Mazda BRAVO B2200 B2600 B2500 1998-2006 Workshop Manual

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🏷️ Basic Information Identification Make: Mazda Model: Bravo B2200 / B2600 / B2500 Alternate Model Names: Drifter Production Years Covered: 1998-2006 Codes Engine Code G6: G6 Engine Code F2: F2 Engine Code Wl Diesel: WL Engine Code Wl Turbo Diesel: WL-T 👋 Introduction Market Position Market Segment: Compact/Mid-size Pickup Truck Target Audience: DIY mechanics, independent repair shops, fleet maintenance. Competitive Analysis Key Competitors: Toyota Hilux/Tacoma, Mitsubishi Triton/Pajero Sport, Nissan Navara/Frontier, Ford Ranger. Key Features Robust Platform: Known for its durable chassis and powertrain options suitable for work and light off-road use. Engine Diversity: Wide range of petrol and diesel engines catering to different performance and economy requirements. 4Wd Capability: Offered with reliable 4WD systems enhancing its versatility. 📋 Manual Details Coverage Areas Primary Coverage: Workshop, Repair, Overhaul Vehicle Variants Covered: 2WD, 4WD, Single Cab, Dual Cab Engine Variants Covered: 2.2L Petrol (F2), 2.6L Petrol (G6), 2.5L Diesel (WL), 2.5L Turbo Diesel (WL-T) Page Count Estimated Page Count: N/A (CD-ROM format implies comprehensive digital content, not a fixed page count) Manual Type Manual Type: Workshop Manual / Repair Manual Language Language: English Format Format: CD-ROM 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, timing, valve train, piston/ring replacement, crankshaft/bearing service. Lubrication System: Oil pump, oil filter, oil cooler (if applicable), oil pressure testing, oil change procedures. Cooling System: Radiator, thermostat, water pump, hoses, coolant types, flush procedures, leak detection, fan operation. Charge System: Alternator testing, charging system diagnosis, battery maintenance, voltage regulation. Start System: Starter motor testing and replacement, ignition switch operation, solenoid function. Emission System: Catalytic converter, EGR system (if applicable), PCV system, oxygen sensors, emission control component diagnosis. Fuel System Petrol: Fuel pump, fuel filter, fuel injectors, throttle body, fuel pressure testing, fuel line routing. Fuel System Diesel: Injection pump, injectors, glow plugs, fuel filter, bleeding procedures, high-pressure fuel lines. Engine Electrical: Ignition system (spark plugs, coils, distributor/ த் electronic control), wiring diagrams, sensor testing (crankshaft, camshaft, MAP, TPS). Clutch: Clutch disc, pressure plate, release bearing, clutch hydraulics, adjustment and replacement. Manual Transmission: Gearbox disassembly, assembly, gear selection, shifting mechanisms, fluid specifications and replacement. Prop Shaft: Driveshaft removal, universal joint service, centering yoke, balancing, installation. Front Rear Hubs Axles: Wheel bearing service, hub assembly replacement, axle shaft removal, differential service (if applicable). Steering System: Power steering pump, steering rack/box, tie rod ends, power steering fluid, alignment procedures. Braking System: Brake pads, rotors, calipers, wheel cylinders, brake fluid flush, bleeding, parking brake adjustment, ABS diagnosis (if equipped). Suspension: Front and rear suspension components (shocks, struts, springs, control arms, ball joints, bushings), alignment specifications. Body: Body panel removal/installation, door mechanisms, interior trim, glass replacement, chassis specifications. Body Electrical: Lighting systems, power windows, power locks, wipers, horn, dashboard indicators, wiring schematics. A C Ventilation: Air conditioning system diagnosis, refrigerant handling, blower motor, HVAC controls, cabin filter replacement. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-up procedures. Troubleshooting: Diagnostic charts for common drivability, electrical, and mechanical issues, symptom-based troubleshooting. Repair: Step-by-step instructions for component replacement, system overhauls, and adjustments. Overhaul: Detailed instructions for complete engine, transmission, and differential rebuilds. Installation: Instructions for installing replacement parts and accessories. Technical Depth Technical Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics. Diagnostic Charts: Includes diagnostic flowcharts for common problems, aiding in systematic troubleshooting. Torque Specifications: Provides crucial torque specifications for critical fasteners across all major systems (engine, drivetrain, chassis). Special Tools: Lists specialized tools required for specific repair or diagnostic procedures, enhancing repair accuracy and efficiency. 📊 Manual Specifications File Format File Format: CD-ROM (likely PDF or proprietary viewer) Searchability: Expected to be searchable if in PDF format. Print Quality Print Quality: N/A (Digital format) Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine 2 6L Petrol G6: 2.6L SOHC 12-valve inline-4 petrol. Known for reliability and decent power output for its class. Approximate output: 110-120 HP, 145-160 lb-ft torque (varies by market and specific variant). Engine 2 2L Petrol F2: 2.2L SOHC 8-valve inline-4 petrol. A smaller, more economical option. Approximate output: 90-100 HP, 120-135 lb-ft torque. Engine 2 5L Diesel Wl: 2.5L SOHC 8-valve naturally aspirated diesel inline-4. Known for fuel economy and longevity. Approximate output: 70-80 HP, 100-115 lb-ft torque. Engine 2 5L Turbo Diesel Wl-T: 2.5L SOHC 8-valve turbocharged diesel inline-4. Offers improved performance over the naturally aspirated version. Approximate output: 90-100 HP, 130-145 lb-ft torque. Performance Horsepower Range: 70 HP (2.5L Diesel) to 120 HP (2.6L Petrol) Torque Range: 100 lb-ft (2.5L Diesel) to 160 lb-ft (2.6L Petrol) Fuel System Petrol Fuel System: Multi-point fuel injection (MPI) or Electronic Fuel Injection (EFI). Diesel Fuel System: Indirect injection with rotary or inline injection pumps. 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission. Optional Optional Transmission: 4-speed...

