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Mazda 626 1997-2002 Service Repair Manual 1998 1999 2000 2001

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🏷️ Basic Information Identification Make: Mazda Model: 626 Generation: GF/GW Codes Chassis Codes: GF (Sedan/Hatchback), GW (Wagon) Platform: Mazda GF-Platform 👋 Introduction Market Position Positioning: The Mazda 626 GF/GW generation was positioned as a reliable, comfortable, and practical mid-size sedan and wagon, offering a good balance of performance, efficiency, and value in its segment. Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Contour, Chevrolet Malibu, Hyundai Sonata Key Features Design Philosophy: Stylish and aerodynamic design, comfortable interior, good handling characteristics ('Zoom-Zoom' heritage beginning to emerge) Manual Utility: Provides professional-level diagnostic and repair information, enabling DIY enthusiasts and professional mechanics to perform accurate maintenance and repairs. 📋 Manual Details Coverage Areas Years Covered: 1997, 1998, 1999, 2000, 2001 Page Count Estimated Page Count: Over 1500 (estimated for comprehensive factory manual) Manual Type Type: Service and Repair Manual (Workshop Manual) Language Language: English Format Digital Format: PDF (Downloadable, potentially zipped) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, exhaust, engine management, transmission (manual and automatic) Chassis: Front and rear suspension, steering system, braking system (including ABS), wheels and tires Body: Body construction, exterior panels, interior trim, doors, windows, locks, seats, HVAC system, body electrical systems Electrical: Wiring diagrams, lighting, instruments, gauges, power windows, power locks, audio system, charging system, starting system, fuse/relay locations, ECUs Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and replacements, spark plug replacement, belt inspection/replacement Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation Repair: Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation Diagnostics: On-Board Diagnostics (OBD-II) information, sensor testing, actuator testing, ECU diagnostics Restoration: Procedures relevant to bringing a vehicle back to original specifications Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Printable without restrictions Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Quality: Not Applicable (Digital Download) File Size Storage Requirement: Up to 5 GB (as per product description) Software Requirements Reader Software: Any PDF Reader (e.g., Adobe Reader) Unzipping Software: WinZip or WinRAR (if file is zipped) ⚙️ Engine Specifications Primary Engine Engine Code 1: FS-DE (2.0L DOHC 16-valve Inline-4) Displacement 1: 1991 cc (2.0 Liters) Bore X Stroke 1: 83.0 mm x 92.0 mm Compression Ratio 1: 9.2:1 or 9.5:1 (depending on variant) Horsepower 1: Approx. 118-125 hp @ 5500-6000 rpm Torque 1: Approx. 128-133 lb-ft @ 3500-4000 rpm Fuel System 1: Multi-Point Fuel Injection (MPI) Emission Control 1: Catalytic Converter, EGR (Exhaust Gas Recirculation), Secondary Air Injection (some models) Secondary Engine Engine Code 2: GZ-DE (2.0L DOHC 16-valve Inline-4 - some markets) Horsepower 2: Approx. 130 hp Torque 2: Approx. 135 lb-ft Performance 0 60 Mph Approx: 9.5 - 10.5 seconds Fuel System Recommended Fuel: 87 Octane Unleaded Gasoline 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic (with Electronically Controlled Lock-up) Features Automatic Transmission Features: Sport mode, overdrive Fluid Specifications Manual Transmission Fluid Type: API GL-4, SAE 75W-90 or 75W-85 (Consult manual for exact specification) Automatic Transmission Fluid Type: Mazda ATF-MV or equivalent (Dexron III/Mercon compatible, but Mazda spec is preferred) 📐 Dimensions Exterior Length Sedan: Approx. 4735 mm (186.4 in) Length Wagon: Approx. 4745 mm (186.8 in) Width: Approx. 1770 mm (69.7 in) Height Sedan: Approx. 1400 mm (55.1 in) Height Wagon: Approx. 1470 mm (57.9 in) Wheelbase: Approx. 2670 mm (105.1 in) Weights Curb Weight Approx: 1350-1450 kg (2976-3197 lbs) Gross Vehicle Weight Rating: Consult vehicle VIN plate/manual Towing Capacity: Not typically specified or recommended for this model Wheels Tires Standard Tire Size: 195/65R15 or 205/55R16 (depending on trim) Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Offset: ET40-ET50 (Consult manual) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4-Star (1998 Model Year) NHTSA Front Impact Passenger: 4-Star (1998 Model Year) Active Features ABS: Optional (standard on higher trims) Traction Control: Rarely available, potentially on top trims Passive Features Airbags: Driver and Passenger Frontal Airbags Seatbelts: Front 3-point ELR seatbelts with pre-tensioners, rear 3-point or lap belts Body Structure: Reinforced chassis with crumple zones 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio systems available, cassette player on some base models Climate Control: Manual or Automatic Climate Control (depending on trim) Driver Assistance Cruise Control: Standard on many trims, optional on base models Connectivity Connectivity Features: Basic by modern standards; primarily focused on audio input. No Bluetooth or USB connectivity inherent to the factory system. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 miles or 6-12 months (depending on oil type and driving conditions) Air Filter Replacement: Every 15,000 - 30,000 miles Spark Plug Replacement: Every 60,000 - 100,000 miles (depending on spark plug type) Coolant...
