Mazda B4000 4WD Truck (2004 year). Instruction

BATTERY

Your vehicle is equipped with a
Mazda maintenance-free battery
which normally does not require
additional water during its life of
service.

However, for severe usage or in high temperature climates, check the
battery electrolyte level. Refer to the service maintenance section for the
service interval schedules.

Keep the electrolyte level in each cell up to the “level indicator”.
Do not overfill the battery cells.

If possible, try to only fill the battery cells with distilled water. If the
battery needs water often, have the charging system checked.

If your battery has a cover/shield, make sure it is reinstalled
after the battery has been cleaned or replaced.

For longer, trouble-free operation, keep the top of the battery clean and
dry. Also, make certain the battery cables are always tightly fastened to
the battery terminals.

If you see any corrosion on the battery or terminals, remove the cables
from the terminals and clean with a wire brush. You can neutralize the
acid with a solution of baking soda and water.

WARNING: Batteries normally produce explosive gases which
can cause personal injury. Therefore, do not allow flames,
sparks or lighted substances to come near the battery. When
working near the battery, always shield your face and protect
your eyes. Always provide proper ventilation.

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200

WARNING: When lifting a plastic-cased battery, excessive
pressure on the end walls could cause acid to flow through the
vent caps, resulting in personal injury and/or damage to the
vehicle or battery. Lift the battery with a battery carrier or with
your hands on opposite corners.

WARNING: Keep batteries out of reach of children. Batteries
contain sulfuric acid. Avoid contact with skin, eyes or clothing.
Shield your eyes when working near the battery to protect
against possible splashing of acid solution. In case of acid
contact with skin or eyes, flush immediately with water for a
minimum of 15 minutes and get prompt medical attention. If
acid is swallowed, call a physician immediately.

WARNING: Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after handling.

Because your vehicle’s engine is electronically controlled by a computer,
some control conditions are maintained by power from the battery. When
the battery is disconnected or a new battery is installed, the engine must
relearn its idle and fuel trim strategy for optimum driveability and
performance. To begin this process:

1. With the vehicle at a complete stop, set the parking brake.

2. Put the gearshift lever in P (Park), turn off all accessories and start

the engine.

3. Run the engine until it reaches normal operating temperature.

4. Allow the engine to idle for at least one minute.

5. Turn the A/C on and allow the engine to idle for at least one minute.

6. Drive the vehicle to complete the relearning process.

• The vehicle may need to be driven to relearn the idle and fuel trim

strategy.

• If you do not allow the engine to relearn its idle trim, the idle

quality of your vehicle may be adversely affected until the idle
trim is eventually relearned.

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When the battery is disconnected or a new battery installed, the
transmission must relearn its adaptive strategy. As a result of this, the
transmission may shift firmly. This operation is considered normal and
will not affect function or durability of the transmission. Over time the
adaptive learning process will fully update transmission operation to its
optimum shift feel.

If the battery has been disconnected or a new battery has been installed,
the clock and the preset radio stations must be reset once the battery is
reconnected.
• Always dispose of automotive

batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center
to find out more about recycling
automotive batteries.

ENGINE COOLANT

Checking engine coolant

Your engine’s cooling system has been factory-filled with a 50/50 mixture
of distilled water and Mazda Genuine Engine Coolant, or an equivalent
premium engine coolant that meets Mazda specification.

A 50/50 mixture of distilled water and Mazda Genuine Engine Coolant
provides:
• maximum cooling system efficiency.
• freeze protection down to -36° C (-34° F).
• boiling protection up to 129° C (265° F).
• protection against rust and other forms of corrosion.
• an accurate temperature readout from the engine coolant

gauge.

The engine coolant must be maintained at the correct fluid level
and concentration to work properly. If the engine coolant fluid
level and concentration is not maintained correctly, damage to
the engine and cooling system may result.

LEAD

RETURN

RECYCLE

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202

• 2.3L engine

• 3.0L & 4.0L engines

When the engine is cold, check the level of the engine coolant in the
reservoir.
• The engine coolant should be at the “cold fill level” or within the “cold

fill range” as listed on the engine coolant reservoir (depending upon
application).

• Confirm the color and type of engine coolant before adding, to avoid

mixing incompatible products.

• Refer to the service maintenance section for service interval

schedules.

• Be sure to read and understand Precautions when servicing your

vehicle in this chapter.

