2004-2007 Mazda RX-8 MIL ON – P2070 SET

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Filed Under (Mazda) by admin on 02-03-2011

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Some vehicles may experience a MIL with DTC P2070 (SSV Stuck Open). This may be caused by carbon build up near the SSV bushing, which may cause driveability concerns (hesitation and / or lack of power) and / or DTC P2070. A cleaning procedure and a revised SSV with stronger actuator force is now available. Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE 1. Verify the following: – P2070 is set. – SSV sticks without failure of SSV solenoid valve switch. 2. Record freeze frame data. 3. Record customer radio station presets. 4. Disconnect negative battery cable. 5. Raise and support vehicle. 6. Drain engine coolant into a clean container for reuse after repair. Refer to Workshop Manual section 01-12 ENGINE COOLANT REPLACEMENT. 7. Remove right front wheel. 8. Remove rubber splash shield from inner fender to access right side of engine. 9. Remove 2 nuts (1) attaching air pipe (2) to exhaust manifold (3). 10. Disconnect port air bleed vacuum hose (4) from intake manifold. 11. Lower vehicle. 12. Remove battery cover, battery and battery tray to make work space. Refer to Workshop Manual section 01- 17 BATTERY REMOVAL / INSTALLATION. 13. Remove air control valve bracket bolt (5). 14. Disconnect main harness from air control valve bracket. 15. Disconnect upper hose (6) and vacuum line (7) from air control valve. 16. Position air control valve and air pipe out of the way by moving toward washer fluid reservoir. 17. Loose 3 water pump pulley bolts (8) but do not remove. 18. Loosen alternator belt tension bolt and remove attaching bolt and nut (9) from alternator and bracket. 19. Remove alternator belt. 20. Remove water pump pulley. 21. Remove 3 nuts (10) and alternator bracket (11). 22. Raise and support vehicle. 23. Remove 2 bolts (12) attaching port air bleed vacuum pipe.

2006-2007 Mazda MX-5 CENTER CONSOLE SIDE WALL REMOVAL CAUTION – SERVICE TIP

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Filed Under (Mazda) by admin on 02-03-2011

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When removing the side wall of the center console panel during service, care must be taken and proper sequence must be followed or the clips and/or hooks on the side wall may break requiring replacement of the side wall. For proper removal of the sidewall, please refer to the following procedure. REPAIR PROCEDURE When removing the side wall(s) of the center console during servicing, care must be taken and the proper pro- cedure must be followed or the clips and/or hooks on the side wall(s) may be broken, requiring unnecessary replacement of the side wall(s). CAUTION: 1. Using a plastic windshield setting tool or equivalent insert between side wall and center panel, then carefully pry rearward (toward rear of vehicle) to disengage clips and hooks. • DO NOT forcibly pull the side wall outward (to the side), to prevent damage. NOTE: • Plastic Windshield Setting Tool (Part Number IS742 – available from Equalizer at 800-334-1334) or similar available through a local supplier. If a flat-tipped screwdriver is to be used, wrap the tip in tape to prevent damage to the center console or the shift panel. • PLASTIC WINDSHIELD SETTING TOOL 1501a 2. Carefully pull the side wall rearward to disengage pins “C” and remove. 3. To install, place pins “C” in place and slide forward (toward front of vehicle) until clips “A”, “B” and hook “D” engage.

2003 Mazda Protege Fuel Tank Removal and Installation

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Filed Under (Mazda) by admin on 02-03-2011

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WARNING: Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. CAUTION: Disconnecting/connecting the quick release connector without cleaning it may possibly cause damage to the fuel pipe and quick release connector. Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material. 1. 2. 3. 4. 5. 6. 7. 8. Level the vehicle. Complete the “BEFORE REPAIR PROCEDURE”. Disconnect the negative battery cable. Remove the rear seat cushion. Remove the service hole cover. Remove the fuel pump unit. Siphon the fuel from the fuel tank. Remove the presilencer. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Complete the “AFTER REPAIR PROCEDURE”. Plastic Fuel Hose Removal Note CAUTION: The retainer must be replaced If removed from the fuel pipe without using the SST. Otherwise, effectiveness of the retainer will be reduced. 1. Inspect that the quick release connector joint area is tree of foreign material. 2. Clean as necessary. 3. Set the SST as shown and push into the quick release connector to disconnect the plastic fuel hose. 4. Cover the disconnected quick release connector and fuel pipe to prevent them from being scratched or contaminated with foreign material.

