Repairing Manual 1990-1998 Mazda 323/ MX-3/ 626/ MX-6/ Millenia/ Protege Timing Belt Cover Removal & Installation

Repairing Manual 1990-1998 Mazda 323/ MX-3/ 626/ MX-6/ Millenia/ Protege Timing Belt Cover Removal & Installation

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REMOVAL & INSTALLATION 1990-94 1.6L and 1.8L (except K8) Engines See Figures 1 and 2 1. Disconnect the negative battery cable. 2. Remove the engine under splash shield. Fig. Fig. 1: Exploded view of the 1990-94 1.6L and 1.8L SOHC timing belt cover assembly Fig. Fig. 2: Exploded view of the 1.8L DOHC timing belt cover assembly 3. Remove the accessory drive belts. Refer to General Information & Maintenance . 4. Remove the crankshaft pulley. 5. Remove the inner and outer timing belt guide plates. 6. Remove the 2 bolts and remove the upper timing belt cover assembly. 7. Remove the 1 bolt and remove the lower timing belt cover assembly and gasket. To install: 8. Install the lower cover gasket and the lower cover. Tighten the bolt to 69-95 inch lbs. (8-11 Nm). 9. Install the upper cover gasket and the upper cover. Tighten the bolts to 69-95 inch lbs. (8-11 Nm). 10. Install the timing belt inner and outer guide plates.

Make sure that the inner guide plate is installed in the proper direction. 11. Install the crankshaft pulley. Tighten the bolts to 109-152 inch lbs. (12-17 Nm). 12. Install the accessory drive belts. Refer to General Information & Maintenance . 13. Install the under engine splash shield. 14. Connect the negative battery cable. 1.5L and 1995 1.6L DOHC Engines See Figure 3 1. Disconnect the negative battery cable. 2. Remove the engine under splash shield. 3. Drain the cooling system. 4. Remove the air intake pipe. Fig. Fig. 3: Exploded view of the timing cover assembly for the 1.5L and 1995 1.6L engines-1995-98 1.8L engine is similar 5. Disconnect the upper radiator hose and the 2 lower coolant hoses from the thermostat housing. 6. Remove the power steering, air conditioning and alternator drive belts. Refer to General Information & Maintenance . 7. Remove the retaining bolts and remove the water pump pulley. 8. Remove the crankshaft pulley bolts and remove the crankshaft pulley. 9. Remove the inner and outer timing belt guide plates. 10. Disconnect the coil electrical connectors and remove coil assembly. Remove the spark plug wires. Be certain to record positioning of plug wires for assembly purposes. 11. Remove the spark plugs. 12. Remove the cylinder head cover bolts and remove the cover.

13. Remove the bolts from the timing belt covers and remove the top, the center and the lower timing belt covers. To install: 14. Install the timing belt covers with gaskets and tighten the bolts to 69-95 inch lbs. (8-11 Nm). 15. Apply silicone sealant to the corners of the cylinder head cover and install the cover. Tighten the bolts to 43-78 inch lbs. (5-9 Nm). 16. Install the spark plugs and tighten them to 11-17 ft. lbs. (15-23 Nm). 17. Install the coil assembly and connect the electrical connectors and the spark plug wires. 18. Install the inner and outer timing belt guide plates. 19. Install the crankshaft pulley and tighten the bolts to 109-152 inch lbs.(12-17 Nm). 20. Install the water pump pulley and tighten the bolts to 69-95 inch lbs. (8-11 Nm). 21. Install the power steering, air conditioning and alternator drive belts. Refer to General Information & Maintenance . 22. Install the coolant and radiator hoses and refill the coolant to the proper level. 23. Install the air intake pipe and connect the negative battery cable. 1995-98 1.8L (except K8) DOHC Engines See Figure 3 1. Disconnect the negative battery cable.

2. Remove the engine under splash shield. 3. Remove the power steering, air conditioning and alternator drive belts. Refer to General Information & Maintenance . 4. Remove the retaining bolts and remove the water pump pulley. 5. Remove the crankshaft pulley bolts and remove the crankshaft pulley. 6. Remove the inner and outer timing belt guide plates. 7. Remove the bolt and remove the upper timing belt cover assembly. 8. Remove the bolts from the middle and lower timing belt cover assembly and remove the covers and the gaskets. To install: 9. Install the upper, the center and the lower timing belt covers. Tighten the bolts to 69-95 inch lbs. (8-11 Nm). 10. Install the timing belt inner and outer guide plates. Make sure that the inner guide plate is installed in the proper direction. 11. Install the crankshaft pulley. Tighten the bolts to 109-152 inch lbs. (12-17 Nm). 12. Install the water pump pulley and tighten the bolts to 69-95 inch lbs. (8-11 Nm). 13. Install the P/S, A/C and alternator drive belts. Refer to General Information & Maintenance . 14. Install the under engine splash shield. 15. Connect the negative battery cable. 2.0L Engine See Figures 4, 5, 6, 7 and 8 1. Disconnect the negative battery cable. 2. Raise and safely support the vehicle. Remove the right front wheel.

