General Information: Other Mazda 5 I

UNITS

UNITS CHART

Conversion to SI Units (Systme 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: 210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi} 270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
2. 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.

Scheme 16

1. Always be sure to cover fenders, seats and floor areas before starting work.

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1. Be sure that all necessary tools and measuring equipment are available before starting any work.

Scheme 18

1. Use special service tools or equivalent when they are required.

Disconnection of the Negative Battery Cable

1. Before beginning any work, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 min. to allow the backup power supply of the SAS control module to deplete its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is necessary to verify those memories before disconnecting the cable.
2. If the battery had been disconnected during vehicle maintenance or for other reasons, the window will not fully close automatically. Carry out the power window each switch initial setting. (See «POWER WINDOW MOTOR REMOVAL/INSTALLATION»(ref-244409-S40178658822006092100000) ).

Using UV light (black light)

1. Remove any oil on the engine or transaxle/transmission. NOTE: Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or ATF (or transaxle/transmission oil).
2. Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission 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 19

1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle/transmission oil), both from the dipstick, and place them next to the leaked oil already gathered on the tissue.
3. Compare the appearance and smell, and identify the type of oil that is leaking.
4. Remove any oil on the engine or transaxle/transmission.
5. Allow the engine to run for 30 min.
6. Check the area where the oil is leaking, then make necessary repairs.

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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 FORMULAS Torque Unit Formula N.m N.m x [L/(L+A)] kgf.m kgf.m x [L/(L+A)] kgf.cm kgf.cm x [L/(L+A)] ft.lbf ft.lbf x [L/(L+A)] in.lbf in.lbf x [L/(L+A)] 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.

Dynamometer

1. When inspecting and servicing the power train on the dynamometer or speed meter 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. Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be below 70°C {158°F} degrees. ) Keep the area around the vehicle uncluttered so that heat does not build up. Watch the water temperature gauge and don't 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 ABS CM determines that there is a malfunction in the ABS and illuminates the following lights: Vehicles with ABS ABS warning light Brake system warning light If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and turn the ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, 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 [ABS] in the on-board diagnostic system. (See «ABS ON-BOARD DIAGNOSIS»(ref-244367-S23556563482006092100000) ).

SST

1. Some global SST or equivalent are used as SSTs necessary for engine 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 (section 01-60)

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Example (except section 01-60)

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Direction of View for Connector

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

Part-side connector

The viewing direction of part-side connectors is from the terminal side.

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

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Other

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

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

Jumper wire

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1. A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch.

Scheme 37

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.

Ohmmeter

Scheme 38

1. The ohmmeter is used to measure the resistance between two points in a circuit and to inspect for continuity and short circuits.

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.

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1. Turn the ignition switch to the LOCK position.
2. Disconnect the battery cables.
3. Securely connect the welding machine ground near the welding area.
4. Cover the peripheral parts of the welding area to protect them from weld spatter.

Jacking Positions

1. Use safety stands to support the vehicle after it has been lifted.

Front

Note. To prevent obstruction between the jack body and front bumper when the jack body is inserted, use a low-floor type jack (frame height is 170 mm or less).

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1. Near the center of the front crossmember.

Rear

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1. At the center of the rear crossmember.

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1. Both sides of the vehicle, on side sills.

Towing

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 front wheels off the ground. If excessive damage or other conditions prevent this, use wheel dollies.
3. When towing with the rear wheels on the ground, release the parking brake.

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Tie Down Hooks

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1. Remove the tie down eyelet, lug wrench and jack lever from the trunk.
2. Wrap the jack lever with a soft cloth to prevent damage to the bumper and open the cap located on the front bumper. CAUTION: The cap cannot be completely removed. Do not use excessive force as it may damage the cap or scratch the painted bumper surface.
3. Securely install the tie down eyelet using the lug wrench.
4. Hook the tying rope to the tie down eyelet. CAUTION: If the tie down eyelet is not securely tightened, it may loosen or disengage from the bumper when tying down the vehicle. Make sure that the tie down eyelet is securely tightened to the bumper.

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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.

SAE STANDARDS

Exterior

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

1. Glass, exterior bright metal and paint for damage
2. Wheel lug nuts
3. All weatherstrips for damage or detachment
4. Tire pressures
5. Headlight cleaner and fluid level (if equipped)
6. Operation of hood release and lock
7. Operation of fuel-filler lid opener
8. Door operation and alignment including side door and back door
9. Headlight aiming

INSTALL the following parts

1. Wheel caps or rings (if equipped)

Underhood - Engine Off

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

1. Fuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks
2. Engine oil level
3. Brake and clutch fluid level
4. Windshield washer reservoir fluid level
5. Automatic transmission/Transaxle fluid level
6. Power steering fluid level
7. Radiator coolant level and specific gravity
8. Tightness of water hose clamps
9. Tightness of battery terminals, electrolyte level and specific gravity

Interior

INSTALL the following items

1. Fuse for accessories

INSPECT the operations of the following items

1. Seat controls (slide and recline) and headrests
2. Folding rear seat
3. Door locks, including child proof door locks
4. Seat belts and warning system
5. Ignition switch and steering lock
6. Transmission/Transaxle range switch
7. Warning buzzers
8. Ignition key reminder alarm
9. Air bag system using warning light
10. Cruise control system (if equipped)
11. Power door lock
12. Shift-lock system (if equipped)
13. Starter interlock
14. All lights including warning, and indicator lights
15. Horn, wipers, and washers
16. Wiper blades performance

Clean wiper blades and windshield, if necessary

1. Antenna
2. Audio system
3. Cigarette lighter and clock
4. Power windows (if equipped)
5. Heater, defroster, and air conditioner at various mode selections (if equipped)

INSPECT the following items

1. Presence of spare fuse
2. Upholstery and interior finish

INSPECT and ADJUST , if necessary, the following items

1. Operation and fit of windows
2. Pedal height and free play of clutch pedal
3. Parking brake

Underhood - Engine Running At Operating Temperature

INSPECT the following items

1. Automatic transmission/Transaxle fluid level
2. Operation of idle-up system for electrical load, air conditioner or power steering (if equipped)
3. Ignition timing
4. Idle speed
5. Operation of throttle position sensor

On Hoist

INSPECT the following items

1. Underside fuel, coolant and hydraulic lines, fittings, connections, and components for leaks
2. Tires for cuts or bruises
3. Steering linkage, suspension, exhaust system, and all underside hardware for looseness or damage

Schedule 1: (Normal driving conditions) U.S.A.

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

SCHEDULED MAINTENANCE TABLE

Schedule 2: CANADA, Puerto Rico and (Unique driving conditions) 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

SCHEDULED MAINTENANCE TABLE