engine MAZDA MODEL B-SERIES 2006 (in English) Workshop Manual

AMERICAN SAMOA
Polynesia Motors, Inc.
P.O. Box 1120, Pago Pago, American Samoa 96799
TEL: (684) 699–1854
WARRANTIES FOR YOUR MAZDA
•New Vehicle Limited Warranty
•Safety Restraint System Limited Warranty
•Anti-perforation Limited Warranty
•Federal Emission Control Warranty
– Emission Defect Warranty
– Emission Performance Warranty
•California Emission Control Warranty (if applicable)
•Replacement Parts and Accessories Limited Warranty
•Tire Warranty
NOTE:Detailed warranty information is provided with your Mazda
portfolio.
Outside the United States
Government regulations in the United States require that automobiles
meet specific emission regulations and safety standards. Therefore,
vehicles built for use in the United States, may differ from those sold in
other countries.
The differences may make it difficult or even impossible for your vehicle
to receive satisfactory servicing in other countries. We strongly
recommend that you NOT take your Mazda outside the United States.
However, in the event that you are moving to Canada permanently,
Mazda vehicles built for use in the United States could be eligible for
exportation to Canada with specific vehicle modifications to comply with
the Canadian Motor Vehicle Safety requirements.
Special Note: The above is applicable for permanent import/export
situations and not related to travelers on vacation.
You may have the following problems if you do take your vehicle outside
of the United States:
•Recommended fuel may be unavailable. Any kind of leaded fuel or
low-octane fuel will affect vehicle performance and damage the
emission controls and engine.
•Proper repair facilities, tools, testing equipment, and replacement
parts may not be available.
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Please refer to your manufacturers warranty booklet for more
information.
Outside Canada
Government regulations in Canada require that automobiles meet specific
emission regulations and safety standards. Therefore, vehicles built for
use in Canada, may differ from those sold in other countries.
The differences may make it difficult or even impossible for your vehicle
to receive satisfactory servicing in other countries. We strongly
recommend that you NOT take your Mazda outside Canada. However, in
the event that you are moving to the United States permanently, Mazda
vehicles built for use in Canada could be eligible for exportation to the
United States with specific vehicle modifications to comply with the
United States Federal Motor Vehicle Safety requirements.
Special Note: The above is applicable for permanent import/export
situations and not related to travelers on vacation.
You may have the following problems if you do take your vehicle outside
of Canada:
•Recommended fuel may be unavailable. Any kind of leaded fuel or
low-octane fuel will affect vehicle performance and damage the
emission controls and engine.
•Proper repair facilities, tools, testing equipment, and replacement
parts may not be available.
Please refer to your manufacturers warranty booklet for more
information.
ADD-ON NON-GENUINE PARTS AND ACCESSORIES
Non-genuine parts and accessories for Mazda vehicles can be found in
stores. These may fit your vehicle, but they are not approved by the
manufacturer for use with Mazda vehicles. When you install non-genuine
parts or accessories, they could affect your vehicle’s performance or
safety system; the manufacturer’s warranty doesn’t cover this. Before you
install any non-genuine parts or accessories, consult an Authorized
Mazda Dealer.
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WARNING: Installation of Non-Genuine Parts or Accessories:
Installation of non-genuine parts or accessories could be
dangerous. Improperly designed parts or accessories could
seriously affect your vehicle’s performance or safety system.
This could cause you to have an accident or increase your
chances of injuries in an accident. Always consult an Authorized
Mazda Dealer before you install non-genuine parts or
accessories.
WARNING: Add-On Electrical and Electronic Equipment:
Incorrectly choosing or installing improper add-on equipment or
choosing an improper installer could be dangerous. Essential
systems could be damaged, causing engine stalling, air-bag
(SRS) activation, ABS inactivation, or a fire in the vehicle. Be
very careful in choosing and installing add-on electrical
equipment, such as mobile telephones, two-way radios, stereo
systems, and car alarm systems.
Mazda assumes no responsibility for death, injury, or expenses that may
result from the installation of add-on non-genuine parts or accessories.
SERVICE PUBLICATIONS
Factory-authorized Mazda service publications are available for owners
who wish to do some of their own maintenance and repair.
When requesting any of our publications through an Authorized Mazda
Dealer, refer to the chart below.
If they don’t have what you need in stock, they can order it for you.
