engine MAZDA MODEL B4000 4WD 2003 Workshop Manual

•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 AND CANADA
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, its territories, and 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 these areas.
You may have these problems if you do:
• 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.
The manufacturer’s warranty applies only to Mazda vehicles registered
and normally operated in the United States, its territories, and Canada.
REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect which could cause a crash or
could cause injury or death, you should immediately inform the National
Highway Traffic Safety Administration (NHTSA) in addition to notifying
your Mazda importer/distributor.
If NHTSA receives similar complaints, it may open an investigation, and
if it finds that a safety defect exists in a group of vehicles, it may order a
recall and remedy campaign. However NHTSA cannot become involved in
individual problems between you, your dealer, or your Mazda
importer/distributor).
To contact NHTSA, you may either call the Auto Safety Hotline toll-free
at 1 (800) 424–9393 (or 366–0123 in Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation. Washington, D.C. 20590. You
can also obtain other information about motor vehicle safety from the
Hotline.
Customer Assistance
172

REPAIRING PAINT CHIPS
Minor scratches or paint damage from road debris may be repaired with
Genuine Mazda Touch-Up Paint. Observe the application instructions on
the products.
Remove particles such as bird droppings, tree sap, insect remains, tar
spots, road salt and industrial fallout immediately.
CLEANING THE WHEELS
Wash with the same detergent as the body of your vehicle. Do not use
acid-based or alcohol-based wheel cleaners, steel wool, fuel or strong
detergents. Never use abrasives that will damage the finish of special
wheel surfaces. Use a tar remover to remove grease and tar.
The brushes used in some automatic car washes may damage the
finish on your wheels. Before going to a car wash, find out if the
brushes are abrasive.
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, available at your authorized
Mazda dealer, on all parts that require cleaning and pressure rinse
clean.
• Cover the highlighted areas to prevent water damage when cleaning
the engine.
Cleaning
177

•2.3L Engine
• 3.0L Engine
2.3L16 VALVE
Cleaning
178

•4.0L Engine
• Never wash or rinse the engine while it is running; water in the
running engine may cause internal damage.
CLEANING NON-PAINTED PLASTIC EXTERIOR PARTS
Use vinyl cleaner for routine cleaning. Clean with a tar remover if
necessary. Do not clean plastic parts with thinners, solvents or
petroleum-based cleaners.
CLEANING MIRRORS
Do not clean your mirrors with a dry cloth or abrasive materials. Use a
soft cloth and mild detergent and water. Be careful when removing ice
from outside mirrors because you may damage the reflective surface.
CLEANING THE EXTERIOR LAMPS
Wash with the same detergent as the exterior of your vehicle. If
necessary, use a tar remover.
To avoid scratching the lamps, do not use a dry paper towel, chemical
solvents or abrasive cleaners.
CLEANING THE WIPER BLADES, WINDSHIELD AND REAR
WINDOW
If the wiper blades do not wipe properly, clean the wiper blade rubber
element with undiluted windshield washer solution or a mild detergent.
To avoid damaging the blades, do not use fuel, kerosene, paint thinner or
other solvents.
If the wiper still does not wipe properly, this could be caused by
substances on the windshield or rear window such as tree sap and some
Cleaning
179

INSIDE WINDOWS
Use glass cleaner for the inside windows if they become fogged.
Leather seats (if equipped)
Your leather seating surfaces have a clear, protective coating over the
leather.
•To clean, use a soft cloth with Deluxe Leather and Vinyl Cleaner. Dry
the area with a soft cloth.
• To help maintain its resiliency and color, use the Deluxe Leather Care
Kit, available at your authorized Mazda dealer.
• Do not use household cleaning products, alcohol solutions, solvents or
cleaners intended for rubber, vinyl and plastics, or oil/petroleum-based
leather conditioners. These products may cause premature wearing of
the clear, protective coating.
UNDERBODY
Flush the complete underside of vehicle frequently. Keep body drain
holes unplugged. Inspect for road damage.
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.
Cleaning
181

