Engine Controls - Removal & Installation: Other Mazda MX-5 NB рестайлинг

TURBOCHARGER

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Disconnect the vacuum hose leading to the air bypass valve and the turbocharger wastegate actuator. (Scheme 314)
4. Unfasten the purge solenoid valve from the charge air cooler outlet duct pipe near the throttle body.
5. Remove the charge air cooler inlet duct pipe between the turbocharger compressor outlet and the charge air cooler top end-tank. (Scheme 314)
6. Remove the air inlet duct pipe between the MAF and the turbocharger compressor inlet.
7. Remove the charge air cooler outlet duct pipe between the charge air cooler bottom end-tank and the throttle body. (Scheme 314)
8. Cap or tape off all openings of the turbo compressor, charge air cooler and the throttle body. This will prevent foreign objects or debris from entering during repair.
9. Disconnect harness connections from both cooling fans.
10. Remove the radiator with intercooler and both fans attached.
11. Disconnect and remove front Heated Oxygen Sensor (HO2S). (Scheme 314)
12. Remove exhaust manifold insulator. (Scheme 314)
13. Remove insulator of the front pipe (between the turbo down pipe and the catalytic converter).
14. Remove the front pipe.
15. Remove intake manifold brace from rear of engine.
16. Disconnect turbocharger oil feed line fitting from three-way tee adapter at the rear of engine. (Scheme 314)
17. Remove turbo down pipe support bracket.
18. Disconnect turbocharger oil drain block from oil pan upper block. (Scheme 314)
19. Loosen EGR pipe nut fully.
20. Disconnect turbocharger coolant feed hose from pipe branch.
21. Disconnect turbocharger coolant return pipe from three-way hose. (Scheme 314)
22. Remove bolts and nuts securing exhaust manifold to cylinder head.
23. Remove primary turbocharger assembly (includes: turbocharger, turbo down pipe, oil and coolant connections attached). (Scheme 314)

Scheme 314

UPPER INTAKE MANIFOLD

Note. Upper intake manifold may also be referred to as a dynamic chamber.

Note. Models not listed do not require upper intake manifold to be removed to access fuel system or engine control components.

COMPUTERIZED ENGINE CONTROLS

POWERTRAIN CONTROL MODULE

Note. Some models may be equipped with an immobilizer system. This system can be identified by the ignition key blanks. If the key ring hole on blank has no metal exposed, vehicle is equipped with system. The immobilizer system requires using a CODE WORD for reprogramming keys to PCM. The CODE WORD is only available to the dealer from Mazda.

PROGRAMING

Note. Programing information is not available from manufacture for Miata, MPV, Protege & Protege5.

Powertrain Control Module Configuration

1. Connect the WDS tester or equivalent to DLC-2. (Scheme 315)
2. Set up the WDS or equivalent (including the vehicle recognition).
3. Select MODULE PROGRAMMING.
4. Select PROGRAMMABLE MODULE INSTALLATION.
5. Select PCM and perform procedures according to directions on the WDS or equivalent screen.
6. If PCM configuration is successful, the PCM stores the DTC P0602 and illuminates the MIL. System is normal. Clear the DTC P0602 using WDS or equivalent. To clear DTC P0602, appropriate SELF DIAGNOSTICS article in ENGINE PERFORMANCE. MIL goes off after 3 drive cycles with no failure. DTCs remain in PCM.

Scheme 315

Retrieving Data From Original PCM & Restoring Data To New Or Different PCM - NGS Tester

Note. If GEM and ICM need to be programmed along with the PCM, program the GEM and ICM first before programming the PCM.

Note. This procedure is used when replacing the original PCM with a NEW or different PCM. Do not replace the PCM until instructed to do so.

Note. When programming a PCM from a different vehicle, the PCM VID block must be cleared first. Contact the Mazda Technical Hotline for more information on this procedure.

