Mazda 6 (GG, GY; 2002–2008) Full Workshop Manual
This detailed guide provides complete information on the maintenance and repair of the first generation Mazda 6 (GG, GY) cars of 2002-2008. Includes step-by-step instructions, illustrations, diagrams and specifications for all vehicle systems, including the engine, transmission, suspension, brake system, electrical equipment and body.
Ideal for owners, mechanics and car enthusiasts who want to service or repair their car themselves. Learn how to effectively eliminate common problems and keep your Mazda 6 in excellent condition.
Engine: L8, LF, L3, MZR-CD (RF Turbo)
Manual Transaxle: G35M-R, A65M-R.
Automatic Transaxle: FN4A-EL, JA5AX-EL
| 2004 Mazda 6 Sport Sedan 5-Door Sport Wagon Workshop Manual | Download |
Mazda 6 Workshop Manual
Mazda 6 Workshop Manual Supplement
| Mazda 6 2002-2008 General Information | Download |
| Mazda 6 2002-2008 Engine L8, LF, L3 | Download |
| Mazda 6 2002-2008 Engine MZR-CD (RF Turbo) | Download |
| Mazda 6 2002-2008 Lubrication System L8, LF, L3 MZR-CD (RF Turbo) | Download |
| Mazda 6 2002-2008 Cooling System L8, LF, L3 MZR-CD (RF Turbo) | Download |
| Mazda 6 2002-2008 Fuel and Emission Control System L8, LF, L3 | Download |
| Mazda 6 2002-2008 Fuel and Emission Control System MZR-CD | Download |
| Mazda 6 2002-2008 Engine Electrical System | Download |
| Mazda 6 2002-2008 Clutch | Download |
| Mazda 6 2002-2008 Manual Transaxle A65M-R | Download |
| Mazda 6 2002-2008 Automatic Transaxle JA5AX-EL | Download |
| Mazda 6 2002-2008 Propeller Shaft | Download |
| Mazda 6 2002-2008 Front and Rear Axles | Download |
| Mazda 6 2002-2008 Steering System | Download |
| Mazda 6 2002-2008 Braking System | Download |
| Mazda 6 2002-2008 Suspension | Download |
| Mazda 6 2002-2008 Body | Download |
| Mazda 6 2002-2008 Body Electrical System | Download |
| Mazda 6 2002-2008 Heater and Air Conditioner Systems | Download |
| Mazda 6 2002-2008 Technical Data | Download |
| Mazda 6 2002-2008 Special Tools | Download |
Mazda 6 2002-2008 BodyShop Manual
| Mazda 6 2002-2008 General Information | Download |
| Mazda 6 2002-2008 Construction | Download |
| Mazda 6 2002-2008 Panel Replacement | Download |
| Mazda 6 2002-2008 Water-Proof and Rust Preventive Treatment | Download |
| Mazda 6 2002-2008 Dimensions | Download |
| Mazda 6 2002-2008 Plastic Body Parts | Download |
| Mazda 6 2002-2008 Primary Color Mixture Chart For Body Colors | Download |
Mazda 6 (GG, GY; 2002–2008) Typical Problems and Malfunctions
1. Body and corrosion
Corrosion is one of the most common problems. Weak points:
Rear wheel arches
Underbody and sills
GY rear door
Hood and door edges
Moisture penetrates under the factory sealant, which accelerates rusting.
Solution: anti-corrosion treatment and regular inspection.
2. Engines
Petrol (1.8, 2.0, 2.3 l MZR)
Increased oil consumption (especially on 2.3 MZR) – occurs due to sticking of oil scraper rings.
Hydraulic compensators – can knock when cold.
Catalyst – can break down and be sucked into the engine, which leads to major repairs.
Timing chain (2.3 l) – tends to stretch after 150-200 thousand km.
Diesel (2.0 MZR-CD)
High pressure fuel pump and injectors – sensitive to fuel quality.
Diesel particulate filter (DPF) – often fails in urban conditions.
Turbine problems – oil gets into the intake tract.
3. Gearbox
Automatic transmission (FN4A-EL, five-speed):
Shocks when shifting, especially when cold.
Overheating during aggressive driving.
Regular oil change required (at least every 50-60 thousand km).
Manual transmission:
Worn synchronizers, especially 2nd gear.
Oil leaks through seals.
4. Suspension
Weak silent blocks of the front levers, last about 50-80 thousand km.
Rear multi-link suspension – requires careful maintenance, wear of levers and bushings is possible.
Stabilizer struts – frequent replacement due to knocking.
5. Electrics
Window lifters – motors often fail.
Generator – problems with the diode bridge and voltage regulator.
Central lock – fails due to moisture getting into the door connectors.
ABS errors – often associated with oxidation of sensor contacts.
6. Interior
Plastic panels creak, especially on uneven surfaces.
Rapid wear of the driver's seat.
Loss of tightness of door seals, which causes creaking and water leakage into the interior.
7. Fuel system
Pump in the tank – can fail due to clogged filter.
Fuel level sensor – does not work correctly, lowering readings.
8. Engine cooling
Radiator leaks due to corrosion of aluminum honeycombs.
Failure of the thermostat, which causes the engine to overheat.