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B-Series 1997
Workshop manual
Mazda B-Series 1997 Workshop Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Contents
Vehicle Identification Numbers (VIN)
General Information
Table of Contents
Important Information
Basic Assumptions
Safety Risk
Possible Loss of Warranty
Warning on Lubricants and Greases
How to Use the Manual
How T O 1 Use this Manual
Preparation
Repair Procedure
Symbols
Notes, Cautions and Warnings
Fundamental Procedures
Protection of the Vehicle
A Word about Safety
Preparation of Tools and Measuring Equipment
Special Tools
Removal of Parts
Disassembly
Assembly
Adjustments
Rubber Parts and Tubing
Jack and Safety Stand (Rigid Rack) Positions
Front End
Vehicle Lift (2-Support Type) Positions
Towing - Preparation
Towing Two-Wheel Drive Vehicles
General Towing Procedure Preparatory Steps
Towing Four-Wheel Drive Vehicles
Towing Equipment
Towing Slings/Chains/Hooks
Towing Connections
Vehicles
Vehicle Identification Number
Sample VIN Number
Safety Compliance Certification Labels
Build Date Stamp Location
Exterior Paint Codes
Model Codes and Gvws
Wheelbase in Centimeters/Inches
Seat Types and Interior Fabric Codes
Rear Axle Codes
Tape Accent Codes
Transmission Codes
Units, Abbreviations
SAE Standard Name
Engine and Emission Systems Abbreviations
Transmission Abbreviations
Electrical Troubleshooting Tools
Test Light
Voltmeter
Ohmmeter
Caution
Caution with Electrical Parts
Wiring Color Codes
Generic OBD II PID List
Pre-Delivery Inspection and Scheduled Maintenance Services
Service Pre-Delivery Inspection Sheet a
Maintenance Tables
Services
Schedule 1 (Normal Driving Conditions)
Schedule 2 (Unique Driving Conditions)
Inspection and Adjustment of Drive Belt
Drive Belt Tension a
Replacement of Drive Belt
Replacement of Engine Oil
Replacement of Engine Oil Filter
Oil Capacity Table
Replacement of Engine Timing Belt (2.3L Only)
Inspection of Cooling System
Coolant Level (Engine Cold)
Coolant Quality
Coolant Leakage
Replacement of Engine Coolant
Coolant Protection
Antifreeze Solution Mixture Percentage
Replacement of Air Cleaner Element
Replacement of Fuel Filter
Ignition Timing
Inspection of Idle Speed
Inspection of Fuel Lines
Replacement of Spark Plugs
Inspection of Emission Hoses and Tubes
Inspection of Brake Lines, Hoses and Connections
Inspection of Disc Brake
Inspection of Drum Brake
Replacement of Brake Fluid
Inspection of Propeller Shaft Dust Boot(S)
Tightening of Bolts and Nuts on Chassis and Body
Inspection of Exhaust System Head Shield
Inspection of PCV Valve
Inspection of Front Suspension Ball Joints
Inspection of Brake and Clutch Fluid
Inspection of Power Steering Fluid Level
Inspection of Tires
Tire Wear
Abnormal Tire Wear
Air Pressure
Air Leakage
Inspection of Manual Transmission Oil
Loose Lug Nut
Tire Rotation
Wheel and Tire Runout
Replacement of Manual Transmission Oil
Inspection of Automatic Transmission Fluid Level
Replacement of Automatic Transmission Fluid
Inspection of Transfer Case Oil
Replacement of Transfer Case Oil
Engine (2.3L)
Engine (2.3L) View
Engine (2.3L) Outline/Specifications
Engine (2.3L) Troubleshooting Guide
Engine Tune-Up Procedure
Engine Oil Inspection
Engine Coolant Inspection
Drive Belt Inspection
HLA Troubleshooting Guide
Ignition Timing, Idle Speed
Compression
Engine On-Vehicle Maintenance (2.3L)
Sst
Timing Belt Removal/Installation
Removal Note - Timing Belt Outer Cover
Timing Belt
Installation Note - Timing Belt
Timing Belt Outer Cover
Checking Camshaft Timing