1. Connect NGS tester and turn key ON, engine OFF.
2. Select model year. If the model year is not displayed, use 2001.
3. Select correct Tribute model in Vehicle Selection (YF is for 4-cylinder and AJ is for V6).
4. Select DIAGNOSTIC DATA LINK and press trigger.
5. Select PCM and press trigger.
6. Select PROGRAMMABLE MODULE INSTALLATION and press trigger.
7. Screen will display TURN IGNITION SWITCH ON. Press trigger.
8. Screen will display DETERMINING PCM PROTOCOL and then Module Configuration menu. Select RETRIEVE MODULE CONFIGURATION - OLD ECU and press trigger.
9. Screen will display a warning that PCM data will only remain in NGS Tester for 48 hours. If any data was previously stored for a PCM of another vehicle, this data will be lost. Press trigger.
10. Screen will display FINDING VID BLOCK IN PCM and then RETRIEVING VID BLOCK FROM PCM. This takes about 1-1/2 minutes.
11. Screen will display MODULE DATA HAS BEEN STORED. REPLACE PCM MODULE. SELECT RESTORE MODULE CONFIGURATION. Press trigger. NOTE: If the NGS Tester is unable to retrieve the data, the new PCM will have to be manually programmed using As-Built Data. See «PCM MANUAL PROGRAMMING WITH AS-BUILT DATA - NGS TESTER»(ref-151901-S16813597282003120500000) .
12. Replace the PCM. See «POWERTRAIN CONTROL MODULE»(ref-151901-S39392855062003010900000) under COMPUTERIZED ENGINE CONTROLS.
13. Select RESTORE MODULE CONFIGURATION - NEW ECU. Turn key ON, engine OFF and press trigger. If error message appears on NGS tester after installing a NEW or different PCM, unplug the NGS tester and reconnect. Advance to the MODULE CONFIGURATION screen and repeat step.
14. Screen will display FINDING VID BLOCK IN PCM and then RETRIEVING VID BLOCK FROM PCM. This takes about one minute.
15. Screen will display ENTERING IVFER, TURN KEY OFF - THEN TURN KEY ON - DON'T CRANK ENGINE. Turn key OFF and then turn key ON, engine OFF.
16. Screen displays DOWNLOADING VID BLOCK which takes about 15-20 seconds. Screen then displays TEST/FUNCTION SUCCESSFUL when finished. Press trigger.
17. Keys must be programmed to new PCM in order for engine to start. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT.

PCM Manual Programming With As-Built Data - NGS Tester

Note. This procedure should only be used if PCM data is corrupted and not retrievable from the original PCM. Contact hotline and provide them with the VIN in order to receive the As-Built Data printout.

Note. When programming a PCM from a different vehicle, the PCM VID block must be cleared first. Contact the Mazda Technical Hotline for more information on this procedure.

1. Connect NGS tester and turn key ON, engine OFF.
2. Select model year. If the model year is not displayed, use 2001.
3. Select correct Tribute model in Vehicle Selection (YF is for 4-cylinder and AJ is for V6).
4. Select DIAGNOSTIC DATA LINK and press trigger.
5. Select PCM and press trigger.
6. Select PROGRAMMABLE MODULE INSTALLATION and press trigger.
7. Screen will display DETERMINING PCM PROTOCOL and then the Retrieve/Restore Module Configuration menu. Select RETRIEVE MODULE CONFIGURATION- OLD ECU and press trigger.
8. Screen will display a warning that PCM data will only remain in NGS Tester for 48 hours. If any data was previously stored for a PCM of another vehicle, this data will be lost. Press trigger.
9. Screen will display, FINDING VID BLOCK FROM PCM. This takes about one minute. Screen will then display NO DATA AVAILABLE FROM PCM. SEE WSM TO VERIFY WHICH VEHICLES REQUIRE CONFIGURATION. PRESS TRIGGER IF CONFIGURABLE. Press trigger.
10. Screen will display, IF PCM HAS BEEN REPLACED, PRESS CANCEL AND RECONNECT OLD PCM TO RETRIEVE DATA. IF DATA CANNOT BE RETRIEVED FROM OLD PCM. PRESS TRIGGER TO CONTINUE. Press trigger.
11. Screen will display, THE FOLLOWING PROCEDURE IS FOR MANUAL DATA ENTRY. THIS SHOULD ONLY BE USED IF DATA FROM OLD PCM IS NOT AVAILABLE. Press trigger.
12. Screen will display CALL AS-BUILT DATA CENTER TO OBTAIN PCM DATA. Press trigger
13. Screen will display RETRIEVING VIN FROM PCM and then ENTER VIN. Enter 17 VIN characters using rotary knob to select the correct character and then pressing trigger to enter the character. Press STORE (key No. 3) when finished to enter the entire VIN.
14. Screen will display DETERMINING PCM PROTOCOL and then RETRIEVING METHOD 1 CONFIGURATION.
15. Screen will display ENTER VEHICLE DATA BELOW and FFFF FFFF FFFF. Using the As-Built Data information under VIN NUMBER, find the 12 characters for VEHICLE DATA. Enter vehicle data from As-Built Data printout by using rotary knob to select correct character and then pressing trigger to select each. Press STORE (key No. 3) when finished to enter the entire vehicle data. If data was entered incorrectly, start over and re-enter the data. If data was entered correctly, the next screen appears: Enter data blocks 1-9 FFFF FFFF FFFF (i.e.: PCM 1-9) from As-Built Data printout using rotary knob to select correct character and then pressing trigger to select each. Press STORE after each data block is entered.
16. After the 9th data block is entered, screen will display DETERMINING PCM PROTOCOL. Screen will then display RETRIEVING METHOD 1 CONFIGURATION.
17. Screen will display RETRIEVING METHOD 1 CONFIGURATION again followed by MODULE DATA HAS BEEN STORED. REPLACE PCM MODULE. Select RESTORE MODULE CONFIG 1 and press trigger.
18. Select RESTORE MODULE CONFIGURATION - NEW ECU and press trigger.
19. Screen will display FINDING VID BLOCK and then RETRIEVING VID BLOCK. This takes about one minute.
20. Screen will display ENTER LAST 8 CHARACTERS OF THE VIN BY USING ROTARY KNOB TO SELECT CORRECT CHARACTER AND THEN PRESSING TRIGGER TO ENTER THE CHARACTER. Press STORE when finished to enter the entire VIN.
21. Screen will display ENTERING IVFR. TURN KEY OFF. TURN KEY ON. DON'T CRANK ENGINE. Turn key OFF and then turn key ON, engine OFF within 10 seconds. If not done within 10 seconds, an error message appears and the 8 VIN characters will have to be entered again.
22. Screen will display DOWNLOADING VID BLOCK and then TEST/FUNCTION SUCCESSFUL when finished. Press trigger.
23. Keys must be programmed to NEW PCM in order for engine to start. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT.

