RANGE OF TOPICS
- This manual 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
- 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.
ADVISORY MESSAGES
| WARNING | A Warning indicates a situation in which serious injury or death could result if the warning is ignored. |
| CAUTION | A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. |
Note. A Note provides added information that will help you to complete a particular procedure.
UPPER & LOWER LIMITS
- The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
Scheme 27
On-Board Diagnosis
- Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
- The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic function.
Engine Tune-Up
- Any necessary adjustments are made after starting the engine.
TEXT SEQUENCE
- The text sequence is indicated by the arrows shown in illustrations.
Example
Scheme 28
UNIT
| Terms | Unit |
|---|---|
| Electrical current | A (Ampere) |
| Electric Potential | V (Volt) |
| Electric Power | W (Watt) |
| Length | Mm (Willimeter) in (inch) |
| Negative Pressure | KPa (Kilo Pascal) mmHg (Millimeters Of Mercury) inHg (inches of mercury) |
| Positive Pressure | KPa (kilo Pascal) kgf/cm 2 (kilogram Force Per Square Centimeter) psi (Pounds Per Square Inch) |
| Resistance | Ohm (Ohm) |
| Torque | N.m (Newton Meter) |
| Torque | Kgf.m (Kilogram Force Per Meter) |
| Torque | Kgf.cm (Kilogram Force Per Centimeter) |
| Torque | Ft.lbf (Foot Pound) |
| Torque | In.lbf (Inch Pound) |
| Volume | L (Liter) |
| Volume | US qt (U.S. Quart) |
| Volume | Imp qt (Imperial Quart) |
| Volume | Ml (Milliliter) |
| Volume | Cc (Cubic Centimeter) |
| Volume | Cu in (Cubic Inch) |
| Volume | Fl oz (Fluid Ounce) |
| Weight | G (Gram) |
| Weight | Oz (Ounce) |
UNIT
CONVERSION TO SI UNITS (SYSTEME INTERNATIONAL D'UNITES)
- All numerical values are used on SI units. Numbers shown in conventional units are converted from these values.
ROUNDING OFF
- 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.
- 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
- 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.
PROTECTION OF THE VEHICLE
- Always be sure to cover fenders, seats and floor areas before starting work.
Scheme 29
PREPARATION OF TOOLS & MEASURING EQUIPMENT
- Be sure that all necessary tools and measuring equipment are available before starting any work.
Scheme 30
DISCONNECTION OF THE NEGATIVE BATTERY CABLE
- Before beginning any work, turn the ignition switch to LOCK, disconnect the negative battery cable and then wait for more than one minute to allow the backup supply of the air bag diagnostic monitor unit 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.
ARRANGEMENT OF PARTS
- All disassembled parts should be carefully arranged for reassembly.
- Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
Scheme 31
Scheme 32
- 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.
HOSE CLAMPS
- 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 33
Vise
- When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
Scheme 34
DYNAMOMETER
- When test-running a vehicle on a dynamometer: Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Watch the water temperature gauge. WARNING: On 4WD vehicles, if the front wheels are on a dynamometer, the rear wheels must be on chassis rollers or the vehicle could learch forward.
Scheme 35
- Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable.
Scheme 36
- Insert the probe into the service hole when connecting a jumper wire to the data link connector. CAUTION: Inserting a jumper wire probe into the data link connector terminal may damage the terminal.
Scheme 37
Scheme 38
- When disconnecting two connectors, grasp the connectors, not the wires.
- Connectors can be disconnected by pressing or pulling the lock lever as shown.
Scheme 39
- When locking connectors, listen for a click indicating they are securely locked.
Scheme 40
Scheme 41
- When a tester is used for checking continuity or measuring voltage, insert the tester probe from the wiring harness side.
- Check 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 42
- Pull lightly on individual wires to check that they are secured in the terminal.
Scheme 43
- Use the appropriate tools to remove a terminal as shown in illustration. While installing a terminal, be sure to insert it until it locks securely.
- 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 44
- Handle sensors, switches and relays carefully. Do not drop them or strike them against other objects.
Scheme 45
- Two-color wires are indicated by a two-color code symbol.
- The first letter indicates the base color of the wire and the second, the color of the stripe. WIRING COLOR CODES COLOR CODE Blue L Orange O Black B Pink P Brown BR Red R Dark Blue DL Purple PU Dark Green DG Sky Blue SB Green G Tan T Gray GY White W Light Blue LB Yellow Y Light Green LG Violet V Natural N
Scheme 46
- 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 checked.
- Be sure the negative battery terminal is disconnected before replacing a main fuse.
- When replacing a pullout fuse, use the fuse puller.
Scheme 47
- A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch. CAUTION: Do not connect a jumper wire from the power source line to a body ground. This may cause burning or other damage to wiring harnesses or electronic components.
Scheme 48
- 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.
Scheme 49
- The ohmmeter is used to measure the resistance between two points in a circuit and to check for continuity and short circuits. CAUTION: Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the ohmmeter.
JACKING
| WARNING | Do not run the engine when jacking the vehicle. The wheels contacting the ground could cause the vehicle to move. |
| WARNING | Make sure the jack and jack stands are correctly located to prevent the vehicle from falling. |
| WARNING | Wheel chocks should be used to prevent the vehicle from rolling and falling off the jack. |
JACKING POINTS - FRONT
- The jacking point is a tab that extends from the front suspension lower control arm at the bolt head of the lower control arm.
