Mazda 6 2002-2014 Full Service Repair Manual

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The Mazda 6, produced from 2002 through 2014, is a mid-size sedan and wagon renowned for its engaging driving dynamics, stylish aerodynamic design, and overall reliability. This generation of Mazda vehicles embodies the brand's 'Zoom-Zoom' philosophy, offering sporty handling, responsive steering, and a well-tuned suspension that sets it apart from many competitors. Available with a range of MZR engines, including naturally aspirated and turbocharged variants, and offering both manual and automatic transmissions, as well as available All-Wheel Drive, the Mazda 6 provided a compelling blend of performance and practicality for a wide array of drivers. Its commitment to safety is reflected in consistently high ratings from organizations like NHTSA and IIHS, with standard active safety features such as ABS, Traction Control, and Dynamic Stability Control. This comprehensive service and repair manual covers the Mazda 6 models from 2002 to 2014, across various global markets. It provides detailed information and step-by-step procedures for all major vehicle systems, including engine mechanicals, fuel and emissions, transmissions (manual and automatic), drivetrain, brakes, suspension, steering, and the electrical system. The manual also delves into HVAC, body and chassis repairs, and restraint systems. Essential maintenance schedules, fluid specifications, diagnostic guidance for common issues, and in-depth troubleshooting techniques are included to assist owners and technicians. With over 1000 pages of high-resolution, searchable content, this manual is an indispensable resource for maintaining, diagnosing, and repairing the Mazda 6 to ensure its optimal performance and longevity. 🏷️ Basic Information Identification Make: Mazda Model: Mazda 6 Generation Covered Years: 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 Codes Chassis Codes: GG, GY, GH (depending on specific model year and market) 👋 Introduction Market Position Segment: Mid-size Sedan/Wagon Perception: Known for engaging driving dynamics, stylish design, and reliability. Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu. Key Features Driving Dynamics: Sporty handling, responsive steering, well-tuned suspension. Design: Aerodynamic styling, distinctive 'Zoom-Zoom' design language. Reliability: Generally good reliability, particularly with routine maintenance. 📋 Manual Details Coverage Areas Regions Covered: Global (primarily North American and European market specifications, adaptable for other regions) Page Count Estimated Pages: 1000+ Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: Digital (likely PDF, downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system (belts/chains), lubrication, cooling, intake, exhaust Engine Management: Fuel injection, ignition system, emissions control, sensors, actuators, ECU (Engine Control Unit) diagnostics and repair Transmission Manual: Gearbox overhaul, clutch, shift mechanism, synchronizers, bearings, seals Transmission Automatic: Automatic transmission repair, valve body, torque converter, planetary gear sets, electronic control, fluid service Drivetrain: Front-wheel drive (FWD) axle shafts, CV joints, differentials (in transaxle), rear suspension mounting points Brakes: Hydraulic system, brake lines, master cylinder, calipers, pads, rotors, ABS (Anti-lock Braking System) components and diagnostics, parking brake Suspension: Front suspension (MacPherson struts, control arms, ball joints, sway bar), rear suspension (multi-link or independent), shock absorbers, springs, bushings Steering: Power steering system (hydraulic or electric), steering rack, tie rods, steering column, wheel alignment specifications Electrical System: Battery, charging system (alternator, starter), lighting, ignition switch, wiring diagrams, fuses, relays, control modules HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, blower motor, evaporator, condenser, refrigerant, climate control module Body And Chassis: Body panels, doors, hood, trunk, glass, interior trim, chassis frame components, collision repair basics Restraint Systems: Airbag system, seat belts, SRS module diagnostics and replacement Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, tire rotations Diagnostics: Troubleshooting common problems, DTC (Diagnostic Trouble Code) interpretation, using scan tools, symptom-based diagnostics Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment Overhaul Procedures: Detailed instructions for complete disassembly and reassembly of major components (engines, transmissions) Electrical Troubleshooting: Interpreting wiring diagrams, tracing circuits, diagnosing electrical faults Calibration And Adjustment: Wheel alignment, throttle body cleaning/relearn, idle speed adjustments Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics) 📊 Manual Specifications File Format Quality: High-resolution, searchable text, printable pages Print Quality Resolution: Excellent (designed for clarity of diagrams and text) Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Family 1: MZR / LF-VE (2.0L DOHC I4) Engine Family 2: MZR / L3-VE (2.3L DOHC I4) Engine Family 3: MZR DISI Turbo / L3-VDT (2.3L DOHC Turbo I4 - Mazdaspeed 6) Engine Family 4: MZR / LF-DE (2.5L DOHC I4 - later models) Performance 2.3L Horsepower 2.3L: Approx. 160-170 hp (naturally aspirated) Torque 2.3L: Approx. 170-180 lb-ft (naturally aspirated) Performance 2.3L Turbo Horsepower 2.3L Turbo: Approx. 274 hp (Mazdaspeed 6) Torque 2.3L Turbo: Approx. 290 lb-ft (Mazdaspeed 6) Performance 2.5L Horsepower 2.5L: Approx. 167-170 hp Torque 2.5L: Approx. 167-170 lb-ft Fuel System Type: Electronic Fuel Injection (EFI), Sequential...

