General Information: Removal & Installation Mazda 3 BK

Removal Of Parts

1. While correcting a problem, also try to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.

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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.

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1. When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems.

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1. All disassembled parts should be carefully arranged for reassembly.
2. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

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1. All parts to be reused should be carefully and thoroughly cleaned in the appropriate method. WARNING: Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective eye wear whenever using compressed air.

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1. Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
2. If removed, the following parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts
3. Depending on location: 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.

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1. Use suitable gauges and testers when making adjustments.

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1. Prevent gasoline or oil from getting on rubber parts or tubing.

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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.

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1. When using a torque wrench- SST or equivalent combination, the written 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.

TORQUE SPECIFICATION

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

L : The length of the torque wrench.

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1. When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

INSTALLATION OF RADIO SYSTEM

1. If a radio system is installed improperly or if a high-powered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions: Install the antenna at the farthest point from control modules. Install the antenna feeder as far as possible from the control module harnesses. Ensure that the antenna and feeder are properly adjusted. Do not install a high-powered radio system.

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1. Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable.

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1. To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.

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1. When disconnecting connector, grasp the connectors, not the wires.
2. Connectors can be disconnected by pressing or pulling the lock lever as shown.

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1. When locking connectors, listen for a click indicating they are securely locked.

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1. When a tester is used to inspect for continuity or measuring voltage, insert the tester probe from the wiring harness side.
2. Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the wiring harness side.

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1. Pull lightly on individual wires to verify that they are secured in the terminal.

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1. Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely.
2. Insert a thin piece of metal from the terminal side of the connector and with the terminal locking tab pressed down, pull the terminal out from the connector.

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1. Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.

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1. Two-color wires are indicated by a two-color code symbol.
2. The first letter indicates the base color of the wire and the second the color of the stripe.

WIRING COLOR CODES

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1. When replacing a fuse, be sure to replace it with one of the same capacity. If a fuse fails again, the circuit probably has a short and the wiring should be inspected.
2. Be sure the negative battery terminal is disconnected before replacing a main fuse.
3. When replacing a pullout fuse, use the fuse puller.