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Mazda 6 Sedan/Mazda 6 Wagon 2002 2003 2004 2005 2006 2007 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: Mazda 6 Body Style: Sedan / Wagon Model Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 Codes Chassis Code: GG (Sedan), GY (Wagon) 👋 Introduction Market Position Market Segment: Mid-size sedan and wagon, aimed at families and professionals seeking a balance of sportiness, practicality, and reliability. Competitive Analysis Key Competitors: Honda Accord, Toyota Camry, Nissan Altima, Ford Fusion, Volkswagen Passat Key Features Vehicle Attributes: Engaging driving dynamics (Zoom-Zoom philosophy), stylish design, practical interior space, available all-wheel drive on some variants. Manual Value Proposition Target User: DIY enthusiasts, independent repair shops, and owners seeking to maintain or repair their vehicles. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Restoration Page Count Estimated Page Count: Variable (typically extensive for full workshop manuals, often exceeding 1000 pages) Manual Type Type: Workshop Repair Service Manual Language Language: English (implied by common industry practice and product description) Format Delivery Format: Digital Download (PDF, ZIP, RAR, EXE) 📖 Manual Coverage Systems Covered Engine: General Information, Engine Mechanical, Lubrication System, Cooling System, Fuel System, Emission Control System, Engine Electrical System Drivetrain: Clutch, Manual Transmission (4-Speed & 5-Speed), Front Axle, Rear Axle Chassis: Steering System, Braking System, Suspension System, Wheels & Tires Body And Interior: Body, Body Electrical System, Heating & Air Conditioning Systems Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspection procedures Repair: Engine repair/rebuild, transmission overhaul, brake system service, suspension component replacement, electrical system diagnosis and repair Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Technical Data: Specifications, torque values, clearances, wiring diagrams, diagnostic trouble codes (DTCs) Technical Depth Depth: Comprehensive (from basic adjustments to complete component disassembly and reassembly) Special Tools: Identification and usage of specialized tools required for specific repair procedures 📊 Manual Specifications File Format Primary Format: PDF Compression Formats: ZIP, RAR (for larger files) Print Quality Printability: High quality, printable on standard printers Illustration Quality: Clear, illustrated step-by-step instructions, zoomable illustrations, exploded views Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: Typically included: 2.0L MZR-CD (diesel), 2.0L MZR-L3 (petrol), 2.3L MZR-LF (petrol), 3.0L MZI V6 (J30A) Performance Horsepower Range: 120-145 hp (2.0L Diesel), 140-160 hp (2.0L Petrol), 160-190 hp (2.3L Petrol), 210-220 hp (3.0L V6) Torque Range: 200-280 Nm (Diesel), 180-200 Nm (2.0L Petrol), 200-220 Nm (2.3L Petrol), 270-280 Nm (3.0L V6) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI or Direct Injection depending on engine) Emission Control Emission Systems: Catalytic converter, EGR (Exhaust Gas Recirculation), secondary air injection, evaporative emission control system (EVAP) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 5-Speed Automatic Transmission (Sport AT), 4-Speed Automatic Transmission (earlier models/specific engines) Features Transmission Features: Clutch operation, gear selection, differential service, transmission fluid specifications and change intervals 📐 Dimensions Exterior Wheelbase: Approx. 2725 mm (Sedan), 2720 mm (Wagon) Length: Approx. 4720 mm (Sedan), 4770 mm (Wagon) Width: Approx. 1780 mm Height: Approx. 1435 mm (Sedan), 1480 mm (Wagon) Weights Curb Weight: Approx. 