MAZDA 6 Sport Sedan 5 Door Sport Wagon 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Mazda Model: Mazda6 Year: 2004 Body Styles: • Sedan • Sport Wagon Codes Platform Code: GG/GY 👋 Introduction Market Position Market Segment: Mid-size Sedan/Wagon Competitive...

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Type: Car

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Sku: 83876

Tags: 2004 6 Sport Sedan 6 Sport Wagon Car Cars Mazda Misc

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Mazda6

Year:

Body Styles:

• Sedan

• Sport Wagon

Codes

Platform Code:

GG/GY

👋 Introduction

Market Position

Market Segment:

Mid-size Sedan/Wagon

Competitive Analysis

Key Competitors 2004:

• Toyota Camry

• Honda Accord

• Nissan Altima

• Ford Fusion

• Volkswagen Passat

Key Features

Vehicle Strengths 2004 Mazda6:

• Engaging Handling (Zoom-Zoom)

• Stylish Design

• Spacious Interior (especially wagon)

• Reliable Powertrains

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete Service and Repair

Page Count

Estimated Page Count:

Approximately 3000+ pages

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

• Engine Mechanical

• Engine Control System (ECU)

• Fuel System

• Ignition System

• Cooling System

• Exhaust System

• Lubrication System

Transmission Systems:

• Automatic Transmission (FS5A-EL)

• Manual Transmission (G25M-R)

Drivetrain Systems:

• Front Wheel Drive (FWD)

• All Wheel Drive (AWD) - if applicable

• Axles and Driveshafts

• Differential

Suspension And Steering:

• Front Suspension

• Rear Suspension

• Steering System

• Power Steering System

Braking Systems:

• Brake System (Front and Rear)

• Anti-lock Braking System (ABS)

• Electronic Brake-force Distribution (EBD)

• Brake Components Diagnosis and Repair

Electrical Systems:

• Battery

• Charging System

• Starting System

• Lighting System

• Ignition System

• Instrument Cluster

• Power Accessories

• Body Control Module (BCM)

• Wiring Diagrams

• Fuses and Relays

HVAC Systems:

• Heating System

• Ventilation System

• Air Conditioning (A/C) System

• Climate Control System

Body And Interior:

• Body Panels

• Doors

• Windows

• Seats

• Interior Trim

• Bumpers

• Hood

• Trunk/Liftgate

Safety Systems:

• Airbag System (SRS)

• Seat Belts

• Passive Safety Components

Procedures Included

Maintenance Procedures:

• Oil Change

• Filter Replacement (Oil, Air, Cabin)

• Fluid Checks and Replenishments

• Spark Plug Replacement

• Brake Pad and Rotor Replacement

• Tire Rotation and Balancing

• Belts and Hoses Inspection/Replacement

Repair Procedures:

• Engine Component Overhaul

• Transmission Overhaul and Repair

• Suspension Component Replacement

• Brake System Component Repair

• Electrical Component Diagnosis and Replacement

• Body Panel Repair and Replacement

• HVAC System Repair

Diagnostics And Troubleshooting:

• Diagnostic Trouble Codes (DTCs)

• Symptom-Based Troubleshooting Guides

• Wiring Diagram Interpretation

• Component Testing Procedures

Technical Specifications And Data:

• Torque Specifications

• Component Clearances

• Electrical Resistance Values

• Fluid Capacities

• Engine and Transmission Specifications

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and bodywork.

📊 Manual Specifications

File Format

File Format Details:

Searchable PDF, allowing quick access to information. High resolution for clear diagrams and text.

Print Quality

Print Quality Suitability:

Suitable for professional printing. Includes all original diagrams, illustrations, and schematics.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code And Type:

LF-VE 2.3L DOHC 16-valve Inline-4 (MZR)

Engine Displacement:

2261 cc (2.3 Liters)

Bore X Stroke:

87.5 mm x 94.0 mm

Compression Ratio:

9.7:1

Performance

Horsepower Peak:

160 hp @ 6,500 rpm

Torque Peak:

155 lb-ft @ 4,000 rpm

Fuel System

Fuel Delivery:

Electronic Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline, 87 Octane Recommended

Engine Components

Timing System:

Timing Chain

Cylinder Head Design:

Aluminum Alloy DOHC

Block Material:

Aluminum Alloy

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission (G25M-R)

Optional

Optional Transmission:

