engine MAZDA MODEL RX 8 2005 (in English) Repair Manual

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WARNING
Keep Flames Away:
Flames and sparks near open battery cells are dangerous. Hydrogen gas, produced
during normal battery operation, could ignite and cause the battery to explode. An
exploding battery can cause serious burns and injuries. Keep all flames including
cigarettes and sparks away from open battery cells. When working near a battery, do
not allow metal tools to contact the positive (
) or negative () terminal of the
battery. Do not allow the positive (
) terminal to contact the vehicle body.
Battery-Related Explosion:
Flames and sparks near open battery cells are dangerous. Hydrogen gas, produced
during normal battery operation, could ignite and cause the battery to explode. An
exploding battery can cause serious burns and injuries. Keep all flames, including
cigarettes, and sparks away from open battery cells.
Low Fluid Level or Frozen Battery:
Jump-starting a frozen battery or one with a low fluid level is dangerous. It may
rupture or explode, causing serious injury.
Don't jump-start a frozen battery or one with a low fluid level.
Connecting to Negative Terminal:
Connecting the end of the second cable to the negative (
) terminal of the discharged
battery is dangerous.
A spark could cause the gas around the battery to explode and injure someone.
Connect the cable to a point away from the battery.
Connecting Jumper Cable to Moving Parts:
Connecting a jumper cable near or to moving parts (cooling fans, belts) is dangerous.
The cable could get caught when the engine starts and cause serious injury. Never
connect a jumper cable to or near any part that moves.
CAUTION
Use only a 12 V booster system. You can damage a 12 V starter, ignition system, and
other electrical parts beyond repair with a 24 V power supply (two 12 V batteries in
series or a 24 V motor generator set).
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In Case of an Emergency
Emergency Starting
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1. Remove the engine cover.
2. Remove the rubber hose from the
battery cover.
3. Remove the battery cover from its rear
side.
4. Make sure the booster battery is 12 V
and that its negative terminal is
grounded.
5. If the booster battery is in another
vehicle, don't allow the vehicles to
touch. Turn off the engine of the
vehicle with the booster battery and all
unnecessary electrical loads in both
vehicles.
6. Connect the jumper cables in the exact
sequence as in the illustration.
lConnect one end of a cable to the
positive terminal on the discharged
battery (1).
lAttach the other end to the positive
terminal on the booster battery (2).
lConnect one end of the other cable
to the negative terminal of the
booster battery (3).
lConnect the other end to a solid,
stationary, exposed metallic point
(for example, the tightening bolt)
away from the discharged battery
(4).
Booster battery
Connect cables
in numerical
order and
disconnect in
reverse order.
Discharged
battery
7. Start the engine of the booster vehicle
and run it a few minutes. Then start the
engine of the other vehicle.
In Case of an Emergency
Emergency Starting
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8. When finished, carefully disconnect the
cables in the reverse order described in
Step 6.
NOTE
Verify that the engine cover is securely
installed.
Push-Starting
WARNING
Towing a Vehicle to Start It:
Towing a vehicle to start it is
dangerous. The vehicle being towed
could surge forward when its engine
starts, causing the two vehicles to
collide. The occupants could be
injured. Never tow a vehicle to start it.
You can't start a vehicle with an automatic
transmission by pushing it.
CAUTION
You shouldn't push-start a vehicle that
has a manual transmission. It can
damage the emission control system.
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In Case of an Emergency
Emergency Starting
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8Maintenance and Care
How to keep your Mazda in top condition.
Introduction .................................................................................. 8-2
Introduction ............................................................................... 8-2
Scheduled Maintenance ................................................................ 8-3
Scheduled Maintenance ............................................................ 8-3
Owner Maintenance ..................................................................... 8-8
Owner Maintenance Schedule .................................................. 8-8
Owner Maintenance Precautions ............................................... 8-9
Engine Compartment Overview .............................................. 8-11
Engine Oil ............................................................................... 8-12
Engine Coolant ....................................................................... 8-15
Brake/Clutch Fluid .................................................................. 8-18
Automatic Transmission Fluid (ATF) ..................................... 8-19
Washer Fluid ........................................................................... 8-21
Body Lubrication .................................................................... 8-22
Air Filter .................................................................................. 8-22
Wiper Blades ........................................................................... 8-23
Battery ..................................................................................... 8-26
Tires ........................................................................................ 8-28
Light Bulbs ............................................................................. 8-33
Fuses ....................................................................................... 8-40
Appearance Care ........................................................................ 8-45
How to Minimize Environmental Paint Damage .................... 8-45
Exterior Care ........................................................................... 8-47
Interior Care ............................................................................ 8-50
8-1
