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Mazda 626 Station Wagon 1997-2002 Service Repair Manual
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Basic Information Identification Make: Mazda Model: 626 Station Wagon Generation: GF/GW Years Covered: 1997, 1998, 1999, 2000, 2001, 2002 Codes Chassis Codes: GF (Sedan/Hatchback), GW (Station Wagon) Introduction Market Position...
Taper: Cars
Distributeur:
UGS: 94607
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| Basic Information | |
| Identification | |
| Make: | Mazda |
| Model: | 626 Station Wagon |
| Generation: | GF/GW |
| Years Covered: | 1997, 1998, 1999, 2000, 2001, 2002 |
| Codes | |
| Chassis Codes: | GF (Sedan/Hatchback), GW (Station Wagon) |
| Introduction | |
| Market Position | |
| Segment: | Compact to Mid-Size Station Wagon |
| Target Audience: | Families, small businesses, individuals seeking practical and reliable transportation with cargo capacity. |
| Competitive Analysis | |
| Key Competitors: | Toyota Camry Wagon, Honda Accord Wagon, Subaru Outback (later models), Ford Mondeo Wagon, Volkswagen Passat Wagon. |
| Key Features | |
| Model Strengths: | Reliability, comfortable ride, spacious interior for its class, practical cargo area, good fuel economy with the 2.0L and 2.5L engines. |
| Manual Value Proposition: | Empowers owners and independent repair shops with the necessary information to maintain, diagnose, and repair the Mazda 626 Station Wagon, potentially saving significant costs compared to dealership service. |
| Manual Details | |
| Coverage Areas | |
| Primary Coverage: | Mazda 626 Station Wagon (GW chassis) |
| Secondary Coverage: | While primarily for the Station Wagon, many sections will be applicable to the GF chassis Sedan and Hatchback variants of the same generation. |
| Page Count | |
| Estimated Page Count: | 1000+ |
| Manual Type | |
| Type: | Service and Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Detailed overhaul procedures, component testing, timing belt replacement, piston/ring/bearing specifications, cylinder head assembly, lubrication system. |
| Engine Management: | Fuel injection system (MPI), ignition system, electronic control unit (ECU) diagnostics, sensor data interpretation, emission controls. |
| Transmission Manual: | Overhaul procedures, clutch replacement, gear selection mechanisms, shift linkage adjustments, component specifications. |
| Transmission Automatic: | Operation, diagnosis of common faults, fluid types and capacities, torque converter removal/installation, valve body overhaul, electronic control unit interface. |
| Drivetrain: | Front-wheel drive (FWD) components, drive axles, CV joints, differential service, wheel bearing replacement. |
| Suspension: | Front and rear suspension component identification, shock absorber/strut replacement, spring replacement, ball joint inspection, bushing replacement, alignment specifications. |
| Steering: | Power steering system diagnosis, pump replacement, rack and pinion overhaul, steering column components, tie rod end replacement. |
| Brakes: | Front and rear brake system diagnosis, disc brake pad replacement, rotor resurfacing/replacement, drum brake service, hydraulic system bleeding, ABS system operation and diagnosis. |
| Cooling System: | Radiator service, coolant types and capacities, thermostat operation and replacement, water pump replacement, fan system operation. |
| Fuel System: | Fuel pump testing, fuel filter replacement, fuel injector service, fuel tank removal/installation, evaporative emission control (EVAP) system. |
| Electrical System: | Battery service, charging system (alternator), starting system (starter motor), lighting system, horn, wipers, power windows, fuses, relays, wiring diagrams. |
| HVAC System: | Air conditioning system diagnosis, refrigerant types, compressor service, heater core replacement, blower motor operation, climate control unit. |
| Body And Interior: | Door panel removal, seat removal, dashboard disassembly, exterior trim, bumper replacement, tailgate service, interior trim component replacement. |