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Mazda 626 1997-2002 Service Repair Manual 1998 1999 2000 2001
🏷️ Basic Information
Identification
Make:
Mazda
Model:
626
Generation:
GF/GW
Codes
Chassis Codes:
GF (Sedan/Hatchback), GW (Wagon)
Platform:
Mazda GF-Platform
👋 Introduction
Market Position
Positioning:
The Mazda 626 GF/GW generation was positioned as a reliable, comfortable, and practical mid-size sedan and wagon, offering a good balance of performance, efficiency, and value in its segment.
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Contour, Chevrolet Malibu, Hyundai Sonata
Key Features
Design Philosophy:
Stylish and aerodynamic design, comfortable interior, good handling characteristics ('Zoom-Zoom' heritage beginning to emerge)
Manual Utility:
Provides professional-level diagnostic and repair information, enabling DIY enthusiasts and professional mechanics to perform accurate maintenance and repairs.
📋 Manual Details
Coverage Areas
Years Covered:
1997, 1998, 1999, 2000, 2001
Page Count
Estimated Page Count:
Over 1500 (estimated for comprehensive factory manual)
Manual Type
Type:
Service and Repair Manual (Workshop Manual)
Language
Language:
English
Format
Digital Format:
PDF (Downloadable, potentially zipped)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, exhaust, engine management, transmission (manual and automatic)
Chassis:
Front and rear suspension, steering system, braking system (including ABS), wheels and tires
Body:
Body construction, exterior panels, interior trim, doors, windows, locks, seats, HVAC system, body electrical systems
Electrical:
Wiring diagrams, lighting, instruments, gauges, power windows, power locks, audio system, charging system, starting system, fuse/relay locations, ECUs
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and replacements, spark plug replacement, belt inspection/replacement
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation
Diagnostics:
On-Board Diagnostics (OBD-II) information, sensor testing, actuator testing, ECU diagnostics
Restoration:
Procedures relevant to bringing a vehicle back to original specifications
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable without restrictions
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper Quality:
Not Applicable (Digital Download)
File Size
Storage Requirement:
Up to 5 GB (as per product description)
Software Requirements
Reader Software:
Any PDF Reader (e.g., Adobe Reader)
Unzipping Software:
WinZip or WinRAR (if file is zipped)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
FS-DE (2.0L DOHC 16-valve Inline-4)
Displacement 1:
1991 cc (2.0 Liters)
Bore X Stroke 1:
83.0 mm x 92.0 mm
Compression Ratio 1:
9.2:1 or 9.5:1 (depending on variant)
Horsepower 1:
Approx. 118-125 hp @ 5500-6000 rpm
Torque 1:
Approx. 128-133 lb-ft @ 3500-4000 rpm
Fuel System 1:
Multi-Point Fuel Injection (MPI)
Emission Control 1:
Catalytic Converter, EGR (Exhaust Gas Recirculation), Secondary Air Injection (some models)
Secondary Engine
Engine Code 2:
GZ-DE (2.0L DOHC 16-valve Inline-4 - some markets)
Horsepower 2:
Approx. 130 hp
Torque 2:
Approx. 135 lb-ft
Performance
0 60 Mph Approx:
9.5 - 10.5 seconds
Fuel System
Recommended Fuel:
87 Octane Unleaded Gasoline
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (with Electronically Controlled Lock-up)
Features
Automatic Transmission Features:
Sport mode, overdrive
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 or 75W-85 (Consult manual for exact specification)
Automatic Transmission Fluid Type:
Mazda ATF-MV or equivalent (Dexron III/Mercon compatible, but Mazda spec is preferred)
