Mazda 6 2002-2016 Workshop Repair & Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: Mazda 6 Model Variants Covered: Mazda 6, 6 i, 6 i Grand Touring, 6 i Sport, 6 i Touring, 6 i Touring Plus, 6 i SV, 6 Mazdaspeed, 6 s, 6 s Grand Touring, 6 s Sport, 6 s Touring, 6 s Touring Plus, MAZDA6 Wagon Generation Generation Range: 2002-2016 Codes Chassis Codes: GG (Hatchback/Wagon), GY (Wagon), GH (Hatchback/Wagon/Sedan), GJ/GL (Sedan) 👋 Introduction Market Position Positioning: The Mazda 6 has consistently been positioned as a sporty and engaging mid-size sedan and wagon, offering a blend of performance, style, and practicality. It competed in a segment dominated by established players like the Toyota Camry, Honda Accord, and Ford Fusion. Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu, Volkswagen Passat, Subaru Legacy, Hyundai Sonata, Kia Optima. Key Features Features: Jinba Ittai (driver-and-horse-as-one) driving philosophy, stylish exterior and interior design, engaging handling, availability of various engine and transmission options, including performance-oriented Mazdaspeed variants. Product Value Value Proposition: This manual is presented as a cost-effective solution for vehicle owners and mechanics, providing professional-level repair and maintenance information to save time and money compared to dealership service. 📋 Manual Details Coverage Areas Regions Covered: Global (UK, European, Japanese, North American variants implied by language options) Manual Type Type: Workshop Repair & Service Manual (Official Shop Manual) Language Languages: English, Dutch, French, German, Italian, Spanish, Swedish Format Format: Digital PDF 📖 Manual Coverage Systems Covered Engine: Cooling System, Exhaust System, Fuel System, Ignition System, Lubrication, Mechanical, Performance (Emission Control, Engine Control System, Intake Air), Starting System, Technical Data, Firing Order & Cylinder Identification. Specific coverage for MZR 2.5L and MZI 3.7L V6 engines. Transmission: Automatic Transaxle (Overhaul, Shift Mechanism, On-Board Diagnostics, Symptom Troubleshooting for AY6A-EL and FS5A-EL), Manual Transaxle (Shift Mechanism, Overhaul for G66M-R), Clutch (G66M-R), Transmission/Transaxle Maintenance & Service Tools, Technical Data. Brakes: Conventional Brake System, Dynamic Stability Control (DSC) (On-Board Diagnostics, Symptom Troubleshooting), Parking Brake System, Brakes - Technical Data, Brakes - Maintenance/Service Tools, General Procedures. Suspension Steering: Front Suspension, Rear Suspension, Steering, Power Steering, Suspension/Steering - Maintenance/Service Tools, Technical Data, General Procedures, Wheel Alignment Specifications, Wheel Alignment, Wheel and Tires. Electrical Electronics: Charging System (MZR 2.5L, MZI 3.7L V6), OEM Wiring System, Lighting Systems, Instrumentation/Driver Information, Multiplex Communication System, Power Systems, On-Board Diagnostics (BCM, Audio, Auto Door Lock, Auto Light/Wiper, Blind Spot Monitoring, Car Navigation, Immobilizer, Instrument Cluster), Symptom Troubleshooting (Audio, BSM, Car Navigation, Immobilizer, Instrument Cluster, Keyless Entry, Radio, Wiper/Washer). Body Chassis: Body & Accessories (Technical Data, Maintenance/Service Tools), Body