Powertrain Control Module Programming - WDS Tester (Procedure 1)

Note. When the PCM is replaced, the NEW PCM must be programmed with the old module's configuration information. The following step by step procedure guides you through replacement of the PCM in a Tribute using WDS with B18 or later software. This procedure was performed using WDS B18 software. Later software versions may have a slightly different screen order or content.

Note. For 3.0L vehicles with PCMs that have tear tag numbers of JYB2 or JYB3. For all other PCM tear tag numbers, refer to Procedure 2. See POWERTRAIN CONTROL MODULE PROGRAMMING - WDS TESTER (PROCEDURE 2) .

1. Connect WDS DLC cable to vehicle's DLC connector (lower portion of dash in front of driver).
2. Press 16 PIN then ALL EXCEPT THOSE BELOW. Press tick.
3. Screen shows cable hookup. Turn ignition switch to ON. Press tick.
4. Screen shows WDS communicating with PCM PROGRESS BAR and OPERATION IN PROGRESS.
5. Wait until WDS finishes collection of PCM information (hard drive light quits flashing). Then the VEHICLE SPECIFICATION screen appears with VIN information. It asks IS THIS CORRECT? Press YES if information is correct.
6. Screen appears to fill out repair order information and mileage. Fill out information (or skip this). Press tick.
7. With screen showing VEHICLE SPECIFICATION, press TOOL BOX.
8. Another menu appears. Select MODULE PROGRAMMING. Press tick. PLEASE WAIT appears.
9. Then another menu appears. Select PROGRAMMABLE MODULE INSTALLATION then select PCM then press tick.
10. Screen shows SET IGNITION SWITCH TO OFF (POSITION 0). Turn ignition switch to the OFF position. Press tick.
11. Screen shows INSTALL A NEW MODULE IN VEHICLE. Replace the PCM with the NEW unit. See «POWERTRAIN CONTROL MODULE»(ref-151901-S39392855062003010900000) under COMPUTERIZED ENGINE CONTROLS. Press tick.
12. Screen shows REMOVE THE FUSES FOR FUEL PUMP AND ADDITIONAL FANS AS THIS MAY CAUSE INTERFERENCE AND BATTERY DRAIN DURING THE PROGRAMMING PROCESS. Press tick.
13. Screen shows downloading data box with progress bar. Please wait 2-3 minutes.
14. Screen now shows SET IGNITION SWITCH TO THE OFF POSITION. Turn ignition switch to the OFF position. Press tick.
15. Screen now shows SET IGNITION SWITCH TO THE ON POSITION. Turn ignition switch to the ON position. Press tick.
16. Screen shows SET THE IGNITION SWITCH TO OFF (POSITION 0). Turn ignition switch to the OFF position. Press tick.
17. Screen shows CALIBRATION HAS BEEN LOADED AND CHECKED. Press tick.
18. Screen shows RE-INSTALL FUSES FOR FUEL PUMP AND ADDITIONAL FANS. Press tick.
19. Screen shows OBTAIN A PCM LABEL AND FILL IN THE PCM DATA SHOWN WITH THE DATE ON THE WDS SCREEN. INSTALL IN THE APPROPRIATE POSITION. (NEW LABEL SHOULD BE IN THE NEW PCM PART BOX) DO NOT FILL OUT PCM LABEL AT THIS TIME! Press tick.
20. Screen shows START ENGINE. DO NOT DEPRESS THROTTLE. You MUST follow the below procedure to start the vehicle: Turn ignition OFF, Turn key ON (Count 3 seconds, security light is ON solid) Turn key OFF, remove key. Insert 2nd key, turn key ON, (security light stays ON for 3 seconds and goes out) then start engine. Turn OFF engine, remove key. Both keys are now programmed.
