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1991 Mazda MX-6 (1st gen) Service and Repair Manual

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$133.00
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$133.00
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🏷️ Basic Information Identification Make: Mazda Model: MX-6 Year: 1991 Codes Chassis Code: GE Platform: Mazda GD platform (shared with Mazda Capella/626) Generation Generation: 1st Generation (1987-1991) 👋 Introduction Market Position Segment: Sporty compact coupe / Personal luxury coupe Target Audience: Enthusiasts seeking a stylish, capable, and driver-focused vehicle. Competitive Analysis Key Competitors: Toyota Celica, Honda Prelude, Mitsubishi Eclipse, Nissan 240SX. Unique Selling Points: Mazda's renowned handling, sophisticated styling for its era, available V6 engine option. Key Features Styling: Sleek, aerodynamic design with pop-up headlights, frameless door windows, and a distinctive greenhouse. Driving Dynamics: Emphasis on Mazda's 'Jinba Ittai' (horse and rider as one) philosophy, tuned suspension, responsive steering. Interior: Driver-oriented cockpit, comfortable seating, optional premium sound systems, typically well-appointed for its class. 📋 Manual Details Coverage Areas Primary Coverage: Vehicle Specific Repair and Service Scope: All Models & All Repairs A-Z Page Count Estimated Page Count: Over 1000 pages (typical for factory service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Printed (as implied by typical dealership use) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, overhaul, component testing, timing belt replacement, cooling system, lubrication system, fuel system, ignition system, emission control systems (including EGR, O2 sensors). Transmission: Manual transmission (G-series) and Automatic transmission (F-series) overhaul, diagnosis, fluid replacement, clutch system, torque converter, shift linkage. Drivetrain: Front-wheel drive, CV axles, differential, driveshaft (if applicable to specific trims), wheel bearings. Suspension: Front McPherson strut, rear independent suspension, control arms, ball joints, bushings, shock absorbers, springs, alignment specifications, steering knuckle, hub assembly. Brakes: Front disc brakes, rear disc or drum brakes (depending on trim), hydraulic system, ABS (if equipped), master cylinder, brake lines, calipers, pads, rotors, parking brake system. Steering: Power steering system, steering rack, tie rods, steering column, intermediate shaft, fluid specifications. Electrical: Complete wiring diagrams, fuse box locations, relay functions, lighting system, charging system (alternator, battery), starting system (starter motor), instrument cluster, gauges, warning lights, accessory circuits, diagnostic connector (OBD-I). Body: Exterior body panels, doors, windows, locks, mirrors, convertible top (if applicable), interior trim, seats, headliner, body sealing, rust prevention, chassis rigidity. HVAC: Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling (R12), compressor, condenser, evaporator, blower motor, control panels, ductwork. Emissions: Detailed explanations of emission control devices, diagnosis and repair procedures for emissions-related faults, catalytic converter, secondary air injection. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, coolant flushes, brake fluid replacement, air filter replacement, belt inspection and replacement. Diagnostics: Troubleshooting flowcharts for common symptoms, diagnostic trouble codes (DTCs) for OBD-I systems, component testing procedures (resistance, voltage, current), fuel pressure testing, compression testing. Repair: Engine overhaul, transmission rebuild, brake caliper replacement, radiator replacement, power steering pump replacement, alternator replacement, starter motor replacement, suspension component replacement, body panel repair, interior component repair. Installation: Component installation procedures, torque specifications for all fasteners, alignment procedures, accessory installation. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic strategies. Accuracy: Factory-level accuracy and detail, specific to Mazda technicians. 