Карманный справочник Мазда PDF

OO Servicing } Pocket Guide -Z 2008 OO }
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Introduction
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About this manual The purpose of this manual is to give mechanics a helping hand with service and repair work. Often, service work does not receive the attention it deserves, in spite of the fact that it is done very frequently compared with other types of work. The service and quality of the work, which your company does is its best advertisement. When a new car is purchased, the owner brings it in regularly for the service work specified. And the quality of the work will decide whether the customer comes back to you for the next service or not. If a customer is not happy, someone else will do the next service. And whether he will then also purchase his next new car from you is also in question. So you see, customer satisfaction lies largely in your hands. Improved Service Procedure To support your efforts to provide high levels of quality Mazda has developed the enhanced Check Sheet Generator (eCSG) as well as the Servicing Pocket Guide. Both tools are designed to ease service and repair to fit the ideal workshop process at its best. The Service Check Sheet provides you with all service items for the vehicle to be serviced in a chronological work order. The Servicing Pocket Guide gives you detailed work procedures for the execution of service related work. On top you will find the most useful technical data of our vehicles as part of the Servicing Pocket Guide. A perfect combination! Simply zoom-zoom
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Introduction About this manual...........................................................................3 Improved service procedures........................................................3 Drive vehicle in the workshop ABS. ....................................................................................................8 Steering function.............................................................................8 Brake pedal.................................................................................. 89 Clutch pedal................................................................................ 910 Windscreen wipers....................................................................1011 Headlight adjustment.....................................................................11 Passenger compartment Parking brake (handbrake)...................................................... 1219 Electrical system........................................................................... 19 Cabin air filter..........................................................................1922 Data Link Control (DLC)........................................................ 2223 Fuel injection system (Diesel).................................................... 23 Safety belts, belt tensioner........................................................ 23 Power window system initial setting. .................................. 2324 Steering angle sensor initialization procedure RX-8 (SE)/ CX-7 (ER)/ Mazda6 (GH). ................................... 2425 Exterior Body condition.............................................................................. 25 Bonnet lock, catch, hinges.................................................... 2627 Door hinges and straps. ................................................................27 Engine compartment Hose connections and pipes........................................................27 Automatic transmission fluid............................................... 2728 E.G.R. System..........................................................................2829 Battery. ........................................................................................... 29 Brake fluid................................................................................2829 Clutch fluid...............................................................................2930 Brake booster................................................................................ 30 Data Link Control (DLC)................................................................31 Accessory drive belt............................................................... 3133 Fuel filter.................................................................................. 3335 Fuel vapour lock system.............................................................. 35 Cooling system........................................................................ 3536 Idling speed. ................................................................................... 36 Steering gear / Power steering fluid.................................. 3637 Air filter element...........................................................................37 Oil separator in the oil filler cap...........................................3739 Valve clearance........................................................................ 3971 Engine toothed belt. ................................................................7273 Injection pump toothed belt..................................................7476 Spark plugs...............................................................................7677
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Cable harness.................................................................................77 Oil Bypass Filter. ............................................................................77
Vehicle underfloor Hose connections and pipes........................................................78 Front wheel, Rear wheel suspension, Steering, Drive shafts, Drive shaft gaiters Checking for Damage, Fixing and Wear. .............................................................................78 Draining automatic transmission fluid......................................78 Gear shift cable....................................................................... 7879 Exhaust system and heat shields.............................................. 80 Brake pipes, hoses and connections......................................... 80 Chassis screw connections......................................................... 80 Rear differential...................................................................... 8081 Transfer box............................................................................. 8182 Fuel pipes....................................................................................... 82 Fuel additive filling................................................................ 8285 Draining the engine oil / Renew oil filter................................. 86 Front wheel bearings / Rear wheel bearings. ................... 8687 Gearbox oil...............................................................................8788 Brakes............................................................................................. 88 Underfloor protection.................................................................. 88 4-wheel drive. ......................................................................... 8889 Final work Fill up the engine oil..................................................................... 89 Engine oil data reset (diesel engine).................................. 8990 Fill up the automatic transmission fluid. .................................. 90 After fuel additive refill procedure. ..................................... 9091 Wheel nuts...................................................................................... 91 Tyre pressure and condition..................................................9192 Final vehicle inspection / test run Final vehicle inspection / test run. ............................................ 92 Final inspection............................................................................. 92 Technical Data / Identification Vehicle Identification.............................................................9395 Engine Code Location........................................................... 95101 Tyre Label Location. .............................................................101104 Technical Data / Liquid Amount & Spec. / Engine Oil Engine Oil...............................................................................104112 Technical Data / Liquid Amount & Spec. / Engine Coolant Engine Coolant....................................................................... 112114 Technical Data / Liquid Amount & Spec. / ATF Automatic Transmission Fluid............................................. 114116
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Technical Data / Liquid Amount & Spec. / Transaxl Oil Transaxl Oil............................................................................. 116119 Technical Data / Liquid Amount & Spec. / Differential Oil Differential Oil....................................................................... 119120 Technical Data / Liquid Amount & Spec. / Transfer Oil Transfer Oil. .................................................................................... 121 Technical Data / Liquid Amount & Spec. / Steering Fluid Steering Fluid........................................................................ 121123 Technical Data / Liquid Amount & Spec. / Clutch Brake Fluid Clutch Brake Fluid....................................................................... 123 Technical Data / Liquid Amount & Spec. / Air Condition Heater & Air Conditioner Systems................................... 124125 Technical Data / Engine Engine Technical Data. ........................................................ 125135 Technical Data / Wheel Alignment Wheel Alignment. ................................................................. 135157 Technical Data / Brake Brake.......................................................................................157172 Technical Data / Wheel & Tire Wheel & Tires. ....................................................................... 172182 Technical Data / Headlight Aiming Engine Technical Data. ........................................................182186
Notes...................................................................................... 187191
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Drive vehicle in the Workshop
ABS
ABS Self-test Bosch ABS System Start the engine Accelerate the vehicle to 6 km/h and listen for any noises of the pump motor. Check that the ABS warning light goes out. Lucas/Girling ABS System The ABS warning light has to be illuminated when the ignition is switched on and go out after the engine has started. All other ABS Systems When the ignition is switched on, the ABS electrical systems self-test for approximately 3 seconds. During this time, the ABS warning light lights up on the instrument panel. If the ABS warning light goes out after approximately 3 seconds, it means that the self-test has not detected any fault in the electrical system. NOTE If any of the above criteria is not met a complete guided diag nostic of the ABS has to be performed. Please refer to workshop manual.
Steering function
Checking the steering wheel and the steering column Checking the steering wheel play 1. Bring the wheels into a straight line, turn the steering wheel slightly to the left and to the right and check the steering wheel play. Play: 030 mm 2. If the play exceeds the limit, either the joints are worn or the rack play in the steering gear is too big. Correct accordingly. Checking the steering wheel for looseness Move the steering wheel and check for wear of the steering column bearings, play in the universal joint, looseness of the steering wheel, looseness of the steering column. NOTE Measure at the outer diameter of the steering wheel. Check if an aftermarket steering wheel is fitted. If so play values cannot be applied.
Brake pedal
Checking the brake pedal Checking the pedal height Measure the distance between the middle of the pedal rubber and the floor mat NOTE Make sure the floor mat is removed before measurement.
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Distance: See Workshop Manual Tightening torque: See Workshop Manual
Adjusting the pedal height 1. Pull out the brake light switch plug 2. Undo locking nut (B) and turn switch (A) until it no longer touches the pedal. 3. Undo locking nut (D) and adjust the pedal height by turning rod (C). 4. Tighten the screw with locking nut (B) until the distance between the screw of brake light switch (A) and the pedal stop is correct.
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5. Plug in the brake light switch. 6. Check the pedal play and brake light function after adjustment.
1 Pedal height Checking the pedal play 1. Operate the brake pedal several times to relief residual vacuum from the brake booster. 2. Remove the spring clip. Make sure that the fork and pedal holes are aligned and refit the spring clip. 3. To check the pedal play, operate the brake pedal lightly by hand (until you feel resistance). Pedal play: See Workshop Manual Adjusting the pedal play 1. Remove the spring clip and remove the fork bolt. 2. Undo locking nut (D) and turn rod (C) to align the fork and pedal holes. 3. Refit the fork bolt and spring clip. 4. Tighten locking nut (D). Tightening torque: See Workshop Manual
Clutch pedal
Checking / adjusting the clutch pedal Pedal height 1. Measure the distance from the top centre of the pedal rubber to the floor mat. Pedal height: See Workshop Manual

2. If necessary, turn adjusting screw (A) and locking nut (B) to adjust the pedal height. Clutch pedal play 1. Depress the clutch pedal by hand until you feel resistance and measure the pedal play. Pedal play: See Workshop Manual Total pedal play: See Workshop Manual
1 Pedal height 2 Pedal play 3 Release height
2. If necessary, undo locking nut (C) and adjust pressure rod (D) to adjust the clutch pedal play. 3. Check whether the release height (between the top of the pedal rubber and the floor mat) is correct when the clutch pedal is depressed completely Release height: See Workshop Manual
Windscreen wipers
Adjusting the windscreen wiper arm and blade 1. Return the windscreen wiper to the home position 2. Adjust the wiper arms as illustrated
1 Edge of the water shield
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Adjusting the windscreen wiper jet

Adjust the spray direction of the wiper jet using a needle or something similar as illustrated.
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1 Centre 2 Trim edge
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Headlight adjustment
NOTE For Auto Leveling System equipped vehicles, initialization proce dure using M-MDS is required first when related parts (such as Auto Leveling Sensor) are replaced. Please refer to Workshop Manual for more detail. While driving the vehicle into workshop check for equal adjustment of both headlights. 1. Set the tyre pressure to the value specified. 2. Park the unloaded vehicle on a level, horizontal surface. 3. The drivers seat has to be occupied. 4. In the case of models with beam width adjustment, set the beam width adjuster to 0. 5. Set the headlamps to the prescribed dimension using a headlamp adjuster device. 6. Set the headlamps by turning the adjusting screws. To do this, undo the screws first and then tighten them again. NOTE If the screws are first tightened and then undone, they may work loose during driving so that the headlamps are no longer set correctly.
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Passenger compartment
Parking brake
All models (except the following models) Checking the parking brake (lever parking brake) 1. Engage the parking brake lever several times. 2. Operate the brake pedal several times. 3. Inspect the parking brake stroke by pulling the parking brake lever with a specified force. Force and stroke please see chapter Technical Data page 157 Adjusting the parking brake (lever parking brake) 1. Start the engine and operate the brake pedal several times. 2. Switch off the engine. 3. Turn the adjusting nut on the front of the parking brake cable.
Illustration shows 323 BJ
4. Check the following points after the adjustment: (1) Switch on the ignition, engage the parking brake lever by one notch and make sure that the parking brake warning lamp lights up. (2)Make sure that the rear wheel brakes do not drag. Mazda2 (DY) Remove the parking brake lever trim panel. Operate the parking brake control firmly ten times. Loosen the parking brake cable adjustment nut to the end of the thread, discard the retaining clip. Release the parking brake.
Make sure the parking brake cable is correctly located. NOTE Prior to carrying out adjustment to a new or relocated parking brake cable, settle the parking brake system.
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Pull the cables at the connector and release.
Make sure the parking brake cables are clean. The parking brake cables and levers must return to the rear brake stops after operation.
Check the operation of the rear brake cables and levers (left-hand side shown).
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NOTE Make sure the parking brake lever is fully released. Using paint or typing correction fluid, mark the parking brake cables (left-hand side shown). NOTE Make sure the parking brake lever is fully released. With the aid of another technician, tighten the parking brake adjustment nut until the parking brake cables start to operate (left- hand side shown). NOTE The parking brake cable should move at the rear brake backing plates within the initial 5 mm of parking brake control movement. Check the parking brake cable adjustment in three stages. Stage 1: Raise the parking brake control eight notches and release three times. Stage 2: With the aid of another technician, check the parking brake cable movement at the rear brake backing plates by operating the parking brake control 5 - 10 mm ten times. If no parking brake cable movement is observed, tighten the parking brake cable adjustment nut two full turns and repeat stages 1 and 2. Stage 3: Rotate the rear wheels and check for brake drag. If brake drag is felt, loosen the parking brake cable adjustment nut to the end of the thread, clean the parking brake cables and repeat the adjustment procedure. Install a new parking brake cable adjustment nut retaining clip. Install the parking brake control trim panel. Mazda3 (BK) Stroke Inspection 1. Pump the brake pedal a few times. 2. Pull the parking brake lever two to three times.
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3. Inspect the parking brake stroke by slowly pulling at point A 50 mm from the end of the parking brake lever with a force of 98 N (10 kg) and counting the number of notches (clicking sound).
A
If not within the specification, adjust the parking brake lever. Standard: 3 7 notches. Parking brake lever adjustment 1. Pump the brake pedal a few times. 2. Remove the service hole cover of the rear console.
1 Service hole cover 2 Adjusting nut
3. Turn the adjusting nut and adjust the parking brake lever. 4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates. 5. Verify that the rear brakes do not drag. Mazda5 (CR) Parking brake lever adjustment 1. Pump the brake pedal a few times.
1 Service hole cover 2 Adjusting nut
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Mazda6 (GG/GY) 1 2 3 4
2. Remove the service hole cover of the center console. 3. Turn the adjusting nut and adjust the parking brake lever. 4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates. 5. Verify that the rear brakes do not drag.
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Parking brake (lever type) adjustment 1. Start the engine and depress the brake pedal several times. 2. Stop the engine.
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Clip A Tab Console Rear ashtray case
3. Pull the underside of the rear ashtray case in the direction shown by the arrow and remove clips A from the console. 4. Disengage the hooks from the console and remove the rear ashtray case.
5. Verify the position of the adjusting nut while looking in from above the console (A) as shown, and set the socket on the nut. 6. Turn the adjusting nut to adjust the parking brake lever. 7. After adjustment, inspect the following points: (1) Turn the ignition switch to ON, pull the parking brake lever one notch, and verify that the parking brake warning light illuminates. (2)Verify that the rear brakes do not drag. MX-5 (NC) Parking brake lever adjustment 1. Depress the brake pedal several times. 2. Remove the parking brake lever boot.
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1 Adjusting nut 3. Turn the adjusting nut and adjust the parking brake lever. 4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates. 5. Verify that the rear brakes do not drag. RX-8 (SE) Parking brake lever adjustment 1. Depress the brake pedal several times. 2. Remove the service hole cover of the rear console. Service hole cover
Adjusting nut
3. Turn the adjusting nut and adjust the parking brake lever. 4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates. 5. Verify that the rear brakes do not drag. CX-7 (ER) Parking brake lever adjustment for MT model 1. Adjust the parking brake shoe. 2. Remove the service hole cover inside the rear console using the following procedure. Service hole cover
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TAB A TAB B TAB C
(1) Remove the storage box from the rear console. (2)Pull the part shown in the figure of the service hole cover in the direction of the arrow to detach the clips.
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(3) Pull up the service hole cover in the direction of the arrow and remove it from the rear console. 3. Turn the adjusting nut and adjust the parking brake lever.
Adjusting nut 4. After adjustment, inspect the following points: (1) Turn the ignition switch on, pull the parking brake lever one notch and verify that the brake system warning light illuminates. (2)Verify that the rear brakes do not drag. CX-7 (ER)/CX-9 (TB) Parking brake inspection and adjustment for AT model Inspection: 1. Depress the parking brake pedal a few times. 2. Inspect the parking brake stroke by depressing the parking brake pedal with a force of 180 N {18.4 kgf, 40.5 lbf}. Parking brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf} 13 notches Adjustment: 1. Adjust the parking brake shoe. 2. Turn the adjusting nut at the front of the parking cable.
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Adjusting nut
3. After adjustment, inspect the following points: (1) Turn the ignition switch on, depress the parking brake pedal one notch, and verify that the brake system warning light illuminates. (2) Verify that the rear brakes do not drag. B-Series UN Parking brake lever stroke inspection (stick type) 1. Pull the parking brake lever a few times. 2. Inspect the parking brake stroke by pulling the parking brake lever with a specified force. 3. If not as specified, adjust the parking brake lever stroke. Parking brake lever stroke adjustment (stick type) 1. Before adjustiment, depress the brake pedal several times while the vehicle is moving in reverse. 2. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range. 3. After adjustment, tighten the locknut A.
4. After adjustment, inspect the following points. (1) Turn the ignition (engine) switch on, pull the parking brake lever one notch, and verify that the brake warning light illuminates. (2) Verify that the rear brakes do not drag when the wheels are turned by hand. BT-50 (UN) Parking Brake Lever Stroke Adjustment 1. Before adjustment, depress the brake pedal several times while the vehicle is moving in reverse.
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Tightening torque: 6.9 9.8 Nm
2. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range. 3. After adjustment, tighten the locknut A.
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4. After adjustment, pull the parking brake lever one notch and verify that the parking brake warning light illuminates. 5. Verify that the rear brakes do not drag.
Electrical system
Checking Check that all instrument lights function Front check: headlamps (main beam and dip beam), parking light, indicator light, fog lamps and high beam head lamps and corre sponding warning lights. Rear check: rear lights, number plate light, rear fog lamp and brake lights and corresponding warning lights. Check the condition of all the outside lights. Check heater blower and electrical air distribution (if fitted). Check power seats. NOTE Make sure power seats and mirrors are set back to customers settings. Check wipers. Check power mirrors. Check heated rear window.
Cabin air filter

Removing / installing the pollen filter NOTE The pollen filter consists of statically charged fibres. When the filter is removed and exposed to the air for any length of time, it will attract dirt and dust, which means it cannot be reused. Therefore, store the pollen filter in a plastic bag when removed. 1. Remove the parts shown in the illustration in the order indicated. 2. Refit in the reverse order.
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illustration shows the Mazda 626 1 Wing nut 2 Rubber seal 3 Pollen filter
Mazda2 (DY) Pollen filter removal 1. Fully open the right-hand glove compartment. A) Press the sides towards the center to release the glove compartment. B) Pull the glove compartment downwards.
A A
B
2. Detach the central junction box (CJB) from the in-vehicle crossbeam.
3. Remove the pollen filter housing cover.
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4. Remove the pollen filter.
Installation 1. To install, reverse the removal procedure. Mazda5 (CR) Air filter removal / installation 1. Disconnect the negative battery cable. 2. Remove the under cover. 3. Partially open the floor mat and slide the BCM bracket (R.H.D.) 4. Disconnect the evaporator temperature sensor connector. (L.H.D.) 5. Disconnect the power MOS FET connector. (L.H.D. Full auto air conditioner) 6. Remove in the order indicated in the table. Air filter attachment direction
Air filter attachment direction
illustration shows L.H.D. 1 Air filter cover 2 Air filter (1) 3 Air filter (2)
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7. Install in the reverse order of removal. Mazda6 (GG/GY)
illustration shows R.H.D. 1 Air filter cover 2 Air filter (2) 3 Air filter (1)
Air filter removal / installation (where applicable) 1. Remove the glove compartment. 2. Remove in the order indicated in the illustration.
1 Air filter cover 2 Air filter
Arrow indicates orientation
3. Install in the reverse order of removal.
Data Link Control (DLC)

Diagnose Electronic Control Units (ECU) Read out all ECUs fault memory. Note any fault code stored. Delete the fault memory. Read out the fault memory again of any ECU with fault codes found after a trial run to see whether any faults still exist. NOTE Reoccurrence of any fault code has to lead to a full diagnosis of the affected system/component.
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The diagnostic connector for vehicles with EOBD is located near the lower panel of the driver side.
NOTE For vehicles without EOBD, the diagnostic connection is on the left of the engine compartment in the direction of travel (see Engine compartment).
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Fuel injection system (Diesel)

Mazda6 (GG/GY) RF engine, MPV (LW) RF engine, Mazda3 (BK) RF engine, Mazda5 (CR) RF engine, Mazda6 (GH) RF/R2 engine Inspect fuel injection system Update to injection amount correction with M-MDS or equivalent.
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Safety belts, belt tensioner

Check That the belts roll up correctly. Check the function of the locks. Pull the full length of the belt out of the winder and check the condition of the fabric. If necessary, check the correct seating of the guides and covers (abrasive points on the belt). Check whether the belt tensioner has been released.
Guide to renewal of the safety belt:
1) Cuts, deformation 2) Damage to the or abrasion on the edges of the belt; belt;
3) Cigarette burns or similar damage.
Power window system initial setting

Mazda2 (DY)/ Mazda2 (DE)/ Mazda3 (BK)/ Mazda5 (CR)/ RX-8 (SE)/ Mazda6 (GG/GY)/ Mazda6 (GH)/ CX-7 (ER)/ CX-9 (TB)/ BT-50 (UN) NOTE Initialization has to be performed for every window (Mazda3, Mazda5, Mazda6 (GG/GY)) The power window initialization procedure can be performed
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either with the power window main switch or the power window subswitch. (Mazda6 (GH)) If the following operations have been performed, initial setting is reset, and auto up/down and two-step down operation are disabled. Therefore, performing initial setting is necessary.
Negative battery cable disconnected or power window system power supply fuse removed (perform initial setting for the switches of all seats.) Power window switch connector disconnected (Perform initial setting for the switch connected with the connector.) 1. Turn the ignition switch to the ON position. Only Mazda2 (DE), Mazda3, Mazda5, RX-8, Mazda6, CX-7, CX-9, BT-50: 2. RX-8/ Mazda2 (DE)/ CX-7 (Drivers door only auto-open/close)/ BT-50: Press the driver-side power window main switch and fully open the driver-side window. Mazda3/ Mazda5/ Mazda6 (GG/GY/GH)/ CX-7 (All doors auto- open/close)/ CX-9: Press the switch of each seat and fully open the door glass. 3. Pull the switch to the manual-up position to fully close the door glass, and keep holding the switch up at the position for approx. 2 s to complete initial setting. Only Mazda2 (DY): 2. Pull the power window control switch until the door window is fully closed and hold the switch in the close position for a further two seconds. 3. Release the power window control switch. 4. Press the power window control switch until the door window is fully open. 5. Briefly pull the power window control switch to the second detent and release the switch. If the door window does not close automatically, repeat the complete procedure. Warning For vehicles with DSC, if the negative battery cable is discon nected, the stored initial position of the steering angle sensor will be cleared and the DSC will not operate properly, making the vehicle unsafe to drive. Perform the steering angle sensor initialization procedure after connecting the negative battery cable.
Steering angle sensor initialization procedure RX-8 (SE)/ CX-7 (ER)/ Mazda6 (GH)
Warning Unless the initialization procedure of the steering angle sensor is completed, the DSC will not operate, causing an unexpected accident. Therefore, always perform the initialization procedure to ensure DSC operation if the power supply to the steering angle sensor has been cut off due to disconnection of the
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steering angle sensor connector or negative battery cable, or any other cause. NOTE The steering angle sensor requires battery power to store the steering angle initial position. Therefore when the battery power supply is cut off, a stored steering angle initial position is cleared.
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1. Inspect the wheel alignment, inflation pressure, and the installation condition of the steering wheel. If there is any malfunction, adjust the applicable part. 2. Connect the negative battery cable. 3. Turn the ignition switch to the ON position. 4. Confirm that the DSC or TCS indicator light illuminates and that the DSC OFF light flashes. 5. Turn the steering wheel to full right lock, then turn it to full left lock. 6. Confirm that the DSC or TCS OFF light goes out. 7. Turn the ignition switch off. 8. Turn the ignition switch to the ON position again, and confirm that the DSC indicator light goes out. If the DSC indicator light does not go out, disconnect the negative battery cable, and perform the procedure again starting from Step 2 shown above. 9. Drive the vehicle for approx. 10 min, and confirm that the ABS warning and DSC indicator lights do not illuminate.
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exterior
Body condition
Visual inspection of body and paintwork. Check certain areas of the vehicle for visible signs of corrosion. Outward signs of this are: Surface corrosion and perforation Stone-chipping damage Scratches Other paint damage which may lead to corrosion. Fouling by birds, insects, tree resin, etc. We recommend starting with the front left-hand wing and continuing the checks anti-clockwise. If these checks are done as part of the routine service, follow the current procedure. If a problem is found, make a note of it and discuss the repair with the customer. All repair work must be done according to the work stages described in the relevant paint and body manuals.
Bonnet lock, catch, hinges

Bonnet lock / Safety catch Check function, grease Checking Open the bonnet and check that the cable and lock are working
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exterior
perfectly. Check the function of the safety catch it must not be possible to open the bonnet completely without operating the safety catch. Check the hinges for damage or stiffness.
Grease Apply a little grease to moving parts of the hinges and bonnet lock.
Door hinges and straps

Door restraint Check function, grease Check Door restraint for damage, wear and check that it works perfectly on all the doors. Check the fixing of the restraint on the doors and also A and B pillars. Open doors must not come into contact with adjacent body areas. Grease Apply a little grease to all the door restraints from top to bottom at the point where they enter the door.
engine compartment
Hose connections and pipes

Pipes, hoses, cables, oil and fuel pipes Check that they are routed correctly, Check leak tightness, abrasion points and damage (if visible). Check Cables and plugs for loose or corroded connections and also that seals are intact (where existing). Secure loose connections. Check fuel supply and return pipes for leaks, laying, kinks and other damage, which could hinder supply. Secure loose pipe connections. Check partial vacuum pipes and air pressure pipes of turbo-engines for leak-tightness, particularly at elbows and connections. Make sure that the accelerator cable can move easily and is set correctly. Check the cooling water hoses for leaks and kinks. Check that the intake system air ducts have been routed correctly and for kinks.
Automatic transmission fluid

