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Mazda 6 2002 Workshop Service Repair Manual Download PDF
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Basic Information Identification Make: Mazda Model: 6 Year: 2002 Codes Chassis Code: GG/GY Introduction Market Position Segment: Mid-size sedan, Sporty sedan. Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima,...
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| Basic Information | |
| Identification | |
| Make: | Mazda |
| Model: | 6 |
| Year: | 2002 |
| Codes | |
| Chassis Code: | GG/GY |
| Introduction | |
| Market Position | |
| Segment: | Mid-size sedan, Sporty sedan. |
| Competitive Analysis | |
| Competitors: | Toyota Camry, Honda Accord, Nissan Altima, Ford Mondeo, Volkswagen Passat. |
| Key Features | |
| Styling: | Sleek, aerodynamic, sporty design. Known for its distinctive 'flow' design language. |
| Driving Dynamics: | Renowned for excellent handling and a engaging driving experience, often praised for its Mazda 'Zoom-Zoom' philosophy. |
| Target Audience | |
| Audience: | Professionals, families, driving enthusiasts. |
| Manual Details | |
| Coverage Areas | |
| General Coverage: | Complete workshop service and repair information for the 2002 Mazda 6. |
| Page Count | |
| Estimated Pages: | 1500+ |
| Manual Type | |
| Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF (Downloadable) |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system. |
| Engine Performance: | Fuel injection system (MPI), ignition system, emissions control, turbocharger (if applicable). |
| Transmission Manual: | Clutch, gearbox assembly, internal components, linkages. |
| Transmission Automatic: | ATX transmission assembly, torque converter, valve body, hydraulic circuits, electronic controls. |
| Drivetrain: | Front-wheel drive, axles, CV joints, differentials. |
| Suspension: | Front suspension (MacPherson struts), rear suspension (multi-link), shock absorbers, springs, control arms, wheel alignment. |
| Steering: | Power steering system, steering rack, column, universal joints. |
| Brakes: | Front disc brakes, rear disc brakes, ABS system, hydraulic lines, calipers, rotors, brake master cylinder. |
| Electrical System: | Battery, charging system, starter motor, ignition system, lighting, horn, power windows, central locking. |
| Body And Interior: | Body panel removal and installation, doors, hood, trunk, bumpers, seats, dashboard, trim panels. |
| HVAC: | Heating, ventilation, and air conditioning system, refrigerant, compressor, evaporator, condenser. |
| Body Electrical: | Wipers, washers, mirrors, interior lighting, instrument cluster, audio system, airbags. |
| Procedures Included | |
| Maintenance: | Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement. |
| Diagnostics: | Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting. |
| Repair: | Step-by-step repair instructions for all major components and systems. |
| Overhaul: | Detailed instructions for engine and transmission overhauls/rebuilds. |
| Specifications: | Torque specifications, clearances, measurements, diagnostic parameters. |
| Wiring Diagrams: | Comprehensive electrical wiring diagrams for all systems. |
| Technical Depth | |
| Depth: | Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. |
| Manual Specifications | |
| File Format | |
| PDF Quality: | High-resolution, searchable text, printable pages. |
| Print Quality | |
| Printability: | Printable via standard PDF viewers. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Code 1: | LF-DE (2.0L DOHC I4) |
| Displacement 1: | 1991 cc |
| Horsepower 1: | 120-130 hp (approx.) |
| Torque 1: | 175-180 Nm (approx.) |
| Optional Engine | |
| Engine Code 2: | FS-ZE (2.3L DOHC I4) |
| Displacement 2: | 2261 cc |
| Horsepower 2: | 160-170 hp (approx.) |
| Torque 2: | 205-215 Nm (approx.) |
| Performance | |
| Induction: | Naturally Aspirated |
