Mazda1985–2003Technical specifications

E Series 2.2: Technical specifications

Workshop data for the 2.2-litre diesel (engine code R2). Covers engine, fluids, brakes, service, torques and air conditioning: the figures to check before a job or a parts order.

Summary

Match the engine code (R2) to the vehicle before ordering parts or applying these figures.

Vehicle specifications

Overview

Make: Mazda
Model: E Series
Years: 1985–2003
Fuel: Diesel
Engine code: R2

Performance & efficiency

Power: 47 kW (64 hp)
Engine size: 2,184 cc
Cylinders: 4 · OHC
Compression ratio: 22.9:1

Fluids & capacities

Engine oil (with the filter): 5.8 litres

All 109 specifications below

Engine & identification

Vehicle identification

No. of cylinders Type	4/OHC
Capacity cc	2184
Compression ratio :1	22,9

Injection system

Fuel/injection pump assembly Make	Kiki
Fuel/injection pump assembly Type	VE
Fuel/injection pump assembly Part No.	104748-0151
Pump type	Rotary
Injector nozzle Make	Bosch Kiki
Nozzle opening pressure - new/used bar	135/116
Leak rate (dribble) bar/secs	113/10

Injection sequence

The injection sequence for the Mazda E Series 2.2 (1985–2003) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances for the Mazda E Series 2.2 (1985–2003) are 0,25 mm inlet and 0,35 mm exhaust, measured cold.

Valve clearance - INLET mm	0,25 cold
Valve clearance - EXHAUST mm	0,35 cold

Engine oil & fluids

Engine oil

The Mazda E Series 2.2 (1985–2003) takes 5.8 litres of engine oil with the filter.

See the reference table for the complete engine oil entries and their conditions.

Manual gearbox

The manual gearbox has a listed capacity of 2.5 litres. The specified oil is SAE 75W-80.

Coolant

The listed total cooling-system capacity is 9.0 litres.

Grades, filling conditions and capacities

Lubricants and capacities — complete reference
Engine oil options
Ambient temperature range	➞-10°C
Engine oil grade SAE	5W-30
Engine oil classification API/ACEA	CF/B2
Ambient temperature range	-25°C➞30°C
Engine oil grade SAE	10W-30
Engine oil classification API/ACEA	CF/B2
Ambient temperature range	-15°C➞35°C
Engine oil grade SAE	15W-40
Engine oil classification API/ACEA	CF/B2
Engine with filter(s) litres	5.8
Other lubricants and capacities
Manual transmission oil grade SAE	75W-80
Manual transmission litres	2.5
Automatic transmission fluid Type	Dexron II
Automatic transmission (dry fill) litres	7.5
Differential oil grade - rear SAE	90W
Differential rear litres	1.3
Cooling system - total capacity litres	9.0
Brake fluid Type	DOT 3/4
Power steering fluid Type	Dexron II
Power steering fluid litres	1.0

Brakes & wear limits

Brake disc thickness

Front brake discs on the Mazda E Series 2.2 (1985–2003) are replaced at a minimum thickness of 18 mm (ventilated).

Minimum disc thickness for replacement - ventilated Front	18 mm

Brake disc and drum dimensions

Minimum pad thickness Front	2 mm
Minimum shoe thickness Rear	1 mm

Service & electrical

Glow plugs

Glow plugs for the Mazda E Series 2.2 (1985–2003): Beru 705 MJ, Bosch 0 250 202 007, Champion CH97 and Lucas/CAV DS026.

Glow plug nominal rating V/A	10,5/16,5
Glow plug activation time secs	20 Max
Glow plug - part no. Beru	705 MJ
Glow plug - part no. Bosch	0 250 202 007
Glow plug - part no. Champion	CH97
Glow plug - part no. Lucas/CAV	DS026

Tuning and emissions

Plunger travel (pump) mm ABDC	1,0
Crankshaft position (n = ATDC) °BTDC	2
Adjusting method Engine/Pump	Pointer/Dial gauge
Dynamic timing v = BTDC, n = ATDC	v
- Time Trac Stanadyne, Snap-on °/rpm	12/780
Idle speed rpm	725±25
Rated no load speed rpm	5100
Oil temperature °C	60
Idle speed - for smoke test rpm	700-750
Governed speed range - for smoke test rpm	4700-4900
Maximum time at governed speed secs	1,0
Test mode A/B	B
Probe type 1/2	1
Smoke opacity - EU limit m-1 (%)	2,50 (66)