Checking the automatic transmission fluid (ATF) Checking the ATF level NOTE The ATF level depends on the ATF temperature. Measure the temperature with a thermometer first when checking the ATF level or when changing the ATF and correct the ATF quantity according to the temperature.
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engine compartment
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1. Park the vehicle on a level surface. 2. Engage the parking brake and chock all the wheels, front and back. 3. Insert the temperature-measuring sensor into the filler neck and measure the temperature. 4. If necessary, check the ATF before starting the engine. In this case, the ATF level must be in the cold range (15C 25 C). 5. Let the engine warm up until the ATF reaches a temperature of 60C 70 C. 6. With the brake pedal operated, shift the lever to all the positions (P L) and leave in each position for a few seconds. 7. Reset the lever to P. 8. Allow the engine to idle and check whether the ATF level is in the warm range (65 C). Top up the ATF level if necessary.
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1 Oil at operating temperature 2 Cold oil
Checking the oil level The ATF level is one criteria for deciding whether the transmission needs to be repaired. Therefore, check whether 1. the ATF is dirty or discoloured; 2. the ATF has a strong or unusual smell.
E.G.R. System
Check EGR system 1. Check for blocked hoses. 2. Check PCM voltage at connector. 3. Check EGR valve. Start the engine and leave idling. Hold one finger on the membrane of the EGR pneumatic valve. Increase the engine speed to approximately 2000 r.p.m. Check whether the diaphragm moves.
Illustration shows FP, FS Engine
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engine compartment
or: Apply vacuum and check airflow between 1 and 2. (see graphic below) Default referring to Workshop manual.
NOTE If the valve is clogged in the open position or does not work easily, replace with new one.
Battery
Battery terminals clean, grease if necessary. Check The external condition of the battery and the terminals, connections tight and clean. Correct If necessary, clean, grease and tighten terminals and connections. Make sure that contact surfaces are clean before tightening. CAUTION In case of a flat, disconnected or defective battery, power window initialization as well as a steering angle initialization has to be performed. Please refer to page 23 and 24.
Brake fluid
Check 1. Press the brake pedal several times and check the brake system for leakages. 2. The fluid level in the brake system reservoir must be between MIN and MAX.
Brake fluid to be used: SAE J1703 or FMVSS 116 DOT-3 or DOT-4
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engine compartment
Air bleeding/brake fluid change
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CAUTION Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is spilled, wipe it off immediately. NOTE Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding. Begin air bleeding with the brake caliper that is furthest from the master cylinder. Brake fluid type please refer to technical data page 123. 1. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 2. Place the other end of the vinyl tube in a clear, fluid-filled container. 3. One person should depress the brake pedal a few times, and then hold it in the depressed position. 4.A second person should loosen the bleeder screw, drain out the fluid and close the screw using a commercially available flare nut wrench. Tightening torque Front: 6.99.8 Nm {7199 kgfcm, 6286 inlbf} Rear: 5.98.8 Nm {6189 kgfcm, 5377 inlbf} 5. Repeat steps 3 and 4 until no air bubbles are seen. 6. Bleed air from each component by following the procedure above. 7. After air bleeding, check the following: Brake operation Fluid leakage Fluid level
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Clutch fluid
Hydraulic fluid Checking the hydraulic fluid NOTE Make sure that the fluid level is between the MIN and MAX marks when changing it. Replacing the hydraulic fluid/bleeding NOTE Do not splash hydraulic fluid onto painted surfaces. If this happens, wash off the fluid immediately. Do not mix different kinds of hydraulic fluid. Do not reuse hydraulic fluid. 1. Drain the hydraulic fluid in the expansion tank using a suction pump. 2. Remove bleed screw cap from the slave cylinder and connect a vinyl hose to the bleed screw. 3. Hang the other end of the hose into a container. 4. Operate the clutch pedal several times slowly. 5. With the clutch pedal down, undo the bleed screw with the SST so that the hydraulic fluid can be drained off. Tighten the bleed screw with the SST.
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engine compartment
6. Repeat stages 5 and 6 until you see clean hydraulic fluid. 7. Tighten the bleed screw. Tightening torque: 5.9 8.8 Nm 8. Fill up with hydraulic fluid up to the MAX mark. 9. Check whether the clutch is working perfectly.
Brake Booster
Checking the brake booster Function test (simple method) Step 1 1. Operate the brake pedal several times with the engine switched off. 2. Start the engine with the brake pedal down. 3. If the pedal moves down slightly immediately after starting the engine, the brake booster is OK. Step 2 1. Start the engine. 2. Stop the engine after driving the vehicle for 1 2 minutes. 3. Operate the brake pedal with normal pressure. 4. If the first pedal stroke is long and the following strokes become shorter, the brake booster is OK. NOTE If a fault is found, check whether the non-return valve or the partial vacuum hose is damaged or has not been installed correctly. If necessary, repair the parts and repeat the test. Step 3 1. Start the engine. 2. Operate the brake pedal with the usual pressure. 3. With the brake pedal operated, switch off the engine. 4. Hold the pedal down for approximately 30 seconds. 5. If the pedal height does not change, the brake booster is OK. NOTE Special features of ABS systems: see In the Work shop: ABS system.
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Data Link Control (DLC)
Diagnose ECUs NOTE All vehicles from model year 1997: Check diagnostic codes of all control units with M-MDS or equivalent The diagnostic plug for vehicles without EOBD is located on the left of the engine compartment in the direction of travel.
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NOTE The diagnostic connector for vehicles with EOBD is located near the lower panel of the driver side.
Accessory drive belt

Check condition, correct tension Check condition Check for any signs of wear on the automatic belt tensioner (if provided) Check for damage, cracks, rubber or dirt deposits on the belt grooves. NOTE Slight signs of wear and cracks do not always require replacement of the belt. See the following diagrams to see whether early replacement of the belt is necessary. Deposits Individual small rubber deposits: renewal not necessary. Longer areas of deposits, up to 50% of the groove height: replace ment not normally necessary. If this causes a loud running noise, replace the belt. Pronounced deposits along the grooves could cause noise or unstable running: renewal urgently necessary.
Cracks Up to 15 cracks in a groove over 100 mm are acceptable. If there are more cracks, renewal is urgently necessary.
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Missing fin parts Whole parts of the belt fins must not be missing. If they are, renewal of the belt is urgently necessary.
Belt fraying Check the accessory drive belt for fraying. The condition of the accessory drive belt should be compared against the illustrations. For levels 1 to 3, the accessory drive belt DOES NOT require changing.
1 2 3
No fraying (new belt) Fraying just starting Slight fraying
For levels 4 and 5 install a new accessory drive belt. Vehicles with diesel engine.
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4 5 High amount of fraying without cord cuts High amount of fraying with cord cuts
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Check the tension A belt should depress by 1 to 4 mm under strong thumb pressure. Drive belt deflection/tension inspection is not necessary in case of use of auto tensioners.
Fuel filter
Changing the fuel filter (petrol engines) Warning Sparks and open fire must be kept well away from all parts of the fuel system After replacing the fuel filter, check that the filter connections are tight. Proceed as follows to change the fuel filter: 1. Remove the parts illustrated in the numbered sequence. 2. Fit the new filter in the reverse order. NOTE When installing the filter, push the hoses onto the connecting sockets as far as possible. Secure the hoses with clips.
NOTE In case of some models, fuel filter is assembled in the fuel pump and it cannot be disassembled. The Fuel pump has to be removed through the service hole under the rear seat cushion. Please refer to the workshop manual for further information. Check the fuel pipes Check all the connections and pipe connections for leaks. There must be no moist or discoloured points, which could indicate leaks. Damaged hoses and clips must be replaced.
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Draining the fuel filter (Diesel) 1. Undo the drainage screw 2. Undo the bleed screw. 3. After draining off the water, bleed the fuel filter. 4. Tighten the bleed screw. 5. Tighten the drainage screw.
1 Bleed screw 2 Drainage screw
WL-C, WE-C Fuel filter removal / installation 1. Disconnect the negative battery cable. 2. Complete the Before repair procedure. (See Workshop Manual Before repair procedure (WL-C, WE-C).) 3. Disassemble in the order indicated in the table. 4. Assemble in the reverse order of removal. 5. Complete the After repair procedure. (See Workshop Manual After repair procedure (WL-C, WE-C).) 6. Bleed air from the fuel filter. 7. Start the engine and verify that fuel does not leak from the fuel system. 8. If fuel leaks, reassemble the fuel filter. With fuel warmer 1925 Nm 1 2 3 4 5 6 7 Connector Fuel hose Priming pump Fuel filter (See Fuel Filter Assembly Note.) Sedimentor switch (See Sedimentor Switch Assembly Note.) Drain plug Fuel warmer
Without fuel warmer 14.7 19.6 Nm 4.4 5.4 Nm
Sedimentor Switch Assembly Note Apply a small amount of fuel to a new O-ring. Tighten the sedimentor switch enough to the fuel filter by hand.
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Fuel Filter Assembly Note Apply a small amount of fuel to the fuel filter O-ring. Tighten the fuel filter approx. 3/4 by hand after the O-ring contacts the priming pump.
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Fuel vapour lock system

Check the fuel vapour lock system
Function test 1. Allow the engine to warm up to the normal operating temperature and then let it ticks over. 2. Remove the partial vacuum hose from the solenoid valve and close as shown in the graphic. No partial vacuum must be perceptible at the solenoid valve. 3. If this is not the case, check the valve.
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illustration shows the FP, FS engine
Cooling system
Checking the cooling system Warning Never remove the radiator cap or coolant filler cap when the engine is hot When removing the radiator cap, wrap a thick cloth round it. When removing the radiator cap or coolant filler cap, first twist back the cap as far as the first notch to allow the excess pres sure to escape before removing it completely. NOTE Use only FL22 if coolant filler cap is signed as FL22. Coolant level (with cold engine) 1. Check whether the coolant level is more or less up to the filler neck. 2. Remove the coolant dipstick from the expansion tank and check whether the coolant level is between the marks F and L. Top up with coolant if necessary. Coolant condition 1. Check whether the radiator cap and filler socket are free from rust or limescale. 2. Check whether the coolant is contaminated with oil. Change the coolant if necessary. Coolant leaks 1. Connect a commercial radiator pressure tester to the radiator filler
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neck using an appropriate adaptor. 2. Supply the system with the pressure indicated in the workshop manual. 3. Check whether the pressure is maintained. If it is not, look for coolant leaks. Anti-freeze CAUTION Do not use anti-freeze containing alcohol or methanol. Only use soft (demineralised) water for mixing anti-freeze. 1. Measure the temperature and density of the coolant with a ther mometer and areometer. 2. If the frost protection is not correct, top up with anti-freeze and water. Volume % Anti-freeze up to - 16C up to - 26C up to - 40C Water 65 55 45 Frost protection35 45 55 Density at 20 C 1,054 1,066 1,078
Idling speed
Check the idling speed Check the idling speed with the tester specified. The adjustment is described in section F of the workshop manual.
Steering gear / Power steering fluid

Checking the level Check the level of the power assisted steering fluid. If necessary, top up the fluid to the prescribed level. CAUTION Only use the types of fluid approved by Mazda. Please refer to technical data section page 121. Leaks in the steering system CAUTION The steering wheel must not be kept in the full lock position for longer than 15 seconds. Otherwise, you may damage the steering servo-pump. Start the engine and leave ticking over. Turn the steering wheel from lock to lock to build up the pressure. Check whether there are any leaks. NOTE In the graphic, the points where leaks may occur are marked by arrows.
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FS, FP Engine
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KL Engine
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Air Filter Element

Air filter insert 1. Check whether the air filter insert is excessively dirty, oily or damaged. CAUTION The air filter insert must not be blown out with compressed air. 2. Change the air filter insert if necessary.
Oil separator in the oil filler cap

Check the oil separator and bleed valve for blockage 121 (ZQ) 1,3 l (09.1997 12.2001) Unclip PCV valve with oil separator hose Check PCV valve and separator for fouling
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Check and clean the oil filler cap Remove the oil filler cap and clean the opening Check the oil filler cap for dirt and deposits
Check and clean the adapter Check the adapter passages for damage and blockage
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Valve clearance
626 (GF) FP-, FS-engine / 323 (BJ) FP-engine / MPV (LW) FS-engine/ Premacy (CP) FP-, FP(Hi-power)-engine
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1 Inlet side 2 Exhaust side
Checking the valve clearance 1. Remove the valve rocker cover. 2. Make sure that the engine is cold. 3. Measure the valve clearance. (1) Turn the crankshaft in the clockwise direction so that piston No. 1 is in the TDC of the compression stroke (2)Measure the valve clearance at the points marked (A). Please refer to technical data section page 125.
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(3) If the valve clearance exceeds the nominal range, replace the shim (see Valve clearance, Adjusting the Valve clearance) (4) Turn the crankshaft 360 clockwise, so that piston No. 4 is in the TDC of the compression cycle. (5) Measure the valve clearance at the points marked (B). (6) If the valve clearance exceeds the nominal range, replace the shim (see Valve clearance, Adjusting the Valve clearance). 4. Refit the valve rocker cover. Adjusting the valve clearance Carry out the following steps on all cams where the valve clearance has to be adjusted: 1. Turn the crankshaft clockwise so that the cam at which the valve clearance has to be adjusted points straight upwards. 2. Undo the following bolts in the camshaft bearing cover. Only undo one pair of bearing cover bolts in each case and refit the two bolts you undo the next pair. A: To replace the shim on the exhaust side of cylinder No. 1, 2, 3 B: To replace the shim on the intake side of cylinder No. 1, 2, 3 C: To replace the shim on the exhaust side of cylinder No. 2, 3, 4 D: To replace the shim on the intake side of cylinder No. 2, 3, 4
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1 Inlet side 2 Exhaust side NOTE To replace the shim on the exhaust side of cylinder No. 2 and/or No. 3, undo either bolts A or bolts C. To replace the shim on the exhaust side of cylinder No. 2 and/or No. 3, undo either bolts B or bolts D. 3. Insert the SST into the holes of the bearing cover bolts as illustrated. Tightening torque: 11.3 14.2 Nm
1 Exhaust side 2 Inlet side
4. Align the marks on the SST (shaft and shaft holder) with each other. 5. Tighten bolts (A) to secure the SST (shaft)
1 Marks
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6. Align the SST (retaining device) on the outside of the cylinder head and secure the other point at which the shim has to be replaced on the SST (shaft).
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7. Align the valve tappet notch so that the tip of a screwdriver can be pushed in.
1 Shim 2 Notches 3 Valve tappet 8. Place the SST with the notch on the tappet. 9. Tighten bolt (B) to secure the SST (retaining device) NOTE The cylinder head may be damaged when you push down the valve tappet. 10. Tighten bolt (C) and press down the tappet.
1 Cams 2 Shim 3 Valve tappet 11. Push the tip of the screwdriver through the tappet notch and loosen the shim. Then remove the shim with a magnet.
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1 Valve tappet 2 Shim 3 Screwdriver 12. Determine the thickness of the shim needed. Example (sample value) Thickness of the shim removed + (measured valve clearance nominal play) = thickness of the new shim 4.00 + (0.30 0.25) = 4.05 mm
13. Press the new shim into the tappet. 14. Undo bolt (C) so that the tappet can move up. 15. Undo bolt (B) and remove the SST (retaining device) 16. Remove the SST and tighten the bearing cover bolts. Tightening torque: 11.3 14.2 Nm 17. Check the valve clearance once more (see Valve clearance, Check ing the Valve clearance) 323 (BA/BJ) B3 engine/ Demio (DW) Checking / Adjustment 1. Let the engine warm up to normal operating temperature 2. Remove the valve rocker cover. 3. Turn the crankshaft and align the ignition timing mark so that the piston cylinder No. 1 or No. 4 is in the TDC of the compression stroke.
4. Measure the valve clearance at the points marked (1) if cylinder No. 1 is in the TDC of the compression stroke and the valve clearance at the points marked (4) if cylinder No. 4 is in the TDC of the compression stroke. Valve clearance (warm engine) Please refer to technical data section page 125.
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5. Adjust the valve clearance and then check again if it does not comply with the figures given. 6. Turn the crankshaft one revolution, measure the remaining valve clearance and adjust if necessary.
7. Refit the valve rocker cover. Tightening torque: (A): 7.9 10.7 Nm 8. Start the engine and check for unusual valve noises.
323 (BA) Z5 engine/ 323 (BJ) ZL engine/ MX-5 (NB) B6, BP engine Check 1. Remove the valve rocker cover 2. Make sure that the engine is cold. 3. Measure the valve clearance (1) Turn the crankshaft clockwise so that piston No. 1 is in the TDC of the compression stroke. (2) Measure the valve clearance at the points marked (A)
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Play (with cold engine) Please refer to technical data section page 125 (3) If the valve clearance exceeds the nominal range, replace the shim(s). (See Valve clearance, Adjustment) (4) Turn the crankshaft 360 clockwise so that piston No. 4 is in the TDC of the compression stroke. (5) Measure the valve clearance at the points marked (B). (6) If the valve clearance exceeds the nominal range, replace the shim(s). (See valve clearance, adjustment) 4. Fit the valve rocker cover.
1 Inlet side 2 Exhaust side Adjustment Carry out the following steps at all cams where the valve clearance has to be adjusted: 1. Turn the crankshaft clockwise so that the cam whose shim has to be replaced points upwards. 2. Undo the following bolts in the camshaft bearing cover: A: To replace the shim on the exhaust side of cylinder No. 1, 2, 3 B: To replace the shim on the intake side of cylinder No. 1, 2, 3 C: To replace the shim on the exhaust side of cylinder No. 2, 3, 4 D: To replace the shim on the intake side of cylinder No. 2, 3, 4
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NOTE To replace the shim on the exhaust side of cylinder No. 2 and / or No. 3, undo bolt (A) or (C) intake side To replace the shim on the exhaust side of cylinder No. 2 and / or No. 3, undo bolt (B) or (D) intake side
3. Fit the SST in the holes for the bearing cover bolts as Tightening torque: 11.3 14.2 Nm
1 Marks
4. Align the marks on the SST (shaft and shaft holder). 5. Tighten bolts (A) to secure the SST (shaft).
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6. Align the SST (retainer) with the centre of the cylinder head and fix to the SST shaft at the point where the shim has to be replaced.
1 Shim 2 Notch 3 Tappet
7. Align the tappet notch so that the tip of a small screwdriver can be inserted.
8. Fit the SST with notch on the tappet. 9. Tighten bolt (B) to secure the SST (retainer). NOTE The cylinder head may be damaged when pressing the tappet down. 10. Tighten bolt (C) and press down the tappet. 11. Insert the tip of a screwdriver into the tappet notch and loosen the shim. Remove the shim with a magnet.
12. Determine the thickness of the shim required. Thickness of the shim removed + (measured valve clearance nominal play) = thickness of the new shim 4.00 + (0.30 0.25) = 4.05 mm
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Please refer to technical data section page 125. 13. Press the new shim into the tappet. 14. Undo bolt (C) so that the tappet can move up. 15. Undo bolt (B) and remove the SST (retainer). 16. Remove the SST and tighten the bolts in the camshaft bearing cover. Tightening torque: 11.3 14.2 Nm 17. Check the valve clearance (see Valve clearance, Check). 323 (BA/BJ) RF engine
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Checking / Adjusting the Valve clearance 1. Remove the valve rocker cover. 2. Remove the upper timing belt cover. 3. Turn the crankshaft so that the piston of cylinder no. 1 is in the TDC of the compression cycle.
1 Timing marks 2 Camshaft wheel 4. Measure the valve clearance on the intake side (no. 1 and 2) and on the exhaust side (no. 1 and 3). Valve clearance (engine cold) Please refer to technical data section page 125
5. Adjust the valve clearance if it does not correspond to the specifi cation (1) Turn the camshaft so that the inlet cam points straight upward. (2) Adjust the tappet so that its notch is on the elbow side. (3) Press down the tappet with the SST so that the shim can be removed. (4) Remove the shim. (5) Select a new shim on the basis of the valve clearance measured and insert the shim.
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Example (sample value) Thickness of the shim removed + (measured valve clearance nominal play) = thickness of the new shim
4.00 + (0.30 0.25) = 4.05 mm NOTE The number on the shim indicates the shim thickness (e.g.: 3825 corresponds to a thickness of 3.825 mm).
1 Inlet cam 2 Valve clearance 3 Shim
(6)
Check the valve clearance once more.
6. Turn the crankshaft so that the piston of cylinder No. 1 is in the TDC of the compression cycle. 7. Measure and adjust the valve clearance on the intake side (No. 3 and 4) and on the exhaust side (No. 2 and 4) in the same way. 8. Install the upper timing belt cover. 9. Fit the valve rocker cover (see workshop manual: Cylinder head seal, replacing the cylinder head seal, fitting instructions for the valve rocker cover. RF-Turbo engine: 323 (BJ)/ Mazda3 (BK)/ Premacy (CP)/ Mazda5 (CR)/ Mazda6 (GG/GY)/ Mazda6 (GH)/ MPV (LW) Checking the valve clearance Only Mazda3, Mazda5, Mazda6, MPV: 1. Remove the engine cover. 2. Remove the timing belt cover bolt as shown.
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Timing belt cover bolt Upper timing belt cover
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All engines: 3. Remove the valve rocker cover. 4. Turn the crankshaft and align the timing marks to set the piston of cylinder No. 1 or 4 in the TDC of the compression cycle. 5. Measure the valve clearance at the points marked A when cylinder No. 1 is in the TDC of the compression cycle. Measure the valve clearance at B when cylinder No. 4 is at the TDC of the compression cycle. If the measurements differ from the valve clearance specified, adjust it. Valve clearance (cold engine): please see chapter Technical Data, page 125.
1 Measuring point
6. Turn the crankshaft 360 and measure the play of the remaining valves. If it differs from the valve clearance specified, adjust. 7. Fit the valve rocker cover. Only Mazda3, Mazda5, Mazda6, MPV: 8. Install the timing belt cover bolt as shown. Tightening torque: Mazda3/ Mazda5: 7.8 10.8 Nm Mazda6 / MPV: 7.9 10.7 Nm
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9. Install the engine cover. Adjusting the valve clearance. Only Mazda3, Mazda5, Mazda6, MPV: 1. Remove the engine cover. 2. Remove the timing belt cover bolt. All engines: 3. Remove the valve rocker cover. 4. Turn the crankshaft clockwise to set the piston of cylinder No. 1 in the TDC of the compression cycle. Only Mazda3, Mazda5, Mazda6, MPV: 5. Remove the fuel injector. 6. Adjust the valve clearance A with the No. 1 cylinder at TDC of com pression, and those of B with the No. 4 cylinder at TDC of compression. Only 323 BJ and Premacy CP: Important If the crankshaft is turned without removing the glow plugs first, the compression pressure acts on the injection nozzle and moves the nozzle under some circumstances. Oil carbon deposits on the nozzle seat washer can affect the seal as a result. To prevent this, undo the glow plugs so that no pressure builds up. If an injection nozzle moves as the result of pressure, remove the oil carbon deposits with a cloth and replace the washer. 7. Undo the glow plugs. Undo the injection nozzle brackets. 8. Adjust the valve clearance at positions A while turning the piston of cylinder no. 1 to the TDC of the compression cycle to adjust the valve clearance at positions B.
All engines: (1) Secure the rocker arm bridge with SST (49 G012 006). (2) Undo locking nut with the SST (49 G012 004) and then turn the adjusting screw with the SST (49 G012 005) until the bolt lifts away from the valve shank completely.
1 Adjusting screw 2 Locking nut 3 Rocker arm bridge
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(3) Undo the locking nut of the rocker arm with the SST (49 G012 004) and then turn the adjusting screw with the SST (49 G012 005) until the bolt lifts off from the rocker arm bridge completely.
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1 Adjusting screw 2 Locking nut
(4) Insert a feeler gauge between the rocker arm and the rocker arm bridge. (5) To adjust the valve clearance, turn the adjusting screw with the SST (49 G012 005). Then temporarily tighten the locking nut of the rocker arm with the SST (49 G012 004). (6) Make sure that the feeler gauge inserted remains firmly clamped even when loosening the adjusting screw between the rocker arm and the rocker arm bridge. If the gauge does not remain firmly clamped, repeat the adjustment from step 1. (7) Turn the adjusting screw with the SST (49 G012 005) until it fits on the valve shank and the feeler gauge is still fixed. Tighten the locking nut with the SST (49 G012 004). Specified tightening torque: 16 20 Nm (8) Undo the locking nut of the rocker arm with the SST (49 G012 004) and adjust the valve clearance again. (9) Temporarily tighten the locking nut of the rocker arm with the SST (49 G012 004). Specified tightening torque: 16 20 Nm (10) Check the valve clearance at again. Only 323 BJ and Premacy CP: 7. Turn the crankshaft 360 degrees and adjust the play of the remaining valves. 8. Fit the injection nozzle bracket. 9. Connect the nozzle return pipe. 10. Tighten the glow plugs. 11. Fit the valve rocker cover.
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Only Mazda3, Mazda5, Mazda6, MPV: 7. Turn the crankshaft one full turn and adjust the remaining valve clearances. 8. Install the fuel injector. 9. Install the cylinder head cover. 10. Install the timing belt cover bolt as shown. Tightening torque: Mazda5: 7.8 10.8 Nm Mazda6 / MPV: 7.9 10.7 Nm 11. Install the engine cover. 121 (ZQ) 1.25L engine Check valve clearance / adjust Nominal value Please refer to technical data section page 125. 1. Disconnect the battery earth cable. 2. Remove the valve rocker cover (if there). Open the cable harness and hose cover Remove the crankcase vent Undo the oil filler cap. Undo the bolts. NOTE Do not pull on the cable when removing the sparkplug terminal. If necessary, remove the ignition coil plug to prevent bending the cable. Turn the sparkplug terminal slightly before removal to loosen the seal. Remove the sparkplug terminal in the axis of the sparkplug. Do not damage the valve rocker cover seal, because this cannot be replaced separately. 3. To remove the valve rocker cover, lift straight up. Remove the sparkplug terminal. Use the special tool for angled sparkplug terminals. Undo three bolts in the upper toothed belt cover. Undo the nuts. 4. NOTE Fit long bolts from the front. Fit a special tool. Undo the outer bolts of the first and last camshaft bearing cover. Special tool with guide Fit the retaining device so that it is pointing outwards. 5. NOTE The cams of the valve concerned must point upwards. Fit the special tool. Insert the retaining device in the rocker arm.
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6. Determine the valve clearance of the valves of the first cylinder.
See diagram. NOTE The valve tappet groove must point to the centre of the engine. Do not press on the shim with the retaining device. 7. Remove the shim. Fit the retaining device on the valve tappet side and press down the tappet. Valve tappet groove for special tool. Remove the shim. 8. Determine the shim thickness with a micrometer. 9. Select new shim. Determine the thickness of the new shim: Example (sample value) Thickness of the shim removed + (measured valve clearance nominal play) = thickness of the new shim
4.00 + (0.30 0.25) = 4.05 mm 10. Fit new valve shim as indicated in the previous stage.
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11. Check the valve clearance and adjust if necessary as described above. 12. Repeat the above for each cylinder on the intake side and the exhaust side respectively.
13. Remove the special tool. NOTE Use a blunt object to apply the silicon grease (e.g. a plastic cable post) in order not to damage the sparkplug terminal seal. Push on the sparkplug terminal in the axis of the ignition plug Coat the inside of the sparkplug terminal with a 5 10 mm layer of silicon grease. 14. Fit the valve rocker cover. Push on the sparkplug terminal until it engages. Tighten three bolts in the upper toothed belt cover. Fit the nuts and tighten in two stages. 1st stage: 3 Nm 2nd stage: 10 Nm 15. Cover fit valve rocker cover (if removed) (1) Tighten bolts. Screw on oil filler cap (2) Push on crankcase vent hose and close cable harness cover. 16. Final routine work. Connect battery earth cable. If necessary, fix cable with cable post. Check fluid levels and correct if necessary. 121 (ZQ) 1.3L engine Check valve clearance Nominal value Please refer to technical data section page 125. 1. Disconnect battery earth cable. 2. Remove sparkplug terminal. Unclip the ignition lead and place on one side. NOTE Turn the sparkplug terminal slightly before removing. Pull on the terminal, not the cable. 3. Remove the oil filler cap. Remove the crankcase bleed hose from the T-piece 4. Remove the valve rocker cover with seal (four bolts with washers) Remove the seal.
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Undo the sparkplugs 5. Raise the vehicle. 6. Remove the timing belt cover. 7. Lower the vehicle.
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8. Adjust the valve clearance. Determine the valve clearance with a feeler gauge. Adjust the valve clearance at the rocker arm bolts. NOTE Only adjust the valve clearance at the rocker arm bolts in the clockwise direction. If the valve clearance is too small, turn the rocker arm bolt in the opposite direction and then adjust again in a clockwise direction. Only turn the crankshaft in the clockwise direction when adjusting the valve clearance. Exhaust valve clearance 0.50 mm (engines produced after 20.11.96, indicated on the valve clearance label on the valve rocker cover). Adjust the valve clearance 1. Inlet valve clearance 0.20 mm. 2. Turn the crankshaft belt pulley until the valves overlap at the 1st or 4th cylinder, i.e. rocker arm and tappet rods move in the opposite direction. 3. If the valves of the 4th cylinder overlap, adjust the valve clearance of the 1st cylinder. 4. Then turn the crankshaft pulley another half revolution. In this position, the valves of the 3rd cylinder overlap and the valves of the 2nd cylinder can be adjusted, etc., according to the ignition sequence. 5. Valves of 4th cylinder overlap Adjust valves of 1st cylinder.
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6. Valves of 3rd cylinder overlap Adjust valves of 2nd cylinder. 7. Valves of 1st cylinder overlap Adjust valves of 4th cylinder. 8. Valves of 2nd cylinder overlap Adjust valves of 3rd cylinder. 9. Raise the vehicle. 10. Clip the coolant hose into the bracket. 11. Fit the timing belt cover from underneath. 12. Lower the vehicle. Fit the valve rocker cover (four bolts with washers). Coat the sparkplug thread with a lubricant and screw in the sparkplugs. Plug in the sparkplug terminal. Clip in the ignition lead. NOTE Use a new seal. Coat the sparkplug terminal seal with a thin layer of silicon grease. 13. Connect the battery earth cable L8, LF, L3, L3-Turbo, L5 engine: Mazda3 (BK)/ Mazda5 (CR)/ Mazda6 (GG/GY)/Mazda6 (GH)/ MPV (LW)/ MX-5 (NC)/ Tribute (EP) Check the valve clearance 1. Make sure the engine is cold. 2. In reference to the instruction described in workshop manual, remove parts accordingly. 3. Remove the valve rocker cover. 4. Measure the valve clearance. (1) Turn the crankshaft clockwise so that piston no. 1 is in the TDC of the compression cycle. (2) Measure the valve clearance of the points marked A. If the valve clearance is out of the standard value, adjust it. Only L3-Turbo: If it is not within the specification, replace the tappet and adjust the valve clearance to the median value of the standard. (Please see Adjusting the Valve clearance) NOTE You must make a note of the measured values to be able to choose a suitable replacement tappet.
Nominal value [cold engine] Please refer to technical data section page 125. (3) Turn the crankshaft 360 clockwise so that piston no. 4 is in the TDC of the compression cycle.
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(4) Measure the valve clearance at the points marked (B). If the valve clearance is out of the standard value, adjust it. Only L3-Turbo: If it is not within the specification, replace the tappet and adjust the valve clearance to the median value of the standard. (Please see Adjusting the Valve clearance) 5. Install in the reverse order of removal. Adjusting the valve clearance 1. In reference to the instruction described in workshop manual, remove parts accordingly. 2. Remove the belt. 3. Disconnect the intermediate shaft from the front wheel drive shaft (right). 4. Undo the bottom blind plug of the front engine cover.
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1 Blind plug
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5. Undo the upper blind plug of the front engine cover.
1 Blind plug 6. Undo the bottom blind plug of the cylinder block. 7. Fit the SST as illustrated
8. Turn the crankshaft clockwise until cylinder no. 1 is in the TDC position. 9. Loosen the timing chain.
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(1) Release the timing chain tensioner ratchet with a suitable screw driver or equivalent tool.
1 Bolt (M6 x 1,0)
(2) Turn the exhaust camshaft at the hexagon pin using a suitable spanner. (3) Insert a suitable bolt (M6 x 1.0, Length 25 - 35 mm) into the hole in the upper blind plug (Caution: Mazda3 and Mazda5 bottom blind plug) at the front engine cover and secure the timing chain guide / tensioner arm in the loose position. 10. Hold the exhaust camshaft against the hexagon pin with a suitable spanner.
11. Remove the exhaust camshaft wheel.
1 Exhaust camshaft wheel
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12. Remove the OCV. (With variable valve timing mechanism.) 13. Loosen the camshaft cap bolts in 2 3 passes in the order shown in the figure.
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NOTE The cylinder head and camshaft bearing cover are numbered to make sure that they are refitted in their original position. If they have been removed, the cover must be kept together with the cylinder heads from which they were removed. Do not confuse the covers. 14. Remove the camshaft. 15. Remove the tappet. 16. Measure the thickness of the shim needed. Example (sample value) Thickness of the shim removed + (measured valve clearance nominal play) = thickness of the new shim 4.00 + (0.30 0.25) = 4.05 mm Please refer to technical data section page 125.
17. Bring cylinder no. 1 to the TDC position and fit the camshaft. Only L3-Turbo: 18. Carefully apply adhesive agent to the area indicated in the figure. Thickness: 1.0 mm
1 Intake rear camshaft cap

