General Information: Other Mazda MPV II рестайлинг

RANGE OF TOPICS

1. This information 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 11

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 12

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 13

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

ADVISORY MESSAGES

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

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

Upper & Lower Limits

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

Scheme 14

CONVERSION TO SI UNITS (SYSTEM INTERNATIONAL D'UNITES)

1. All numerical values in this information 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 265 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 15

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

Scheme 16

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

Scheme 17

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.

Using UV Light (Black Light)

1. Remove any oil on the engine or transaxle.
2. Pour the fluorescent dye into the engine oil or ATF (or 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.

Scheme 18

1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle 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.

Scheme 19

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.

Scheme 20

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 21

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

Scheme 22

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.

CLEANING OF PARTS

1. All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.

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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, these parts should be replaced with new ones: Oil seals Gaskets O-rings Lockwashers 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.

Scheme 25

1. Use suitable gauges and testers when making adjustments.

Scheme 26

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

Scheme 27

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 28

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 FORMULA 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.

Scheme 29

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 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 wheels are being rotated on the dynamometer, the ABS warning light could illuminate. If the ABS warning light illuminates, turn the ignition switch to the LOCK position, then turn it back to the ON position, run the vehicle at 10km/h and check that the ABS warning light goes off. (In this case, a DTC will be stored in the memory. To delete this data from the memory, follow the procedure for deleting DTCs (ABS) from memory.) (See «PRECAUTION»(ref-177977-S21598631672005061000000) to turn off the warning light.)

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. SST numbers are indicated in two ways, as shown in the following examples: Both MAZDA and global SST numbers are indicated for reference. Either only the MAZDA SST number or both the MAZDA SST and global SST numbers are shown.

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Scheme 31

Data Link Connector

1. Insert the probe into the terminal when connecting a jumper wire to the data link connector.

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Scheme 33

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

Scheme 34

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

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Scheme 36

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. CAUTION: To prevent damage to the terminal, wrap a thin wire around the lead before inserting into terminal.

Scheme 37

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

Scheme 38

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.

Scheme 39

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

Scheme 40

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 CODE COLOR B Black BR Brown G Green GY Gray L Blue LB Light Blue LG Light Green O Orange P Pink R Red V Violet W White Y Yellow

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Scheme 42

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.

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

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

Scheme 43

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.

Scheme 44

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

Jumper Wire

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 45

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

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

Scheme 46

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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Scheme 48

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

1. At the jacking plate of the engine support member.

Rear

1. At the center of torsion beam axle.

Front & Rear

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

Scheme 49

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

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1. Proper lifting and towing are necessary to prevent damage to the vehicle. State 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.

TIE DOWN HOOKS

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