PUBLICATION ORDER NUMBER PUBLICATION DESCRIPTION
9999 95 022B 05 WORKSHOP MANUAL
9999 95 020G 05 WIRING DIAGRAM
9999 95 023C 05 OWNER’S MANUAL
WORKSHOP MANUAL:
Covers recommended maintenance and repair procedures of the drive
train, body and chassis.
WIRING DIAGRAM:
Provides electrical schematics as well as component location for the
entire electrical system.
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PAINT CHIPS
Your dealer has touch-up paint to match your vehicle’s color. Touch-up
paint can be used to repair minor scratches to painted surfaces.
•Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
•Always read the instructions before using the products.
ALUMINUM WHEELS AND COVERS
Aluminum wheel rims or covers are coated with a clearcoat paint finish.
In order to maintain their shine:
•Clean with cool or lukewarm water and a neutral pH shampoo.
•Never apply any cleaning chemical to hot or warm wheel rims or
covers.
•Some automatic car washes may cause damage to the finish on your
wheel rims or covers. Chemical-strength cleaners, or cleaning
chemicals, in combination with brush agitation to remove brake dust
and dirt, could wear away the clearcoat finish over time.
•Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergent.
•To remove tar and grease, use Extra Strength Tar and Road Oil
Remover (0000–77–410E-01), available from your authorized Mazda
dealer.
ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Never spray the engine or other engine components with water. Water
will damage the engine or other engine components.
•Spray Engine Shampoo and Degreaser (0000–77–410E-09), available at
your authorized Mazda dealer, on all parts that require cleaning and
pressure rinse clean.
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•Cover the highlighted areas to prevent water damage when cleaning
the engine.
•2.3L Engine
•3.0L Engine
2.3L16 VALVE
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•4.0L Engine
•Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
PLASTIC (NON-PAINTED) EXTERIOR PARTS
Use only approved products to clean plastic parts. These products are
available from your dealer.
•For routine cleaning, use cool or lukewarm water with a neutral pH
shampoo.
•If tar or grease spots are present, use Extra Strength Tar and Road Oil
Remover (0000–77–410E-01), available at your authorized Mazda
dealer.
WINDOWS AND WIPER BLADES
The windshield, rear and side windows and the wiper blades should be
cleaned regularly. If the wipers do not wipe properly, substances on the
vehicle’s glass or the wiper blades may be the cause. These may include
hot wax treatments used by commercial car washes, water repellant
coatings, tree sap, or other organic contamination; these contaminants
may cause squeaking or chatter noise from the blades, and streaking and
smearing of the windshield. To clean these items, follow these tips:
•The windshield, rear windows and side windows may be cleaned with
a non-abrasive cleaner such as Ultra-Clear Spray Glass Cleaner
(0000–77–400E-01 and 0000–77–400E-02), available from your
authorized Mazda dealer.
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INTERIOR
For fabric, carpets, cloth seats, and safety belts:
•Remove dust and loose dirt with a vacuum cleaner.
•Remove light stains and soil with Upholstery Cleaner and Spot
Remover (0000–77–430E-01), available at your authorized Mazda
dealer.
•If grease or tar is present on the material, spot-clean the area first
with Spot and Stain Remover (0000–77–410E-01), available at your
authorized Mazda dealer.
•If a solvent ring forms on the fabric after spot cleaning, clean the
entire area immediately (but do not oversaturate) or the ring will set.
•Do not use household cleaning products or glass cleaners, which can
stain and discolor the fabric and affect the flame retardant abilities of
the seat materials.
UNDERBODY
Flush the complete underside of your vehicle frequently. Keep body and
door drain holes free from packed dirt.
MAZDA CAR CARE PRODUCTS
Your Mazda dealer has many quality products available to clean your
vehicle and protect its finishes. These quality products have been
specifically engineered to fulfill your automotive needs; they are custom
designed to complement the style and appearance of your vehicle. Each
product is made from high quality materials that meet or exceed rigid
specifications. For best results, use these products or products of
equivalent quality. These products are available at your authorized Mazda
dealer.
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CHART SYMBOLS
I: Inspect and if necessary, correct, clean or replace
AAdjust
R: Replace
L: Lubricate
Normal driving service intervals — perform at the months or distances
shown, whichever occurs first.
