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1995 Mazda MX-6 BRAKE SYSTEM’ ‘1995-96 BRAKES Mazda – Disc & Drum Removal & Installation
1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . Pivot caliper upward and support using rope. 2. Remove pads, shims, guide plates or pad guides and “V” springs (if equipped). Replace pad if lining
thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Exploded View Of Front Brake Disc Assembly FRONT DISC BRAKE CALIPER Removal & Installation FRONT BRAKE ROTOR Removal & Installation REAR DISC BRAKE PADS Removal & Installation Exploded View Of Rear Disc Brake Assembly (Miata & Protege Shown; MX-6 & 626 Are Similar) Exploded View Of Rear Drum Brake Assembly (MX-3 Shown; MX-6 626 Are Similar) Removing Power Brake Unit (Typical)

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Much has been written about swapping Suzuki’s G16B 1.6 liter 16-valve engine into the Samurai. It is mechanically very simple (as engine swaps go) but the wiring can be a daunting challenge for many. To date it has been necessary for the DIY builder to perform extensive research, gather all the information they can find, try to make sense of it, and take their best shot (or pay someone that has already done it). There is no one “correct” way to make this engine swap. The variations are nearly endless. Much of it involves personal preference. What is presented here is a process that is known to be successful, along with some of the more familiar options. ALL WIRING SHOULD BE DONE WITH THE BATTERY REMOVED FROM THE VEHICLE 1.1. It is HIGHLY RECCOMMENED that you purchase the appropriate Field Service Manual for your engine model year (either digital or print copy). Though there are only two sections that are relevant to a transplanted engine the information is absolutely invaluable. Much – but not all – of the required Information is also available in most aftermarket vehicle specific service manuals (Haynes, Chilton’s, etc.) The pertinent sections (6 & of the 1996 Tracker FSM may be downloaded for free from Acksfaq.com (donations are appreciated). 1.2. 1992 through 1998 Suzuki/Geo (GM) vehicles with G16B (1.6 liter 16-valve) engines can be identified by the 8th digit in the Vehicle Identification Number. “0” for Suzuki badged vehicles, “6” for Geo’s (“U” indicates an 8-valve 1.6L). 1.3. The most common set-up, and arguably the simplest, mates a donor Tracker or Sidekick engine, with the Samurai 5- spd Manual Transmission. Donor engines with Automatic Transmissions (3 or 4 A/T) are easily rewired to work with the Samurai 5-spd M/T. Specific notations for installing the donor engine with a 3 A/T appear where necessary. The 4 A/T is significantly more complicated and is not included in these instructions. 1.4. It is preferred (but not required) that the ECM and engine be of the same model year. However, as long as the computer has all the necessary inputs and outputs it makes no difference what motor it is physically controlling. It should be noted that OBD1 vehicles (1995 & earlier) are much less complex than OBD2 vehicles (1996 & after). The earlier technology is far easier for the amateur auto electrician to manage. OBD2, being more modern, has nearly twice as many sensors & controls. Properly tuned, OBD2 engines will provide slightly more power, better fuel economy, and cleaner emissions. Replacement parts are also easier to find, but of course, are more expensive.

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Valve clearance [Engine cold] Compression Front oil seal press-in amount Cylinder Head Bolt Length L Cylinder Head Bolt Maximum Oil control valve resistance Ignition timing Idle speed Idle mixture Oil pressure (reference value) [oil temperature: 100° C {212°F}] Engine oil capacity (approx. quantity) (AT, 5MT) Engine oil capacity (approx. quantity) (AT, 5MT) Engine oil capacity (approx. quantity) (6MT) Engine coolant capacity (approx. quantity) Cooling system cap valve opening pressure Thermostat initial-opening temperature Thermostat full-open temperature Thermostat full-open lift Cooling fan motor current Fuel line pressure 250 kPa {2.55 kgf/cm2 , 36.2 psi} or more Fuel injector resistance 11.4-12.6 ohms [20°C {68°F}] Fuel injector leakage amount Less than 1 drop/2 min Fuel injection volume 204-216 ml {204-216 cc, 12.5-13.1 cu in}/min Battery electrolyte specific gravity [20°C {68°F}] 1.22-1.29 Battery load test current 46B24L (36): 135 A Battery back-up current Vehicles with immobilizer system: 25-45 mA Vehicles without immobilizer system: 30 mA or less Battery slow charge current 46B24L (36): 3.5-4.5 A Battery quick charge current [30 min,] 46B24L (36): 25 A Terminal B: B+ Terminal P: Approx. 1 V or less Generator standard voltage [IG-ON] Fuel hold pressure

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Condition General Motors has decided to conduct a Voluntary Emission Campaign involving certain 1997, 1998 and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located in fifteen U.S. high salt corrosion states and in Ontario. Quebec and Atlantic provinces; and certain 1995, 1996, 1997, 1998, and 1999 Chevrolet Cavalier and Pontiac Sunfire model vehicles located Manitoba, Saskatchewan, Alberta, British Columbia, the Yukon and Northwest Territories. These vehicles have the potential to experience moisture entering the Powertrain Control Module (PCM), as a result of corrosion after extended exposure to road salt, Moisture entering the PCM can lead to symptoms including illumination of the Check Engine light or the engine running rough. If these symptoms are ignored, the engine may stall and may not be able to be restarted.

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APPLICABLE MODEL(S)/VINS 1995-2007 B-Series (A/T only) 1997-2003 Protege (A/T only) 1997-2005 Miata (A/T only) 1997-2002 626 (A/T only) 1997-2002 Millenia (A/T only) 1997-2006 MPV (A/T only) 2001-2006 Tribute (A/T only) 2003-2007 Mazda6 (A/T only) 2004-2007 Mazda3 (A/T only) 2004-2007 RX-8 (A/T only) 2006-2007 Mazda5 (A/T only) 2006-2007 MX-5 (A/T only) 2007 CX-7 (A/T only) DESCRIPTION Automatic Transmission (A/T) oil cooler/lines must be power flushed completely before an overhauled or replacement A/T is installed. One of the causes of repeat A/T failures is an internal automatic transmission fluid (ATF) restriction at the inlet side of the oil cooler. This restriction is usually caused by an accumulation of metal particles and debris (from a previous A/T failure) on the internal mesh type baffle of the oil cooler. Power flush- ing will remove the restriction by back flushing the cooler/lines followed by forward flushing. This will in turn ensure full ATF flow for the transmission when it is operating.NOTE: Repeat repairs caused by improper or lack of cooler line flushing will not be covered under warranty, and are subject to review and debit by Mazda Recommended Power Flushing Equipment