1 NOTE Make sure that the adhesive does not leak into the sliding part.
All engine: 19. Tightens the bolts in the camshaft bearing cover in the following two stages.
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(1) Tighten with 5.0 9.0 Nm. (2)Tighten with 14.0 17.0 Nm.
20. Install the OCV. (With variable valve timing mechanism.) 21. Install a new washer.
22. Fit the exhaust camshaft sleeve. NOTE Do not tighten the camshaft wheel bolt at this stage. Check the control cams first and then tighten the bolt. 23. Fit the SST and the camshaft as illustrated.
1 European version
24. Undo the bolt (M6 x 1.0, Length 25 - 35 mm) on the front engine cover to tension the timing chain. 25. Turn the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position. 26. Hold the exhaust camshaft against the hexagon pin with a suitable spanner as illustrated. 27. Tighten the locking screw with the exhaust camshaft wheel. Tightening torque: Mazda3/ Mazda5/ MPS/ MX-5/ Mazda6 (GH)/ Tribute/ CX-7: 69 75 Nm
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Mazda6 (GG/GY)/ MPV: Bolt and washer assembly: 69 75 Nm Washer based bolt: 89 95 Nm 28. Remove the SST from the camshaft. 29. Remove the SST from the bottom blind plug of the cylinder block. 30. Turn the crankshaft two revolutions clockwise to the TDC position. If the marks are not aligned, undo the locking screw of the camshaft belt pulley and repeat the operations from stage 27. 31. Apply silicon sealant to the upper blind plug of the front engine cover. 32. Tighten the upper blind plug of the front engine cover. Tightening torque: Mazda3/ Mazda5/ MPS/ MPV/ MX-5/ Mazda6 (GH)/ Tribute/ CX-7: 8 11,5 Nm Mazda6: 10 Nm 43. Tighten the bottom blind plug of the cylinder block. Tightening torque: 18 - 22 Nm
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1 Blind plug 34. Tighten the new bottom blind plug of the front engine cover. 35. 36. Tightening torque: Mazda3/ Mazda5/ MPS/ MPV/ MX-5/ Mazda6 (GH)/ Tribute/ CX-7: 1014 Nm Mazda6: 12 Nm Connect the intermediate shaft to the front wheel drive shaft (right). Install in the reverse order of removal.
Mazda2 (DY) 1.25L/ 1.4L/ 1.6L engine Check valve clearance / adjust 1. Remove the valve cover. 2. Turn the engine until piston No. 1 is at top dead center (TDC). CAUTION Only turn the engine in the normal direction of rotation. 3. Using a suitable set of feeler gauges, measure the valve clearances. Nominal value: Please refer to technical data section page 125. NOTE Note down each cylinder number and the valve clearances measured.
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4. Turn the engine until each piston is at TDC and measure the valve clearances. CAUTION Only turn the engine in the normal direction of rotation. NOTE Only carry out the following steps when the valve clearance(s) require adjustment. 5. Remove the camshafts. 6. Determine the tappet thickness required: 1) Remove the tappet and read the thickness from the underside. 2) Example (sample value) Thickness of the tappet removed + (measured valve clearance nominal play) = thickness of the new tappet 4.00 + (0.30 0.25) = 4.05 mm 3) Install the correct tappet. NOTE The number on the tappet indicates the tappet thickness. 7. Install the camshafts. NOTE Do not install the timing belt at this stage. 8. Measure the valve clearances and repeat this procedure as necessary until all valve clearances are within the specified tolerance. NOTE Turn the camshafts to measure the valve clearances. 9. Install the timing belt. 10. Install the valve cover. ZJ, ZY, Z6 engine: Mazda2 (DE)/ Mazda3 (BK) Valve clearance inspection 1. Remove the battery cover. 2. Disconnect the negative battery cable. 3. Remove the under cover and splash shield (RH). 4. Remove the air cleaner component. 5. Remove the ignition coils. 6. Disconnect the ventilation hose.
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A B 3 NR. NR. 4 A B NR. 1 NR. 2 A A B B
7. Remove the cylinder head cover. 8. Measure the valve clearance. 1) Rotate the crankshaft clockwise so that the No. 1 cylinder is at TDC of the compression stroke. 2) Measure the valve clearance at a shown in the figure.
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1 Exhaust 2 Intake
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If not within the specification, replace the tappet and adjust the valve clearance to the median value. Standard valve clearance (Engine cold). Please refer to technical data section page 125. NOTE Make sure to note down the measured values for choosing the suit able replacement tappets. 3) Rotate the crankshaft clockwise 360 so that the No. 4 cylinder is at TDC of the compression stroke. 4) Measure the valve clearance at B shown in the figure. If mot within the specification, replace the tappet and adjust the valve clearance to the median value. NOTE Make sure to note down the measured values for choosing the suitable replacement tappets. 9. Install the cylinder head cover. 10. Connect the ventilation hose. 11. Install the ignition coils. 12. Install the air cleaner component. 13. Install the under cover and splash shield (RH). Valve clearance adjustment 1. Remove the negative battery cover. 2. Disconnect the negative battery cable. 3. Remove the front wheel and tire (RH). 4. Remove the air cleaner component. 5. Remove the ignition coils. 6. Disconnect the ventilation hose. 7. Remove the cylinder head cover. 8. Remove the splash shield (RH). (Mazda2) 9. Remove the drive belt. 10. Remove the engine front cover blind plug shown in the figure.
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1 Blind plug
11. Insert a bolt into the service hole an the right side by hand as shown in the figure until it stops on the tensioner arm. Then rotate the bolt back out approx. halfway so that it sits slightly in front of the tensioner arm. Insert bolt Front cover service hole M10 x 1.25 10 mm M6 x 1.25 7 mm
1
1 Bolt 2 Front cover 3 Tensioner arm
11. Release tension on the timing chain.
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1) Press down the link plate of the tensioner from the service hole on the left side using a thin flathead screwdriver (precision screwdriver). Then rotate the crank pulley backwards (counter clockwise) with the plunger lock released.
1 Link plate 2 Plunger
2) When the timing chain loosens, shift the tensioner arm to the position shown in the figure at the same time.
3 2 1
1 Service hole 2 Rib 3 Tensioner arm NOTE The timing chain presses the tensioner arm by the rotation of the crank pulley backwards (counterclockwise).
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3) Rotate the bolt (M10 or M6) installed to the front cover by hand and insert it to the position where it catches the inside of the rib on the tensioner arm.
1 1
1 Rib
NOTE Fix the tensioner arm by inserting the bolt and rotate it to the right six to seven times until it reaches to the position shown in the figure. 12. Fix the camshaft using a wrench on the cast hexagon.
13. Remove the camshaft sprocket installation bolt. 14. Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way.
15. Loosen the camshaft cap installation bolts 2-3 passes in the order shown in the figure.
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16. 17. 18. 19.
Remove the camshaft caps. Remove the intake and exhaust camshafts. Remove the tappets. Select a proper tappet according to the result of the valve clearance inspection and install it. Example (sample value) Thickness of the tappet removed + (measured valve clearance nominal play) = thickness of the new tappet 4.00 + (0.30 0.25) = 4.05 mm
20. Align the timing marks on the crank pulley and the engine front cover, and then align the No. 1 cylinder to the TDC.
1 Timing mark 2 TDC 21. 22. Install the intake and exhaust camshafts with the No. 1 cylinder so that it is near TDC of the compression stroke. Install the camshaft caps to the position shown in the figure, and temporarily tighten the No. 2 and No. 7 camshaft installation bolts.
23. Tighten the camshaft installation bolts in 2-3 passes uniformly in the order shown in the figure.
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Tightening torque: 11.3 14.2 Nm
24. Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.
1 Timing mark 2 Cylinder head upper surface
25. Fix the camshaft using a wrench on the cast hexagon.
26. Tighten the camshaft sprocket installation bolt. 27. 28. 29. 30. Tightening torque: 49.6 60.8 Nm Remove the bolt (M10 or M6) holding the tensioner arm. Verify that there is no slack in the timing chain, and then verify that the marks on the camshaft sprocket and the crank pulley are aligned. Inspect the valve timing by rotating the crankshaft clockwise twice. Apply silicone sealant to the blind plug as shown in the figure.
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1 Blind plug
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31. Install the engine front cover blind plug.
Tightening torque: 3.0 5.0 Nm 32. Install in the reverse order of removal. Tribute (EP) YF-engine Valve clearance adjustment 1. Remove the timing belt. NOTE Measure each valves clearance at base circle with the lobe pointed away from the tappet, before removing the camshafts. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time. 2. Use a feeler gauge to measure each valves clearance and record its location.
3. Remove the camshafts.
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CAUTION If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions. 4. Remove the valve tappets from the cylinder head.
NOTE A midrange clearance is the most desirable: Please refer to technical data section page 125. Select tappets using this formula: Example (sample value) Thickness of the tappet removed + (measured valve clearance nominal play) = thickness of the new tappet
4.00 + (0.30 0.25) = 4.05 mm 5. Select tappets and mark installation location. NOTE Lubricate the tappets with engine oil. 6. Install the tappets. 7. Install the camshafts. 8. Confirm each valves clearance at base circle with the lobe pointed away from the tappet. 9. Install the timing belt. B-Series (UN) WL, WL-Turbo, WL-3, WLT-3 engine/ BT-50 (UN) WL-C, WE-C engine Valve clearance inspection / adjustment 1. Remove the EGR pipe (WL3,WLT3). 2. Remove the cylinder head cover. 3. Turn the crankshaft and align the timing mark with the indicator pin so that the piston of the No. 1 or No. 4 cylinders is at TDC of the compression. 4. Measure the valve clearances A with the No. 1 cylinder at TDC of compression, and those of B with the No. 4 cylinder at TDC of compression. Valve clearance (Engine cold): Only WL-, WL Turbo-, WL-3-, WLT-3-engine: Please refer to technical data section page 125.
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1 Engine front 1 2 3 4 Claw Cam lobe Adjust screw Locknut
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CAUTION Loosening the locknut and the adjust screw while the cam lobe is not pressing down the rocker arm will damage the claw of the rocker arm. When loosening the locknut and the adjust screw, rotate the crankshaft clockwise and be sure that the cam lobe presses down the rocker arm firmly as shown in the figure.
5. If not within the specification, adjust and recheck the valve clearance. 6. Turn the crankshaft one full turn and measure the remaining valve clearances. Adjust if necessary. Tightening torque (locknut): Only WL-, WL Turbo-, WL -3-, WLT-3-engine: 16 20 Nm Only WL-C-, WE-C-engine: 20 24 Nm
1 Feeler gauge 2 Adjust screw 3 Locknut 7. Install the cylinder head cover. 8. Install the EGR pipe (WL3,WLT3).
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Engine toothed belt
1 at least 25 mm
Timing belt CAUTION Do not twist, turn or bend the timing belt with force. Do not allow any oil or grease to get onto the timing belt.
1 Teeth broken out 2 Cracking 3 Damage, wear 1. If the timing belt has any oil or grease spots, it has to be replaced. 2. Check the timing belt for damage, wear, broken teeth, cracks and embitterment. Replace the timing belt if necessary. Timing belt tensioning roller CAUTION The tensioning roller has an enclosed bearing. It must not be cleaned with solvent or steam jets. If necessary, clean it with a soft cloth. Make sure that it is not scratched.
1. Check whether the tension roller turns easily. Check for any unusual noises. 2. Check the spring holder and bush for loose seat and damage. 3. Check the tension roller for silicon oil leaks. 4. Replace the roller if necessary.
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Timing belt guide roller
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CAUTION The guide roller has an enclosed bearing. It must not be cleaned with solvents or steam jets. Clean with a soft cloth if necessary. Make sure it is not scratched.
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Check whether the guide roller moves easily. Check for unusual noises. Replace the roller if necessary. Tensioning roller spring Measure the length of the tensioning roller spring in the relaxed state. Replace the spring if necessary. Relaxed length: See Workshop Manual
Crankshaft wheel and camshaft wheels CAUTION The crankshaft wheel and the camshaft wheels for the timing belt must not be cleaned with solvents or steam jets. Use a clean cloth to clean them if necessary. Make sure that they are not scratched.
Check the teeth of the crankshaft wheel and camshaft wheels for wear, deformation and other damage. Replace the wheels if necessary.
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Injection pump toothed belt

121 (ZQ) Removing the toothed belt 1. Remove the V-belt, belt pulley, engine bracket and toothed belt. 2. Turn the crankshaft in the direction of engine rotation until the slot in the drive wheel of the injection pump is in the 12 oclock position. 3. Turn back the crankshaft until the slot is in the 11 oclock position.
4. After removing the plugs, fit the (1) adjusting pin 49 JE01 050 for the TDC position of the crankshaft.
5. Turn the crankshaft slowly and carefully in the direction of rotation of the engine until the crankshaft cheek (2) abuts the TDC adjusting pin (3).
6. Lock the camshaft drive wheel on the cylinder head with (2) camshaft locking pins SST 49 JE01 063. 7. Adjust the injection pump gear-wheel by inserting a 9.5 mm drill (3) into the slot. 8. Undo both tensioning roller bolts, tighten tension springs again.
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9. Undo the 4 bolts of the injection pump gears by two revolutions so that the gears can move in the slots. 10. Remove both toothed belts.
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Installing the toothed belt and adjusting the timing 1. The drive wheels of the injection pump and camshaft must be aligned so that the bolts are central in the slots.
2. Fit both new toothed belts as follows: Arrows in direction of engine rotation The belt must be taut on the tension side. The bolts must remain central in the slots The locking pin and 9.5 mm drill must remain inserted. 3. Undo both tension roller bolts until the belt is taut. 4. Tighten the tension roller bolts (1) and fixing bolts (3) of both timing belts (2) with the torque specified. 5. Remove all adjusters.
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6. Turn the engine twice in the direction of rotation and set the crank shaft to TDC with the TDC setting pin. 7. Insert the camshaft adjusting pin and 9.5 mm drill. 8. Undo the bolts of both drive wheels by half a revolution. 9. Undo the tension roller bolts by a quarter revolution so that the tension roller presses against the slot.
10. Tighten all the bolts again with the correct torque as in step 4. 11. Check whether all the adjusters are correctly inserted and that the crankshaft firmly abuts the TDC adjustment pin. 12. Remove the TDC adjustment pin, camshaft locking pin and 9.5 mm drill. 13. Tighten the plug for the crankshaft TDC setting pin. 14. Fit the belt covers, engine bracket, pulley, V-belt, etc.
Sparkplugs
Adjusting the electrode distance of the sparkplugs. Check the following points. If defects are found, replace the plug
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1 2 3 4 5
concerned Damaged isolator Burned electrode Oil carbon deposits If cleaning is necessary, use a sparkplug cleaning device or wire brush. Also clean the top of the insulator. Damaged O-ring Considerable burning and ageing.
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Electrode gap Burning and carbon deposits Burning Damage and ageing Damage
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Electrode gap: See Workshop Manual CAUTION When removing the ignition lead, pull on the plug terminal, not the cables. Xedos 9 (TA) Removing the rear intake bridge.
Cable harnesses
Check cable harnesses, plug connections where visible to make sure that they are laid and fixed correctly. Pay attention to kinks and abrasions and also damaged insulation. Check that plug connectors are firmly seated.
Oil Bypass Filter

(for diesel engines) Replacement 1. Remove the oil bypass filter using a suitable filter spanner. 2. Clean the surface in contact with the engine with a clean cloth. 3. Apply engine oil to the rubber seal of the new oil bypass filter. 4. Fit the oil bypass filter and tighten completely by hand. 5. Then tighten the filter with a suitable spanner, preferably a strap wrench, by a further 2/3 revolution. CAUTION Do not use a chain spanner, because this can damage and distort the oil bypass filter. 6. Start up the engine and check the oil bypass filter seal for leaks. Check the oil level and top up to the F mark if necessary. Oil bypass filter fill: 0.40 l
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Hose connections and pipes

Hoses, cables, oil and fuel pipes Check that they are laid correctly, are leak-tight, check for abrasions and damage (where visible) Check The fuel supply and return pipes for leaks, incorrect laying, kinks and other damage which could affect the fuel supply. Tighten any loose connections. Check air pressure pipes in turbo-engines for leaks, particularly at elbows and connections. Check cooling water hoses for leaks and kinks. Check underneath the radiator for damage and leaks.
Front wheel, Rear wheel suspension, Steering, Drive shafts, Drive shaft gaiters Checking for Damage, Fixing and Wear
Check Check wheel suspension, shock absorbers and steering linkage for excessive play or wear with the wheels freely suspended Check the joints by turning and moving the drive shaft sideways by hand. Check the gaiters and other rubber parts for cracks and oil or grease leaks.
Draining automatic transmission fluid

Changing the automatic transmission fluid (ATF) CAUTION If the transmission and ATF are hot, this can cause serious burns. Therefore, switch off the engine and allow the transmission and ATF to cool down before changing the ATF. 1. Remove the oil dipstick. 2. Undo the drainage plug and remove the washer. 3. Drain the ATF into a suitable container. 4. Fit a new washer and insert the drainage plug. Tightening torque: 40 53 Nm 5. Top up with ATF: see Final Work and Technical Data
Gear shift cable

Automatic transmission (CTX) Adjusting the shift lever linkage (Only 121 ZQ on 1st service) Adjusting the shift cable NOTE The shift lever must be in the P position. Undo the fork head of the shift cable of the shift lever. Unclip the locking pin, swivel down and remove fork head.
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If necessary, reset the shift lever exactly to the P position. At the same time, turn both wheels in the same direction until they lock, i.e. the parking lock has correctly engaged.
Check the cable adjustment. The locking pin must fit easily into the holes in the fork head and shift lever.
3 2
Adjust the cable: push back the rubber sleeve on the fork head cable and adjust the length of the cable so that the locking pin fits in easily. Push the rubber sleeve back onto the fork head.
Fit the locking pin and clip.
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Exhaust system and heat shields

Check Exhaust pipes for damage and leaks. Check that the exhaust system is in the correct position and that the suspension is intact.
Brake pipes, hoses and connections

Check the brake pipes, brake pipe connections and brake hoses. Check the following points. Replace the parts if necessary. 1. Signs of cracking, damage and corrosion on the brake pipes. 2. Signs of damage on the connecting threads of the brake hoses. 3. Signs of abrasion, cracking and swelling of the brake hoses. 4. Signs of leaks in the brake hydraulics.
Chassis screw connections

Tighten the bolt connections on the chassis and body 1. Tighten all the fixing bolts. 2. Tighten any loose nuts and bolts on the chassis and body with the torque specified. (See Workshop Manual).
Rear differential
Differential oil MX-5 (NC)/ Mazda6 (GG) MPS/ RX-8 (SE)/ CX-7 (ER)/ CX-9 (TB)/ BT-50 (UN) CAUTION Place vehicle on level surface. Check 1. Remove the filler plug and washer.
1 Filler plug 2 Washer
2. Verify that the oil is at the brim of the filler plughole. 3. If it is low, add the specified oil. 4. Install a new washer and the filler plug, and tighten. Tightening torque: 39.253.9 Nm Changing the oil 1. Remove the filler and drainage plug. 2. Drain off the differential oil into a suitable container.
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3. Install a new washer and the drain plug, and tighten. Tightening torque: 39.253.9 Nm 4. Add the specified differential oil from the filler plug until the level reaches the brim of the plughole. Specification: Please see chapter Technical Data, page 119. 5. After filling with differential oil, perform oil level inspection.
6. Install a new washer and the drain plug, and tighten. Tightening torque: 39.2 53.9 Nm
Transfer Box
Mazda6 (GG) MPS/ CX-7 (ER)/ BT-50 (UN) Transfer box oil inspection 1. Park the vehicle on a flat, horizontal surface. 2. Undo the oil level screw with washer. 3. Check whether the oil is at the bottom edge of the screw hole.
4. If the oil level is too low, top up with the correct quantity of the oil specified. Specification: please see chapter Technical Data, page 121.
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5. Screw in a new oil level screw with washer. Tightening torque: 39.2 58.8 Nm
Changing the oil 1. Undo the drainage screw with washer and drain the oil into a suitable container. 2. Tighten the drain plug with a new washer. Tightening torque: 39.2 58.8 Nm
3. Remove the oil level screw with washer and top up with the oil specified through the oil level screw hole until the level has reached the bottom edge of the screw hole. Specification: please see chapter Technical Data, page 121. 4. Tighten the oil level plug with a new washer. Tightening torque: 39.2 58.8 Nm
Fuel pipes
Checking the fuel pipes Check all the connections and pipe connections to see if there are any leaks. There must be no moist or discoloured patched which might indicate a leak. Damaged hoses and clips have to be replaced.
Fuel additive filling

Mazda3 (BK) Y6 engine Warning Failure to follow these instructions may result in personal injury: As this procedure involves handling fuel additives, be prepared for fuel additive spillage at all times and always observe fuel handling precautions.
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Eye, hand ear protection and protective clothing are required to be worn during any general or removal and installation procedure of fuel additive system components. In case of fuel additive fluid contact with the skin or the eyes, flush immediately with water for a minimum of 15 minutes and seek prompt medical attention. If fuel additive fluid is swallowed, call a physician immediately. Rinse mouth immediately with water, do not induce vomiting. Always provide adequate ventilation when working on the fuel additive system or related components. Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite.
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NOTE Perform the After fuel additive refill procedure after refill the fuel additive to the fuel additive tank, please see After fuel additive refill procedure. 1. Lift up vehicle. 2. Remove the fuel additive tank overflow pipe cap. 1 2 3 4 Rear crossmember front Overflow pipe and cap (Quick release connector, Type D) Filler pipe and cap (Quick release connector, Type D)
NOTE Securely connect the fuel additive filler kit overflow hose to the overflow bottle in the kit. 3. Connect the fuel additive filler kit overflow hose to the vehicle-side fuel additive tank overflow pipe. 4. Remove the fuel additive tank filler pipe cap. NOTE Make sure the fuel additive filler kit fuel additive container is positioned below the fuel additive tank. Make sure the fuel additive container valve is closed. 5. Connect the filler hose of the container for fuel additive filling (hereinafter referred to as fuel additive container) to the fuel additive tank filler pipe. 6. Install the fuel additive filler kit overflow bottle to the underside of the vehicle using the hook and net.
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NOTE When raising the fuel additive container, make sure that it is maintained in a horizontal position with the vehicle-side fuel additive tank. 7. Raise the fuel additive container above the fuel additive tank using a suitable stand.
CAUTION Do not allow air to enter the filler hose. NOTE Fuel additive can be filled faster if the overflow bottle cap is loosened to release the pressure in the tank. However, if fuel additive escapes from the overflow hose, tighten the fuel additive container cap immediately to prevent fuel additive spill from the overflow bottle. If the fuel additive container is emptied during the filling procedure, close the filler hose valve, lower the fuel additive container and disconnect the filler hose. Connect the filler hose to the new fuel additive container and raise the fuel additive container, then open the filler hose valve. 8. Open the fuel additive container valve and fill the vehicle side fuel additive tank with fuel additive until fuel additive escapes from the overflow hose connected to the fuel additive tank. Close the valve when fuel additive escapes from the fuel additive container filler hose.
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Fuel additive tank Valve Filler hose Overflow hose Overflow bottle
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9. Lower the fuel additive filler kit fuel additive container below the fuel additive tank. 10. Open the fuel additive filler kit filler hose valve to allow the fuel additive remaining in the hose return to the fuel additive container.
11. Close the fuel additive filler kit filler hose valve. 12. Disconnect the fuel additive filler kit filler hose from the fuel additive tank filler pipe. 13. Install the fuel additive tank filler pipe cap. 14. Disconnect the fuel additive filler kit overflow hose from the fuel additive tank overflow pipe. 15. Install the fuel additive tank overflow pipe cap. 16. Lower the vehicle. 17. Connect the filler hose and the overflow hose using the fuel additive filler kit joint connector to allow the fuel additive spilled in the overflow bottle to return to the fuel additive container. 18. Perform the After fuel additive refill procedure, please see After fuel additive refill procedure. CAUTION After completing the filling procedure, make sure the fuel additive tank filling kit is stored in a dry and secure area away from dust. Foreign matter from work on clutches, brakes or from machining or welding operations can contaminate the fuel additive fluid. 19. Perform the DTC inspection and verify that no DTCs are displayed.
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Draining the engine oil / Renew oil filter