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Type: Truck

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Sku: 319395

Collections: ALL Featured Mazda

Availability: In stock

Tags: 1998 1999 2000 2001 2002 2003 2004 2005 2006 B2200 B2500 B2600 BRAVO Cars Drifter Featured Mazda Truck

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Description

🏷️ Basic Information

Identification

Make:

Mazda

Model:

Bravo B2200 / B2600 / B2500

Alternate Model Names:

Drifter

Production Years Covered:

1998-2006

Codes

Engine Code G6:

Engine Code F2:

Engine Code Wl Diesel:

Engine Code Wl Turbo Diesel:

👋 Introduction

Market Position

Market Segment:

Compact/Mid-size Pickup Truck

Target Audience:

DIY mechanics, independent repair shops, fleet maintenance.

Competitive Analysis

Key Competitors:

Toyota Hilux/Tacoma, Mitsubishi Triton/Pajero Sport, Nissan Navara/Frontier, Ford Ranger.

Key Features

Robust Platform:

Known for its durable chassis and powertrain options suitable for work and light off-road use.

Engine Diversity:

Wide range of petrol and diesel engines catering to different performance and economy requirements.

4Wd Capability:

Offered with reliable 4WD systems enhancing its versatility.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop, Repair, Overhaul

Vehicle Variants Covered:

2WD, 4WD, Single Cab, Dual Cab

Engine Variants Covered:

2.2L Petrol (F2), 2.6L Petrol (G6), 2.5L Diesel (WL), 2.5L Turbo Diesel (WL-T)

Page Count

Estimated Page Count:

N/A (CD-ROM format implies comprehensive digital content, not a fixed page count)

Manual Type

Manual Type:

Workshop Manual / Repair Manual

Language

Language:

English

Format

Format:

CD-ROM

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, timing, valve train, piston/ring replacement, crankshaft/bearing service.

Lubrication System:

Oil pump, oil filter, oil cooler (if applicable), oil pressure testing, oil change procedures.

Cooling System:

Radiator, thermostat, water pump, hoses, coolant types, flush procedures, leak detection, fan operation.

