Mazda B4000 (2002 year). Instruction

MAZDA IMPORTERS/DISTRIBUTORS

U.S.A (Importer/Distributor)

Mazda North American Operations
7755 Irvine Center Drive
Irvine, CA 92618–2922
P.O. Box 19734
Irvine, CA 92623–9734
TEL: 1 (800) 222–5500 (in U.S.A.)
(949) 727–1990 (outside U.S.A.)

(Distributor in each area)

CANADA

Mazda Canada Inc.
305 Milner Avenue, Suite 400
Scarborough, Ontario M1B 3V4 Canada
TEL: 1 (800) 263–4680 (in Canada)
(416) 609–9909 (outside Canada)

PUERTO RICO

Plaza Motors Corp. (Mazda de Puerto Rico)
P.O. Box 362722, San Juan, Puerto Rico 00936–2722
TEL: (787) 788–9300

GUAM

Triple J. Motors
P.O. Box 6066 Tamuning, Guam
TEL: (671) 649–6555

SAIPAN

Triple J Saipan, Inc.
(d.b.a. Triple J Motors)
P.O. Box 500487 Saipan, MP 96950–0487
TEL: (670) 234–7133 / 3051

AMERICAN SAMOA

Polynesia Motors, Inc.
P.O. Box 1120, Pago Pago, American Samoa 96799
TEL: (684) 699–9347

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ADD-ON NON-GENUINE PARTS AND ACCESSORIES

Non-genuine parts and accessories for Mazda vehicles can be found in
stores. These may fit your vehicle, but they are not approved by the
manufacturer for use with Mazda vehicles. When you install non-genuine
parts or accessories, they could affect your vehicle’s performance or safety
system; the manufacturer’s warranty doesn’t cover this. Before you install
any non-genuine parts or accessories, consult an Authorized Mazda Dealer.

WARNING: Installation of Non-Genuine Parts or Accessories:
Installation of non-genuine parts or accessories could be
dangerous. Improperly designed parts or accessories could
seriously affect your vehicle’s performance or safety system. This
could cause you to have an accident or increase your chances of
injuries in an accident. Always consult an Authorized Mazda
Dealer before you install non-genuine parts or accessories.

WARNING: Add-On Electrical and Electronic Equipment:
Incorrectly choosing or installing improper add-on equipment or
choosing an improper installer could be dangerous. Essential
systems could be damaged, causing engine stalling, air-bag
(SRS) activation, ABS inactivation, or a fire in the vehicle. Be
very careful in choosing and installing add-on electrical
equipments, such as mobile telephones, two-way radios, stereo
systems, and car alarm systems.

Mazda assumes no responsibility for death, injury, or expenses that may
result from the installation of add-on non-genuine parts or accessories.

WARRANTIES FOR YOUR MAZDA

• New Vehicle Limited Warranty
• Safety Restraint System Limited Warranty
• Anti-perforation Limited Warranty
• Federal Emission Control Warranty

– Emission Defect Warranty
– Emission Performance Warranty

• California Emission Control Warranty (if applicable)
• Replacement Parts and Accessories Limited Warranty
• Tire Warranty
NOTE:Detailed warranty information is provided with your Mazda.

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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
Mazda Motor Corporation (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 Mazda Motor
Corporation (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.

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(Note)
If you live in the U.S.A., all correspondence to Mazda Motor Corporation
should be forwarded to:

Mazda North American Operations
7755, Irvine Center Drive
Irvine, California 92618–2922
P.O. Box 19734
Irvine, CA 92623–9734
Customer Assistance Center
or toll free at 1 (800) 222–5500

If you live outside of the U.S.A., please contact the nearest Mazda
Distributor. ( See the Mazda Importers/Distributors section of this
manual).

SERVICE PUBLICATIONS

Factory-authorized Mazda service publication are available for owners
who wish to do some of their own maintenance and repair.

When requesting any of our publications through an Authorized Mazda
Dealer, refer to the chart below.

If they don’t have what you need in stock, they can order it for you.