Panels, Control System, Doors and Liftgate, Exterior Trim, Glass/Windows/Mirrors, Interior Trim, Seats, Sunroof, Cabin Air Filter, Security and Locks, Body Repair Manual (J61S). HVAC: Basic System, Control System (Manual Air Conditioner, Full-Auto Air Conditioner), HVAC - Maintenance/Service Tools, HVAC - On-Board Diagnostics, HVAC - Technical Data, Refrigerant System, Symptom Troubleshooting (Manual Air Conditioner, Full-Auto Air Conditioner). Restraints: Air Bag System, Restraints - Maintenance/Service Tools, Restraints - On-Board Diagnostic, Restraints - Symptom Troubleshooting, Seat Belt. Drivetrain: Drive Shaft, Front Axle, Rear Axle, Driveline/Axle - Maintenance/Service Tools, Technical Data, General Procedures. Fuel Emission: Emission System (MZR 2.5L, MZI 3.7L V6), EGR Function Testing. Body Accessories: Maintenance/Service Tools, Technical Data, Body Panels, Control System, Cruise Control, Doors/Liftgate, Exterior Trim, Glass/Windows/Mirrors, Interior Trim, Lightning Systems, On-Board Diagnostic systems for various accessories, Seats, Sunroof, Symptom Troubleshooting for various accessories, Wiper/Washer System. Chassis Systems: Brakes (Conventional, DSC, Parking Brake), Suspension (Front, Rear, Wheel Alignment, Wheel/Tires), Steering (Power Steering). Accessories Equipment: Extensive coverage of Accessories & Equipment, including Body & Accessories, Control Systems, Doors, Exterior/Interior Trim, Glass, Lighting, Power Systems, Seats, Sunroof, and detailed sections on On-Board Diagnostics and Symptom Troubleshooting for numerous electronic and comfort systems. Procedures Included Procedures: Disassembly, Inspection, Assembly, Maintenance, Repair, Rebuilding, Refurbishing, Restoration, Troubleshooting, Diagnostic Procedures, Technical Data, General Procedures, Symptom Troubleshooting, Reminder Indicator Reset Procedures, Cruise Control System Installation/Repair (MZR 2.5L, MZI 3.7L V6). Diagnostic Procedures: Detailed diagnostic procedures are included for all major systems, covering symptom troubleshooting and on-board diagnostic (OBD) interpretation. Maintenance Procedures: Routine maintenance tasks, fluid changes, filter replacements, and component inspections are comprehensively covered. Repair Procedures: Step-by-step instructions for the repair, overhaul, rebuilding, refurbishment, and restoration of virtually all vehicle components and systems. Technical Depth Depth: Comprehensive (Professional Mechanic Level), including detailed diagnostic and repair procedures, overhaul instructions, and technical specifications for a complete restoration or professional repair. Wiring Diagrams: Includes comprehensive system wiring diagrams (SYSTEM WIRING DIAGRAMS 1 & 2) and specific electrical wiring diagrams (e.g., 07?20022312 (GH) EWD, Mazda6 F_L, MPS EWD). Technical Data Sections: Dedicated sections for Technical Data cover various systems including Engine, Brakes, Driveline/Axle, Steering, Suspension, and HVAC, providing specifications crucial for repairs and diagnostics. 📊 Manual Specifications File Format Format: Cross-platform PDF Searchability: PDF format is generally searchable, allowing users to quickly locate specific topics or keywords within the manual. Print...