Changing the engine oil Warning Be careful when draining off the engine oil, because the oil is hot. 1. Warm up the engine to normal operating temperature. Then switch the engine off again. 2. Remove the oil filler cap and undo the oil drainage plug. 3. Collect the oil in a suitable container. 4. Fit the oil drainage plug with a new O-ring and screw in again. Tightening torque: 30 41 Nm 5. Topping up the engine oil: Pleas see Final Work: Fill up the Engine Oil on page 104. Changing the engine oil filter 1. Undo the oil filter with a special tool. 2. Wipe the sealing surface on the engine with a clean cloth. 3. Coat the O-ring of the new oil filter with a thin film of engine oil.
4. Fit the oil filter and tighten by hand until the O-ring abuts the sealing surface on the engine side. 5. Turn the oil filter 1 and 1/6 of a revolution further with a special tool. 6. Leave the engine running and check whether there are any leaks. 7. Check the oil level and top up if necessary.
Front wheel bearings / Rear wheel bearings

Checking the wheel hub and axle stub Wheel bearing play 1. Place a gauge on the wheel hub. Push and pull the wheel hub in the actual direction by hand and measure the wheel bearing play. Maximum wheel bearing play: 0.05 mm
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Illustration shows front axle
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2. If the play exceeds the limit, replace the locking nut first of all and tighten with the prescribed tightening torque and then replace the wheel bearing if necessary.
Gearbox Oil
Checking the gearbox oil 1. Park the vehicle on a flat, horizontal surface. 2. Undo the oil level screw with washer. 3. Check whether the oil is at the edge of the screw hole.
1 2 3 4
Oil level High Low Approximately 6 mm
4. If the oil level is too low, add the correct quantity of the oil specified through the oil level screw hole. Gearbox oil: Oil type: API Service GL-4 or GL-5 Viscosity: All-year oil: SAE 75W-90 above 10C: 80W-90 5. Screw in an oil level screw with a new washer. Tightening torque: See Workshop Manual Changing the oil 1. Undo the drainage screw with washer. 2. Drain the oil into a suitable container. 3. Screw in the drainage screw with a new washer. Tightening torque: See Workshop Manual 4. Undo the oil level screw with washer and add the correct volume of the oil specified (see page 121) through the oil level screw hole until the oil level has reached the bottom of the screw hole. Volume: See Workshop Manual
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1 2 3 4
Oil level High Low Approximately 6 mm
5. Screw the oil level screw in again with a new washer. Tightening torque: See Workshop Manual
Brakes
Checking the disc brakes Check the disc brakes as follows: 1. Check whether the calipers move easily. Check for leaks. 2. Check the disk brake linings for wear. 3. Check the condition and thickness of the brake disks.
NOTE Please refer to technical data section page 157.
Under-floor Protection
Check underneath the vehicle Check the condition of the paint and under-body protection. If you find any rust, tell the customer the repair work that needs to be done quickly.
4-Wheel Drive
Four-wheel drive 1. Measure the steering play of the steering wheel Play: 0 30 mm 2. Check that the front wheel steering and rear wheel steering are working properly. Check whether the steering gears are firmly bolted. 3. Check the steering gear housing (front and rear) and also the special hoses for leaks.
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Testing the four-wheel drive steering system and steering linkage
1. With the vehicle stationary and the engine running, check whether the front and rear wheels turn in the opposite direction when turning the steering wheel. Also check for any unusual noises.
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2. Check the track rod ends and rack guides of the front and rear wheel steering system for excessive play. 3. Check the front and rear steering gaiters for damage. 4. Check the track rod ends of the front and rear wheel steering system to see whether they are loose and whether there are any lubricating grease leaks.
final work
Fill up the engine oil

1. Fill the engine with new engine oil of the specified type. Specification: Please see chapter Technical Data, page 104.. 2. Fully close the oil filler cap. 3. Allow the engine to run and check whether there are any leaks. 4. Check the oil level and top up if necessary.
Engine oil data reset (diesel engine)

Mazda6 (GG) VIN 600001-, (GY) VIN 400001- RF-T engine/ Mazda5 (CR) RF-T engine/ Mazda3 (BK) RF-T engine/ Mazda6 (GH) RF-T, R2 engine 1. Connect the M-MDS or equivalent to DLC-2. 2. Set up the M-MDS or equivalent (including the vehicle recognition). 3. Select Powertrain. 4. Select Data Reset. 5. Select Engine Oil and perform procedures according to directions
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final work
on the M-MDS or equivalent screen.
Illustration shows Mazda6
NOTE Because DTCs are still stored in the PCM even the engine oil data reset is performed, after the engine oil data reset is finished, erase all DTCs using the M-MDS or equivalent. 6. Retrieve DTCs using the M-MDS or equivalent, then verify that DTCs are present. If a DTC is present, perform the applicable DTC inspection.
Fill up the automatic transmission fluid

1. Introduce sufficient quantity of the prescribed ATF through the oil filler neck. Specification: please see chapter Technical Data, page 114. 2. Insert the dipstick. 3. Check whether the ATF level is in the warm range (65C). Top up the ATF if necessary.
After fuel additive refill procedure

Mazda3 (BK) Y6 engine 1. Connect the M-MDS or equivalent to the DLC-2.
2. Set up the M-MDS or equivalent (including the vehicle recognition). 3. Select Toolbox. 4. Select Powertrain. 5. Select Service Function. 6. Select FACM. 7. Select Refill FAT and perform procedures according to the direc tions on theM-MDS or equivalent screen.
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final work
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8. Retrieve DTCs using the M-MDS or equivalent, then verify that there in no DTC present.
If a DTC is present, perform the applicable DTC inspection. (Please see Workshop Manual DTC Table Mazda3 MZ-CD 1.6 (Y6).)
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Wheel nuts
Loose wheel nuts Check whether the wheel nuts are tightened with the prescribed tightening torque. Tightening torque: See Workshop Manual
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Tyre pressure and condition

Checking the tyres Checking and adjustment Check the following points. Adjust or replace parts if necessary. 1. Tyre pressure. Measure the tyre pressure of the wheels, including the spare wheel, with a pressure gauge and correct if necessary. CAUTION Measure the tyre pressure when the tyres are cold.
2. Tyre wear NOTE Observe legal minimum tread depth requirements. 3. Check the tyres for damage, cracking and foreign objects like nails and stones. 4. Check that the tyre valves are not leaking.
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final work
1 Wear indicator
final vehicle inspection / test run
Final inspection / test run

Watch out for the following during the test run: Brake function Clutch function (with mechanical gear shift) Steering (play and steering wheel position, straight line) Instrument and display functions (including instrument lights) Unusual noises, squeaking, rattling Engine power and acceleration Safety belts Speed control system (Tempomat / if available) After the test run, check all the fluid levels again and top up if necessary. NOTE If there are excessive fluid losses, find the cause (leaks, etc.).
Final Inspection

Remove the protective covers from the seats, floor-mats and steering wheel. Make sure everything is clean and remove any dirt resulting from the work both inside the vehicle and in the boot and engine compartment. Check whether the important vehicle documents (operating instructions, etc.), spare wheel, toolkit are in the vehicle. If the battery has been disconnected, restore all the customers radio settings (tuning, volume). (Make a note of these before you start work). Check whether all the labels and stickers (brake fluid change, oil change) are affixed and completed.
Tip Many customers like the vehicle to be washed (possibly free of charge) and any products left over from the service (windscreen cleaner, rubber door seal care products).
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Technical data / Identification
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Vehicle Identification
121 ZQ
Vehicle Identification (VIN) Plate Locations
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DEMIO DW/ 323 BA/ 323 BJ/ 626 GF GW/ XEDOS9 TA/ MX-5 NB/ MX-5 NC/ MAZDA3 BK/ MAZDA5 CR/ MPV LV/ MPV LW/ RX-8 SE/ TRIBUTE EP
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MAZDA2 DY
MAZDA2 DE/ MAZDA6 GG GY/ MAZDA6 GH/ CX-7 ER
PREMACY CP
94

CX-9 TB
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B-Series UN/ BT-50 UN Front RH wheel
Engine Code Location

121 ZQ The engine number is stamped on the engine block (viewed from the drivers seat). 1.3 EGI engine - Near gearbox on front left-hand side facing the radiator 1.25 16V engine - Front right, under engine/transmission flange 1.8 DE diesel engine - Front left adjacent to the gearbox 1.8 D Turbo diesel engine - on the left-hand above injection pump
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MAZDA2 DY Depending on the engine type, the engine number is located on the engine block (viewed from the drivers seat): 1.25L, 1.4L and 1.6L gasoline engine - near gearbox on front left-hand side facing the radiator. Y4/ Y6 engine MAZDA2 DY/ MAZDA2 DE/ MAZDA3 BK
ZJ/ ZY/ Z6 engine MAZDA2 DE/ MAZDA3 BK
B3/ B5/ Z5/ ZL engine DEMIO DW/ 323 BA/ 323 BJ
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B6 engine MX-5 NB
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BP engine MX-5 NB
13B RX-8 SE
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KF/ KL/ KJ engine 323 BA/ XEDOS9 TA
FP/ FS engine PREMACY CP/ 626 GF GW/ MPV LW
L8/ LF/ L3/ L3-Turbo/ L5 engine MAZDA3 BK/ MAZDA5 CR/ MAZDA6 GG GY/ MAZDA6 GH/ CX-7 ER/ MPV LW/ MX-5 NC/ TRIBUTE EP
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RF engine 323 BJ/ 626 GF GW/ MAZDA3 BK/ MAZDA5 CR/ MAZDA6 GG GY/ MAZDA6 GH/ MPV LW/ PREMACY CP
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G6 engine B-Series UN/ BT-50 UN
F2 engine B-Series UN/ BT-50 UN
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WL/ WL-Turbo/ WL-3/ WL-C/ WE-C MPV LV/ B-Series UN/ BT-50 UN
JE engine MPV LV
GY/ AJ engine MPV LW/ Tribute EP
100

CA engine CX-9
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Tyre Label Location

DEMIO DW Drivers side
MAZDA2 DE/ CX-9 TB Drivers side
101

323 BA/ 323 BJ
MAZDA3 BK/ MAZDA5 CR/ MAZDA6 GH/ CX-7 ER Drivers side
MAZDA6 GG GY/ XEDOS9 TA Drivers side
102

Drivers side
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626 GF GW/ PREMACY CP/ MPV LV/ MPV LW/ B-Series UN/ BT-50 UN
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MX-5 NB/ MX-5 NC (RHD) Drivers side
MX-5 NC (LHD) Drivers side
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RX-8 SE Drivers side
Liquid amount & Spec. / ENGINE OIL
Engine Oil
Engine Type Applicable model 1.3L Endura-E 121 ZQ Specification Ambient temperature -20 to above +40C: SAE 10W30 API/SG/CD -20 to above +40C: SAE 10W40 API/SG/CD -30 to above +40C: SAE 5W40 API/SG/CD -15 to above +40C: SAE 15W40 API/SG/CD Ambient temperature -20 to above +40C: SAE 10W30 API/SG/CD -20 to above +40C: SAE 10W40 API/SG/CD -30 to above +40C: SAE 5W50 API/SG/CD -15 to above +40C: SAE 5W30 API/SG/CD Capacity Initial fill capacity incl. Filter: 3.40 L with filter change: 3.25 L without filter change: 2.75 L Initial fill capacity incl. Filter: 4.25 L with filter change: 4.0 L without filter change: 3.5 L
1.25 Zetec-SE
121 ZQ
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Specification Engine Type Applicable model 1.8 Endura-DE 121 ZQ Ambient temperature -15 to above +40C: SAE 15W40 CCMC PD2 -10 to above +40C: SAE 20W50 CCMC PD2 -20 to above +40C: SAE 10W40 CCMC PD2 -30 to above +40C: SAE 5W50 CCMC PD2 1.25L/ 1.4L gasoline MAZDA2 DY ACEA A1/B1 or ACEA A3/B3 5W30, 10W40, 5W40

Capacity
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without filter change: 4.5 L
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Initial fill capacity incl. Filter: 5.0 L with filter change: 5.0 L Initial fill incl. oil filter: 4.25 L Service fill incl. oil filter: 3.80 L Service fill excl. oil filter: 3.50 L Initial fill incl. oil filter: 4.50 L Service fill incl. oil filter: 4.25 L Service fill excl. oil filter: 3.75 L Oil replacement: 3.0 L {2.6 Imp qt} Oil and oil filter replacement: 3.2 L {2.8 Imp qt} Total (dry engine): 3.4 L {3.0 Imp qt}
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1.6L gasoline
MAZDA2 DY
ACEA A1/B1 or ACEA A3/B3 5W30, 10W40, 5W40
B3/ B5
DEMIO DW 323 BA 323 BJ
API service SD, SE, SF or SG Above 30C: SAE 40 0C-40C: SAE 30 -10C-20C: SAE 20W-20 -25C-30C: SAE 10W-30 Above -25C: SAE 10W-40, 10W-50 Above -10C: SAE 20W-40, 20W-50 Below -20C: SAE 5W-20 Below 0C: SAE 5W-30 API service SG/SH/SJ Above 30C: SAE 40 0-40C: SAE 30 -10-20C: SAE 20W-20 -25-30C: SAE 10W-30 Above -25C: SAE 10W-40, 10W-50, 10W-30 Above -10C: SAE 5W-20 Below -20C: SAE 5W-20 Below 0C: SAE 5W-30
B6
MX-5 NB
Oil replacement: 3.2 L {2.8 Imp qt} Oil and oil filter replacement: 3.4 L {3.0 Imp qt} Total (dry engine): 3.6 L {3.2 Imp qt}
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Engine Type Applicable model BP MX-5 NB Specification API service SG/SH/SJ Above 30C: SAE 40 0-40C: SAE 30 -10-20C: SAE 20W-20 -25-30C: SAE 10W-30 Above -25C: SAE 10W-40, 10W-50, 10W-30 Above -10C: SAE 5W-20 Below -20C: SAE 5W-20 Below 0C: SAE 5W-30 API service SG Above -25C: SAE 10W-30 Below 0C: 5W-30 Capacity Oil replacement: 3.6 L {3.2 Imp qt} Oil and oil filter replacement: 3.8 L {3.3 Imp qt} Total (dry engine): 4.0 L {3.5 Imp qt}
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323 BA
Oil replacement: 3.2 L {2.8 Imp qt} Oil and oil filter replacement: 3.4 L {3.0 Imp qt} Total (dry engine): 3.6 L {3.2 Imp qt} Oil replacement: 3.0 L {2.6 Imp qt} Oil and oil filter replacement: 3.2 L {2.8 Imp qt} Total (dry engine): 3.4 L {3.0 Imp qt} Oil replacement: 2.7 L {2.4 Imp qt} Oil and oil filter replacement: 2.9 L {2.6 Imp qt} Total (dry engine): 3.4 L {3.0 Imp qt} Oil replacement: 3.7 L {3.3 Imp qt} Oil and oil filter replacement: 3.9 L {3.4 Imp qt} Total (dry engine): 4.2 L {3.7 Imp qt} Oil replacement: 3.3 L {3.9 Imp qt} Oil and oil filter replacement: 3.5 L {3.1 Imp qt} Total (dry engine): 3.7 L {3.3 Imp qt}
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323 BJ
API service SG, SH, SJ Above -25C: SAE 10W-30 Below 0C: 5W-30
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323 BJ
API service SG, SH, SJ Above -25C: SAE 10W-40 Below 0C: 5W-30
ZJ/ ZY/ Z6 MAZDA2 DE MAZDA3 BK
API SL or ACEA A3/A5: 5W-30 API SL or ACEA A3: 10W-40 API SL/SM or ACEA A3/A5: 5W-30, 5W-20, 10W-40 API service SG, SH, SJ Above -25C: SAE 10W-30 -30 - 37C: 5W-30 (PREMACY) Below 0C: 5W-30 (323, 626)
FP/ FS
323 BA 323 BJ 626 GF/GW PREMACY CP MPV LW
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Specification Engine Type Applicable model KF/ KL XEDOS9 TA 323 BA API SG, SH or SJ: 5W-30, 10W-30 L8/ LF/ L3 MAZDA3 BK MAZDA5 CR MX-5 NC MAZDA6 GG/GY (except L3) MAZDA6 GH MX-5 NC VIN1282 94API SL or ACEA A3/A5: 5W-30 API SL or ACEA A3: 10W-40, 5W-20

Capacity
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Oil replacement: 3.7 L {3.3 Imp qt} Oil and oil filter replacement: 4.0 L {3.5 Imp qt} Total (dry engine): 4.9 L {4.3 Imp qt} Oil replacement: 3.9 L {3.4 Imp qt} Oil and oil filter replacement: 4.3 L {3.8 Imp qt} Total (dry engine): 4.6 L {4.0 Imp qt} Oil replacement: 4.05 L {3.56 Imp qt} Oil and oil filter replacement: 4.45 L {3.92 Imp qt} (without oil cooler)/ 4.55 L {4.0 Imp qt} (with oil cooler) Total (dry engine): 4.6 L {4.0 Imp qt} (without oil cooler)/ 4.85 L {4.27 Imp qt} (with oil cooler) Oil replacement: 3.1 L {2.7 Imp qt} (Dipstick A)/ 4.0 L {3.5 Imp qt} (Dipstick B) Oil and oil filter replacement: 3.5 L {3.1 Imp qt} (Dipstick A)/ 4.4 L {3.9 Imp qt} (Dipstick B) Total (dry engine): 4.2 L {3.7 Imp qt} (Dipstick A)/ 5.1 L {4.5 Imp qt} (Dipstick B)
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L8/ LF
API SL or ACEA A3/A5: 5W-30 API SL or ACEA A3: 10W-40, 5W-20
L3
MAZDA6 GG VIN 100001600000 MAZDA6 GY VIN 100001400000
API SL or ACEA A3/A5: 5W-30 API SL or ACEA A3: 10W-40, 5W-20
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Engine Type Applicable model L3 MAZDA6 GG VIN600001MAZDA6 GY VIN400001PV LW VIN200001300000 Specification API SL or ACEA A3/A5: 5W-30 API SL or ACEA A3: 10W-40, 5W-20 Capacity Oil replacement: 4.0 L {3.4 Imp qt} Oil and oil filter replacement: 4.3 L {3.8 Imp qt} Total (dry engine): 4.6 L {4.0 Imp qt} Oil replacement: 4.0 L {3.5 Imp qt} Oil and oil filter replacement: 4.4 L {3.9 Imp qt} Total (dry engine): 5.1 L {4.5 Imp qt}
L3
MPV LW API SL or ACEA A3/A5: VIN300001- 5W-30 API SL or ACEA A3: 10W-40, 5W-20
L3
TRIBUTE EP
API SG/SH/SJ/SL or ILSAC GF-2/GF-3
Oil replacement: 4.1 L {3.6 Imp qt} (Dipstick A)/ SAE 40, 30, 20, 20W- 4.0 L {3.5 Imp qt} 20, 10W-30, 10W-40, (Dipstick B) 10W-50, 20W-40, 15W- Oil and oil filter 40, 20W-50, 15W-50, replacement: 4.5 L {4.0 Imp qt} 5W-20, 5W-30 (Dipstick A)/ 4.4 L {3.9 Imp qt} (Dipstick B) Total (dry engine): 5.2 L {4.6 Imp qt} (Dipstick A)/ 5.1 L {4.5 Imp qt} (Dipstick B) API SL or ACEA A3/A5: 5W-30 API SL/SM or ACEA A3/A5: 5W-30 (MAZDA3, CX-7) API SL or ACEA A3: 10W-40 (MAZDA6) API SL or ACEA A3/A5: 5W-30 API SL or ACEA A3: 10W-40 API SL/SM or ACEA A3/A5: 5W-30, 5W-20, 10W-40 Oil replacement: 5.3 L {4.7 Imp qt} Oil and oil filter replacement: 5.7 L {5.0 Imp qt} Total (dry engine): 6.4 L {5.6 Imp qt} Oil replacement: 4.6 L {4.0 Imp qt} Oil and oil filter replacement: 5.0 L {4.4 Imp qt} Total (dry engine): 5.5 L {4.8 Imp qt}
L3-Turbo
MAZDA3 BK MAZDA6 GG CX-7 ER
L5
MAZDA6 GH
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Engine Type Applicable model 13B RX-8 SE VIN 100001300000 Specification Capacity
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API SG/SH/SJ/SL or ACEA A1/A3: 5W-30 API SG/SH/SJ/SL: 10W-30 RX-8 SE VIN 300001-
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Oil replacement: 3.3 L {2.9 Imp qt} Oil and oil filter replacement: 3.5 L {3.1 Imp qt} Total (dry engine): 5.8 L {5.1 Imp qt} with single oil cooler Total (dry engine): 6.7 L {5.9 Imp qt} with twin oil cooler
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13B
API SG/SH/SJ/SL or Oil replacement: ACEA A1/A3/A5: 5W-30 4.2 L {3.7 Imp qt} Oil and oil filter API SG/SH/SJ/SL: replacement: 4.4 L {3.9 Imp qt} 10W-30 Total (dry engine): 7.0 L {6.2 Imp qt (MT) Total (dry engine): 6.3 L {5.5 Imp qt} (AT) API service SG -25C-30C: SAE 10W-30 Below 0C: 5W-30 Oil replacement: 4.5 L {4.0 Imp qt} Oil and oil filter replacement: 4.8 L {4.2 Imp qt} Total (dry engine): 5.2 L {4.6 Imp qt} Oil replacement: 4.7 L {4.1 Imp qt} Oil and oil filter replacement: 5.2 L {4.6 Imp qt} Total (dry engine): 5.7 L {5.0 Imp qt} Oil and oil filter replacement: 4.25 L {3.74 Imp qt}
JE
MPV LV
GY
MPV LW
ILSAC (GF-II)
YF
TRIBUTE EP TRIBUTE EP
5W-20
AJ
API SH/SJ/SL or ILSAC Oil replacement: 4.7 L {4.1 Imp qt} GF-2/GF-3 (O-ring: pink)/ 5.2 SAE 10W-30, 5W-20, L {4.6 Imp qt} (O5W-30 ring: black) Oil and oil filter replacement: 5.2 L {4.6 Imp qt} (O-ring: pink)/ 5.7 L {5.0 Imp qt} (Oring: black)
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Engine Type Applicable model AJ TRIBUTE EP Specification Capacity
API SH/SJ/SL or ILSAC Total (dry engine): 5.7 L {5.0 Imp qt} GF-2/GF-3 (O-ring: pink)/ 6.2 SAE 10W-30, 5W-20, L {5.5 Imp qt} (O5W-30 ring: black) API SL or ACEA A3/A5: Oil replacement: 5.2 L {4.6 Imp qt} 5W-30 Oil and oil filter API SL or ACEA A3: replacement: 5.7 L {5.0 Imp qt} 10W-40, 5W-20 Total (dry engine): 6.2 L {5.5 Imp qt} API SL/SM or ILSAC GF-3/GF-4 SAE 10W-30, 10W-40, 5W-20, 5W-40 Oil replacement: 4.7 L {4.1 Imp qt} Oil and oil filter replacement: 5.2 L {4.6 Imp qt} Total (dry engine): 5.9 L {5.2 Imp qt} Oil replacement: 3.9 L {3.4 Imp qt} Oil and oil filter replacement: 4.2 L {3.7 Imp qt} Total (dry engine): 4.6 L {4.0 Imp qt} Oil replacement: 4.5 L {4.0 Imp qt} Oil and oil filter replacement: 4.7 L {4.4 Imp qt} Total (dry engine): 5.5 L {4.8 Imp qt} Initial fill incl. oil filter: 4.20 L Service fill incl. oil filter: 3.80 L Service fill excl. oil filter: 3.40 L Oil replacement: 3.4 L {3.0 Imp qt} Oil and oil filter replacement: 3.8 L {3.3 Imp qt} Total (dry engine): 4.2 L {3.7 Imp qt}
AJ
MPV LW
CA
CX-9 TB
F2
B-Series UN
API service SG Above -25C: SAE 10W-30 Below 0C: SAE 5W-30
G6
B-Series UN
API service SG Above -25C: SAE 10W-30 Below 0C: SAE 5W-30
Y4
MAZDA2 DY
ACEA A1/B1 or ACEA A3/B3 5W30, 10W40, 5W40
Y4/ Y6
MAZDA2 DE API CF or ACEA B1/B3/ MAZDA3 BK B5: 5W-30 API CF or ACEA B3: 10W-40 API CD/CE/CF-4 or ACEA B3/B4: 5W-30, 10W-30 (MAZDA2)
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Specification Engine Type Applicable model RF 323 BA 323 BJ API service CD 0C-40C: SAE 30 -10C-25C: SAE 20W-20 -15C-30C: SAE 10W-30 Below -10C: 5W-30 RF-Turbo RF-Turbo MAZDA5 CR ACEA C1 or VIN100001- JASO DL-1 300000 SAE 5W-30 MAZDA6 GG VIN600001MAZDA6 GY VIN400001-