Repairing Manual 2002 Mazda Protege LX Timing Belt Removal

Repairing Manual 2002 Mazda Protege LX Timing Belt Removal

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1. Disconnect negative battery cable. Remove Crankshaft Position (CKP) and Camshaft Position (CMP) sensors from front of engine (if equipped). See Fig. 1 . Remove spark plugs. 2. Remove accessory drive belts. Leaving hoses attached, remove power steering pump and position aside. Remove the water pump pulley. See Fig. 2 . Rotate crankshaft so No. 1 cylinder is on TDC of compression stroke. CAUTION: On models with a crankshaft position sensor, rotor is on rear of crankshaft pulley. DO NOT damage rotor when removing crankshaft pulley. 3. Using Coupling Flange Holder (49 S120 710) and Adapter (49 E011 1A1), or equivalent, hold the crankshaft and remove crankshaft pulley bolt. See Fig. 3 . Remove crankshaft pulley and guide plate (large washer). 4. Loosen valve cover bolts in 2-3 steps in order shown. See Fig. 4 . Remove valve cover and gasket. 5. Remove dipstick tube. Remove upper and lower timing belt covers.

Support engine from above. Remove No. 3 engine mount at timing belt end of engine. 6. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Install crankshaft pulley bolt finger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. See Fig. 5 . 7. Turn tensioner clockwise using a Allen wrench to relieve spring tension, and then disconnect spring from the hook pin. See Fig. 6 . Remove timing belt. Remove crankshaft sprocket, tensioner and idler pulley (if necessary). Inspection CAUTION: Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life. Check timing belt for cracks, peeling, abrasion or other damage. See Fig. 7 . Check tensioner bearing for looseness or roughness of rotation.

Inspect tensioner spring for stretching. Tensioner spring free length should be 1.44″ (36.6 mm). Measure spring free length from inside edge to inside edge of hooked portion of spring. See Fig. 8 . Replace parts as necessary. Install the tensioner. Rotate tensioner. See Fig. 9 . If tensioner rotates with no resistance or does not rotate, replace tensioner. Installation 1. Ensure all timing marks are aligned. See Fig. 10 . 2. Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley, and camshaft sprockets. Ensure slack does not exist on idler pulley side of timing belt. 3. Complete timing belt installation on slack (tensioner) side. With tensioner spring removed, allow tensioner to ride against timing belt. Turn crankshaft 2 revolutions in normal direction of rotation (clockwise). Ensure camshaft and crankshaft timing marks are still correctly aligned. See Fig. 5 . If not correctly aligned, timing belt will have to be removed and repositioned.

4. If all timing marks are okay, turn tensioner clockwise using an Allen wrench. Connect tensioner spring to pin on engine block. See Fig. 11 . Turn crankshaft 2 revolutions. Ensure camshaft and crankshaft timing marks are still aligned. See Fig. 5 . 5. To install remaining components, reverse removal procedure. When installing valve cover gasket, apply small amount of silicone sealer to 4 corners of gasket where the front of both camshafts go through cylinder head. See Fig. 12 . Tighten valve cover bolts to specification in correct sequence. See Fig. 13 . Adjust drive belts to proper tension. 6. Inspect crankshaft position sensor air gap. Air gap between outer edge of crankshaft pulley rotor tooth and center of CKP sensor should be 0.029-0.059″ (0.5-1.5 mm). See Fig. 14 . Air gap is not adjustable. If gap is incorrect, check for damaged parts.

