Contents Section: Procedures All sections

Maintenance Information Mazda Navajo I

Procedures 6 illustrations ~1581 words

MODEL IDENTIFICATION

Note. For scheduled maintenance intervals and the related fluid capacities, fluid specifications and labor times for major service intervals, see SCHEDULED SERVICES article in this section. Warranty information and specifications for fluid capacities, lubrication specifications, wheel and tire size, and battery type are covered in this article.

VIN LOCATION

The Vehicle Identification Number (VIN) is stamped on a metal tab that is riveted to the instrument panel close to the windshield. The VIN number is easily seen through the front windshield on the driver's side. The VIN number is also found on the Safety Compliance Certification Label.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 2

Scheme 2: VIN Code ID Explanation

SEVERE & NORMAL SERVICE DEFINITIONS

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Normal Service

  1. Driven More Than 10 Miles Daily
  2. No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

  1. Short Trips (About 10 Miles) In Freezing Temperatures
  2. Towing Or Heavily Loaded
  3. Severe Dust Conditions
  4. Hot Weather, Stop-And-Go Driving
  5. Extensive Idling Conditions (Taxi Or Delivery Type Service)
  6. Snow Plowing
  7. High Speed Operation With Fully Loaded Vehicle

EXTREME SERVICE VEHICLES

If vehicle is operated off-highway, perform the following items every 1000 miles. If vehicle is operated in mud and/or water, perform the following items daily

  1. Lubricate front axle, steering and clutch linkages, axle and drive shaft U-joints, and slip yoke if equipped with fittings.
  2. Lubricate automatic transmission external controls (cables).
  3. Inspect front wheel bearings and lubrication.
  4. Inspect disc and drum brake systems, hoses and lines, lube caliper slide rails.
  5. Inspect exhaust system for leaks, damage and loose parts, and remove any foreign material trapped by shielding.

Scheme 3

Scheme 3: SERVICE POINT LOCATIONS

SERVICE LABOR TIMES

Note. Labor times are provided, where available, within appropriate SERVICE INTERVAL table in SCHEDULED SERVICES article.

TIRE INFLATION

Inflation pressure can be found on Safety Compliance Certification Label decal attached to rear face of left door or door pillar.

WHEEL TIGHTENING

Tighten wheel lug nuts to 100 ft. lbs. (135 N.m). If wheels are equipped with locking lug nuts, position KEYED nut opposite valve stem.

BATTERY SPECIFICATIONS

CAUTIONWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION Section.

If battery is replaced, new battery should be of same group number as shown on original battery's label.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG SYSTEM

Note. See the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT Section.

The SRS has no user-servicable parts. Always have servicing done by an authorized dealer.

When performing maintenance on air bag equipped vehicles always observe proper safety precautions.

WARNINGTo avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.
CAUTIONDisconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

ANTI-LOCK BRAKE SYSTEM (ABS)

CAUTIONNever mix different diameter tires. On loose or uneven surfaces, the ABS system may require longer stopping distances than conventional brake systems. Exercise caution when removing mud or snow from the wheels so as not to damage the ABS wiring or speed sensors.

BATTERY WARNING

WARNINGWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See appropriate COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section below.

REPLACING BLOWN FUSES

CAUTIONBefore replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

CAUTIONIndicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

CAUTIONContinued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and vehicle.

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

CAUTIONTo avoid possible damage to vehicle use only ethylene-glycol based coolants with a mixture ratio from 44-68% anti-freeze. DO NOT use 100% anti-freeze as it will cause the formation of cooling system deposits. This results in coolant temperatures of over 300° F (149°C) which can melt plastics. 100% anti-freeze has a freeze point of only -8° F (-22°C).
CAUTIONPropylene-Glycol Mixtures has a smaller temperature range than Ethylene-Glycol. The temperature range (freeze-boil) of a 50/50 Anti-Freeze/Water Mix is as follows: Propylene-Glycol -26° F (-32°C) - 257° F (125°C) Ethylene-Glycol -35° F (-37°C) - 263° F (128°C)
CAUTIONPropylene-Glycol/Ethylene-Glycol Mixtures can cause the destabilization of various corrosion inhibitors. Also Propylene-Glycol/Ethylene-Glycol has a different specific gravity than Ethylene-Glycol coolant, which will result in inaccurate freeze point calculations.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNINGMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

ENGINE OIL

CAUTIONNever use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component (fuel injection models).