Adjusting Camshaft Timing
Cylinder Head Gasket Replacement
Removal Note - Spark Plugs
Exhaust Manifold Removal
Cylinder Head Cover
Lower Intake Manifold
Exhaust Manifold
Water Inlet Tube
DPF EGR Sensor
Hydraulic Lash Adjuster Removal/Installation
Front Oil Seal Replacement
Camshaft Oil Seal Replacement
Oil Pump Oil Seal Replacement
Rear Oil Seal Replacement
Engine (2.3L) Removal Procedure
Engine (2.3L) Disassembly - Preparation
Engine Auxiliary Parts
Engine (2.3L) Disassembly - Diagram
Timing Belt Disassembly
Cylinder Head Disassembly
Cylinder Block (External Parts) Disassembly
Oil Pan
Oil Pump Strainer and Tube
Front Cover Disassembly
Cylinder Block (Internal Parts) Disassembly
Connecting Rod Removal
Piston Ring
Piston Pin
Main Bearing Caps
Engine Inspection/Repair
Cylinder Head Inspection
Valve Mechanism Inspection
Valve and Valve Guide Inspection
Valve Seat Inspection
Valve Spring Inspection
Camshaft Inspection
Cylinder Block Inspection
Piston, Piston Ring and Piston Pin Inspection
Connecting Rod Inspection
Crankshaft Inspection
Main Bearing and Connecting Rod Bearing Inspection
Pulley Inspection
Timing Belt Outer Cover Inspection
Flywheel (MT) Inspection
Engine Assembly - Preparation
Cylinder Block (Internal Parts) Assembly
Oil Clearance Inspection
Rear Oil Seal Installation
Piston Pins Installation
Piston Rings Installation
Pistons Installation
Connecting Rod Cap
Front Cover Assembly
Cylinder Block (External Parts) Assembly
Oil Pump Strainer and Tub Installation
Oil Pan Installation
Water Pump Installation
Flywheel, Clutch Disc, and Clutch Cover (MT) Installation
Drive Plate (AT) Installation
Cylinder Head Assembly
Valve Seals
Valve Spring Assembly
Camshaft Bearings Installation
Camshaft Installation
Valve Keepers
Rocker Arms
Camshaft Thrust Plate
Cylinder Head
Timing Belt Assembly
Camshaft Pulley
Timing Belt Tensioner Installation
Timing Belt Outer Cover Installation
Crankshaft Pulley Installation
Exhaust Manifold Installation
Lower Intake Manifold Installation
Cylinder Head Cover Installation
Dipstick Tube and Bracket Installation
Engine Installation Procedure
Steps after Installation of the Engine
Engine 3.0L
Engine 3.0L View
Engine 3.0L Specifications
Engine 3.0L Troubleshooting
Engine Tune-Up Procedures
Engine Oil - to Inspect
Engine Coolant - to Inspect
Drive Belt - to Inspect
Ignition Timing, Idle Speed Initial Timing
Compression (3.0L)
Engine On-Vehicle Maintenance (3.0L)
Cylinder Head Gasket Replacement (3.0L)
Ignition Coil Removal (3.0L)
Auxiliary Parts Removal (3.0L)
Cylinder Head Cover (3.0L)
Rocker Arms (3.0L)
Lower Intake Manifold (3.0L)
Cylinder Head (3.0L)
Lower Intake Manifold Installation (3.0L)
Rocker Arms Installation (3.0L)
Dipstick Tube Installation (3.0L)
Spark Plugs Installation (3.0L)
Cylinder Head Covers Installation (3.0L)
Steps after Installation (Engine 3.0L)
Tappet Removal/Installation (3.0L)
No. 3 Intake Valve Rocker Arm Removal (3.0L)
Tappets Removal (3.0L)
Tappets Installation (3.0L)
Front Oil Seal Replacement (3.0L)
Damper (3.0L)
Front Oil Seal (3.0L)
Front Oil Seal Installation (3.0L)
Damper Installation (3.0L)
Rear Oil Seal Replacement (3.0L)
Flywheel (MT) Removal (3.0L)
Drive Plate (AT) Removal
Rear Oil Seal Installation (3.0L)
Engine (3.0L) Removal Procedure
Drive Plate (AT) Installation (3.0L)
Flywheel (MT) Installation (3.0L)
Wiring and Harness Connectors (3.0L Engine)
Hydraulic Clutch Pipe (MT) (3.0L)
Drive Plate (AT) (3.0L)
Engine (3.0L) Disassembly
Engine (3.0L) Disassembly - Diagram
Cylinder Head Cover Disassembly (3.0L)
