The Mazda 6, first introduced in 2002, represents a significant entry into the mid-size sedan market, celebrated for its sporty handling, stylish design, and reliable powertrains. This first-generation model, built on the GG platform and available with either a 2.0L FS-DE or a more powerful 2.3L ZY-VE engine, offered a compelling blend of performance and practicality. With its spacious interior for its class and a commitment to driving dynamics, the Mazda 6 quickly earned accolades, including a spot on Car and Driver's 10Best list for 2003, establishing itself as a strong contender against established rivals. This comprehensive workshop manual provides detailed technical information and procedural guidance for the 2002 Mazda 6. It covers all major systems, including engine mechanical and performance, transmissions (manual and automatic), brakes, steering, suspension, and electrical systems. The manual includes preventative maintenance schedules, step-by-step component replacement instructions, diagnostic troubleshooting flowcharts, special tool requirements, and precise torque specifications. Its extensive coverage is designed to empower DIY enthusiasts, independent repair shops, and fleet maintenance personnel in effectively maintaining and repairing this vehicle. 🏷️ Basic Information Identification Make: Mazda Model: 6 Year: 2002 Codes Chassis Code: GG Engine Code Primary: FS-DE (2.0L) Engine Code Optional: ZY-VE (2.3L) Transmission Code Primary: GF4A-EL (4-speed automatic) Transmission Code Optional: GZ5 (5-speed manual) 👋 Introduction Market Position Segment: Mid-size Sedan / Sport Sedan Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance. Competitive Analysis Key Competitors 2002: Toyota Camry, Honda Accord, Nissan Altima, Ford Mondeo, Volkswagen Passat. Key Features Vehicle Highlights: Sporty handling, stylish design, reliable powertrains, spacious interior for its class. Manual Value Proposition: Provides in-depth technical knowledge and procedural guidance for maintaining and repairing the Mazda 6 of this era, empowering owners and technicians alike. 📋 Manual Details Coverage Areas Covered Regions: Global (primarily North America and Europe) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing belt/chain, valves, lubrication system, cooling system. Engine Performance: Fuel system (injectors, pump, lines), ignition system, exhaust system, emission control systems (catalytic converter, O2 sensors). Transmission Mechanical: Manual transmission overhaul, automatic transmission overhaul (including valve body, clutch packs, torque converter), clutch system (for manual). Transmission Electronic: Transmission control module (TCM) diagnostics and operation, shift solenoid testing. Brakes: Hydraulic system, ABS system (including sensors, control module, hydraulic unit), brake pad replacement, rotor replacement, caliper service, brake fluid bleeding. Steering: Power steering system (pump, rack, lines), steering column, wheel alignment specifications. Suspension: Front and rear suspension components (struts, shocks, control arms, bushings), wheel bearings, sway bars. Electrical System: Battery, charging system (alternator, starter), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM) basics. HVAC: Air conditioning system (compressor, refrigerant, condenser, evaporator), heating system, climate control module, cabin air filter replacement. Body And Interior: Body panel removal and installation, door mechanisms, seat removal, trim panel replacement, glass replacement. Diagnostics: On-Board Diagnostics (OBD-II) procedures, diagnostic trouble codes (DTCs) with descriptions and troubleshooting steps. Procedures Included Preventative Maintenance: Oil changes, filter replacements, fluid checks and changes, tire rotations, spark plug replacement, belt inspection/replacement. Troubleshooting: Diagnostic flowcharts for common drivability issues, electrical problems, and system failures. Component Replacement: Step-by-step instructions for replacing major and minor components across all systems. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Torque Specifications: Detailed torque values for all fasteners throughout the vehicle. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced diagnostics). 📊 Manual Specifications File Format Format Details: Searchable PDF with high-resolution diagrams and text. Print Quality Printability: Printable pages for easy workshop use. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Displacement Primary: 2.0 Liters (1991 cc) Engine Type Primary: Inline-4 Cylinder, DOHC, 16-valve Engine Code Primary Details: FS-DE (Naturally Aspirated) Horsepower Primary: 134 hp @ 6000 rpm (US spec) Torque Primary: 135 lb-ft @ 4000 rpm (US spec) Optional Engine Engine Displacement Optional: 2.3 Liters (2261 cc) Engine Type Optional: Inline-4 Cylinder, DOHC, 16-valve Engine Code Optional Details: ZY-VE (Naturally Aspirated) Horsepower Optional: 160 hp @ 6000 rpm (US spec) Torque Optional: 155 lb-ft @ 4000 rpm (US spec) Fuel System Fuel Type: Unleaded Gasoline Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Octane Rating: 87 Octane (Recommended for 2.0L), 87 Octane (Recommended for 2.3L) 🔧 Transmission Standard Standard Transmission: 5-speed Manual (GZ5) Optional Optional Transmission: 4-speed Automatic (GF4A-EL) Features Automatic Transmission Features: Electronically controlled, lock-up torque converter. Manual Transmission Clutch: Hydraulically actuated, single dry plate clutch. Fluid Specifications Automatic Transmission Fluid Type: Mazda ATF-MV or equivalent (e.g., Dexron III compatible) Manual Transmission Fluid Type: API GL-4, SAE 75W-90 Gear Oil 📐 Dimensions Exterior...