🏷️ Basic Information Identification Make: Mazda / Ford Model: B2200 / B2600i / Courier Body Style: Light Commercial Vehicle (Pickup Truck) Chassis Code: UN Series (Mazda), PD Series (Ford Courier) Generation Generation: Second Generation (Mazda B-Series) / Third Generation (Ford Courier) Codes Engine Code Primary: G6 (2.2L Petrol) Engine Code Secondary: G6-P / G6-E (2.6L Petrol) 👋 Introduction Market Position Market Position: The Mazda B-Series and Ford Courier of this era were positioned as reliable, robust, and affordable compact pickup trucks, popular for work, light commercial use, and recreational activities. Competitive Analysis Competitors: Competed against vehicles like the Toyota Hilux/Pickup, Nissan Hardbody/Navara, Mitsubishi Mighty Max/L200, Isuzu KB/Rodeo, and Chevrolet S-10/GMC Sonoma. Key Features Key Features Vehicle: Durable chassis, practical utility, available 4WD for off-road capability, reliable (though sometimes basic) powertrains. Key Features Manual: Comprehensive factory coverage, detailed diagrams and procedures, covers both EFI and Carbureted variants, includes 2WD and 4WD systems. Manual Value Value Proposition: Provides essential, factory-accurate information for maintenance and repair, potentially saving significant costs compared to dealer service or less detailed aftermarket manuals. 📋 Manual Details Coverage Areas Years Covered: 1987-1995 (Explicitly stated in product description, though product name suggests 1996) Markets Covered: Global (indicated by Mazda B-Series and Ford Courier branding) Drivetrain Configurations: 2WD (Rear-Wheel Drive), 4WD (Four-Wheel Drive) Engine Types: Carburetor (Carby) and Fuel Injection (EFI) Engine Displacements: 2.2 Liters (2184cc), 2.6 Liters (2606cc) Page Count Page Count: Not specified, but described as comprehensive Manual Type Manual Type: Factory Repair Manual / Service Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, pistons, crankshaft, camshaft, lubrication, cooling system, timing components. Engine Fuel And Ignition: Carburetor systems, EFI systems (ECU, sensors, injectors), ignition timing, spark plugs, distributors. Transmission Manual: Gearbox disassembly, assembly, troubleshooting, clutch operation, drive shafts. Transmission Automatic: Automatic transmission overhaul, fluid service, torque converter, hydraulic controls, electrical solenoids. Transfer Case: 4WD transfer case disassembly, assembly, maintenance, and operation. Driveline: Front and rear differentials, axle shafts, universal joints, CV joints (if applicable). Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment specifications. Steering: Steering column, steering rack/box, power steering system, tie rod ends. Brakes: Front disc brakes, rear drum brakes, hydraulic system, parking brake, ABS (if equipped). Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting, accessories, fuses, relays. Body And Interior: Body panel removal/installation, interior trim, seats, door mechanisms, glass, weatherstripping. HVAC: Heating, ventilation, and air conditioning systems (if equipped). Procedures Included Maintenance: Routine maintenance tasks: oil changes, filter replacements, fluid checks, spark plug service, belt adjustments. Troubleshooting: Diagnostic procedures for common and uncommon problems across all systems. Repair And Rebuild: Detailed step-by-step instructions for component disassembly, repair, and reassembly. Diagnostics: Fault code interpretation (OBD-I), circuit testing, sensor testing, mechanical diagnostic procedures. Wiring Diagrams: Comprehensive electrical schematics for various systems, aiding in diagnosis and repair. Specifications: Torque specifications, clearances, fluid capacities, pressure readings, diagnostic parameters. Technical Depth Depth: Comprehensive Factory-Level Detail: Covers basic maintenance to complete engine and transmission overhauls, including diagnostic routines and specifications. Information Source: Factory Mazda documentation, considered superior by the seller. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely searchable text within the PDF for ease of use. Print Quality Print Quality: Designed for easy reading and printing. Binding Type Binding Type: Not applicable (Digital PDF) Paper Type Paper Type: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 2 2L Petrol: G6 (FE-DOHC) - 2.2L SOHC 8-Valve Inline-4 Petrol Engine 2 2L Power: Approx. 