📊 Manual Specifications File Format Digital Format: N/A (Likely printed, but PDF scans are common for aftermarket sales) Print Quality Print Quality: High-resolution images and diagrams (when scanned or originally printed). Binding Type Binding: Professional binding (e.g., spiral-bound or hardcover) for dealership use, facilitating ease of use on a workbench. Paper Type Paper Type: Durable, often coated paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Code Inline4: FE-DOHC (2.0L DOHC 16-valve Inline-4) Displacement Inline4: 1998 cc (2.0 Liters) Horsepower Inline4: Approx. 145-160 hp (depending on market and specific variant) Torque Inline4: Approx. 130-140 lb-ft (depending on market and specific variant) Optional Engine Engine Code V6: KF-DE (2.5L DOHC 24-valve V6) Displacement V6: 2490 cc (2.5 Liters) Horsepower V6: Approx. 185-190 hp Torque V6: Approx. 170-175 lb-ft Performance 0 60 Mph Inline4: Approx. 8.5-9.5 seconds 0 60 Mph V6: Approx. 7.0-7.5 seconds Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Fuel Octane Rating: Premium Unleaded (91 Octane Recommended) 🔧 Transmission Standard Type Inline4: 5-speed Manual Transmission (Mazda G-series) Optional Type V6: 4-speed Automatic Transmission (Mazda F-series) with Lock-up Torque Converter Features All Wheel Drive: Not typically available for MX-5, primarily FWD. (Note: Some GD chassis variants of the 626 had AWD, but not the MX-6 coupe). Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 or SAE 75W-85 gear oil (specific Mazda part number: MAZDA Gear Oil GL-4 75W-90 or equivalent) Automatic Transmission Fluid: Dexron II / Mercon (specific Mazda part number: MAZDA ATF M-III or equivalent) 📐 Dimensions Exterior Length: Approx. 176.4 inches (4480 mm) Width: Approx. 69.1 inches (1755 mm) Height: Approx. 51.2 inches (1300 mm) Wheelbase: Approx. 100.4 inches (2550 mm) Front Track: Approx. 58.3 inches (1480 mm) Rear...
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1991 Mazda MX-6 (1st gen) Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
MX-6
Year:
1991
Codes
Chassis Code:
GE
Platform:
Mazda GD platform (shared with Mazda Capella/626)
Generation
Generation:
1st Generation (1987-1991)
👋 Introduction
Market Position
Segment:
Sporty compact coupe / Personal luxury coupe
Target Audience:
Enthusiasts seeking a stylish, capable, and driver-focused vehicle.
Competitive Analysis
Key Competitors:
Toyota Celica, Honda Prelude, Mitsubishi Eclipse, Nissan 240SX.
Unique Selling Points:
Mazda's renowned handling, sophisticated styling for its era, available V6 engine option.
Key Features
Styling:
Sleek, aerodynamic design with pop-up headlights, frameless door windows, and a distinctive greenhouse.
Driving Dynamics:
Emphasis on Mazda's 'Jinba Ittai' (horse and rider as one) philosophy, tuned suspension, responsive steering.
Interior:
Driver-oriented cockpit, comfortable seating, optional premium sound systems, typically well-appointed for its class.
📋 Manual Details
Coverage Areas
Primary Coverage:
Vehicle Specific Repair and Service
Scope:
All Models & All Repairs A-Z
Page Count
Estimated Page Count:
Over 1000 pages (typical for factory service manuals of this era)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Printed (as implied by typical dealership use)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, overhaul, component testing, timing belt replacement, cooling system, lubrication system, fuel system, ignition system, emission control systems (including EGR, O2 sensors).
Transmission:
Manual transmission (G-series) and Automatic transmission (F-series) overhaul, diagnosis, fluid replacement, clutch system, torque converter, shift linkage.
Drivetrain:
Front-wheel drive, CV axles, differential, driveshaft (if applicable to specific trims), wheel bearings.
Suspension:
Front McPherson strut, rear independent suspension, control arms, ball joints, bushings, shock absorbers, springs, alignment specifications, steering knuckle, hub assembly.
Brakes:
Front disc brakes, rear disc or drum brakes (depending on trim), hydraulic system, ABS (if equipped), master cylinder, brake lines, calipers, pads, rotors, parking brake system.