Repairing Manual 2004-2005 Mazda3 Engine Controls – MIL ON/DTC P0172/P2178/P2188

Repairing Manual 2004-2005 Mazda3 Engine Controls – MIL ON/DTC P0172/P2178/P2188

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2004-2005 MAZDA3 – MIL ILLUMINATION – P0172/P2178/P2188 SET APPLICABLE MODEL(S)/VINS 2004-2005 Mazda3 vehicles with VINs lower than JM1BK**** **350581 ( produced before July 1, 2005) DESCRIPTION Some vehicles may experience MIL Illumination with DTC P0172/P2178/P2188 stored in PCM memory. This may be caused by a poor connection between the terminal and harness wire at the airflow sensor connector. Other possible causes for this condition are as follow: – Erratic signal from air flow sensor due to foreign material. – Oxygen sensor malfunction. – Engine coolant temperature sensor malfunction. – Purge solenoid valve malfunction. DTCs vary depending on vehicle. -

P0172 (Fuel system too rich) – California Spec 2.0L – P2178 (Fuel system too rich at off idle) – Federal Spec 2.0L All 2.3L – P2188 (Fuel system too rich at idle) – Federal Spec 2.0L All 2.3L Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE 1. Verify customer concern. 2. Record radio presets. 3. Remove battery cover and battery duct. See Workshop Manual section 01-17 BATTERY REMOVAL/INSTALLATION. Use flat screwdriver to remove clip if necessary. 4. Disconnect negative battery cable using 10mm wrench. Zoom 5. Disconnect airflow sensor connector. Sized for Print Zoom 6. Identify and carefully cut Black, protective tube of airflow sensor harness using scissors. Sized for Print 7. Using 1/16″ (1.7mm) wide pin extractor from Terminal repair kit, remove Black ground wire terminal from airflow sensor connector. Cut off ground wire terminal at base with wire cutter. 9. Remove approximately 1/2″ (10mm) of insulation from Black ground wire.

Repairing Manual 2001 Mazda 626 ES How to Install Headlight

Repairing Manual 2001 Mazda 626 ES How to Install Headlight

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CAUTION: When you install the headlight, the headlight may hit the edge of the front fender panel. This may cause scratches on the front fender panel. To avoid this, attach protective tape to the edge of the front fender panel. 1. Disconnect the negative battery cable. 2. Remove the front combination light. 3. Remove in the order as indicated below. 1. 2. 3. 4. 5. Bolt Connector Headlight Install in the reverse order of removal. Adjust the headlight aiming.

Repairing Manual 1985 Mazda RX-7 GS Wheel Alignment Specifications & Procedures

Repairing Manual 1985 Mazda RX-7 GS Wheel Alignment Specifications & Procedures

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DESCRIPTION Mazda uses independent front suspension with MacPherson type struts. Strut assemblies mount between lower control arms and upper fender panels. Strut assemblies consist of inner shock absorbers and coil springs surrounding outside of strut tube housing. The steering knuckle is connected to lower control arm and strut. Lower control arms pivot at crossmember and are connected by ball joints to steering knuckle. Some models are equipped with a stabilizer bar. Strut rods are installed to maintain alignment and stability. ADJUSTMENT WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES See WHEEL ALIGNMENT SPECIFICATIONS & PROCEDURES in WHEEL ALIGNMENT section.
WHEEL BEARING 1. Raise and support vehicle. Remove brake caliper and support out of the way. Remove brake caliper bracket. Remove grease cap, cotter pin and nut lock. Tighten spindle nut to 18-22 ft. lbs. (24-30 N.m). 2. Turn wheel hub a few times to seat bearings. Loosen adjusting nut slightly until it can be turned by hand. Install one hub-to-wheel bolt and connect a spring scale to it. 3. Check the hub turning torque and note that value. Adjust wheel bearing preload by turning the adjusting nut until the drag value, determined earlier, is increased an additional 1.0-1.43 lbs. (.45-.65 kg). Reinstall all removed components. INSPECTION BALL JOINT CHECKING 1. Disconnect strut assembly and tie rod end from steering knuckle arm. Check ball joint dust boot for cracks or other damage. Rotate ball joint

Repairing Manual 1995 Mazda MX-6 How to Remove and Install Front Disc Brake Pads

Repairing Manual 1995 Mazda MX-6 How to Remove and Install Front Disc Brake Pads

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Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . Pivot caliper upward and support using rope. 2. Remove pads, shims, guide plates or pad guides and “V” springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD LININGSPECIFICATIONS (FRONT) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS .

Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system. FRONT BRAKE ROTOR Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). Remove rotor. 2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table.To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation 1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See Fig. 3 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston. 2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire.

Remove “M” springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04″ (1.0 mm). 3.To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn. REAR BRAKE CALIPER Removal & Installation 1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Disconnect brake hose from caliper. 2. Remove manual adjustment gear concealment plug from caliper. See Fig. 3 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston. 3. Remove guide bolts from caliper. Remove brake caliper from caliper mount. To install, reverse removalprocedure. Bleed air from system. Removal & Installation Raise and support rear of vehicle. Remove rear wheel assemblies. Disconnect brake flexhose from caliper. Remove rear brake pads. See REAR DISC BRAKE PADS . Remove remaining caliper guide bolt. Remove brake caliper from caliper mount. To install, reverse removal procedure. Bleed air from system.