98-105 hp @ 4800-5000 rpm (Varies by market and year) Engine 2 2L Torque: Approx. 130-135 lb-ft @ 2500-3000 rpm (Varies by market and year) Secondary Engine Engine 2 6L Petrol: G6 (G6-P, G6-E) - 2.6L SOHC 12-Valve Inline-4 Petrol (Mitsubishi 4G54 variant used in some markets) Engine 2 6L Power: Approx. 108-120 hp @ 4500-4800 rpm (Varies by market and year) Engine 2 6L Torque: Approx. 145-150 lb-ft @ 2500-3000 rpm (Varies by market and year) Fuel System Fuel Delivery: Carbureted (e.g., Hitachi, Nikki) or Electronic Fuel Injection (EFI) depending on model year and market. Fuel Type: Unleaded Gasoline Engine Management ECU Type: OBD-I compliant for EFI models. 🔧 Transmission Standard Manual Transmission: 5-speed manual gearbox Optional Automatic Transmission: 4-speed automatic gearbox (e.g., Jatco/Mazda, likely an evolution of the Jatco 3N71/4N71 series). Features Transfer Case Operation: Manual engagement for 4WD models (e.g., 2WD, 4WD High, 4WD Low). Fluid Specifications Manual Transmission Fluid: API GL-4 gear oil, typically SAE 75W-90 or 80W-90. Automatic Transmission Fluid: Dexron III/Mercon equivalent ATF (Automatic Transmission Fluid). Clutch Clutch Type: Dry, single plate, diaphragm spring clutch (for manual transmission). 📐 Dimensions Exterior Wheelbase Short: Approx. 108.7 inches (2760 mm) Wheelbase Long: Approx. 117.7 inches (2990 mm) Overall Length: Varies by configuration (short/long bed, cab type). Weights Curb Weight: Approx. 3000-3600 lbs...
Second Generation (Mazda B-Series) / Third Generation (Ford Courier)
Codes
Engine Code Primary:
G6 (2.2L Petrol)
Engine Code Secondary:
G6-P / G6-E (2.6L Petrol)
👋 Introduction
Market Position
Market Position:
The Mazda B-Series and Ford Courier of this era were positioned as reliable, robust, and affordable compact pickup trucks, popular for work, light commercial use, and recreational activities.
Competitive Analysis
Competitors:
Competed against vehicles like the Toyota Hilux/Pickup, Nissan Hardbody/Navara, Mitsubishi Mighty Max/L200, Isuzu KB/Rodeo, and Chevrolet S-10/GMC Sonoma.
Key Features
Key Features Vehicle:
Durable chassis, practical utility, available 4WD for off-road capability, reliable (though sometimes basic) powertrains.
Key Features Manual:
Comprehensive factory coverage, detailed diagrams and procedures, covers both EFI and Carbureted variants, includes 2WD and 4WD systems.
Manual Value
Value Proposition:
Provides essential, factory-accurate information for maintenance and repair, potentially saving significant costs compared to dealer service or less detailed aftermarket manuals.
📋 Manual Details
Coverage Areas
Years Covered:
1987-1995 (Explicitly stated in product description, though product name suggests 1996)
Markets Covered:
Global (indicated by Mazda B-Series and Ford Courier branding)
Comprehensive Factory-Level Detail: Covers basic maintenance to complete engine and transmission overhauls, including diagnostic routines and specifications.
Information Source:
Factory Mazda documentation, considered superior by the seller.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Likely searchable text within the PDF for ease of use.
Print Quality
Print Quality:
Designed for easy reading and printing.
Binding Type
Binding Type:
Not applicable (Digital PDF)
Paper Type
Paper Type:
Not applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 2 2L Petrol:
G6 (FE-DOHC) - 2.2L SOHC 8-Valve Inline-4 Petrol
Engine 2 2L Power:
Approx. 98-105 hp @ 4800-5000 rpm (Varies by market and year)
Engine 2 2L Torque:
Approx. 130-135 lb-ft @ 2500-3000 rpm (Varies by market and year)
Secondary Engine
Engine 2 6L Petrol:
G6 (G6-P, G6-E) - 2.6L SOHC 12-Valve Inline-4 Petrol (Mitsubishi 4G54 variant used in some markets)
Engine 2 6L Power:
Approx. 108-120 hp @ 4500-4800 rpm (Varies by market and year)
Engine 2 6L Torque:
Approx. 145-150 lb-ft @ 2500-3000 rpm (Varies by market and year)
Fuel System
Fuel Delivery:
Carbureted (e.g., Hitachi, Nikki) or Electronic Fuel Injection (EFI) depending on model year and market.
