Mazda 6 2002-2014 Service Manual Service Manual

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🏷️ 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) 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...

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Sku: 89077

Collections: ALL Mazda

Availability: In stock

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

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Description

🏷️ 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.