2003 2004 2005 2006 2007 Mazda 6 Workshop Service Manual

2006 Mazda6 I .JlAZDASPEED6 Workshop Manual FOREWORD This manual oonlaQ on-vehlcle service !lncVor diagno6is procedures lor the Mazda6 , MAZOASPEED6 , For proper repair and maintenance, a thorough tamiliartutlon with this manual is Important, and n. should always be kepi in • handy place tor quick and uS)' relerent8. AI the oontents of tIU manual, Including clr8Mlgs and specifications, are the latest avaJlable at the Hme 01 printing. As modifications affecting repair or malnlenanoe occor. relevant infoonatiofl "upplamentary to this volume will be made l ajlable at Mazda dealers. Thll manual IhouId be kepi up- to-date. Ma1da Mellor CoIporation reservea the ~t 10 ,Iter the specifICation. and contents of IhI8 manual without oblioatlon or advance ootioe. All rights reserved. No part of !his book may be reproduced or used in any form or by any moana, electrooicor~ p/'IOtOCCIpying and recording and !he use 01 any kind of information storage and retrieval 'yslem---without permission in writing . APPLI CATI ON: Mazda Mot or CorpoNltlon HIROSHIMA, JAPAN This manual Is applicable 10 .... "' .... I~. beginning with the Vehicle Identification N~ (yIN), and related malerials shown on the following page. CONTENTS GENERAL INFORMATION ENGINE SUSPENSION DRIVELINEIAXLE BRAKES TRANSMISSIONfTRANSAXLE STEERING RESTRAINTS BODY & ACCESSORIES ALPHABETICAL INDEX C 2005 Mud. Motor Corpol1!ltJon PRINTED IN U.S.A., AUGUST 2005 Form No. l~lU-05H Part No. D999 95-063EHl6 Seetlon

WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks 01 injury, property damage, and failure of servicing Increase. The recommended S8I'Vlclng procedures fOf the vehicle In this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians. but a technician with our service-related training and experience will be at less risk when perlorming service operations. However, aM users ot this manual ara expected to at least know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks oot normally encountered In a general technician's experience. They should be followed to reduce the risk 01 injury and the risk that improper setvlce or repair may damage the vehicle or render it unsafa. It Is also important to understand that the "Wamlngs' and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to folaw the procedures. The procedures recommended and described In this manual are effective methods 01perlorming service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools which are not recommended by Mazda Motor Corporation must salisfy themselves thoroughly that neither personal safely nor safety of the vehicle will be Jeopardized. The cootents 01 this manual, including drawings and spec~ications, are the latest available attha lime of printing, and Mazda Motor Cofporation reserves the right to change the vehicle designs and alter the contents 01 this manual without notice end wilhoul inCurring obligation. Parts should be replaced with genuioe Mazda replacement parts or with paris which match the quality of genuine Mazda replacement pans. Persons using replacemoot parts oIiesser quality than that 01 genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal sefety nor safely of the vehicle will be jeopardized. Mazda Motor CorporatiOn la not responsible f or any problema which may arise from the use of this manual. The cause of such problems includes but is not limited to Insufficient service-retated training, use of improper tools, use 01 replacement parts of lesser quality than thaI 01 genuine Mazda replacement perts, or not being eware 01 any reviSion 01 this manual.