Lower Intake Manifold Disassembly (3.0L)
Exhaust Manifolds (3.0L)
Timing Chain Disassembly (3.0L)
Damper Disassembly (3.0L)
Oil Pan Removal (3.0L)
Timing Cover Removal (3.0L)
Front Oil Seal Removal (3.0L)
Timing Chain Removal (3.0L)
Cylinder Head Disassembly (3.0L)
Rocker Arm Removal (3.0L)
Valve Keepers Removal (3.0L)
Valve Seals Removal (3.0L)
Cylinder Block (External Parts) Disassembly (3.0L)
Flywheel Removal (3.0L)
Drive Plate Removal (3.0L)
Oil Pump Removal (3.0L)
Cylinder Block (Internal Parts) Disassembly (3.0L)
Tappets Removal
Camshaft Removal (3.0L)
12. Crankshaft
14. Rear Oil Seal
Pistons
Camshaft Bearings (3.0L)
Connecting Rods Removal (3.0L)
Piston Rings Removal (3.0L)
Piston Pins Removal (3.0L)
Engine (3.0L) Inspection/Repair
Cylinder Head Inspection (3.0L)
Main Bearing Caps Removal (3.0L)
Crankshaft Removal (3.0L)
Valve Mechanism Inspection (3.0L)
Valve and Valve Guide Inspection (3.0L)
Valve Seat Removal (3.0L)
Valve Spring Inspection (3.0L)
Camshaft Inspection (3.0L)
Tappet Inspection (3.0L)
Cylinder Block Inspection (3.0L)
Pistons Inspection (3.0L)
Piston Rings Inspection (3.0L)
Piston Pins (3.0L)
Connecting Rods Inspection (3.0L)
Crankshaft Inspection (3.0L)
Main Bearing and Connecting Rod Bearing Check (3.0L)
Pulleys Check (3.0L)
Timing Chain Outer Cover Inspection (3.0L)
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Mazda B-Series
Workshop
Manual
@
1997 Mazda Motor Corporation
Printed in U.S.A. 7/96
(9999-95-0228-97)
Table of
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Table of Contents
Troubleshooting
Electrical troubleshooting tools
30
Engine (2.3L) outline/specifications
62
HLA troubleshooting guide
65
Engine 3.0L specifications
133
Engine (4.0L) specifications
202
Lubrication System Specifications
267
Lubrication System Specifications (3.0L)
276
Lubrication System Specifications (4.0L)
286
Cooling System Specifications (2.3L)
298
Cooling System Specifications (3.0L)
313
Cooling System (4.0L) Specifications
330
Engine Control Troubleshooting - 2.3L/3.0L/4.0L
346
Troubleshooting guide (engine control system)
376
Troubleshooting chart
377
Symptom troubleshooting (engine control system)
380
On-board diagnostic system - troubleshooting
427
Electrical system specifications
583
SYMPTOM TROUBLESHOOTING
584
Charging system troubleshooting
590
Electronic ignition system troubleshooting
608
Clutch specifications
644
Manual Transmission Specifications
660
Manual shift transfer case troubleshooting
698
Electronic shift transfer case troubleshooting
713
Electronic shift transfer case troubleshooting/circuit diagram
727
Electronic shift transfer case - diagnostic troubleshooting guide
731
Automatic Transmission (Electronically Controlled) Troubleshooting
751
Automatic Transmission (Electronically Controlled) Symptom Troubleshooting
763
Shift mechanism troubleshooting
944
Propeller Shaft Troubleshooting
958
Front axle troubleshooting
977
Rear axle troubleshooting
978
Manual steering troubleshooting guide
1069
Power Steering Troubleshooting
1099
Conventional Brake System Troubleshooting
1135
Parking brake system troubleshooting
1161
Rear anti-lock brake system (RABS) troubleshooting
1164
Rear anti-lock brake system - system troubleshooting
1168
4-Wheel Anti-Lock Brake System (4WABS) Description
1194
Wheels and Tires Troubleshooting
1253
Suspension troubleshooting
1262
NVH troubleshooting guide
1263
Troubleshooting guide - diagnostic index (body)
1368
Waterleak troubleshooting
1372
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