Charge System:

Alternator testing, charging system diagnosis, battery maintenance, voltage regulation.

Start System:

Starter motor testing and replacement, ignition switch operation, solenoid function.

Emission System:

Catalytic converter, EGR system (if applicable), PCV system, oxygen sensors, emission control component diagnosis.

Fuel System Petrol:

Fuel pump, fuel filter, fuel injectors, throttle body, fuel pressure testing, fuel line routing.

Fuel System Diesel:

Injection pump, injectors, glow plugs, fuel filter, bleeding procedures, high-pressure fuel lines.

Engine Electrical:

Ignition system (spark plugs, coils, distributor/ த் electronic control), wiring diagrams, sensor testing (crankshaft, camshaft, MAP, TPS).

Clutch:

Clutch disc, pressure plate, release bearing, clutch hydraulics, adjustment and replacement.

Manual Transmission:

Gearbox disassembly, assembly, gear selection, shifting mechanisms, fluid specifications and replacement.

Prop Shaft:

Driveshaft removal, universal joint service, centering yoke, balancing, installation.

Front Rear Hubs Axles:

Wheel bearing service, hub assembly replacement, axle shaft removal, differential service (if applicable).

Steering System:

Power steering pump, steering rack/box, tie rod ends, power steering fluid, alignment procedures.

Braking System:

Brake pads, rotors, calipers, wheel cylinders, brake fluid flush, bleeding, parking brake adjustment, ABS diagnosis (if equipped).

Suspension:

Front and rear suspension components (shocks, struts, springs, control arms, ball joints, bushings), alignment specifications.

Body:

Body panel removal/installation, door mechanisms, interior trim, glass replacement, chassis specifications.

Body Electrical:

Lighting systems, power windows, power locks, wipers, horn, dashboard indicators, wiring schematics.

A C Ventilation:

Air conditioning system diagnosis, refrigerant handling, blower motor, HVAC controls, cabin filter replacement.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-up procedures.

Troubleshooting:

Diagnostic charts for common drivability, electrical, and mechanical issues, symptom-based troubleshooting.

Repair:

Step-by-step instructions for component replacement, system overhauls, and adjustments.

Overhaul:

Detailed instructions for complete engine, transmission, and differential rebuilds.

Installation:

Instructions for installing replacement parts and accessories.

Technical Depth

Technical Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics.

Diagnostic Charts:

Includes diagnostic flowcharts for common problems, aiding in systematic troubleshooting.

Torque Specifications:

Provides crucial torque specifications for critical fasteners across all major systems (engine, drivetrain, chassis).

Special Tools:

Lists specialized tools required for specific repair or diagnostic procedures, enhancing repair accuracy and efficiency.

📊 Manual Specifications

File Format

File Format:

CD-ROM (likely PDF or proprietary viewer)

Searchability:

Expected to be searchable if in PDF format.

Print Quality

Print Quality:

N/A (Digital format)

Binding Type

Binding Type:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine 2 6L Petrol G6:

2.6L SOHC 12-valve inline-4 petrol. Known for reliability and decent power output for its class. Approximate output: 110-120 HP, 145-160 lb-ft torque (varies by market and specific variant).

Engine 2 2L Petrol F2:

2.2L SOHC 8-valve inline-4 petrol. A smaller, more economical option. Approximate output: 90-100 HP, 120-135 lb-ft torque.

Engine 2 5L Diesel Wl:

2.5L SOHC 8-valve naturally aspirated diesel inline-4. Known for fuel economy and longevity. Approximate output: 70-80 HP, 100-115 lb-ft torque.

Engine 2 5L Turbo Diesel Wl-T:

2.5L SOHC 8-valve turbocharged diesel inline-4. Offers improved performance over the naturally aspirated version. Approximate output: 90-100 HP, 130-145 lb-ft torque.

Performance

Horsepower Range:

70 HP (2.5L Diesel) to 120 HP (2.6L Petrol)

Torque Range:

100 lb-ft (2.5L Diesel) to 160 lb-ft (2.6L Petrol)

Fuel System

Petrol Fuel System:

Multi-point fuel injection (MPI) or Electronic Fuel Injection (EFI).