Capacity
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Oil replacement: 5.0 L {4.4 Imp qt} Oil and oil filter replacement: 5.8 L {5.1 Imp qt} Total (dry engine): 6.4 L {5.6 Imp qt} Oil replacement: 4.5 L {4.0 Imp qt} Oil and oil filter replacement: 4.7 L {4.1 Imp qt} Total (dry engine): 5.4 L {4.8 Imp qt} Oil replacement: 4.5 L {4.0 Imp qt} (Dipstick A)/ 3.9 L {3.4 Imp qt} (Dipstick B) Oil and oil filter replacement: 4.7 L {4.1 Imp qt} (Dipstick A)/ 4.1 L {3.6 Imp qt} (Dipstick B) Total (dry engine): 5.1 L {4.5 Imp qt} (Dipstick A)/ 4.5 L {4.0 Imp qt} (Dipstick B) Oil replacement: 3.9 L {3.4 Imp qt} Oil and oil filter replacement: 4.1 L {3.6 Imp qt} Total (dry engine): 4.5 L {4.0 Imp qt} Oil replacement: 4.8 L {4.2 Imp qt} Oil and oil filter replacement: 5.0 L {4.4 Imp qt} Total (dry engine): 5.5 L {4.8 Imp qt} Oil replacement: 6.0 L {5.3 Imp qt}
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323 BJ API service CD PREMACY CP Above -15C-40C: SAE 626 GF/GW 10W-30 Below 10C: 5W-30
RF-Turbo
MAZDA5 CR ACEA C1 or VIN300001- JASO DL-1 MAZDA6 GH SAE 5W-30
RF-Turbo
MAZDA6 GG VIN100001600000 MAZDA6 GY VIN100001400000 MPV LW MPV LV
API CF or ACEA B1/B3: 5W-30 API CF or ACEA B3: 10W-40 API CD/CE/CF-4 or ACEA B3/B4: 5W-30, 10W-30 API service CD -25C-30C: SAE 10W-30 Below 0C: 5W-30
WL-Turbo
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Engine Type Applicable model WL-Turbo MPV LV Specification API service CD -25C-30C: SAE 10W-30 Below 0C: 5W-30 WL/ WLTurbo B-Series UN API service CD -25-40C: SAE 10W-30 Below 10C: SAE 5W-30 Capacity Oil and oil filter replacement: 6.8 L {6.0 Imp qt} Total (dry engine): 7.1 L {6.2 Imp qt} Oil replacement: 5.6 L {4.9 Imp qt} Oil and oil filter replacement: 6.3 L {5.5 Imp qt} Total (dry engine): 6.7 L {5.9 Imp qt} Oil replacement: 6.8 L {6.0 Imp qt} Oil and oil filter replacement: 7.0 L {6.2 Imp qt} Total (dry engine): 8.0 L {7.0 Imp qt}
WL-C/ WE-C BT-50
API CF or ACEA B1/B3/B5 API CF-4 or ACEA B1/B3/B5 SAE 5W-30
Liquid amount & Spec. / ENGINE COolant
Engine Coolant
Applicable model 121 ZQ MAZDA2 DY MAZDA2 DY MAZDA2 DE MAZDA2 DE DEMIO DW 323 BA 323 BJ Engine 1.8L Diesel Capacity 9.3 L
Gasoline engine 5.0 L Diesel engine Y4 ZJ/ ZY B3/ B5/ BP/ ZL/ ZM 5.5 L 6.2 L {5.5 Imp qt} 5.2 L {4.6 Imp qt} (MT) 5.0 L {4.4 Imp qt} (AT) 6.0 L {5.3 Imp qt}
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Applicable model 323 BJ MAZDA6 GG/GY MAZDA6 GH PREMACY CP 323 BA 323 BJ XEDOS9 TA 626 GF/GW PREMACY CP 626 GF/GW MX-5 NB MX-5 NC MAZDA6 GG/GY MAZDA6 GH MAZDA3 BK MAZDA3 BK MAZDA3 BK MAZDA5 CR VIN300001TRIBUTE EP MAZDA3 BK MAZDA3 BK MAZDA5 CR MAZDA5 CR VIN100001300000 MAZDA6 GG RX-8 SE VIN100001300000 RX-8 SE VIN300001MPV LV Engine RF/ RF-Turbo Capacity RF FP/ FS RF-Turbo B6/ BP
9.0 L {7.9 Imp qt}
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6.4 L {5.6 Imp qt} 7.5 L {6.6 Imp qt}
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With heater: 9.0 L {7.9 Imp qt} Without heater: 8.5 L {7.5 Imp qt} With heater: 6.0 L {5.3 Imp qt} Without heater: 5.5 L {4.8 Imp qt}
L8/ LF/ L3/ L5 7.5 L {6.6 Imp qt}
Y6 ZJ/ ZY/ Z6 L8/ LF/ L3
With heater: 9.0 L {7.9 Imp qt} Without heater: 8.5 L {7.5 Imp qt} With heater: 6.0 L {5.3 Imp qt} Without heater: 5.5 L {4.8 Imp qt} With heater: 7.5 L {6.6 Imp qt} Without heater: 6.9 L {6.1 Imp qt}
L3-Turbo RF-Turbo RF-Turbo L8/ LF
7.5 L {6.6 Imp qt} With heater: 9.4 L {8.3 Imp qt} Without heater: 8.8 L {7.7 Imp qt} With heater: 8.5 L {7.5 Imp qt} Without heater: 8.0 L {7.0 Imp qt} With heater: 7.0 L {6.2 Imp qt} Without heater: 6.5 L {5.7 Imp qt} 8.0 L {7.0 Imp qt} 9.8 L {8.6 Imp qt}
L3-Turbo 13B
13B JE
10.0 L {8.80 Imp qt} (MT) 9.8 L {8.6 Imp qt} (AT) 9.4 L {8.3 Imp qt}
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Applicable model MPV LV MPV LW MPV LW MPV LW TRIBUTE EP TRIBUTE EP Engine WL-Turbo FS/ L3 GY RF-Turbo YF AJ Capacity 7.5 L {6.6 Imp qt} With heater: 10.5 L {9.3 Imp qt} Without heater: 8.8 L {7.7 Imp qt} With heater: 12.0 L {10.6 Imp qt} Without heater: 10.2 L {9.0 Imp qt} With heater: 10.7 L {9.4 Imp qt} Without heater: 8.6 L {7.6 Imp qt} 6.6 L {5.8 Imp qt} With heater: 7.5 L {6.6 Imp qt} Without heater: 10 L {8.8 Imp qt} (LHD) Without heater: 6.9 L {6.1 Imp qt} (RHD) 9.0 L {7.9 Imp qt} Single fan control module: 12.9 L {11.4 Imp qt} Dual fan control module: 13.3 L {11.7 Imp qt} With heater: 7.5 L {6.6 Imp qt} Without heater: 6.9 L {6.1 Imp qt} With heater: 9.4 L {8.3 Imp qt} Without heater: 8.8 L {7.7 Imp qt} 8.8 L {7.7 Imp qt}
CX-7 ER CX-9 TB
L3-Turbo CA
B-Series UN BT-50 UN B-Series UN BT-50 UN BT-50 UN
F2/ G6 WL/ WL-Turbo WLT-1/ WLT-2/ WL-C/ WE-C WL-3
Liquid amount & Spec. / ATF
Automatic Transmission Fluid

Applicable model 121 ZQ Transmission Type WSS-M2C 202-B Capacity 4.2 L (with oil cooler) 4.1 L (without oil cooler) * new transmissions are pre-filled with 0.6 L
114
OO
ZO
Type Applicable model 323 BA 626 GF VIN100001400000 626 GW VIN100001200000 MPV LW XEDOS9 TA 323 BJ 626 GF VIN400001626 GW VIN200001BT-50 UN CX-7 ER CX-9 TB DEMIO DW MAZDA2 DE MAZDA3 BK MAZDA3 BK VIN500001MAZDA5 CR Transmission GF4A-EL ATF M-III or equivalent (e.g. DexronII) FN4A-EL ATF M-III or equivalent (e.g. DexronII)

Capacity
FB4A-EL ATF M-III or DexronII 5.4 L {4.8 Imp qt} 8.0 L {7.0 Imp qt}
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7.2 L {6.3 Imp qt}
}
9.93 L {8.74 Imp qt} 7.0 L {6.2 Imp qt}
-Z
5R55S AW6AXEL
MerconV JWS3309
FN4A-EL ATF M-III or equiva- 7.0 L {6.2 Imp qt} lent (e.g. DexronII) FN4A-EL ATF M-V FN4A-EL ATF M-V 7.0 L {6.1 Imp qt} 7.6 L {6.1 Imp qt} (ZY) 7.0 L {6.1 Imp qt} (Z6) 7.2 L {6.1 Imp qt} (LF) 8.14 L {7.16 Imp qt} (without air-cooled oil cooler) 8.39 L {7.38 Imp qt} (with air-cooled oil cooler) 7.2 L {6.3 Imp qt}
FS5A-EL ATF M-V
MAZDA5 CR MAZDA6 GG VIN100001600000 MAZDA6 GY VIN100001400000 MAZDA6 GG VIN100001600000 MAZDA6 GY VIN100001400000
FN4A-EL ATF M-V
JA5AXEL
ATF M-III or equiva- 8.3 L {7.3 Imp qt} lent (e.g. DexronIII)
115

Applicable model MAZDA3 BK VIN500001MAZDA6 GG VIN600001MAZDA6 GY VIN400001MAZDA6 GH MPV LW MPV LW MX-5 NB MX-5 NC PREMACY CP VIN100001300000 Transmission Type Capacity 8.14 L {7.2 Imp qt}
FS5A-EL ATF M-V
FN4A-EL ATF M-V
7.8 L {6.9 Imp qt}
JA5A-EL ATF M-III or equiva- 9.7 L {8.5 Imp qt} lent (e.g. DexronIII) SB4A-EL ATF M-III or equiva- 6.7 L {5.9 Imp qt} lent (e.g. DexronII) SJ6A-EL JWS3309 7.4 L {6.5 Imp qt}
FN4A-EL ATF M-III or equiva- 7.2 L {6.3 Imp qt} lent (e.g. DexronII) (VIN100001300000) ATF M-V (VIN300001-) RC4A-EL ATF M-III or equiva- 8.7 L {7.7 Imp qt} lent (e.g. DexronII) SJ6A-EL JWS3309 GF4AXEL 8.0 L {7.0 Imp qt}
RX-8 SE VIN100001300000 RX-8 SE VIN300001TRIBUTE EP
ATF M-III or equiva- 8.2 L {7.2 Imp qt} lent (e.g. DexronIII)
Liquid amount & Spec. / Transaxl oil
Transaxle Oil
Applicable model MX-5 NB MX-5 NC B-Series UN BT-50 UN Transmission M15M-D Type Capacity API Service GL-4 2.0 L or GL-5 {1.8 lmp qt} All season: SAE 75W-90 Above 10C: SAE 80W-90
116

Applicable model BT-50 UN MAZDA3 BK CX-7 ER MAZDA2 DE MAZDA3 BK Transmission S15M-D S15MX-D A26M(X)-R Type Capacity
OO
ZO
F35M-R B65M-R G35M-R
Manual transmis- 3.55 L sion fluid type A {3.12 lmp qt} API Service GL-4 2.5 L or GL-5 {2.2 lmp qt} SAE 75W-90
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2.3 L {2.0 lmp qt}
}
2.77 L {2.44 lmp qt} (MAZDA6 GH) 2.87 L {2.53 lmp qt} (Others)
-Z
API Service GL-4 3.04 L or GL-5 {2.67 lmp qt} All-season: SAE 75W-90 Above 10 C: SAE 80W-90 WSD-M2C200-C API Service GL-4 or GL-5 All-season: SAE 75W-90 Above 10 C: SAE 80W-90
MAZDA2 DE MAZDA3 BK MAZDA5 CR MAZDA6 GG/GY MAZDA6 GH
MAZDA3 BK
J65M-R
API Service GL-3 1.9 L or GL-4 {1.67 lmp qt} All-season: SAE 75W-90 API GL-4/ GL-5 All-season: SAE 75W-90 Above 10C: SAE 80W-90 2.85 L {2.51 lmp qt} (MAZDA6 GH) 2.95 L {2.60 lmp qt} (Others)
MAZDA3 BK MAZDA6 GG VIN600001MAZDA6 GY VIN400001MAZDA6 GH MAZDA6 GG VIN100001600000 MAZDA6 GY VIN100001400000 MPV LW VIN200001TRIBUTE EP MAZDA5 CR MAZDA6 GG VIN600001MAZDA6 GY VIN400001-
G66M-R
A65M(X)-R
API Service GL-4 2.3 L or GL-5 {2.0 lmp qt} All-season: check filler hole SAE 75W-90
A26M-R
API Service GL-4 2.55 L or GL-5 {2.24 lmp qt} All-season: SAE 75W-90 Above 10 C: SAE 75W-90
117

Applicable model MAZDA6 GG VIN600001MAZDA6 GY VIN400001MAZDA6 GH MX-5 NC RX-8 SE VIN300001RX-8 SE MPV LV B-Series UN BT-50 UN Transmission A26MX-R Type Capacity
API Service GL-4 2.55 L or GL-5 {2.24 lmp qt} SAE 75W-90
P66M-D
API Service GL-4 2.1 L {1.8 lmp qt} (MX-5) SAE 75W-90 1.95 L {1.72 lmp qt} (RX-8) API Service GL-4 or GL-5 All season: SAE 75W-90 Above 10C: SAE 80W-90 2.5 L {2.2 lmp qt} (RX-8, MPV) 2.8 L {2.5 lmp qt} (B-Series, BT-50)
R15M-D
RX-8 SE VIN100001300000 121 ZQ 323 BJ TRIBUTE EP PREMACY CP MPV LW
Y16M-D
API Service GL-4 1.75 L or GL-5 {1.54 lmp qt} All season: SAE 75W-90 SAE 75W-90 2.8 L
G15M-R
API Service GL-4 2.7 L or GL-5 {2.4 lmp qt} All season: SAE 75W-90 Above 10C: SAE 80W-90 API Service GL-4 or GL-5 All season: SAE 75W-90 Above 10C: SAE 80W-90 2.7 L {2.4 lmp qt} (626) 2.2 L {2.4 lmp qt} (TRIBUTE)
626 GF/GW TRIBUTE EP
G25M-R
B-Series UN
M15MX-D
API Service GL-4 2.5 L or GL-5 {2.2 lmp qt} All season: SAE 75W-90 Above 10C: SAE 80W-90 API Service GL-4 3.2 L or GL-5 {2.8 lmp qt} All season: SAE 75W-90 Above 10C: SAE 80W-90
B-Series UN BT-50 UN
R15MX-D
118

Applicable model DEMIO DW 323 BA 323 BJ PREMACY CP Transmission F25M-R Type Capacity
OO
ZO
Y16M-D
API Service GL-4 2.68 L or GL-5 {2.36 lmp qt} All season: SAE 75W-90 Above 10C: SAE 80W-90 WSD-M2C200-C SAE 75W-90 2.3 L
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}
2.0 L {1.8 lmp qt}
-Z
MAZDA2 DY MX-5 NB
API Service GL-4 1.8 L or GL-5 {1.6 lmp qt} All-season: SAE 75W-90 Above 10C: SAE 80W-90 ATF M-III or DexronII
XEDOS9 TA
H25M-R
Liquid amount & Spec. / Differential oil
Differential Oil
Applicable model MX-5 NB MX-5 NC RX-8 SE MAZDA6 GG/GY MPV LV Item Rear differential oil Rear differential oil Rear differential oil Rear differential oil Type API service GL-5 SAE 90 API service GL-5 SAE 90 API service GL-5 SAE 90 Capacity 1.0 L {0.9 lmp qt} 0.6-0.8 L {0.53-0.70 Imp qt} 1.2-1.4 L {1.1-1.2 Imp qt}
1.00 L API service GL-5 Above -18C: SAE 90 {0.88 Imp qt} Below -18C: SAE 80
1.5 L Rear differ- API service GL-5 Above -18 C: SAE 90 {1.3 lmp qt} ential oil Below -18 C: SAE 80
119
Liquid amount & Spec. / Differential oil

Applicable model CX-7 ER CX-9 TB Item Rear differential oil Type API service GL-5 SAE 80W-90 Capacity 1.00 L {0.88 Imp qt}
B-Series UN Front differential oil
API service GL-5 1.20 L Above -18 C: SAE 90 {1.06 lmp qt} (MFW) Below -18 C: SAE 80 1.50 L {1.32 lmp qt} (RFW)
BT-50 UN
Front diffe- API service GL-5 1.4-1.6 L rential oil Above -18 C: SAE 90 {1.3-1.4 lmp qt} (G6/ WLT-1/ Below -18 C: SAE 80 WLT-2) Front differential oil (WL-C/WE-C except for Russia) Front differential oil (WL-C/ WE-C for Russia) Rear differential oil (F2/ G6/ WLT-1/ WLT2/ WL-3) 1.8-2.0 L API service GL-5 Above -18 C: SAE 90 {1.6-1.7 lmp qt} Below -18 C: SAE 80
BT-50 UN
BT-50 UN
API service GL-5 SAE 75W-90, 80W90 API service GL-5 (STANDARD DIFFERENTIAL) API service GL-6 (LSD) SAE 90
1.8-2.0 L {1.6-1.7 lmp qt}
B-Series UN BT-50 UN
1.3-1.5 L {1.15-1.32 lmp qt} (4x2) 1.75-1.95 L {1.85-2.06 lmp qt} (4x4) 2.35-2.55 L {1.96-2.12 lmp qt} (4x2, except HiClearance model) 2.85-3.05 L {2.512.68 lmp qt} (4x4, Hi-Clearance model) 2.85-3.05 L {2.512.68 lmp qt}
BT-50 UN
Rear diffe- API service GL-5 rential oil SAE 80W-90 (WL-C/ WE-C except for Russia)
BT-50 UN
Rear differential oil (WL-C/ WE-C for Russia)
API service GL-5 SAE 75W-90, 80W-90
120
OO
ZO
Type API Service GL-5 SAE 80W-90
Liquid amount & Spec. / transfer OIL
Transfer Oil
Applicable model Transmission TRIBUTE EP G15M-R G25MX-R A65M(X)-R GF4AX-EL TRIBUTE EP LA4AX-EL CX-7 ER MAZDA6 GG CX-9 TB BT-50 UN BT-50 UN B-Series UN BT-50 UN A26MX-R AW6AX-EL S15MX-D 5R55S M15MX-D R15MX-D
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Capacity 1.2 L {1.1 lmp qt} 0.532 L {0.468 lmp qt} 1.85 L {1.63 lmp qt}
}
check filler hole check filler hole 1.2 L {1.1 lmp qt} 2.0 L {1.8 lmp qt}
-Z
API Service GL-5 SAE 75W-140 API Service GL-5 SAE 80W-90 API Service GL-5 SAE 75W-140 Manual Transmission Fluid Type A Transfer case oil Mercon V API Service GL-4 or GL-5 All season: SAE 75W-90 Above 10 C: SAE 80W-90
Liquid amount & Spec. / Steering fluid
Steering Fluid
Applicable model DEMIO DW Type ATF M-III or equivalent (e.g. DexronII) Capacity 0.9 L {0.8 lmp qt} 1.2-1.3 L 1.1 L {0.97 lmp qt}
MAZDA2 DY WSA-M2C195-A 323 BA ATF M-III or equivalent (e.g. DexronII)
121

Applicable model 323 BJ Type ATF M-III or equivalent (e.g. DexronII) Capacity 0.8 L {0.7 lmp qt} (B3) 1.0 L {0.9 lmp qt} (ZL, FP, RF) 0.86L {0.76 lmp qt} (RF-Turbo RHD) 0.92L {0.81 lmp qt} (RF-Turbo LHD) 1.20 L {1.06 lmp qt} (ZJ, Z6) 0.80 L {0.70 lmp qt} (ZY, LF, L3, Y6) 1.10 L {0.96 lmp qt} (L3-Turbo) 0.94 L {0.83 lmp qt} (RF-Turbo, RHD) 0.99 L {0.87 lmp qt} (RF-Turbo, LHD) 1.25 L {1.10 lmp qt} (2WS) 2.0 L {1.8 lmp qt} (4WS) 1.0 L {0.88 lmp qt} (FP) 0.86 L {0.76 lmp qt} (RF-Turbo RHD) 0.92 L {0.81 lmp qt} (RF-Turbo LHD)
MAZDA3 BK ATF M-III, M-V or equivalent (e.g. DexronII)
XEDOS9 TA
ATF M-III or equivalent (e.g. DexronII)
PREMACY CP ATF M-III or equivalent (e.g. DexronII)
MAZDA5 CR ATF M-III or equiva- 0.8 L {0.7 lmp qt} (L8, LF) lent (e.g. DexronII) 0.97 L {0.85 lmp qt} (RF-Turbo) MX-5 NB ATF M-III or equivalent (e.g. DexronII) 0.79 L {0.70 lmp qt} (LHD) 0.81 L {0.71 lmp qt} (RHD MT) 0.71 L {0.62 lmp qt} (RHD AT)
MX-5 NC 626 GF/GW
ATF M-III or equiva- 1.19 L {1.04 lmp qt} (LHD) lent (e.g. DexronII) 1.17 L {1.03 lmp qt} (RHD) ATF M-III or equivalent (e.g. DexronII) 0.84 L {0.74 lmp qt} 0.94 L {0.83 lmp qt} (RF-Turbo RHD) 0.82 L {0.72 lmp qt} (RF-Turbo LHD) 1.10 L {0.97 lmp qt} (4WD) 0.98 L {0.86 lmp qt} (2WD)
626 GF ATF M-III VIN439064- or equivalent 626 GW (e.g. DexronII) VIN208843MAZDA6 GG ATF M-III VIN100001- or equivalent 600000 (e.g. DexronII) MAZDA6 GY VIN100001400000 MAZDA6 GG ATF M-III VIN600001- or equivalent MAZDA6 GY (e.g. DexronII) VIN400001-
0.80 L {0.70 Imp qt} (MT except RF-Turbo) 0.87 L {0.77 Imp qt} (AT except 4WD) 0.86 L {0.76 Imp qt} (RF-Turbo) 0.89 L {0.78 Imp qt} (4WD) 0.80 L {0.70 Imp qt} (2WD MT L8, LF, L3 except 18inch wheel) 0.82 L {0.72 Imp qt} (2WD MT L3 18inch wheel) 0.87 L {0.77 Imp qt} (2WD AT LF, L3 except 18inch wheel) 0.89 L {0.78 Imp qt} (2WD AT L3 18inch wheel) 0.89 L {0.78 Imp qt} (4WD L3, L3-Turbo) 0.86 L {0.76 Imp qt} (RF-Turbo)
122

Applicable model MPV LV MPV LW VIN100001200000 MPV LW VIN200001Type Capacity
OO
ZO
ATF M-III or equivalent (e.g. DexronII) ATF M-III or equivalent (e.g. DexronII)
ATF M-III or equiva- check level gauge lent (e.g. DexronII)
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1.05 L {0.92 lmp qt} (GY) 1.00 L {0.88 lmp qt} (FS)
-Z
1.09 L {0.96 lmp qt} (L3 LHD) 1.04 L {0.92 lmp qt} (L3 RHD) 0.96 L {0.84 lmp qt} (RF-Turbo LHD) 0.90 L {0.79 lmp qt} (RF-Turbo RHD)
TRIBUTE EP ATF M-III or equiva- 1.10 L (UK spec) lent (e.g. DexronII) 1.00 L (except UK spec) CX-7 ER CX-9 TB B-Series UN BT-50 UN B-Series UN BT-50 UN ATF M-III, M-V or equi- 0.98 L (LHD) valent (e.g. DexronII) 0.8 L (RHD) ATF M-III, M-V or equi- 1.27 L {1.11 lmp qt} valent (e.g. DexronII) Power steering: ATF 1.1 L {1.0 lmp qt} M-III or equivalent (e.g. DexronII) Manual steering: API 0.34 L {0.30 lmp qt} service GL-4, SAE90
Liquid amount & Spec. / clutch/brake fluid
Clutch/Brake Fluid
Type SAE J1703, FMVSS 116 DOT-3 or DOT-4
123
Liquid amount & Spec. / Air Condtition
Heater and Air Conditioner Systems

Refrigent type: R134-a A/C compressor lubrication oil Applicable model MAZDA6 GH BT-50 UN Refrigent amount 475-525 g 475 g Type Sealed volume
ZXL 100PG (LF, L8, L5) 120 ml ATMOS GU10 (RF Turbo) FD46XG (G6, WE-C, 180 ml WL-3, WLC, WLT-1, WLT-2) ZXL 100PG (F2) MTX: 150 ml ATX: 120 ml 160 ml
CX-7 ER CX-9 TB MAZDA2 DE MAZDA3 BK
475-525 g (LHD) ATMOS GU10 500-550 g (RHD) 660-710 g 470-500 g 650 g (Y6) 500 g 500 g 470 g (LHD) 430 g (RHD) DENSO OIL8
ATMOS GU10 (ZJ, ZY) 110 ml (ZJ, ZY) FD46XG (Y4) 120 ml (Y4) SP-10 (Y6) ATMOS GU10 ATMOS GU10 ATMOS GU10 200 ml (Y6) 125 ml (ZJ, Z6) 155 ml (LF, RF-Turbo) 150 ml 120 ml (except RF-Turbo) 150 ml (RF-Turbo)
MAZDA5 CR MAZDA6 GG VIN100001600000 MAZDA6 GY VIN100001400000 MAZDA6 GG VIN600001MAZDA6 GY VIN400001MX-5 NC RX-8 SE 121 ZQ 323 BA 323 BJ 626 GF/GW
470 g (LHD) 430 g (RHD)
ATMOS GU10
150 ml
450 g 430 g 730-750 g
DH-PR DENSO OIL8
130 ml 60 ml 200 ml 150 ml 150 ml 150 ml
750 g (5HB, LHD) ATMOS GU10 700 g (RF) 600 g (LHD) 625 g (RHD)
ATMOS GU10 700 g (condenser 32 lines) 625 g (condenser 26 lines)
124
Liquid amount & Spec. / Air Condtition

A/C compressor lubrication oil Applicable model B-Series UN DEMIO DW MAZDA2 DY Refrigent amount 550 g 650 g (LHD) 600 g (RHD) 650 g Type
OO
ZO
800 g ND-OIL8 850 g (Twin A/C) ND-OIL8 650 g (Single A/C) 800 g (Twin A/C) ND-OIL8 600 g (Single A/C) 700 g (LHD, ATMOS GU10 extremly hot areas) 650 g (other) 900 g 675 g ATMOS GU10
O}
180 ml 150 ml 200 ml 160 ml
}
Sealed volume 160 ml 150 ml
-Z
207 ml WSH-M1C231-B (Diesel engine) SP10 (Gasoline engine)
MPV LV MPV LW VIN100001200000 MPV LW VIN200001PREMACY CP
TRIBUTE EP XEDOS9 TA
170 ml (AJ, YF) 180 ml (L3) 150 ml (KF, KL) 175 ml (KJ)
technical data / engine
Engine Technical Data

Model 121 ZQ Item Valve clearance (engine cold) Engine 1.3 Endura-E 1.25 Zetec-SE Specification In: 0.20 mm Ex: 0.30 mm In: 0.17-0.23 mm Ex: 0.27-0.33 mm
1.8 In: 0.300-0.400 mm Endura-DE Ex: 0.450-0.550 mm
125

Model 121 ZQ Item Firing order Engine Specification
1.3 Endura-E 1-2-4-3 1.25 Zetec-SE 1-3-4-2 In: 0.30 mm Ex: 0.30 mm 1.27-1.29 max. 20 mA S46A24L(S): 135 A In: 0.17-0.23 mm Ex: 0.27-0.33 mm In: 0.17-0.23 mm Ex: 0.31-0.37 mm In: 0.103-0.118 mm Ex: 0.113-0.128 mm
DEMIO DW
Valve clearance (engine cold)
B3, B5
Battery electrolyte B3, B5 specific gravity [20C] Battery back-up current Battery test load current MAZDA2 Valve clearance DY (engine cold) B3, B5 B3, B5 1.25, 1.4L gasoline 1.6L gasoline Y4 Firing order MAZDA2 Valve clearance DE (engine cold)
1-3-4-2 1.25, 1.4, 1.6L gasoline 1.4 DI Turbo ZJ, ZY In: 0.1030.118 mm Ex: 0.1130.128 mm In: 0.270.33 mm Ex: 0.270.33 mm
Battery electrolyte ZJ, ZY, 1.221.29 specific gravity [20C] 1.4 DI Turbo Battery back-up current (When the ignition switch is off, the ignition key is removed, and all doors are closed.) Battery test load current Vehicles with ZJ, ZY, 1.4 DI Turbo immobilizer system: 1535 mA Vehicles without immobilizer system: 20 mA or less ZJ, ZY 55D23L (48): 180 A 75D23L (52): 195 A
1.4 DI Turbo 80D26L (55): 195 A Cylinder head bolt length Firing order ZJ, ZY Standard: 128.9129.5 mm Maximum: 130.2 mm 1342 (all cylinders independent firing)
ZJ, ZY
126

