light MAZDA MODEL B3000 TRUCK 2004 Repair Manual

WARNING: The fuel system may be under pressure. If the fuel
filler cap is venting vapor or if you hear a hissing sound, wait
until it stops before completely removing the fuel filler cap.
Otherwise, fuel may spray out and injure you or others.
WARNING: If you do not use the proper fuel filler cap,
excessive pressure or vacuum in the fuel tank may damage the
fuel system or cause the fuel cap to disengage in a collision,
which may result in possible personal injury.
Choosing the right fuel
Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law
and could damage your vehicle.
If your vehicle is a flexible fuel vehicle (FFV), use only UNLEADED
FUEL and (E85) FUEL ETHANOL. The use of leaded fuel is prohibited
by law and could damage your vehicle.
Do not use fuel containing methanol. It can damage critical fuel system
components.
Your vehicle was not designed to use fuel or fuel additives with metallic
compounds, including manganese-based additives.
Repairs to correct the effects of using a fuel for which your vehicle was
not designed may not be covered by your warranty.
Octane recommendations
Do not be concerned if your engine
sometimes knocks lightly. However,
if it knocks heavily under most
driving conditions while you are
using fuel with the recommended
octane rating, see your authorized Mazda dealership to prevent any
engine damage.
Unleaded Gasoline engines
Your vehicle is designed to use “Regular” unleaded gasoline with an
(R+M)/2 octane rating of 87. We do not recommend the use of gasolines
labeled as “Regular” that are sold with octane ratings of 86 or lower in
high altitude areas.
87(R+M)/2 METHOD
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•Perform all regularly scheduled maintenance items. Follow the
recommended maintenance schedule and owner maintenance checks
found in your vehicle service maintenance section.
Conditions
• Heavily loading a vehicle or towing a trailer may reduce fuel economy
at any speed.
• Carrying unnecessary weight may reduce fuel economy (approximately
0.4 km/L [1 mpg] is lost for every 180 kg [400 lb] of weight carried).
• Adding certain accessories to your vehicle (for example bug
deflectors, rollbars/light bars, running boards, ski/luggage racks) may
reduce fuel economy.
• Using fuel blended with alcohol may lower fuel economy.
• Fuel economy may decrease with lower temperatures during the first
12–16 km (8–10 miles) of driving.
• Driving on flat terrain offers improved fuel economy as compared to
driving on hilly terrain.
• Transmissions give their best fuel economy when operated in the top
cruise gear and with steady pressure on the gas pedal.
• Four-wheel-drive operation (if equipped) is less fuel efficient than
two-wheel-drive operation.
• Close windows for high speed driving.
EPA window sticker
Every new vehicle should have the EPA window sticker. Contact your
dealer if the window sticker is not supplied with your vehicle. The EPA
window sticker should be your guide for the fuel economy comparisons
with other vehicles.
It is important to note the box in the lower left corner of the window
sticker. These numbers represent the Range of L/100 km (MPG)
expected on the vehicle under optimum conditions. Your fuel economy
may vary depending upon the method of operation and conditions.
EMISSION CONTROL SYSTEM
Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
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•Use only the specified fuel listed.
• Avoid running out of fuel.
• Do not turn off the ignition while your vehicle is moving, especially at
high speeds.
• Have the items listed in your service maintenance section performed
according to the specified schedule.
The scheduled maintenance items listed in the scheduled maintenance
section are essential to the life and performance of your vehicle and to
its emissions system.
If other than Mazda authorized parts are used for maintenance
replacements or for service of components affecting emission control,
such non-Mazda parts should be equivalent to genuine Mazda parts in
performance and durability.
WARNING: Do not park, idle, or drive your vehicle in dry grass
or other dry ground cover. The emission system heats up the
engine compartment and exhaust system, which can start a fire.
Illumination of the
CHECK
ENGINEindicator, 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 your “Warranty Information” for complete emission
warranty information.
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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 “Check Engine/Service Engine
Soon” light is on, refer to the description in theWarning lights and
chimes section of the Instrument cluster chapter. Your vehicle may not
pass the I/M test with the “Check Engine/Service Engine Soon” light on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test”
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:
• First, at least 10 minutes of driving on an expressway or highway.
