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Mazda MX-6 GT 4WS GT-R Turbo 1989-1992 Service Repair Shop Manual

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🏷️ Basic Information Identification Make: Mazda Model: MX-6 Generation: Second Generation (GE) Years Covered: 1989, 1990, 1991, 1992 Trim Levels Covered: GT, GT-R, 4WS Engine Variants Covered: 2.2L Turbocharged I4 (F2T) Codes Chassis Codes: GE series 👋 Introduction Market Position Vehicle Segment: Sporty Personal Luxury Coupe / Grand Tourer Target Audience: Enthusiasts seeking a capable and stylish coupe with performance credentials. Competitive Analysis Key Competitors: Toyota Supra, Nissan 240SX, Mitsubishi Eclipse GSX, Honda Prelude Si. Key Features Distinctive Features: Optional 4WS (Four-Wheel Steering) system for enhanced agility, turbocharged engine for strong performance, stylish coupe design. Manual Value Proposition Primary Benefit To Owner: Enables DIY maintenance and repair, saving significant costs on dealership or independent mechanic services. Target User Expertise: Suitable for hobbyist mechanics and professional technicians alike due to its depth. 📋 Manual Details Coverage Areas Primary Regions Of Operation: North America, Japan, Europe (specific market variations may exist) Market Focus: Service and repair for performance-oriented models Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Service and Repair Shop Manual Language Language: English Format Format: Digital Download (PDF compatible) 📖 Manual Coverage Systems Covered Engine: 2.2L F2T Turbocharged Engine: Overhaul, diagnostics, component replacement, tuning, fuel injection, ignition, cooling, lubrication. Transmission: Manual (G5M-R) and Automatic Transmissions: Repair, adjustment, fluid changes, clutch service, differential overhaul. Drivetrain: Driveshafts, CV joints, limited-slip differentials, front and rear suspension geometry, wheel alignment. Steering: Power Steering System, Rack and Pinion, 4WS (Four-Wheel Steering) System: Operation, service, troubleshooting, calibration. Brakes: Front/Rear Disc Brakes, ABS (Anti-lock Braking System): Hydraulic system service, pad/rotor replacement, bleeding procedures, ABS sensor diagnostics. Electrical System: Wiring Diagrams, Fuses, Relays, Lighting, Instruments, Audio, Power Windows/Locks, Cruise Control, Alarm System. Engine Control System: ECU (Engine Control Unit) operation, sensor diagnostics (MAP, TPS, Knock, O2), actuator testing, boost control. Chassis And Body: Frame, body panels, doors, glass, interior trim, seats, exterior trim, rust prevention, sound deadening. Climate Control: HVAC system, A/C refrigerant service, blower motor, heater core, climate control panel. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel filter replacement. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug service, belt inspections/replacement, brake fluid flush. Troubleshooting: Diagnostic flowcharts for common drivability issues, electrical faults, starting problems, performance complaints. Repair: Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension component replacement, bodywork repairs. Diagnostics: On-board diagnostics (OBD-I), fault code interpretation, sensor testing, component testing with multimeter and specialized tools. Adjustments: Idle speed adjustment, ignition timing, clutch pedal free play, parking brake adjustment. Specifications: Torque specifications for all fasteners, fluid capacities, electrical component resistance values, alignment specifications. Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to full engine/transmission rebuilds) Diagnostic Focus: Advanced diagnostics for turbocharged systems and 4WS functionality 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text (OCR processed) Print Quality Print Quality: High-resolution scans with clear text and diagrams Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: F2T (FE3) Engine Type: Inline 4-Cylinder, DOHC, 16 Valves, Turbocharged and Intercooled Displacement: 2.2 Liters (2184 cc) Performance Horsepower Net: 190 hp @ 6000 rpm (approx.) Torque Net: 203 lb-ft @ 3500 rpm (approx.) Bore X Stroke: 86.0 mm x 94.0 mm Compression Ratio: 8.3:1 Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Turbocharger Recommended Fuel: Premium Unleaded Gasoline (91+ Octane) Turbocharger Turbocharger Model: Mitsubishi TD05H-14B (typical) Boost Pressure Stock: Approximately 10-12 psi (controllable) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual (G5M-R) Optional Transmission Type Optional: 4-Speed Automatic with Overdrive Features Manual Transmission Features: Close-ratio gearing, limited-slip differential (LSD) often standard on GT-R. Automatic Transmission Features Automatic Transmission Features: Electronically controlled, 'Sport' mode programming. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (refer to manual for exact spec) Automatic Transmission Fluid: Mazda ATF-M III or equivalent (Dexron III compatible) 📐 Dimensions Exterior Length: 176.4 inches (4480 mm) Width: 69.1 inches (1755 mm) Height: 50.2 inches (1275 mm) Wheelbase: 104.5 inches (2655 mm) Front Track: 59.3 inches (1505 mm) Rear Track: 58.5 inches (1485 mm) (4WS models may vary slightly) Weights Curb Weight: 3080 - 3250 lbs (1397 - 1474 kg) (depending on options) Gross Vehicle Weight Rating: Approx. 4000 lbs (1814 kg) Cargo Trunk Volume: Approx. 10.2 cu ft 🛡️ Safety Features Ratings NHTSA Crash Test Ratings: Not extensively rated by modern standards, but generally considered robust for its era. Focus on structural integrity. Active Features Active Safety Features: Optional Anti-lock Braking System (ABS). Passive Features Passive Safety Features: 3-point seat belts, reinforced passenger cage, side-impact door beams, driver airbag (late models/optional). Lighting Headlight Type: Pop-up (retractable) halogen headlights 💡 Technology Features Infotainment Audio System: Factory AM/FM Stereo Cassette player, optional CD player, speaker configurations (e.g., 6-speaker system). Climate Control Interface: Manual or automatic climate control systems with...
