service MAZDA MODEL B-SERIES 2002 (in English) Service Manual

Illumination of the ªService Engine Soonº light, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
WARNING: Exhaust leaks may result in entry of harmful and
potentially lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle's emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your ªCheck Engine/Service Engine
Soonº light is on, refer to the description in theWarning lights and
chimessection of theInstrument Clusterchapter. Your vehicle may not
pass the I/M test with the ªCheck Engine/Service Engine Soonº light on.
If the vehicle's powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a ªnot ready for I/M testº
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
²First, at least 10 minutes of driving on an expressway or highway.
²Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
Maintenance and Specifications
260

CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the service maintenance
section for the service interval
schedules. If adding fluid is
necessary, use only MERCONtAT F.
1. Start the engine and let it run until it reaches normal operating
temperature (the engine coolant temperature gauge indicator will be
near the center of the normal area between H and C).
2. While the engine idles, turn the steering wheel left and right several
times.
3. Turn the engine off.
4.If your vehicle is equipped with a 3.0L V6 engine,check the
fluid level on the dipstick. It should be within the FULL HOT range.
Do not add fluid if the level is within this range.
5.If your vehicle is equipped with a 4.0L SOHC V6 or 2.3L I4
engine,check the fluid level in the reservoir. It should be between
the MIN and MAX lines. Do not add fluid if the level is within this
range.
6. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL HOT range. Be sure to put the
dipstick back in the reservoir.
Maintenance and Specifications
261

BRAKE FLUID
Checking and adding brake fluid
Brake fluid should be checked and
refilled as needed. Refer to the
service maintenance section for the
service interval schedules.
1. Clean the reservoir cap before
removal to prevent dirt or water
from entering the reservoir.
2. Visually inspect the fluid level.
3. If necessary, add brake fluid
from a clean un-opened
container until the level reaches
MAX. Do not fill above this line.
4. Use only a DOT 3 brake fluid
certified to meet Mazda specification . Refer toLubricant
specificationsin this chapter.
WARNING: Brake fluid is toxic. If brake fluid contacts the
eyes, flush eyes with running water for 15 minutes. Seek
medical attention if irritation persists. If taken internally, drink
water and induce vomiting. Seek medical attention immediately.
WARNING: If you use a brake fluid that is not DOT 3, you will
cause permanent damage to your brakes.
WARNING: Do not let the reservoir for the master cylinder run
dry. This may cause the brakes to fail.
MAX
Maintenance and Specifications
262

CLUTCH FLUID (IF EQUIPPED)
Check the fluid level. Refer to the service maintenance section for the
service interval schedules.
During normal operation, the fluid level in the clutch reservoir should
remain constant. If the fluid level drops, refill the fluid level to the step
in the reservoir.
Use only a DOT 3 brake fluid designed to meet Mazda specification.
Refer toLubricant Specificationsin this chapter.
WARNING: Brake fluid is toxic. If brake fluid contacts the
eyes, flush eyes with running water for 15 minutes. Seek
medical attention if irritation persists. If taken internally, drink
water and induce vomiting. Seek medical attention immediately.
1. Clean the reservoir cap before
removal to prevent dirt and
water from entering the
reservoir.
2. Remove cap and rubber
diaphragm from reservoir.
3. Add fluid until the level reaches
the step in the reservoir.
4. Reinstall rubber diaphragm and
cap onto reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to your service maintenance section for scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Maintenance and Specifications
263

INFORMATION ABOUT UNIFORM TIRE QUALITY GRADING
New vehicles are fitted with tires that
have a rating on them called Tire
Quality Grades. The Quality grades
can be found where applicable on the
tire sidewall between tread shoulder
and maximum section width. For
example:
²Treadwear 200 Traction AA Temperature A
These Tire Quality Grades are determined by standards that the United
States Department of Transportation has set.
Tire Quality Grades apply to new pneumatic tires for use on passenger
cars. They do not apply to deep tread, winter-type snow tires,
space-saver or temporary use spare tires, tires with nominal rim
diameters of 10 to 12 inches or limited production tires as defined in
Title 49 Code of Federal Regulations Part 575.104(c)(2).
U.S. Department of Transportation-Tire quality grades:The U.S.
Department of Transportation requires Mazda to give you the following
information about tire grades exactly as the government has written it.
Treadwear
The treadwear grade is a comparative rating based on the wear rate of
the tire when tested under controlled conditions on a specified
government test course. For example, a tire graded 150 would wear one
and one-half (1 1/2) times as well on the government course as a tire
graded 100. The relative performance of tires depends upon the actual
conditions of their use, however, and may depart significantly from the
norm due to variations in driving habits, service practices, and
differences in road characteristics and climate.
Traction AA A B C
The traction grades, from highest to lowest are AA, A, B, and C. The
grades represent the tire's ability to stop on wet pavement as measured
under controlled conditions on specified government test surfaces of
asphalt and concrete. A tire marked C may have poor traction
performance.
NOTE:The traction grade assigned to this tire is based on
straight-ahead braking traction tests, and does not include acceleration,
cornering, hydroplaning or peak traction characteristics.
Maintenance and Specifications
268