Diesel Fuel System:

Indirect injection with rotary or inline injection pumps.

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission.

Optional

Optional Transmission:

4-speed automatic transmission (availability varies by engine and market).

Features

Transmission Features:

Robust construction, suitable for towing and load carrying.

📐 Dimensions

Exterior

Body Styles:

Single Cab, Dual Cab.

Wheelbase Range:

Approximately 118-125 inches (varies by cab configuration).

Weights

Curb Weight Range:

Approximately 3300-3800 lbs (varies by configuration and engine).

Gross Vehicle Weight Rating Gvwr:

Typically around 5000-5500 lbs.

🛡️ Safety Features

Ratings

Safety Ratings:

Not extensively tested by modern standards like NHTSA/Euro NCAP for this generation. Generally considered basic for its era.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) available on some later models/trims. Standard disc front/drum rear brakes.

Passive Features

Passive Safety Features:

Seat belts. Limited airbag availability, often driver-side only or optional.

💡 Technology Features

Infotainment

Infotainment Features:

Basic factory radio with AM/FM and cassette player. Some models may have CD players. Limited connectivity options for the era.

Driver Assistance

Driver Assistance Features:

ABS available on select models. No advanced driver-assistance systems (ADAS) like lane keeping or adaptive cruise control.

Connectivity

Connectivity Options:

Basic, typically limited to optional auxiliary inputs on later models. No Bluetooth or USB connectivity from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or 6 months, depending on driving conditions and oil type. Refer to manual for specific recommendations.

Coolant Flush Interval:

Approximately every 30,000 miles or 2 years.

Timing Belt Replacement:

For petrol engines (G6, F2): Typically around 60,000 miles. Crucial to check and replace if due to prevent catastrophic engine damage. Diesel engines (WL) often use timing chains, which are generally maintenance-free but may require tensioner checks.

Spark Plug Replacement:

Petrol engines: 30,000-60,000 miles depending on plug type (copper vs. iridium). Diesel engines: Glow plug inspection/replacement as needed.

Fluid Specifications

Engine Oil Petrol:

API SG or higher, SAE 10W-30 or 10W-40 recommended. Check manual for precise viscosity based on ambient temperature.

Engine Oil Diesel:

API CD/CF or higher, SAE 15W-40 recommended. Check manual for specific viscosity.

Coolant Type:

Ethylene glycol based, typically a 50/50 mix with distilled water. Refer to manual for specific Mazda-approved coolant.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90. Capacity around 2.0-2.5 liters.

Transmission Fluid Automatic:

Dexron III or equivalent. Capacity around 3.0-3.5 liters for torque converter drain and fill.

Brake Fluid:

DOT 3 or DOT 4. Fluid should be flushed and replaced every 2-3 years due to moisture absorption.

Power Steering Fluid:

Dexron II/III or specific Mazda PS fluid.

Known Issues

Common Issues Petrol G6:

Oil leaks from valve cover and oil pan gaskets, occasional ignition coil failure, exhaust manifold cracks.

Common Issues Diesel Wl:

Glow plug issues, injector pump seals, turbocharger wear (WL-T), exhaust manifold gaskets.

Common Issues General:

Rust on chassis and body panels (especially in certain climates), wear in suspension bushings and ball joints, clutch wear, rear main seal leaks.

📚 Vehicle History

Brand Heritage

Mazda Truck Heritage:

Mazda has a long history of producing reliable and capable pickup trucks, often known for their value and practicality.

Model Evolution

Bravo Lineage:

The Bravo (and its rebadged counterparts like the Ford Courier and Mazda Drifter) is based on Mazda's B-series platform, which saw numerous generations and variations globally. This specific manual covers the later iterations of this popular truck.

Production

Production Locations:

Primarily manufactured in Japan and various international assembly plants.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for this model are scarce, the Mazda B-series platform has consistently been recognized for its reliability, durability, and value in the compact pickup truck segment.