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qSchedule 1
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48
×1000 km 12 24 36 48 60 72 84 96
×1000 miles 7.5 15 22.5 30 37.5 45 52.5 60
ENGINE
Engine oil R R R R R R R R
Engine oil filter R R R R R R R R
Drive belt I I
AIR FILTER
Air filter C C R C
IGNITION SYSTEM
Spark plugs R
FUEL SYSTEM
Fuel filter Replace every 160,000 km (100,000 miles)
Fuel lines, hoses and connections
*1II
COOLING SYSTEM
Cooling system I I
Engine coolantReplace at first 96,000 km (60,000 miles) or 48 months;
after that, every 24 months
CHASSIS and BODY
Brake line, hoses and connection I I
Disk brakes I I I I
Tire (Rotation) Rotate every 12,000 km (7,500 miles)
Steering operation and linkages I I
Front and rear suspension and ball joints I I
Manual transmission oilR
Rear differential oilR
Driveshaft dust boots I I
Exhaust system and heat shields Inspect every 72,000 km (45,000 miles) or 60 months
All locks and hinges L L L L L L L L
Flat tire repair kit
*2Inspect every year
8-4
Maintenance and Care
Scheduled Maintenance
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qSchedule 2
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 4 8 12 16 20 24 28 32 36 40 44 48
×1000 km 8 16 24 32 40 48 56 64 72 80 88 96
×1000 miles 5 10 15 20 25 30 35 40 45 50 55 60
ENGINE
Engine oilPuerto Rico Replace every 5,000 km (3,000 miles) or 3 months
Others R R R R R R RRRRRR
Engine oil filter R R R R R R RRRRRR
Drive belt I I
AIR FILTER
Air filter C C R C
IGNITION SYSTEM
Spark plugs R
FUEL SYSTEM
Fuel filter Replace every 160,000 km (100,000 miles)
Fuel lines, hoses and connections
*1II
COOLING SYSTEM
Cooling system I I
Engine coolantReplace at first 96,000 km (60,000 miles) or 48 months;
after that, every 24 months
Engine coolant level I I I I I I IIIIII
ELECTRICAL SYSTEM
Function of all lights I I I I I I IIIIII
CHASSIS and BODY
Brake line, hoses and connection I I
Brake and clutch fluid level I I I I I IIIII
Brake fluid R R
Disk brakesIIII
Tire (Rotation) Rotate every 8,000 km (5,000 miles)
Tire inflation pressure and tire wear I I I I I I IIIIII
Steering operation and linkages I I
Front and rear suspension and ball joints I I
Manual transmission oil R R
Rear differential oil R R
Driveshaft dust boots I I
Exhaust system and heat shields Inspect every 72,000 km (45,000 miles) or 60 months
All locks and hinges L L L L L LLLLLLL
Washer fluid level I I I I I I IIIIII
Flat tire repair kit
*2Inspect every year
8-6
Maintenance and Care
Scheduled Maintenance
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Owner Maintenance Schedule
The owner or a qualified service technician should make these vehicle inspections at the
indicated intervals to ensure safe and dependable operation.
Bring any problem to the attention of an Authorized Mazda Dealer or qualified service
technician as soon as possible.
qWhen Refueling
lBrake and clutch fluid level (page 8-18)
lEngine coolant level (page 8-15)
lEngine oil level (page 8-13)
lWasher fluid level (page 8-21)
qAt Least Monthly
Tire inflation pressures (page 8-28)
qAt Least Twice a Year (For Example, Every Spring and Fall)
lAutomatic transmission fluid level (page 8-19)
You can do the following scheduled maintenance items if you have some mechanical
ability and a few basic tools and if you closely follow the directions in this manual.
lAir filter (page 8-22)
lEngine coolant (page 8-15)
lEngine oil (page 8-14)
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Maintenance and Care
Owner Maintenance
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Owner Maintenance Precautions
Improper or incomplete service may result in problems. This section gives instructions only
for items that are easy to perform.
As explained in the Introduction (page 8-2), several procedures can be done only by a
qualified service technician with special tools.
Improper owner maintenance during the warranty period may affect warranty coverage.
For details, read the separate Mazda Warranty statement provided with the vehicle. If
you're unsure about any servicing or maintenance procedure, have it done by an
Authorized Mazda Dealer.
There are strict environmental laws regarding the disposal of waste oil and fluids. Please
dispose of your waste properly and with due regard to the environment.
We recommend that you entrust the oil and fluid changes of your vehicle to an Authorized
Mazda Dealer.
WARNING
Maintenance Procedures:
Performing maintenance work on a vehicle is dangerous if not done properly. You can
be seriously injured while performing some maintenance procedures. If you lack
sufficient knowledge and experience or the proper tools and equipment to do the work,
have it done by a qualified technician.
Running the Engine:
Working under the hood with the engine running is dangerous. It becomes even more
dangerous when you wear jewelry or loose clothing.
Either can become entangled in moving parts and result in injury.
Therefore, if you must run the engine while working under the hood, make certain
that you remove all jewelry (especially rings, bracelets, watches, and necklaces) and
all neckties, scarves, and similar loose clothing before getting near the engine or
cooling fan which may turn on unexpectedly.
Electrical Fan and Engine Inspection:
Working near the electrical cooling fan when it is running is dangerous. You could be
hit by the fan and seriously injured. Turn off the ignition switch and make sure the
fan is not running before attempting to work near the electrical cooling fan.
Maintenance and Care
Owner Maintenance
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NOTE
Once the engine coolant exceeds a preset temperature, an electrical cooling fan turns on.
It will continue running for about 10 minutes after the ignition switch is turned to off.
8-10
Maintenance and Care
Owner Maintenance
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Engine Compartment Overview
BatteryEngine oil dipstick Engine oil-filler cap
Air filter Engine coolant reservoir Cooling system cap
Brake/Clutch fluid
reservoir Automatic transmission fluid-level dipstick
(only for automatic transmission)
Windshield washer
fluid reservoir
Fuse block (next
to air filter)
Fuse block
(near battery)
Maintenance and Care
Owner Maintenance
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