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Mazda MX-6 GT 4WS GT-R Turbo 1989-1992 Service Repair Shop Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
MX-6
Generation:
Second Generation (GE)
Years Covered:
1989, 1990, 1991, 1992
Trim Levels Covered:
GT, GT-R, 4WS
Engine Variants Covered:
2.2L Turbocharged I4 (F2T)
Codes
Chassis Codes:
GE series
👋 Introduction
Market Position
Vehicle Segment:
Sporty Personal Luxury Coupe / Grand Tourer
Target Audience:
Enthusiasts seeking a capable and stylish coupe with performance credentials.
Competitive Analysis
Key Competitors:
Toyota Supra, Nissan 240SX, Mitsubishi Eclipse GSX, Honda Prelude Si.
Key Features
Distinctive Features:
Optional 4WS (Four-Wheel Steering) system for enhanced agility, turbocharged engine for strong performance, stylish coupe design.
Manual Value Proposition
Primary Benefit To Owner:
Enables DIY maintenance and repair, saving significant costs on dealership or independent mechanic services.
Target User Expertise:
Suitable for hobbyist mechanics and professional technicians alike due to its depth.
📋 Manual Details
Coverage Areas
Primary Regions Of Operation:
North America, Japan, Europe (specific market variations may exist)
Market Focus:
Service and repair for performance-oriented models
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Service and Repair Shop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF compatible)
📖 Manual Coverage
Systems Covered
Engine:
2.2L F2T Turbocharged Engine: Overhaul, diagnostics, component replacement, tuning, fuel injection, ignition, cooling, lubrication.
Transmission:
Manual (G5M-R) and Automatic Transmissions: Repair, adjustment, fluid changes, clutch service, differential overhaul.
Drivetrain:
Driveshafts, CV joints, limited-slip differentials, front and rear suspension geometry, wheel alignment.
Steering:
Power Steering System, Rack and Pinion, 4WS (Four-Wheel Steering) System: Operation, service, troubleshooting, calibration.
Brakes:
Front/Rear Disc Brakes, ABS (Anti-lock Braking System): Hydraulic system service, pad/rotor replacement, bleeding procedures, ABS sensor diagnostics.
Electrical System:
Wiring Diagrams, Fuses, Relays, Lighting, Instruments, Audio, Power Windows/Locks, Cruise Control, Alarm System.
Engine Control System:
ECU (Engine Control Unit) operation, sensor diagnostics (MAP, TPS, Knock, O2), actuator testing, boost control.
Chassis And Body:
Frame, body panels, doors, glass, interior trim, seats, exterior trim, rust prevention, sound deadening.
Climate Control:
HVAC system, A/C refrigerant service, blower motor, heater core, climate control panel.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, fuel filter replacement.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug service, belt inspections/replacement, brake fluid flush.
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, starting problems, performance complaints.
Repair:
Step-by-step repair instructions for all major vehicle systems, including engine rebuilds, transmission overhauls, suspension component replacement, bodywork repairs.
Diagnostics:
On-board diagnostics (OBD-I), fault code interpretation, sensor testing, component testing with multimeter and specialized tools.
Adjustments:
Idle speed adjustment, ignition timing, clutch pedal free play, parking brake adjustment.
Specifications:
Torque specifications for all fasteners, fluid capacities, electrical component resistance values, alignment specifications.
Technical Depth
Depth Of Coverage:
Comprehensive (from basic maintenance to full engine/transmission rebuilds)
Diagnostic Focus:
Advanced diagnostics for turbocharged systems and 4WS functionality
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Searchable text (OCR processed)
Print Quality
Print Quality:
High-resolution scans with clear text and diagrams
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
F2T (FE3)
Engine Type:
Inline 4-Cylinder, DOHC, 16 Valves, Turbocharged and Intercooled
Displacement:
2.2 Liters (2184 cc)
Performance
Horsepower Net:
190 hp @ 6000 rpm (approx.)