Repairing Manual 2004-2008 Mazda RX-8 Engine Cranks No Start

Repairing Manual 2004-2008 Mazda RX-8 Engine Cranks No Start

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Description some vehicles may experience difficulty starting (cranks no start). A cranks, no start condition may occur after driving the vehicle a short distance without engine reaching normal operating temperature. Examples: starting a vehicleand moving it to wash it, engine stall due to mis-application of clutch then restart. This commonly occurs at port facilities or dealer lots where vehicles are frequently started cold, moved for short distances and then turned off. A cranks, no start condition may be caused either by fuel flooded spark plugs or lower than normal compression due to apex seals locked into rotor groove from carbon accumulation.

Note: • after repairs, provide customers with customer information on the last page of this bulletin (for customers to try after a “cranks, no start” condition, before towing to dealership). Repair procedure “a” 1. Verify concern by attempting to start engine. – if engine starts, return vehicle to customer. – if engine fails to start, go to step 2. 2. Disconnect the secondary air injection pump electrical connector (b1-04). Note: • this will protect the catalytic converter by preventing rapid light off due to unburned fuel purging from the engine in the following steps. 1273a caution: • the following steps will force un-burnt fuel from the combustion chambers through the spark plug holes. Use caution not to create sparks or other sources of ignition during these steps. Perform this procedure in a well ventilated area. 3. Remove all 4 spark plugs from the engine. See workshop manual section 01-18 spark plug removal / installation.

4. Disconnect eccentric shaft position sensor (esps) b1-27 connector. Note: • this will cut fuel injection and spark while performing the procedure. 5. Place cloth near spark plug holes to absorb fuel residue. 6. Crank the engine until all fuel is purged from spark plug holes. (do not crank engine longer than 10 seconds. If more than 10 seconds is required, wait 5 seconds in between cranking.) perform this procedure in a well ventilated area. 7. Connect esps connector b1-27. 8. Install new spark plugs. 9. Attempt to start engine without depressing accelerator pedal. – if the engine starts, go to step 10. – if engine fails to start, the engine compression may be lower than specification. Go to repair proce- dure “b”. 10. Keep engine running between 1500-2000 rpm until engine speed has stabilized. Maintain this engine speed until all smoke has dissipated and / or engine has come to full operating temperature. Note: 11. Shut engine off. 12. Connect the secondary air injection pump connector b1-04. 13. Erase all dtcs and confirm repairs. • do not race the engine, this may cause catalyst damage.

Repairing Manual 1998 Mazda Millenia Timing Belt Removal & Installation

Repairing Manual 1998 Mazda Millenia Timing Belt Removal & Installation

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TIMING BELT Removal 1. Disconnect negative battery cable. On Millenia, raise and support vehicle. Remove right front wheel. Remove lower engine covers. 2. On all models, remove accessory drive belts. Remove water pump pulley. Removedrive belt idler pulley bracket. Remove retaining bolts and power steering pump with hoses attached, and secure pump out of way. Remove spark plugs. CAUTION: DO NOT damage crankshaft position sensor rotor on rear of crankshaft pulley during crankshaft pulley removal.

3. Holding crankshaft stationary, remove the crankshaft pulley retaining bolt. Using gear puller, remove crankshaft pulley. 4. Remove oil dipstick and oil dipstick tube. Remove crankshaft position sensor from front of engine. See Fig. 1 . Support engine using hoist or floor jack. Remove right (timing belt side) engine mount. Remove retaining bolts, timing belt covers, and gaskets. See Fig. 1 . 5. Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke.

Ensure groove on crankshaft sprocket aligns with indicator on oil pump body. See Fig. 2 . Ensure camshaft sprocket timing marks are aligned with marks on rear cover. 6. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Loosen the 2 timing belt tensioner bolts. Hold timing belt tensioner, and remove lower retaining bolt. Remove No. 1 idler pulley and timing belt. Inspection 1. Inspect timing belt for damaged teeth, cracking and oil contamination. Ensure idler pulleys (No. 1 and No. 2) and tensioner pulley rotate freely. Replace damaged components. 2. Inspect timing belt tensioner for signs of oil leakage. Replace timing belt tensioner if oil leakage exists. Measure timing belt tensioner rod protrusion from end of rod to edge of housing. See Fig. 3 . There are 2 types of tensioners used on this engine. See Fig. 4 . Replace timing belt tensioner if rod protrusion distance is not as specified. See TIMING BELT TENSIONER ROD PROTRUSION table.

