Mazda Millenia 1993-2002 Factory Service & Shop Manual
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🏷️ Basic Information Identification Make: Mazda Model: Millenia Model Alias: Xedos 9 Year Range: 1993-2002 Codes Engine Code Primary: KL 👋 Introduction Market Position Target Audience: Professional automotive technicians, dealership service departments, and knowledgeable DIY enthusiasts. Competitive Analysis Advantage: Provides OEM-level documentation, mirroring the information used by Mazda dealerships. Key Features Completeness: Comprehensive workshop and service manual covering all aspects of vehicle maintenance and repair. Technical Accuracy: Factory-sourced information ensuring accuracy and reliability for all procedures. Accessibility: Digital PDF format allows for easy viewing, searching, and printing across various devices. 📋 Manual Details Coverage Areas Coverage Type: Factory Service & Shop Manual Primary Focus: Workshop & Service Procedures Page Count Total Pages: 1,386 Main Body Pages: 1,252 Supplementary Pages: 134 Manual Type Manual Classification: Factory Service Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul, disassembling, assembling, adjustment, tune-up, inspecting, diagnostic & troubleshooting for 2.5L (KL) V6 engine. Electrical Systems: Comprehensive Electrical Wiring Diagrams included. Fuel System: Detailed procedures for fuel line residual pressure testing, pressure regulator, and fuel pump hold pressure inspection. Drivetrain: Includes transmission maintenance, overhaul, and related diagnostics. Brakes: Coverage for brake system maintenance and repair procedures. Suspension Steering: Procedures for suspension and steering system maintenance and repair. Body Chassis: Includes bodywork, chassis adjustments, and related repairs. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, and general upkeep. Repair: Detailed repair instructions for all major vehicle systems. Diagnostics: Extensive diagnostic procedures and troubleshooting guides for identifying and resolving issues. Overhaul: Comprehensive overhaul procedures for major components like the engine. Technical Depth Depth Level: Dealer-level technical information, suitable for professional technicians and advanced DIY enthusiasts. Illustrations: Detailed illustrations accompanying each section and procedure for clarity. Information Retrieval: Easily navigable with a table of contents at the beginning of each section; pages are expandable for greater detail. 📊 Manual Specifications File Format PDF Quality: High Quality PDF Searchability: Searchable text for quick access to information. Printability: Printable documents, ensuring functionality on all devices. Bookmarked: Yes, the PDF is bookmarked for easy navigation. Print Quality Clarity: Guaranteed to be fully functional and intact without any missing pages. Binding Type Binding: Digital (PDF) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated V6 Displacement: 2.5 Liters (2490 cc) Engine Code: KL-DE Valvetrain: DOHC (Dual Overhead Camshaft), 24 Valves (4 per cylinder) Fuel Delivery: Multi-port Fuel Injection (MPI) Performance Horsepower Range: Approximately 170-180 HP (depending on specific market and year) Torque Range: Approximately 210-220 lb-ft (depending on specific market and year) Fuel System Fuel Pressure Specification: More than 150 kPa {1.5 kgf/cm², 21 psi} (Residual Pressure) Fuel Type: Unleaded gasoline (typically 87 octane or higher) 🔧 Transmission Standard Transmission Type Standard: Automatic Transmission (e.g., 4-speed electronically controlled) Optional Transmission Type Optional: Manual Transmission (less common, typically 5-speed) Features Transmission Control: Electronic control systems for shift quality and performance tuning. 📐 Dimensions Exterior Wheelbase: Approximately 2705 mm (106.5 inches) Length: Approximately 4870 mm (191.7 inches) Width: Approximately 1780 mm (70.1 inches) Height: Approximately 1385 mm (54.5 inches) Weights Curb Weight: Approximately 1500-1600 kg (3300-3530 lbs), varies by trim and options 🛡️ Safety Features Ratings Crash Test Data: Refer to NHTSA and IIHS reports for specific model year data; generally aimed for good passenger protection for its era. Active Features ABS: Standard Anti-lock Braking System (ABS) on most models. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: Three-point inertia-reel seat belts with pretensioners for front occupants. 