• Next, 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.
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INFORMATION CONTAINED ON THE TIRE SIDEWALL
Federal law requires tire manufacturers to place standardized
information on the sidewall of all tires. This information identifies and
describes the fundamental characteristics of the tire and also provides a
tire identification number for safety standard certification and in case of
a recall.
Information on “P” type tires
P215/65R15 95H is an example of a
tire size, load index and speed
rating. The definitions of these
items are listed below. (Note that
the tire size, load index and speed
rating for your vehicle may be
different than this example.)1. P:Indicates a tire, designated
by the Tire and Rim Association
(T&RA), that maybe used for
service on cars, SUVs, minivans
and light trucks.
Note: If your tire size does not
begin with a letter this may mean it
is designated by either ETRTO
(European Tire and Rim Technical Organization) or JATMA (Japan Tire
Manufacturing Association).
2. 215: Indicates the nominal width of the tire in millimeters from
sidewall edge to sidewall edge. In general, the larger the number, the
wider the tire.
3. 65: Indicates the aspect ratio which gives the tire’s ratio of height to
width.
4. R: Indicates a “radial” type tire.
5. 15: Indicates the wheel or rim diameter in inches. If you change
your wheel size, you will have to purchase new tires to match the
new wheel diameter.
6. 95: Indicates the tire’s load index. It is an index that relates to how
much weight a tire can carry. You may find this information in your
owner’s guide. If not, contact a local tire dealer.
Note: You may not find this information on all tires because it is not
required by federal law.
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Additional information contained on the tire sidewall for “LT” type
tires
“LT” type tires have some additional
information than those of “P” type
tires; these differences are
described below:1. LT: Indicates a tire, designated
by the Tire and Rim Association
(T&RA), that is intended for
service on light trucks.
2. Load Range/Load Inflation
Limits: Indicates the tires
load-carrying capabilities and its
inflation limits.
3. Maximum Load Dual kg
(lbs.) at kPa (psi) cold:
Indicates the maximum load and
tire pressure when the tire is
used as a dual; a dual is defined as when four tires are put on the
rear axle (a total of six or more tires on the vehicle).
4. Maximum Load Single kg (lbs.) at kPa (psi) cold: Indicates the
maximum load and tire pressure when the tire is used as a single; a
single is defined as when two tires (total) are put on the rear axle.
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Information on “T” type tires
T145/80D16 is an example of a tire
size.
Note:The temporary tire size for
your vehicle may be different than
this example.
1. T:Indicates a type of tire,
designated by the Tire and Rim
Association (T&RA), that is
intended for temporary service
on cars, SUVs, minivans and
light trucks.
2. 145: Indicates the nominal
width of the tire in millimeters
from sidewall edge to sidewall
edge. In general, the larger the
number, the wider the tire.
3. 80: Indicates the aspect ratio
which gives the tires ratio of height to width. Numbers of 70 or
lower indicate a short sidewall.
4. D: Indicates a “diagonal” type tire.
R: Indicates a “radial” type tire.
5. 16: Indicates the wheel or rim diameter in inches. If you change
your wheel size, you will have to purchase new tires to match the
new wheel diameter.
Location of the tire label
You will find a tire label containing tire inflation pressure by tire size and
other important information located on the B-Pillar or the driver’s door.
TIRE CARE
Improper or inadequate vehicle maintenance can also cause tires to wear
abnormally. Here are some of the important maintenance items
Tire inflation pressure
Use a tire gauge to check the tire inflation pressure at least monthly
(check the tire inflation in the spare tire every 6 months) and before
long trips. You are strongly urged to buy a reliable tire pressure gauge, as
automatic service station gauges may be inaccurate. Mazda recommends
the use of a digital or dial type tire pressure gauge rather than a stick
type of tire pressure gauge.
SPARETIRE
TEMPORARYUSEONLY
INFLATETO60P.S.I.T
T145/80D16105M
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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.
6Brake fluid will drop slowly as the brakes wear and will rise when brake
components are replaced. Fluid levels below the MAX line that do not
trigger the brake warning light are within the normal operating range,
there is no need to add fluid. If the levels are outside the normal
operating range, the performance of your brake system could be
compromised, seek service from your local Mazda dealer immediately.