Temperature A B C
The temperature grades are A (the highest), B, and C, representing the
tire's resistance to the generation of heat and its ability to dissipate heat
when tested under controlled conditions on a specified indoor laboratory
test wheel. Sustained high temperature can cause the material of the tire
to degenerate and reduce tire life, and excessive temperature can lead to
sudden tire failure. The grade C corresponds to a level of performance
which all passenger car tires must meet under the Federal Motor Vehicle
Safety Standard No. 109. Grades B and A represent higher levels of
performance on the laboratory test wheel than the minimum required by
law.
WARNING: The temperature grade for this tire is established
for a tire that is properly inflated and not overloaded.
Excessive speed, underinflation, or excessive loading, either
separately or in combination, can cause heat buildup and
possible tire failure.
SERVICING YOUR TIRES
Checking the tire pressure
²Use an accurate tire pressure gauge.
²Check the tire pressure when tires are cold, after the vehicle has been
parked for at least one hour or has been driven less than 5 km
(3 miles).
²Adjust tire pressure to recommended specifications found on the
Certification Label or the Tire Label.
WARNING: Improperly inflated tires can affect vehicle
handling and can fail suddenly, possibly resulting in loss of
vehicle control.
Tire rotation
Because your vehicle's tires perform different jobs, they often wear
differently. To make sure your tires wear evenly and last longer, rotate
them as indicated in the service maintenance section. If you notice that
the tires wear unevenly, have them checked.
Maintenance and Specifications
269

Fluid Mazda Part
NameApplication Capacity
Rear axle
lubricant
5Mazda SAE
80W-90
Premium Rear
Axle LubricantAll 2.4-2.5L (5.0-5.3
pints)
Windshield
washer fluidUltra-Clear
Windshield
Washer
ConcentrateAll 2.6L (2.75
quarts)
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCONtand MERCONtV are not interchangeable. DO NOT
mix MERCONtand MERCONtV. Refer to the service maintenance
section to determine the correct service interval.
2Service refill capacity is determined by filling the transmission to the
bottom of the filler hole with the vehicle on a level surface.
3Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size and if equipped with an in-tank cooler. The amount
of transmission fluid and fluid level should be set by the indication on
the dipstick's normal operating range.
4Use Mazda Premium Engine Coolant (green in color). DO NOT USE
Mazda Extended Life Engine Coolant (orange in color). Refer toAdding
engine coolant, in the Maintenance and Care chapter.
5Traction-Lok axles use 2.2±2.4L (4.75±5.0 pints) of rear axle lubricant.
Add 118 ml (4 oz.) of Additive Friction Modifier meeting Mazda
specifications for complete refill of Traction-Lok axles.
Service refill capacities are determined by filling the rear axle 6 mm to
14 mm (1/4 inch to 9/16 inch) below the bottom of the filler hole.
Maintenance and Specifications
275

LUBRICANT SPECIFICATIONS
Item Mazda part name or equivalent
Front axle (4X4)SAE 80W-90 Premium Rear Axle
Lubricant
Rear axleSAE 80W-90 Premium Rear Axle
Lubricant
1
Brake fluid and clutch fluid (if
equipped)High Performance DOT 3 Motor
Vehicle Brake Fluid
Door weather strips Silicone Lubricant
Engine coolant Mazda Premium Engine Coolant
Engine oil 2.3L I4 and 3.0L V6
enginesSAE 5W-20 Super Premium Motor
Oil
Engine oil 4.0L V6 engines SAE 5W-30 Super Premium Motor
Oil
Hinges, door checks, latches,
striker plates, fuel filler door hinge
and seat tracksMulti-Purpose Grease
Transmission /steering/parking
brake linkages and pivots, brake
and clutch pedal shaft, clutch pilot
bearing and input shaft spline
(manual transmission).Premium Long-Life Grease
Power steering fluid, transfer case
fluid (4X4) and transmission fluid
(manual)MERCONtAT F
Automatic transmission (5R44E
and 5R55E)MERCONtVATF
2
Windshield washer fluidUltra-clear Windshield Washer
Concentrate
1Add 118 ml (4 oz.) of Additive Friction Modifier meeting Mazda
specifications for complete refill of Traction-Lok axles. If submerged in
water, the rear axle lubricant should be changed.
2Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCONtand MERCONtV are not interchangeable. DO NOT
mix MERCONtand MERCONtV. Refer to your service maintenance
section to determine the correct service interval.
Maintenance and Specifications
276

Child safety restraints ..............136
child safety belts ....................136
Child safety seats ......................137
attaching with tether straps ..141
in front seat ............................139
in rear seat ..............................139
Cleaning your vehicle ...............223
engine compartment ..............219
exterior ............................219, 223
exterior lamps .........................221
instrument cluster lens ..........222
instrument panel ....................222
interior .....................................222
mirrors .....................................221
plastic parts ............................221
safety belts ..............................223
washing ....................................218
waxing .....................................218
wheels ......................................219
windows ..................................223
wiper blades ............................221
Climate control (see Air
conditioning or Heating) ......72, 74
Clock ....................26, 33, 47, 55, 68
Clutch
fluid ..........................................263
operation while driving ..........161
recommended shift speeds ....162
Compass, electronic ..............90±91
calibration .................................92
set zone adjustment .................91
Console ........................................98
Coolant
checking and adding ..............246
refill capacities ................249, 273
specifications ..................276±277
Cruise control
(see Speed control) ....................93Customer
Assistance ..........180, 207±208, 211
Getting roadside assistance ...180
D
Daytime running lamps
(see Lamps) ................................77
Dipstick
automatic transmission
fluid ..........................................263
engine oil .................................238
Doors
door ajar warning .....................18
lubricant specifications ..........276
Driveline universal joint and
slip yoke ....................................267
Driving under special
conditions ..........................167±168
mud ..........................................167
sand .........................................167
snow and ice ...........................168
through water .................167, 169
E
Emergencies, roadside
jump-starting ..........................201
Emission control system ..........259
Engine ........................................277
check engine/service engine
soon light ..................................14
cleaning ...................................219
coolant .....................................246
idle speed control ...................244
lubrication
specifications ..................276±277
refill capacities ........................273
service points ..................234±236
Index
282