VEHICLE IDENTIFICATION NUMBERS (VIN) 1 YV FP8OC* 65 1 YV FP80D:t- 65 IVY FP81 C*65 IVY FP810:!:65 1 YV FP82D*65 1 YV FP83D* 65 1 YV fP84 C*65 1 VV fP84D :j:65 1 YV FP8SC" .j; 65 1 YY FP85D* 65 lVV HPBOC* SS lVV HP8 0D* 65 lVV HP81C*65 lVV HPB1D*65 1YV HPB2D*65 IVY HP83[):;:65 1YV HP84C:t : 65 lVV HP84 O:!:65 lVV HP8SC:;:65 lVV HP85D*65 JMl GG12 l*61 M00001- M00001- M00001- M00001- M00001 - M00001- M00001- M00001 - M00001 - M00001 - M00001 - M00001 - M00001 - M00001 - M00001 - M00001 - M00001- 100001- (MAZOASPEED6) RELATED MATERIALS MIII«IaI N ..... MNAO PIorI No. _ ......... 2003 (IJ .SAY2OCM (~Mud.e Senob Hl96Jb SSJC 115 IOI~ =-HH'" 20001 MatdIII MX-6 ~.5, ~. MPY 8«\oIcIIliQtoliglilS \l!ilge 115 ' 'OOl-G4 ""-,., .... 2004 Mud18 H .. ' ."'*'" W.., SeMel I ~ ... So,, __ 1111 15 IOI~ --,,,..,,.. 2005 1oINd18 SeMoe IlIgtolgl ~ ~ sasil I15-IOtF-Q5 "'"-, ,,...,. 200fI Mlu:dMI, t.4AZDA.SP£EDe s.M::e IlighIgI'oIa Il199O CIS MOOl-48 :M 11)-11J-{I5H 'M. tille , 1 m, ,we. 1 m. 2000 061).11 SeMoe I lIgIoIigI ... 5:99 e5 0802-00 -,~ EngIne W_JIap MatIUIIl ~ wIIh VArIable v.,.. Trning 11999 15 EA 1Y...(13 lli5&- 11J-(121 ~ WorQhop ~ LF L3 .......... ",.. , lie&- I IJ-()5H EngIne WotkIhop ........... l3 WITH TC e9IiI8 II&-«.3T-oI l &n- lu-05H Manual T...... ,. ..-.;I T ......... WlAIQoIOOV ,.., .... A28oOI.fI '5sa 15 0"& 01 1134-1U-051i ........ ~ Woobhop"...... A65M-R I191III 111!5 GAllS 03 1755-1 tJ.-02I ~TI1I""'''''''''IciI...,..-''''G36M-R a55S 15 M3!03 17S&-l lHl2I ...... Ik: T~WOO ..... """'~FN4A·n cas 1115 fNU-Q4 l7Q-lu-031 _lie T -.cIit Wooloot"", u.nu.I FSSA-EL ............... 1858-1 tJ-(I6F 2IlO3 (U.S. A.)I2OO4 (c.n.c.) ~ 6oofI)onp "'--I iSiS es CIi- 03 3373-nJ~1 2004 Mudle Halc:hbKt<W/IfiPl Bodyshop U-..I9."_ ........-... ""-, ".."..

M . teri.1 H.m, MHAO Pa" No. .... ~No. 200!1 MAZOASPEE06 ~ M ...... Supplemoo1 ~ :MQ:l-l lHl5H 2006 .... <WI., w.z&.SPEED& WIr1ng Diarpm ...... ..." .... , 565 t_t~