Steering:
Power steering system, steering rack, tie rods, steering column, intermediate shaft, fluid specifications.
Electrical:
Complete wiring diagrams, fuse box locations, relay functions, lighting system, charging system (alternator, battery), starting system (starter motor), instrument cluster, gauges, warning lights, accessory circuits, diagnostic connector (OBD-I).
Body:
Exterior body panels, doors, windows, locks, mirrors, convertible top (if applicable), interior trim, seats, headliner, body sealing, rust prevention, chassis rigidity.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system diagnosis, refrigerant handling (R12), compressor, condenser, evaporator, blower motor, control panels, ductwork.
Emissions:
Detailed explanations of emission control devices, diagnosis and repair procedures for emissions-related faults, catalytic converter, secondary air injection.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, coolant flushes, brake fluid replacement, air filter replacement, belt inspection and replacement.
Diagnostics:
Troubleshooting flowcharts for common symptoms, diagnostic trouble codes (DTCs) for OBD-I systems, component testing procedures (resistance, voltage, current), fuel pressure testing, compression testing.
Repair:
Engine overhaul, transmission rebuild, brake caliper replacement, radiator replacement, power steering pump replacement, alternator replacement, starter motor replacement, suspension component replacement, body panel repair, interior component repair.
Installation:
Component installation procedures, torque specifications for all fasteners, alignment procedures, accessory installation.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic strategies.
Accuracy:
Factory-level accuracy and detail, specific to Mazda technicians.
📊 Manual Specifications
File Format
Digital Format:
N/A (Likely printed, but PDF scans are common for aftermarket sales)
Print Quality
Print Quality:
High-resolution images and diagrams (when scanned or originally printed).
Binding Type
Binding:
Professional binding (e.g., spiral-bound or hardcover) for dealership use, facilitating ease of use on a workbench.
Paper Type
Paper Type:
Durable, often coated paper to withstand workshop conditions.
⚙️ Engine Specifications
Primary Engine
Engine Code Inline4:
FE-DOHC (2.0L DOHC 16-valve Inline-4)
Displacement Inline4:
1998 cc (2.0 Liters)
Horsepower Inline4:
Approx. 145-160 hp (depending on market and specific variant)
Torque Inline4:
Approx. 130-140 lb-ft (depending on market and specific variant)
Optional Engine
Engine Code V6:
KF-DE (2.5L DOHC 24-valve V6)
Displacement V6:
2490 cc (2.5 Liters)
Horsepower V6:
Approx. 185-190 hp
Torque V6:
Approx. 170-175 lb-ft
Performance
0 60 Mph Inline4:
Approx. 8.5-9.5 seconds
0 60 Mph V6:
Approx. 7.0-7.5 seconds
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Fuel Octane Rating:
Premium Unleaded (91 Octane Recommended)
🔧 Transmission
Standard
Type Inline4:
5-speed Manual Transmission (Mazda G-series)
Optional
Type V6:
4-speed Automatic Transmission (Mazda F-series) with Lock-up Torque Converter
Features
All Wheel Drive:
Not typically available for MX-5, primarily FWD. (Note: Some GD chassis variants of the 626 had AWD, but not the MX-6 coupe).
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or SAE 75W-85 gear oil (specific Mazda part number: MAZDA Gear Oil GL-4 75W-90 or equivalent)
Automatic Transmission Fluid:
Dexron II / Mercon (specific Mazda part number: MAZDA ATF M-III or equivalent)
📐 Dimensions
Exterior
Length:
Approx. 176.4 inches (4480 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 51.2 inches (1300 mm)
Wheelbase:
Approx. 100.4 inches (2550 mm)
Front Track:
Approx. 58.3 inches (1480 mm)
Rear Track:
Approx. 58.1 inches (1475 mm)
Weights
Curb Weight Inline4:
Approx. 2800-3000 lbs (1270-1360 kg)
Curb Weight V6:
Approx. 3000-3200 lbs (1360-1450 kg)
Gross Vehicle Weight Rating:
Typically around 3700-3900 lbs (1680-1770 kg)
Cargo
Trunk Volume:
Approx. 10.5 cubic feet (0.30 m³)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Not rated or available for this specific model year/testing era.
