1993–2002 Mazda 929 & 929 2.0i Workshop Manual Set (P/N 03–0620)

The supplement adds fuel-injection service procedures and changes to the base manual. It directs readers to the included base volume for shared service instructions and procedures outside its own coverage.

Wiring coverage: System schematics and connector views are included. The separately published Section 16 wiring-diagram manuals are not part of this set.

FE Engine, Injection and Driveline Service

• Engine repair: Timing-belt replacement, cylinder-head overhaul, valve-guide service, engine removal and internal inspection, with component-specific tolerances and tightening specifications.

• Fuel and emissions: Carburetor overhaul and adjustment, plus separate 2.0i fuel-pressure, injector, air-flow-meter and throttle-position-sensor tests.

• Transmission service: Manual gearbox disassembly and inspection, L4N71B automatic transmission overhaul, lock-up and overdrive diagnosis, and hydraulic pressure tests.

• Axles and suspension: Propeller-shaft service, differential overhaul, wheel-bearing inspection, and separate procedures for five-link and independent rear suspension.

• Steering and brakes: Manual and power-steering service, pump-pressure testing, hydraulic bleeding, master-cylinder repair, and disc- and drum-brake inspection.

• Electrical diagnosis: Charging and starting tests, body wiring schematics, connector views, and troubleshooting for cruise control and auto-adjusting suspension.

• Body and air conditioning: Interior trim removal, door-glass adjustment, body dimensions, refrigerant-system testing, and compressor disassembly and assembly.

Written for service technicians at authorized Mazda dealers, these manuals assume familiarity with vehicle systems, basic repair procedures and the specified special tools.

FE Engine, Lubrication and Cooling

Scheduled maintenance and pre-delivery inspections lead into engine troubleshooting, timing-belt work and cylinder-head overhaul. The internal inspection pages cover camshaft, crankshaft, piston and bearing measurements, with assembly clearances and wear limits.

Cylinder-head guidance addresses valve-seat recession, compensating washers and the limit requiring head replacement. It also distinguishes the original intake and exhaust guide shapes and identifies the exhaust guide as the service replacement for both positions.

The timing-belt section explains how reversing a reused belt’s direction can shorten its service life. Lubrication and cooling coverage adds oil-pump inspection, oil-pressure checks, thermostat testing and water-pump overhaul, supported by oil-flow and coolant-flow diagrams.

Carburetor Service and 2.0i Injection Diagnosis

The base manual covers carburetor disassembly, float-level checks, choke controls and market-specific emission equipment. The supplement adds intake-manifold and surge-tank work, sensor checks and fuel-injection diagnosis.

For a cranks-but-will-not-start complaint, the supplement links relay, fuel-pressure, sensor and injector checks to their component sections. These cross-references help locate the tests relevant to the symptom before selecting a component for replacement.

Air-flow-meter resistance tables, throttle-position continuity checks and control-unit terminal-voltage tables support electrical diagnosis. A separate vacuum-hose diagram helps identify connections for the documented emission-control arrangements.

The injector volume-test section specifies checker 49 9200 040 and warns that applying battery voltage directly can damage an injector.

Gearbox and Rear-Axle Overhaul

The L4N71B chapter connects lock-up and overdrive symptoms with electrical checks and hydraulic circuitry. Stall, line-pressure and governor-pressure tests accompany control-valve service, clutch-pack inspection and geartrain end-play measurements.

Manual-transmission coverage includes synchronizer inspection and shim selection. Clutch hydraulic repairs and propeller-shaft procedures sit in their own sections.

Rear-axle instructions distinguish five-link and independent rear suspension configurations. Differential overhaul includes bearing-preload, backlash and tooth-contact checks, helping readers select the procedure that matches the axle arrangement.

Body Circuits, Interior Repairs and A/C

Body-electrical pages provide sedan and hardtop wiring schematics, cluster-switch circuits and connector views with terminal designations and wire-color codes. Cruise-control and auto-adjusting-suspension diagnosis covers the relevant switches, sensors, actuators and control units.

Body work extends to door-glass alignment, interior fittings and underbody dimensions. The air-conditioning section includes a circuit diagram, leak and performance tests, and compressor overhaul.

Observe the manual’s vehicle-support, pressurized-fuel and refrigerant precautions when planning these jobs.

Selected Cylinder-Head and Sensor Test Specifications

Cylinder-head fasteners: The scheduled-maintenance table specifies 8.2–8.8 m-kg with a cold engine and 9.5–10.0 m-kg with a warm engine, retaining the temperature distinction for the documented tightening check.

Injection-system sensor testing: The 2.0i water-temperature sensor table gives 2.45 ± 0.24 kΩ at 20°C and 0.322 ± 0.032 kΩ at 80°C. These temperature-dependent readings support sensor assessment during starting and idle diagnosis.

Section Bookmarks and PDF Contents

Navigation and wiring detail: PDF text search is unavailable. The 22 embedded bookmarks provide access to the base manual’s main sections and the beginning of the supplement; the supplement has no detailed internal bookmark hierarchy. Small wire-color, connector and pin labels on dense circuit diagrams require zooming.

The set is supplied as one printable, 878-page PDF in English, including both publications listed above and one shared cover marked P/N 03–0620.