21. Now with key OFF, press SELECT SYSTEMS OPTIONS or MENU icon (at the upper right hand side of screen). Press EXIT and push the Green tick. This will return you to the Vehicle Specifications screen.
22. Now press the CLOSE SESSION icon (lower left side of screen, 3rd icon) and press DELETE (deletes session). Press tick.
23. Now, press 16 PIN and ALL EXCEPT THOSE BELOW. Press tick.
24. Screen shows WDS communicating with PCM progress bar and OPERATION IN PROGRESS.
25. Wait until WDS finishes collection of PCM information (hard drive light quits flashing). Then the Vehicle Specification screen appears with VIN number information. It asks IS THIS CORRECT? Press NO.
26. Then the Vehicle Specification screen appears again and asks: IS THIS CORRECT? Press NO again.
27. Screen shows INCORRECT CALIBRATION PROGRAMMED. Press tick.
28. Screen shows TO ENABLE WDS TO IDENTIFY PCM, PLEASE ENTER ONE OF THE FOLLOWING INFORMATION: PCM PART NUMBER CALIBRATION NUMBER (7, 10, or 15 DIGITS) TEAR TAG NUMBER
29. Press tick.
30. Press the Light Blue box area next to TEAR TAG and enter JYB2 or JYB3 (whatever the tear tag number of the NEW PCM is). Press tick.
31. Vehicle specification screen appears asking IS THIS CORRECT? Now press YES.
32. Screen shows TURN IGNITION SWITCH OFF. Turn ignition switch to the OFF position. Press tick.
33. Screen shows REMOVE THE FUSES FOR FUEL PUMP AND ADDITIONAL FANS AS THIS MAY CAUSE INTERFERENCE AND BATTERY DRAIN DURING THE PROGRAMMING PROCESS. Remove the fuses for fuel pump and additional fans. Press tick.
34. Screen shows TURN IGNITION SWITCH ON. Turn ignition switch to the ON position. Press tick.
35. Screen shows downloading data box with progress bar. It takes about 2-3 minutes.
36. Screen shows TURN IGNITION SWITCH OFF. Turn ignition switch to the OFF position. Press tick.
37. Screen shows TURN IGNITION SWITCH ON. Turn ignition switch to the ON position. Press tick.
38. Screen changes to progress bar and then changes to Vehicle Specifications with VIN number and asks IS THIS CORRECT? Press YES.
39. Screen to fill out repair order information appears. Press tick.
40. Vehicle Specifications screen appears. Now re-install fan and fuel pump fuses.
41. Now select TOOL BOX, then MODULE PROGRAMMING. Press tick. PLEASE WAIT appears.
42. Now select MODULE REPROGRAMMING and PCM. Press tick.
43. Screen should say NO LATER CALIBRATION IS AVAILABLE ON THE SYSTEM FOR THIS PCM. THE LATEST LEVEL FOR THIS VEHICLE :1U7A-12A650-AYB. Now, fill out the PCM label mentioned previously, with this information and install it next to the vehicle emissions label on the hood.
44. Press tick.
45. Now turn key OFF, press SELECT SYSTEMS OPTIONS or MENU icon (at the upper right side of screen). Press EXIT and push the Green tick. This will return you to the Vehicle Specifications screen.
46. Now press the CLOSE SESSION icon (lower left side of screen, 3rd icon) and press DELETE (deletes session). Press tick.
47. Disconnect WDS cable. PCM is now programmed with the latest calibration.

