General Information: Other Mazda 2 II рестайлинг

Range of Topics

1. This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: Removal/Installation Disassembly/Assembly Replacement Inspection Adjustment
2. Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.

Scheme 23

1. Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations. (Scheme 23): Inspecting Fluid Pressure Using SST

Scheme 24

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part. (Scheme 24): Procedural Explanation

Symbols

1. There are nine symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service.

Scheme 25

Advisory Messages

1. You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual.

Note. A Note provides added information that will help you to complete a particular procedure.

Specification

1. The values indicate the allowable range when performing inspections or adjustments.

Upper and lower limits

1. The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

Typical DTC Troubleshooting Flow Chart. Scheme 26

UNITS

Conversion to SI Units (System International d'Units)

1. All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values.

Rounding Off

1. Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.

Upper and Lower Limits

1. When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm 2 in the following specifications
2. 210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}
3. 270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
4. The actual converted values for 2.7 kgf/cm 2 are 264 kPa and 38.4 psi. In the first specification, 2.7 is used as an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is used as a lower limit, so the converted values are rounded up to 270 and 39.

Injury/damage Prevention Precautions

1. Depending on the vehicle, the cooling fan may operate suddenly even when the ignition is switch to off. Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing the cooling fan or parts near the cooling fan.

Scheme 27

1. Always be sure to cover fenders, seats and floor areas before starting work. (Scheme 27): Identifying Vehicle Cover Fenders

Scheme 28

1. Be sure that all necessary tools and measuring equipment are available before starting any work. (Scheme 28): Precaution For Preparation Of Tools And Measuring Equipment

Scheme 29

1. Use special service tools or the equivalent when they are required. (Scheme 29): Identifying Special Service Tools

Negative Battery Cable Disconnection/connection

Warning

1. Before removing the SRS air bag system-related parts, always disconnect the negative battery cable and wait for 1 min. or more to allow the back-up power supply to deplete its stored power. (See «AIR BAG SYSTEM SERVICE WARNINGS»(ref-517434-S35063875162012121200000) .)

Negative battery cable disconnection/required procedures after connecting

Using UV light (black light)

1. Remove any oil on the engine or transmission/transaxle. NOTE: Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or transmission/transaxle oil.
2. Pour the fluorescent dye into the engine oil or transmission/transaxle oil.
3. Allow the engine to run for 30 min .
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min . or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs. NOTE: To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the fluorescent dye instruction manual.

Scheme 30

1. Gather sample of the leaking oil using an absorbent white tissue.
2. Then, gather some samples of engine and transaxle oil onto a white cloth or piece of paper. MT vehicles: Transmission/transaxle oil AT vehicles: ATF
3. Compare the appearance and smell, and identify the type of oil that is leaking. (Scheme 30): Identifying Leaking Oil On Engine And Transmission/Transaxle
4. Remove any oil on the engine or transmission/transaxle.
5. Allow the engine to run for 30 min.
6. Check the area where the oil is leaking, then make necessary repairs.

Scheme 31

1. While correcting a problem, also try to determine its cause. Begin work only after first learning which parts and sub-components must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering. (Scheme 31): Precaution For Removal Parts

Scheme 32

1. If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance, and identified so that reassembly can be performed easily and efficiently. (Scheme 32): Locating Marked Parts

Scheme 33

1. When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems. (Scheme 33): Removing And Inspecting Parts

Scheme 34

1. All disassembled parts should be carefully arranged for reassembly. (Scheme 34): Identifying Parts Arrangement
2. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

Scheme 35

1. All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. (Scheme 35): Cleaning Parts

Scheme 36

Scheme 37

1. Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. (Scheme 36): Loosening Nut
2. If removed, these parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts
3. Depending on location: (Scheme 37): Applying Grease On Sealant And Gaskets Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. Oil should be applied to the moving components of parts. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.

Scheme 38

1. Use suitable gauges and testers when making adjustments. (Scheme 38): Adjusting Engine Component Using Gauges

Scheme 39

1. Prevent gasoline or oil from getting on rubber parts or tubing. (Scheme 39): Precaution For Rubber Parts And Tubing

Scheme 40

1. When reinstalling, position the hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit. (Scheme 40): Locating Hose Clamp

Scheme 41

1. When using a torque wrench- SST or equivalent combination, the specified torque must be recalculated due to the extra length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you. (Scheme 41): Identifying Torque Wrench Length

A The length of the SST past the torque wrench drive.