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Sku: 98063

Collections: ALL Mazda

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

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Mazda 6

Generation

Covered Years:

2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014

Codes

Chassis Codes:

GG, GY, GH (depending on specific model year and market)

👋 Introduction

Market Position

Segment:

Mid-size Sedan/Wagon

Perception:

Known for engaging driving dynamics, stylish design, and reliability.

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu.

Key Features

Driving Dynamics:

Sporty handling, responsive steering, well-tuned suspension.

Design:

Aerodynamic styling, distinctive 'Zoom-Zoom' design language.

Reliability:

Generally good reliability, particularly with routine maintenance.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (primarily North American and European market specifications, adaptable for other regions)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, downloadable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system (belts/chains), lubrication, cooling, intake, exhaust

Engine Management:

Fuel injection, ignition system, emissions control, sensors, actuators, ECU (Engine Control Unit) diagnostics and repair

Transmission Manual:

Gearbox overhaul, clutch, shift mechanism, synchronizers, bearings, seals

Transmission Automatic:

Automatic transmission repair, valve body, torque converter, planetary gear sets, electronic control, fluid service

Drivetrain:

Front-wheel drive (FWD) axle shafts, CV joints, differentials (in transaxle), rear suspension mounting points

Brakes:

Hydraulic system, brake lines, master cylinder, calipers, pads, rotors, ABS (Anti-lock Braking System) components and diagnostics, parking brake

Suspension:

Front suspension (MacPherson struts, control arms, ball joints, sway bar), rear suspension (multi-link or independent), shock absorbers, springs, bushings

Steering:

Power steering system (hydraulic or electric), steering rack, tie rods, steering column, wheel alignment specifications

Electrical System:

Battery, charging system (alternator, starter), lighting, ignition switch, wiring diagrams, fuses, relays, control modules

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, blower motor, evaporator, condenser, refrigerant, climate control module

Body And Chassis:

Body panels, doors, hood, trunk, glass, interior trim, chassis frame components, collision repair basics

Restraint Systems:

Airbag system, seat belts, SRS module diagnostics and replacement

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, tire rotations

Diagnostics:

Troubleshooting common problems, DTC (Diagnostic Trouble Code) interpretation, using scan tools, symptom-based diagnostics

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment

Overhaul Procedures:

Detailed instructions for complete disassembly and reassembly of major components (engines, transmissions)

Electrical Troubleshooting:

Interpreting wiring diagrams, tracing circuits, diagnosing electrical faults

Calibration And Adjustment:

Wheel alignment, throttle body cleaning/relearn, idle speed adjustments

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics)

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable text, printable pages

Print Quality

Resolution:

Excellent (designed for clarity of diagrams and text)

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper Quality:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Family 1:

MZR / LF-VE (2.0L DOHC I4)

Engine Family 2:

MZR / L3-VE (2.3L DOHC I4)

Engine Family 3:

MZR DISI Turbo / L3-VDT (2.3L DOHC Turbo I4 - Mazdaspeed 6)

Engine Family 4:

MZR / LF-DE (2.5L DOHC I4 - later models)

Performance 2.3L

Horsepower 2.3L:

Approx. 160-170 hp (naturally aspirated)

Torque 2.3L:

Approx. 170-180 lb-ft (naturally aspirated)

Performance 2.3L Turbo

Horsepower 2.3L Turbo:

Approx. 274 hp (Mazdaspeed 6)

Torque 2.3L Turbo:

Approx. 290 lb-ft (Mazdaspeed 6)

Performance 2.5L

Horsepower 2.5L:

Approx. 167-170 hp

Torque 2.5L:

Approx. 167-170 lb-ft

Fuel System

Type:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (S-MPI) or Direct Injection (DISI for turbo).

Required Octane:

87 Octane (Premium recommended for turbo models)

🔧 Transmission

Standard Transmission 1

Type:

5-speed Manual

Standard Transmission 2

Type:

6-speed Manual (often on sportier trims or later models)

Optional Transmission 1

Type:

5-speed Automatic

Optional Transmission 2

Type:

6-speed Automatic (often on later models or specific engines)

Features

AWD Option:

All-Wheel Drive (AWD) available on select models, often paired with the 2.3L and 2.5L engines.

