Mazda B-Series 1997 Instruction manual

Mazda B-Series
Workshop
Manual
@ 1997Mazda Motor Corporation
Printed
in U.S.A. 7/96
(9999-95-0228-97)

WARNING
Servicing a vehicle can be dangerous. If you have not received service-
relatedtraining, the risks of injury and property damage increase. The
recommendedservicing proceduresfor the vehicle in this troubleshooting
manual were developed with Mazda-trained technicians in mind. This
manual may be usefulto non-Mazda trainedtechnicians, but a technician
with our service-related training and experience will be at less risk when
performing servicing operations. However, all users of this manual are
expectedto knowgeneralsafety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks not
normally encountered in a generaltechnician's experience. They should
befollowed to reduce the risk of injuryand the risk that improper serviceor
repair may damage the vehicle or render it unsafe. It is also important to
understand that the "Warnings" and "Cautions" are not exhaustive. It is
impossible to warn
crf all the hazardous consequences that might result
from failure to follow the procedures.
The procedures recommended and described in this manualare effective
methods of performing troubleshooting and repair. Some require tools
specifically designed for a specific purpose. Nonrecommendedproce-
dures and tools shoijld includeconsideration for safety of the technician
and continuedsafe operation of the vehicle.
Parts should be replaced with genuine Mazda replacements parts, not
parts
of lesser quality. Use of a nonrecommended replacement part
should include consideration for safety of the technician and continued
safe operationof the vehicle.

4..
1997
Mazda
B-Series
Workshop
Manual
FOREWORD
Thisworkshop manualisintendedfor use by
service technicians of Authorized Mazda
DealerstohelpthemserviceMazdavehicles.
For proper repair and maintenance, a
thorough familiarization with this manual is
important, and it should always be kept in a
handy placefor quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
--
available at the time of printing. As modifi-
cations affecting repair or maintenance
occur, relevantinformationsupplementaryto
this volumewill be madeavailable at Mazda
dealers. This manual sho~~ldbe kept up-to-
date.
MazdaMotor Corporation reservesthe right
toalterthespecificationsandcontentsof this
manualwithoutobligationor advancenotice.
All rights reserved.Nopart of this book may
be reproducedor used in any form or byany
means, electronic or mechanical-including
photocopyingand recording and the use of
any kind of informationstorageand retrieval
system-without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manualis applicableto vehicles with
the Vehicle IdentificationNumbers(VIN)
shownon the following page.
CONTENTS
LubricationSystem
Fuel and Emission
* Refer to the 1997 B-SeriesBody ~lehricalTroubleshooting
Manual (Form
No. 1563-10-96H, Part No. 9999-95-094F-97)
for servicingof the body electrical components.
O 1996 Mazda Motor Corporation
PRINTED IN USA.AUGUST '96 1562-10-96H

VEHICLE IDENTIFICATIONNUMBERS (VIN)