Powertrain Control Module Programming - WDS Tester (Procedure 2)

Note. When the PCM is replaced, the NEW PCM must be programmed with the old module's configuration information. The following step by step procedure guides you through replacement of the PCM in a Tribute using WDS with B18 or later software. This procedure was performed using WDS B18 software. Later software versions may have a slightly different screen order or content.

Note. For all 2.0L vehicles and 3.0L vehicles with PCMs that have tear tag numbers of SJC0, SJC1, SJC2, HQP1, HQP2, or HQP3.

Note. When performing this procedure, if the WDS PTU is not docked and connected to 115-120 volts, it is recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 amps to keep the vehicle battery up to capacity. If you exceed 20 amps it will damage the WDS PTU.

1. Connect WDS DLC cable to vehicle's DLC connector (lower portion of dash in front of driver).
2. Press 16 PIN then ALL EXCEPT THOSE BELOW. Press tick.
3. Screen shows cable hookup. Turn ignition switch to ON. Press tick.
4. Screen shows WDS communicating with PCM progress bar and OPERATION IN PROGRESS.
5. Wait until WDS finishes collection of PCM information (hard drive light quits flashing). Then the Vehicle Specification screen appears with VIN number information. It asks IS THIS CORRECT? YES OR NO? Press YES if information is correct.
6. Screen appears to fill out repair order information and mileage. Fill out information (or skip this). Press tick.
7. If vehicle is not equipped with ABS, screen will appear showing the STANDARD EQUIPMENT MODULES AND FAIL-ABS. This is normal. Press EXIT. Press tick.
8. With screen showing, Vehicle Specification, press TOOL BOX.
9. A menu appears. Select MODULE PROGRAMMING. Press tick. PLEASE WAIT appears.
10. Another menu appears. Select PROGRAMMABLE MODULE INSTALLATION then select PCM. Press tick.
11. Screen shows, SET IGNITION SWITCH TO THE OFF POSITION. Turn ignition switch to the OFF position. Press tick.
12. Screen shows NOW INSTALL THE NEW MODULE. Replace the PCM with the NEW unit. Press tick.
13. Screen shows, REMOVE THE FUSES FOR FUEL PUMP AND ADDITIONAL FANS AS THIS MAY CAUSE INTERFERENCE AND BATTERY DRAIN DURING THE PROGRAMMING PROCESS. Remove the fuses for fuel pump and additional fans. Press tick.
14. Screen shows a progress bar on the bottom of the screen and PLEASE WAIT.
15. Screen shows, SET IGNITION SWITCH TO THE ON POSITION. Turn ignition switch to the ON position. Press tick.
16. Screen shows, downloading data box with progress bar. Please wait 2-3 minutes.
17. Screen now shows, SET IGNITION SWITCH TO THE OFF POSITION. Turn ignition switch to the OFF position. Press tick.
18. Screen now shows, SET IGNITION SWITCH TO THE ON POSITION. Turn ignition switch to the ON position. Press tick.
19. Screen now shows, SET IGNITION SWITCH TO THE OFF POSITION. Turn ignition switch to the OFF position. Press tick.
20. Screen shows, CALIBRATION HAS BEEN LOADED AND CHECKED. Press tick.
21. Screen shows, RE-INSTALL FUSES FOR FUEL PUMP AND ADDITIONAL FANS. Re-install fuses for fuel pump and additional fans. Press tick.
22. Screen shows, OBTAIN A PCM LABEL AND FILL IN THE PCM DATA SHOWN WITH THE DATE ON THE WDS SCREEN. INSTALL IN THE APPROPRIATE POSITION. New label should be in the NEW PCM part box. Press tick.
23. Screen shows START ENGINE. DO NOT DEPRESS THROTTLE. You MUST follow the below procedure to start the vehicle: Turn key ON (Count 3 seconds, security is ON solid). Remove key. Insert 2nd key, turn key ON, (security stay ON for 3 seconds, goes out) Turn key OFF. Then start engine. Turn OFF engine, remove key. Both keys programmed.
24. Disconnect WDS from vehicle. PCM replacement procedure is completed.

ACCELERATOR PEDAL POSITION SENSOR

Note. Accelerator Pedal Position (APP) sensors No. 1 and 2 are integrated with accelerator pedal assembly and are not serviced separately If APP sensor is faulty, accelerator pedal assembly must be replaced.

CAMSHAFT POSITION SENSOR

Note. Care should be taken when disconnecting Camshaft Position (CMP) sensor harness connector. Wires can be broken easily at connector.