Model Item Engine BP RF Battery electrolyte specific gravity [20C] Battery back-up current 323 BJ Valve clearance (engine cold)
OO
ZO
B3 ZL FP RF RF-Turbo
323 BA Valve clearance (engine cold)
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Specification In: 0.18-0.24 mm Ex: 0.28-0.34 mm In: 0.20-0.30 mm Ex: 0.30-0.40 mm In: 0.30 mm Ex: 0.30 mm In: 0.25-0.31 mm Ex: 0.25-0.31 mm In: 0.225-0.295 mm Ex: 0.225-0.295 mm In: 0.20-0.30 mm Ex: 0.30-0.40 mm In: 0.12-0.18 mm Ex: 0.32-0.38 mm 1.27-1.29
B3, Z5, BP, 1.27-1.29 RF B3, Z5, BP, max. 20 mA RF
-Z
Battery electrolyte specific gravity [20C] Battery back-up current Battery test load current
B3, ZL, ZM, FP, FS, RF, RF-Turbo B3, ZM, FS, RF-Turbo B3, ZL, ZM, FP, FS RF, RFTurbo
max. 20 mA 50D20L: 150 A 75D23L: 195 A 95D31L: 250 A 115D31L: 320 A In: 0.27-0.33 mm {0.0107-0.0129 in} Ex: 0.27-0.33 mm {0.0107-0.0129 in} In: 0.22-0.28 mm {0.0087-0.0110 in} Ex: 0.27-0.33 mm {0.0107-0.0129 in} Standard: 128.9-129.5 mm {5.075-5.098 in} Maximum: 130.2 mm {5.125 in}
MAZDA3 Valve clearance BK (engine cold)
ZJ, Z6
LF
Cylinder head bolt length
ZJ, Z6
127

Model Item Engine LF Specification Standard: 145.2-145.8 mm {5.72-5.74 in} Maximum: 146.5 mm {5.77 in}
MAZDA3 Cylinder head BK bolt length
Battery electrolyte specific gravity [20C] Battery back-up current Battery test load current
ZJ, Z6, LF, 1.22-1.29 Y6 ZJ, Z6, LF, max. 20 mA Y6 ZJ, Z6, LF 50D20L(40): 150 A 75D23L(52): 195 A 75D26L(52): 195 A 80D26L(55): 195 A (Z6) Y6 80D26L (55) 195 A Maintenance free In: 0.27-0.33 mm Ex: 0.27-0.33 mm
XEDOS9 Valve clearance TA (engine cold)
KF, KL KJ
Battery electrolyte KF, KL, KJ 1.27-1.29 specific gravity [20C] Battery back-up current Firing order PREMACY Valve clearance CP (engine cold) KF, KL, KJ max. 20 mA KF, KL FP RF-Turbo Cylinder head bolt length FP RF-Turbo Battery electrolyte FP, specific gravity [20C] RF-Turbo Battery back-up current Battery test load current FP, RF-Turbo FP RF-Turbo MAZDA5 Valve clearance CR (engine cold) L8, LF 1-2-3-4-5-6 In: 0.225-0.295 mm Ex: 0.225-0.295 mm In: 0.12-0.18 mm Ex: 0.32-0.38 mm Standard: 104.2-104.8 mm Maximum: 105.5 mm Standard: Maximum: 116.8 mm 1.27-1.29 max. 20 mA 50D20L: 150 A 75D23L: 195 A 95D31L: 250 A 115D31L: 320 A In: 0.220.28 mm {0.00870.0110 in} Ex: 0.270.33 mm {0.01070.0129 in}
128

Model Item Engine RF-Turbo
OO
ZO
L8, LF RF-Turbo
MAZDA5 Valve clearance CR (engine cold)
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Specification In: 0.090.21 mm {0.0040.008 in} Ex: 0.290.41 mm {0.0120.016 in} 1.221.29 VIN 100001-300000: 30 mA max.
Standard: 145.2145.8 mm {5.725.74 in} Maximum: 146.5 mm {5.77 in}
-Z
Standard: 159.7160.3 mm {6.2886.311 in} Maximum: 161.0 mm {6.338 in}
Battery electrolyte L8, LF, specific gravity [20C] RF-Turbo Battery back-up current L8, LF, RF-Turbo
VIN 300001-: Vehicles with immobilizer system: 2545 mA Vehicles without immobilizer system: 30 mA or less Battery test load current L8, LF, RF-Turbo Firing order MX-5 NB Valve clearance (engine cold) L8, LF, B6 BP MX-5 NC Valve clearance (engine cold) L8, LF 50D20L (40): 150 A 75D23L (52): 195 A 95D31L (64): 250 A 115D31L (70): 320 A 1342 (all cylinders independent firing) In: 0.17-0.23 mm Ex: 0.27-0.33 mm In: 0.18-0.24 mm Ex: 0.28-0.34 mm In: 0.220.28 mm {0.00870.0110 in} Ex: 0.270.33 mm {0.01070.0129 in} Compression [L8] Standard: 145.2145.8 mm {5.725.74 in} Maximum: 146.5 mm {5.77 in}
MX-5 NC
L8, LF
129

Model MX-5 NC Item Engine Specification 1.221.29 46B24L (36): 135 A Vehicles with immobilizer system: 2545 mA Vehicles without immobilizer system: 30 mA or less 1342 (all cylinders independent firing) VIN100001300000: 1.271.29 VIN300001-: 1.221.29 VIN100001300000: 50D20L (40): 150 A 75D23L (52): 195 A 75D26L (52): 195 A VIN300001-: 80D26L (55): 195 A Vehicles with immobilizer system: 2545 mA Vehicles without immobilizer system: 30 mA or less In: 0.225-0.295 mm Ex: 0.225-0.295 mm In: 0.12-0.18 mm Ex: 0.32-0.38 mm 1.27-1.29 20 mA 55D23L: 180 A 75D26L: 195 A 95D31L: 250 A 115D31L: 320 A In 0.220.28 {0.0087 0.0110} Ex 0.270.33 {0.01070.0129} Standard: 145.2145.8 {5.725.74} Maximum: 146.5 {5.77}
Battery electrolyte L8, LF specific gravity [20C] Battery test load current Battery back-up current L8, LF L8, LF
Firing order RX-8 SE
L8, LF
Battery electrolyte 13B specific gravity [20C] Battery test load current 13B
Battery back-up current
13B
626 GF/ Valve clearance GW (engine cold)
FP, FS RF-Turbo
Battery electrolyte FP, FS, specific gravity [20C] RF-Turbo Battery back-up current Battery test load current FP, FS, RF-Turbo FP, FS RF-Turbo MAZDA6 Valve clearance GG/GY (engine cold) L8, LF, L3, L3-Turbo L8, LF, L3,
130

Model Item Engine
OO
ZO
L3-Turbo L8, LF, L3
MAZDA6 Cylinder head GG/GY bolt length
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Specification
GG VIN100001-600000, GY VIN100001-400000: Standard 159.7160.3 {6.2886.311} Maximum 161.0 {6.338}
GG VIN600001-, GY VIN400001-: Standard: 144.7145.3 mm {5.7005.720 in} Maximum: 146 mm {5.748 in} Battery electrolyte L8, LF, L3, 1.271.29 specific gravity [20C] L3-Turbo Battery test load current 50D20L (48): 150 A 75D23L (52): 195 A 75D26L (52): 195 A 80D26L (55): 195 A 95D31L (64): 250 A 115D31L (70)*3: 320 A
*3 = cold area
-Z
L3-Turbo
Battery back-up current
L8, LF, L3, GG VIN100001-600000, L3-Turbo GY VIN100001-400000: max: 20mA GG VIN600001-, GY VIN400001-: Vehicles with immobilizer system: 2545 mA Vehicles without immobilizer system: 30 mA or less
MAZDA6 Valve clearance GH (engine cold)
L8, LF, L5
In: 0.220.28 mm {0.0090.011 in} Ex: 0.270.33 mm {0.0110.012 in} In: 0.090.21 mm {0.0040.008 in} Ex: 0.290.41 mm {0.0120.016 in} Standard: 145.2145.8 mm {5.7175.740 in} Maximum: 146.5 mm {5.767 in} Standard: 159.7160.3 mm {6.2886.311 in} Maximum: 161.0 mm {6.34 in}
RF-Turbo
L8, LF, L5
RF-Turbo
131

Model Item Engine Specification
MAZDA6 Battery electrolyte L8, LF, L5, 1.221.29 GH specific gravity [20C] RF-Turbo Battery test load current L8, LF, L5 55D23L (48): 180 A 75D23L (52): 195 A 80D26L (55): 195 A 95D31L (64): 250 A 115D31L (70): 320 A Vehicles with immobilizer system: 5065 mA Vehicles without immobilizer system: 55 mA or less 5065 mA 1342 (all cylinders independent firing) Maintenance free In: 0.10 mm Ex: 0.20 mm In: 0.225-0.295 mm Ex: 0.225-0.295 mm Maintenance free In: 0.22-0.28 mm Ex: 0.27-0.33 mm In: 0.12-0.18 mm Ex: 0.32-0.38 mm Standard: 104.2-104.8 mm Minimum: 105.5 mm Standard: 145.2-145.8 mm Minimum: 146.5 mm Standard: 159.7-160.3 mm Minimum: 161.0 mm 1.27-1.29 1.22-1.29
RF-Turbo Battery back-up current L8, LF, L5
RF-Turbo Firing order MPV LV Valve clearance (engine cold) L8, LF, L5 JE WL-Turbo FS GY L3 RF-Turbo Cylinder head bolt length FS L3 RF-Turbo Battery electrolyte FS, GY specific gravity [20C] L3, AJ, RF-Turbo Battery back-up current Battery test load current
MPV LW
FS, GY, L3, max. 20 mA AJ, RF-Turbo FS, GY, L3, 55D23L: 180 A AJ, 75D26L: 195 A RF-Turbo 80D26L: 195 A 95D31L: 250 A 115D31L: 320 A
132

Model Item Engine YF L3
OO
ZO
L3 L3 AJ L3, AJ YF, L3 AJ
TRIBUTE Valve clearance EP (engine cold)
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Specification In 0.15 {0.006} Ex 0.3 {0.012} In 0.220.28 {0.00870.0110} Ex 0.270.33 {0.01070.0129} 1.221.29 55D23L (48): 180 A
-Z
Standard: 145.2145.8 {5.7175.740} Maximum: 146.5 {5.768}
Battery electrolyte L3, AJ specific gravity [20C] Battery test load current
80D26L (55): 195 A GROUP 40R (50): 240 A max. 20 mA 1342 142536 In: 0.220.28 mm {0.00870.011 in} Ex: 0.270.33 mm {0.0110.012 in} Standard: 144.7145.3 mm {5.697 5.720 in} Maximum: 146 mm {5.74 in} 1.221.29 55D23L (48): 180 A 80D26L (55): 195 A Vehicles with immobilizer system: 5565 mA Vehicles without immobilizer system: 60 mA or less 1342 (all cylinders independent firing) In: 0.1500.250 mm {0.005910.00984 in} Ex: 0.3000.400 mm {0.01190.0157 in} 1.221.29
Battery back-up current Firing order
CX-7 E
L3-Turbo
L3-Turbo
Battery electrolyte L3-Turbo specific gravity [20C] Battery test load current Battery back-up current L3-Turbo L3-Turbo
Firing order CX-9 TB Valve clearance (engine cold)
L3-Turbo CA
Battery electrolyte CA specific gravity [20C]
133

Model CX-9 TB Item Battery test load current Battery back-up current Engine CA CA Specification 80D26L (55): 195 A Vehicles with immobilizer system: 5060 mA Vehicles without immobilizer system: 55 mA or less 1-4-2-5-3-6 In: 0.05-0.15 mm Ex: 0.15-0.25 mm Standard: 101.2-101.8 mm (Bolt head mark W) Standard: 113.2-113.8 mm (Bolt head mark N) Minimum: 102.5 mm (Bolt head mark W) Minimum: 114.5 mm (Bolt head mark N)
Firing order BSeries UN Valve clearance (engine cold) Cylinder head bolt length
CA WL, WL-Turbo WL, WL-Turbo
Battery electrolyte G6, F2, WL, 1.27-1.29 specific gravity [20C] WL-Turbo Battery back-up current Battery test load current G6, F2, WL, max. 20 mA WL-Turbo G6 F2 WL, WL-Turbo BT-50 UN Valve clearance (engine cold) G6, F2 WL-3, WLT-1, WLT-2 WL-C, WE-C 80D26R: 195 A 34B19R: 110 A 55D23R: 180 A 75D26L: 195 A 75D26R: 195 A 95D31R: 250 A 0.15 mm {0.0059 in} max. In: 0.05 0.15 mm {0.0020 0.0059 in} Ex: 0.15 0.25 mm {0.0060 0.0098 in} In: 0.100.16 mm {0.00400.0062 in} Ex: 0.170.23 mm {0.00670.0090 in} Bolt head mark W Standard: 101.2101.8 mm {3.985 4.007 in} Maximum: 102.5 mm {4.035 in}
WL-3, WL-C, WE-C, WLT-1, WLT-2
134

Model BT-50 UN Item Cylinder head bolt length Engine WL-3, WL-C, WE-C, WLT-1, WLT-2
OO
ZO
G6, F2, WL-3, WL-C, WE-C, WLT-1, WLT-2 G6 F2 WL-3 WL-C, WE-C
O}
Specification
Bolt head mark N Standard: 113.2113.8 mm {4.457 4.480 in} Maximum: 114.5 mm {4.508 in}
-Z
1.221.29 Battery electrolyte G6, F2, specific gravity [20C] WL-3, WL-C, WE-C, WLT-1, WLT-2 Battery back-up current Vehicles with immobilizer system: 525 mA Vehicles without immobilizer system: 10 mA or less 80D26R (55): 195 A 55D23R (48): 180 A 65D31R (56): 165 A 65D31R (56): 165 A 75D26R (52): 195 A 75D26L (55): 195 A 95D31R (64): 250 A 95D31R (64): 250 A
Battery test load current
WLT-1, WLT-2
technical data / wheel alignment
Wheel Alignment
121 ZQ Item Front Caster Nominal Specification Manual steering: 1,34 or 120 Power steering: 2,23 or 214
Tolerance Manual steering: 2,59 to 0,09 or range 235 to 005 Power steering: 3,48 to 0,98 or 329 to 059
135

Item Front Camber Nominal Specification Manual steering: -0,66 or -040 Power steering: -0,62 or -037
Tolerance Manual steering: 0,74 to -2,06 or range 044 to -204 Power steering: 0,78 to -2,02 or 047 to -201 Toe setting all variants Allowable 0,43 Toe in to -0,43 toe out tolerance Setting ad- 0,00 Toe in 0,17 justment, if required Allowable 025 Toe in to -025 toe out tolerance Setting ad- 0,00 Toe in 0,10 justment, if required Allowable 2,5 mm Toe in to -2,5 toe out tolerance Setting ad- 0,0 mm Toe in 1,0 mm justment, if required Rear Camber Nominal -1,00 or -100
Tolerance -0,50 to -2,00 or -030 to -200 range Toe setting Nominal 2,3 mm (Toe in) or 0,40 (Toe in)
Tolerance 4,3 to 0,3 mm (Toe in) or 0,72 to 0,05 range (Toe in)
Maximum variation Camber 115 (1,25) left to right hand side
DEMIO DW Item Fuel gauge indication Front Max. steering Inner angle (referOuter ence value) Total toe-in (mm {in}) Specification Empty 1/4 40 33 Rim inner: 23 {0.080.12}, Tire: 34 {0.120.16} 1/2 3/4 Full
136
OO
ZO
(degree) Item Fuel gauge indication Front Total toe-in Empty 1/4 018 24 Caster angle VIN100001- 155 (reference value) [TolerVIN300001- 210 ance 1] Camber angle VIN100001- 035 1 VIN300001- 010 1 Steering axis inclination (Reference value) Rear Total toe-in (mm {in}) (degree) Camber angle (reference value) 1415

Specification
O}
1/2 3/4
}
Full
157 159 200 202
-Z
Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16} 012 24 -130 1
Mazda2 DY Item Front Caster angle Tolerance range Setting or Nominal Specification 218 to 432 325
Max. variance left or right 100 Camber angle Tolerance range Setting or Nominal -207 to 039 -044
Max. variance left or right 115 Toe-in total Tolerance range Setting or Nominal Rear Camber angle Tolerance range Setting or Nominal 0.0 2.2 mm, 000 021 0.0 1.0 mm, 000 010 -224 to 007 -108
Max. variance left or right 115 Toe-in total Tolerance range 3.2 2.1 mm, 031 020
137

Mazda2 DE Item Fuel gauge indication Front Max. steering Inner angle [TolerOuter ance 3] Total toe-in (mm {in}) (degree) Caster angle (reference value) [Tolerance 1] Camber angle (reference value) [Tolerance 1] Steering axis inclination (reference value) Rear Total toe-in (reference value) (mm {in}) (degree) Specification Empty 1/4 4012 3312 Rim inner: 23 {0.080.12}, Tire: 34 {0.120.16} 017 024 310 -041 1316 1318 1319 1321 1322 Rim inner: 23 {0.080.12}, Tire: 34 {0.120.16} 017 024 -131 0 312 313 315 316 1/2 3/4 Full
Camber angle (reference value) [Tolerance 1] Thrust angle (reference value) [Tolerance 048]
323 BA Item Fuel gauge indication Front Max. except Inner steering KF Outer angle (referKF Inner ence value) Outer Total toe-in (mm {in}) Specification Empty 1/4 403 333 383 323 Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16} 1/2 3/4 Full
(degree) 012 24 Camber angle except KF -044 1 KF -052 1
138
OO
ZO
KF Item Fuel gauge indication Front Caster angle Empty 1/4 VIN except KF/ 153 1 100001- 3HB 300000 except KF/ 155 1 except 204 1 VIN except KF/ 140 300001- 3HB 1 except KF/ 142 except 1 KF Steering axis inclination Rear Total toe-in 155 1

Specification
O}
1/2 3/4
}
Full
-Z
143 146 150 153 1 1 1 1 145 149 152 155 1 1 1 1 157 200 202 204 1 1 1 1
except KF/ 1322 KF (mm {in}) (degree) 1336 Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16} 012 24
Camber angle
except KF/ -049 1 KF -056 1 0 48
Thrust angle
323 BJ Item Fuel gauge indication Front Max. steering angle Inner Outer Total toe-in (mm {in}) Specification Empty 1/4 372 332 Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16} 1/2 3/4 Full
(degree) 012 24 Camber angle VIN 100001VIN 400001-048 1 -048 -049 1 -049
139

Item Fuel gauge indication Front Caster angle VIN 100001VIN 400001Steering axis inclination (reference value) VIN 100001VIN 400001(mm {in}) (degree) Camber angle (reference value) Thrust angle Mazda 3BK Item Fuel gauge indication Front Max. steering angle Inner [Tolerance 3] Outer Total toe-in (mm {in}) Specification Empty 1/4 1/2 3/4 Full Specification Empty 1/4 145 1 146 1234 1234 1/2 3/4 Full
148 151 1 1 148 151 1235
154 159 1 1 153 156 1237
1235 1236
Rear Total toe-in
Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16} 012 24 -027 -029 -030 -032 -034 1 1 1 1 1 0 6
3948 (except L3T) 3600 (L3T) 3248 (except L3T) 3012 (L3T) Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16}
(degree) 011 022 (VIN100001-500000) 011 011 (VIN500001-) Caster angle exept L3T (reference value) [ToleL3T rance 1] Camber angle (reference value) [Tolerance 1] VIN 100001-500000 255 257 300 302 304 300 301 303 305 307 -039 -040 -040 -055 -041 -041
VIN except L3T -039 500001L3T -054
140
OO
ZO
Item Fuel gauge indication Front Steering axis inclination (reference value) VIN 100001500000 Empty 1/4 VIN except L3T 1352 500001L3T 1417 Rear Total toe-in (mm (reference value) {in}) Caster angle (reference value) [Tolerance 1] VIN 100001500000 -110

Specification
O}
1/2 3/4 1353 1418
}
Full 1402 1355 -114 -117 -119 -128 -141
1359 1400 1401
-Z
Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16}
(degree) 011 022 (VIN100001-500000) 011 011 (VIN500001-) -112
except L3T -120 -122 -124 -126 VIN 500001L3T -134 -136 -137 -139
Thrust angle (reference value) 0 [Tolerance 048]
XEDOS9 TA Item Front Maximum steering angle Inner [Tolerance 3] Outer Total toe-in Toe-in (per side) Caster angle Camber angle Steering axis inclination Rear Total toe-in Toe-in (per side) Camber angle (mm {in}) (mm {in}) Specification 36 30 Tire: 33 {0.120.12}, Rim inner: 22 {0.080.08}
(degree) 00830 830 232 45 -011 45 906 45 Tire: 33 {0.120.12}, Rim inner: 22 {0.080.08}
(degree) 00830 830 -017 45
141

Item Rear Maximum steering angle (4WS) [Tolerance 1] Thrust angle Inner Outer Specification 7 7 0 10
PREMACY CP Item Fuel gauge indication Front Max. steering angle Inner [Tolerance 3] Outer Total toe-in (mm {in}) Specification Empty 1/4 37 33 Tire: 24 {0.080.16} Rim inner: 13 {0.040.12}, 1/2 3/4 Full
(degree) 012 24 Caster angle VIN 100001-300000 235 (reference value) [Tole- VIN 300001154 rance 1] Camber angle [Tolerance 1] Steering axis inclination (reference value) VIN 100001-300000 VIN 300001(mm {in}) (degree) Camber angle (reference value) [Tolerance 1] Thrust angle -048 1235 1235 1234 1234 1233 1233 234
Rear Total toe-in
Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16} 012 24 -032 -034 -035 -037 -038 0 6
142
OO
ZO
Inner Outer Inner Outer Total toe-in (mm {in}) Mazda5 CR Item Fuel gauge indication Front Max. steering Front angle [Tolerance 3] Empty 1/4 4030 3348 383 323 (degree) 011 22 L8, LF Caster angle (reference value) [Tolerance 1] RF-T Camber angle L8, LF (reference value) RF-T [Tolerance 1] Steering axis L8, LF inclination (reference value) RF-T Rear Total toe-in (mm (reference value) {in})
Specification
O}
1/2 3/4
}
Full 313 314 -042 -044 1359 1404
-Z
Rim inner: 13 {0.040.12}, Tire: 24 {0.080.16}
308 309 311
305 307 308 310 312 -041 -042 -043 1357 1401 1402
Rim inner: 2 {0.08} (Allowable range: 0-3 {0-0.12}) Tire: 3 {0.12} (Allowable range: 0-5 {0-0.2}) 016 (Allowable range: 000 027) -122 -124 -126 -127 -129 -121 -124 -125 -127 -129 -123 0 -125 -127 -128 -129
(degree) Camber VIN10000- L8, LF angle 300000 RF-T (reference value) [ToleVIN300001rance 1] Thrust angle (reference value) [Tolerance 048]
MX-5 NB Item Front Maximum steering Inner angle [Tolerance 3] Outer Specification 38 33
143

Item Front Total toe-in (mm {in}) Specification Rim inner: 23 {0.080.12} Tire: 34 {0.120.16} 017 24
(degree) Caster angle (Reference value) [Tolerance 1] Height from center of wheel to front fender brim (mm {in})
346-355 {13.7-13.9} 617 356-365 {14.0-14.3} 603 366-375 {14.4-14.7} 548 376-385 {14.8-15.1} 534 386-395 {15.2-15.5} 520
Camber angle [Tolerance 1]
Height from center of wheel to front fender brim (mm {in})
327-336 {12.9-13.2} -032 337-346 {13.3-13.6} -012 347-356 {13.7-14.0} -006 357-366 {14.1-14.4} -023 367-376 {14.5-14.8} -038
Steering axis inclination (reference value) 1138 Rear Total toe-in (mm {in}) Rim inner: 23 {0.080.12} Tire: 34 {0.120.15} 019 24
(degree) Caster angle [Tolerance 1] Height from center of wheel to front fender brim (mm {in})
346-355 {13.7-13.9} -114 356-365 {14.014.3} -059
366-375 {14.4-14.7} -047 376-385 {14.8-15.1} -038 386-395 {15.2-15.5} -032
Thrust angle [Tolerance 048]
MX-5 NC Item Specification 16-inch wheel Front Steering angle [Tolerance 3] Inner Outer 3842 3254 17-inch wheel
144
OO
ZO
Item Front Total toe-in (mm {in}) (degree) Caster angle (reference value) [Tolerance 1] 011 22

Specification
16-inch wheel Rim inner: 1.22.4 {0.050.09} Tire: 24 {0.080.15}
O}
Rim inner: 1.42.8 {0.060.11} Tire: 24 {0.080.15}
}
17-inch wheel 349-358 634 {13.8-14.0} 359-368 620 {14.2-14.4} 369-378 606 {14.6-14.8} 379-388 553 {15.0-15.2} 389-398 539 {15.4-15.7} 351-360 -051 {13.8-14.1} 361-370 -031 {14.3-14.5} 371-380 -014 {14.7-14.9} 381-390 002 {15.0-15.3} 391-400 015 {15.4-15.7} 1047 Rim inner: 2.22.8 {0.0830.110} Tire: 34 {0.120.15}
-Z
Vehicle height: From 354-363 627 the end of the front {14.0-14.2} fender to the center of the wheel (mm {in}) 364-373 613 {14.4-14.6} 374-383 559 {14.8-15.0} 384-393 545 {15.2-15.4} 394-403 531 {15.6-15.8}
Vehicle height: From 356-365 -041 the end of the front {14.1-14.3} fender to the center of the wheel (mm {in}) 366-375 -022 {14.5-14.7} 376-385 -006 {14.8-15.1} 386-395 009 {15.2-15.5} 396-405 021 {15.6-15.9}
Steering axis inclination (reference value) Rear Total toe-in (mm {in})
1039 Rim inner: 1.82.4 {0.0710.094} Tire: 34 {0.120.15} 017 22
(degree) Camber angle [Tolerance 1]
Vehicle height: From 354-363 -133 the end of the front {14.0-14.2} fender to the center of the wheel (mm {in}) 364-373 -118 {14.4-14.6} 374-383 -104 {14.8-15.0}
349-358 -142 {13.8-14.0} 359-368 -125 {14.2-14.4} 369-378 -111 {14.6-14.8}
145