Maintenance ItemMaintenance Interval (Number of months or Miles (km),
whichever comes first)
Months 4 8 12 16 20 24 28 32 36 40 44 48
x 1000 miles 5 10 15 20 25 30 35 40 45 50 55 60
(x 1000 km) (8) (16) (24) (32) (40) (48) (56) (64) (72) (80) (88) (96)
ENGINE
Engine oil RRRRRRRRRRR R
Oil filter RRRRRRRRRRR R
PCV valve *3
AIR CLEANER
Air cleaner filter R R
IGNITION SYSTEM
Spark plugs *4
COOLING SYSTEM
Engine Coolant (yellow) Replace at first 100,000 miles (160,000 km) or 60
months; after that, every 50,000 miles (80,000 km)
or 36 months
Coolant condition and protection,
hoses and clamps — annually —
prior to cold weather every 12
monthsIII I
CHASSIS AND BODY
Wheel lug nut torque *1 IIIIIIIIIII I
Inspect tires for wear and rotate (X
= recommended interval for optimal
tire life)IX I XX I XX I XX I
Clutch reservoir fluid level I IIIII
Front wheel bearings (4x2) L
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*5 The California Air Resources Board has determined that the failure to
perform this maintenance item will not nullify the emission warranty nor
limit recall liability prior to completion of the vehicle’s useful life.
Schedule 1 continued
Maintenance
ItemMaintenance Interval (Number of months or Miles (km),
whichever comes first)
Months 52 56 60 64 68 72 76 80 84 88 92 96
x 1000 miles 65 70 75 80 85 90 95 100 105 110 115 120
(x 1000 km) (104) (112) (121) (128) (136) (144) (152) (160) (168) (176) (184) (192)
ENGINE
Engine oilRRRRRRRRRRRR
Oil filterRRRRRRRRRRRR
PCV valve *3
AIR CLEANER
Air cleaner filter R R
IGNITION SYSTEM
Spark plugs *4 R
COOLING SYSTEM
Engine Coolant (yellow) Replace at first 100,000 miles (160,000 km) or 60 months; after
that, every 50,000 miles (80,000 km) or 36 months
Coolant condition and
protection, hoses and
clamps — annually
—prior to cold weather
every 12 monthsIIII
CHASSIS AND BODY
Wheel lug
nut torque*1IIIIIIIIIIII
Inspect tires for wear
and rotate (X =
recommended interval
for optimal tire life)XX I XX I XX I XX I
Clutch reservoir fluid
levelIIIIII
Front wheel bearings
(4x2)L
Disc brake system I I I I
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*2 Replace every 150,000 miles (240,000 km) unless submerged in water.
*3 At 60,000 miles (96,000 km), the dealer will replace the PCV valve at
no cost, except Canada and California vehicles.
*4 Refer to vehicle emission control information label for spark plug and
gap specifications.
*5 The California Air Resources Board has determined that the failure to
perform this maintenance item will not nullify the emission warranty nor
limit recall liability prior to completion of the vehicle’s useful life.
SCHEDULE 2 — SPECIAL OPERATING CONDITIONS
If your driving habitsFREQUENTLYinclude one or more of the
following conditions:
•Short trips of less than 10 miles (16 km) when outside temperatures
remain below freezing.
•Towing a trailer, or carrying maximum loads.
•Operating in severe dust conditions.
•Operating duringhot weatherin stop-and-go “rush hour” traffic.
•Extensive idling, such as police, taxi or door-to-door delivery service.
•High speed operation with a fully loaded vehicle (max. GVW).
•Off-road operation
Change ENGINE OIL AND OIL FILTER every 3 months or 3,000 miles
(4,800 km) whichever occurs first.
NOTE:Idling the engine for extended periods will accumulate more
hours of use on your vehicle than is actually indicated by the mileage
odometer. Consequently, the odometer reading can be often misleading
when determining the right time to change your engine oil and filter. If
you are using your vehicle in a manner which allows it to remain
stationary while the engine is running for long periods (door-to-door
delivery, taxi, police, power/utility company trucks, or similar duty), then
Mazda recommends you increase the frequency of oil and filter changes
to an interval equivalent to 200 ENGINE HOURS or use. Since most
vehicles are not equipped with hour-meters, it may be necessary for you
to approximate your idle time and plan oil/filter changes accordingly.
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