PUBLICATION ORDER NUMBER

PUBLICATION DESCRIPTION

9999 95 062B 02

2002 WORKSHOP MANUAL

9999 95 038G 02

2002 WIRING DIAGRAM

9999 95 014C 02

2002 OWNER’S MANUAL

WORKSHOP MANUAL:

Covers recommended maintenance and repair procedures of the drive
train, body and chassis.

WIRING DIAGRAM:

Provides electrical schematics as well as component location for the
entire electrical system.

OWNER’S MANUAL:

This booklet contains information regarding the proper care and
operation of your vehicle. This is not a technician’s manual.

Please note that your Authorized Mazda Dealership has trained
personnel and special service tools to correctly and safely
maintain Mazda vehicles.

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IN CALIFORNIA (U.S. ONLY)

California Civil Code Section 1793.2(d) requires that, if a manufacturer
or its representative is unable to repair a motor vehicle to conform to the
vehicle’s applicable express warranty after a reasonable number of
attempts, the manufacturer shall be required to either replace the
vehicle with one substantially identical or repurchase the vehicle and
reimburse the buyer in an amount equal to the actual price paid or
payable by the consumer (less a reasonable allowance for consumer
use). The consumer has the right to choose whether to receive a refund
or replacement vehicle.

California Civil Code Section 1793.22(b) presumes that the manufacturer
has had a reasonable number of attempts to conform the vehicle to its
applicable express warranties if, within the first 18 months of ownership
of a new vehicle or the first 29 000 km (18 000 miles), whichever occurs
first:

1. Two or more repair attempts are made on the same nonconformity

likely to cause death or serious bodily injury OR

2. Four or more repair attempts are made on the same nonconformity

(a defect or condition that substantially impairs the use, value or
safety of the vehicle) OR

3. The vehicle is out of service for repair of nonconformities for a total

of more than 30 calendar days (not necessarily all at one time)

In the case of 1 or 2 above, the consumer must also notify the
manufacturer of the need for the repair of the nonconformity at the
following address:

Mazda North American Operations
7755, Irvine Center Drive
Irvine, CA 92618–2922

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WASHING THE EXTERIOR

Wash your vehicle regularly with cool or lukewarm water and a neutral
Ph shampoo, such as Detail Wash (ZC-3–A), which is available from your
dealer.
• Never use strong household detergents or soap, such as dish washing

or laundry liquid. These products can discolor and spot painted
surfaces.

• Never wash a vehicle that is “hot to the touch” or during exposure to

strong, direct sunlight.

• Always use a clean sponge or carwash mitt with plenty of water for

best results.

• Dry the vehicle with a chamois or soft terry cloth towel in order to

eliminate water spotting.

• It is especially important to wash the vehicle regularly during the

winter months, as dirt and road salt are difficult to remove and cause
damage to the vehicle.

• Immediately remove items such as gasoline, diesel fuel, bird droppings

and insect deposits because they can cause damage to the vehicle’s
paintwork and trim over time.

• Remove any exterior accessories, such as antennas, before entering a

car wash.

• Suntan lotions and insect repellents can damage any painted

surface; if these substances come in contact with your vehicle,
wash off as soon as possible.

WAXING

Applying a polymer paint sealant to your vehicle every six months will
assist in reducing minor scratches and paint damage.
• Wash the vehicle first.
• Do not use waxes that contain abrasives.
• Do not allow paint sealant to come in contact with any non-body

(low-gloss black) colored trim, such as grained door handles, roof
racks, bumpers, side moldings, mirror housings or the windshield cowl
area. The paint sealant will “gray” or stain the parts over time.

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PAINT CHIPS

Your dealer has touch-up paint to match your vehicle’s color. Touch-up
paint can be used to repair minor scratches to painted surfaces.
• Remove particles such as bird droppings, tree sap, insect deposits, tar

spots, road salt and industrial fallout before repairing paint chips.

• Always read the instructions before using the products.

ALUMINUM WHEELS AND COVERS

Aluminum wheel rims or covers are coated with a clearcoat paint finish.
In order to maintain their shine:
• Clean with One Step Wash and Wax Concentrate, which is available

from your local Mazda dealer.