Repairing Manual 2006-2007 Mazda MX-5 Water Accumulation In Footwell / Plugged Soft Top Drains

Repairing Manual 2006-2007 Mazda MX-5 Water Accumulation In Footwell / Plugged Soft Top Drains

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Applicable model(s)/vins 2006-2007 mx-5 soft top models with vins lower than jm1 nc**** ** 131736 (produced before november 20, 2006) description some vehicles equipped with the folding soft top may experience water accumulation inthe foot wells due to the soft top drains becoming clogged with leaves and other debris. As mass production changes: – a filter has been added to the drain valve assembly to prevent leaves or other foreign substance from clogging the drain. – ribs have been added to the upper and lower valves of the drain valve assembly to prevent the valves (rubber flaps) from getting being forced out of position in the event compressed air is used to clear the drains from under the vehicle.

Vehicles with clogged drains should have the drain assemblies updated as described in the following repair pro- cedure, also included in this bulletin are maintenance tips for the customers to perform to ensure dependable operation of these drains. Repair procedure note: • 1. Verify customer concern. 2. Remove rear package trim and related components, then remove the left and right side shelves. Refer to appropriate workshop manual section 09-17 side shelf removal /installation. Removal of the soft top is not required to perform the repair procedure. Illustrations in this bulletin are forcomponent identification and location purposes only. 3. Remove the seat belt retractors and covers. Refer to appropriate workshop manual section 08-11 seat belt removal / installation. 4. Using seat belt retractor holes for access, remove thedrain valve assemblies. Drain cover filter installation 5. Clean and degrease the drain cover assemblies, to assure proper adhesion of the filter to drain cover assemblies wipe down contact area indicated with isopropyl alcohol.

Repairing Manual 2003 Mazda Protege5 Front Combination Light Removal/ Installation

Repairing Manual 2003 Mazda Protege5 Front Combination Light Removal/ Installation

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1. Disconnect the negative battery cable. 2. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .) 3. Remove in the order indicated in the figure(s). 4. Install in the reverse order of removal. 5. Adjust the headlight aiming. (See HEADLIGHT ADJUSTMENT .) HEADLIGHT ADJUSTMENT 1. 2. 3. 4. 5. Adjust the tire air pressure to the specification. Position the unloaded vehicle on a flat, level surface. Seat one person in the driver’s seat. Position the vehicle straight ahead and perpendicular to a wall. Set the headlights 3 m {10 ft} from the wall. 6. 7. 8. 9. While adjusting oneheadlight, disconnect the connector of the other. Start the engine to charge the battery. Turn on the low-beamheadlight. Adjust the headlights by turning the adjusting screws as shown in the figure. Loosen the screws first, then tighten them. NOTE: If the adjusting screws are tightened first, then loosened, they will continue to loosen when the vehicle is in motion and may cause the headlights to become misaligned.

1993 Mazda 626 Engine Mount Removal

1993 Mazda 626 Engine Mount Removal

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Engine mount member Caution Support the engine before removing the member. 1. Suspend the engine by using a chain block. 2. Remove the engine mount No.2 nuts. 3. Remove the engine mount member bolts and nuts and remove the engine mount member. Removal note: Engine and transaxle assembly Caution Do not damage any components in the engine compartment. Lift the engine and transaxle assembly out as a unit.

1993 Mazda 626 Speedometer – Replacement Procedure

1993 Mazda 626 Speedometer – Replacement Procedure

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Subject: SPEEDOMETER REPLACEMENT PROCEDURE DESCRIPTION In accordance with Federal regulations, follow the procedures listed below when replacing a speedometer. NOTE: 1. Mazda vehicles are manufactured with tamper-proof speedometers and the mileage can not be altered or adjusted. 2. When a speedometer is replaced, the new speedometer will read zero (0). 3. This procedure is extremely important to accurately represent actual vehicle mileage. 4. The “Speedometer Replacement Label” referenced below is available through the Mazda Program Center for a limited time. Mazda Motor of America, Inc. is providing 1 sheet of 20 labels with this bulletin (see Illustration). REPLACEMENTPROCEDURE 1. Remove and replace the speedometer according to the workshop manual. 2. Complete the following information on the “Speedometer Replacement Label.” ^ Mileage before speedometer replacement ^ Date ofreplacement ^ Dealer code. 3. Attach the label to the driver’s side “B” pillar. 4. Complete the “SpeedometerReplacement Record” in the Warranty Information Booklet as referenced.

