Mazda1997–2003Technical 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: 1997–2003
Fuel: Diesel
Engine code: R2

Performance & efficiency

Power: 52 kW (71 hp)
Engine size: 2,184 cc
Cylinders: 4 · OHC
Compression ratio: 22.9:1

Fluids & capacities

Engine oil (with the filter): 5.7 litres

All 88 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
Pump type	Rotary
Injector nozzle Make	Bosch Kiki

Injection sequence

The injection sequence for the Mazda E Series 2.2 (1997–2003) is 1-3-4-2.

Injection sequence	1-3-4-2

Valve clearances

Valve clearances for the Mazda E Series 2.2 (1997–2003) are 0,20-0,30 mm inlet and 0,30-0,40 mm exhaust, measured cold.

Valve clearance - INLET mm	0,20-0,30 cold
Valve clearance - EXHAUST mm	0,30-0,40 cold

Engine oil & fluids

Engine oil

The Mazda E Series 2.2 (1997–2003) takes 5.7 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-90, with classification GL-4.

Coolant

The listed total cooling-system capacity is 9.0 litres.

See the reference table for the complete coolant entries and their conditions.

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	CD
Ambient temperature range	-15°C➞40°C
Engine oil grade SAE	10W-30
Engine oil classification API/ACEA	CD
Engine with filter(s) litres	5.7
Other lubricants and capacities
Manual transmission oil grade SAE	75W-90
Manual transmission oil classification	GL-4
Manual transmission litres	2.5
Differential oil grade - rear SAE	90W
Differential rear litres	1.2-1.3
Coolant Type	FL22
Coolant Colour	Green
Cooling system - total capacity litres	9.0
Brake fluid Type	DOT 3/4
Clutch fluid Type	DOT 3/4
Power steering fluid Type	Dexron II
Power steering fluid litres	1.0

Brakes & wear limits

Brake disc thickness

Brake discs on the Mazda E Series 2.2 (1997–2003) are replaced at a minimum thickness of 22 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 271,5 mm.

Minimum disc thickness for replacement - ventilated Front	22 mm
Maximum drum diameter for replacement Rear	271,5 mm

Brake disc and drum dimensions

Disc thickness variation Front	0,015 mm
Disc runout Front	0,10 mm
Minimum pad thickness Front	2 mm
Minimum shoe thickness Rear	1 mm

Service & electrical

Tuning and emissions

Plunger travel (pump) mm ABDC	1,0
Adjusting method Engine/Pump	Pointer/Dial gauge
Idle speed rpm	725±25
Rated no load speed rpm	4950-5250
Oil temperature °C	80
Idle speed - for smoke test rpm	700-750
Governed speed range - for smoke test rpm	4950-5250
Maximum time at governed speed secs	1,0
Test mode A/B	B
Probe type 1/2	1
Smoke opacity - homologation value m-1 (%)	2,50 (66)

Service checks and adjustments

Compression pressure bar	26-29
Oil pressure bar/rpm	1,5/1000
Radiator cap bar	0,74-1,02
Thermostat opens °C	80-84

Tightening torques

Cylinder head bolt torque

The cylinder head bolts on the Mazda E Series 2.2 (1997–2003) are tightened in 3 stages: 29 Nm, then 90°, then a final 90°.

Cylinder head
Maximum bolt length	114,5 mm
Tighten	29 Nm
Tighten	90°
Tighten	90°

Other engine tightening torques
Cylinder head instructions	—
Sump bolts	10±1 Nm
Sump drain bolt	35±5 Nm
Clutch pressure plate	27±5 Nm
Crankshaft pulley/damper centre bolt	172±5 Nm
Camshaft sprocket/gear	60±5 Nm
Camshaft carrier/cap	23±3 Nm
Camshaft/rocker cover	10±1 Nm
Inlet manifold to cylinder head	24±2 Nm
Exhaust manifold to cylinder head	24±2 Nm
Exhaust downpipe to manifold	44±6 Nm
Water pump	22±3 Nm
Fuel/injection pump sprocket/gear	64±4 Nm
Glow plugs	17±2 Nm
Engine oil pressure switch	15±2 Nm
Chassis tightening torques
Rear hub	290±25 Nm
Steering wheel	45±5 Nm
Steering rack/box mounting	84±9 Nm
Steering track rod end	68±10 Nm
Brake caliper to carrier Front	88±5 Nm
Brake caliper/carrier to hub Front	120±7 Nm
ABS sensor Front	23±2 Nm
ABS sensor Rear	23±2 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	R134a
Air conditioning refrigerant quantity grams	700
Air conditioning oil group	PAG
Air conditioning oil Type	ZXL 100 PG
Air conditioning oil quantity cm³	150
Air conditioning oil viscosity ISO	46

Additional reference

Air brakes

Minimum pressure to deactivate spring brake bar	7-9

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 (1997–2003) is 1-3-4-2.

How much oil does the Mazda E Series 2.2 take?

The Mazda E Series 2.2 (1997–2003) takes 5.7 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 (1997–2003) are 0,20-0,30 mm inlet and 0,30-0,40 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 (1997–2003) are tightened in 3 stages: 29 Nm, then 90°, then a final 90°.

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

Brake discs on the Mazda E Series 2.2 (1997–2003) are replaced at a minimum thickness of 22 mm (ventilated) front; the rear brake drums are replaced at a maximum diameter of 271,5 mm.