General Information: Other Mazda RX-8 I рестайлинг

Range of Topics

1. This Service 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.

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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 18

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 19

1. There are eight symbols indicating oil, grease, fluids, sealant, and the use of 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 Service Information.

Warning

1. A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution

1. A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note

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

Upper and lower limits

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

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UNITS

ELECTRIC CURRENT REFERENCE

Conversion to SI Units (System International Unites)

1. All numerical values in this Service 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.

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 kg/cm 2 in the following specifications
2. The actual converted values for 2.7 kg/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.

Injury/damage Prevention Precautions

1. Depending on the vehicle, the cooling fan may operate suddenly even when the ignition switch is turned off. Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing the cooling fan or parts near the cooling fan.

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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.

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

Disconnection Of The Negative Battery Cable

1. When working with the negative battery cable disconnected, wait for 1 min or more to allow the back up power supply of the SAS control module to deplete its stored power after the cable is disconnected.
2. If the negative battery cable is disconnected, the clock and audio memory settings will be erased therefore record the clock and audio settings prior to disconnecting and reset them after reconnecting.

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 dye instruction information.

Scheme 24

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 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 25

1. While correcting a problem, also try to determine its cause. Begin work only after first learning which parts and sub-components 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.

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, the following parts should be replaced with new ones: Oil seals Gaskets O-rings Lock washers Cotter pins Nylon nuts
3. Depending on location

Scheme 31

1. 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.
2. Oil should be applied to the moving components of parts.
3. 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.

Dynamometer

1. When inspecting and servicing the power train on the dynamometer or speedometer 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 do not 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/DSC HU/CM determines that there is a malfunction in the ABS/DSC and illuminates the following lights: Vehicles with ABS ABS warning light Brake system warning light Vehicles with DSC ABS warning light Brake system warning light DSC indicator 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]/[DSC] in the on-board diagnostic system. (See ON-BOARD DIAGNOSIS [ABS] ), (See ON-BOARD DIAGNOSIS [DYNAMIC STABILITY CONTROL (DSC)] ).

Disconnecting Connectors

1. When disconnecting connector, grasp the connectors, not the wires.

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1. Connectors can be disconnected by pressing or pulling the lock lever as shown in illustration.

Scheme 37

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

Scheme 40

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

Scheme 41

1. Use the appropriate tools to remove a terminal as shown in illustration. 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 42

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

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.

Scheme 44

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

Jumper Wire

Scheme 45

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 46

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 47

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

1. At the center of the front crossmember.

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1. At the center of the differential.

Front And Rear

Scheme 51

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 drive wheels (rear wheels) off the ground. If excessive damage or other conditions prevent this, use wheel dollies.

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Tiedown

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1. Remove the tiedown eyelet and the lug wrench from the trunk.
2. Wrap a lug wrench with a soft cloth to prevent damage to the bumper and open the cap located on the front and rear 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 tiedown eyelet using the lug wrench.
4. Hook the tying rope to the tiedown eyelet.

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TIEDOWN HOOK

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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 Service Information. The table below lists the names and abbreviations that have been used in Mazda Service Informations up to now and their SAE equivalents.

SAE EQUIVALENTS REFERENCE

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 trunk lid and fuel-filler lid opener
8. Door operation and alignment including side door and back door
9. Headlight aiming

INSTALL the following parts

1. Flap (front)
2. Wheel caps or rings (if equipped)

Under Hood-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. Manual transmission oil level
6. Radiator coolant level and specific gravity
7. Tightness of water hose clamps
8. Tightness of battery terminals, electrolyte level and specific gravity
9. Differential oil level

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 childproof door locks
4. Seat belts and warning system
5. Ignition switch and steering lock
6. Transmission 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

Under Hood-Engine Running At Operating Temperature

INSPECT the following items

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

Schedule 1 (Normal Driving Conditions) For USA

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

SCHEDULED MAINTENANCE CHART - SCHEDULE 1

Remarks

1. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
2. Refer below for a description of items marked* in the maintenance chart.

*1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant.

*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.

*3: Check the tire repair fluid expiration date every year when performing the periodic maintenance. Replace the tire repair fluid bottle with new one before the expiration date.

Schedule 2 CANADA, Puerto Rico, And (Unique Driving Conditions) For USA

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
8. Driving in extremely hot conditions
9. Driving in mountainous conditions continually

SCHEDULED MAINTENANCE CHART - SCHEDULE 2

Remarks

1. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
2. Refer below for a description of items marked* in the maintenance chart.

*1: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant.

*2: According to state/provincial and federal regulations, failure to perform maintenance on these items will not void your emissions warranties. However, Mazda recommends that all maintenance services be performed at the recommended time or mileage/kilometer period to ensure long-term reliability.

*3: Check the tire repair fluid expiration date every year when performing the periodic maintenance. Replace the tire repair fluid bottle with new one before the expiration date.

Except U.S.A., Canada and Puerto Rico

SCHEDULED MAINTENANCE CHART

Remarks

Emission control and related systems

1. The ignition and fuel systems are highly important to the emission control system and to efficient engine operation.
2. After the prescribed period, continue to follow the described maintenance at the recommended intervals.
3. Refer below for a description of items marked* in the maintenance chart.

*1: If the vehicle is operated primarily under any of the following conditions, replace the engine oil and oil filter more often than the recommended intervals.

1. Driving in dusty conditions
2. Extended periods of idling or low speed operation
3. Driving for long period in cold temperatures or driving regularly at short distance only
4. Driving in extremely hot conditions
5. Driving in mountainous conditions continually

*2: Also inspect and adjust the air conditioner drive belts, if installed.

If the vehicle is operated primarily under any of the following conditions, inspect the drive belts more often than the recommended intervals.

1. Driving in dusty conditions
2. Extended periods of idling or low speed operation
3. Driving for long period in cold temperatures or driving regularly at short distance only
4. Driving in extremely hot conditions
5. Driving in mountainous conditions continually

*3: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding area. Use FL22 when replacing the coolant.

*4: If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air cleaner element more often than the recommended intervals.

*5: If the vehicle is operated in extremely heat and extremely cold areas, inspect the battery electrolyte level and specific gravity at every 10,000 km (6,250 miles) or 6 months.

*6: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is operated in extremely humid climates, replace the brake fluid annually.

*7: Check the tire repair fluid expiration date every year when performing the periodic maintenance. Replace the tire repair fluid bottle with new one before the expiration date.