GENERAL INFORMATION
IMPORTANTINFORMATION ...................... GI- 2
.............................
BASIC ASSUMPTIONS GI- 2
SAFETY RISK ............................................ GI- 2
POSSIBLE LOSSOF WARRANTY
...........
GI- 2
WARNING ON LUBRICANTSAND
GREASES
................................................ GI- 2
HOWTO1 USETHIS MANUAL
..................... GI- 3
PREPARATION
......................................... GI- 3
REPAIR PROCEDURE
.............................. GI- 4
SYMBOLS
.................................................. GI- 5
NOTES. CAUTIONS. AND WARNINGS
.... GI- 5
................
FUNDAMENTALPROCEDURES GI- 5
PROTECTIONOF THE VEHICLE .............
GI- 5
........................ A WORD ABOUT SAFETY GI- 6
PREPARATIONOFTOOLSAND
MEASURING EQUIPMENT
..................... GI- 6
....................................... SPECIALTOOLS GI- 6
REMOVALOF PARTS
............................... GI- 6
DISASSEMBLY .......................................... GI- 6
ASSEMBLY ................................................ GI- 7
ADJUSTMENTS ......................................... GI- 8
RUBBER PARTSAND TUBING ................ GI- 8
JACK AND SAFETY STAND(RIGID RACK)
POSITIONS
................................................. GI- 9
..............................................
FRONT END GI-10
REAR END
................................................. GI-10
VEHICLE LIFT(2-SUPPORTTYPE)
.................................................
POSITIONS GI-1 1
FRONT END .............................................. GI-12
REAR END
............................................... GI-12
.......................................................
TOWING GI-13
GENERAL TOWING PROCEDURE
PREPARATORYSTEPS
......................... GI-13
TOWllVG TWO-WHEELDRIVE
...............................................
VEHICLES GI-13
TOWllVG FOUR-WHEEL DRIVE
VEHICLES
............................................... GI-14
TOWllVG EQUIPMENT .............................. GI-15
TOWllVG CONNECTIONS ......................... GI-1 6
VEHICLE IDENTIFICATIONNUMBER ........ GI-17
SAFETY COMPLIANCECERTIFICATION
......................................................
LABELS GI-1 9
...........................................................
UNITS GI-23
ABBREVIATIONS
........................................ GI-23
SAE STANDARDNAME
.............................. GI-24
......................................................
CAUTION GI-26
ELECTRICALTROUBLESHOOTING
TOOLS
..................................................... GI-26
.....
CAUTION WITH ELECTRICAL PARTS GI-27
4BUGIX-001

IMPORTANT INFORMATION
IMPORTANTINFORMATION
BASIC ASSUMPTIONS
Thisworkshop manualassumesthat you havecertainspecialtools that are necessaryforthe safeand
efficient performance of service operations on Mazda vehicles and that you know how to use them
properly. It also assumes that you are familiar with automobilesystems and basic service and repair
procedures.You should not attempt to use this manualunless these assumptions are correct and you
understand the consequences describedbelow.
4BUGIX-002
SAFETY RISK
This manual contains certain notes, warnings, and other precautionary information that you should
carefully readandfollowto reducethe riskof personalinjurytoyourselfor othersandtheriskof improper
servicethat may damagethevehicle or render it unsafe.If there is no such informationin regardto any
specific service method,thisdoes not meanthere is nopossibilitythat personalsafety or vehicle safety
will bejeopardized by the use of incorrectmethods or tools.
4BUGIX-003
POSSIBLE LOSSOF WARRANTY
Themanufacturer'swarrantyonMazdavehiclesandenginescanbevoided
if improperserviceor repairs
are performedby personsother than those at an Authorized Mazda Dealer.
4BUGIX-004
WARNING ON LUBRICANTSAND GREASES
Avoid allprolongedand repeatedcontactwith mineraloils, especially usedoils. Usedoilscontaminated
during service (e.g., engine oils) are more irritatingand more likely to cause serious effects, including
skin cancer, in the event of gross and prolongedskin contact.
Wash skin thoroughly after work involvingoil.
Protectivehandcleanersmaybeof value providedthey canberemovedfromtheskinwithwater.Donot
use gasoline, paraffin,or other solventsto removeoil from the skin.
Lubricants and greases may be slightly irritatingto the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary.
Particularcare should betaken with usedoils and greasescontaininglead. Do not allow work clothing
to becontaminatedwith oil. Dry clean or launder such clothingat regular intervals.
4BUGiX-005

HOW TO USE THlS MANUAL
HOW TO USE THlS MANUAL
PREPARATION
PREPARATION points out the needed Special Service Tool (SST) for the service operation that it
precedes.Gather all necessary
SSTs beforebeginningwork.
Example:
MANUAL STEERING
1
PREPARATION SST NUMBER USAGE
SST
49 01 18 850C
Puller, ball joint
49 01 18 850C
For
removal of tte rod
end
SST NAME SST ILLUSTRATION