JACKING POINTS - REAR
- The rear jacking point is located on the rear trailing arms.
Scheme 50
| CAUTION | Damage to the suspension, exhaust or steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle. |
- The lifting points are part of the uni-body structure.
Scheme 51
Proper lifting and towing are necessary to prevent damage to the vehicle. State and local laws must be followed.
When a vehicle is towed on its front wheels, lock the steering wheel in a straight ahead position with a steering wheel clamp.
On 2WD vehicles, it is acceptable to tow the vehicles with the front wheels on the ground and the rear wheels off the ground.
On 4WD vehicles, it is recommended that the vehicle be towed with a wheel lift or flatbed equipment.
Do not tow with sling belt equipment.
FRONT TOWING
Before the vehicle is towed on its front wheels, with rear wheels on dolly, release the parking brake and put the gearshift (both manual and automatic) in N (Neutral).
REAR TOWING
Before the vehicle is towed on its rear wheels, with front wheels on dolly, release the parking brake and put the gearshift (both manual and automatic) in N (Neutral).
TOWING TWO-WHEEL DRIVE VEHICLES
Towing A Vehicle With A Manual Transmission With The Front Wheels Off The Ground
- Place the transmission in N (Neutral).
Towing A Vehicle With An Automatic Transmission With The Front Wheels Off The Ground
- Place the transmission in N (Neutral).
TOWING FOUR-WHEEL DRIVE VEHICLES
On 4x4 vehicles, it is recommended that the vehicle be towed with a wheel lift and dolly or flatbed equipment.
SAE STANDARDS
- The table below lists the names and abbreviations that have been used by Mazda up to now and their SAE equivalents.
| Abbr. | Name | Remark |
|---|---|---|
| 3GR | Third Gear | — |
| 4GR | Fourth Gear | — |
| A/C | Air Conditioning | — |
| ACL | Air Cleaner | — |
| AIR | Secondary Air Injection | Inject With Compressor |
| AP | Accelerator Pedal | — |
| B+ | Battery Positive Voltage | — |
| BARO | Barometric Pressure | — |
| CAC | Charge Air Cooler | — |
| CC | Oxidation Catalytic Converter | — |
| CIS | Continuous Fuel Injection System | — |
| CKP | Crankshaft Position Sensor | — |
| CLS | Closed Loop System | — |
| CMP | Camshaft Position Sensor | — |
| CPP | Clutch Pedal Position | — |
| CTP | Closed Throttle Position | — |
| Dl | Distributor Ignition | — |
| DLC | Data Link Connector | — |
| DLI | Distributorless Ignition | — |
| DTC | Diagnostic Trouble Code(s) | — |
| DTM | Diagnostic Test Mode | Diagnostic Trouble Codes Depend On The Diagnostic Test Mode |
| ECM | Engine Control Module | — |
| ECT | Engine Coolant Temperature | — |
| EGR | Exhaust Gas Recirculation | — |
| El | Electronic Ignition | Controlled By The ECM/PCM |
| EM | Engine Modification | — |
| EVAP | Evaporative Emission | — |
| FC | Fan Control | — |
| FF | Flexible Fuel | — |
| FP | Fuel Pump | — |
| FPR | Fuel Pump Relay | In Some Models, There Is A Fuel Pump Relay That Controls Pump Speed. That Relay Is Now Called The Fuel Pump Relay (Speed) |
| GEN | Generator | — |
| GND | Ground | — |
| HO2S | Heated Oxygen Sensor | With Heater |
| IAC | Idle Air Control | — |
| IAT | Intake Air Temperature | — |
| ICM | Ignition Control Module | — |
| KS | Knock Sensor | — |
| MAF/IAT | Mass Air Flow/Intake Air Temperature Sensor | — |
| MAP | Manifold Absolute Pressure | — |
| MFI | Multiport Fuel Injection | — |
| MIL | Malfunction Indicator Lamp | — |
| O2S | Oxygen Sensor | — |
| OBD | On-Board Diagnostic | — |
| OL | Open Loop | — |
| PAIR | Pulsed Secondary Air Injection | Pulsed Injection |
| PCM | Powertrain Control Module | Device That Controls Engine & Powertrain |
| PNP | Park/Neutral Position | — |
| PSP | Power Steering Pressure | — |
| SAPV | Secondary Air Pulse Valve | — |
| SFI | Sequential Multipoint Fuel Injection | — |
| TB | Throttle Body | — |
| TC | Turbocharger | — |
| TCC | Torque Converter Clutch | — |
| TCM | Transmission (Transaxle) Control Module | — |
| TP | Throttle Position Sensor | — |
| TR | Transmission (Transaxle) Range | — |
| TWC | Three Way Catalytic Converter | — |
| VAF | Volume Air Flow Sensor | — |
| VR | Voltage Regulator | — |
| VSS | Vehicle Speed Sensor | — |
| WOT | Wide Open Throttle Position | — |
| WU-TWC | Warm Up Three Way Catalytic Converter | Directly Connected To Exhaust Manifold |
SAE STANDARDS (NEW)
SCHEDULE 1
I : Inspect and repair, clean, adjust, or replace if necessary (Oil-permeated air filter cannot be cleaned using the airblow method).
R : Replace.
Scheme 52
Scheme 53
SCHEDULE 2
I : Inspect and repair, clean, adjust, or replace if necessary (Oil-permeated air filter cannot be cleaned using the airblow method).
R : Replace.
