and rider as one).

Mazda6 Generation 1:

The 2002 Mazda 6 marked the debut of the first generation (GG platform), replacing the Mazda Capella/626. It was designed with a focus on European styling and performance, winning praise for its handling and design.

Production Location:

Hofu, Japan; Flat Rock, Michigan, USA (for North American market)

Production Years Gen1:

2002-2008

🏆 Awards & Recognition

Car And Driver 10Best:

Mazda 6 was named to Car and Driver's 10Best list for 2003.

Design Awards:

Praised for its 'sporty' and 'European' styling.