• Never apply any cleaning chemical to hot or warm wheel rims or

covers.

• Some automatic car washes may cause damage to the finish on your

wheel rims or covers. Chemical-strength cleaners, or cleaning
chemicals, in combination with brush agitation to remove brake dust
and dirt, could wear away the clearcoat finish over time.

• Do not use hydrofluoric acid-based or high caustic-based wheel

cleaners, steel wool, fuels or strong household detergent.

• To remove tar and grease, use Extra Strength Tar and Road Oil

Removal, available from your local Mazda dealer.

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 local Mazda

dealer, on all parts that require cleaning and pressure rinse clean.

• Cover the highlighted areas to prevent water damage when cleaning

the engine.

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• 4.0L Engine

• Never wash or rinse the engine while it is running; water in the

running engine may cause internal damage.

PLASTIC (NON-PAINTED) EXTERIOR PARTS

Use only approved products to clean plastic parts. These products are
available from your dealer.
• For routine cleaning, use One Step Wash and Wax Concentrate,

available at your local Mazda dealer.

• If tar or grease spots are present, use Extra Strength Tar and Road Oil

Removal, available at your local Mazda dealer.

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.

WINDOWS AND WIPER BLADES

The windshield, rear window and wiper blades should be cleaned regularly.
If the wiper does not wipe properly, substances on the windshield, rear
window or the wiper blades may be the cause. These may include hot wax
treatments used by commercial car washes, tree sap, or other organic
contamination. To clean these items, please follow these tips:
• The windshield or rear window may be cleaned with a non-abrasive

cleaner such as Ultra Clear Spray Glass Cleaner, available from your
local Mazda dealer.

• Do not use abrasives, as they may cause scratches.

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• Do not use fuel, kerosene, or paint thinner to clean any parts.
• Wiper blades can be cleaned with isopropyl (rubbing) alcohol or

windshield washer solution. Be sure to replace wiper blades when they
appear worn or do not function properly.

CLEANING THE INSTRUMENT PANEL

Clean the instrument panel with a damp cloth, then dry with a dry cloth.

Avoid cleaners or polish that increase the gloss of the upper portion of
the instrument panel. The dull finish in this area helps protect the driver
from undesirable windshield reflection.

Your vehicle is designed with painted controls and features which
are particularly sensitive to certain products such as insect
repellent and suntan lotion. When operating the various features
on your vehicle, be certain to wash or wipe your hands clean if
you have been in contact with any of these types of products in
order to avoid possible damage to the painted surfaces.

WARNING: Do not use chemical solvents or strong detergents
when cleaning the steering wheel or instrument panel to avoid
contamination of the air bag system.

CLEANING THE INSTRUMENT CLUSTER LENS

Clean with a damp cloth, then dry with a dry cloth.

Do not use household or glass cleaners as these may damage the lens.

INTERIOR

For fabric, carpets, cloth seats, safety belts and seats equipped with side
air bags:
• Remove dust and loose dirt with a vacuum cleaner.
• Remove light stains and soil with Extra Strength Upholstery Cleaner,

available at your local Mazda dealer.

• If grease or tar is present on the material, spot-clean the area first

with Spot and Stain Remover, available at your local Mazda dealer.

• Never saturate the seat covers with cleaning solution.
• Do not use household cleaning products or glass cleaners, which can

stain and discolor the fabric and affect the flame retardant abilities of
the seat materials.

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WARNING: Do not use chemical solvents or strong detergents
when cleaning the seat where the side air bag is mounted. Such
products may contaminate the side air bag system and affect
performance of the side air bag in a collision. The air bag may
not function correctly and not provide any injury reduction
benefits.

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 local 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 local Mazda
dealer.

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INTRODUCTION

Be extremely careful to prevent injury to yourself and others and
damage to your vehicle when using this manual for inspection and
maintenance.

If you’re unsure about any procedure it describes, we strongly urge you
to have a reliable and qualified service shop perform the work, preferably
an Authorized Mazda Dealer.