5-speed Automatic Transmission (FS5A-EL)

Features

Automatic Transmission Features:

Sequential Sport Shift (manual mode)

Fluid Specifications

Automatic Transmission Fluid:

Mazda ATF-FZ (or equivalent Dexron III/Mercon)

Manual Transmission Fluid:

GL-4 SAE 75W-90 Gear Oil

📐 Dimensions

Exterior

Sedan Length:

186.8 inches

Sedan Width:

70.1 inches

Sedan Height:

57.1 inches

Wagon Length:

187.6 inches

Wagon Width:

70.1 inches

Wagon Height:

58.5 inches

Wheelbase:

105.3 inches

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Wheel Size:

16-inch, 17-inch (optional)

Interior

Passenger Volume:

Approximately 97.0 cu ft (Sedan), 100.3 cu ft (Wagon)

Cargo

Trunk Volume Sedan:

14.2 cu ft

Cargo Volume Wagon Seats Up:

26.1 cu ft

Cargo Volume Wagon Seats Down:

59.4 cu ft

Weights

Curb Weight Sedan Manual:

3,241 lbs

Curb Weight Sedan Auto:

3,285 lbs

Curb Weight Wagon Manual:

3,351 lbs

Curb Weight Wagon Auto:

3,395 lbs

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5 Stars

NHTSA Front Impact Passenger:

5 Stars

NHTSA Side Impact Front Seat:

5 Stars

NHTSA Side Impact Rear Seat:

4 Stars

IIHS Front Offset Crash Test:

IIHS Side Impact Crash Test:

Active Features

Active Safety Features:

• Anti-lock Braking System (ABS)

• Electronic Brake-force Distribution (EBD)

• Traction Control System (TCS)

• Dynamic Stability Control (DSC) - often standard or optional

Passive Features

Passive Safety Features:

• Front Airbags

• Side Airbags

• Side Curtain Airbags (optional on some trims)

• Pretensioner seat belts

• Crumple zones

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player with 4-6 speakers. Bose premium audio optional on higher trims.

Climate Control:

Manual climate control standard, automatic climate control optional on select trims.

Driver Assistance

Driver Assistance Features:

• Cruise Control

• Tire Pressure Monitoring System (TPMS) - typically optional

Connectivity

Connectivity Options:

Auxiliary input for audio (often added aftermarket or on later models). No standard Bluetooth or USB in this era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 miles or 6 months, whichever comes first (under normal driving conditions).

Air Filter Replacement:

Every 30,000 miles or 2 years.

Cabin Air Filter Replacement:

Every 15,000 miles or 1 year.

Spark Plug Replacement:

Every 100,000 miles (platinum or iridium plugs).

Transmission Fluid Change Auto:

Every 60,000 miles (under normal driving conditions).

Brake Fluid Flush:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-20 (API SM or ILSAC GF-4 or higher)

Engine Oil Capacity:

4.8 US quarts (with filter)

Coolant Type:

Mazda Super Long Life Coolant (Blue) - or equivalent OAT type

Power Steering Fluid:

Mazda Genuine Power Steering Fluid (or Dexron III/Mercon ATF)

Known Issues

Common Wear Items:

• Front control arm bushings

• Sway bar links

• Brake components (pads, rotors)

• Oxygen sensors

• Mass Air Flow (MAF) sensor

Potential Engine Issues:

• Carbon buildup on intake valves (direct injection engines, though this model is port injection)

• Oil consumption in higher mileage engines

• PCV valve issues can lead to oil sludge

Potential Transmission Issues:

• Occasional rough shifting in automatic transmissions

• Transmission fluid leaks

📚 Vehicle History

Brand Heritage

Mazda Brand Philosophy:

Focus on driving dynamics, sportiness, and innovative design, often encapsulated in the 'Zoom-Zoom' marketing.

Model Evolution

Mazda6 First Generation Launch:

Introduced as a replacement for the Mazda Capella/626.

Gg Gy Platform Significance:

Marked a significant shift for Mazda's mid-size offerings, emphasizing European-style driving dynamics and upscale interior appointments.

Production

Production Locations:

• Hofu, Yamaguchi, Japan

• Flat Rock, Michigan, USA (for North American market)

🏆 Awards & Recognition

Recognitions

Car And Driver Year:

Car and Driver's 10Best List (2004)

Motor Trend Award:

MotorTrend's Car of the Year contender (2004)