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Lubrication: Removal & Installation Mazda RX-8 I

Lubrication System 17 illustrations ~1072 words

ENGINE OIL REPLACEMENT

WARNINGPerform engine oil replacement when the engine is cold, otherwise it can cause severe burns or serious injury. A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands. Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
CAUTIONIn case you spill the engine oil on the exhaust system, wipe it off completely. If you fail to wipe the spilled engine oil, it will produce fumes because of the heat.

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6
  1. Position the vehicle on level ground.
  2. Remove the engine cover. See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000) .
  3. Remove the oil filler cap.
  4. Remove the oil pan drain plug, and drain the engine oil.
  5. Install the oil pan drain plug with a new washer. Oil pan drain plug tightening torque 29.4-39.2 N.m {3.00-3.99 kgf.m, 21.7-28.9 ft.lbf} NOTE: The amount of residual oil in the engine can vary according to the replacement method, oil temperature, etc. Verify the oil level after engine oil replacement.
  6. Refill the engine with the type and amount of engine oil specified. Recommended oil Oil capacity (Approx. quantity)
  7. Install the oil filler cap.
  8. Start the engine and confirm that there is no oil leakage. If there is any oil leakage, find the cause and repair or replace the applicable part.
  9. Inspect the oil level. (See «ENGINE OIL LEVEL INSPECTION»(ref-178319-S09793761132005061400000) .)
  10. Install the engine cover. See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000) .

OIL FILTER REPLACEMENT

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
CAUTIONWhen removing the oil filter, cover up the surrounding area with cloth to prevent oil in the filter from spilling on other parts. In case you spill the engine oil on the exhaust system, wipe it off completely. If you fail to wipe the spilled engine oil, it will produce fumes because of the heat.

Note. Since two types of the oil filters have been adopted, make sure to choose the appropriate procedure according to the oil filter manufacturer (Tokyo Roki or Denso) indicated on the label of the filter.

Scheme 7

Scheme 7: Tokyo Roki
Scheme 7: Tokyo Roki
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000) .)
  2. Remove the oil filter using the SST.
  3. Clean the installation surface of the oil filter.
  4. Apply engine oil to the O-ring of the new oil filter.
  5. When the O-ring contacts the oil filter installation surface, turn the filter another one rotation by hand.
  6. Fill with the specified amount of engine oil. (See «ENGINE OIL REPLACEMENT»(ref-178319-S09925340282005061400000) .)
  7. Start the engine and confirm that there is no oil leakage. If there is any oil leakage, find the cause and repair or replace the applicable part.
  8. Inspect the oil level. (See «ENGINE OIL LEVEL INSPECTION»(ref-178319-S09793761132005061400000) .)
  9. Install the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000) .)

Scheme 8

Scheme 8: Denso
Scheme 8: Denso
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000) .)
  2. Remove the oil filter using a commercially available, cap-type oil filter wrench (diameter- 64 mm {2.5 in}, 14 sided) .
  3. Clean the installation surface of the oil filter.
  4. Apply engine oil to the O-ring of the new oil filter.
  5. When the O-ring contacts the oil filter installation surface, turn the filter another three-quarter rotation by hand.
  6. Fill with the specified amount of engine oil. (See «ENGINE OIL REPLACEMENT»(ref-178319-S09925340282005061400000) .)
  7. Start the engine and confirm that there is no oil leakage. If there is any oil leakage, find the cause and repair or replace the applicable part.
  8. Inspect the oil level. (See «ENGINE OIL LEVEL INSPECTION»(ref-178319-S09793761132005061400000) .)
  9. Install the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000) .)

OIL COOLER REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 9

Scheme 9
Scheme 9
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Remove the following. Front tire (LH) Front tire (RH) (with twin oil cooler) Splash shield Under cover
  5. Remove in the order indicated. (Scheme 9)
  6. Install in the reverse order of removal.
  7. Add engine oil. (See «ENGINE OIL REPLACEMENT»(ref-178319-S09925340282005061400000).)
  8. Start the engine and confirm that there is no oil leakage from areas worked on. If there is any oil leakage, find the cause and repair or replace the applicable part.
  9. Inspect the oil level. (See «ENGINE OIL LEVEL INSPECTION»(ref-178319-S09793761132005061400000).)

Oil Cooler Hose Removal Note

Note. Use a drain pan to catch the oil when the oil hoses are disconnected.