RADIATOR

COOLANT

ONLY

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203

If the engine coolant has not been checked at the recommended interval,
the engine coolant reservoir may become low or empty. If the reservoir is
low or empty, add engine coolant to the reservoir. Refer to Adding
engine coolant in this chapter.

WARNING: Automotive fluids are not interchangeable; do not
use engine coolant, antifreeze or windshield washer fluid
outside of its specified function and vehicle location.

Adding engine coolant

Use only Mazda Genuine Engine Coolant or a premium engine
coolant that meets a Mazda specification.
• DO NOT USE Extended Life Engine Coolant (orange in color).
• DO NOT USE a DEX-COOLt engine coolant or an equivalent

engine coolant.

• DO NOT USE alcohol or methanol antifreeze or any engine

coolants mixed with alcohol or methanol antifreeze.

• DO NOT USE supplemental coolant additives in your vehicle.

These additives may harm your engine’s cooling system.

• DO NOT MIX different colors or types of coolant in your

vehicle. Make sure the correct coolant is used.

• DO NOT MIX recycled coolant and conventional coolant

together in your vehicle. Mixing of engine coolants may harm
your engine’s cooling system.

• The use of an improper coolant may harm engine and cooling

system components and may void the warranty of your vehicle’s
engine cooling system. If you are unsure which type of coolant
your vehicle requires, contact your local dealer.

WARNING: Do not put engine coolant in the windshield washer
fluid reservoir. If engine coolant is sprayed onto the windshield,
it could make it difficult to see through the windshield.

When the engine is cool, add a 50/50 mixture of engine coolant and
distilled water to the engine coolant reservoir, until the coolant is at the
“cold fill level” or within the “cold fill range” as listed in the engine
coolant reservoir (depending upon application).
• NEVER increase the coolant concentration above 60%.

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204

• NEVER decrease the coolant concentration below 40%.
• Engine coolant concentrations above 60% or below 40% will

decrease the freeze protection characteristics of the engine
coolant and may cause engine damage.

Plain water may be added in an emergency, but you must replace it with
a 50/50 mixture of engine coolant and distilled water as soon as possible.

Check the coolant level in the reservoir before you drive your vehicle the
next few times (with the engine cool). If necessary, add a 50/50
mixture of engine coolant and distilled water to the engine coolant
reservoir until the coolant level is at the “cold fill level” or within the
“cold fill range” as listed on the reservoir (depending upon application).

Have your dealer check the engine cooling system for leaks if you have
to add more than 1.0 liter (1.0 quart) of engine coolant per month.

WARNING: To avoid scalding hot steam or coolant from being
released from the engine cooling system, never remove the
reservoir cap while the engine is running or hot. Failure to
follow this warning may result in damage to the engine’s cooling
system and possible severe personal injury.

If you must remove the coolant cap, follow these steps to avoid personal
injury:

1. Before you remove the cap, turn the engine off and let it cool.

2. When the engine is cool, wrap a thick cloth around the cap. Slowly

turn cap counterclockwise until pressure begins to release.

3. Step back while the pressure releases.

4. When you are sure that all the pressure has been released, use the

cloth to turn it counterclockwise and remove the cap.

Recycled engine coolant

Not all coolant recycling processes produce coolant which meets Mazda
specification. Use of a recycled engine coolant which does not meet
Mazda specifications may harm engine and cooling system components.

Always dispose of used automotive fluids in a responsible manner.

Follow your community’s regulations and standards for recycling and
disposing of automotive fluids.

Coolant refill capacity

To find out how much fluid your vehicle’s cooling system can hold, refer
to Refill capacities in this chapter.

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Fill your engine coolant reservoir as outlined in Adding engine coolant
in this chapter.

Severe climates

If you drive in extremely cold climates (less than –36° C [–34° F]):
• It may be necessary to increase the coolant concentration

above 50%.

• NEVER increase the coolant concentration above 60%.
• Increased engine coolant concentrations above 60% will

decrease the overheat protection characteristics of the engine
coolant and may cause engine damage.

• Refer to the chart on the coolant container to ensure the

coolant concentration in your vehicle will provide adequate
freeze protection at the temperatures in which you drive in the
winter months.

If you drive in extremely hot climates:
• It is still necessary to maintain the coolant concentration

above 40%.

• NEVER decrease the coolant concentration below 40%.
• Decreased engine coolant concentrations below 40% will

decrease the corrosion protection characteristics of the engine
coolant and may cause engine damage.