| Chassis And Frame: | Frame inspection, unibody construction principles, rust prevention. |
| Procedures Included | |
| Routine Maintenance: | Oil and filter changes, air filter replacement, spark plug replacement, tire rotation, brake fluid flush, coolant flush, transmission fluid change. |
| Troubleshooting: | Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems. |
| Repair And Overhaul: | Complete step-by-step instructions for engine, transmission, suspension, brake, and electrical system repairs. |
| Component Replacement: | Detailed guidance on replacing specific parts such as alternators, starter motors, fuel pumps, water pumps, radiators, clutch kits, etc. |
| Diagnostic Testing: | Procedures for testing sensors, actuators, and electrical circuits using multimeters and scan tools. |
| Alignment And Balancing: | Wheel alignment specifications and procedures, wheel balancing. |
| Emissions Service: | Diagnosis and repair of emission control systems, catalytic converter testing, EGR valve service. |
| Bodywork And Collision: | Minor body panel adjustments, trim piece replacement, potential for larger repair guidance (depending on manual detail). |
| Technical Depth | |
| Depth: | Comprehensive |
| Diagnostics Scope: | Advanced diagnostic procedures, including interpretation of error codes and live data streams. |
| Rebuild Procedures: | Detailed instructions for engine and transmission rebuilds, including torque specifications and clearances. |
| Schematics: | Includes detailed electrical wiring diagrams for various vehicle systems. |
| Manual Specifications | |
| File Format | |
| File Type: | Portable Document Format (PDF) |
| Searchability: | Likely text-searchable PDF for quick information retrieval. |
| Print Quality | |
| Quality: | Variable (depends on source scan), but expected to be clear for professional use. |
| Binding Type | |
| Binding: | N/A (Digital PDF) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF) |
| Engine Specifications | |
| Primary Engine | |
| Engine Code Common: | FS-DE (2.0L DOHC) |
| Displacement 2.0L: | 1991 cc |
| Horsepower 2.0L: | Approx. 120-130 hp (varies by market and year) |
| Torque 2.0L: | Approx. 130-135 lb-ft (varies by market and year) |
| Optional Engine | |
| Engine Code Optional: | KF-ZE (2.5L DOHC V6 - less common in wagons, more in sedans, but potentially available) |
| Displacement 2.5L: | 2490 cc |
| Horsepower 2.5L: | Approx. 160-170 hp |
| Torque 2.5L: | Approx. 150-160 lb-ft |
| Performance | |
| Fuel Type: | Unleaded Gasoline |
| Engine Layout: | Inline 4-cylinder (2.0L), V6 (2.5L) |
| Fuel System | |
| Induction: | Multi-Point Fuel Injection (MPI) |
| Ignition Type: | Distributorless Ignition System (DIS) or Distributor-based (depending on market/year) |
| Transmission | |
| Standard | |
| Type: | 5-speed Manual Transmission |
| Optional | |
| Type: | 4-speed Automatic Transmission (with electronic control) |
| Features | |
| Automatic Modes: | Possibly 'Power' and 'Economy' modes on some automatic transmissions. |
| Fluid Specifications | |
| Manual Transmission Fluid: | API GL-4 SAE 75W-90 (refer to manual for exact Mazda specification) |
| Automatic Transmission Fluid: | Mazda ATF-III or equivalent Dexron III/Mercon |
| Dimensions | |
| Exterior | |
| Length: | Approx. 4705 mm (185.2 in) |
| Width: | Approx. 1770 mm (69.7 in) |
| Height: | Approx. 1475 mm (58.1 in) |
| Wheelbase: | Approx. 2615 mm (103.0 in) |
| Cargo | |
| Cargo Volume Seats Up: | Significant volume, designed for family practicality. |
| Cargo Volume Seats Down: | Very large, flat load floor suitable for bulky items. |
| Weights | |
| Curb Weight: | Approx. 1350-1450 kg (2976-3197 lbs), depending on engine and equipment. |
| Gross Vehicle Weight Rating: | Refer to vehicle VIN plate/sticker for exact GVWR. |
| Safety Features | |
| Ratings | |
| NHTSA Front Impact: | Generally performed well for its era. Manual will detail specific test results if available. |
| IIHS Side Impact: | Likely rated 'Acceptable' or 'Marginal' in older tests, as side airbags were less common. |
| Active Features | |