L The length of the torque wrench.

Scheme 42

1. When using a vise, put protective plates in the jaws of the vise to prevent damage to parts. (Scheme 42): Identifying Protective Plates

Dynamometer

1. When inspecting and servicing the power train on the dynamometer or speedometer tester, pay attention to the following: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Make sure the vehicle is in a facility with an exhaust gas ventilation system. Keep the rear bumper cool by placing a cooling fan near the exhaust pipe so that the rear bumper does not get deformed by the heat from the exhaust. Keep the area around the vehicle uncluttered so that heat does not build up. Watch the water temperature gauge and do not overheat the engine. Avoid added load to the engine and maintain normal driving conditions as much as possible.

Note. When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the DSC HU/CM determines that there is a malfunction in the DSC and illuminates the following lights: ABS warning light Brake system warning light DSC indicator light If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and switch the ignition to off. Then, switch the ignition to ON, run the vehicle at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the memory. Clear the DTC from the memory by following the memory clearing procedure [DSC] in the on-board diagnostic system. (See ON-BOARD DIAGNOSIS [DYNAMIC STABILITY CONTROL (DSC)] .)

SST

1. Some global SST or equivalent are used as SSTs necessary for vehicle repair. Note that these SSTs are marked with global SST numbers.
2. Note that a global SST number is written together with a corresponding Mazda SST number as shown below.

Example (SST List)

Identifying Crankshaft Damper Remover (SST List). Scheme 43

Example (In text)

Identifying Crankshaft Damper Remover (Mazda SST Number With Global SST Number). Scheme 44

Viewing orientation for Connectors

1. The viewing orientation for connectors is indicated with a symbol.
2. The figures showing the viewing orientation are the same as those used in Wiring Diagrams.
3. The viewing orientations are shown in the following three ways.

Part-side connector

The viewing orientation for part-side connectors is from the terminal side.

Identifying PCM Connector Terminals (Part-Side Connector). Scheme 45

* Part names are shown only when there are multiple connector drawings.

Other

When it is necessary to show the terminal side of the vehicle wiring harness-side connectors, such as the following connectors, the viewing orientation is from the terminal side.

Identifying DLC-2 Connector Terminals. Scheme 46

1. Main fuse block and the main fuse block relays
2. Data link connector
3. Check connector
4. Relay box

Identifying Jumper Wire. Scheme 47

Scheme 48

1. The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage will be measured and the negative (-) probe (black lead wire) to a body ground. (Scheme 48): Measuring Circuit Voltage Using DC Voltmeter

Precaution For Measuring Resistance Between Power Source Line And Ground Line Using Ohmmeter. Scheme 49

Precautions Before Welding

A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be sure to perform the following procedure.

Scheme 50

Scheme 51

1. Switch the ignition to off.
2. Disconnect the battery cables. (Scheme 50): Disconnecting Battery Cables
3. Securely connect the welding machine ground near the welding area. (Scheme 51): Connecting Welding Machine Ground Welding Area
4. Cover the peripheral parts of the welding area to protect them from weld spatter.

Jacking Positions

Front

Note. To prevent obstruction between the jack body and front bumper when the jack body is inserted, use a low-floor type jack. Near the center of the front suspension crossmember.

Rear

1. Near the center of the rear torsion beam.

Identifying Front/Rear Jacking Points And Block Wheels. Scheme 52

Front and rear

Identifying Vehicles Side Step Molding Vehicle Lift Points. Scheme 53

Scheme 54

1. Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed.
2. A towed vehicle usually should have its drive wheels (front wheels) off the ground. If excessive damage or other conditions prevent this, use wheel dollies. (Scheme 54): Lifting Towing Vehicle
3. When towing with the rear wheels on the ground, release the parking brake.