• Decreased engine coolant concentrations below 40% will

decrease the freeze protection characteristics of the engine
coolant and may cause engine damage.

• Refer to the chart on the coolant container to ensure the

coolant concentration in your vehicle will provide adequate
protection at the temperatures in which you drive.

Vehicles driven year-round in non-extreme climates should use a 50/50
mixture of engine coolant and distilled water for optimum cooling system
and engine protection.

What you should know about Limp to Safety cooling (2.3L I4
engines only)

If the engine coolant supply is depleted, this feature allows the vehicle to
be driven temporarily to a place of safety. The distance it can be driven
depends on ambient temperatures, vehicle load and terrain, so when the
engine drops into this mode, it is because the engine has overheated and
you need to take special care to avoid it shutting down.

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How Limp to Safety works

If the engine begins to overheat:
• The engine coolant temperature

gauge will move to the red (hot)
area.

• The

symbol will illuminate.

• The “Service Engine Soon”

indicator light will illuminate.

If the engine reaches a preset over-temperature condition, the engine
will automatically switch to alternating cylinder operation. Each disabled
cylinder acts as an air pump and cools the engine.

When this occurs the vehicle will still operate. However:
• The engine power will be limited.
• The air conditioning system will be disabled.
This system has given you an early warning of engine damage and you
should immediately drive to a place of safety where the engine can be
cooled or the vehicle towed to a service shop. Continuing to drive in this
Limp to Safety mode will increase engine temperature some more,
increasing the chance of engine damage, and:
• The engine will completely shut down.
• Steering and braking effort will increase.
If you have decided not to have the vehicle towed, and when the engine
temperature cools, you try to re-start it and it appears to have returned
to normal operation, don’t delay in getting to a service facility as soon as
possible to diagnose what caused the overheat and prevent further
engine damage.

When Limp to Safety mode is activated

You have limited engine power when in the Limp to Safety mode, so
drive the vehicle with caution. The vehicle will not be able to maintain
high speed operation and the engine will run rough. Remember that the
engine is capable of completely shutting down automatically to prevent
engine damage, therefore:

1. Pull off the road as soon as safely possible and turn off the engine.

2. Arrange for the vehicle to be taken to a service facility.

3. If this is not possible, wait for the engine to cool down.

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4. When the engine has cooled down, first check the coolant level. If

low, then use a rag and carefully turn the cap one notch
counter-clockwise carefully to avoid being burned by hot steam.
When there is no steam, keep you face back as you carefully remove
the cap and then replenish the coolant to the full line.

WARNING: Never remove the coolant reservoir cap while the
engine is running or hot.

5. Replace the cap and see if the engine starts and runs normally and

drive it to a service place under reduced load and with the air
conditioning off. If it quickly goes into Limp to Safety mode again, shut
it down in a safe location and have the vehicle towed for service.

WHAT YOU SHOULD KNOW ABOUT AUTOMOTIVE FUELS

Important safety precautions

WARNING: Do not overfill the fuel tank. The pressure in an
overfilled tank may cause leakage and lead to fuel spray and
fire.

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.

WARNING: Automotive fuels can cause serious injury or death
if misused or mishandled.

WARNING: Fuel ethanol and gasoline may contain benzene,
which is a cancer-causing agent.

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208

Observe the following guidelines when handling automotive fuel:
• Extinguish all smoking materials

and any open flames before
fueling your vehicle.

• Always turn off the vehicle before

fueling.

• Automotive fuels can be harmful

or fatal if swallowed. Fuels such as gasoline and ethanol are highly
toxic and if swallowed can cause death or permanent injury. If fuel is
swallowed, call a physician immediately, even if no symptoms are
immediately apparent. The toxic effects of fuel may not be visible for
hours.

• Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind

can lead to eye and respiratory tract irritation. In severe cases,
excessive or prolonged breathing of fuel vapor can cause serious
illness and permanent injury.

• Avoid getting fuel liquid in your eyes. If fuel is splashed in the eyes,

remove contact lenses (if worn), flush with water for 15 minutes and
seek medical attention. Failure to seek proper medical attention could
lead to permanent injury.

• Fuels can also be harmful if absorbed through the skin. If fuel is

splashed on the skin and/or clothing, promptly remove contaminated
clothing and wash skin thoroughly with soap and water. Repeated or
prolonged skin contact with fuel liquid or vapor causes skin irritation.

