Mazda 6 2002-2014 Service Manual Service Manual

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The Mazda 6, produced across its first generation (GG/GY, 2002-2014) and second generation (GH), is a mid-size sedan and wagon celebrated for its distinctive 'Zoom-Zoom' design language, sporty handling, and driver-focused experience. This model lineup offered a range of naturally aspirated and turbocharged engines, from efficient inline-fours to more powerful V6 options, paired with manual and automatic transmissions and available All-Wheel Drive on select performance variants like the Mazdaspeed 6. Known for its engaging driving dynamics and stylish aesthetics, the Mazda 6 consistently competed in its segment, earning accolades such as Car and Driver's 10Best list and achieving strong safety ratings. This comprehensive service and repair manual provides detailed information essential for the maintenance and repair of the Mazda 6, covering both the first and second generations. It encompasses a vast array of systems, including engine mechanicals, transmissions, brakes, suspension, steering, electrical systems, HVAC, and bodywork. The manual details routine maintenance procedures, component replacement, advanced diagnostics, troubleshooting guides, and complete disassembly/reassembly instructions, along with critical specifications and settings. Its purpose is to equip owners, mechanics, and technicians with the precise knowledge required to keep their Mazda 6 vehicles operating at peak performance and reliability. 🏷️ Basic Information Identification Make: Mazda Model: 6 Model Generations Covered: First Generation (GG/GY), Second Generation (GH) Year Range: 2002-2014 Codes Chassis Codes First Gen: GG (Sedan/Hatchback), GY (Wagon) Chassis Codes Second Gen: GH 👋 Introduction Market Position Segment: Mid-size sedan/wagon, known for sporty handling and stylish design Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu Key Features First Gen Design: Distinctive 'Zoom-Zoom' design language, available in sedan, hatchback, and wagon body styles Key Features Second Gen Design: Refined styling, improved aerodynamics, focus on premium interior feel Manual Value Proposition Benefit: Empowers owners and technicians with detailed procedures to maintain and repair the vehicle effectively. 📋 Manual Details Coverage Areas Primary Coverage: Complete Official Full Service Repair Manual Geographical Markets: Global (North America, Europe, Asia, etc. applicable models) Page Count Estimated Pages: Thousands (exact count not specified, typical for comprehensive manuals) Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging systems Transmission: Manual and Automatic transmissions, clutch, driveline, axles, driveshafts Brakes: Hydraulic system, ABS, EBD, brake pads, rotors, calipers, parking brake Suspension: Front and rear suspension components, shock absorbers, springs, control arms, wheel bearings Steering: Power steering system, steering column, tie rods, steering rack Electrical: Wiring diagrams, lighting system, power distribution, fuses, relays, battery, alternator, starter HVAC: Heating, ventilation, and air conditioning systems, refrigerant handling Body: Body panels, doors, glass, interior trim, bumpers, chassis frame Safety Systems: Airbag system, seatbelts, pre-tensioners Diagnostics: OBD-II diagnostics, diagnostic trouble codes (DTCs), sensor data interpretation Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation Repair: Component replacement, system diagnostics and repair, troubleshooting guides Troubleshooting: Step-by-step diagnostic procedures for common and complex issues Disassembly Reassembly: Detailed procedures for removing and reinstalling all major components Specifications Settings: Torque specifications, alignment procedures, calibration instructions Technical Depth Depth: Comprehensive from basic maintenance to major component overhauls and diagnostics Diagnostics Level: Advanced diagnostic procedures, including wiring diagrams and sensor data analysis Rebuild Procedures: Detailed instructions for engine, transmission, and major component rebuilds 📊 Manual Specifications File Format Format: PDF Searchable Text: Yes (typically, depending on PDF origin) Print Quality Quality: High-resolution digital reproduction of original factory documentation Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) Completeness Coverage: Complete factory service manual covering all aspects of vehicle repair and maintenance ⚙️ Engine Specifications Primary Engine First Gen Common Engine 1: 2.3L DOHC I4 (MZR L3-VE) First Gen Common Engine 1 Power: Approx. 160-170 hp @ 6000 rpm First Gen Common Engine 1 Torque: Approx. 150-155 lb-ft @ 4000 rpm First Gen Optional Engine 1: 3.0L DOHC V6 (Ford AJ-V6 / Mazda AJ-DE) First Gen Optional Engine 1 Power: Approx. 215-220 hp @ 6300 rpm First Gen Optional Engine 1 Torque: Approx. 200-205 lb-ft @ 5000 rpm Second Gen Common Engine 1: 2.5L DOHC I4 (MZR L5-VE) Second Gen Common Engine 1 Power: Approx. 170-175 hp @ 6000 rpm Second Gen Common Engine 1 Torque: Approx. 165-170 lb-ft @ 4000 rpm Second Gen Optional Engine 1: 3.7L DOHC V6 (Mazda-Ford Cyclone V6) Second Gen Optional Engine 1 Power: Approx. 270-275 hp @ 6300 rpm Second Gen Optional Engine 1 Torque: Approx. 260-265 lb-ft @ 4000 rpm Performance Induction System: Naturally Aspirated (some markets offered Turbocharged 'MazdaSpeed 6' with 2.3L DISI Turbo MZR L3-VDT) Fuel System Injection Type: Electronic Fuel Injection (EFI), Direct Injection (DISI) on some turbo models Fuel Type: Unleaded gasoline (Octane rating specified by region) 🔧 Transmission Standard First Gen Common: 5-speed Manual Transmission (FS5A-EL, GF4A-EL for automatic)...