GENERAL INFORMATION 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (YIN) cooe ...................... 00-00-2 Vehicle ldentificalion NlI/l'tler ( VIN) Code {Ma.zda6] .................. oo-oG-2 Vehicle Ideo ,bflcalion Number ( YIN) Code {MAZl».SPEE06] ..... •• .• •• ()O...(IO-2 VEHICLE IOENTlACAT1QM NUMBER (YIN) ....... ... . ........... ...... CIO-OO-'J HOW TO US E THIS MANUAl ••••.•••. OO-OO-3 Range 01 Topics •••••••••. ••••••• . 0D-00-3 s.r.;c. Procedure • .. •• ..... •••••. 00-00-3 SynmoIs •.••••.•••.••.••••...••. ~ AdvisoIy Messages • .. •• .. ••• .. ••• . (l(l...IJ()...6 Troo.bIeshooting Procedure . ..••.. •• . OQ-(I()-«i Procedures lor Use ••.••...•••..••. 00-00-7 UNITS •..• .. . .... .•.. ••. .. ••• .. ... 00-00-12 CorMIf'lOO to 81 Unit s (Sysl h-.e International d'Unl16.) .. ... 00-00-12 Rounding Off .•• . ••...•...•••..••. 00-00-12 Upper and lower Limilll •...••...••• 00-00-12 SERVICE CAIITI ONS . .. .. .. •...••••• 00-00-13 ProI Ktiofl 01 the Vehicle •..••••..••. 00-00-13 Pr.paration 01 T oole and Meul.lfIng Equlpmotrt . ......... •. .. ..•..••. 0CHI()-13 Special Service Tools •••••••••.•••• 00-00-13 DiIcomecIion of !he Negatwo. Batt.,y Cable ................... 1»-00-13 Oil Leaka~ Intpeetion ..•••••.• , •.. 0IH)0- 13 RemlMll 01 Parta., .•• " ..• " .•• ,' . 0IH)0- 14 DiNlQefTIbIy • , ........ •• , , , .• , , . . 1»-00-14 Inspection During F\emoYt.I , DIH~,." ....... , ..... , .. 1»-00- 15 Arrllngement 01 P.r" ' .. , , , .. • , , , .. 1»-00- 15 CI.anlng 01 PMI .. .. . .. ••• ... , , , . • 1»-00- 15 ReanerrtJly ., . • , .. •..•••• .... • .• 1»-00-111 Adj Ulilmeni ., .. , , .. , ..• , , , ..•• • .• 1»-00- 11 1 Rl!bber PIInund Tubing ... , .. ,.,. , 1»-00-18 Ho N CIe"..,.. . ........... , ....... 1»-00- 17 TOf'QIUI Formulas • ••••••••••••••••• 1»-00-11 Vile ........ ......... ........... 0IH)0-17 Oyna" iOO I ......................... 1»-00-18 SST ••.••.••.••.•••..•••..••••.• 1»-00-11 INSTALLATION OF RADIO SYSTEM ............ ... .......... 1»-00-11 ELECTRICAL SYST£M ..•.••••• ..... 00-00- 19 EleclrIcII Parta ................... 00-00-19 W orYIg~ .••••••••.••.••.••• 00-00-11 ~O<$ ••••...•••••••••... . •. 1»-00-20 T ernnls ....................... 1»-00-21 Seneots. s. ....... end AeIeys ••••• . I»-OO-ZI: W n-.g ~ ................... I»-OO-ZI: F .................... , ... , ...... 1»-00-23 Dio....wl cI ViIw bf 0 .... """" .••.•• 1»-00-23 EJec:biaol T ~ TooII ...... 1»-00-24 P..,..orionI ~ W-'ding ..•.••... 1»-00-25 JACKING POSfTlOf\IS, VfHICLE LIFT (2 SUPf>OftTS) AND SAFETY STAND (RIGID RACK) POSrT1CJtIS ..• •.•• . •• 00-00-26 ./acUIg F'oIitiooII [Mazda6) .••.••..• 00-00-26 Jadcing PoiIitioo .. [MAZDo\SPEE06] . •...••• . .. . .. .. 00-00-21 Vehicle UII f'osiIionI •••••••.••..•.. 00-00-27 Safely Stand PoiIitioo .............. . 00-00-28 TOWING .... •.••• .... •.•.. . .. . .. .. 1»-00-28 Towing • 2WD vehicle •.•••.••.•••. 00-00-28 Towing • <lWO Vehicle •••••.••.•••• 1»-00-29 TlEDOWN HOOK .............. ..... 00-00-29 TIlIdown Hook {MUdfo6). ••••••.•••• 00-00-29 TIlIdown Hook [MAZOASPEE06] .•••• 00-00-29 IOEHTlFlCATlON NUMSER LOCATIONS ......... . ...... ..... ()()..OO-3 1 ~ kIeod'ai1ioro ~ {VI M) ......................... . (l().... 4».31 Engine IdenIiIication Number .. ••••• . (l() .... 4».3 1 SAE STANDARDS •.••.•.••...•..•. . 00-00-32 ABBREVlAT~S ..••.•.••...•..•.. IJO.... OO-33 PRE·DELIVER'!' INSPECTION .. •..• .. 00-00-34 Pre-DeMry '~ion T ible .. • ..••. 00-00-34 SCHEDU LED MAINTENANCE .• • .• •• . 00-00-36 Scheduled MIIlntenara Tebl. for U.S. A., CANAOA. end """"0 RIco ~I ...................... ~ Scheduled MIint_ra TItH for U.S.A., CANAOA, end Pueno Aloo (MAZOASPEE06] •••.•.•••.••.••• CIO-<IO-3I Scheduled MIIlnt_ra TIIM for Mnico (MazOe6J . .. ............ .... ... 00-00-41 , ---- ------------------------------- O!Hl(H