• Be particularly careful if you are taking “Antabuse” or other forms of

disulfiram for the treatment of alcoholism. Breathing gasoline and/or
ethanol vapors, or skin contact could cause an adverse reaction. In
sensitive individuals, serious personal injury or sickness may result. If
fuel is splashed on the skin, promptly wash skin thoroughly with soap
and water. Consult a physician immediately if you experience an
adverse reaction.

• FFV fuel tanks may contain zero to 85 percent ethanol. Any fuel

blends containing gasoline and ethanol should be treated the same as
“Fuel Ethanol ”. To identify if your vehicle is an FFV, check your VIN
or the label on the inside of your fuel filler door. When checking the
VIN look for the engine type identifier (8th character). If your vehicle
is an FFV, then the character will be labeled as a “V.”

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209

Ethanol

Pure ethanol is the alcohol which is the intoxicating agent in liquor, beer
and wine. It is distilled from the fermentation of plants such as field corn
and sugar cane. When ethanol is used in the making of motor fuels, a
small amount of a bad tasting chemical is added to discourage beverage
use. The resulting fuel is called E

100 meaning 100% pure ethanol

diluted by 2% to 5% gasoline as the “denaturant.”

Fuel ethanol (summer blend

) is then made by adding 15% more

unleaded gasoline. The resulting fuel also has a higher octane rating than
unleaded regular gasoline and other properties which allow engine
designs with greater efficiency and power.

Winter blends may contain up to 30% (E70)unleaded gasoline (25% plus
the denaturant) to enhance cold engine starts. Severely cold weather
may require additional measures for reliable starting. Refer to Cold
Weather Starting in the Driving chapter.

Ethanol is more chemically active than gasoline. It corrodes some metals
and causes some plastic and rubber components to swell, break down or
become brittle and crack, especially when mixed with gasoline. Special
materials and procedures have been developed for flexible fuel vehicles
and the dispensers used by ethanol fuel providers.

WARNING: Flexible fuel components and standard unleaded
gasoline fuel components are not interchangeable. If your
vehicle is not serviced in accordance with flexible fuel vehicles
procedures, damage may occur and your warranty may be
invalidated.

WARNING: When refueling always shut the engine off and
never allow sparks or open flames near the filler neck. Never
smoke while refueling. Fuel vapor is extremely hazardous under
certain conditions. Care should be taken to avoid inhaling
excess fumes.

WARNING: The flow of fuel through a fuel pump nozzle can
produce static electricity, which can cause a fire if fuel is
pumped into an ungrounded fuel container.

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Use the following guidelines to avoid static build-up when filling an
ungrounded fuel container:
• Place approved fuel container on

the ground.

• DO NOT fill a fuel container while

it is in the vehicle (including the
cargo area/pickup bed).

• Keep the fuel pump nozzle in contact with the fuel container while

filling.

• DO NOT use a device that would hold the fuel pump handle in the fill

position.

Fuel Filler Cap

Your fuel tank filler cap has an indexed design with a 1/4 turn on/off
feature.

When fueling your vehicle:

1. Turn the engine off.

2. Carefully turn the filler cap counterclockwise 1/4 of a turn until it

stops.

3. Pull to remove the cap from the fuel filler pipe.

4. To install the cap, align the tabs on the cap with the notches on the

filler pipe.

5. Turn the filler cap clockwise 1/4 of a turn until it stops.

“Check Fuel Cap” illuminates when the ignition is turned to the ON
position to ensure your bulb is working. When this light turns on, check
the fuel filler cap. Continuing to operate the vehicle with the Check Fuel
Cap light on, can activate the Service Engine Soon warning. When the
fuel filler cap is properly re-installed, the light(s) will turn off after a
period of normal driving. It may take a long period of time for the
system to detect an improperly installed fuel filler cap.

If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The warranty may be void
for any damage to the fuel tank or fuel system if the correct
genuine Mazda fuel filler cap is not used.

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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.

(R+M)/2 METHOD

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FFV engine (if equipped)

Your vehicle is designed to use (E85) Fuel Ethanol, “Regular” unleaded
gasoline or any percentage of the two fuels combined.

U.S. government regulations require fuel ethanol dispensing
pumps to have a small, square, orange and black label with the
common abbreviation or the appropriate percentage for that
region. Use of other fuels such as Fuel Methanol may cause
powertrain damage, a loss of vehicle performance, and your
warranty may be invalidated.

