Mazda B2200/B2600i 1987–1993 Workshop Manual Set (P/N 9999-95-022B-92)

The workshop manual provides repair procedures, the wiring booklet supports circuit tracing for its own application, and the parts extract adds exploded views, part numbers, application notes, and estimating labor entries.

Coverage note: This is a mixed-year reference set, not a complete year-by-year 1987–93 workshop-manual run. The workshop manual references a different 1992 wiring volume, P/N 5201-10-91G / 9999-95-020G-92, which is not included.

The supplied 1991 wiring PDF omits the windshield-wiper/washer section D, with printed pages Z-58–Z-59 absent. Wiper/washer diagnosis and service are covered in the 1992 workshop manual's Body section. Match coverage by VIN, 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.

PDF Search, Navigation and File Contents

Finding text and diagrams: The workshop PDF has chapter bookmarks but no searchable text. Search in the wiring PDF is limited to introductory text, and some bookmarks lead to the wrong section. Searchable text in the parts reference is limited to its first five pages; that file has no bookmarks. Small wiring labels require zooming.

RAR download containing three printable PDFs, with 1,521 pages total, including original front matter, 10 blank workshop pages, two workshop memo pages, and four wiring section-divider pages.

Engine, Fuel-Control and Driveline Repair

These selected coverage highlights outline the main repair areas. Other topics include pre-delivery inspection and separate U.S. and Canadian maintenance schedules.

• Engine overhaul: Step-by-step removal, disassembly, inspection, assembly, and installation procedures for the F2 and G6 engines, including their different timing systems.
• Fuel and emissions: Carburetor feedback and EGI diagnosis, vacuum routing, self-diagnosis, symptom charts, sensor tests, idle adjustment, and after-repair verification.
• Clutch and transmissions: Hydraulic-clutch service, manual-transmission and transfer-case overhaul, hydraulic and electronic automatic-transmission diagnosis, pressure tests, and shift-lock troubleshooting.
• Axles and four-wheel drive: Propeller shafts, remote free-wheel diagnosis, drive shafts, wheel bearings, differential overhaul, pinion setup, backlash, and bearing preload.
• Steering, brakes and suspension: Manual and power steering, front discs, rear drums, parking brake, rear-wheel ABS diagnosis, wheel alignment, and suspension repair.
• Electrical diagnosis: Charging, starting, ignition, and body-electrical tests, supported by schematics, connector views, harness-routing diagrams, and component-location drawings.
• Body and climate control: Doors, glass, instrument-panel removal, heater and blower service, refrigerant-system testing, and compressor repair.

Written for service technicians at authorized Mazda dealers, the workshop manual assumes familiarity with vehicle systems, basic repair procedures, and the specified special tools.

Engine, Lubrication and Fuel-System Diagnosis

Engine coverage extends from compression testing and hydraulic lash-adjuster diagnosis to cylinder-head-gasket replacement, oil-seal service, engine-stand mounting, and cylinder-head/block inspection. The G6 section also covers the balancer chain, timing chain, and chain case.

Lubrication and cooling chapters cover oil-pressure diagnosis, oil-pump and oil-pan service, the G6 oil cooler, coolant replacement and air bleeding, radiator-cap and cooling-fan checks, water-pump replacement, and thermostat service.

Carburetor controls: Feedback-system tests address the air/fuel solenoid, oxygen sensor, air injection, EGR, deceleration controls, evaporative emissions, PTC heater, and altitude compensation. Electric and mechanical fuel pumps, carburetor controls, the malfunction indicator lamp, and Mazda self-diagnosis checks are covered separately.

EGI troubleshooting: System, vacuum, and wiring diagrams accompany engine-control operation charts, code-cycle interpretation, switch-monitor checks, and ECU input testing. Component tests cover intake and idle-speed control, injectors, the fuel pump, pressure regulator, pulsation damper, and circuit-opening relay.

Transmission Testing and Internal Repair

Manual-transmission groups provide structural views and power-flow diagrams. Clutch coverage includes pedal adjustment, master- and release-cylinder overhaul, hydraulic bleeding, and inspection of the clutch disc, release bearing, and flywheel.

Hydraulic automatic: The K1 section covers stall, time-lag, line-pressure, governor-pressure, and road tests, followed by clutch and band service, planetary units, oil pump, valve body, and hydraulic-circuit diagrams.

Electronic automatic: K2 adds malfunction-code retrieval, input/output signal checks, speed and temperature sensors, solenoids, EC-AT control-unit diagnosis, and shift-lock repair. Its cross-sectional and power-flow views show the internal assemblies.

The quick-diagnosis charts distinguish on-vehicle checks from faults requiring transmission removal, helping you plan the scope of the job before teardown. J3 contains transfer-case overhaul procedures; K3 provides automatic-transfer-case specifications and refers service work to J3.

Four-Wheel Drive, Steering and Chassis

Remote free-wheel coverage follows the control unit, vacuum reservoir, lock/free solenoids, actuator, joint shaft, and transfer-case indicator and neutral switches. Front and rear differential procedures include gear-contact inspection and preload adjustment.

Chassis sections distinguish 4x2 and 4x4 rear drums and cover the proportioning bypass valve, power-steering bleeding, steering-gear and pump service, double-wishbone front suspension, torsion bars, stabilizers, shock absorbers, and rear leaf springs.

Wiring, Body and Air Conditioning

The electrical booklet includes Ground Points, the Electrical Wiring Schematic, system circuit/connector diagrams, harness routing, Common Connector Lists, parts locations, and component indexes. Circuit examples include engine control, HAT/EC-AT, rear-wheel ABS, and remote free-wheel control. Lighting, instruments, cruise control, warning circuits, audio, and heater/air-conditioning circuits are also represented.

Body procedures cover hood and bumper removal, seats and belts, trim, tailgate adjustment, and body dimensions. HVAC diagnosis covers blower and heater units, performance testing, refrigerant charge and pressure checks, evaporator, compressor, condenser, receiver/drier, relay, and pressure-switch checks.

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.

Timing and Differential Assembly Cautions

The timing sections flag B2200 belt damage from reversed installation or contamination and loss of B2600i chain-adjuster operation if its retaining pin remains installed. Differential assembly cautions address excessive pinion-bearing preload and replacement of the collapsible spacer when preload cannot be set within the specified tightening-torque range.

Service Data and Mazda Diagnostic Tools

Technical Data consolidates torque tables, capacities, pressure-test specifications, wear limits, clearances, adjustment data, and electrical test values. The Special Tools section identifies the 49 H018 9A1 self-diagnosis checker, 49 G019 901A EC-AT tester, and 49 9200 162 engine signal monitor, along with engine, transmission, differential, steering, brake, and air-conditioning equipment.

G6 Bearing-Clearance and End-Play Preview

For G6 main-bearing inspection, the manual lists an oil clearance of 0.025–0.044 mm and a maximum of 0.08 mm.

Crankshaft end play is 0.08–0.18 mm, with a maximum of 0.30 mm. The accompanying instructions cover crankshaft inspection and bearing selection.