📐 Dimensions

Exterior Length

Approx Length:

186-191 inches (depending on generation and body style)

Exterior Width

Approx Width:

70-71 inches

Exterior Height

Approx Height:

57-58 inches

Wheelbase

Approx Wheelbase:

105-106 inches

Weights

Curb Weight:

Approx. 3100-3500 lbs (depending on engine, transmission, and trim)

🛡️ Safety Features

Ratings Nhtsa

Front Impact Driver:

5-Star (typically for most years and configurations)

Front Impact Passenger:

5-Star (typically for most years and configurations)

Side Impact Front Driver:

5-Star (typically)

Side Impact Front Passenger:

5-Star (typically)

Side Impact Rear Driver:

5-Star (typically)

Side Impact Rear Passenger:

4-Star or 5-Star (depending on year/configuration)

Ratings Iihs

Overall Rating:

Good (in most categories for applicable years)

Active Features

Standard Anti-lock Braking System

Traction Control:

Standard Traction Control System (TCS)

Electronic Stability:

Standard Electronic Stability Control (DSC - Dynamic Stability Control)

Passive Features

Airbags:

Front airbags, side-impact airbags, side-curtain airbags (standard on most trims/years)

Seatbelts:

Pretensioner seatbelts with load limiters

💡 Technology Features

Infotainment Generation 1

Features:

Basic AM/FM/CD player, optional satellite radio, steering wheel audio controls.

Infotainment Generation 2

Features:

Color LCD displays, Bluetooth connectivity (later models), MP3 CD player, Bose audio system option, navigation system option.

Driver Assistance

Features:

Cruise control, available rain-sensing wipers, automatic headlights, parking sensors (on some trims).

Connectivity

Auxiliary Input:

Auxiliary audio input jack available on many models.

Bluetooth:

Available on mid-to-late generation models for hands-free calling and audio streaming.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000-7,500 miles or 6-12 months, depending on driving conditions and oil type.

Air Filter:

Inspect every 15,000 miles, replace as needed (typically every 30,000 miles).

Cabin Filter:

Replace every 15,000-30,000 miles or annually.

Spark Plugs:

Replace every 60,000-100,000 miles (depending on plug type: copper, iridium).

Coolant Flush:

Replace every 50,000-100,000 miles or 4-5 years.

Transmission Fluid Auto:

Inspect every 30,000 miles, service every 60,000-100,000 miles (refer to manual for specific fluid type and procedure).

Fluid Specifications

Engine Oil:

API SN or higher, SAE 0W-20 or 5W-30 (verify with owner's manual for specific engine and climate).

Coolant:

Mazda FL22 Long Life Coolant (or equivalent Asian-spec green/blue coolant).

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

ATF Dexron III or equivalent (verify for specific model year/type, some may use specific Mazda fluid).

Transmission Fluid Manual:

SAE 75W-90 GL-4 gear oil.

Transmission Fluid Auto:

Mazda ATF-Type M-III or M-V (verify for specific model year/transmission).

Known Issues

Engine Oil Consumption:

Some 2.3L MZR engines (especially early ones) may exhibit oil consumption. Regular checks and using the correct oil viscosity are important.

Rust And Corrosion:

Common in areas with road salt. Check wheel wells, rocker panels, and undercarriage for corrosion.

Vibrations:

Wheel balance, suspension components, or exhaust system issues can cause vibrations. Engine mount wear is also a possibility.

Power Steering Pump:

Early models could experience power steering pump noise or leaks.

Catalytic Converter:

Can become clogged over time, affecting performance. Often related to engine oil consumption or misfires.

📚 Vehicle History

Brand Heritage

Mazda Philosophy:

Mazda's 'Zoom-Zoom' philosophy emphasizes driving enjoyment and responsive handling.

Model Evolution

Generation 1:

First Generation (2002-2008, chassis GG/GY): Introduced globally, available as sedan and wagon. Known for its distinctive styling and driving characteristics.

Generation 2:

Second Generation (2008-2013, chassis GH): Redesigned with a larger footprint, improved interior, and updated powertrains. Offered sedan, hatchback (in some markets), and wagon. Introduction of 2.5L engine.

Generation 3:

Third Generation (2013-2014, chassis KE/GH facelift): Minor update for the 2014 model year often considered part of the second generation's lifecycle, with some powertrain refinements and feature updates.

Production

Manufacturing Locations:

Japan (primarily Hofu Plant)

🏆 Awards & Recognition

Recognitions

Car Of The Year:

Named Car of the Year by various automotive publications in different markets upon its introduction.

Top Safety Pick:

Many Mazda 6 models have received 'Top Safety Pick' ratings from the IIHS.