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