Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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SYMPTOM The windshield washer pump does not work. PROBABLE CAUSE Impact to the front bumper pushes the bumper back far enough to break the washer pump hose fitting. CORRECTIVE ACTION Replace the windshield washer reservoir and washer motor with updated parts. REPAIR PROCEDURE 1. Turn the ignition switch to ACC (I) to unlock the steering column. 2. Raise the vehicle on a lift. 3. Remove the right front inner fender. Unhook and pull back the bumper for better access. CLIPS (6 places.) SCREWS (6 places.) RIGHT FRONT INNER FENDER 4. Release the hooks on the upper right side of the front bumper. 5. Remove the clip from the filler neck, then remove the filler neck. FILLER NECK CLIP WINDSHIELD WASHER RESERVOIR CLIP WASHER MOTOR CONNECTOR BOLT BOLTS WASHER TUBES 6. Remove the right front fender trim, and disconnect the washer hose from the 90-degree fitting. CLIP FRONT FENDER TRIM FRONT HOSE 7. Disconnect the 2P connector and the two washer tubes from the washer motor. 8. Remove the washer reservoir clip and the three bolts, then pull out the reservoir. 9. Assemble the new reservoir components, but do not install the filler neck. 10. Trim 85 mm off the end of the 1,260 mm washer tube only. 11. Route the washer tubes on the reservoir. NOTE: The black fitting is for the front windshield nozzles, and the white fitting is for the rear nozzle. 85 mm 12. Install the reservoir. 13. Connect the rear tube to the straight fitting in the wheelwell. 14. Connect the 2P connector to the washer motor. NEW RESERVOIR Connect the rear washer tube. CLIP BOLT 9.8 N•m (7.2 lb•ft) 15. Install the filler neck with the original clip. Connect the front washer tube to the 90-degree fitting. Then reinstall the front fender trim. WASHER FLUID DIPSTICK 2P CONNECTOR FRONT FENDER TRIM FILLER NECK CLIP

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Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02. 2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. Clean the area around the quick disconnect coupling. 3. Lower the vehicle. 4. Remove the two screws and the lower steering column finish panel. 5. Remove the five bolts and the lower reinforcement panel. 6. Disconnect the clutch pedal position (CPP) switch electrical connector. 7. Disconnect the clutch master cylinder rod from the clutch pedal arm. 8. Remove the CPP switch. Lift the upper cover from the lock tabs and pull the upper cover up. Rotate and remove the CPP switch from the clutch master cylinder rod. 9. Remove the reservoir. 10. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 11. Unclip the hydraulic line-to-frame retainer. 12. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder counterclockwise 45 degrees to unlock it from the support bracket. 13. Remove the reservoir, the hydraulic line and the clutch master cylinder as an assembly. 14. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, wash the surface with water immediately. To install, reverse the removal procedure. Install a new push rod retainer. Depress and release the clutch pedal 15 strokes.

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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.

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Removal of Factory Intake 1. 2. Pull upwards to remove the engine cover. Unclip the battery cover and remove, then disconnect the negative battery cable. Disengage the plastic rivet. Slide the battery cold air vent backwards and remove from the engine compartment. Disconnect the mass air sensor electrical connection. Depress the retaining clip and disconnect the rank case vent hose from the stock intake tube. Remove the switch/sensor from the air cleaner cover. Loosen the clamp at the throttle body. Unclip the coolant hose from the air cleaner cover. Unclip the air cleaner cover and remove the complete upper air cleaner assembly. Remove the rubber retainer from the core support. Remove the lower air cleaner assembly. Unclip the wire harness from the side of the battery box. Remove the mass air sensor from the air cleaner cover. Remove the plastic clip from the crank case vent on the stock intake tube. Slide the clamps off rubber rank case vent. Remove the plastic vent from the stock intake tube. Slide the plastic clip from before back onto the crank case vent. Raise the vehicle up and support by jack stands, then remove the left front tire. Remove the four bolts and one plastic rivet from the inner valance, then remove the valance. Remove the three plastic rivets and six hex bolts on the inner valance, then pull the inner valance downward. Remove the three bolts that secure the air intake resonator to the inner fender, then remove the resonator. Secure the rubber mounted stud to the hole on the battery tray. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Install of Intake 24. Install reducer and clamps onto the throttle body. 25. Install the hose onto the vent on the intake tube. 26. Install the mass air sensor into the intake tube. 27. Slide the tube into the reducer and line up the bracket with stud, then tighten the clamps at the throttle body. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Secure the switch to the bracket (not for the 06 Mazda 5 model). Install the crank case vent into the hose on the intake tube. Reconnect the crank case vent. Install the rubber mounting stud into the resonator threaded hole. Install the reducer and clamps onto the cold air tube. From underneath the vehicle install the cold air tube. Slide the cold air tube onto the short ram tube. Secure the bracket to the tuber mounted stud. Install the filter onto the cold air tube from the underneath vehicle. Reconnect the mass air sensor. Reverse the removal process and reinstall the inner fender valance. Reinstall the front tire and torque to factory specs. Slide the vent into the core support and line up the other end with the battery box and secure with plastic rivet. 41. Reconnect the negative battery cable, then reinstall the battery cover. 42. Reinstall the engine cover. Resetting the ECU This is to be completed at your own risk. This procedure will reset the computer so that it may “learn” of your new intake. We are not to be held liable for any mishaps that you may occur while completing this process. • • Disconnect the Negative battery cable for 5 minutes. Reconnect the battery cable and false panel cover.

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WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard. 1. If the fuel tank, fuel transfer pump or fuel delivery module is being removed drain the fuel tank. For additional information, refer to Fuel Tank Draining in this section. 2. If the fuel tank is being removed, remove the driveshaft. For additional information, refer to Section 205-00. 3. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: Part Steps 4. To install, reverse the removal procedure. 5. Fill the fuel tank. 6. Turn the ignition key to the ON position to pressurize the fuel system. 7. Visually inspect the fuel system for leaks. Item 5: Fuel Filler Pipe Removal Note 1. Remove the right rear well inner fender splash shield. 2. CAUTION: Some fuel will remain in the filler pipe after draining the fuel tank. Carefully drain the filler pipe into an approved container. Loosen the clamp at the fuel tank filler pipe and remove the filler pipe.