OIL PAN REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 10

Scheme 10
Scheme 10
  1. Remove the engine cover. See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Drain the engine oil. (See «ENGINE OIL REPLACEMENT»(ref-178319-S09925340282005061400000).)
  5. Remove in the order indicated. (Scheme 10)
  6. Install in the reverse order of removal.
  7. Add engine oil. (See «ENGINE OIL REPLACEMENT»(ref-178319-S09925340282005061400000).)
  8. Start the engine and confirm that there is no oil leakage from areas worked on. If there is any oil leakage, find the cause and repair or replace the applicable part.
  9. Inspect the oil level. (See «ENGINE OIL LEVEL INSPECTION»(ref-178319-S09793761132005061400000).)

Scheme 11

Scheme 11: Oil Pan Component Removal Note
Scheme 11: Oil Pan Component Removal Note
  1. Remove the oil pan using the separator tool.

Oil Pan Component Installation Note

CAUTIONApply the silicon sealant in a single, unbroken line around the whole perimeter. Install the oil pan within 5 min after applying the silicone sealant. Using bolts with the seal adhering could cause cracks in the housing.

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13
  1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the housing and oil pan.
  2. When reusing oil pan installation bolts, clean any old sealant from the bolts.
  3. Apply silicone sealant to areas shown. (Scheme 13) Bead thickness 2.5-6.5 mm {0.10-0.26 in}
  4. Tighten the oil pan installation bolt. Tightening torque 8.8-11.8 N.m {89.8-120.3 kgf.cm, 77.9-104.4 in.lbf}

METERING OIL PUMP REMOVAL/INSTALLATION

WARNINGRemove and install and parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Remove the engine cover. See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Remove the battery, battery box, and battery tray.
  5. Remove in the order indicated. (Scheme 14)
  6. Install in the reverse order of removal.
  7. Start the engine and confirm that there is no oil leakage from areas worked on. If there is any oil leakage, find the cause and repair or replace the applicable part.
  8. Inspect the oil level. (See «ENGINE OIL LEVEL INSPECTION»(ref-178319-S09793761132005061400000).)

OIL NOZZLE REMOVAL/INSTALLATION

WARNINGRemove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Remove the engine cover. (See «ENGINE COVER REMOVAL/INSTALLATION»(ref-178318-S07019118052005061400000).)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Remove the battery, battery box, and battery tray.
  5. Remove extension manifold. (upper, lower). (See «INTAKE-AIR SYSTEM REMOVAL/INSTALLATION»(ref-178322-S25288823672005061400000).)
  6. Remove in the order indicated. (Scheme 16)
  7. Install in the reverse order of removal.
  8. Start the engine and confirm that there is no oil leakage from areas worked on. If there is any oil leakage, find the cause and repair or replace the applicable part.

Scheme 18

Scheme 18: Metering Oil Pump Voltage Inspection
Scheme 18: Metering Oil Pump Voltage Inspection
  1. Disconnect the metering oil pump connector (6-pin).
  2. Measure the voltage at terminals C and D. If not within the specification, repair or replace the related harnesses. Voltage Battery voltage [IG-ON, 20°C {68°F}]

Scheme 19

Scheme 19: Metering Oil Pump Resistance Inspection
Scheme 19: Metering Oil Pump Resistance Inspection
  1. Disconnect the metering oil pump connector (6-pin).
  2. Measure the resistance between terminals D-B, D-F, C-A, and C-E using a tester. If not within the specification, replace the metering oil pump. Resistance 30.6-35.6 ohms [20°C {68°F}]

Scheme 20

Scheme 20: Positioning Switch Resistance Inspection
Scheme 20: Positioning Switch Resistance Inspection
  1. Idle the engine.
  2. Stop the engine.
  3. Disconnect the metering oil pump connector (3-pin).
  4. Measure the coil resistance between A/C terminals using a tester. If not within the specification, replace the metering oil pump. Resistance 400 ohms or less [20°C {68°F}]

Scheme 21

Scheme 21: Oil Nozzle Inspection
Scheme 21: Oil Nozzle Inspection
  1. Remove the oil nozzle.
  2. Use a vacuum pump to apply a vacuum of 66.5 kPa {0.68 kgf/cm 2 , 9.65 psi} or more on end of oil nozzle and verify that vacuum holds: If the vacuum drops 2.66 kpa {0.027 kgf/cm 2 , 0.39 psi} or more in 1 min, replace the oil nozzle.

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