📐 Dimensions
Exterior
Length Sedan:
Approx. 4735 mm (186.4 in)
Length Wagon:
Approx. 4745 mm (186.8 in)
Width:
Approx. 1770 mm (69.7 in)
Height Sedan:
Approx. 1400 mm (55.1 in)
Height Wagon:
Approx. 1470 mm (57.9 in)
Wheelbase:
Approx. 2670 mm (105.1 in)
Weights
Curb Weight Approx:
1350-1450 kg (2976-3197 lbs)
Gross Vehicle Weight Rating:
Consult vehicle VIN plate/manual
Towing Capacity:
Not typically specified or recommended for this model
Wheels Tires
Standard Tire Size:
195/65R15 or 205/55R16 (depending on trim)
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Offset:
ET40-ET50 (Consult manual)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-Star (1998 Model Year)
NHTSA Front Impact Passenger:
4-Star (1998 Model Year)
Active Features
ABS:
Optional (standard on higher trims)
Traction Control:
Rarely available, potentially on top trims
Passive Features
Airbags:
Driver and Passenger Frontal Airbags
Seatbelts:
Front 3-point ELR seatbelts with pre-tensioners, rear 3-point or lap belts
Body Structure:
Reinforced chassis with crumple zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems available, cassette player on some base models
Climate Control:
Manual or Automatic Climate Control (depending on trim)
Driver Assistance
Cruise Control:
Standard on many trims, optional on base models
Connectivity
Connectivity Features:
Basic by modern standards; primarily focused on audio input. No Bluetooth or USB connectivity inherent to the factory system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles or 6-12 months (depending on oil type and driving conditions)
Air Filter Replacement:
Every 15,000 - 30,000 miles
Spark Plug Replacement:
Every 60,000 - 100,000 miles (depending on spark plug type)
Coolant Replacement:
Every 2-3 years or 30,000-50,000 miles
Fluid Specifications
Engine Oil Type:
API SJ or SL, ILSAC GF-3, SAE 5W-30 or 5W-40 (Consult manual for exact specification and temperature ranges)
Engine Oil Capacity:
Approx. 4.2 Liters (4.4 US Quarts) with filter change
Coolant Type:
Ethylene Glycol based, HOAT (Hybrid Organic Acid Technology) or similar compatible antifreeze (Mazda FL22 recommended for later models, but for this era, a good quality green or orange coolant is typically suitable. Verify manual.)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Mazda Genuine Power Steering Fluid or Dexron II/III compatible ATF
Known Issues
Common Issues:
Slightly rough idle on some engines, potential for power window motor failure, occasional AC system leaks, exhaust hanger corrosion, dashboard plastic degradation (common for the era)
Maintenance Tips:
Regularly check and replace PCV valve, inspect vacuum lines, clean throttle body, use quality filters and fluids.
📚 Vehicle History
Brand Heritage
Mazda Legacy:
Mazda has a long history of producing reliable and engaging vehicles, with the 626 serving as a significant model in its global lineup for many years.
Model Evolution
Previous Generation:
Mazda Capella/626 (GD/GV) 1987-1992
Next Generation:
Mazda Atenza/Mazda6 (GG/GY) 2002-2008
Production
Production Period:
1997-2002 (for this generation)
Manufacturing Locations:
Japan (primary), potentially assembly in other regions
🏆 Awards & Recognition
Recognitions
Initial Reviews:
Generally well-received for its styling, comfort, and handling upon introduction, although sometimes overshadowed by more refined competitors.
Ratings
Consumer Reports Reliability:
Variable; typically rated average to above average for its time, with specific models and years showing better reliability trends.
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