CHART SYMBOLS
I: Inspect, and if necessary correct, clean or replace
A: Adjust
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 — every 6 months R RRRRRRRRRR R
Oil filter — every 6 months R RRRRRRRRRR R
PCV valve
AIR CLEANER
Air cleaner filter R R
IGNITION SYSTEM
Spark plugs *4
COOLING SYSTEM
Engine Coolant (green) Replace at first 45,000 miles (72,000 km) or 36 months, after that, every 30,000 miles(48,000 km) or 24 months
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 months III I
CHASSIS AND BODY
Wheel lug nut torque *1 I IIIIIIIIII I
Inspect tires for wear and rotate
(X = recommended interval for
optimal tire life) IXIXXIXXIXX I
Clutch reservoir fluid level I IIIII
Maintenance and Specifications
183

*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 I 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 oil — every 6 months R RRRRRRRRRR R
Oil filter — every 6 months R RRRRRRRRRR R
PCV valve R
AIR CLEANER
Air cleaner filter R R
IGNITION SYSTEM
Spark plugs *4 R
COOLING SYSTEM
Engine Coolant (green) Replace at first 45,000 miles (72,000 km) or 36 months, after that, every 30,000 miles(48,000 km) or 24 months
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 months III I
CHASSIS AND BODY
Wheel lug nut torque *1 I IIIIIIIIII I
Inspect tires for wear and rotate
(X = recommended interval for
optimal tire life) XXIXXIXXIXX I
Clutch reservoir fluid level I IIIII
Front wheel bearings (4x2) L
Disc brake system I I I I
Maintenance and Specifications
185

SCHEDULE II — 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 during hot 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.
Maintenance and Specifications
187

Special Operating
Conditions
Replace Engine Oil and Filter
Inspect Brake System
Replace Fuel Filter
Change Automatic Transmission Fluid
Replace Spark Plugs
Replace Engine Air Filter
Change Manual Transmission Fluid
Inspect and Lubricate U-Joints
Lubricate Front Wheel Bearing (4x2)
Change Transfer Case Fluid (4x4)
Suggested Maintenance
Interval3,000
miles or
3 months 5,000
miles 15,000
miles 30,000
miles 60,000
miles As
required As
required As
required 30,000
miles 60,000
miles
Towing a trailer or
using a camper or
car top carrier XXXX
Extensive idling or
low-speed driving
for long distances
as in heavy
commercial use
such as delivery,
taxi or patrol car X XXXX XX
Operating in dusty
conditions such as
unpaved or dusty
roads XXX X
Off road operation X X X
For specific recommendations see your authorized Mazda dealer or
qualified service professional.
OWNER MAINTENANCE
Owner Maintenance Schedule
The owner or a qualified service technician should make these vehicle
inspections at the indicated intervals to ensure safe and dependable
operation.
Bring any problem to the attention of an Authorized Mazda Dealer or
qualified service technician as soon as possible.
Maintenance and Specifications
188

While operating your vehicle
•Note any changes in the sound of the exhaust or any smell or exhaust
fumes in the vehicle.
• Check for vibrations in the steering wheel. Notice any increased
steering effort or looseness in the steering wheel, or change in the
straight ahead position.
• Notice if your vehicle constantly turns slightly or “pulls” to one side
when traveling on a smooth, level road.
• When stopping, listen and check for strange sounds, pulling to one
side, increased brake pedal travel or “hard to push” brake pedal.
• If any slipping or changes in the operation of your transmission occur,
check the transmission fluid level.
• Check automatic transmission Park function.
• Check parking brake.
At least monthly
• Check function of all interior and exterior lights.
• Check tires for wear and proper air pressure.
• Check engine oil level.
• Check coolant level in the coolant reservoir.
• Check washer fluid level.
At least twice a year (for example, every spring and fall)
• Check power steering fluid level.
• Check clutch fluid level (if equipped).
• Check and clean body and door drain holes.
• Check and lubricate all hinges, latches, and outside locks.
• Check and lubricate door rubber weather strips.
• Check parking brake for proper operation.
• Check lap/shoulder belts and seat latches for wear and function.
• Check air pressure in spare tire.
• Check windshield washer spray and wiper operation. Clean wiper
blades with clean cloth dampened with washer fluid.
• Check safety warning lamps (brake, ABS, air bag, safety belt) for
operation.
Maintenance and Specifications
189