Mazda B3000 (2002 year). Instruction

Illumination of the “Service Engine Soon” 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 your Warranty Guide for 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 “Check Engine/Service Engine
Soon” light is on, refer to the description in the Warning 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.

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 MERCON

t ATF.

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.

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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 to Lubricant
specifications in 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

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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 to Lubricant Specifications in this chapter.

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.

Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating

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263

temperature (approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.

1. Drive the vehicle 30 km (20 miles) or until it reaches normal

operating temperature.

2. Park the vehicle on a level surface and engage the parking brake.

3. With the parking brake engaged and your foot on the brake pedal,

start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.

4. Latch the gearshift lever in P (Park) and leave the engine running.

5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If

necessary, refer to Identifying components in the engine
compartment in this chapter for the location of the dipstick.

6. Install the dipstick making sure it is fully seated in the filler tube.

7. Remove the dipstick and inspect the fluid level. The fluid should be

in the designated area for normal operating temperature or ambient
temperature.

Low fluid level

Do not drive the vehicle if the fluid
level is at the bottom of the dipstick
and the ambient temperature is
above 10°C (50°F).

Correct fluid level

The transmission fluid should be checked at normal operating
temperature 66°C-77°C (150°F-170°F) on a level surface. The normal
operating temperature can be reached after approximately 30 km (20
miles) of driving.

You can check the fluid without driving if the ambient temperature is
above 10°C (50°F). However, if fluid is added at this time, an overfill
condition could result when the vehicle reaches normal operating
temperature.

The transmission fluid should be in
this range if at normal operating
temperature (66°C-77°C
[150°F-170°F]).

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264

The transmission fluid should be in
this range if at ambient temperature
(10°C-35°C [50°F-95°F]).

High fluid level

Fluid levels above the safe range
may result in transmission failure.
An overfill condition of transmission
fluid may cause shift and/or
engagement concerns and/or
possible damage.

High fluid levels can be caused by an overheating condition.

Adjusting automatic transmission fluid levels

Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick and also in the
Lubricant specifications section in this chapter.

Use of a non-approved automatic transmission fluid may cause
internal transmission component damage.

If necessary, add fluid in 250 ml (1/2 pint) increments through the filler
tube until the level is correct.

If an overfill occurs, excess fluid
should be removed by a qualified
technician.

An overfill condition of
transmission fluid may cause
shift and/or engagement concerns and/or possible damage.

Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.

Maintenance and Specifications

265

Checking and adding manual transmission fluid (if equipped)

1. Clean the filler plug.

2. Remove the filler plug and

inspect the fluid level.

3. Fluid level should be at bottom

of the opening.

4. Add enough fluid through the

filler opening so that the fluid
level is at the bottom of the
opening.

5. Install and tighten the fill plug

securely.

Use only fluid that meets Mazda specifications. Refer to Lubricant
Specifications in this chapter.

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266

Checking and adding transfer case fluid (if equipped)

Vehicle must be on level surface.

1. Clean the filler plug.

2. Remove the filler plug and

inspect the fluid level.

3. Add only enough fluid through

the filler opening so that the
fluid level is at the bottom of
the opening.

Use only fluid that meets Mazda specifications. Refer to Lubricant
Specifications in this chapter.

DRIVELINE UNIVERSAL JOINT AND SLIP YOKE

Your vehicle may be equipped with universal joints that require
lubrication. If the original universal joints are replaced with universal
joints equipped with grease fittings, lubrication will also be necessary.

Maintenance and Specifications

267

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:
• Treadwear 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 climates.

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.

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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

• Use an accurate tire pressure gauge.
• Check 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).

• Adjust 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.

The following procedure applies to vehicles equipped with single rear
wheels, if your vehicle is equipped with dual rear wheels it is
recommended that only the front wheels be rotated (side to side).

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269

WARNING: When replacing full size tires, never mix radial
bias-belted, or bias-type tires. Use only the tire sizes that are
listed on the Certification Label. Make sure that all tires are
the same size, speed rating, and load-carrying capacity. Use only
the tire combinations recommended on the label. If you do not
follow these precautions, your vehicle may not drive properly
and safely and an accident can occur.

WARNING: Make sure that all replacement tires are of the
same size, type, load=carrying capacity and tread (e.g., “All
Terrain”, etc.), as originally offered by Mazda. Failure to do so
can result in tire failure and a serious accident.

WARNING: Do not replace your tires with “high performance”
tires or larger size tires.

WARNING: Failure to follow these precautions may adversely
affect the handling of the vehicle, damage parts of the tire and
make it easier for the driver to lose control and roll over.

Tires that are larger or smaller than your vehicle’s original tires may also
affect the accuracy of your speedometer.