1400-1550 kg (depending on engine and body style) 🛡️ Safety Features Ratings NHTSA Ratings: Good ratings in frontal offset and side impact tests (IIHS), 4/5 stars in NHTSA frontal and side crash tests (depending on specific year and test) Active Features Active Safety: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), TCS (Traction Control System), DSC (Dynamic Stability Control - optional/standard on higher trims) Passive Features Passive Safety: Front airbags, side curtain airbags (optional/standard), pre-tensioner seatbelts 💡 Technology Features Infotainment Infotainment System: Basic infotainment systems with CD player, AM/FM radio, optional navigation system. Bluetooth connectivity typically added in later model years or as an aftermarket upgrade. Driver Assistance Driver Assistance Features: Cruise control (standard/optional), rain-sensing wipers (optional on higher trims), auto-dimming rearview mirror (optional). Connectivity Connectivity Options: Limited native connectivity; primarily focused on audio playback. AUX input may be present on some models. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type. Major Service Interval: Spark plug replacement often around 60,000-100,000 miles, timing belt (if applicable, though many used chains) or chain inspection/service around 100,000 miles. Fluid Specifications Engine Oil: API SN/SP or ILSAC GF-5/GF-6, viscosity typically 0W-20 or 5W-30 (refer to owner's manual for specific engine requirement) Transmission Fluid Manual: GL-4 or GL-5 gear oil, specific viscosity grade (e.g., 75W-90) Transmission Fluid Automatic: Mazda Genuine ATF JWS3309 or equivalent Coolant: Mazda Genuine Super Long Life Coolant (FL22) or equivalent ethylene glycol-based coolant Known Issues Common Problems: Rust issues (especially in salt-belt regions), potential for oil consumption in higher mileage engines, front suspension wear (control arms, ball joints), power steering pump noise/leaks, ignition coil failure, DMF (Dual Mass Flywheel) wear on diesel models. Part Numbers Oil Filter...
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Mazda 6 Sedan/Mazda 6 Wagon 2002 2003 2004 2005 2006 2007 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
Mazda 6
Body Style:
Sedan / Wagon
Model Years Covered:
2002, 2003, 2004, 2005, 2006, 2007
Codes
Chassis Code:
GG (Sedan), GY (Wagon)
👋 Introduction
Market Position
Market Segment:
Mid-size sedan and wagon, aimed at families and professionals seeking a balance of sportiness, practicality, and reliability.
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Ford Fusion, Volkswagen Passat
Key Features
Vehicle Attributes:
Engaging driving dynamics (Zoom-Zoom philosophy), stylish design, practical interior space, available all-wheel drive on some variants.
Manual Value Proposition
Target User:
DIY enthusiasts, independent repair shops, and owners seeking to maintain or repair their vehicles.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Repair and Service
Secondary Coverage:
Maintenance, Diagnostics, Troubleshooting, Restoration
Page Count
Estimated Page Count:
Variable (typically extensive for full workshop manuals, often exceeding 1000 pages)
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English (implied by common industry practice and product description)
Format
Delivery Format:
Digital Download (PDF, ZIP, RAR, EXE)
📖 Manual Coverage
Systems Covered
Engine:
General Information, Engine Mechanical, Lubrication System, Cooling System, Fuel System, Emission Control System, Engine Electrical System
Drivetrain:
Clutch, Manual Transmission (4-Speed & 5-Speed), Front Axle, Rear Axle
Chassis:
Steering System, Braking System, Suspension System, Wheels & Tires
Body And Interior:
Body, Body Electrical System, Heating & Air Conditioning Systems
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspection procedures
Repair:
Engine repair/rebuild, transmission overhaul, brake system service, suspension component replacement, electrical system diagnosis and repair
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides
Technical Data:
Specifications, torque values, clearances, wiring diagrams, diagnostic trouble codes (DTCs)
Technical Depth
Depth:
Comprehensive (from basic adjustments to complete component disassembly and reassembly)
Special Tools:
Identification and usage of specialized tools required for specific repair procedures
📊 Manual Specifications
File Format
Primary Format:
PDF
Compression Formats:
ZIP, RAR (for larger files)
Print Quality
Printability:
High quality, printable on standard printers
Illustration Quality:
Clear, illustrated step-by-step instructions, zoomable illustrations, exploded views
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Typically included: 2.0L MZR-CD (diesel), 2.0L MZR-L3 (petrol), 2.3L MZR-LF (petrol), 3.0L MZI V6 (J30A)
Performance
Horsepower Range:
120-145 hp (2.0L Diesel), 140-160 hp (2.0L Petrol), 160-190 hp (2.3L Petrol), 210-220 hp (3.0L V6)
Torque Range:
200-280 Nm (Diesel), 180-200 Nm (2.0L Petrol), 200-220 Nm (2.3L Petrol), 270-280 Nm (3.0L V6)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI or Direct Injection depending on engine)
Emission Control
Emission Systems:
Catalytic converter, EGR (Exhaust Gas Recirculation), secondary air injection, evaporative emission control system (EVAP)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
5-Speed Automatic Transmission (Sport AT), 4-Speed Automatic Transmission (earlier models/specific engines)
Features
Transmission Features:
Clutch operation, gear selection, differential service, transmission fluid specifications and change intervals
📐 Dimensions
Exterior
Wheelbase:
Approx. 2725 mm (Sedan), 2720 mm (Wagon)
Length:
Approx. 4720 mm (Sedan), 4770 mm (Wagon)
Width:
Approx. 1780 mm
Height:
Approx. 1435 mm (Sedan), 1480 mm (Wagon)
Weights
Curb Weight:
Approx. 1400-1550 kg (depending on engine and body style)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Good ratings in frontal offset and side impact tests (IIHS), 4/5 stars in NHTSA frontal and side crash tests (depending on specific year and test)
Active Features
Active Safety:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), TCS (Traction Control System), DSC (Dynamic Stability Control - optional/standard on higher trims)
Passive Features
Passive Safety:
Front airbags, side curtain airbags (optional/standard), pre-tensioner seatbelts
💡 Technology Features
Infotainment
Infotainment System:
Basic infotainment systems with CD player, AM/FM radio, optional navigation system. Bluetooth connectivity typically added in later model years or as an aftermarket upgrade.
Driver Assistance
Driver Assistance Features:
Cruise control (standard/optional), rain-sensing wipers (optional on higher trims), auto-dimming rearview mirror (optional).
Connectivity
Connectivity Options:
Limited native connectivity; primarily focused on audio playback. AUX input may be present on some models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type.
Major Service Interval:
Spark plug replacement often around 60,000-100,000 miles, timing belt (if applicable, though many used chains) or chain inspection/service around 100,000 miles.
Fluid Specifications
Engine Oil:
API SN/SP or ILSAC GF-5/GF-6, viscosity typically 0W-20 or 5W-30 (refer to owner's manual for specific engine requirement)
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, specific viscosity grade (e.g., 75W-90)
Transmission Fluid Automatic:
Mazda Genuine ATF JWS3309 or equivalent
Coolant:
Mazda Genuine Super Long Life Coolant (FL22) or equivalent ethylene glycol-based coolant
Known Issues
Common Problems:
Rust issues (especially in salt-belt regions), potential for oil consumption in higher mileage engines, front suspension wear (control arms, ball joints), power steering pump noise/leaks, ignition coil failure, DMF (Dual Mass Flywheel) wear on diesel models.
Part Numbers
Oil Filter Example:
e.g., Mazda L3K9-14-302A, Mazda PY01-14-302
Air Filter Example:
e.g., Mazda GJ6A-13-Z40
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Known for 'Zoom-Zoom' driving dynamics, sporty handling, and driver-focused design.
Model Evolution
First Generation:
The first generation Mazda 6 (GG/GY) was launched in 2002, replacing the Mazda Capella/626. It introduced Mazda's 'Nagare' design language and emphasized a more engaging driving experience in its class.
Production
Production Locations:
Primary production in Hofu, Japan.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Received IIHS Top Safety Pick awards in multiple years for its segment.
Car Of The Year Awards:
Won various 'Car of the Year' awards from automotive publications globally upon its introduction.
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