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
OBD-I compliant for EFI models.
🔧 Transmission
Standard
Manual Transmission:
5-speed manual gearbox
Optional
Automatic Transmission:
4-speed automatic gearbox (e.g., Jatco/Mazda, likely an evolution of the Jatco 3N71/4N71 series).
Dry, single plate, diaphragm spring clutch (for manual transmission).
📐 Dimensions
Exterior
Wheelbase Short:
Approx. 108.7 inches (2760 mm)
Wheelbase Long:
Approx. 117.7 inches (2990 mm)
Overall Length:
Varies by configuration (short/long bed, cab type).
Weights
Curb Weight:
Approx. 3000-3600 lbs (1360-1630 kg), depending on configuration.
Payload Capacity:
Up to approximately 1600-1800 lbs (725-815 kg).
Towing Capacity:
Varies significantly, typically 2000-5000 lbs (900-2270 kg) depending on configuration and brakes.
Wheel And Tire
Standard Tire Size:
Commonly P205/75R14, P215/70R15.
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size:
14-inch or 15-inch steel or alloy wheels.
🛡️ Safety Features
Ratings
Crash Test Ratings:
No standardized ratings (like NHTSA/IIHS) available for this era of light trucks in many markets. Generally considered basic safety by modern standards.
Active Features
Active Safety Features:
Primarily Anti-lock Braking System (ABS) available on rear wheels or all four wheels on later models/higher trims.
Passive Features
Passive Safety Features:
Seat belts (lap and shoulder belts for front occupants), reinforced cabin structure.
💡 Technology Features
Infotainment
Infotainment System:
Basic factory radio (AM/FM, Cassette), optional CD player on later models. Speakers generally basic quality.
Driver Assistance
Driver Assistance Features:
Very limited by modern standards. ABS was the primary electronic driver aid.
Connectivity
Connectivity Options:
No integrated Bluetooth or USB connectivity from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 3-6 months, depending on driving conditions and oil type used.
Transmission Fluid Change Manual:
Inspect annually, change as per manual recommendations (often around 30,000-60,000 miles or 2-4 years).
Transmission Fluid Change Auto:
Typically every 30,000-60,000 miles (50,000-100,000 km) or 2-4 years.
Spark Plug Replacement:
Intervals vary by plug type (copper, platinum), typically 30,000-60,000 miles.
Timing Belt Replacement:
For the 2.6L engine (if belt-driven), typically 60,000-90,000 miles. The 2.2L G6 engine (FE-DOHC) is generally timing chain driven.
Fluid Specifications
Engine Oil Capacity 2 2L:
Approx. 4.7 US quarts (4.4 Liters) with filter.
Engine Oil Capacity 2 6L:
Approx. 5.3 US quarts (5.0 Liters) with filter.
Engine Oil Viscosity:
SAE 10W-30 or 10W-40 is common, refer to manual for specific climate recommendations.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Green or orange coolant compatible with Asian vehicles.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, clutch wear, exhaust system corrosion, radiator leaks, thermostat failures, starter motor issues.
Transfer case linkage binding, front CV joint wear (on 4WD models with independent front suspension if applicable).
📚 Vehicle History
Brand Heritage
Mazda Heritage:
Mazda has a long history of producing reliable and practical vehicles, including their B-Series pickup trucks which have been a staple in many global markets for decades.
Ford Courier Heritage:
The Ford Courier was Ford's compact pickup truck offering in many international markets, often a rebadged Mazda B-Series or a closely related platform, showcasing a strong global product strategy.
Model Evolution
Generation Transition:
This manual covers a period when the B-Series/Courier platform underwent styling updates and powertrain refinements, moving from carbureted to EFI systems, and evolving suspension and braking components.
Production
Production Location:
Manufactured globally, including Japan (Mazda) and various Ford assembly plants.
🏆 Awards & Recognition
Recognitions
Awards Received:
No specific widely publicized awards are generally associated with these models, but they were highly regarded for their value and utility in their respective markets.