HALOGEN BULBS

WARNINGHalogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

RADIATOR CAP

CAUTIONAlways disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNINGKeep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

FUEL PUMP SHUT-OFF SWITCH

This switch stops flow of fuel to engine after a collision. Impact does not have to be great for switch to be triggered. To reset switch, press White reset button on switch, located under instrument panel, right of transmission hump.

CHECKING AUTOMATIC TRANSMISSION FLUID

When checking ATF, have 4x4 gear selector in any position other than NEUTRAL.

4WD

Due to lack of differential action between front and rear axles, driving in 4L or 4H on dry, hard-surfaced roads may cause unnecessary noise and tire wear. Driving in 2H is recommended under these conditions.

WARRANTY INFORMATION

CAUTIONAlways refer to customer copy of warranty information for specific model application and/or coverage limitations .

BASIC NEW CAR WARRANTY

Basic components are warranted against defects in materials and workmanship for 36 months or 50,000 miles, whichever occurs first. Tires are covered by a separate warranty offered by tire manufacturer.

ANTI-PERFORATION WARRANTY

Covers body sheet metal panels for 60 months, regardless of mileage, against perforation due to corrosion.

SAFETY RESTRAINT SYSTEM WARRANTY

Supplemental air bag system, seat belts and related components are warranted for 5 years or 60,000 miles, whichever comes first, against defects in materials and workmanship.

REPLACEMENT PARTS & ACCESSORIES

Manufacturer-supplied parts and accessories are warranted against defects in material and workmanship for 12 months without regard to mileage. If installed by a Mazda dealer, part or accessory will be repaired or replaced without charge during warranty period. If not installed by a dealer, part or accessory will be repaired or replaced without charge for parts, but labor cost will be responsibility of owner.

EMISSION DEFECT WARRANTY (EXCEPT CALIFORNIA)

Warrants that vehicle was designed, built and equipped to conform with applicable Federal emission regulations at time of sale and that vehicle is free of defects in materials and workmanship which may cause vehicle to fail to conform with applicable regulations for 5 years or 50,000 miles, whichever occurs first.

EMISSION PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)

Covers all repairs, adjustments and replacements if vehicle fails to conform to applicable emission standards and such failure results in vehicle owner bearing a penalty or other sanction under local, state or Federal law. Warranty period is 5 years or 50,000 miles, whichever comes first. After 2 years or 24,000 miles, manufacturer will make necessary adjustments, repairs and replacements at no cost to owner only when noncompliance is caused by failure of components which have been installed in vehicle for sole or primary purpose of reducing vehicle emissions. See copy of warranty for specific components covered.

EMISSION DEFECT WARRANTY (CALIFORNIA)

For 3 years or 50,000 miles, whichever occurs first, if any emission-related part on vehicle is defective, it will be repaired or replaced by manufacturer at no cost to owner. Certain emission-related parts are covered for repair or replacement for 7 years or 70,000 miles, whichever occurs first. See copy of warranty for specific components covered.

EMISSION PERFORMANCE WARRANTY (CALIFORNIA)

For 3 years or 50,000 miles, manufacturer will make all necessary repairs and adjustments to ensure vehicle passes a required Smog Check inspection.

FUSE PANEL LOCATION

Vehicle has a fuse panel and a Power Distribution Box (PDB). Fuse panel is located under instrument panel, left of steering column. PDB is located on right side of engine compartment.

CAUTIONAlways replace a fuse with one of correct amperage rating. Using a fuse with a higher amperage rating can cause severe wire damage and could possibly start a fire.

Scheme 4

Scheme 4: FUSE PANEL IDENTIFICATION (1991-93)