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Mazda 6

Model Variants Covered:

Mazda 6, 6 i, 6 i Grand Touring, 6 i Sport, 6 i Touring, 6 i Touring Plus, 6 i SV, 6 Mazdaspeed, 6 s, 6 s Grand Touring, 6 s Sport, 6 s Touring, 6 s Touring Plus, MAZDA6 Wagon

Generation

Generation Range:

2002-2016

Codes

Chassis Codes:

GG (Hatchback/Wagon), GY (Wagon), GH (Hatchback/Wagon/Sedan), GJ/GL (Sedan)

👋 Introduction

Market Position

Positioning:

The Mazda 6 has consistently been positioned as a sporty and engaging mid-size sedan and wagon, offering a blend of performance, style, and practicality. It competed in a segment dominated by established players like the Toyota Camry, Honda Accord, and Ford Fusion.

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu, Volkswagen Passat, Subaru Legacy, Hyundai Sonata, Kia Optima.

Key Features

Features:

Jinba Ittai (driver-and-horse-as-one) driving philosophy, stylish exterior and interior design, engaging handling, availability of various engine and transmission options, including performance-oriented Mazdaspeed variants.

Product Value

Value Proposition:

This manual is presented as a cost-effective solution for vehicle owners and mechanics, providing professional-level repair and maintenance information to save time and money compared to dealership service.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (UK, European, Japanese, North American variants implied by language options)

Manual Type

Type:

Workshop Repair & Service Manual (Official Shop Manual)

Language

Languages:

English, Dutch, French, German, Italian, Spanish, Swedish

Format

Format:

Digital PDF

📖 Manual Coverage

Systems Covered

Engine:

Cooling System, Exhaust System, Fuel System, Ignition System, Lubrication, Mechanical, Performance (Emission Control, Engine Control System, Intake Air), Starting System, Technical Data, Firing Order & Cylinder Identification. Specific coverage for MZR 2.5L and MZI 3.7L V6 engines.

Transmission:

Automatic Transaxle (Overhaul, Shift Mechanism, On-Board Diagnostics, Symptom Troubleshooting for AY6A-EL and FS5A-EL), Manual Transaxle (Shift Mechanism, Overhaul for G66M-R), Clutch (G66M-R), Transmission/Transaxle Maintenance & Service Tools, Technical Data.

Brakes:

Conventional Brake System, Dynamic Stability Control (DSC) (On-Board Diagnostics, Symptom Troubleshooting), Parking Brake System, Brakes - Technical Data, Brakes - Maintenance/Service Tools, General Procedures.

Suspension Steering:

Front Suspension, Rear Suspension, Steering, Power Steering, Suspension/Steering - Maintenance/Service Tools, Technical Data, General Procedures, Wheel Alignment Specifications, Wheel Alignment, Wheel and Tires.

Electrical Electronics:

Charging System (MZR 2.5L, MZI 3.7L V6), OEM Wiring System, Lighting Systems, Instrumentation/Driver Information, Multiplex Communication System, Power Systems, On-Board Diagnostics (BCM, Audio, Auto Door Lock, Auto Light/Wiper, Blind Spot Monitoring, Car Navigation, Immobilizer, Instrument Cluster), Symptom Troubleshooting (Audio, BSM, Car Navigation, Immobilizer, Instrument Cluster, Keyless Entry, Radio, Wiper/Washer).

Body Chassis:

Body & Accessories (Technical Data, Maintenance/Service Tools), Body Panels, Control System, Doors and Liftgate, Exterior Trim, Glass/Windows/Mirrors, Interior Trim, Seats, Sunroof, Cabin Air Filter, Security and Locks, Body Repair Manual (J61S).

HVAC:

Basic System, Control System (Manual Air Conditioner, Full-Auto Air Conditioner), HVAC - Maintenance/Service Tools, HVAC - On-Board Diagnostics, HVAC - Technical Data, Refrigerant System, Symptom Troubleshooting (Manual Air Conditioner, Full-Auto Air Conditioner).

Restraints:

Air Bag System, Restraints - Maintenance/Service Tools, Restraints - On-Board Diagnostic, Restraints - Symptom Troubleshooting, Seat Belt.

Drivetrain:

Drive Shaft, Front Axle, Rear Axle, Driveline/Axle - Maintenance/Service Tools, Technical Data, General Procedures.

Fuel Emission:

Emission System (MZR 2.5L, MZI 3.7L V6), EGR Function Testing.

Body Accessories:

Maintenance/Service Tools, Technical Data, Body Panels, Control System, Cruise Control, Doors/Liftgate, Exterior Trim, Glass/Windows/Mirrors, Interior Trim, Lightning Systems, On-Board Diagnostic systems for various accessories, Seats, Sunroof, Symptom Troubleshooting for various accessories, Wiper/Washer System.

Chassis Systems:

Brakes (Conventional, DSC, Parking Brake), Suspension (Front, Rear, Wheel Alignment, Wheel/Tires), Steering (Power Steering).

Accessories Equipment:

Extensive coverage of Accessories & Equipment, including Body & Accessories, Control Systems, Doors, Exterior/Interior Trim, Glass, Lighting, Power Systems, Seats, Sunroof, and detailed sections on On-Board Diagnostics and Symptom Troubleshooting for numerous electronic and comfort systems.