1993 Mazda 626 Component Diagnosis & Testing

1993 Mazda 626 Component Diagnosis & Testing

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1. Turn ignition switch and cruise control main switch to On position. 2. Ensure main switch indicator lamp illuminates. If lamp does not illuminate, check continuity between terminals of cruise control main switch, Fig. 16 through 19 . If switch operates correctly, repair wire harness. 3. Measure voltage at following terminals of the control unit, Fig. 20 through 25 . If terminal voltage are correct, replace cruise control unit. 4. Disconnect cruise stop lamp and clutch switches and ensure continuity exists between terminals only with pedal depressed. 5. If switches operate correctly, repair wiring to switches. 6. Check for continuity between terminals of cruise control switch, Fig. 26 through 29 .

If switch operates correctly, repair wire harness. 7. Disconnect stop lamp switch and ensure continuity exists betweenterminals only with pedal released. 8. Measure actuator solenoid resistance using an ohmmeter, Fig. 30 through 33 . If continuity is not as specified, replace actuator. 9. If continuity is as specified, disconnect actuator cable, start engine and run at a idle. 10. Apply battery voltage to terminals shown in Fig. 34 through 36 , and check actuator operation. If not as specified, replace actuator. 11. Remove instrument cluster as described in appropriate chassis section. 12. Connect an ohmmeter between the following terminals on the 12-pin connector: a. On Miata models, connect between terminals 2F and 2D. b. On 1993-95 MPV models , connect between terminals 1J and 2A. 13. Ensure intermittent continuity betweenterminals while rotating speedometer cable shaft. If four times per rotation, replace speedometer.

2004 Mazda 6 i How to Remove and Install Water Pump Drive Belt

2004 Mazda 6 i How to Remove and Install Water Pump Drive Belt

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1. Verify that the water pump drive belt auto tensioner indicator mark does not exceeds the limit.  if it exceeds the limit, replace the water pump drive belt. (see water pump drive belt .) fig. 21: water pump drive belt auto tensioner limitindicator mark – malfunction/worn belt water pump drive belt 1. Remove the plug hole plate. 2. Rotate the water pumpdrive belt auto tensioner counterclockwise to release the drive belt tension and remove the water pump drive belt. Fig. 23: locating water pump drive belt auto tensioner 3. Reinstall the water pump drive belt or install a new water pumpdrive belt. Water pump drive belt pulley removal note 1. Replace part a of the sst [303-009 (49 un30 3009)] with the sst [303-457 (49 un30 3457)]. Fig. 31: water pump pulley removal special tools 2. Remove the water pump pulley using the ssts. Fig. 32: removing water pump pulley water pump drive belt pulley installation note 1. Install the water pumppulley using the sst.

1995 Mazda 626 Es Drive Belt Adjustment

1995 Mazda 626 Es Drive Belt Adjustment

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Drive belt adjustment note: note: ensure drive belts are not worn, cracked or frayed and are correctly mounted on pulleys. See fig. 1 . If a new belt is used, adjust belt deflection at midpoint of new belt specification. Fig. 1: identifying correct belt mounting 2.0l engine alternator loosen alternator mounting bolts “a” and “b” and adjust belt deflection by turning adjusting bolt “c”. See fig. 2 and fig. 7 . See adjustment specifications . Tighten bolts to specification. See torquespecifications . None a/c compressor/power steering pump loosen bolts “a” and “b” and adjust belt deflection by turning adjusting bolt “c”. See fig. 3 and fig. 8 . See adjustment specifications . Tighten bolts to specification. See torquespecifications .

1983 Mazda RX-7 GSL Testing Engine Compression

 1983 Mazda RX-7 GSL Testing Engine Compression
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Engine compression the manufacturer recommends using a special compression tester (49 0820 280k). Compression testers for piston engines will read only the highest pressure of the 3 combustion chambers in the rotor housing. High tension wire resistance carefully remove high tension wires from spark plugs and distributor cap. Using an ohmmeter, measure resistance of wires while gently twisting wires. If resistance is not to specifications, or fluctuates from infinity to any value, replace high tension wire(s). High tension wire resistance adjustments distributor all models are equipped with mitsubishI electronic ignition with 2 pick-up coils. Air gap is non-adjustable. Ignition timing note: on vehicles equipped with automatic transmission, place selector lever in “d” position and block the wheels. 1. Warm engine to normal operating temperature. Connect a tachometer, then connect timing light to leading (lower) spark plug of front rotor. Start engine and run at idle speed. 2. Check ignition timing and rotate distributor to correct if necessary. Tighten distributor lock nut and recheck timing. 3. Connect timing light to trailing (upper) plug of front rotor. Start engine and check timing. If not correct, loosen vacuum unit attaching screws. Move vacuum unit in or out to adjust trailing timing. Remove test equipment.