Starting and charging

Starter motor Make	Mitsubishi
Starter motor Type	12V/2,0 kW
Alternator Make	Mitsubishi
Alternator output A/V/rpm	50/12/2500
Regulated voltage V	14,7±0,3

Service checks and adjustments

Compression pressure bar	26-29
Oil pressure bar/rpm	4,1-4,9/3000
Radiator cap bar	0,75-1,05
Thermostat opens °C	86,5-89,5
Drive belt size - alternator mm	12,5x1100
Drive belt size - PAS/AC mm	12,5x875
Drive belt tension - alternator/PAS/AC mm	12-14
Drive belt size - AC mm	12,5x900
Drive belt tension - AC mm	5-6

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Mazda E Series 2.2 (1985–2003) are tightened in 3 stages: 30 Nm, then 90°, then a final 90°.

Cylinder head
Maximum bolt length	114,5 mm
Tighten	30 Nm
Tighten	90°
Tighten	90°

Other engine tightening torques
Cylinder head instructions	—
Main bearings Renew bolts/nuts	No
Main bearings Stage 1	40 Nm
Main bearings Stage 2	85 Nm
Big end bearings Renew bolts/nuts	No
Big end bearings Stage 1	33 Nm
Big end bearings Stage 2	67 Nm
Oil pump to cylinder block	M8=22 Nm M10=45 Nm
Sump bolts	8-11 Nm
Sump drain bolt	29-41 Nm
Flywheel/driveplate	162-171 Nm
Clutch pressure plate	22-32 Nm
Crankshaft pulley/damper centre bolt	167-176 Nm
Camshaft sprocket/gear	57-66 Nm
Camshaft carrier/cap	20-26 Nm
Camshaft/rocker cover	7-10 Nm
Inlet manifold to cylinder head	19-25 Nm
Exhaust manifold to cylinder head	22-26 Nm
Injector/clamp	65 Nm
Injector pipe unions	23 Nm
Injector nozzle to holder	60-70 Nm
Fuel/injection pump sprocket/gear	75 Nm
Fuel/injection pump flange	23 Nm
Fuel/injection pump mounting	46 Nm
Glow plugs	18 Nm
Chassis tightening torques
Steering track rod end	60-80 Nm
Brake caliper to carrier Front	90 Nm
Brake caliper/carrier to hub Front	100 Nm
Road wheels	90-120 Nm

Air conditioning

No. of AC service connectors	2
Air conditioning restrictor type	Expansion valve
Compressor clutch/magnetic coupling	Yes
Compressor variable displacement solenoid	No
Air conditioning refrigerant Type	R12
Air conditioning refrigerant quantity grams	1600
Air conditioning oil Type	Suniso 5GS

Frequently asked questions

What is the injection sequence of the Mazda E Series 2.2?

The injection sequence for the Mazda E Series 2.2 (1985–2003) is 1-3-4-2.

What glow plugs does the Mazda E Series 2.2 use?

Glow plugs for the Mazda E Series 2.2 (1985–2003): Beru 705 MJ, Bosch 0 250 202 007, Champion CH97 and Lucas/CAV DS026.

How much oil does the Mazda E Series 2.2 take?

The Mazda E Series 2.2 (1985–2003) takes 5.8 litres of engine oil with the filter. See the reference table for the complete engine oil entries and their conditions.

What are the valve clearances for the Mazda E Series 2.2?

Valve clearances for the Mazda E Series 2.2 (1985–2003) are 0,25 mm inlet and 0,35 mm exhaust, measured cold.

What is the cylinder head torque for the Mazda E Series 2.2?

The cylinder head bolts on the Mazda E Series 2.2 (1985–2003) are tightened in 3 stages: 30 Nm, then 90°, then a final 90°.

What is the minimum brake disc thickness for the Mazda E Series 2.2?

Front brake discs on the Mazda E Series 2.2 (1985–2003) are replaced at a minimum thickness of 18 mm (ventilated).