| ABS: | Anti-lock Braking System (ABS) often standard or optional. |
| Traction Control: | Less common on base models, may be available on higher trims or optional. |
| Passive Features | |
| Airbags: | Driver and front passenger airbags standard. Side airbags were rare on this generation. |
| Seatbelts: | Front 3-point with pretensioners, rear 3-point seatbelts. |
| Crumple Zones: | Designed with front and rear crumple zones for energy absorption. |
| Technology Features | |
| Infotainment | |
| Audio System: | Factory fitted AM/FM stereo with CD player or cassette tape. Speaker configurations typically 4 or 6 speakers. |
| Climate Control: | Manual air conditioning and heating, with optional automatic climate control on higher trims. |
| Driver Assistance | |
| Cruise Control: | Standard or optional on most models. |
| Power Features: | Power windows, power door locks, power mirrors often standard or optional. |
| Connectivity | |
| Auxiliary Inputs: | None from factory. Aftermarket solutions required for modern device connectivity. |
| Bluetooth: | Not available from factory. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions). |
| Engine Oil Filter: | Replace with every oil change. |
| Air Filter Replacement: | Every 15,000 miles (24,000 km) or 12 months. |
| Spark Plug Replacement: | Every 30,000 miles (48,000 km) for standard spark plugs, longer for iridium/platinum (refer to manual). |
| Timing Belt Replacement: | Critical: Every 60,000 miles (96,000 km) or 5 years (whichever comes first) for the 2.0L engine. Failure can cause catastrophic engine damage. |
| Coolant Flush Interval: | Every 2 years or 30,000 miles (48,000 km). |
| Brake Fluid Flush: | Every 2 years or 30,000 miles (48,000 km). |
| Fluid Specifications | |
| Engine Oil Capacity 2.0L: | Approx. 4.0-4.3 liters (4.2-4.5 US quarts) with filter change. |
| Engine Oil Viscosity: | 5W-30 or 10W-30 API SJ or SL certified (refer to manual for specific climate recommendations). |
| Coolant Type: | Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Refer to Mazda's specific recommendation. |
| Known Issues | |
| Engine Mounts: | Can degrade over time, leading to increased vibration. |
| Oil Leaks: | Common areas include valve cover gasket, oil pan gasket, and front/rear main seals, especially at higher mileage. |
| Cooling System: | Radiator leaks, thermostat failure, and hose degradation are not uncommon. |
| Suspension Wear: | Worn ball joints, bushings, and struts can lead to noise and poor handling. |
| Automatic Transmission: | Some units may exhibit delayed shifting or torque converter shudder if fluid and filter are not maintained. |
| Power Steering: | Leaking power steering pumps or hoses can occur. |
| Rust Corrosion: | While generally good, areas like wheel arches, rocker panels, and the underside can be susceptible in certain climates. |
| Vehicle History | |
| Brand Heritage | |
| Mazda Philosophy: | Mazda's focus on 'Jinba Ittai' (horse and rider as one) driving feel, even in practical vehicles. |
| Model Evolution | |
| Generation Name: | The GF/GW generation replaced the previous GE generation. |
| Platform: | Shared platform with the Mazda Capella and Ford Telstar in some markets. |
| Design Language: | Rounded, aerodynamic styling characteristic of late 1990s Japanese vehicles. |
| Production | |
| Manufacturing Locations: | Primarily Japan, with potential assembly in other global locations. |
| Production Run: | 1991-2002 (GF/GW generation, with facelifts and updates within this period). |
| Awards & Recognition | |
| Recognitions | |
| Car And Driver 10Best: | While the 626 Sedan/Hatchback sometimes made '10 Best' lists in earlier generations, the specific wagon variant's direct awards are less prominent, though the model line was generally well-regarded for value. |
| Ratings | |
| Consumer Reports: | Generally rated as 'Average' to 'Above Average' for reliability during its production run, particularly the powertrain. |
| Certifications | |
| Safety Certifications: | Meets all applicable safety standards for its model years in target markets (e.g., FMVSS in the US). |