Procedures Included

Procedures:

Disassembly, Inspection, Assembly, Maintenance, Repair, Rebuilding, Refurbishing, Restoration, Troubleshooting, Diagnostic Procedures, Technical Data, General Procedures, Symptom Troubleshooting, Reminder Indicator Reset Procedures, Cruise Control System Installation/Repair (MZR 2.5L, MZI 3.7L V6).

Diagnostic Procedures:

Detailed diagnostic procedures are included for all major systems, covering symptom troubleshooting and on-board diagnostic (OBD) interpretation.

Maintenance Procedures:

Routine maintenance tasks, fluid changes, filter replacements, and component inspections are comprehensively covered.

Repair Procedures:

Step-by-step instructions for the repair, overhaul, rebuilding, refurbishment, and restoration of virtually all vehicle components and systems.

Technical Depth

Depth:

Comprehensive (Professional Mechanic Level), including detailed diagnostic and repair procedures, overhaul instructions, and technical specifications for a complete restoration or professional repair.

Wiring Diagrams:

Includes comprehensive system wiring diagrams (SYSTEM WIRING DIAGRAMS 1 & 2) and specific electrical wiring diagrams (e.g., 07?20022312 (GH) EWD, Mazda6 F_L, MPS EWD).

Technical Data Sections:

Dedicated sections for Technical Data cover various systems including Engine, Brakes, Driveline/Axle, Steering, Suspension, and HVAC, providing specifications crucial for repairs and diagnostics.

📊 Manual Specifications

File Format

Format:

Cross-platform PDF

Searchability:

PDF format is generally searchable, allowing users to quickly locate specific topics or keywords within the manual.

Print Quality

Quality:

High-resolution, allowing for detailed examination of diagrams and procedures. Pages are easily found by category and expandable for great detail.

Binding Type

Binding:

Digital (No physical binding)

Paper Type

Paper:

N/A (Digital format)

Completeness

Completeness Statement:

The manual is stated to be 100% complete and intact, providing the same factory shop manual information used by dealers.

Ease Of Use

Usability:

Designed for ease of use, with a clear table of contents for each section and expandable pages for detailed information. No advanced computer skills are required.

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.3L MZR I4, 3.0L MZI V6 (early models), 2.5L MZR I4, 3.7L MZI V6 (later models), 2.3L DISI TURBO MZR (Mazdaspeed6).

Performance

Typical Hp Range:

155-270 hp (depending on engine and model variant)

Typical Torque Range:

140-270 lb-ft (depending on engine and model variant)

Fuel System

Fuel Delivery:

Electronic Port Fuel Injection (PFI), Direct Injection (DISI for Mazdaspeed6).

Engine Codes Detailed

Common Engine Codes:

LF-VE (2.0L), L3-VE (2.3L), L3-VDT (2.3L Turbo), LF-DE (2.0L Diesel), Y601 (2.0L Diesel), WEA1 (2.2L Diesel), GY2A (2.5L), YV5 (3.0L V6), MZ-CD (Diesel Variants).

Engine Details Specific

Engine Variants Detailed:

Covers various inline-4 (MZR) and V6 (MZI) engines, including naturally aspirated and turbocharged variants. Specific data for 2.3L, 2.5L, 3.0L, and 3.7L engines, as well as the Mazdaspeed6's 2.3L DISI Turbo (L3-VDT).

🔧 Transmission

Standard

Standard Transmission:

5-speed manual, 6-speed manual (later models), 5-speed automatic, 6-speed automatic (later models), 6-speed automatic transaxle (A6 family).

Optional

Optional Transmission:

Automatic transmissions were commonly optional, with specific types like AW6A-EL and FS5A-EL noted in the manual.

Features

Features:

Manual and automatic transaxle options, performance-oriented transmissions for Mazdaspeed models, available AWD (AWD variant for specific markets/years).

Transmission Codes Detailed

Specific Transmission Codes:

AY6A-EL, FS5A-EL (Automatic Transaxles), G66M-R (Manual Transaxle, Clutch).

📐 Dimensions

Exterior

Body Styles:

4-door Sedan, 5-door Hatchback, 5-door Wagon.

Weights

Curb Weight Range:

Approximately 3,100 - 3,600 lbs (1400 - 1630 kg), varying by body style, engine, and trim.