Fuel quality

Many of the world’s automakers approved the World-wide Fuel Charter
that recommends gasoline specifications to provide improved
performance and emission control system protection for your vehicle.
Gasolines that meet the World-wide Fuel Charter should be used when
available. Ask your fuel supplier about gasolines that meet the
World-wide Fuel Charter.

It should not be necessary to add any aftermarket products to your fuel
tank if you continue to use high quality fuel of the recommended octane
rating. Aftermarket products could cause damage to the fuel system.
Repairs to correct the effects of using an aftermarket product in your
fuel may not be covered by your warranty.

Unleaded Gasoline engines

If you are experiencing starting, rough idle or hesitation driveability
problems during a cold start, try a different brand of “Regular” unleaded
gasoline. “Premium” unleaded gasoline is not recommended (particularly
in the United States) because it may cause these problems to become
more pronounced. If the problems persist, see your authorized Mazda
dealership.

FFV engine (if equipped)

Your FFV will operate well on ordinary “Regular” unleaded gasoline, but
only the highest quality fuel ethanol will provide the same level of
protection and performance. To identify if your vehicle is an FFV, check
your VIN or the label on the inside of your fuel filler door. When
checking the VIN, look for the engine type identifier (8th character). If
your vehicle is an FFV, then the character will be labeled as a “V.”

If you operate your vehicle 50% or more of the time on ethanol, you
should follow a different maintenance schedule. See the Service
Maintenance Section for more information.

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213

If you are experiencing a rough or rolling idle after start-up with the
outside temperature above 27° C (80° F), the idle should improve within
10 to 30 seconds. If the problems persist below this temperature, see
your authorized Mazda dealership.

Cleaner air

Mazda endorses the use of reformulated “cleaner-burning” gasolines to
improve air quality.

Running out of fuel

Avoid running out of fuel because this situation may have an adverse
affect on powertrain components.
If you have run out of fuel:
• You may need to cycle the ignition from OFF to ON several times after

refueling, to allow the fuel system to pump the fuel from the tank to
the engine.

• Your “Check Engine” indicator may come on. For more information on

the “Check Engine” indicator, refer to the Instrument Cluster
chapter.

Fuel Filter

For fuel filter replacement, see your authorized Mazda dealership. Refer
to the service maintenance section for the appropriate intervals for
changing the fuel filter.
Replace the fuel filter with an authorized Mazda part. The
customer warranty may be void for any damage to the fuel system
if an authorized Mazda fuel filter is not used.

ESSENTIALS OF GOOD FUEL ECONOMY

The advertised capacity is the amount of the indicated capacity and the
empty reserve combined. Indicated capacity is the difference in the
amount of fuel in a full tank and a tank when the fuel gauge indicates
empty. Empty reserve is the small amount of fuel remaining in the fuel
tank after the fuel gauge indicates empty.

The amount of usable fuel in the empty reserve varies and should
not be relied upon to increase driving range. When refueling your
vehicle after the fuel gauge indicates empty, you might not be
able to refuel the full amount of the advertised capacity of the
fuel tank due to the empty reserve still present in the tank.

For consistent results when filling the fuel tank:
• Turn the engine/ignition switch to the off position prior to refueling,

an error in the reading will result if the engine is left running.

• Use the same filling rate setting (low — medium — high) each time

the tank is filled.

• Allow no more than 2 automatic click-offs when filling.
• Always use fuel with the recommended octane rating.
• Use a known quality gasoline, preferably a national brand.
• Use the same side of the same pump and have the vehicle facing the

same direction each time you fill up.

• Have the vehicle loading and distribution the same every time.
Your results will be most accurate if your filling method is consistent.

Calculating fuel economy

1. Fill the fuel tank completely and record the initial odometer reading

(in kilometers or miles).

2. Each time you fill the tank, record the amount of fuel added (in

liters or gallons).

3. After at least three to five tank fill-ups, fill the fuel tank and record

the current odometer reading.

4. Subtract your initial odometer reading from the current odometer

reading.

5. Follow one of the simple calculations in order to determine fuel

economy:

Calculation 1: Multiply liters used by 100, then divide by total
kilometers traveled.

Calculation 2: Divide total miles traveled by total gallons used.

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Mazda B4000 4WD Truck (2004 year). Instruction - part 13