Torque Net:
203 lb-ft @ 3500 rpm (approx.)
Bore X Stroke:
86.0 mm x 94.0 mm
Compression Ratio:
8.3:1
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Turbocharger
Recommended Fuel:
Premium Unleaded Gasoline (91+ Octane)
Turbocharger
Turbocharger Model:
Mitsubishi TD05H-14B (typical)
Boost Pressure Stock:
Approximately 10-12 psi (controllable)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual (G5M-R)
Optional
Transmission Type Optional:
4-Speed Automatic with Overdrive
Features
Manual Transmission Features:
Close-ratio gearing, limited-slip differential (LSD) often standard on GT-R.
Automatic Transmission Features
Automatic Transmission Features:
Electronically controlled, 'Sport' mode programming.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (refer to manual for exact spec)
Automatic Transmission Fluid:
Mazda ATF-M III or equivalent (Dexron III compatible)
📐 Dimensions
Exterior
Length:
176.4 inches (4480 mm)
Width:
69.1 inches (1755 mm)
Height:
50.2 inches (1275 mm)
Wheelbase:
104.5 inches (2655 mm)
Front Track:
59.3 inches (1505 mm)
Rear Track:
58.5 inches (1485 mm) (4WS models may vary slightly)
Weights
Curb Weight:
3080 - 3250 lbs (1397 - 1474 kg) (depending on options)
Gross Vehicle Weight Rating:
Approx. 4000 lbs (1814 kg)
Cargo
Trunk Volume:
Approx. 10.2 cu ft
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Not extensively rated by modern standards, but generally considered robust for its era. Focus on structural integrity.
Active Features
Active Safety Features:
Optional Anti-lock Braking System (ABS).
Passive Features
Passive Safety Features:
3-point seat belts, reinforced passenger cage, side-impact door beams, driver airbag (late models/optional).
Lighting
Headlight Type:
Pop-up (retractable) halogen headlights
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM Stereo Cassette player, optional CD player, speaker configurations (e.g., 6-speaker system).
Climate Control Interface:
Manual or automatic climate control systems with physical knobs and buttons.
Driver Assistance
Driver Assistance Features:
ABS (Anti-lock Braking System), Cruise Control.
Connectivity
Connectivity Options:
N/A (pre-smartphone era, basic wired connectivity for audio).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months (depending on driving conditions).
Air Filter Replacement:
Every 15,000 miles or annually.
Spark Plug Replacement:
Every 30,000 miles (specific type recommended in manual).
Timing Belt Replacement:
Crucial: Every 60,000 miles or 5 years due to it being an interference engine.
Fluid Specifications
Engine Oil Capacity:
4.8 US quarts (4.5 Liters) with filter change.
Engine Oil Type:
API SJ/SL or higher, SAE 10W-30 or 10W-40 (check manual for specific temp recommendations).
Coolant Capacity:
7.0 US quarts (6.6 Liters).
Coolant Type:
Ethylene glycol-based antifreeze with water (50/50 mix recommended).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Issues Engine:
Turbocharger wear, blown head gaskets (due to heat/age), distributor issues, MAF sensor (if applicable, though likely MAP), fuel injector clogging.
Common Issues Drivetrain:
Worn clutch components, differential seals, CV joint boots.
Common Issues Suspension:
Worn bushings, ball joints, tie rod ends, struts/shocks.
Common Issues Electrical:
Corroded grounds, aging wiring harnesses, power window motor failure, HVAC blower resistor issues.
Common Issues 4Ws:
Hydraulic leaks in the 4WS system, sensor malfunctions, actuator wear.
📚 Vehicle History
Brand Heritage
Mazda Performance Heritage:
Mazda's history of sporty, driver-focused vehicles, exemplified by the RX-7, provided a foundation for the MX-6's performance aspirations.
Model Evolution
Mx6 First Generation:
First generation (1987-1991) was a coupe based on the Mazda Capella (626) platform.
Mx6 Second Generation:
Second generation (1991-1997) shared its platform with the Ford Probe and Mazda MX-6 (Japan market). This manual covers the latter part of the second generation.
Gt R Trim Significance:
GT-R designation often indicated a higher performance variant, sometimes with AWD (though primarily FWD in the US market MX-6 context, focus is on the GT Turbo 4WS).
Production
Manufacturing Plant:
Hofu Plant, Yamaguchi Prefecture, Japan
Production Volume:
Moderate volume, as it was a niche performance coupe.
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
Often praised for its styling and performance in period reviews, but specific major awards are less common than for some contemporaries.
Ratings
Handling Performance:
Generally well-regarded for its handling, especially with the optional 4WS system enhancing agility.
Certifications
Emissions Standards:
Meets emissions standards for its respective model years (e.g., EPA, CARB).
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