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.

FUNDAMENTAL PROCEDURES GI
I. Inspectionof parts
When removed, each part should becarefullyinspected
.,- ~ for malfunctioning, deformation, damage, and other
problems.
MGll009-A 4BUGIX-017
2. Arrangement of parts
All disassembledparts should be carefully arrangedfor
assembly.
Besure to separate or otherwise identify the partsto be
replacedfrom those that will be reused.
3. Cleaning partsfor reuse
All partsto be reusedshouldbecarefully andthoroughly
cleaned in the appropriatemethod.
I I
MGI1011-A 4BllGIX-019
ASSEMBLY
Standard values, such as torques and certain adjust-
ments, must be strictly observed in the assembly of all
parts. Referto STANDARD BOLT AND NUT TIGHTEN-
ING TORQUE in Section TD for tightening torques not
mentionedin the main text.
If removed,thesepartsshouldbereplacedwithnewones:
(1) Oil seals
(2) Gaskets
(3) O-rings
(4) Lockwashers
~~11012-A (5) Cotter pins
(6) Nylon nuts

GI FUNDAMENTAL PROCEDURES
Dependingon location:
(1) Sealant shouldbe applied to gaskets.
(2) Oil should be applied to the moving components of
parts.
(3) Specifiedoil or grease should be applied at the pre-
scribedlocations(suchas oil seals) beforeassembly.
I I
MG11013-A 4BUGIX-020 ADJUSTMENTS
Usesuitablegauges and/or testerswhen makingadjust-
ments.
RUBBER PARTSAND TUBING
Prevent gasoline or oil from getting on rubber parts or
tubing.

JACK AND SAFETY STAND (RIGID RACK) POSITIONS
JACK AND SAFETY STAND (RIGID RACK)
POSITIONS I
Warning
To minimizethe riskof personalinjury, do not put
any portion of your body under the vehicle while
the vehicle isonthe jack. The jack isprovidedfor
emergency wheel and tire changing only. If the
vehicle is to be serviced, support the vehicle on
safety stands. Never start the engine while the
vehicle issupported onthe jack.
Onvehiclesequippedwithalimitedslipaxle, n ver
runtheenginewithonewheel offtheground, such
as when changing a tire. The wheel still on the
ground couldcausethe vehicleto move.
When lifting a vehicle with the vehicle jack or any floor
jack, set the parking brake and block the diagonally
oppositewheel to preventthe vehicle from moving.
Caution
Donotusethedifferentialcover asaliftingpoint.If
any liftingdeviceisallowedtocontactthecoverat
any pointwhere thecoverjoins the housing,leaks
and/ordamagetothedifferentialcovermay occur.
Positionthefloorjack undertheaxlesor shockabsorbers,
asclosetothewheelsaspossible.Refertotheillustration,
alsoshown onthejacking decalandinthevehicle owner
guide.

JACK AND SAFETY STAND (RIGID RACK) POSITIONS
FRONT END
Jack position: Safety stand positions:
At the center of the crossrnember.
On both sides of the frame rail.

VEHICLE LlFT(2-SUPPORTTYPE) POSITIONS
VEHICLE LlFT(2-SUPPORTTYPE)
POSITIONS
Damageto the suspension and/or steeringlinkage com-
ponents may occur when positioning the hoist adapter
pads.The front adapter padsshould be positionedcare-
fully to ensure maximum contact under the frame. Rear
adapterpadsshouldbeplacedunderthespring shackle,
but the adapters must not interfere with the shock ab-
sorber bracketsor the stabilizer bar brackets.
When raising
a vehicle on a 2-support type lift, care
shouldbetakentopositionthevehicle
so thattheadapter
pads do not damage the axle carrier casting or contact
the stabilizer bar and/or brackets.
Caution
Always placeawoodblockbetweentheframe, the
lift point and the adapter pads to prevent lower
body damage.
On vehicles equipped with an under-chassis
mountedspare tire, remove the tire, wheel or tire
carrierfromthevehiclebefore
iit isplacedinahigh
liftposition. These componentsmustberemoved,
inorder to avoid sudden weight releasefrom the
chassis.
GI-I I

TOWING
TOWING
GENERALTOWING PROCEDUREPREPARATORY
STEPS
Releasethe parking brake and place .thetransmission in
(N)Neutral.Asageneralrule,thevehicle shouldbetowed
with the driving wheels off the ground and on a wheel lift
or on a "roll-back" dolly. If the driving wheels cannot be
raisedofftheground,thevehiclewill haveto beplacedon
a flat-bed truck, and not towed.
When
a vehicle istowed on its front wheels, the steering
wheel must be clamped in the straight-ahead position.
Useasteeringwheelclampingdevicedesignedfortowing
service, such asthose provided bytowing system manu-
facturers. Donotusethevehicle'ssteeringcolumnlockto
lock the wheels in
a straight-ahead position when the
vehicle is pulled from the rear. If the ignition key is not
available, place
a dolly underneaththe driving wheels of
the vehicle and tow with the non-drivingwheels raised.
Fornon-emergencytowing,suchasbehindarecreational
vehicle,orwith allfourwheelsontheground,pleaserefer
to the owner guide for the proper procedure.
Note
Onfour-wheel drivevehicles, ifadistanceof80km
(50 miles) or a speed of 56 kmlh (35 mph) must
be exceeded, disconnect the propeller shafts.
(Maximumspeedis
88kmlh (55 mph)withpropeller
shafts disconnected.)
Caution
Itisrecommendedthatonlyanunloadedvehicle be
towed. Iftowingwithaminimalloadisunavoidable,
care must be taken to properly restrain the load
from shifting. Distributethe loadevenly.
Warning
Never use a tow bar that attaches tothe bumper
when towing the vehicle. The bumper could be
looseand/or damaged and may separate fromthe
vehicle, which couldcause an accident.
5BUGLX-001
TOWING TWO-WHEEL DRIVE VEHICLES
Towing with the rear wheels off the ground
For manual or automatictransmissions:
1. Placethe transmission in N (Neutral).
2. Lockthe steering wheel straight ahead.
3. Do not exceed 88 kmlh (55 mph).
4BUGIX-026
Towing avehicle with a manualtransmission with all
four wheels onthe groundor with the front wheels off
the ground:
1. Placethe transmission in N (Neutral).
2. There is no limitation on the distance you cantow with a
vehicle with a manualtransmission.
3. Do notexceedthe maximumspeed lirnitedbythetowing
equipment manufacturer's recommendations.
4BUGIX-027