ENGINE COOLANT TEMPERATURE SENSOR

Note. The B2300 (2.3L) and Tribute (2.0L) have a Cylinder Head Temperature (CHT) sensor. See CYLINDER HEAD TEMPERATURE SENSOR .

Removing & Installing (Tribute 3.0L)

1. Raise and support the vehicle.
2. Disconnect the Heated Oxygen Sensor (HO2S) harness connector. (Scheme 316)and/or (Scheme 317).
3. Using the Special Tool (303-476), remove the HO2S. (Scheme 318)and/or (Scheme 319).

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Mazda6

Note. For proper antifreeze-to-water mixture percentages, see appropriate COOLING SYSTEM - MECHANICAL article in ENGINES.

1. Slowly pour the coolant into the radiator up to the coolant filler port. (Scheme 320)
2. Fill the engine coolant into the coolant reservoir tank up to the "F" mark on the coolant reservoir tank.
3. Tighten the cooling system cap.
4. Start the engine and idle it until the cooling fan operates.
5. After engine warms up, perform the following steps: Run the engine at 2500 RPM for 5 minutes. Run the engine at 4500 RPM for 5 seconds, then idle. Repeat 5 times. Idle the engine for one minute.
6. Stop the engine and wait until it is cool.
7. Inspect the coolant level. If it is low, repeat steps 1 - 6 on 2.3L models or steps 2 - 6 on 3.0L models.
8. Install the cooling system cap.
9. Inspect for coolant leakage.

Scheme 320

Miata

1. Slowly add coolant to radiator until coolant level is up to filler port.
2. Add coolant up to FULL mark on coolant reservoir.
3. Tighten cooling system cap on radiator.
4. Start engine and warm it up.
5. After engine warms up, run it at about 2500 RPM for 5 minutes.
6. Increase engine speed to about 3000 RPM for 5 minutes, then return to idle. Repeat several times.
7. Stop engine and wait until it is cool.
8. Inspect coolant level. If coolant level is low, repeat steps 1 - 6 .
9. Inspect for coolant leakage.

MPV

Note. Cooling system is filled through coolant reservoir.

1. Add correct coolant mixture to FULL mark on coolant reservoir.
2. Tighten cooling system cap on reservoir.
3. Start engine and allow to idle until cooling fan operates.
4. After engine warms up, perform following steps: Run engine at 4000 RPM for one minute. Run engine at idle for one minute. Repeat 2 previous steps several times. Turn on main and rear heaters (if equipped) and verify heat from heater vents.
5. Stop engine and wait until it is cool.
6. Inspect coolant level. If coolant level is low, repeat steps 1 - 5 .
7. Verify there is no coolant leakage.

Protege & Protege5

1. Slowly add coolant to radiator until coolant level is up to filler port.
2. Add coolant up to FULL mark on coolant reservoir.
3. Tighten cooling system cap on radiator.
4. Start engine and idle for about 10 minutes.
5. After engine warms up, run it at about 2500 RPM for 5 minutes.
6. Increase engine speed to about 3000 RPM for 5 minutes, then return to idle. Repeat several times.
7. Stop engine and wait until it is cool.
8. Inspect coolant level. Repeat steps 1 - 8
9. Inspect for coolant leakage.

Tribute

1. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the COOLANT FILL LEVEL marks.
2. Select maximum heater temperature and blower motor speed settings. Position control to discharge air at vents in instrument panel.
3. Start the engine and allow to idle. While engine is idling, feel for hot air at vents.
4. Shut engine off and allow to cool.
5. Check engine for coolant leaks.
6. Check engine coolant level in degas bottle and fill as necessary.

FUEL SYSTEM

1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Remove the fuel pump relay. (Scheme 321)
3. Start the engine.
4. After the engine stalls, crank the engine several times.
5. Turn the ignition switch to the LOCK position.
6. Install the fuel pump relay.

Scheme 321

1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Disconnect the fuel pump relay (FP RLY) harness connector (6-pin type connector: 4 terminal) located above the accelerator pedal. (Scheme 322)
3. Start the engine.
4. After the engine stalls, crank the engine several times.
5. Turn the ignition switch to the LOCK position.
6. Connect the FP RLY harness connector.

Scheme 322

1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Remove the fuel pump relay. (Scheme 323)
3. Start the engine.
4. After the engine stalls, crank the engine several times.
5. Turn the ignition switch to LOCK position.
6. Install the fuel pump relay.