2007 Mazda Speed 3 Exhaust System Installation

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Filed Under (Mazda) by admin on 01-03-2011

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Original Exhaust System Removal Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaust fasteners and allowing a signifi- cant period of time for the chemical to lubricate the threads before attempting to disassemble. 1. Cut the factory exhaust as shown in figure 1 directly behind the resonator muffler. 2. Lubricate all the hangers and rubber isolators . 3. Using a muffler stand or an additional person to hold the rear muffler assembly in position, remove the hangers from the rubber isolators and remove the rear muffler assembly from the vehicle. as shown in figure 2. 4. Unbolt and remove the center support as shown in figure 3. Place the hardware to the side for use during the installation of your new exhaust system. 5. Unbolt the flange shown in figure 4 and place the hardware to the side for use during the installation of your new exhaust system. 6. Using a muffler stand or an additional person to hold the remain- ing exhaust in position, remove the hangers from the rubber iso- lators and remove the remaining exhaust from the vehicle as shown in figure 5. 1. Using the original hardware, install the front pipe as shown in figure 6 making sure to install the hanger into the rubber isolator. 2. Place a clamp over the expanded end of the muffler assembly and set it into position as shown in figure 7 .making sure to install the hanger into the rubber isolator. Do Not tighten the clamp. 3. Place a clamp over the expanded end of the tail pipe assembly and set it into position as shown in figure 8 making sure to install the hanger into the rubber isolator. Do Not tighten the clamp. 5. Check your exhaust system for proper clearance under the vehi- cle and also for tip alignment. 6. Once position has been determined to be correct, tighten the Ac- cuseal™ clamps to 32-35 ft. lbs. making sure the clamp opening is not over any of the notches in the pipe. 7. Using the original hardware re install the center support as shown in figure 9. 8. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the ex- haust system. 9. Start vehicle and check for any leaks. If any leaks are found, de- termine cause (such as loose hardware or incorrectly positioned clamp) and repair as necessary.

2007-2008 Mazda CX-9 AIRBAG WARNING LIGHT ON – B1342, B2477 AND / OR C1946 SET

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Filed Under (Mazda) by admin on 01-03-2011

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DESCRIPTION On some vehicles, when a power plug with improper fabrication (such as a phone charger) is inserted into either of the accessory sockets (center and/or rear), the airbag warning light may illuminate with DTC B1342, B2477 AND / OR C1946 stored in memory. Due to the improper power plug, the center or rear accessory socket fuse blows, and a short-circuit occurs in the SAS control module, causing the airbag warning light illumination with DTC B1342, B2477 AND / OR C1946 set. Despite the DTCs and airbag warning light being illumi- nated, the airbag system will continue to function. After verifying customer concern, perform the following repair procedures in order: • A – FUSE INSPECTION AND REPLACEMENT • B – SAS CONTROL MODULE CONFIGURATION AND REMOVAL / INSTALLATION (1) • C – PERFORM SSP78 A – FUSE INSPECTION AND REPLACEMENT 1. Visually inspect OUTLET CTR (15A) and OUTLET RR (15A) fuses located in the main fuse block in the engine compartment. Refer to MS3 online information or Workshop Manual WIRING DIAGRAMS. NOTE: – - In the wiring diagram these fuses are referred to as 19 and 20. In the owners manual these fuses are referred to as 17 and 18. 2. Replace any blown fuses with a new 15A fuse (9970-51-315). 3. Proceed to B – SAS CONTROL MODULE CONFIGURATION AND REMOVAL / INSTALLATION. B – SAS CONTROL MODULE CONFIGURATION AND REMOVAL / INSTALLATION