Fuse & Circuit Breaker Identification

  1. A - 15 Amp - 4-Way Flasher, Stoplights, Speed Control Inhibit
  2. B - 6 Amp (Circuit Breaker) - Windshield Washer/Wiper
  3. C - 15 Amp - Dome Lights, Courtesy Lights
  4. D - 20 Amp - Horn
  5. E - 10 Amp - A/C Switches, A/C Clutch Coil
  6. F - 15 Amp - Rear Window Washer/Wiper
  7. G - 15 Amp - Turn Lights, Back-Up Lights, Rear Defroster
  8. H - 10 Amp - Instrument Panel Illumination
  9. I - 20 Amp (Circuit Breaker) - Cigarette Lighter, Flash To Pass, Power Lumbar
  10. J - 15 Amp - Cruise Control Amp, Electric 4WD, Radio
  11. K - 15 Amp - Park Lights, License Light
  12. L - 30 Amp - Blower Motor
  13. M - 20 Amp - Premium Radio Amplifier, Trailer Towing
  14. N - 20 Amp - Rear Anti-Lock Brake System Module
  15. O - 30 Amp (Circuit Breaker) - Power Windows
  16. P - 10 Amp - HEGO heater
  17. Q - 15 Amp - Cluster Warning Lights

Scheme 5

Scheme 5: FUSE PANEL IDENTIFICATION (1994)
  1. A - 15 Amp (Lt. Blue) - 4-Way Flasher, Stoplights
  2. B - 6 Amp (Circuit Breaker) - Front Windshield Washer/Wiper
  3. C - 15 Amp (Lt. Blue) - Dome Lights, Courtesy Lights, Power Mirrors
  4. D - 20 Amp (Yellow) - Horn
  5. E - 15 Amp (Lt. Blue) - Cluster Warning, Electric All Wheel Drive
  6. F - 10 Amp (Red) - Speed Control
  7. G - 15 Amp (Lt. Blue) - Turn Lights, Back-Up Lights, Rear Defroster, Blower
  8. H - 10 Amp (Red) - Instrument Panel Illumination
  9. I - 20 Amp (Circuit Breaker) - Cigarette Lighter, Flash To Pass, Power Lumbar
  10. J - 15 Amp (Lt. Blue) - Radio, Cruise Control Amp
  11. K - 15 Amp (Lt. Blue) - Park Lights, License Lights, Trailer Towing
  12. L - 10 Amp (Red) - A/C Switches, A/C Clutch Coil
  13. M - 20 Amp (Yellow) - Premium Radio Amplifier
  14. N - 10 Amp (Red) - Anti-Lock Brake System Module
  15. P - 30 Amp (Circuit Breaker) - Power Windows
  16. Q - 15 Amp (Lt. Blue) - HEGO heater
  17. R - 15 Amp (Lt. Blue) - Rear Window Washer/Wiper

Scheme 6

Scheme 6: POWER DISTRIBUTION BOX IDENTIFICATION (1991-92)
  1. 1 - 30 Amp - Electric Fuel Pump
  2. 2 - 40 Amp - Headlight Switch Feed
  3. 3 - Blank
  4. 4 - 40 Amp - Fuse Panel
  5. 5 - 30 Amp - Power Locks
  6. 6 - 40 Amp - Rear Window Defroster
  7. 7 - Blank
  8. 8 - 30 Amp - Electronic Engine Control Relay
  9. 9 - 40 Amp - Electric 4x4 Transfer Case Shift
  10. 10 - 60 Amp - Ignition Switch Feed
  11. 11 - 15 Amp (Not Shown) - Underhood Light
  12. 12 - 15 Amp (Not Shown) - Alternator

Scheme 7

Scheme 7: POWER DISTRIBUTION BOX IDENTIFICATION (1993-94)
  1. 1 - 60 Amp - Ignition, Interior Fuse Panel
  2. 2 - 40 Amp - Headlight Switch Feed
  3. 3 - 60 Amp - Fuse Panel
  4. 4 - 30 Amp - Electronic Engine Control
  5. 5 - 50 Amp - Blower Motor
  6. 6 - 30 Amp - Power Door Locks
  7. 7 - 20 Amp - Electric All Wheel Drive
  8. 8 - 60 Amp - Power Seats
  9. 9 - 30 Amp - ABS Pump
  10. 10 - 30 Amp - ABS Control Unit
  11. 11 - 40 Amp - Rear Window Defogger
  12. 12 - Not Used
  13. 13 - Not Used
  14. 14 - Not Used
  15. 15 - Not Used
  16. 16 - 15 Amp - Alternator
  17. 17 - 15 Amp - Hood Light
  18. 18 - 20 Amp - Fuel Pump
  19. 19 - 20 Amp - Trailer Towing
  20. 20 - Not Used
  21. 21 - Not Used
  22. 22 - Not Used