Mazda 6 GH 2007–2012 Workshop Manual

Welcome to the Mazda 6 GH (2007–2012) Repair and Maintenance Manual page. This manual is a comprehensive source of information for owners, mechanics, and service station specialists, allowing for diagnostics, repair, and scheduled maintenance of the vehicle. Engine and control systems. Electrical equipment and comfort systems. Maintenance and work schedule. Error Codes List, PDF Free Download

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Engines:

Petrol: 1.8, 2.0, 2.5

Diesel: 2.2 MZR-CD

1. Body and corrosion issues

Despite improved anti-corrosion protection compared to the previous generation, the Mazda 6 GH is susceptible to rust, especially in the following areas:

Fenders (front and rear) – rust formation on the inner edges due to accumulation of dirt and moisture.

Sills and wheel arches – insufficient protection by the factory coating, which leads to corrosion.

Hood and trunk lid – weak points in the area of seams and joints.

Solution: anti-corrosion treatment and regular washing of the underbody, installation of mudguards.

2. Engine and its problems

Mazda 6 GH was equipped with petrol engines 1.8, 2.0, 2.5 MZR and diesel 2.2 MZR-CD, which have their own weak points:

Petrol engines:

Increased oil consumption (especially 2.5 l) - due to wear of oil scraper rings.

Hydraulic compensators - knocking during cold start, require regular oil changes.

Problems with the timing chain (on 2.0 and 2.5) - stretching at high mileage over 150 thousand km.

Diesel engines (2.2 MZR-CD):

Coking of the EGR valve - loss of power, increased fuel consumption.

Turbine wear - problems with untimely oil changes.

DPF diesel particulate filter - clogged with frequent short trips.

Solution: use high-quality oil, change filters on time and monitor the oil level.

3. Transmission

Mazda 6 GH was equipped with 5- and 6-speed manual and automatic transmissions. Main faults:

Manual transmission:

Worn synchronizers (especially 2nd and 3rd gears).

Hard gear shifting due to lack of oil or contamination.

Automatic transmission (5- and 6-speed):

Jerking when shifting - often associated with oil contamination.

Slippage in high gears - worn clutches.

Solution: change the oil every 50-60 thousand km, regularly diagnose the condition of the automatic transmission.

4. Suspension and steering

Mazda 6 GH has a soft, comfortable suspension, but there are several weak points:

Rapid wear of the silent blocks of the front levers, especially when driving on bad roads.

Stabilizer struts – frequent replacement every 30–50 thousand km.

Steering rack – knocking and power steering fluid leakage at mileage over 120 thousand km.

Solution: use high-quality analogs of spare parts, regularly check the suspension at a service station.

5. Electrical equipment

The Mazda 6 GH electrics are quite reliable, but over time the following problems are possible:

The "Check Engine" lamp lights up due to problems with the oxygen sensors or injection system.

Central lock malfunctions – malfunctions due to oxidation of contacts.

Problems with the BCM (Body Control Module) unit – failure of lighting or window lifters.

Failure of the multimedia system – overheating of the unit due to poor ventilation.

Solution: regular diagnostics of electrical circuits, cleaning of contacts, protection of connectors from moisture.

6. Brake system

Increased wear of the front brake discs – overheating due to intensive driving.

Rear calipers often seize up due to exposure to moisture and dirt.

Worn ABS sensors, which causes errors on the dashboard.

Solution: regular lubrication of caliper guides and timely replacement of brake fluid.

7. Climate control and heating

Typical faults in the climate control system include:

Failure of the heater motor - noisy operation or complete failure.

Clogging of the heater radiator, which reduces the efficiency of heating the cabin.

Faulty temperature sensors - incorrect operation of the cooling system.

Solution: regular maintenance of the air conditioner, cleaning the radiator, replacing the cabin filter.

8. Consumables and operational nuances

Low beam lamps often burn out due to unstable voltage.

Rear shock absorber struts are prone to leaks at mileage over 100 thousand km.

Frequent contamination of the throttle valve, causing unstable speed.

Solution: use high-quality consumables, regular maintenance.