Mazda B-Series B2200 or B2600i Workshop Manual 1987–1993 (P/N 29528 )

System Coverage Highlights

• Covers the 1992 Mazda B2200 and B2600i repair platform from the listed VIN break *`N0 250001~`**, with separate F2 2.2L and G6 2.6L engine sections and full removal, teardown, inspection, assembly, and installation coverage.
• Separates the 2.2L carburetor system from 2.2L EGI and 2.6L EGI, including vacuum routing, system diagrams, self-diagnosis, symptom charts, fuel-system testing, sensor checks, idle adjustment, and after-repair verification.
• Details B2200 and B2600i manual transmissions, manual-transfer-case service, hydraulically and electronically controlled automatic transmissions, internal overhaul, pressure and road testing, self-diagnosis, and shift-lock diagnosis.
• Covers 4x2 driveline work and B2600i 4x4 repair, including propeller shafts, the remote free-wheel system, front and rear axles, drive shafts, wheel bearings, differentials, pinion setup, backlash, and bearing preload.
• Includes manual and power steering, rear-wheel ABS, wheel alignment, front and rear suspension repair, plus electrical schematics, connector and routing diagrams, ground-point layouts, and circuit-specific fault tracing.

Technical Specifications

Coverage note: This is a mixed-year reference set, not a complete year-by-year 1987–93 workshop-manual run. The core repair manual is the 1992 publication. The standalone electrical booklet is the 1991 publication 5172-10-90G; the 1992 workshop contents page references a different wiring volume, 5201-10-91G / 9999-95-020G-92. Match coverage by model year, VIN break, engine and fuel system, transmission, and 4x2/4x4 configuration rather than DX, SE-5, LE-5, or Turbo trim names. No separate Turbo repair chapter is included.

Diagnostic Data and Sub-System Details

Engine and cooling systems. The B2200 chapter covers the belt-driven F2 engine, including tune-up checks, hydraulic lash-adjuster diagnosis, compression testing, timing-belt service, cylinder-head-gasket replacement, oil seals, engine removal, engine-stand mounting, complete disassembly, cylinder-head and block inspection, repair limits, assembly, and installation. The B2600i chapter provides the same repair depth for the chain-driven G6 engine while adding the balancer chain, timing chain, chain case, and related setup procedures. Separate lubrication and cooling groups cover oil-pressure diagnosis, oil pump and oil pan service, the G6 oil cooler, coolant replacement and air bleeding, radiator-cap testing, cooling-fan checks, water-pump repair, and thermostat service.

Carburetor and EGI diagnosis. The carburetor section covers the feedback carburetor, air/fuel solenoid, oxygen sensor, air injection, EGR, deceleration controls, evaporative emissions, PTC heater, altitude compensation, electric and mechanical fuel pumps, carburetor controls, the malfunction indicator lamp, and diagnosis with the Mazda self-diagnosis checker. The EGI section adds system, vacuum, and wiring diagrams; engine-control operation charts; code-cycle and switch-monitor functions; intake and idle-speed control; fuel-pump, injector, pressure-regulator, pulsation-damper, and circuit-opening-relay checks; ECU input testing; and defined after-repair procedures.

Transmissions and 4x4 driveline. Manual-transmission groups are split between the B2200 and B2600i and include structural views, power-flow diagrams, removal, disassembly, inspection, assembly, and installation. The hydraulically controlled automatic section covers quick-diagnosis charts, stall and time-lag tests, line- and governor-pressure tests, road tests, clutch and band service, planetary units, oil pump, valve body, and hydraulic-circuit diagrams. The electronically controlled unit adds self-diagnostic retrieval, signal inspection, speed and temperature sensors, solenoids, EC-AT control-unit diagnosis, and shift-lock repair.

Four-wheel-drive material includes front and rear propeller shafts, transfer cases, 4x4 indicator and neutral switches, the remote free-wheel control unit, vacuum reservoir, lock/free solenoids, actuator, joint shaft, front drive shafts, axles, and differential overhaul. Steering, brake, and suspension groups add power-steering bleeding and testing, steering-gear and pump service, front discs, separate 4x2 and 4x4 rear drums, parking brake, proportioning bypass valve, rear-wheel ABS, wheel alignment, double-wishbone front suspension, torsion bars, stabilizers, shock absorbers, and rear leaf springs.

Electrical, body, and HVAC. The 1991 wiring booklet provides ground-point diagrams, the main electrical schematic, system circuit and connector diagrams, harness-routing diagrams, common-connector and joint-box views, parts locations, and component indexes. Representative circuits include charging and starting, 2.2L carburetor feedback control, 2.2L EGI and 2.6L engine control, hydraulically controlled automatic and EC-AT circuits, rear-wheel ABS, and 4x4 remote free-wheel control. Lighting, instruments, cruise control, heater and air conditioning, wipers, warning circuits, and audio are also mapped.

Body repair coverage includes hood and bumper removal, doors and glass, instrument-panel removal, seats and belts, trim, tailgate adjustment, and body dimensions. The HVAC group includes electrical troubleshooting, blower and heater-unit service, refrigerant safety, performance testing, charge and pressure checks, evaporator, compressor, condenser, receiver/drier, relay, and pressure-switch diagnosis.

Specifications and special tools. Technical Data consolidates torque tables, capacities, pressure-test specifications, wear limits, clearances, adjustment data, and electrical test values by workshop section. The Special Tools group identifies Mazda equipment by part number, including the 49 H018 9A1 self-diagnosis checker, 49 G019 901A EC-AT tester, 49 9200 162 engine signal monitor, and system-specific engine, transmission, differential, steering, brake, and air-conditioning tools.

Repair-Critical Notes

A reused B2200 timing belt must remain in its original rotation direction and free of oil, grease, and water; reversing or contaminating it can shorten belt life and risk timing failure. On the B2600i timing-chain system, the chain-adjuster retaining pin must be removed before the service cover is installed, or the tensioner cannot operate correctly. During differential setup, the collapsible spacer is treated as a one-way preload component; continuing to tighten or reusing an over-crushed spacer can overload the pinion bearings and compromise gear contact.

Fuel pressure must be released before opening fuel lines, and the battery should be disconnected before circuit, starter, alternator, transmission, or powertrain electrical work. Refrigerant recovery and brake or steering hydraulic procedures require the specified service equipment and the safety precautions in the applicable section.