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2002-2007 MAZDA 2 DY Factory Service Manual
Engines covered;
1.25L MZI
1.4L MZI
1.6L MZI
1.4L Ford 1.4 TDCi/MZ-CDTi Diesel
This is a very comprehensive and structured factory service manual for 2002-2007 MAZDA 2. More than 2000++ pages. This manual has been written in a format that is designed to meet the needs of Mazda technicians worldwide. You will never be disappointed with the content of this workshop manual.
CONTENTS
1: General Information
Service Information
General Information
100-00
Identification Codes
100-01
Jacking and Lifting
100-02
2: Chassis
Suspension
Suspension System – General Information
204-00
Front Suspension
204-01
Rear Suspension
204-02
Wheels and Tires
204-04
Driveline
Front Drive Halfshafts
205-04
Brake System
Brake System – General Information
206-00
Drum Brake
206-02
Front Disc Brake
206-03
Parking Brake and Actuation
206-05
Hydraulic Brake Actuation
206-06
Power Brake Actuation
206-07
Anti-Lock Control
206-09A
Anti-Lock Control – Traction Control
206-09B
Anti-Lock Control – Stability Assist
206-09C
Steering System
Steering System – General Information
211-00
Power Steering
211-02
Steering Linkage
211-03
Steering Column
211-04
Steering Column Switches
211-05
3: Powertrain
Engine
Engine System – General Information
303-00
Engine – 1.25L/1.4L/1.6L
303-01A
Engine – 1.4L Diesel
303-01B
Engine Cooling – 1.25L/1.4L/1.6L
303-03A
Engine Cooling – 1.4L Diesel
303-03B
Fuel Charging and Controls – 1.25L/1.4L/1.6L
303-04A
Fuel Charging and Controls – 1.4L Diesel
303-04B
Fuel Charging and Controls – Turbocharger – 1.4L Diesel
303-04C
Accessory Drive
303-05
Starting System
303-06
Engine Ignition
303-07A
Glow Plug System
303-07B
Engine Emission Control – 1.25L/1.4L/1.6L
303-08A
Engine Emission Control – 1.4L Diesel
303-08B
Intake Air Distribution and Filtering
303-12
Evaporative Emissions
303-13
Electronic Engine Controls
303-14
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission / Transaxle and Clutch – General Information
308-00
Clutch
308-01
Clutch Controls
308-02
Manual Transmission / Transaxle
308-03
Manual Transmission / Transaxle External Controls
308-06
Manual Transmission / Transaxle Automated Gearshift System
308-11
Exhaust System
Exhaust System
309-00
Fuel System
Fuel System – General Information
310-00
Fuel Tank and Lines
310-01
Acceleration Control – 1.25L/1.4L/1.6L
310-02
4: Electrical
Climate Control System
Climate Control System – General Information
412-00
Air Distribution and Filtering
412-01
Heating and Ventilation
412-02A
Auxiliary Heating
412-02B
Air Conditioning
412-03
Control Components
412-04
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination
413-00
Instrument Cluster
413-01
Horn
413-06
Clock
413-07
Battery and Charging System
Charging System – General Information
414-00
Battery, Mounting and Cables
414-01
Generator and Regulator
414-02
Entertainment Systems
Entertainment System – General Information
415-00
Audio Unit
415-01
Antenna
415-02
Lighting
Exterior Lighting
417-01
Interior Lighting
417-02
Daytime Running Lamps (DRL)
417-04
Electrical Distribution
Module Communications Network
418-00
Module Configuration
418-01
Electronic Feature Group
Anti-Theft – Active
419-01A
Anti-Theft – Passive
419-01B
5: Body and Paint
Body and Paint
Front End Body Panels
501-02
Body Closures
501-03
Interior Trim and Ornamentation
501-05
Rear View Mirrors
501-09
Seating
501-10
Glass, Frames and Mechanisms
501-11
Instrument Panel and Console
501-12
Handles, Locks, Latches and Entry Systems
501-14
Wipers and Washers
501-16
Bumpers
501-19
Safety Belt System
501-20A
Supplemental Restraint System
501-20B
Body Repairs – Corrosion Protection
501-25A
Body Repairs – Plastic Repairs
501-25B
Body Repairs – Water Leaks
501-25C
Body Repairs – Wind Noise
501-25D
Body Repairs – Paintless Dent Removal
501-25E
Body Repairs – Noise, Vibration and Harshness
501-25F
Body Repairs – Vehicle Specific Information and Tolerance Checks
501-26
Front End Sheet Metal Repairs
501-27
Roof Sheet Metal Repairs
501-28
Side Panel Sheet Metal Repairs
501-29
Rear End Sheet Metal Repairs
501-30
Frame and Mounting
Uni-Body, Subframe and Mounting System
502-00 X
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