Scheme 323

1. Remove the fuel-filler cap and release the pressure in the fuel tank.
2. Remove the fuel pump relay. (Scheme 324)
3. Start the engine.
4. After the engine stalls, crank the engine several times.
5. Turn the ignition switch off.
6. Install the fuel pump relay.

Scheme 324

Tribute (2.0L)

1. Remove the left engine compartment relay panel cover.
2. Remove the fuel pump relay.
3. Start the engine.
4. After the engine stalls, crank the engine over 2 more times to be sure all the pressure has been released.
5. Turn the ignition switch to the OFF position. Install the fuel pump relay.

Tribute (3.0L)

1. Remove the Schrader valve cap at the end of the fuel injection supply manifold and attach the fuel pressure gauge. (Scheme 325)
2. Position a suitable container for the fuel to drain into. Open the manual valve slowly to relieve the system pressure. This may drain fuel from the system. (Scheme 326)

Scheme 325

Scheme 326

Disconnect (Spring Lock Coupling)

1. Relieve the fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-151901-S29954760902003010900000).
2. Remove the fuel tube clip. (Scheme 327)
3. Install the appropriate Disconnect Tool SST 49-UN01-0510 or 49-UN01-0520 (310-D005) or equivalent. (Scheme 328)
4. Close and push Disconnect Tool (49-UN01 0510) or (49-UN01 0520) (310-D005) or equivalent into the open side of the cage. (Scheme 329)
5. Separate the fitting. (Scheme 330)
6. Remove disconnect tool. (Scheme 331)

Scheme 327

Scheme 328

Scheme 329

Scheme 330

Scheme 331

Connect (Spring Lock Coupling)

1. Inspect and clean both the coupling ends. (Scheme 332)
2. Connect the fitting by inserting the male end into the female end of the fitting. Push the fitting together until the garter spring is engaged. (Scheme 333)
3. Pull on the fitting to make sure it is fully engaged. (Scheme 334)
4. Install the safety clip. (Scheme 335)

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Disconnect (R-Clip Fitting)

1. Relieve the fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-151901-S29954760902003010900000).
2. Remove the shipping tab by bending downward. (Scheme 336)
3. Spread the R-clip legs and push the clip into the fitting. (Scheme 337)
4. Separate the fitting from the tube. (Scheme 338)

Scheme 336

Scheme 337

Scheme 338

Connect (R-Clip Fitting)

1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions.
2. Insert the R-clip into the fitting. (Scheme 339)
3. Align the tube and the fitting.
4. Insert the tube in the fitting and push together until a click is heard. (Scheme 340)
5. Pull on the connection to make sure it is fully engaged. (Scheme 341)

Scheme 339

Scheme 340

Scheme 341

Disconnect (Vapor Tube Fitting - Push Release)

Note. Numbers in parenthesis refer to numbers in illustrations.

1. Disconnect the negative battery cable.
2. Press the retainer clip in (1). (Scheme 342)
3. Disconnect the vapor tube from the fitting (2). (Scheme 342)

Scheme 342

Connect (Vapor Tube Fitting - Push Release)

1. Inspect the fitting and the tube for damage.
2. Remove any dirt or obstructions.
3. Push the tube into the fitting until it snaps in place. (Scheme 343)
4. Pull on the connection to make sure the fitting is secure. (Scheme 344)

Scheme 343

Scheme 344

Disconnect (Vacuum Tube Fitting - Pinch Release)

Note. Numbers in parenthesis refer to numbers in illustrations.

1. Squeeze the fitting ears (1). (Scheme 345)
2. Disconnect the vapor tube from the fitting (2). (Scheme 345)

Scheme 345

Connect (Vacuum Tube Fitting - Pinch Release)

1. Inspect the fitting and the tube for damage.
2. Remove any dirt or obstructions.
3. Push the tube into the fitting until it snaps in place.
4. Pull on the connection to make sure the fitting is secure. (Scheme 346)

Scheme 346

Disconnect

1. Push the tab on the locking coupler 90 degrees until it stops.
2. Pull the fuel hose straight back. NOTE: The stopper may be removed from the quick connector. Take care not to lose it. Reinstall it to the quick release connector before reconnecting the fuel line. (Scheme 347) NOTE: The locking coupler has two internal locking tabs which retain the fuel pipe. (Scheme 348) Be sure that the tab on the locking coupler is rotated until it stops to release 2 internal locking tabs.
3. Cover the disconnected quick release connector and fuel pipe with vinyl sheets or the like to prevent them from being scratched or contaminated with foreign material. (Scheme 349)

Scheme 347

Scheme 348

Scheme 349

Connect

Note. A checker tab is integrated with quick release connector for NEW plastic fuel hoses. (Scheme 350) The checker tab will be released from the quick release connector after it is completely engaged with the fuel pipe.