💡 Technology Features Infotainment Audio System: Factory-installed premium audio systems, often with CD players and AM/FM radio. Bose premium sound systems were available on higher trims. Climate Control: Automatic climate control systems with digital displays were common. Driver Assistance Cruise Control: Standard cruise control. Traction Control: Traction Control System (TCS) was available on some models. Connectivity Connectivity Features: Limited by era; primarily focused on audio and climate control features. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6 months, consult manual for specific recommendation based on driving conditions. Timing Belt Replacement: Crucial for KL-DE engine; recommended every 60,000-90,000 miles or 5-7 years. Failure can cause severe engine damage. Fluid Specifications Engine Oil Type: API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for precise specification). Coolant Type: Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant with a 50/50 mix. Transmission Fluid: Mazda Genuine ATF MV or equivalent Dexron-III/Mercon compatible fluid. Known Issues Power Steering Pump: Some models may experience leaks or noise from the power steering pump or lines. Coil Packs And Spark Plugs: Ignition coil failures and worn spark plugs can lead to misfires and reduced performance. Vacuum Leaks: Aging vacuum hoses can develop leaks, affecting engine idle and performance. Automatic Transmission Issues: Occasional reports of rough shifting or transmission failure;...
Manual Transmission (less common, typically 5-speed)
Features
Transmission Control:
Electronic control systems for shift quality and performance tuning.
📐 Dimensions
Exterior
Wheelbase:
Approximately 2705 mm (106.5 inches)
Length:
Approximately 4870 mm (191.7 inches)
Width:
Approximately 1780 mm (70.1 inches)
Height:
Approximately 1385 mm (54.5 inches)
Weights
Curb Weight:
Approximately 1500-1600 kg (3300-3530 lbs), varies by trim and options
🛡️ Safety Features
Ratings
Crash Test Data:
Refer to NHTSA and IIHS reports for specific model year data; generally aimed for good passenger protection for its era.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point inertia-reel seat belts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory-installed premium audio systems, often with CD players and AM/FM radio. Bose premium sound systems were available on higher trims.
Climate Control:
Automatic climate control systems with digital displays were common.
Driver Assistance
Cruise Control:
Standard cruise control.
Traction Control:
Traction Control System (TCS) was available on some models.
Connectivity
Connectivity Features:
Limited by era; primarily focused on audio and climate control features.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 6 months, consult manual for specific recommendation based on driving conditions.
Timing Belt Replacement:
Crucial for KL-DE engine; recommended every 60,000-90,000 miles or 5-7 years. Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 or 10W-30 (check owner's manual for precise specification).
Coolant Type:
Mazda Genuine Long Life Antifreeze/Coolant (Blue) or equivalent ethylene glycol-based coolant with a 50/50 mix.
Transmission Fluid:
Mazda Genuine ATF MV or equivalent Dexron-III/Mercon compatible fluid.
Known Issues
Power Steering Pump:
Some models may experience leaks or noise from the power steering pump or lines.
Coil Packs And Spark Plugs:
Ignition coil failures and worn spark plugs can lead to misfires and reduced performance.
Vacuum Leaks:
Aging vacuum hoses can develop leaks, affecting engine idle and performance.
Automatic Transmission Issues:
Occasional reports of rough shifting or transmission failure; regular fluid changes are critical.
📚 Vehicle History
Brand Heritage
Mazda Philosophy:
Mazda is known for its innovative engineering, distinctive design, and focus on driving enjoyment (Jinba Ittai - horse and rider as one).
Model Evolution
Millenia Introduction:
Introduced in North America in 1994 as a 1995 model year vehicle, it was based on the Japanese Eunos Cosmo. It was positioned as a premium sedan.
Engine Development:
Featured Mazda's innovative Miller-cycle supercharged V6 engine in earlier models (Millenia S), later transitioning to a naturally aspirated 2.5L V6 (KL-DE) for wider appeal and reliability.
Production
Production Period:
1993-2002
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Five Best:
The Mazda Millenia (specifically the Millenia S with the Miller-cycle engine) was featured on Car and Driver's 10Best list in 1995.