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Typ: Car

Anbieter:

Art.-Nr: 89077

Sammlungen: ALL Mazda

Verfügbarkeit: Auf Lager

Stichworte: 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 6 Car Cars Mazda Misc

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Model Generations Covered:

First Generation (GG/GY), Second Generation (GH)

Year Range:

2002-2014

Codes

Chassis Codes First Gen:

GG (Sedan/Hatchback), GY (Wagon)

Chassis Codes Second Gen:

👋 Introduction

Market Position

Segment:

Mid-size sedan/wagon, known for sporty handling and stylish design

Competitive Analysis

Competitors:

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

Key Features First Gen

Design:

Distinctive 'Zoom-Zoom' design language, available in sedan, hatchback, and wagon body styles

Key Features Second Gen

Design:

Refined styling, improved aerodynamics, focus on premium interior feel

Manual Value Proposition

Benefit:

Empowers owners and technicians with detailed procedures to maintain and repair the vehicle effectively.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Official Full Service Repair Manual

Geographical Markets:

Global (North America, Europe, Asia, etc. applicable models)

Page Count

Estimated Pages:

Thousands (exact count not specified, typical for comprehensive manuals)

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, starting and charging systems

Transmission:

Manual and Automatic transmissions, clutch, driveline, axles, driveshafts

Brakes:

Hydraulic system, ABS, EBD, brake pads, rotors, calipers, parking brake

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, wheel bearings

Steering:

Power steering system, steering column, tie rods, steering rack

Electrical:

Wiring diagrams, lighting system, power distribution, fuses, relays, battery, alternator, starter

HVAC:

Heating, ventilation, and air conditioning systems, refrigerant handling

Body:

Body panels, doors, glass, interior trim, bumpers, chassis frame

Safety Systems:

Airbag system, seatbelts, pre-tensioners

Diagnostics:

OBD-II diagnostics, diagnostic trouble codes (DTCs), sensor data interpretation

Procedures Included

Maintenance:

Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation

Repair:

Component replacement, system diagnostics and repair, troubleshooting guides

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues

Disassembly Reassembly:

Detailed procedures for removing and reinstalling all major components

Specifications Settings:

Torque specifications, alignment procedures, calibration instructions

Technical Depth

Depth:

Comprehensive from basic maintenance to major component overhauls and diagnostics

Diagnostics Level:

Advanced diagnostic procedures, including wiring diagrams and sensor data analysis

Rebuild Procedures:

Detailed instructions for engine, transmission, and major component rebuilds

📊 Manual Specifications

File Format

Format:

Searchable Text:

Yes (typically, depending on PDF origin)

Print Quality

Quality:

High-resolution digital reproduction of original factory documentation

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

Completeness

Coverage:

Complete factory service manual covering all aspects of vehicle repair and maintenance

⚙️ Engine Specifications

Primary Engine

First Gen Common Engine 1:

2.3L DOHC I4 (MZR L3-VE)

First Gen Common Engine 1 Power:

Approx. 160-170 hp @ 6000 rpm

First Gen Common Engine 1 Torque:

Approx. 150-155 lb-ft @ 4000 rpm

First Gen Optional Engine 1:

3.0L DOHC V6 (Ford AJ-V6 / Mazda AJ-DE)

First Gen Optional Engine 1 Power:

Approx. 215-220 hp @ 6300 rpm

First Gen Optional Engine 1 Torque:

Approx. 200-205 lb-ft @ 5000 rpm

Second Gen Common Engine 1:

2.5L DOHC I4 (MZR L5-VE)

Second Gen Common Engine 1 Power:

Approx. 170-175 hp @ 6000 rpm

Second Gen Common Engine 1 Torque:

Approx. 165-170 lb-ft @ 4000 rpm

Second Gen Optional Engine 1:

3.7L DOHC V6 (Mazda-Ford Cyclone V6)

Second Gen Optional Engine 1 Power:

Approx. 270-275 hp @ 6300 rpm

Second Gen Optional Engine 1 Torque:

Approx. 260-265 lb-ft @ 4000 rpm

Performance

Induction System:

Naturally Aspirated (some markets offered Turbocharged 'MazdaSpeed 6' with 2.3L DISI Turbo MZR L3-VDT)

Fuel System

Injection Type:

Electronic Fuel Injection (EFI), Direct Injection (DISI) on some turbo models

Fuel Type:

Unleaded gasoline (Octane rating specified by region)

🔧 Transmission

Standard

First Gen Common:

5-speed Manual Transmission (FS5A-EL, GF4A-EL for automatic)

Second Gen Common:

6-speed Manual Transmission (FS6A-EL, FNR5 for automatic)

Optional

First Gen Optional:

5-speed Automatic Transmission

Second Gen Optional:

6-speed Automatic Transmission

Features

Drivetrain:

Front-Wheel Drive (FWD), All-Wheel Drive (AWD) available on select models (e.g., MazdaSpeed 6)

Clutch Type:

Dry, single-plate (manual transmission models)

📐 Dimensions

Exterior

First Gen Sedan Length:

Approx. 187.6 inches (4765 mm)

First Gen Sedan Width:

Approx. 70.1 inches (1780 mm)

First Gen Sedan Height:

Approx. 57.1 inches (1450 mm)

Second Gen Sedan Length:

Approx. 191.7 inches (4869 mm)

Second Gen Sedan Width:

Approx. 72.4 inches (1839 mm)

Second Gen Sedan Height:

Approx. 57.7 inches (1465 mm)

Cargo

First Gen Sedan Trunk Volume:

Approx. 14.2 cu ft (402 L)

Second Gen Sedan Trunk Volume:

Approx. 16.4 cu ft (464 L)

Weights

First Gen Curb Weight:

Approx. 3100 - 3500 lbs (1400 - 1600 kg) depending on engine/trim

Second Gen Curb Weight:

Approx. 3200 - 3700 lbs (1450 - 1700 kg) depending on engine/trim

Wheelbase:

First Gen: 106.3 inches (2700 mm) / Second Gen: 112.2 inches (2845 mm)

Track Width:

Varies by generation and model, detailed in manual

🛡️ Safety Features

Ratings

NHTSA First Gen Sedan:

Good (Frontal Offset), Acceptable (Side Impact) in early IIHS tests; later models improved.

IIHS First Gen Sedan:

Top Safety Pick awards achieved in later model years.

NHTSA Second Gen Sedan:

5-star ratings for frontal and side impact, 4-star rollover.

IIHS Second Gen Sedan:

Good ratings across most categories, Top Safety Pick awards for many model years.