Don't Tow Vehicle Pointed Backward With Driving Wheels On Ground. Scheme 55

Don't Tow With Sling-Type Equipment. Scheme 56

Scheme 57

1. When transporting the vehicle by flat bed tow truck or trailer, secure the vehicle to the trailer using the holes and left tiedown loop shown in the figure. (Scheme 57): Identifying Left Tiedown Loop Points

Scheme 58

Scheme 59

1. The VIN marking position is located on the floor on the front passenger-side. (Scheme 58): Identifying Vehicle Identification Number (VIN)
2. If the VIN plate is adhered to the dashboard, it is located in the position shown in the figure. (Scheme 59): Identifying VIN Plate

Identifying Engine Identification Number. Scheme 60

SAE STANDARDS

1. In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and abbreviations are now used in this manual. The table below lists the names and abbreviations that have been used in Mazda manuals up to now and their SAE equivalents.

1. #1: Diagnostic trouble codes depend on the diagnostic test mode.
2. #2: Controlled by the PCM
3. #3: Device that controls engine and powertrain
4. #4: Directly connected to exhaust manifold

Exterior

INSPECT and ADJUST , if necessary, the following items to specification

Glass, exterior bright metal and paint for damage

Wheel lug nuts

All weatherstrips for damage or detachment

Tire pressures

Headlight cleaner and fluid level (if equipped)

Operation of hood release and lock

Operation of trunk lid and fuel-filler lid opener

Door operation and alignment including side door and back door

Headlight aiming INSTALL the following parts

Flap (if equipped)

Under hood-engine off

INSPECT and ADJUST , if necessary, the following items to specification

Fuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks

Engine oil level

Brake and clutch fluid level

Windshield washer reservoir fluid level

Coolant level and specific gravity

Tightness of water hose clamps

Tightness of battery terminals, electrolyte level and specific gravity

Tension of drive belt

Interior

INSTALL the following items

Fuse for accessories INSPECT the operations of the following items

Seat controls (slide and recline) and headrests

Folding rear seat

Door locks, including childproof door locks

Seat belts and warning system

Ignition switch and steering lock

Transaxle range switch

Warning buzzers

Ignition key reminder alarm

Air bag system using warning light

Cruise control system (if equipped)

Power door lock

Shift-lock system (if equipped)

Starter interlock

All lights including warning, and indicator lights

Horn, wipers, and washers

Wiper blades performance Clean wiper blades and windshield, if necessary

Audio system

Cigarette lighter and clock

Power windows (if equipped)

Heater, defroster, and air conditioner at various mode selections (if equipped)

INSPECT the following items

Presence of spare fuse

Upholstery and interior finish

INSPECT and ADJUST , if necessary, the following items

Operation and fit of windows

Pedal height and free play of clutch and brake pedal

Parking brake

Under hood-engine running at operating temperature

INSPECT the following items

Automatic transaxle fluid level

Operation of idle-up system for electrical load, air conditioner or power steering (if equipped)

Ignition timing

Idle speed

Operation of throttle position sensor

On hoist

INSPECT the following items

Manual transaxle oil level

Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks

Tires for cuts or bruises

Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage

Schedule 1: (Normal Driving Conditions) for U.S.A.

1. The vehicle is mainly operated where none of the "unique driving conditions" apply.

Chart symbols

1. I : Inspect: Inspect and clean, repair, adjust, fill up, or replace if necessary.
2. R : Replace
3. C : Clean
4. L : Lubricate
5. T : Tighten Remarks
6. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
7. Refer below for a description of items marked* in the maintenance chart. *1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.

Schedule 2: CANADA, Puerto Rico, and (Unique Driving Conditions) for U.S.A.

1. Repeated short-distance driving
2. Driving in dusty conditions
3. Driving with extended use of brakes
4. Driving in areas where salt or other corrosive materials are used
5. Driving on rough or muddy roads
6. Extended periods of idling or low-speed operation
7. Driving for long periods in cold temperatures or extremely humid climates
8. Driving in extremely hot conditions
9. Driving in mountainous conditions continually

Chart symbols

1. I : Inspect: Inspect and clean, repair, adjust, fill up, or replace if necessary.
2. R : Replace
3. C : Clean
4. L : Lubricate
5. T : Tighten Remarks
6. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
7. Refer below for a description of items marked* in the maintenance chart. *1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant. *2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.