SNOW TIRES AND CHAINS

WARNING: Driving too fast for conditions creates the
possibility of loss of vehicle control. Driving at very high speeds
for extended periods of time may result in damage to vehicle
components.

NOTE: Snow tires must be the same size and grade as the tires you
currently have on your vehicle.
The tires on your vehicle have all weather treads to provide traction in
rain and snow. However, in some climates, you may need to use snow
tires and chains. If you need to use snow tires and chains, it is
recommended that steel wheels are used of the same size and
specifications as those originally installed.
Follow these guidelines when using snow tires and chains:
• Do not use tire chains on aluminum wheels. Chains may chip the

wheels.

Maintenance and Specifications

271

• Use only SAE Class S chains.
• Install chains securely, verifying that the chains do not touch any

wiring, brake lines or fuel lines.

Drive cautiously. If you hear the cables rub or bang against the
vehicle, stop and retighten them. If this does not work, remove
the cables to prevent vehicle damage.
• If possible, avoid fully loading your vehicle.
• Remove the tire chains when they are no longer needed. Do not use

tire chains on dry roads.

• The suspension insulation and bumpers will help prevent vehicle

damage. Do not remove these components from your vehicle when
using snow tires and chains.

REFILL CAPACITIES

Fluid

Mazda Part
Name

Application

Capacity

Engine oil
(includes filter
change)

Mazda SAE 5W-
20 Super
Premium Motor
Oil

2.3L engine

3.8L (4.0
quarts.)

3.0L V6 engines

4.3L (4.5
quarts)

Mazda SAE 5W-
30 Super
Premium Motor
Oil

4.0L V6 engine

4.7L (5.0
quarts)

Brake fluid

High
Performance
DOT 3 Motor
Vehicle Brake
Fluid

All

Fill to line on
reservoir

Power steering
fluid

Mazda
MERCON

t ATF

All

Fill to range on
dipstick

Maintenance and Specifications

272

Fluid

Mazda Part
Name

Application

Capacity

Transmission
fluid

Mazda
MERCON

t ATF

5-speed manual

2.65L (2.8
quarts)

Mazda
MERCON

ATF

4x2 vehicles
with automatic
and 2.3L I4
engine

9.4L (9.9
quarts)

4x2 vehicles
with automatic
and 3.0L or 4.0L
engines

9.5L (10.0
quarts)

4x4 vehicles
with automatic
and 3.0L or 4.0L

9.8L (10.3
quarts)

Engine coolant

Premium Engine
Coolant

2.3 L I4 engine
with manual
transmission

10.0L (10.5
quarts)

2.3L I4 engine
with automatic
transmission

9.7L (10.2
quarts)

3.0L V6 engine
with manual
transmission

14.3L (15.1
quarts)

3.0L V6 engine
with automatic
transmission

14.0L (14.8
quarts)

4.0L V6 engine
with manual
transmission

13.0L (13.7
quarts)

4.0L V6 engine
with automatic
transmission

12.5L (13.2
quarts)

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273

Fluid

Mazda Part
Name

Application

Capacity

Fuel tank

N/A

Regular cab
(Short wheel
base)

62.4L (16.5
gallons)

Regular cab
(Long wheel
base)

75.7L (20.0
gallons)

SuperCab

73.8L (19.5
gallons)

Transfer Case
Fluid

Mazda
MERCON

t ATF

4x4 Vehicles

1.2L (1.25
quarts)

Front axle
lubricant

Mazda SAE
80W-90
Premium Rear
Axle Lubricant

4x4 Vehicles

1.7L (3.6 pints)

Rear axle
lubricant

Mazda SAE
80W-90
Premium Rear
Axle Lubricant

All

2.4-2.5L (5.0-5.3
pints)

Windshield
washer fluid

Ultra-Clear
Windshield
Washer
Concentrate

All

2.6L (2.75
quarts)

Ensure the correct automatic transmission fluid is used. Transmission

fluid requirements are indicated on the dipstick or on the dipstick
handle. MERCON

t and MERCONt V are not interchangeable. DO NOT

mix MERCON

t and MERCONtV. Refer to the service maintenance

section to determine the correct service interval.

Service refill capacity is determined by filling the transmission to the

bottom of the filler hole with the vehicle on a level surface.

Indicates 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.

Use Mazda Premium Engine Coolant (green in color). DO NOT USE

Mazda Extended Life Engine Coolant (orange in color). Refer to Adding
engine coolant, in the Maintenance and Care chapter.

Maintenance and Specifications

274

Traction-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.

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

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
engines

SAE 5W-20 Premium Synthetic
Blend 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 tracks

Multi-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

t ATF

Automatic transmission (5R44E
and 5R55E)

MERCON

tV ATF

Windshield washer fluid

Ultra-clear Windshield Washer
Concentrate

Maintenance and Specifications

275

Mazda B3000 (2002 year). Instruction - part 17