TOWING
Towing avehicle with an automatic transmissionwith
allfour wheels onthe ground or with the front wheels
off the ground:
1. Placethe transmission in N (Neutral).
2. Do not drive faster than 56 kmlh(35 mph).
3. Do not tow farther than 80 km(50 miles).
4BUGIX-028
TOWING FOUR-WHEELDRIVE VEHICLES
Vehicleswith a manualshift transfer case
For manual or automatic transmissions:
1. Place the transmission in N (Neutral).
2. Lock the steering wheel straight ahead if the vehicle will
betowed with the rear wheels off the ground.
3. Placethe transfer case in N (Neutral).
Note
With the ignition inthe ON position, both the 4x4
andLOW RANGElightswillbeoffwhenthetransfer
case isinN(Neutral).
4. Set the manual locking hubs in the FREE position.
5.Vehicle speed should not exceed 88kmlh (55 mph)
regardless of which wheels are on or off the ground.
4BUGIX-029
Towing with an electronic shift control system
transfer case
For manual or automatic transmissions:
1. Placethe transmission in N (Neutral).
2. Placethe transfer case in 2H.
Note
With the ignition inthe ON position, both the 4x4
andLOW RANGElightswillbeoffwhenthetransfer
case isin
2H.
3. Lockthe steeringwheel straight ahead if the vehicle isto
betowed with the rear wheels off the ground.
Ifyoutowyourvehiclewith therearwheelsoff theground,
the front axle automatic locking hubs mustfirst bedisen-
gaged by shifting the transfer case to
2H and moving
forward for a minimum of
3m (10f) in a straight line.
4. Do not tow faster than 88 kmlh (55 mph).
Note
Confirm by observation that the front propeller
shaft is not rotating prior to towing with the r ar
wheels off the ground.
5BUGIX-002

TOWING
TOWING EQUIPMENT
Towing Slings/Chains/Hooks
Caution
Usecautionwhen attaching tow hooksand safety
chainsto the vehicle. Position and remove hooks
withcaretoavoiddamagetothebrakehoses,brake
pipes, and steering linkagecomponents.
To avoidmetal-to-metalcontact and possibledamageto
chrome,thebumper,or lowerbodypanels,aspecialwide-
beltslingshouldbeusedto liftandtow allvehicles. When
attaching the towbar, take care to avoid damage to the
license plate,frame, and the bumper.
TOWINGSLING
rC--1
CROSSBEAMSPACERBLOCKS
MATERIAL
- CROSSBEAMS
ONE
- 4 X 4 X 60" LONG
ONE
- 4 X 4 X 48" LONG
SPACER BLOCKSCAN BE FABRICATEDAS SHOWN.
MATERIALSPACER BLOCKS
DETAILA FOUR
- 2 x 4 x 6" LONG
TWO-4x4x3112"LONG
EIGHT - 114" x 7" CARRIAGEBOLT
EIGHT
- 114" NUT
SIXTEEN
- '1 14" WASHER
CROSSBEAM-WITHOUT SPACER BLOCKS
4 X 4 WOOD BLOCK
q-=g
NOTE: 2 x 4 LUMBER ACTUALLY MEASURES1-112" x 3-112"
4 x 4 LUMBERACTUALLY MEASURES3-112" x 3-112"

TOWING
I T-HOOK 1
FRONT TOWING, T-HOOKS, 4x2 VEHICLES
HORIZONTAL
T-HOOK SLOT
AIRDAM T-HOOK /
WOOD BLOCK SAFETY
CHAINS
MAIN VIEW
I FRONTTOWING - T-HOOKS - 4x4 VEHICLES I
TOWING CONNECTIONS
4x2 and 4x4 Vehicles
Front connections
1 . InserttheT-hooks intotheslots intheframeforwardof the
wheels.
2. Positiona 4x4 wood block underthe bumper, behindthe
airdam and forward of the crossmember.
3. Positionthe towbar under theairdamandagainstthe4x4
wood block.
4. Attachthesafetychainsto theaxle,inboardof thesprings
on
4x4 vehicles, and outboard of the springs on 4x2
vehicles.
Rear connections (with rear bumper)
I. Insert the T-hooks in the horizontal slots in the frame
behind the wheels.