| Fuel System | |
| Type: | Electronic Multi-Point Fuel Injection (MPI) |
| Engine Management | |
| ECU: | Mazda ECU with diagnostic capabilities. |
| Transmission | |
| Standard | |
| Manual: | 5-speed manual transmission. |
| Optional | |
| Automatic: | 4-speed automatic transmission (ATX). |
| Features | |
| Automatic Features: | Selectable 'Sport' mode on some variants. |
| Clutch | |
| Type: | Dry single plate (manual transmission). |
| Fluid Specifications | |
| Manual Transmission Fluid: | API GL-4, SAE 75W-90 (check manual for specific Mazda fluid part numbers). |
| Automatic Transmission Fluid: | Mazda ATF J, Mercon V compatible (check manual for specific Mazda fluid part numbers). |
| Dimensions | |
| Exterior | |
| Length: | Approx. 4.75 m (187 in) |
| Width: | Approx. 1.79 m (70.5 in) |
| Height: | Approx. 1.44 m (56.7 in) |
| Wheelbase | |
| Wheelbase: | Approx. 2.67 m (105.1 in) |
| Weights | |
| Curb Weight: | Approx. 1350-1450 kg (2976-3197 lbs), varies by model and transmission. |
| Safety Features | |
| Ratings | |
| NHTSA Front Impact: | Likely 4-star or 5-star (specific ratings may vary by testing region and year update). |
| IIHS Front Impact: | Likely 'Good' (specific ratings may vary by testing region and year update). |
| Active Features | |
| ABS: | Standard on most models. |
| Traction Control: | Available on some higher trims. |
| Passive Features | |
| Airbags: | Front driver and passenger airbags standard. Side airbags and curtain airbags available on some trims. |
| Seatbelts: | 3-point seatbelts with pretensioners and load limiters. |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory fitted AM/FM/CD player. Higher trims may have premium audio systems (e.g., Bose). |
| Navigation: | Optional navigation system available on select higher trim levels. |
| Driver Assistance | |
| Cruise Control: | Standard on most trims. |
| Connectivity | |
| Aux Input: | Rarely available on this generation; aftermarket solutions are common. |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type (refer to manual for specifics). |
| Air Filter Replacement: | Every 15,000-30,000 miles or as needed. |
| Spark Plug Replacement: | Every 60,000-100,000 miles depending on plug type (e.g., iridium). |
| Timing Belt Or Chain: | This generation uses a timing chain, which generally does not require periodic replacement but should be inspected. |
| Fluid Specifications | |
| Engine Oil Type: | API SG/SH/SJ/SL, ILSAC GF-II/GF-III, SAE 5W-20 or 5W-30 (verify with manual based on climate). |
| Coolant: | Ethylene glycol-based coolant, Mazda FL22 long-life coolant recommended (refer to manual for specific type and capacity). |
| Brake Fluid: | DOT 3 or DOT 4 (verify with manual). |
| Known Issues | |
| Rust: | Prone to rust, especially in the rear wheel arches and rocker panels, depending on climate. |
| Engine Mounts: | Worn engine mounts can lead to increased vibration. |
| Window Regulators: | Power window regulators can fail over time. |
| Suspension Components: | Bushings and ball joints can wear, leading to clunks or poor handling. |
| Vehicle History | |
| Brand Heritage | |
| Mazda Philosophy: | Known for 'Zoom-Zoom' driving dynamics, innovative technology, and stylish design. |
| Model Evolution | |
| Generation: | First generation Mazda 6 (2002-2008). |
| Platform: | GG/GY platform. Introduced as a replacement for the Mazda Capella/626. |
| Production | |
| Manufacturing Locations: | Japan (Hofu), USA (Flat Rock, Michigan). |
| Awards & Recognition | |
| Recognitions | |
| Car Of The Year: | Voted 'Car of the Year' by several automotive publications upon its debut in some markets. |
| Ratings | |
| Consumer Reports: | Generally received good ratings for reliability and driving dynamics, though some specific model years or powertrains might have had average ratings for certain components. |