Item Specification 16-inch wheel Rear Camber angle [Tolerance 1] Vehicle height: From 384-393 -054 the end of the front {15.2-15.4} fender to the center of the wheel (mm {in} 394-403 -045 {15.6-15.8} 17-inch wheel 379-388 -059 {15.0-15.2} 389-398 -049 {15.4-15.6}
RX-8 SE VIN100001-300000 Item Specification Standard suspension Sport suspension Front Steering angle [Tolerance 3] Total toe-in Inner Outer 3841 3315 Rim inner: 1.22.4 {0.050.09} Tire: 24 {0.080.15} 011 21 354-363 641 {13.9-14.2} 364-373 628 {14.3-14.6} 374-383 616 {14.7-15.0} 384-393 603 {15.1-15.4} 394-403 550 {15.5-15.8} 361-370 -045 {14.2-14.5} 371-380 -025 {14.6-14.9} 381-390 -006 {15.0-15.3} 391-400 011 {15.4-15.7} 401-410 026 {15.8-16.1} 3836 3307 Rim inner: 1.42.8 {0.060.11} Tire: 24 {0.080.15}
(mm {in})
(degree) Caster angle (reference value) [Tolerance 1]
Vehicle height: From 361-370 631 the end of the front {14.2-14.5} fender to the center of the wheel (mm {in}) 371-380 618 {14.6-14.9} 381-390 606 {15.0-15.3} 391-400 553 {15.4-15.7} 401-410 540 {15.8-16.1}
Vehicle height: From 367-376 -033 the end of the front {14.4-14.8} fender to the center of the wheel (mm {in}) 377-386 -013 {14.9-15.1} 387-396 004 {15.2-15.5} 397-406 020 {15.6-15.9} 407-416 033 {16.0-16.3}
146
OO
ZO
Item Front Steering axis inclination (reference value) Rear Total toe-in (mm {in}) 1052 (degree) Camber angle [Tolerance 1] 016 20

Specification
Standard suspension Sport suspension 1102
O}
}
Rim inner: 2.12.8 {0.0830.110} Tire: 34 {0.120.15} 354-363 -144 {13.9-14.2} 364-373 -124 {14.3-14.6} 374-383 -107 {14.7-15.0} 384-393 -052 {15.1-15.4} 394-403 -040 {15.5-15.8}
Rim inner: 1.92.5 {0.0750.098} Tire: 34 {0.120.15}
-Z
Vehicle height: From 361-370 -130 the end of the front {14.2-14.5} fender to the center of the wheel (mm {in}) 371-380 -112 {14.6-14.9} 381-390 -056 {15.0-15.3} 391-400 -043 {15.4-15.7} 401-410 -033 {15.8-16.1}
RX-8 SE VIN300001Item Specification Standard suspension Front Steering Inner 3836 angle [TolerOuter 3318 ance 3] Tire: 24 {0.080.15} Total (mm toe-in {in}) (degree) 011 22 Caster angle (reference value) [Tolerance 1] Vehicle height: From the end of the front fender to the center of the wheel (mm {in}) 375-384 633 {14.8-15.1} 385-394 621 {15.2-15.5} 395-404 608 {15.6-15.9} 405-414 555 {16.0-16.2} 366-375 645 {14.5-14.7} 376-385 633 {14.9-15.1} 386-395 620 {15.2-15.5} 396-405 607 {15.6-15.9} 364-373 647 {14.4-14.6} 374-383 635 {14.8-15.0} 384-393 622 {15.2-15.4} 394-403 609 {15.6-15.8} Sport suspension Sport suspenstion equipped with Bilstein
147

Item Specification Standard suspension Front Caster angle (reference value) [Tolerance 1] Vehicle 415-424 543 height: {16.4-16.6} From the end of the front fender to the center of the wheel (mm {in}) Vehicle height: From the end of the front fender to the center of the wheel (mm {in}) 365-374 -037 {14.414.7} 375-384 -017 {14.8-15.1} 385-394 001 {15.2-15.5} 395-404 017 {15.6-15.9} 405-414 031 {16.0-16.2} Steering axis inclina- 1056 tion (reference value) Rear Sport suspension 406-415 555 {16.0-16.3} Sport suspenstion equipped with Bilstein 404-413 557 {16.0-16.2}
363-372 -041 {14.314.6} 373-382 -021 {14.7-15.0} 383-392 -003 {15.1-15.4} 393-402 014 {15.5-15.8} 403-412 028 {15.9-16.2} 1059
356-365 -057 {14.114.3} 366-375 -035 {14.5-14.7} 376-385 -015 {14.9-15.1} 386-395 002 {15.2-15.5} 396-405 018 {15.6-15.9} 1112
Total (mm {in}) Tire: 3.64 {0.120.15} toe-in (degree) 019 20 Camber angle [Tolerance 1] Vehicle height: From the end of the front fender to the center of the wheel (mm {in}) 375-384 -104 {14.8-15.1} 385-394 -047 {15.2-15.5} 395-404 -032 {15.6-15.9} 405-414 -020 {16.0-16.2} 415-424 -010 {16.4-16.6} 366-375 -122 {14.5-14.7} 376-385 -102 {14.9-15.1} 386-395 -045 {15.2-15.5} 396-405 -031 {15.6-15.9} 406-415 -018 {16.0-16.3} 364-373 -126 {14.4-14.6} 374-383 -106 {14.8-15.0} 384-393 -048 {15.2-15.4} 394-403 -033 {15.6-15.8} 404-413 -021 {16.0-16.2}
148
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382 32.52 (mm {in}) Item Fuel gauge indication Front Maximum Inner steering angle Outer Total toe-in Specification Empty 1/4 (degree) 017 023 Camber angle [Tolerance 1] GF GW without suspension control system -018

626 GF/GW
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1/2 3/4 -020
}
Full
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Rim inner: 24 {0.080.16} Tire: 34 {0.120.16}
without rear -018 -018 -019 -019 -019 third seat with rear -005 -005 -006 -006 -007 third seat -018 -018 -019 -019 -019 143 without rear 137 third seat with rear 135 third seat 131 1243 without rear 1241 third seat with rear 1220 third seat 1241 Rim inner: 0.54 {0.020.16} Tire: 14 {0.040.16} 006023 145 139 137 133 148 140 139 135 150 142 140 137 152 144 142 139
GW with suspension control system Caster angle [Tolerance 1] GF GW without suspension control system
GW with suspension control system Steering axis inclination (Reference value) GF GW without suspension control system
GW with suspension control system Rear Total toe-in (mm {in})
(degree) 005023 Camber angle (reference value) [Tolerance 1] GF GW without suspension control system
-041 -043 -044 -046 -047 without rear -037 -038 -039 -040 -041 third seat with rear -032 -033 -034 -035 -036 third seat
149

Item Fuel gauge indication Specification Empty 1/4 1/2 3/4 Full
Rear GW without suspension -035 -036 -037 -038 -039 control system Thrust angle (reference value) 0 048
Mazda6 GG/GY Item Fuel gauge indication Front Max. steering angle Inner [Tolerance 3] Specification Empty 1/4 1/2 3/4 Full
18 inch wheel and 4SDN/4x4: 36 except the above and WGN: 39
Outer 18 inch wheel and 4SDN/4x4: 30 except the above and WGN: 31 Total toe-in (mm {in}) Rim inner: 13 {0.040.12} Tire: 24 {0.080.16}
(degree) 011 22 Caster 4SDN/ normal 337 339 angle 5HB height 332 334 (Referup* ence value) WGN normal 330 332 [Tolerance elevated* 325 327 1] and 4x4 4SDN 4x4 341 336 344 347 339 342 340 335 353
334 337 329 332
346 348 350 351 -017 -010 -015 -008 -017 528 518
Camber 4SDN/ normal -016 angle 5HB height -009 (Referup* ence value) WGN normal -014 [Tolerance elevated* -007 1] and 4x4 4SDN 4x4 -016
Steering 4SDN/ normal 526 axis incli- 5HB height 517 nation up*
150
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(mm {in}) Item Fuel gauge indication Specification Empty 1/4 Front Steering WGN normal 524 axis inclielevated* 515 nation and 4x4 (Reference value) 4SDN 4x4 528 Rear Total toe-in (degree) 01122
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1/2 3/4 516 530
}
Full -103
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Rim inner: 13 {0.040.12} Tire: 24 {0.080.16}
Camber 4SDN normal -105 -107 -109 -111 -113 angle 4x4 height -056 -058 -100 -102 -105 [Tolerup* ance 1] WGN normal -059 -100 -102 -104 -106 elevated* -052 -053 -055 -056 -058 4x4 4SDN 4x4 Thrust angle [Tolerance 048] -055 -057 -059 -101
-128 -130 -133 -135 -137 0
* Please refer to Workshop Manual for detail.
Mazda6 GH Item Fuel gauge indication Front Max. steering angle Inner [Tolerance 3] Specification Empty 1/4 1/2 3/4 Full
Equipped with 16-inch or 17-inch tire: 3930 Equipped with 18-inch tire: 3724
Outer Equipped with 16-inch or 17-inch tire: 3224 Equipped with 18-inch tire: 3112 Total toe-in (mm {in}) Rim inner: 13 {0.040.12} Tire: 24 {0.080.16}
(degree) 010 20
151

Item Fuel gauge indication Front Caster angle (Reference value) [Tolerance 1] Specification Empty 1/4 1/2 333 335 323 330 332 333 335 323 331 321 3/4 335 Full 337
L8 4SDN 330 and 5HB 333 LF (MTX) WGN 321 LF (ATX) and L5 4SDN 329 5HB WGN 332 321
338 340 325 335 337 325 328 337 339 327
MZ-CD 4SDN 328 329 (RF Turbo) WGN 319 Camber angle (Reference value) [Tolerance 1]
334 336 323 325
L8 except -015 -016 and WGN LF (MTX) WGN -012 -013 LF (ATX) and L5 except -016 WGN WGN -013 -017 -014 -019
MZ-CD except -018 (RF WGN Turbo) WGN -015 -016 Steering axis inclination (Reference value) [Tolerance 1] L8, LF and L5 except 636 WGN WGN 633 634 639 637
MZ-CD except 638 (RF WGN Turbo) WGN 636 (mm {in})
637
Rear Total toe-in
Rim inner: 13 {0.040.12} Tire: 24 {0.080.16}
(degree) 01020 Camber angle 4SDN -101 -102 -105 -107 -110 [Tolerance 1] 5HB -106 -108 -111 -113 WGN Thrust angle [Tolerance 048] -053 0 -055 -057 -059
152
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(mm {in}) (degree) MPV LV Item Fuel gauge indication Front Maximum Inner steering angle [Tolerance 2] Outer Total toe-in Empty 4045 3150 0.4 0.4 Right side 521 Caster angle (Reference value) [Tolerance 1] Left side 454 Camber angle Right side 028 (Reference value) Left side 024 [Tolerance 1]
Specification
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1/2 Full 524 456 025 023 527 457 022 022
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Rim inner: 33 {0.120.11} Tire: 44 {0.160.15}
MPV LW Item Front Maximum steer- Inner ing angle [Tolerance 3] Outer Total toe-in Specification 376 31
(mm {in}) Rim inner: 13 {0.040.12} Tire: 24 {0.080.16} (degree) 011 022 154
Caster angle (Reference value) [Tolerance 1]
Camber angle [Tolerance 1] -054 Steering axis inclination (reference value) Rear Total toe-in (reference value) 1112
(mm {in}) Rim inner: 23 {0.080.12} Tire: 34 {0.120.16} (degree) 08 011 -1
Camber angle (reference value) [Tolerance 1]
153

TRIBUTE EP Item Fuel gauge indication Front Maximum steering angle [Tolerance 3] Specification Empty 1/4 1/2 3/4 Full
215/70R16 Inner 3706 tires Outer 3054 235/70R16 Inner 3518 tires Outer 2948 (mm {in}) Tire: -1.04 {0.040.16}
Total toe-in
(degree) YF and L3/AJ (Column shift type) European (LHD): -00448 01402 YF and L3/AJ (Column shift type) UK: -00230 007 L3/AJ (Floor shift type): 01348 01348 Caster angle [Tolerance 1] Camber angle [Tolerance 1] Steering axis inclination (Reference value) Rear Total toe-in (mm {in}) YF and L3/AJ (Column shift type): 14724 L3/AJ (Floor shift type): 136 YF and L3/AJ (Column shift type): -02848 L3/AJ (Floor shift type): -1 1106 Tire: 14 {0.040.16}
(degree) YF and L3/AJ (Column shift type) European (LHD): 00224 00954 YF and L3/AJ (Column shift type) UK: 005 007 L3/AJ (Floor shift type): 006 012 Camber angle (reference value) [Tolerance 1] Thrust angle (reference value) YF and L3/AJ 01308 01026 00744 00506 00224 (Column shift type) L3/AJ (Floor shift type) 006
YF and L3/AJ 0048 (Column shift type) L3/AJ (Floor shift type) 0018
154
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0 {0.00} CX-7 ER Item Fuel gauge indication Specification Empty 1/4 Front Maximum Inner 3606 steering angle [Tolerance 3] Outer 3054 Total toe-in [Tole(mm rance 2 {in}) {0.08}] (degree) Caster angle (reference value) [Tolerance 1] Camber angle (reference value) [Tolerance 1] Steering axis inclination (Reference value) Rear Total toe-in [Toler- (mm ance 4 {in}) {0.16}] (degree) Camber angle (reference value) [Tolerance 1] Thrust angle (reference value) [Tolerance 048] 000 009 -019 1142 2 {0.08}
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1/2 3/4
}
Full 255 257 -020 1144
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247 250 253
1143
009018 -051 -054 -057 -100 -103 0
CX-9 TB Item Fuel gauge indication Specification Empty 1/4 1/2 3/4 Full
Front Max. steering angle Inner 38 [Tolerance 3] Outer 32 Total toe-in (degree) [Toler- (mm ance 4 {in}) {0.16}] 2 {0.08}
018 018 304 305 -020 -021
Caster angle [Tolerance 1] 302 303 Camber angle [Tolerance 1] -019
155

Item Fuel gauge indication Front Steering axis inclination (Reference value) Rear Total toe-in (degree) Camber angle (reference value) [Tolerance 1] [Toler- (mm ance 4 {in}) {0.16}] Specification Empty 1/4 1131 1/2 3/4 Full
1132 1133 1134 1135
2 {0.08}
009018 -027 -028 -030 -031 -033
0 Thrust angle (reference value) [Tolerance 048] B-Series UN Item Specification 4x2 Front Max. steering angle Inner Outer Total toe-in (mm {in}) (degree) Camber angle Caster angle 3500 +2 to -3 3300 +2 to -3 4x4 3330 +2 to -3 3000 +2 to -3
33 {0.120.12} 016 16 05630 13745 014 14 10630 20245
BT-50 UN Item Specification Regular cab Freestyle cab Front Maximum steering angle Inner Outer Double cab High clearance model (Regular and Freestyle cab) High clearance model (Double cab)
4x2: 3300-3700 3130-3530 4x4: 3130-3530 4x2: 3000-3500 2700-3200 4x4: 2700-3200
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Item Regular cab Freestyle cab Front Total toe-in Tire [Toler- (mm ance 3 {in}) {0.12}] Total toe-in Caster angle (reference value) [Tolerance 1] Steering axis inclination (reference value)

Specification
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Double cab High clearance model (Regular and Freestyle cab) 6 {0.23}
}
High clearance model (Double cab) 045 206 1035
4x2: 5 {0.19} 4x4: 6 {0.23}
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(degree) 4x2: 025 15 028 14 4x4: 028 14
Camber angle (reference 4x2: 035 4x2: 035 044 4x4: 044 4x4: 045 value) [Tolerance 1] 4x2: 156 4x2: 154 207 4x4: 207 4x4: 206 4x2: 825 4x2: 825 1037 4x4: 1037 4x4: 1035
technical data / Brake
Brake
Model 121 ZQ Brake Item Remarks Solid disc Ventilated disc Specification 240 mm 12 mm 20 mm Front Disc disc diameter brakes New disc nominal thickness
157

Model 121 ZQ Brake Item Remarks Solid disc Ventilated disc Specification 8 mm 18 mm 0.1 mm 0.025 mm 48 mm 54 mm 1.5 mm 180 mm 203 mm 181 mm 204 mm 29 mm 36 mm 17.78 mm 22.2 mm 6 mm 4 mm 1.0 mm 2.0 mm 20 mm 0.05 mm 201.5 mm 1.0 mm 6-8 notches
Front Worn disc disdisc card thickness brakes Max. disc thickness variation Caliper piston diameter
Max. disc runout Solid disc Ventilated disc
Min. pad thickness New drum nominal Standard braking Rear thickness drum ABS braking brakes Worn drum discard thickness Shoe width Standard braking ABS braking Standard braking ABS braking Wheel cylinder bore diameter New leading shoe lining thickness New trailing shoe lining thickness Min. shoe lining thickness DEMIO Front DW disc brake Min. disc pad thickness Min. disc plate thickness Disc plate runout limit Rear drum brake Max. inner diameter Max. lining thickness Standard braking ABS braking -
Parking Parking brake brake lever stroke (when pulled at 98 N {10 kgf, 22lbf})
158
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Model Brake Item Remarks MAZDA2 Front DY disc brake Brake disc diameter New brake disc nominal thickness Worn brake disc discard thickness Max. brake disc thickness variation Worn brake pad discard thickness Drum brake New brake drum nominal thickness Worn brake drum discard thickness Brake shoe width -
O}
258 mm 22 mm 20 mm 1.5 mm 203 mm 204 mm 36 mm 1 mm
}
Specification 0.025 mm
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Worn brake shoe lining discard thickness MAZDA2 Front DE disc brake disc plate runout limit Min. disc plate thickness -
0.04 mm 21 mm 21.8 mm
Min. disc plate thickness after machining by using a brake lathe on-vehicle Min. front disc pad thickness European (L.H.D. U.K.) specs. General (L.H.D.) specs. Drum brake Min. lining thickness Brake drum wear maximum Parking Parking brake brake lever stroke when pulled at 98 N {10 kgf, 22 lbf} -
2.0 mm 1.5 mm 1.0 mm 201.5 25 notches
159

Model Brake Item Remarks Specification 3800 x 10 4300 x 10 5180 x 10 235 x 18 235 x 22 257 x 22 274 x 22 2600 x 8.0
323 BA Front disc brake
Pad dimensions B3, Z5 (area [mm2] x thickness [mm]) BP, RF KF Disc plate diB3 mensions (outer Z5 diameter x thickness) mm BP, RF KF
Rear disc brake Rear disc brake Rear drum brake
Pad dimensions KF (area [mm2] x thickness [mm]) Disc plate diKF mensions (outer diameter x thickness) mm Wheel cylinder inner diameter B3, Z5, BP, RF
251 x 9.0
17.4 mm (non-ABS) 19.0 (ABS) 35.0 x 192.0 x 4.0 200 mm
Lining dimenB3, Z5, BP, RF sions (width x length x thickness) mm Drum inner diameter 323 BJ Front disc brake Front disc brake Min. disc pad thickness Min. disc plate thickness B3, Z5, BP, RF
B3, ZL, ZM, FS, FP, 2.0 mm RF, RF-Turbo 1.5 mm (B3, VIN400001-) B3, ZM, FS, FP 20 mm (B3, ZL) 22 mm (ZM, FS, FP, RF, RF-Turbo) max. 0.05 mm 2.0 mm (FP VIN100001400000) 1.5 mm (VIN400001-) 8 mm
Disc plate runout limit Rear disc brake Min. disc pad thickness
B3, ZL, ZM, FP, RF, RF-Turbo ZM, FS, FP, RF-Turbo
Min. disc plate thickness
ZM, FS, FP, RF-Turbo
160

Model Brake Item Disc plate runout limit Max. inner diameter Remarks
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B3, ZL, RF Min. lining thick- B3, ZL, RF ness Disc plate runout limit Min. disc plate thickness -
323 BJ Rear disc brake Rear drum brake
ZM, FS, FP, RF-Turbo max. 0.05 mm 201.5 mm 1.0 mm
O}
0.05 mm 23 mm 23.8 mm
}
Specification 5-7 notches
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B3, ZL, FP, RF Parking Parking brake brake lever stroke (when pulled at 98 N {10 kgf, 22lbf}) MAZDA3 Front BK disc brake
Min. disc plate thickness after machining by using a brake lathe onvehicle Min. disc pad thickness Rear disc brake Min. disc pad thickness Min. disc plate thickness -
2.0 mm 2.0 mm 9 mm 9.8 mm
Min. disc plate thickness after machining by using a brake lathe onvehicle Runout limit Min. rear brake shoe thickness Rear drum brake Max. inner diameter -
0.05 mm 1.0 mm 230.2 mm
37 notches
161

Model Brake Item Pad dimensions (area [mm2] x thickness [mm]) Remarks Specification 5530 x 10.0
XEDOS9 Front TA disc brake
Disc plate dimensions (outer diameter x thickness) mm Rear disc brake Pad dimensions (area [mm2] x thickness [mm]) Disc plate dimensions (outer diameter x thickness) mm Parking Lining dimendrum sions (width x brake length x thickness) mm Drum inner diameter PREMACY Front CP disc brake Min. disc pad thickness Min. disc plate thickness Disc plate runout limit Rear drum brake Rear drum brake Rear disc brake Max. inner diameter Min. lining thickness Min. disc pad thickness Min. disc plate thickness Disc plate runout limit -
274 x 28.0
3300 x 10
286 x 9.5
30 x 3.5
190 mm 2.0 mm 22 mm max. 0.05 mm 230.1 mm
1.0 mm
1.0 mm 8.0 mm 0.05 mm 5-7 notches
Parking Parking brake lever brake stroke (Lever type) (when pulled at 98 N {10 kgf, 22lbf})
162

Model Brake Item Remarks
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Min. disc pad thickness Min. disc pad thickness after machi ning by using a brake lathe onvehicle Min. disc plate thickness Disc plate runout limit -
PREMACY Parking Parking brake lever CP brake stroke (Foot actuated type) (when depressed at 98 N {10 kgf, 22lbf}) MAZDA5 Front CR disc brake
O}
2.0 mm 23.8 23 mm
}
Specification 1-3 notches 0.04 mm 2.0 mm 9 mm 9.8 mm
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Rear disc brake
Min. disc pad thickness Min. disc plate thickness
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit -
0.05 mm 36 notches
Parking Parking brake lever brake stroke (when pulled at 98 N {10 kgf, 22lbf}) MX-5 NB Front disc brake Min. disc pad thickness Sports and hard suspension Sports and hard suspension -
8.0 mm 10.0 mm 20 mm 22 mm 0.05 mm
Min. disc plate thickness
Disc plate runout limit Rear disc brake Min. disc pad thickness
8.0 mm
163

Model MX-5 NB Brake Rear disc brake Item Min. disc plate thickness Remarks Sports and hard suspension Specification 9.0 mm 10.0 mm 0.05 mm 2.0 mm 20 mm 20.8 mm
Disc plate runout limit MX-5 NC Front disc brake Min. disc pad thickness Min. disc plate thickness
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Rear disc brake Min. disc pad thickness Min. disc plate thickness -
0.05 mm 2.0 mm 8 mm 8.8 mm
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit -
0.05 mm 13 notches
Parking Parking brake lever brake stroke (when pulled at 98 N {10 kgf, 22lbf}) RX-8 SE Front disc brake Min. disc pad thickness Min. disc plate thickness -
2.0 mm 22 mm 22.8 mm
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit -
0.05 mm
164
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Model RX-8 SE Brake Rear disc brake Item Min. disc pad thickness Min. disc plate thickness Remarks Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Parking Parking brake lever brake stroke (when pulled at 98 N {10 kgf, 22lbf}) 626 GF/ Front GW disc brake Min. disc pad thickness Min. disc plate thickness Disc plate runout limit Rear disc brake Min. disc pad thickness Min. disc plate thickness Disc plate runout limit Rear drum brake Max. inner diameter -
O}
2.0 mm 16 mm 16.8 mm 0.05 mm
}
Specification 13 notches 2.0 mm 22 mm min. 0.05 mm 2.0 mm 8 mm min. 0.05 mm 230.1 mm 1.0 mm 5-7 notches
-Z
Min. lining thickness -
Parking Parking brake lever brake stroke (when pulled at 98 N {10 kgf, 22lbf}) MAZDA6 Front GG/GY disc brake Minimum front disc pad thickness (European (L.H.D. U.K.) specs.)
L8 (4SDN, 5HB) L8 (WGN), LF, L3, L3 Turbo, MZR-CD (RF Turbo)
min. 2.0 mm min. 1.5 mm
165

Model Brake Item Min. disc pad thickness (General (L.H.D. R.H.D.) specs.) Remarks L8 (4SDN, 5HB) 4SD (except L3 Turbo), 5HB, WGN (except Australian specs.) 4SD (L3 Turbo) Min. disc plate L8 (4SDN, 5HB) thickness (European (L.H.D. L8 (WGN), LF, L3, U.K.) specs.) L3 Turbo, MZR-CD (RF Turbo) Min. disc plate thickness General (L.H.D. R.H.D.) specs.) 4SD (except L3 Turbo), 5HB, WGN (except Australian specs.) 4SD (L3 Turbo) Min. disc plate thickness after machining by using a brake lathe onvehicle (L.H.D. U.K.) specs.) Min. disc plate thickness after machining by using a brake lathe onvehicle (General (L.H.D. R.H.D.) specs.) Disc plate runout limit Rear disc brake Min. disc pad thickness Min. disc plate thickness L8 (4SDN, 5HB) Specification min. 2.0 mm
MAZDA6 Front GG/GY disc brake
min. 1.5 mm 22 mm 23 mm
22 mm
23 mm 22.8 mm
L8 (WGN), LF, L3, L3 Turbo, MZR-CD (RF Turbo) 4SD (except L3 Turbo), 5HB, WGN (except Australian specs.) 4SD (L3 Turbo)
23.8 mm
22.8 mm
23.8 mm
Except 18 inch wheel: 18 inch wheel
0.05 mm 2.0 mm 8 mm 9 mm 8.8 mm 9.8 mm
Except 18 inch Min. disc plate thickness after wheel machining by using a brake lathe 18 inch wheel onvehicle
166
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Model Brake Item Disc plate runout limit Remarks MAZDA6 Rear GG/GY disc brake Parking Parking brake brake lever stroke (when pulled at 98 N {10 kgf, 22lbf}) MAZDA6 Front GH disk brake Min. disc pad thickness Min. disc plate thickness Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Rear disc brake Min. disc pad thickness Min. disc plate thickness -
O}
0.05 mm min. 2.0 mm 23 mm 23.8 mm
}
Specification 36 notches
GG VIN100001600000/ GY VIN100001400000
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GG VIN600001-/GY 25 notches VIN400001-
0.05 mm 2.0 mm 8 mm 8.8 mm
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Parking Parking brake brake lever stroke (when pulled at 98 N {10 kgf, 22lbf}) MPV LV Front disc brake -
0.14 mm 13 notches
Disc pad thickness - Standard Disc pad thickness - Limit Disc plate thickness - Standard -
10.5 mm 2.0 mm 28 mm
167

Model Brake Item Disc plate thickness - Limit Disc plate runout limit Disc pad thickness - Standard Disc pad thickness - Limit Disc plate thickness - Standard Disc plate thickness - Limit Disc plate runout limit Parking Parking brake drum lever stroke brake (when pulled at 196 N {20 kgf, 44lbf}) Remarks Specification 26 mm min. 0.05 mm 10.0 mm 1.0 mm 18 mm 16 mm min. 0.1 mm 6-9 notches
MPV LV Front disc brake
Rear disc brake
Parking brake shoe thickness Standard Parking brake shoe thickness - Limit -
3.2 mm
1.0 mm
Disc plate inner diameter Standard Disc plate inner diameter - Limit MPV LW Front disc brake Min. disc pad thickness Min. disc plate thickness Disc plate runout limit Rear drum brake -
190.0 mm
191.0 mm 2.0 mm 26 mm 0.05 mm 255.5 mm 1.0 mm
Max. brake drum diameter Min. lining thickness -
168