Factory-trained Mazda technicians and genuine Mazda parts are best for
your vehicle. Without this expertise and the parts that have been
designed and made especially for your Mazda, inadequate, incomplete,
and insufficient servicing may result in problems. This could lead to
vehicle damage or an accident and injuries.

For expert advice and quality service, consult an Authorized Mazda
Dealer.

The owner should retain evidence that proper maintenance has been
performed as prescribed.

A claim against a warranty will not qualify if it results from lack of
maintenance and not from defective material or authorized Mazda
workmanship.

Any auto repair shop using parts equivalent to your Mazda’s original
equipment may perform maintenance. But we recommend that it
always be done by an Authorized Mazda Dealer using genuine
Mazda parts.

SCHEDULED MAINTENANCE

Schedule I – Normal Driving Conditions/Emission Control
Systems

Follow Schedule I if the vehicle is operated mainly where none of the
following conditions apply. If any do apply follow Schedule II.
• Repeated short-distance driving.
• Driving in dusty conditions.
• Towing a trailer.
• Operating in hot weather in stop-and-go “rush hour” traffic.
• Extended periods of idling or low-speed operation.
• High-speed operation with a fully loaded vehicle.
• Off-road operation.
NOTE:After the described period, continue to follow the described
maintenance at the recommended intervals.

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224

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 Item

Maintenance Interval (Number of months or km (miles),

whichever comes first)

Months

x 1000 Miles

(x 1000 km)

(8) (16) (24) (32) (40) (48) (56) (64) (72) (80) (88) (96)

ENGINE

Engine oil —every 6 months

Oil filter—every 6 months

PCV valve

AIR CLEANER

Air cleaner filter

IGNITION SYSTEM

Spark plugs

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

Coolant condition and protection,
hoses and clamps — annually —prior
to cold weather every 12 months

CHASSIS AND BODY

Wheel lug nut torque

Inspect tires for wear and rotate
(X = recommended interval for
optimal tire life)

Clutch reservoir fluid level

Front wheel bearings (4x2)

Disc brake system

Caliper slide rails

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225

Maintenance Item

Maintenance Interval (Number of months or km (miles),

whichever comes first)

Months

x 1000 Miles

(x 1000 km)

(8) (16) (24) (32) (40) (48) (56) (64) (72) (80) (88) (96)

Drum brake system, lines and hoses

Exhaust system for leaks, damage,
looseness

Manual transmission fluid

Automatic
transmission fluid

Exhaust system shielding (for
trapped material)

Propeller shaft U-joints (if equipped
with grease fittings)

Parking brake system (for damage
and operation)

Ball joints (4x2)

I/L

Transfer case fluid (4x4)

Replace every 150,000 miles (240,000 km)

Rear axle lubricant

Does not require replacement unless rear axle

submerged in water

Accessory drive belts

Fuel filter

Steering linkage, ball joints,
suspension and driveshaft

Remarks: For * marked items in this maintenance chart, please pay
attention to the following points:

1. The wheel lug nuts must be retightened to the proper specifications

at 800 km (500 miles) of new vehicle operation, at any wheel
change, or at any other time the wheel lug nuts have been loosened.

2. Replace every 150,000 miles (240,000 km) unless submerged in

water.

3. At 60,000 miles (96,000 km), the dealer will replace the PCV valve at

no cost, except Canada and California vehicles.

4. Refer to vehicle emission control information label for spark plug and

gap specifications.

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226

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.

Maintenance Item

Maintenance Interval (Number of months or Miles (km),

whichever comes first)

Months

x 1000 Miles

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

Oil filter—every 6 months

PCV valve

AIR CLEANER

Air cleaner filter

IGNITION SYSTEM

Spark plugs

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

Coolant condition and
protection, hoses and clamps
— annually —prior to cold
weather every 12 months

CHASSIS AND BODY

Wheel lug nut
torque

Inspect tires for wear and
rotate (X = recommended
interval for optimal tire life)

Clutch reservoir fluid level

Front wheel bearings (4x2)

Disc brake system

Caliper slide rails

Drum brake system, lines and
hoses

Maintenance and Specifications

227

Mazda B4000 (2002 year). Instruction - part 14