Mazda 6 2006 Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: Mazda 6 Year: 2006 Generation Model Generation: First Generation (GG/GY) Codes Chassis Code: GG (Sedan/Hatchback), GY (Wagon) 👋 Introduction Market Position Vehicle Segment:...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Mazda 6

Year:

Generation

Model Generation:

First Generation (GG/GY)

Codes

Chassis Code:

GG (Sedan/Hatchback), GY (Wagon)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size sedan/wagon

Manufacturer Philosophy:

Mazda's 'Zoom-Zoom' philosophy emphasizing driving dynamics and sporty handling

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu

Key Features

Design Philosophy:

Stylish 'Nagare' design language (early interpretation), sporty driving dynamics, refined interior

Performance Orientation:

Often praised for its chassis tuning and engaging handling compared to segment rivals

📋 Manual Details

Coverage Areas

Manual Scope:

Comprehensive Service and Repair

Page Count

Estimated Page Count:

1500-2500 (typical for comprehensive factory service manuals)

Manual Type

Manual Classification:

Factory Service Manual (FSM) / Workshop Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, exhaust, engine management (ECU), turbocharging (if applicable)

Transmission:

Automatic Transmission (AT) and Manual Transmission (MT) - overhaul, diagnosis, removal/installation, fluid specifications, shift control systems

Drivetrain:

Front Wheel Drive (FWD) system, driveshafts, CV joints, differentials

Suspension:

Front suspension (MacPherson strut), rear suspension (multi-link), shock absorbers, springs, control arms, alignment procedures

Steering:

Power steering system (hydraulic), steering rack, steering column, linkage, diagnosis and repair

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake fluid specifications, pad/rotor replacement, caliper overhaul, bleeding procedures

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), wiring diagrams, fuses, relays, circuit protection

Body And Frame:

Body construction, chassis, doors, hood, trunk, glass, interior trim, exterior trim, corrosion prevention

HVAC System:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, controls

Safety Systems:

Airbag system (SRS - Supplemental Restraint System), seatbelts, SRS diagnosis and repair (cautionary notes for handling)

Diagnostics:

OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), scan tool usage, troubleshooting procedures, sensor testing

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection/replacement

Component Removal And Installation:

Detailed steps for removing and reinstalling all major and minor components

Component Overhaul And Rebuild:

Instructions for disassembling, inspecting, cleaning, and reassembling major components like engines and transmissions

Troubleshooting Guides:

Systematic diagnostic procedures for identifying and resolving common and uncommon problems

Electrical Troubleshooting:

Detailed wiring diagrams, circuit testing, and fault tracing for all electrical systems

Torque Specifications:

Precise torque values for all critical fasteners

Special Tools:

Identification and usage of specialized tools required for specific repairs

Technical Service Bulletins (Tsbs):

Likely includes references or summaries of manufacturer-issued TSBs for common issues and fixes

Technical Depth

Diagnostic Capability:

Advanced diagnostics, including sensor data interpretation and circuit analysis

Repair Complexity:

Covers everything from basic maintenance to complex engine and transmission overhauls, body repairs, and electrical system diagnostics

Target Audience:

Primarily professional technicians, but with sufficient detail for experienced DIY enthusiasts

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, text-searchable PDF with clear diagrams and images

Printability:

Printable pages for workshop use

Binding Type

Digital Format Description:

Downloadable PDF document

Paper Type

Digital Content Description:

Digital reproduction of original factory service manual content

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

L3-VE

Engine Type:

Naturally Aspirated Inline-4

Displacement:

2.3 Liters (2261 cc)

Bore X Stroke:

87.5 mm x 94.0 mm

Compression Ratio:

9.7:1

Valve Train:

DOHC (Dual Overhead Camshafts), 16 valves, VVT-i (Variable Valve Timing - Intake)

Performance

Horsepower Peak:

160 hp @ 6000 rpm (approx.)