GENERAL INFORMATION VEHI CLE IDENTI FICATION NUUBER (VIN) CODE ~ " Vehicle identification Number (VIN) Code IMucla6] 1YVFP80C*65MOOOO1 l I MOI)O(Il1rOMW009 -~ NOOO(lllO Ni1911911 - 60 MI. AII1 -'101i<:figoMJ.s.A. - ~- - ·.OlOl. ~ c.L.3(2.3L) 0- AJ (3.0 l) ~-- ~-- For IJ.S.A.(E>ocoo:JI1Df c.r..) : 8cdy 1YI» ~- 00 Ccn~ Spon_ l·ttWo~.Spon_ 2- Ccn ~ Sj>oo'1 w.p ~ H1g1o ~. Sj>oo'1 w.gcn 400 Ccn gra;.. Mloor For ~ ~ Body 1YI» 60 ttgIo~. Mloor '*"'- ~- ~- ~' ~~ F-_~oirbOe. ___ """"'t.Q ~ .. HooYm'lln>nl. __ ~"'o.c ---- IVV- _ p•• , ~ ...... pt'O<O.oOt<I 01 ....... , .. '00II Vehicle ldenlillealion Number (VIN) CocIe I~SPEE oeJ JM1GG12L *6' 123456 l I .. ~~ 001_.,. - .-- ~- ·. OlOl.~ , .... L.o Ul (l.3 WITH Te) ~~ l. o.t.w_ .... ...--.SIcIo. _ c.onIIIII Nt s.g __ - Go. w.zD.O.SPEE06 --_ ..... . , JlMI.~'" - 00-00-2

GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (YIN) 1 VY F P8OC' SS MOOOOI 1 VY F POOO' 65 MOOOOI- V FP81C" 65 MOOOO1_ · V FP810'SS MOOOO1 - IVY FP820' SS MOOOO1- IVY FP830'SS MOOOQ1_ IVY F P84C'SS MOOOO1- lVV FP840' 65 MOOOO1 - IVY F P85C'SS MOOOOI- "" "V 'VV 'VV 'VV~~:~~j: ' VV "" "" "" "" "" JMt GG1 2L'6f 100001- (t.1AZOASPEE06) HOW TO USE THIS MANUAL RangtI 01 Topics - .. ' " • This manual containe procedures lor perfofrTling all requi red service operatk>ns. 1""- procedures are divided Imo the following live basi<: opera.6o<ls: Remowlll nslallatilln - OisassemblylAsSlJrT'bIy - Replacement - lnsp&Ction - Adjustment • SirT¥>le operations which can be perbrmed easiy just by looking at the vehicle (I. • .. l emova.Vlnst aliation of parts. jadcing, vehicle ~Iting. clHning 01 pans. and viIIual lnspection) haw been omined. Servia Ptocedure InlJj)Kllon, . djustment • Inspection and adju81ment procedures are dMded InIO steps. Important points reg ardino 1he 1oc:a6o<l811d contents of 1he procedures are explained in detail and shown In the iIIuslrations. ORO'"

GENERAL INFORMATION Repa ir procedure 1. Mo$t repair operations begin with an overview iluslllllion. It identifies !he ~ oenIs. shorIrts how IhfI parI$ m Iogeltltr, and de ..... ibes vItuaI pert .1SP8ctioI~ 1 10" •• '8'. only remoYaIfon6IaIlalioo procedures that need to be peOOmled methodicalty till ... written nstruClions. ( 2. Expendable parts, tigh1&ning torque$, and symbols br oil , II'Yase, and l&aIant a<e $t\own n!he O'I'8rv1_ illustration. In addition, lyrrboIS Ondicating part, req~king th y use ot epe<;iIIl seMc9 tool' 0< equMllenl ere also ,. ' In, t. , __ ~-.- 00-00-4 r •

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2003 2004 2005 2006 2007 Mazda 6 Workshop Service Manual

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