Active Features

Standard Anti-lock Braking System

Standard Electronic Brake-force Distribution

Traction Control:

Available Traction Control System (TCS)

Stability Control:

Available Dynamic Stability Control (DSC) on many models

Passive Features

Airbags:

Front, side, and curtain airbags (availability varies by trim and model year)

Seatbelts:

Three-point seatbelts with pretensioners and load limiters

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

First Gen Features:

Optional Bose premium audio system, CD player, auxiliary input (later models). Basic climate controls.

Second Gen Features:

Available touch-screen navigation, Bluetooth hands-free connectivity, USB integration, improved audio systems.

Driver Assistance

First Gen Availability:

Limited; primarily ABS, TCS, and optional DSC.

Second Gen Availability:

More advanced features like Blind Spot Monitoring (BSM), Adaptive Front-lighting System (AFS), and rearview camera became available on higher trims.

Connectivity

Bluetooth:

Available on later models (second generation and late first generation) for hands-free calling and audio streaming.

Usb Aux:

Available on later models for audio playback and device charging.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on oil type and driving conditions. Consult manual for specifics.

Air Filter Replacement:

Every 30,000-45,000 miles (48,000-72,000 km), or as needed based on conditions.

Spark Plug Replacement:

I4 engines: 60,000-100,000 miles (96,000-160,000 km) depending on plug type. V6 engines vary.

Coolant Flush:

Every 45,000-60,000 miles (72,000-96,000 km) or 3-5 years.

Transmission Fluid Change:

Automatic: Every 45,000-75,000 miles (72,000-120,000 km). Manual: Inspect periodically, fluid changes recommended at higher mileages (e.g., 90,000-120,000 miles).

Fluid Specifications

Engine Oil:

0W-20 or 5W-30 synthetic recommended (verify specific engine requirement in manual). API SN/SM or ILSAC GF-5/GF-4 certified.

Coolant:

Mazda Long Life Antifreeze/Coolant (or equivalent HOAT, typically pink or blue) mixed 50/50 with distilled water.

Transmission Fluid Automatic:

Mazda ATF-FZ or equivalent DEXRON III/MERCON compatible fluid for older models, specialist fluids for Skyactiv.

Transmission Fluid Manual:

GL-4 SAE 75W-90 gear oil (verify specific grade).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Mazda Genuine ATF Dextron III or equivalent.

Known Issues

First Gen Common 1:

Rust issues, particularly on underbody and wheel arches. EGR valve clogging on some diesel engines (in European markets).

First Gen Common 2:

Oil leaks from valve cover gasket or oil pan gasket. Premature wear of front control arm bushings.

Second Gen Common 1:

Carbon buildup on intake valves (especially direct injection engines if not maintained). Some reports of power steering pump noise.

Second Gen Common 2:

Water pump leaks. Strut mount bearing failure.

Mazdaspeed Specific:

Turbocharger issues, clutch wear under aggressive driving, piston ring land failures on high-mileage early turbo engines (requires careful maintenance).

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

'Zoom-Zoom' driving dynamics, focus on driver engagement and sporty feel.

Model Evolution

First Gen Launch:

Launched in 2002 for the 2003 model year, replacing the Mazda Capella/626.

First Gen Facelift:

Mid-cycle refresh in 2005 for the 2006 model year, with styling and equipment updates.

Second Gen Launch:

Launched in 2007 for the 2008 model year, with a significant redesign.

Second Gen Facelift:

Facelift for the 2010 model year, introducing new styling and Skyactiv-G engine options in later years.

Production

Manufacturing Locations:

Primarily Japan (Hiroshima), also in other Mazda or Ford plants globally depending on market.

🏆 Awards & Recognition

Recognitions

Car And Driver 10 Best:

First generation Mazda 6 was a multiple-time recipient of Car and Driver's 10Best list.

IIHS Top Safety Pick:

Achieved Top Safety Pick status in various years, particularly for the second generation.

Motor Trend Car Of The Year Nominee:

Strong contender in its segment, frequently praised for driving dynamics.

Certifications

Emissions Standards:

Meets applicable federal and regional emissions standards for its model years.