IIHS Crash Tests:
Not specifically rated or tested by IIHS for this generation.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on some models, especially V6 variants.
Traction Control:
Not typically available on this model year.
Passive Features
Airbags:
Driver-side airbag standard for 1991 model year in many markets. Passenger airbag not available.
Seatbelts:
3-point front seatbelts, often with pre-tensioners. Rear lap belts.
Rollover Protection:
Reinforced A-pillars and B-pillars, but no specific roll bar or hoop.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player, and premium speaker systems (e.g., Bose on higher trims).
Climate Control:
Manual HVAC controls, with optional automatic climate control on some V6 models.
Driver Assistance
Cruise Control:
Standard or optional cruise control system.
Connectivity
Diagnostic Port:
OBD-I (On-Board Diagnostics, First Generation) diagnostic connector, typically located under the dashboard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first.
Engine Oil Filter:
Replace at every oil change.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement:
Every 30,000 miles (check for specific plug type).
Timing Belt Replacement:
Every 60,000 miles or 4 years (critical for DOHC engines). Specific Mazda part number for belt often relates to FE or KF engine series.
Coolant Flush:
Every 30,000 miles or 2 years.
Brake Fluid Replacement:
Every 2 years.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 10W-30 or 10W-40 (specific Mazda part number: MAZDA Engine Oil 10W-30 or equivalent)
Engine Oil Capacity:
Approx. 4.2 US quarts (4.0 Liters) with filter for Inline-4, 4.6 US quarts (4.4 Liters) with filter for V6.
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water). Specific Mazda part number: MAZDA Long Life Coolant (Blue) or equivalent.
Power Steering Fluid:
Dexron II / Mercon (same as ATF).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Mounts:
Deterioration of engine mounts, leading to vibration and harshness, particularly in the V6 models.
Cooling System:
Plastic radiator end tanks can become brittle and leak; water pump seal failures.
Electrical Connectors:
Corrosion or poor connections in the engine bay and dashboard wiring harnesses can cause intermittent faults.
Suspension Bushings:
Wear and tear on control arm bushings and sway bar links, leading to clunks and imprecise handling.
HVAC Blend Door:
Actuator or cable failure for the HVAC blend door, resulting in improper temperature control.
Exhaust Manifold:
Cracked exhaust manifolds on the V6 engine due to heat cycles.
Oil Leaks:
Valve cover gasket leaks, oil pan gasket leaks, and front/rear main seal leaks are common with age.
📚 Vehicle History
Brand Heritage
Mazda Dna:
Mazda's reputation for building driver-focused, reliable, and sporty vehicles, extending from the RX-7 legacy to accessible coupes.
Model Evolution
Predecessor:
Mazda RX-7 (first generation) for the sporty coupe segment, though the MX-6 was front-wheel drive and more of a personal luxury coupe.
Generation I Timeline:
1987-1991
Generation Ii Transition:
The second generation MX-6 (1992-1997) featured a more advanced chassis and design, often with the option of a V6 engine and active suspension.
Production
Manufacturing Location:
Japan (primarily Hofu Plant)
Sales Performance:
Moderately successful, appealing to a segment looking for style and performance without the V6 pricing of some competitors.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
While not directly winning 10Best, Mazda models often featured in these lists for their driving dynamics, which the MX-6 inherited.
Ratings
Consumer Reports:
Consumer Reports reliability ratings for this era varied, but generally Mazda was considered above average for import brands.
Certifications
Epa Fuel Economy:
EPA estimates for the 1991 MX-6 varied by engine and transmission, typically ranging from 18-22 MPG city and 25-28 MPG highway.
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