HOW TO USE THIS MANUAL
REPAIR PROCEDURE
1. Most repair operations beginwith an overview illustration.It identifiesthe components,shows howthe
partsfittogether,andvisualpartsinspections.If a damagedor worn partisfound, repairor replace it as
necessary.
2. Expendableparts,tighteningtorques,andsymbolsforoil,grease,andsealantareshownintheoverview
illustration.
3. Pages relatedto service proceduresare shown under the illustration. Refer to this informationwhen
servicingthe relatedpart.
Example:
73-!07 (7 4-10 9 54-79)
\ '1^1 SELECTIVE
\ / '21
SHOWS
EXPENDABLE
PARTS
SHOWS
APPLICATION
POINT OF OIL,
ETC .
SERVICE
SHOWS TIGHTENING
TORQUE
SPECIFICATION '2
SHOWS TIGHTENING
TORQUE UNIT
16 Beanna ~nnerrace I
2 Cock ptate
3 Bear~ngcup
4 Adjusting screw
5 Bearing outer race
6 Locknut
7 Washer
17 Spacer
18 Dr~veplnlon
Removal page M-21
L I
*I: The numbering(ex. O) shows service procedure.
**: Unitsshown in N.m {kgfm, ft.lbf} unlessotherwise specified.
MG11001 -C 4BUGIX-007

HOW TO USETHIS MANUAL, FUNDAMENTALPROCEDURES
GI
SYMBOLS
Therearesixsymbolsindicatingoil,grease,andsealant.Thesesymbolsshowthepointsof applyingsuch
materialsduring service.
I
I
i ~pp~yoil New engine oil or gear oil as appropriate
--
Symbol
Only brakefluid
Meaning
I
Apply automatictransmissionfluid
Appropriate grease
Apply sealant Appropriate sealant
I
Apply petroleumjelly Appropriate petroleumjelly
MGll002-A 4BUGIX-008
Note
When special oil or grease is needed,this is shown inthe illustration.
4BUGIX-009
NOTES, CAUTIONS, AND WARNINGS
As you readthroughthe procedures,youwill comeacrossNOTES,CAUTIONS,andWARNINGS.Each
oneisthere for a specific purpose.
NOTES givesyou added information thatwill helpyou to complete
aparticularprocedure.
CAUTIONS aregivento preventyoufrom makinganerrorthat could damagethe
vehicle.WARNINGS
remindyouto beespeciallycarefulinthose areaswherecarelessnesscan cause
personal injury.
4BUGIX-010
I7 FUNDAMENTALPROCEDURES
PROTECTIONOF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas
beforestartingthe work.

GI FUNDAMENTAL PROCEDURES
1 A WORD ABOUT SAFETY
Thefollowingprecautionsmustbefollowedwhenjacking
up the vehicle:
1. Block the wheels.
2. Use only the specifiedjacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine
compartment isclear of tools and people.
I I
MG11004-B 5BUGIX-017
PREPARATION OFTOOLS AND MEASURING
EQUIPMENT
Besurethatallnecessarytoolsandmeasuringequipment
are availablebeforestarting any work.
Note
Mazdaspecial servicetools are specificallyidenti-
fied. If a Mazda special service tool is not
suggested, please use an equivalent tool.
MGll005-A 4BUGIX-013
SPECIAL TOOLS
Use special tools when they are required.
I J
MG11006-A 4BUGIX-014
REMOVALOF PARTS
While correcting
a problem, try also to determine its
cause. Beginworkonly afterfirst learningwhichpartsand
subassembliesmust be removedand disassembledfor
replacementor repair.
I I
MGll007-A 4BUGIX-015
DISASSEMBLY
If thedisassembly procedureis complex,requiringmany
parts to be disassembled, all parts should be disas-
sembled in away that will not affect their performanceor
external appearance and identified so that reassembly
can be performedeasily and efficiently.