1990-1998 Mazda 323/ MX-3/ 626/ MX-6/ Millenia/ Protégé Ignition Switch/ Lock Cylinder Removal And Installation

1990-1998 Mazda 323/ MX-3/ 626/ MX-6/ Millenia/ Protégé Ignition Switch/ Lock Cylinder Removal And Installation

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See Figures 1 and 2 CAUTION Some models covered by this information may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Chassis Electrical . The ignition lock is an integral component of the steering lock mechanism. If the ignition lock must be replaced, perform the following procedure. Fig. Fig. 1: Exploded view of the ignition switch/lock cylinder assembly Fig. Fig. 2: Remove the break-off head retaining bolts by chiseling a slot in the bolt, then removing them with a screwdriver Millenia 1. Disconnect the negative battery cable. 2. Properly disarm the air bag system. 3. Remove the rear console box, brake boot and center panel (disconnect the harness connectors).

4. Remove the rear console. 5. Remove the undercover, glove compartment and compartment cover. 6. Remove the upper and lower steering column covers. 7. Tilt the steering shaft down. Remove the cap and panel light control switch. Remove the meter hood mounting screws. Pull the meter hood forward to disengage the clips. 8. Remove the instrument cluster, 9. Remove the drivers side air bag and the steering wheel. 10. Remove the combination switch. 11. Remove the passenger side air bag mounting bolts, electrical connector and remove the air bag module. 12. Remove the hood panel release lever. Pull the side panel forward to disengage the clips, remove the side panel. 13. Remove the side covers. 14. Remove the dashboard mounting bolts, pull the dashboard up and forward and remove. 15. Remove the steering shaft. 16. Remove the screw and the ignition switch and disconnect the ignition switch connector. 17. Using a chisel and a hammer make a groove in the heads of the steering lock mounting bolts. Remove the bolts and the steering lock assembly. To install: 18. Install the steering lock mechanism to the steering column jacket. Make sure that the lock operates correctly. Install new mounting bolts and tighten the bolts till the heads break off. 19. Reconnect the ignition switch connector to the ignition switch and install the ignition switch to the steering lock mechanism with the screw. 20. Replace the dashboard close to its mounts and connect all harness connectors.

Install all mounting bolts. Torque to 14-18 ft. lbs. (19-25 Nm). 21. Install the side covers. 22. Instal the side panels. 23. Install the steering shaft and torque the mounting bolts to 12-16 ft. lbs. (16-22 Nm). 24. Connect the passenger side air bag module electrical connector and replace the module to the dash and install the mounting bolts. 25. Install the combination switch on the steering column. 26. Install the steering wheel and drivers side air bag module. 27. Install the instrument cluster. 28. Install the meter hood. 29. Install the upper and lower steering column covers. 30. Install the glove compartment cover, compartment and the undercover. 31. Install the rear console, bracket, center panel, brake lever boot and the rear console box. 32. Reconnect the negative battery cable, 33. Place the steering column securely on a workbench. Use a chisel and hammer to make slots in the head of the lock screws. Remove the screws. Except Millenia 1. Disconnect the negative battery cable. 2. If equipped, disarm and remove the air bag. 3. Remove the steering wheel and the combination switch. 4. Remove the steering column by performing the following: a. Remove the driver’s side under dash covers. b. If equipped, disconnect the key interlock cable from the steering column. c. Detach any remaining electrical wire harness connectors from the column. d. Remove the upper column-to-dash mounting bolts. Support the steering column. e. Remove the intermediate shaft-to-steering column shaft coupling bolt and remove the steering column-to-firewall bracket bolts/nuts. f. Remove the steering column from the vehicle. 5. Place the steering column securely on a workbench. Use a chisel and hammer to make slots in the head of the lock screws. Remove the screws. 6. Remove the ignition lock assembly.

2008 Mazda CX-9 Accelerator Pedal Vibration

2008 Mazda CX-9 Accelerator Pedal Vibration

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Some vehicles may exhibit accelerator pedal vibration around 1750-2000 engine RPMs, regardless of speed. The vibration may also be felt at the brake pedal and steering wheel. On vehicles built after February 21, 2008, the No.2 dynamic chamber stay (bracket) was deleted on all production vehicles. The absence of the No.2 stay can cause pedal vibration. This procedure details installation of the No. 2 stay. The No. 2 dynamic chamber stay components required are the stay (1), the top fastener (2) and the bottom fastener (3). Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE 1. Verify customer concern. 2. Record customer radio station presets. 3. Remove negative battery cable. 4. Remove engine cover. Refer to Workshop Manual section 01-10 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].