🛡️ Safety Features

Ratings

NHTSA Ratings:

Varies by model year and specific crash test. Early models generally received good ratings, with later models often achieving 5-star ratings in various categories.

Active Features

Active Safety:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Dynamic Stability Control (DSC), Blind Spot Monitoring (BSM) (on later models).

Passive Features

Passive Safety:

Front airbags, front side-impact airbags, side-curtain airbags (on select models/trims), 3-point seat belts with pretensioners, LATCH child seat anchors.

Safety Systems Coverage

Airbag System:

Detailed coverage of the Air Bag System, including its components, operation, maintenance, and troubleshooting, as well as related Restraint System diagnostics.

💡 Technology Features

Infotainment

Infotainment Systems:

Available with various Mazda infotainment systems, including CD players, MP3 compatibility, SiriusXM Satellite Radio, auxiliary audio inputs, USB ports, Bluetooth connectivity, and integrated navigation systems on higher trims and later models. Touchscreen interfaces and voice command capabilities were introduced in later generations.

Driver Assistance

Driver Assistance Features:

Available features include adaptive cruise control, forward collision warning, automatic emergency braking, lane departure warning, and adaptive front-lighting systems (AFS) on select models and trims.

Connectivity

Connectivity Options:

Bluetooth for hands-free calling and audio streaming, voice command systems, and available telematics or connected services on newer models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (consult manual for specific recommendations based on engine and year).

Major Service Intervals:

Spark plug replacement (e.g., 60,000-100,000 miles), timing belt/chain inspection/replacement (if applicable, typically chain-driven on most models), coolant flush, brake fluid service, transmission fluid service (often around 30,000-60,000 miles for automatics, consult manual).

Fluid Specifications

Engine Oil:

API SN or ILSAC GF-5 certified synthetic engine oil, typically SAE 0W-20 or 5W-30 (refer to specific engine and climate conditions in manual).

Transmission Fluid Auto:

Mazda ATF-FZ (for Skyactiv-Drive automatics), ATF SP-III or equivalent (for older automatic transmissions). Exact specification is critical and detailed in the manual.

Coolant:

Mazda Genuine Long Life Coolant (FL22) or equivalent ethylene glycol-based coolant with long-life additives. Typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Problems:

Rust/corrosion (especially in northern climates), HVAC blower motor resistor failure, power steering pump issues (early models), oil consumption (certain engine variants), suspension component wear, catalytic converter failure, electrical gremlins (especially with multiplex systems).

Maintenance Tools

Special Tools:

The manual references Special Service Tools (SSTs) for specific procedures, such as snap ring removal/installation in the automatic transaxle, indicating the need for specialized equipment for certain tasks.

📚 Vehicle History

Brand Heritage

Heritage:

Mazda has a long history of producing reliable and sporty vehicles, often emphasizing driving dynamics ('Jinba Ittai'). The Mazda 6 lineage evolved from earlier Mazda sedans and hatchbacks, building on the brand's reputation for driver-focused engineering.

Model Evolution

Generations:

First Generation (2002-2008, GG/GY chassis): Introduced with a focus on distinctive styling and driving dynamics. Second Generation (2007-2013, GH chassis): Redesigned with a sleeker profile and improved interior. Third Generation (2012-present, GJ/GL chassis): Launched with Skyactiv technology, emphasizing fuel efficiency and refined driving experience.

Production

Manufacturing Locations:

Primarily manufactured in Japan, with some production potentially occurring in other global facilities depending on market demand and strategy.

Model Trims Covered

Trim Levels:

Includes information for various trim levels such as i (standard), s (sportier variants), Grand Touring, Sport, Touring, Touring Plus, SV, and the performance-oriented Mazdaspeed.

🏆 Awards & Recognition

Recognitions

Industry Awards:

The Mazda 6 has received numerous accolades throughout its production run, including 'Car of the Year' awards from various automotive publications, 'Best Family Car' distinctions, and consistent high marks for reliability and driving dynamics from sources like Consumer Reports and JD Power.

Ratings

Reliability Ratings:

Generally receives good to excellent reliability ratings, particularly in its later generations and with properly maintained engines and transmissions.