1. Inspect the fuel pump unit sealing surface for damage and deformation. Replace as necessary.
2. Slightly apply clean engine oil to the sealing surface of the fuel pump unit. (Scheme 351)
3. Align the fuel pipe on the fuel pump unit and quick release connector so that the tabs of the retainer are correctly fitted into the quick release connector. Push the quick release connector straight into the retainer until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand and verify that it can move 0.08-0.11" (2.0-3.0 mm) and it is connected securely. If quick release connector does not move at all, verify that "O" ring is not damaged and slipped, and reconnect the quick release connector.

Scheme 350

Scheme 351

1. Inspect that the quick release connector joint area is free of foreign material.
2. Clean if necessary.
3. Squeeze the tabs of the retainer and disconnect the quick release connector. (Scheme 352)
4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign materials. (Scheme 353)

Scheme 352

Scheme 353

Note. The retainer must be replaced when any of the following applies: Retainer has been removed. Scratches or damage is observed on the retainer. Plastic fuel hose has been replaced. Fuel filter (high-pressure) has been replaced.

1. If removal of the retainer is required, remove it in the following procedure: Open tabs of the retainer outward. (Scheme 354) Remove and discard the retainer.
2. When the retainer is not removed, observe the following procedure: Inspect the plastic fuel hose for kinks, replace if necessary. Verify that the inside of the fuel pipe and the quick release connector is free of foreign material and damage. Clean if necessary, taking care not to damage the sealing surfaces. Align the fuel pipe and quick release connector so that the tabs of the retainer are correctly fitted into the quick release connector. Push the quick release connector into the retainer until a click is heard. (Scheme 355) Pull the quick release connector by hand and verify that it is installed securely. Visually inspect that the tabs of the retainer are securely fitted into the quick release connector.
3. When the retainer is removed, observe the following procedure: Install a new retainer onto the quick release connector. Visually inspect that the tabs of the retainer are securely fitted into the quick release connector. Verify that the inside of the fuel pipe and the quick release connector is free of foreign material and damage. Clean if necessary, taking care not to damage the sealing surfaces. Push the quick release connector into the fuel pipe until a click is heard. (Scheme 356) Pull the quick release connector by hand and verify that it is installed securely.

Scheme 354

Scheme 355

Scheme 356

FUEL TANK (TRIBUTE)

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

1. Drain the fuel tank.
2. Remove the leftr rear wheel. For additional information, refer to «WHEELS AND TIRES»(ref-194636) .
3. Remove the rivets and the fuel tank filler tube shield.
4. Disconnect the fuel tank filler hose and the fuel tank filler vent hose from the fuel filler tube.
5. Remove the muffler. For additional information, refer to «MUFFLER AND TAILPIPE»(ref-203945-S40261631412005110700000) .
6. On 4WD vehicles, remove the driveshaft. For addition information, refer to «DRIVE SHAFT»(ref-194642) .
7. Remove the differential mounting bracket-to-subframe mounting bolt.
8. Remove the rear differential mass damper. Remove the bolts. Remove the rear differential mass damper.
9. Disconnect the electrical connector.
10. Using a suitable jack, support the rear differential assembly.
11. Position the axle assembly rearward. Remove the differential-to-bracket bolts. Loosen the differential mounting bracket-to-subframe mounting bolts, rotate the brackets and position the axle assembly rearward.
12. Use a suitable jack to support the fuel tank.
13. Disconnect the vapor hose.
14. Disconnect the pin-type retainer from the fuel tank strap and position the parking brake cable aside. NOTE: For 4WD vehicles, it will be necessary to disconnect a wiring harness clip from the fuel tank strap.
15. Remove the bolts and the fuel tank straps
16. Lower and remove the fuel tank.
17. To install, reverse the removal procedure. Use the Heavy-Duty Riveter to install the rivets.

CHARCOAL CANISTER

CHARCOAL CANISTER LOCATION

MAZDA6 2.3L & 3.0L

TORQUE SPECIFICATIONS (MAZDA6 2.3L & 3.0L)

TORQUE SPECIFICATIONS (MIATA)

TORQUE SPECIFICATIONS (MPV)

TORQUE SPECIFICATIONS (PROTEGE & PROTEGE5)

TRIBUTE 2.0L & 3.0L

TORQUE SPECIFICATIONS (TRIBUTE 2.0L & 3.0L)