LUBRICANT SPECIFICATIONS
Item Mazda part name or equivalent
Front axle (4X4) SAE 80W-90 Premium Rear Axle
Lubricant
Rear axle SAE 80W-90 Premium Rear Axle
Lubricant
1
Brake fluid and clutch fluid (if
equipped)High Performance DOT 3 Motor
Vehicle Brake Fluid
4
Door weather strips
Silicone Lubricant
Engine coolant Mazda Premium Engine Coolant3
Engine oil 2.3L I4 and 3.0L V6 engines SAE 5W-20 Motor Oil
Engine oil 4.0L V6 engines SAE 5W-30 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) MERCON
AT F
Automatic transmission (5R44E and
5R55E) MERCONVATF
2
Windshield washer fluid
Ultra-clear Windshield Washer
Concentrate
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(mbs)
Owners Guide (post-2002-fmt)
USA English (fus)
Maintenance and Specifications
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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. MERCON and MERCONV are not interchangeable. DO NOT
mix MERCON and MERCONV. Refer to your service maintenance
section to determine the correct service interval.
3Do not mix different types or colors of engine coolant.
4Brake fluid will drop slowly as the brakes wear and will rise when brake
components are replaced. Fluid levels below the MAX line that do not
trigger the brake warning light are within the normal operating range,
there is no need to add fluid. If the levels are outside the normal
operating range, the performance of your brake system could be
compromised, seek service from your local Mazda dealer immediately.
ENGINE SPECIFICATIONS
Engine 2.3L I4 engine 3.0L V6 engine 4.0L V6 engine
Cubic inches 138 182 245
Required fuel 87 octane 87 octane 87 octane
Firing order 1-3-4-2 1-4-2-5-3-6 1-4-2-5-3-6
Spark plug gap 1.04-1.19mm
(0.041-0.047
inch)1.07-1.17mm
(0.042-0.046
inch)1.3-1.4 mm
(0.052-0.056
inch)
Ignition system EDIS EDIS EDIS
Compression
ratio 9.7:1 9.14:1 9.7:1
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A
ABS (see Brakes) .....................110
Air bag supplemental restraint
system ..........................................77and child safety seats ..............80
description ................................77
disposal ......................................83
driver air bag ............................81
indicator light ...........................83
operation ...................................81
passenger air bag .....................81
passenger deactivation
switch ........................................84
Ambulance packages ....................7
Antifreeze
(see Engine coolant) ................202
Anti-lock brake system
(see Brakes) ......................110–111
Audio system 6-CD in dash .............................22
Single CD ..................................19
Audio system
(see Radio) ................18–19, 22, 26
Automatic dimming rear view
mirror ...........................................46
Automatic transmission ............114 driving an automatic
overdrive .................................115
fluid, refill capacities ..............240
fluid, specification ..................244
Auxiliary power point .................45
Axle lubricant specifications ..243–244
refill capacities ........................240
traction lok ..............................113
B
Battery .......................................200 acid, treating emergencies .....200
jumping a disabled battery ....157
maintenance-free ....................200
servicing ..................................200
Bed extender ..............................53
BeltMinder ...................................73
Brakes ........................................110 anti-lock ...........................110–111
anti-lock brake system (ABS)
warning light ...........................111
fluid, checking and adding ....221
fluid, refill capacities ..............240
fluid, specifications .........243–244
lubricant specifications ..243–244
parking ....................................112
shift interlock ..........................114
Break-in period .............................5
Bulbs ............................................36
C
Calculating load ........................127
Capacities for refilling fluids ....240
Cassette tape player .............19, 22
Cell phone warning ...................248
Certification Label ....................247
Changing a tire ...................49, 149
Child safety restraints ................90 child safety belts ......................90
Child safety seats ........................93 attaching with tether straps ....98
in front seat ..............................95
in rear seat ................................95
LATCH .....................................101
tether anchorage hardware .....98
Chimes (warning) .......................16
2004 Mazda B Series (mbs)
Owners Guide (post-2002-fmt)
USA English (fus)
Index
Index
249