Torque Peak:

155 lb-ft @ 4000 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher for optimal performance)

Fluid Specifications

Engine Oil Type:

SAE 5W-20 (API SN or higher)

Engine Oil Capacity:

4.7 US Quarts (4.4 Liters) with filter change

Engine Management

ECU Type:

Bosch Motronic or similar ECU (specific part number varies)

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual Transmission

Optional

Transmission Type Opt:

5-speed Sport Automatic Transmission (Activematic)

Features

Automatic Transmission Features:

Sequential shift mode (Steptronic-like capability)

Fluid Specifications

Automatic Transmission Fluid Type:

Mazda Genuine ATF JWS3309 / Type T-IV compatible

Manual Transmission Fluid Type:

API GL-4, SAE 75W-90 (specific Mazda part number recommended)

📐 Dimensions

Exterior

Length:

186.2 inches (4729 mm) for Sedan

Width:

70.1 inches (1781 mm)

Height:

57.7 inches (1465 mm) for Sedan

Wheelbase:

105.3 inches (2675 mm)

Interior

Passenger Volume:

Approx. 99.3 cubic feet

Cargo

Trunk Capacity:

Approx. 14.2 cubic feet for Sedan

Weights

Curb Weight Min:

Approx. 3230 lbs (1465 kg) for manual transmission sedan

Gross Vehicle Weight Rating:

Approx. 4365 lbs (1980 kg)

Wheels Tires

Standard Wheel Size:

16-inch alloy wheels

Optional Wheel Size:

17-inch alloy wheels

Standard Tire Size:

205/55R16

Optional Tire Size:

215/50R17

Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Center Bore:

67.1 mm

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

5-Star (Driver and Passenger)

NHTSA Side Impact Crash Test:

5-Star (Front and Rear Passenger)

IIHS Moderate Overlap Front:

IIHS Side Impact:

Active Features

Standard Anti-lock Braking System

Standard Electronic Brake-force Distribution

Optional Traction Control System

Optional Electronic Stability Control (VSC - Vehicle Stability Control)

Passive Features

Airbags Front:

Dual front advanced airbags

Airbags Side:

Standard front side-impact airbags

Airbags Curtain:

Optional front and rear side-curtain airbags

Seatbelts:

3-point seatbelts with pretensioners and load limiters

💡 Technology Features

Infotainment

Audio System:

Optional Bose premium audio system, CD player, AM/FM radio. Basic models have standard audio.

Climate Control:

Manual or optional automatic climate control

Driver Assistance

Cruise Control:

Standard cruise control on most trims

Keyless Entry Start:

Optional keyless entry and start system (Smart Card or Key Fob)

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack

Bluetooth:

Not widely available on early 2006 models; some later trims or aftermarket options.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (with synthetic oil).

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Spark Plug Replacement:

Iridium spark plugs: 100,000 miles (160,000 km).

Transmission Fluid Change Auto:

Recommended every 60,000 miles (96,000 km) under normal driving, more frequently under severe conditions.

Transmission Fluid Change Manual:

Recommended every 60,000 miles (96,000 km) or as needed.

Coolant Flush:

Mazda FL22 Coolant: First change at 10 years or 120,000 miles, then every 5 years or 60,000 miles.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

Mazda Genuine Power Steering Fluid (or Dexron III compatible)

Known Issues

Engine Sludge:

Early models (pre-facelift) were subject to oil sludge buildup if oil changes were neglected. Regular maintenance is critical.

Transmission Issues Auto:

Some reports of automatic transmission solenoid failures or shifting issues. Proper fluid maintenance is key.

Suspension Noise:

Worn sway bar links or bushings can cause clunking noises over bumps. Control arm bushings are also common wear items.

Electrical Gremlins:

Minor electrical issues like faulty window regulators or interior light failures can occur, often due to age and wear.

Rust Corrosion:

Check for rust on wheel arches, rocker panels, and subframes, especially in regions with heavy road salt usage.

📚 Vehicle History

Brand Heritage

Mazda History:

Mazda Motor Corporation, founded in 1920, known for innovation and unique engineering (e.g., Wankel rotary engine).

Model Evolution

Model Launch Year:

2002 (as Mazda Atenza in Japan), 2003 (as Mazda6 globally)

First Generation Period:

2003-2008

Facelift Year:

2005 (minor refresh for 2006 model year onwards, updated styling, features)

Production

Manufacturing Locations:

Japan (Hofu Plant), Thailand, Russia, China

🏆 Awards & Recognition

Recognitions

Car Of The Year Nominations:

Often cited in automotive publications as a strong contender in its segment for driving dynamics.

IIHS Top Safety Pick:

Received 'Good' ratings in crash tests, indicating strong safety performance.