Model MPV LW Brake Rear disc brake Item Min. disc pad thickness Min. disc plate thickness Disc plate runout limit Remarks -
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2.0 mm 16 mm 0.05 mm
}
Specification 4-7 notches 4-5 notches (no drag) (VIN200001-) 190.0 mm 1.0 mm 1.0 mm 3.0 mm 22 mm 24 mm 0.02 mm 0.1 mm 230.1 mm 1.0 mm 3.0 mm 11.0 mm 11.6 mm
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Parking Parking brake le- brake ver stroke (when pulled at 98 N {10 kgf, 22lbf}) Parking Max. brake drum drum brake diameter (with rear disc brake) Min. lining thickness TRIBUTE Front EP disc brake Min. disc pad thickness YF, Column shift type (L3, AJ) Floor shift type (L3, AJ) Min. disc plate thickness YF, Column shift type (L3, AJ) Floor shift type (L3, AJ) Disc plate runout limit YF, Column shift type (L3, AJ) Floor shift type (L3, AJ) Rear drum brake Max. inner diameter YF, Column shift type (L3, AJ)
Min. lining thick- YF, Column shift ness type (L3, AJ) Min. disc pad thickness Min. disc plate thickness Floor shift type (L3, AJ) Floor shift type (L3, AJ)
Rear disc brake
Floor shift type Min. disc plate thickness after (L3, AJ) machining by using a brake lathe onvehicle
169

Model Brake Item Remarks YF, Column shift type (L3, AJ) Floor shift type (L3, AJ) Specification 3-5 notches 5 notches
TRIBUTE Parking Parking brake EP brake lever stroke (Lever type) (when pulled at 98 N {10 kgf, 22lbf}) CX-7 ER Front disc brake Min. disc pad thickness Min. disc plate thickness
2.0 mm 26 mm 26.8 mm
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Rear disc brake Min. disc pad thickness Min. disc plate thickness -
0.05 mm 2.0 mm 16 mm 16.8 mm
Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Max. disc plate inner diameter -
0.05 mm 191.0 mm max. 5 notches
Parking Parking brake brake lever stroke (Lever type) (when pulled at 98 N {10 kgf, 22lbf}) Parking brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf} (ATX) Parking Min. shoe thick- brake ness
13 notches
1.0 mm
170
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Model CX-9 TB Brake Front disc brake Item Min. disc pad thickness Min. disc plate thickness Remarks Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Rear disc brake Min. disc pad thickness Min. disc plate thickness -
O}
2.0 mm 26 mm 26.8 mm 0.05 mm 2.0 mm 16 mm 16.8 mm
}
Specification
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Min. disc plate thickness after machining by using a brake lathe onvehicle Disc plate runout limit Max. disc plate inner diameter -
0.05 mm 191.0 mm 13 notches
Parking Parking brake brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf} Min. shoe thickness BSeries UN Front disc brake Min. disc pad thickness Min. disc plate thickness -
1.0 mm 2.0 mm 22 mm 26 mm (4x4, VIN300001-) 0.05 mm 1.0 mm
Disc plate runout limit Rear drum brake Min. lining thickness
171

Model BSeries UN Brake Rear drum brake Item Drum max. diameter Remarks Specification 271.5 mm 296.5 mm (4x4) 1-7 notches
technical data / Wheel & Tire
Wheel and tires

Wheel
Wheel size Offset (mm {in}) Pitch circle diameter (mm {in}) Material
13 inch 121 ZQ 13x4.5 in (155/70R13-T) 13x5 in (165/70R13-T) 13x4 1/2J 45 {1.77} Steel
DEMIO DW 14 inch DEMIO DW Mazda2 DE 323 BA MX-5 NB 323 BJ 626 GF/GW Premacy CP B-Series UN
100 {3.94}
Steel
14x5 1/2JJ 14x6J 14x5 1/2JJ 14x5 1/2J 14x5 1/2JJ
45 {1.77} 45 {1.77} 45 {1.77} 45 {1.77} 45 {1.77}
100 {3.94} 100 {3.94} 100 {3.94}
Steel or aluminum alloy Steel Steel
100 {3.94} (323) Steel or alu114.3 {4.450} (626) minum alloy 114.3 {4.450} 139.7 {5.50} Steel
14x5J 40 {1.57} (195R14C-8PR) 14x5 1/2J (205/75R14C)
172

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45 {1.77} 45 {1.77} 52.5 {2.07} 15x6J 15x6JJ 15x6J 15x6JJ 50 {1.97}
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100 {3.94} 114.3 {4.450}
}
Steel or aluminum alloy Steel or aluminum alloy Steel or aluminum alloy Steel or aluminum alloy
15 inch Mazda2 DE 323 BJ 626 GF/GW Mazda3 BK Mazda5 CR
100 {3.94} (323) Steel or alu114.3 {4.450} (626) minum alloy
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Premacy CP 15x6JJ (5-seater/ 195/65R15 85V) Xedos9 TA Premacy CP (5-seater/ 195/55R15 85V) Premacy CP (7-seater/ 195/65R15 85V) Premacy CP (7-seater/ 195/55R15 85V) MX-5 NB
50 {1.97} (FP) 114.3 45 {1.77} (RF-T) {4.450}
114.3 {4.450}
15x6JJ
50 {1.97} (Premacy) 40 {1.57} (MX-5) 50 {1.97}
114.3 {4.450} (Premacy) 100 {3.94} (MX-5) 114.3 {4.450}
Aluminum alloy
Mazda6 GG/ 15x6J GY MPV LV MPV LW MPV LW 15x6JJ 15x6J
Steel Steel Aluminum alloy
40 {1.57} (LV) 114.3 50 {1.97} (LW) {4.450} 50 {1.97} 10 {0.39} 20 {0.79} 114.3 {4.450}
B-Series UN 15x7JJ BT-50 UN (215/70R15C 106/104S) 15x6 1/2J
139.7 {5.50} 139.7 {5.50} Steel or aluminum alloy 139.7 {5.50} Steel
15x6 1/2J BT-50 UN (235/75R15 109S) Mazda2 DE 16x6 1/2J
25 {0.98}
50 {1.97}
100 {3.94}
Aluminum alloy
173

15 inch 323 BJ Premacy CP Mazda3 BK Mazda5 CR 626 GF/GW 16 inch Mazda6 GH Mazda6 GH MX-5 NC MX-5 NC MX-5 NB RX-8 SE 16x6J 16x6 1/2J 16x6 1/2JJ 16x6 1/2J 16x7 1/2JJ 50 {1.97} 55 {2.17} 55 {2.17} 40 {1.57} 50 {1.97} 50 {1.97} 114.3 {4.450} 114.3 {4.450} 114.3 {4.450} 100 {3.94} 114.3 {4.450} 114.3 {4.450} 114.3 {4.450} Steel Aluminum alloy Steel Aluminum alloy Aluminum alloy Steel or aluminum alloy Aluminum alloy 16x6JJ 16x6 1/2J 16x6JJ 50 {1.97} 52.5 {2.07} 50 {1.97} 114.3 {4.450} 114.3 {4.450} 114.3 {4.450} Aluminum alloy Aluminum alloy Steel or aluminum alloy
MPV LW 16x6 1/2J Tribute EP (P215/70R16) Mazda6 GG/ 16x7J GY Tribute EP (P235/70R16) B-Series UN 16x6JJ BT-50 UN 17 inch Mazda3 BK Mazda5 CR 17x6 1/2J 16x7J
55 {2.17} (Mazda6) 45 {1.8} (Tribute) 35 {1.38} 10 {0.39}
139.7 {5.50} 139.7 {5.50} Steel or aluminum alloy
52.5 {2.07} 55 {2.17}
114.3 {4.450} 114.3 {4.450} 114.3 {4.450} 114.3 {4.450}
Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy
Mazda6 GG/ 17x7J GY MX-5 NC Mazda6 GH RX-8 SE 17x7J 17x7 1/2J
60 {2.4} 50 {1.97}
174

OO
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52.5 {2.07} (Mazda3) 55 {2.17} (Mazda6) 60 {2.4} (Mazda6) 50 {1.97} (CX-7) 45 {1.77} (CX-9) 50 {1.97} 18x7 1/2J 18x8J or 18x8JJ
O}
114.3 {4.450} 114.3 {4.450}
}
Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy Aluminum alloy
18 inch Mazda3 BK 18x7J Mazda6 GG/ GY Mazda6 GH CX-7 ER CX-9 TB
-Z
RX-8 SE More than 19 inch RX-8 SE CX-9 TB
114.3 {4.450}
19x8J 20x7 1/2J
47 {1.9} 45 {1.8}
114.3 {4.450} 114.3 {4.450}
Tire
Remaining tread Standard tire (mm {in}) Snow tire 1.6 {0.063} 50% of tread
Tire pressure kPa {bar, psi} (121/Mazda2 DY: bar {lb/in2}) Tire size Front Front Up to full Full load passengers Rear Rear Up to full Full load passengers
13 inch 121 ZQ 155/70R13-T 2.4 {35} 2.5 {36} 1.8 {26} 2.8 {41}
175

13 inch 121 ZQ 165/70R1 3-T 2.1 {31} 2.5 {36} (Gasoline/MT) 2.2 {32} (Gasoline/AT) 2.4 {35} (Diesel) 200 {2.0, 29} 210 {2.1, 30} 220 {2.2, 32} 220 {2.2, 32} 220 {2.2, 32} 250 {2.5, 36} 1.8 {26} 2.8 {41}
DEMIO DW 323 BA 323 BA 14 inch 121 ZQ Mazda2 DY
165/70R13 79T 175/70R13 155/80R13 155R1378
200 {2.0, 29} 210 {2.1, 30} 220 {2.2, 32}
280 {2.8, 41} 270 {2.7, 39} 280 {2.8, 41}
175/65R14 2.4 {35} (ZQ) 2.5 {36} 175/65R14 82T 2.1 {31} (DY) 175/65R14 82H
1.8 {26} (ZQ) 2.0 {29} (DY) 2.1 {31} (DY/ 82H/outside Europe) 2.0 {29} 200 {2.0, 29} 200 {2.0, 29}
2.8 {41} (ZQ) 3.0 {44} (DY) 3.1 {46} (DY/82H) 2.8 {41} 280 {2.8, 41} 280 {2.8, 41}
121 ZQ DEMIO DW Mazda2 DE
185/55R14 2.2 {32} 175/60R14 200 79H {2.0, 29} 175/65R14 220 82H {2.2, 32} 185/60R14 82H 185/65R14 210 {2.1, 30} 175/65R14 82T 185/65R14 86T 185/65R14 86H 210 {2.1, 30} 220 {2.2, 32} (RF)
2.5 {36} 220 {2.2, 32} 240 {2.4, 35}
323 BA 323 BJ
220 {2.2, 32} 220 {2.2, 32} 230 {2.3, 33} (RF) 240 {2.4, 35}
210 {2.1, 30} 210 {2.1, 30} 220 {2.2, 32} (RF) 220 {2.2, 32}
270 {2.7, 39} 280 {2.8, 41} 310 {3.2, 45} (FS, B3, RF) 280 {2.8, 41}
626 GF/GW
185/65R14 220 86H {2.2, 32} 195/65R14 89H
176

Tire pressure kPa {bar, psi} (121/Mazda2 DY: bar {lb/in2}) Tire size Front Front Up to full Full load passengers
OO
ZO
180 {1.8, 26} 220 {2.2, 32} 230 {2.3, 33} (RF-T) 210 {2.1, 30}
O}
180 {1.8, 26} 210 {2.1, 30}
}
180 {1.8, 26} 280 {2.8, 41} 450 {4.5, 63} 2.9 {43}
Rear Rear Up to full Full load passengers
14 inch MX-5 NB 185/60R14 180 82H {1.8, 26} Premacy 185/65R14 210 CP 86T {2.1, 30} 220 {2.2, 32} (RF-T) B-Series 195R14C-8PR 210 UN 205/75R14C {2.1, 30} 15 inch Mazda2 DY 195/50R15 2.1 82H {31} 2.5 {36} 1.9 {28} (Europe) 2.1 {31} (outside Europe) 200 {2.0, 29} 210 {2.1, 30} 210 {2.1, 30} 220 {2.2, 32} (RF) 220 {2.2, 32}
-Z
210 {2.1, 30}
Mazda2 DE 323 BA 323 BJ
185/55R15 220 82V {2.2, 32} 195/55R15 220 {2.2, 32} 195/55R15 210 85V {2.1, 30} 220 {2.2, 32} (RF) 195/65R15 230 {2.3, 91H 33} (Y6) 220 {2.2, 32}
240 {2.4, 35} 240 {2.4, 35} 220 {2.2, 32} 230 {2.3, 33} (ZM, FP, RF) 230 {2.3, 33}
280 {2.8, 41} 270 {2.7, 39} 280 {2.8, 41} 290 {3.0, 43} (ZM, FP, RF) 310 {3.1, 45}
Mazda3 BK
Premacy 195/65R15 210 {2.1, CP 85V 30} (FP) 230 {2.3, 33} (RF-T) Premacy 195/55R15 220 CP 85V {2.2, 32} (FP, FS) 230 {2.3, 33} (RF-T)
240 {2.4, 35}
210 {2.1, 30}
280 {2.8, 41}
240 {2.4, 35} (FP, FS) 250 {2.5, 36} (RF-T)
220 {2.2, 32}
280 {2.8, 41}
177

15 inch Premacy 195/55R15 CP 85V (7-seater) 240 {2.4, 35} 250 {2.5, 36} 240 {2.4, 35} 240 {2.4, 35} 230 {2.3, 33} 220 {2.2, 32} 220 {2.2, 32} 290 {3.0, 42} 280 {2.8, 41} 280 {2.8, 41} (Mazda5) 300 {3.0, 44} (Mazda6) 280 {2.8, 41}
Premacy 195/60R15 220 CP 88V {2.2, 32} (7-seater) Mazda5 CR Mazda6 GG/GY 195/65R15 220 91V {2.2, 32}
626 GF/GW
185/65R15 220 88H {2.2, 32} 195/60R15 88V 195/65R15 91H
240 {2.4, 35}
220 {2.2, 32}
MX-5 NB 195/50R15 180 82V {1.8, 26} MPV LV MPV LW 215/65R15 200 96H {2.0, 29} 205/65R15 240 94T {2.4, 35} 205/65R15 92S 205/65R15 216 94V {2.2, 32} 205/65R15 94W
180 {1.8, 26} 220 {2.2, 32} 250 {2.5, 36}
180 {1.8, 26} 210 {2.1, 30} 240 {2.4, 35}
180 {1.8, 26} 280 {2.8, 41} 290 {3.0, 42}
Xedos9 TA
236 {2.4, 35}
196 {2.0, 29}
275 {2.8, 40}
B-Series 265/70R15 210 UN 110S {2.1, 30} 265/70R15 112S BT-50 UN 215/70R15C 220 106/104S {2.2, 32}
210 {2.1, 30}
210 {2.1, 30}
210 {2.1, 30}
220 {2.2, 32}
210 {2.1, 30}
375 {3.8, 54}
178

OO
ZO
235/75R15 210 109S {2.1, 30} 210 {2.1, 30} 195/45R16 80V 195/45R16 84V 2.1 {31} (Europe) 2.2 {32} (outside Europe) 2.5 {37}
O}
210 {2.1, 30} 2.0 {29} (Europe) 2.1 {31} (outside Europe) 200 {2.0, 29} 210 {2.1, 30} (323) 220 {2.2, 32} (Premacy) 230 {2.3, 33} (Mazda3/ RF-T) 220 {2.2, 32} 2.8 {41}
}
270 {2.7, 39} (VIN600001800000) 290 {3.0, 42} (VIN800001-) 280 {2.8, 41} 290 {3.0, 42} (323) 280 {2.8, 41} (Premacy) 310 {3.1, 45} (Mazda3) 280 {2.8, 41} (Mazda5) 270 {2.7, 39} (Mazda6) 300 {3.0, 44} 310 {3.1, 45} 180 {1.8, 26} 200 {2.0, 29} (MX-5) 280 {2.8, 41} (626) 250 {2.5, 36}
15 inch BT-50 UN
-Z
16 inch Mazda2 DY
Mazda2 DE
195/45R16 220 80W {2.2, 32}
240 {2.4, 35} 230 {2.3, 33} (323) 240 {2.4, 35} (Premacy) 230 {2.3, 33} (Mazda3) 240 {2.4, 35}
323 BJ 195/50R16 210 {2.1, Premacy 84V 30} (323) CP 220 {2.2, 32} (Premacy) Mazda3 BK Mazda5 CR Mazda6 GG/GY 205/55R16 230 91V {2.3, 33} (Mazda3/ RF-T) 220 {2.2, 32}
Mazda6 GH Mazda6 GH
195/65R16 92V
220 {2.2, 32}
250 {2.5, 36} 260 {2.6, 38} 180 {1.8, 26} 200 {2.0, 29} (MX-5) 240 {2.4, 35} (626) 220 {2.2, 32}
220 {2.2, 32} 220 {2.2, 32} 180 {1.8, 26} 200 {2.0, 29} (MX-5) 220 {2.2, 32} (626) 220 {2.2, 32}
205/60R16 220 92V {2.2, 32}
MX-5 NB 205/45R16 180 83W {1.8, 26} MX-5 NC 205/50R16 200 {2.0, 87V 29} (MX-5) 626 220 {2.2, GF/GW 32} (626) RX-8 SE 225/55R16 95V 220 {2.2, 32}
179

16 inch MPV LW Tribute EP 215/60R16 240 95H {2.4, 35} 250 {2.5, 36} 240 {2.4, 35} 290 {3.0, 42}
P215/70R16 see safety certification sticker located on the 99T driver door side panel P215/70R16 99H P235/70R16 104T 210 {2.1, 30} 210 {2.1, 30} 210 {2.1, 30} 210 {2.1, 30} 210 {2.1, 30} 450 {4.5, 63} 270 {2.7, 39}
B-Series 205R16CUN 8PR BT-50 UN 17 inch Mazda3 BK
245/70R16 210 111S {2.1, 30}
205/50R17 230 89V {2.3, 33} (RF-T) 220 {2.2, 32} 205/50R17 230 93V {2.3, 33} (RF-T) 220 {2.2, 32} 215/45R17 87W 220 {2.2, 32}
240 {2.4, 35} (RF-T) 230 {2.3, 33} 240 {2.4, 35}
230 {2.3, 33} (RF-T) 220 {2.2, 32} 230 {2.3, 33} (RF-T) 220 {2.2, 32} 220 {2.2, 32}
310 {3.1, 45}
Mazda5 CR
280 {2.8, 41}
Mazda6 GG/GY Mazda6 GG/GY
240 {2.4, 35}
270 {2.7, 39}
215/45R17 230 {2.3, 240 {2.4, 91W 33} (2WD) 35} (2WD) (reinforced) 250 {2.5, 250 {2.5, 36} (4WD) 36} (4WD) 215/50R17 220 91W {2.2, 32} 260 {2.6, 38} 200 {2.0, 29} 220 {2.2, 32}
230 {2.3, 270 33} (2WD) {2.7, 39} 250 {2.5, 36} (4WD) 220 {2.2, 32} 200 {2.0, 29} 220 {2.2, 32} 300 {3.0, 44} 200 {2.0, 29} 250 {2.5, 36}
Mazda6 GH
MX-5 NC 205/45R17 200 84W {2.0, 29} RX-8 SE 225/50R17 220 94W {2.2, 32}
180

OO
ZO
260 {2.6, 38} (MPS) 220 {2.2, 32} 215/45R18 230 93Y {2.3, 33} 215/45R18 93Y (MPS) 215/45R18 89W 240 {2.4, 35} 270 {2.7, 39} (MPS) 240 {2.4, 35} 220 {2.2, 32} (RX-8) 260 {2.6, 38} (Mazda6) 220 {2.2, 32} 230 {2.3, 33} (Russia) 250kPa {36psi} 225/45R18 220 91W {2.2, 32}
O}
220 {2.2, 32} 260 {2.6, 38} (MPS) 220 {2.2, 32} 220 {2.2, 32}
}
310 {3.1, 45} 290 {2.9, 42} (MPS) 270 {2.7, 39} 270 {2.7, 39} (RX-8) 310 {3.1, 45} (Mazda6) 270 {2.7, 39} 230 {2.3, 33} (Russia) 250kPa {36psi}
18 inch Mazda3 BK Mazda6 GG/GY
-Z
RX-8 SE Mazda6 GH
CX-7 ER
235/60R18 220 103V {2.2, 32} 230 {2.3, 33} (Russia) 245/60R18 250kPa 104H {36psi}
220 {2.2, 32} 230 {2.3, 33} (Russia) 250kPa {36psi}
CX-9 TB
More than 19 inch RX-8 SE CX-9 TB 225/40R19 220 89W {2.2, 32} 245/50R20 230kPa 102V {34psi} 220 {2.2, 32} 230kPa {34psi} 220 {2.2, 32} 230kPa {34psi} 270 {2.7, 39} 230kPa {34psi}
Wheel and tire

Wheel nut tightening torque (Nm {kgfm, ftlbf}) 89-117 {9-12, 66-86} (others) 107.8-147.0 {11.0-14.9, 79.6-108.4} (CX-9)
181

Spare wheel and tire
Wheel Size DEMIO DW MX-5 NB Mazda2 DE 323 BJ Premacy CP MX-5 NB Mazda3 BK Mazda5 CR Mazda6 GG/GY MPV LW Mazda3 BK Mazda5 CR Mazda6 GH Mazda5 CR MPV LW CX-7 ER RX-8 SE Mazda3 BK Mazda6 GG/GY Tribute EP CX-9 TB CX-7 ER 14x4T 14x4T 14x4T 15x4T 15x4T 15x4T 15x4T 15x4T 16x4T Offset (mm {in}) 40 {1.57} 45 {1.77} 40 {1.57} 45 {1.77} 45 {1.77} 45 {1.8} 40 {1.57} 45 {1.77} 45 {1.8} 45 {1.8} 45 {1.77} 45 {1.77} 40 {1.57} Tire Size T105/70D14 T115/70D14 Tire pressure (kPa {bar, psi}) 412 {4.2, 60} 420 {4.2, 60}
T115/70D14 88M 420 {4.2, 60} T115/70D15 T105/70D15 T115/70D15 T115/70D15 T135/90D15 T135/90D15 T125/70D16 420 {4.2, 60} 420 {4.2, 60} 420 {4.2, 60} 420 {4.2, 60} 420 {4.2, 60} 420 {4.2, 60} 420 {4.2, 60} 420 {4.2, 60} 250 {2.5, 36} 420 {4.2, 60}
16x4T 16x4T 16x5J 17x4T
T135/80D16 T145/80D16 205/80R16 100M T125/70D17 T145/70D17
17x4T 17x5 1/2J 18x4T
50 {2.0} 45 {1.8} 40 {1.57}
T135/90R17 T145/90R17
420 {4.2, 60}
195/80R17 99M 250kPa {36psi} T115/90D18 103M 420 {4.2, 60}
182
technical data / headlight aiming
OO
ZO
L.H.D. Center of headlight
Headlight aiming
7.6 m {25 ft} 3 m {10 ft}
Distance between headlight and wall (adjustment screen)
O}
B-Series UN, MX-5 NB/ VIN100001200000 All models except the above
-Z
Adjustment screen 323 BJ, DEMIO, MPV LW, MX-5 NB
Out Off Line R.H.D.
Elbow point
Center of headlight
Elbow point
Out Off Line
MAZDA3 BK, MAZDA5 CR, MAZDA6 GG/GY, MX-5 NC L.H.D. Center of headlight
Elbow point
183

R.H.D. Elbow point Center of headlight
MAZDA2 DE, RX-8 SE L.H.D. Center of headlight Elbow point
Brightness Borderline R.H.D. Center of headlight Elbow point
Brightness Borderline
184

MAZDA6 GH L.H.D. Center of headlight Elbow point
OO
ZO
Brightness Borderline R.H.D.
O}
Measurement point for brightness
-Z
Center of headlight Elbow point
TRIBUTE EP
L.H.D. Center of headlight Elbow point
Brightness Borderline R.H.D.
Measurement point for brightness Center of headlight Elbow point
185

CX-7 ER, CX-9 TB L.H.D. Center of headlight Elbow point
Terminator
R.H.D.
Center of headlight Elbow point
Terminator
BT-50 UN L.H.D. Center of headlight
R.H.D.
Center of headlight
186
notes
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O}
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187
notes
188
OO
notes
ZO
O}
-Z
189
notes
190
OO
notes
ZO
O}
-Z
191
OO
-Z O
O}
O}
ZO
O}
Mazda Motor Europe GmbH Hitdorfer Strasse 73 51371 Leverkusen Germany Phone: 0049 (0) 2173-943-0 Fax: 0049 (0) 2173-943-317 www.mazda.com
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O

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OO Servicing } Pocket Guide -Z 2008 OO }

Cable harness.................................................................................77 Oil Bypass Filter. ............................................................................77

Drive vehicle in the Workshop

Drive vehicle in the Workshop

Drive vehicle in the Workshop

1 Pedal height 2 Pedal play 3 Release height

1 Edge of the water shield

Drive vehicle in the Workshop

Illustration shows 323 BJ

1 Service hole cover 2 Adjusting nut

1 Service hole cover 2 Adjusting nut

Clip A Tab Console Rear ashtray case

Cabin air filter

3. Remove the pollen filter housing cover.

4. Remove the pollen filter.

Air filter attachment direction

Air filter attachment direction

Air filter attachment direction

1 Air filter cover 2 Air filter

Arrow indicates orientation

3. Install in the reverse order of removal.

Data Link Control (DLC)

Fuel injection system (Diesel)

Safety belts, belt tensioner

Guide to renewal of the safety belt:

3) Cigarette burns or similar damage.

Power window system initial setting

Bonnet lock, catch, hinges

Door hinges and straps

Hose connections and pipes

Automatic transmission fluid

1 Oil at operating temperature 2 Cold oil

Illustration shows FP, FS Engine

Brake fluid to be used: SAE J1703 or FMVSS 116 DOT-3 or DOT-4

Data Link Control (DLC)

Accessory drive belt

No fraying (new belt) Fraying just starting Slight fraying

1 Bleed screw 2 Drainage screw

Without fuel warmer 14.7 19.6 Nm 4.4 5.4 Nm

Fuel vapour lock system

illustration shows the FP, FS engine

Steering gear / Power steering fluid

Air Filter Element

Oil separator in the oil filler cap

1 Inlet side 2 Exhaust side

1 Exhaust side 2 Inlet side

1 Inlet side 2 Exhaust side

1 Exhaust side 2 Inlet side

1 Exhaust side 2 Inlet side

1 Shim 2 Notch 3 Tappet

1 Inlet cam 2 Valve clearance 3 Shim

Check the valve clearance once more.

1 Adjusting screw 2 Locking nut 3 Rocker arm bridge

1 Adjusting screw 2 Locking nut

6. Determine the valve clearance of the valves of the first cylinder.

5. Undo the upper blind plug of the front engine cover.

1 Bolt (M6 x 1,0)

11. Remove the exhaust camshaft wheel.

1 Exhaust camshaft wheel

1 Intake rear camshaft cap

1 Bolt 2 Front cover 3 Tensioner arm

11. Release tension on the timing chain.

1 Link plate 2 Plunger