5. Remove the air cleaner cover and resonance chamber. Disconnect the MAF/IAT sensor connector. Refer to Workshop Manual section 01-13 INTAKE-AIR SYSTEM REMOVAL / INSTALLATION [3.7L]. 6. Remove dynamic chamber assembly (upper intake manifold). Refer to Workshop Manual section 01-13 INTAKE-AIR SYSTEM REMOVAL / INSTALLATION [3.7L]. a. Remove one 8mm fastener from No.1 stay (just underneath throttle body) b. Remove three (3) harness clips from dynamic chamber using body removal tool (or equivalent). c. Remove six (6) 8mm bolts from dynamic chamber. NOTE: • When removing dynamic chamber assembly, leave back hose connected and position out of the way. Remove purge valve from mounting bracket to provide additional room to work. • 7. Remove two (2) 8mm bolts (A) and loosen one (1) 8mm bolt (B) from the rear exhaust manifold insulator (heat shield) as shown.

Refer to Workshop Manual section 01-15 EXHAUST SYSTEM REMOVAL / INSTALLATION [3.7L]. NOTE: • An inspection mirror may be helpful to see the bolts. 8. Reposition the heat shield (D) to gain access for No. 2 stay bottom fastener installation. 9. Install bottom fastener (C). Start threads but do not tighten the fastener at this time. NOTE: • Apply Loctite # 272 to bottom fastener threads before installation. 10. Install the No. 2 stay so that slotted side of the stay is placed on top of the bottom fastener installed in the previous step. Do not tighten the fastener at this time. 11. Check that all dynamic chamber gaskets are in place and mounting surfaces are clean. 12. Place dynamic chamber onto the lower intake manifold. 13. Install top fastener through the top bolt hole of the No.2 stay but do not tighten at this time. This will align the No.2 stay properly.

2003 Mazda B2300 Instrument Cluster Removal/ Installation

2003 Mazda B2300 Instrument Cluster Removal/ Installation
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1. Disconnect the battery. See BATTERY DISCONNECT . 2. Remove the screws (1) and pull the center finish trim panel finish panel (2) out from the instrument panel. Fig. 3: Removing Center Finish Trim Panel Finish Panel 3. Disconnect the electrical connectors and remove the radio and center instrument panel finish panel. 4. Remove the screws (1) and remove the inner hood lock release handle (2). 5. Remove the screws (1) and remove the instrument panel steering column cover (2). 6. Remove the four screws (1) and remove the instrument panel steering column opening cover reinforcement (2). 7. If equipped, position the column gear shift lever aside. 8. Remove the screws (1) and pull out the instrument cluster finish panel (2). 9. Disconnect the connectors (1) and pull out the instrument cluster finish panel (2). 10. Remove the instrument cluster screws (1). 11. If equipped with an automatic transmission, pull out the cluster and remove the transmission range indicator. 12. Disconnect the electrical connectors (1) and remove the instrument cluster (2).

2006 Mazda 3 s Engine Front Cover Installation

 2006 Mazda 3 s Engine Front Cover Installation
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1. Apply silicone sealant to the engine front cover as shown in the figure. CAUTION: Install the engine front cover within 10 min of applying the silicone sealant. Silicone sealant is not need in area C as indicated below due to an existing. They are oil and a thing without adhesion of dust to a seal side. Thickness A: 2.2-3.2 mm {0.087-0.125 in} B: 1.5-2.5 mm {0.059-0.098 in} Fig. 38: Applying Silicone Sealant To Engine Front Cover 2. Install the engine front cover bolts in the order shown in the figure. 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Compress the oil seal using the SST and a hammer. NO. 3 ENGINE MOUNT RUBBER AND NO. 3 ENGINE MOUNT BRACKET INSTALLATION NOTE 1. Tighten the stud bolt of the No. 3 engine mount bracket. Tightening torque 7.0-13 N.m {71.4-132.5 kgf.cm, 62.0-115.0 in.lbf} NOTE: Tightening stud bolt when the nut of No. 3 engine mount nut is loosened. 2. Hand-tighten the No. 3 engine mount rubber and No. 3 engine mount bracket. 3. Tighten the bolts and nuts in the order as shown in the figure.