Mazda 2009 RX-8 Service-Handbuch

Title Section

GENERAL INFORMATION 00

ENGINE 01

SUSPENSION 02

DRIVELINE/AXLE 03

BRAKES 04

TRANSMISSION/TRANSAXLE 05

STEERING 06

HEATER, VENTILATION &

AIR CONDITIONING (HVAC) 07

RESTRAINTS 08

BODY & ACCESSORIES 09

CONTENTS

2009

Mazda

RX-8

Service

Highlights

FOREWORD

This manual contains on-vehicle service

and/or diagnosis procedures for the Mazda

RX-8.

For proper repair and maintenance,

a thorough familiarization with this manual is

important, and it should always be kept in a

handy place for quick and easy reference.

All the contents of this manual, including

drawings and specifications, are the latest

available at the time of printing.

As modifications affecting repair or

maintenance occur, relevant information

supplementary to this volume will be made

available at Mazda dealers. This manual

should be kept up-to-date.

Mazda Motor Corporation reserves the right

to alter the specifications and contents of

this manual without obligation or advance

notice.

be reproduced or used in any form or by any

means, electronic or mechanical—including

photocopying and recording and the use of

any kind of information storage and retrieval

system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

APPLICATION:

This manual is applicable to vehicles

beginning with the Vehicle Identification

Numbers (VIN), and related materials

shown on the following page.

There are explanation given only for the sections

marked with shadow ( ).

PRINTED IN U.S.A., MARCH 2008

Form No. 3452–1U–08C

Part No. 9999–95–102F–09

VEHICLE IDENTIFICATION NUMBERS (VIN)

JM1 FE172✻9# 400001—

JM1 FE174✻9# 400001—

JM1 FE17M✻9# 400001—

JM1 FE17P✻9# 400001—

RELATED MATERIALS

Material Name MNAO Part No.Mazda Material No.

2004 Mazda RX-8 Service Highlights 9999-95-102F-04 3378-1U-03C

2005 Mazda3, Mazda MX-5 Miata, Mazda MX-5, MAZDASPEED

MX-5, Mazda MPV, Mazda RX-8 Service Highlights 9999-95-MODL-05 3400-1U-04H

2006 Mazda RX-8 Service Highlights 9999-95-102F-06 3409-1U-05J

2007 Mazda3, MAZDASPEED3, Mazda5, Mazda MX-5, Mazda6,

MAZDASPEED6, Mazda RX-8 Service Highlights 9999-95-MODL-07 3422-1U-06G

2008 Mazda3, MAZDASPEED3, Mazda5, Mazda MX-5, Mazda6,

Mazda CX-7, Mazda RX-8, Mazda CX-9 Service Highlights 9999-95-010F-08 3431-1U-07I

1995, 1996, 1997, 1998, 1999, 2000 OBD-II Service Highlights 9999-95-OBD2-00 3344-1U-99K

2009 Mazda RX-8 Workshop Manual 9999-95-064B-09 1927-1U-08C

Engine Worlshop Manual 13B-MSP 9999-95-E13B-MSP 1773-1U-03C

Manual Transmission Workshop Manual P66M-D 9999-95-423H-06 1848-1U-05F

Automatic Transmission Workshop Manual SJ6A-EL 9999-95-SJ6A-EL 1876-1U-06J

2004 Mazda RX-8 Bodyshop Manual 9999-95-120F-04 3379-1U-03D

2009 Mazda RX-8 Wiring Diagram 9999-95-040G-09 5762-1U-08C

GENERAL INFORMATION

00-00–1

SECTION

00-00

Toc of SCT

GENERAL INFORMATION . . . .00-00

Toc of SCT

00-00 GENERAL INFORMATION

AIM OF DEVELOPMENT . . . . . . . . . . . . 00-00–1

Outline . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–1

VEHICLE IDENTIFICATION

NUMBER (VIN) CODE. . . . . . . . . . . . . . 00-00–5

VEHICLE IDENTIFICATION

NUMBER (VIN) . . . . . . . . . . . . . . . . . . . 00-00–5

End of Toc

NG: GENERAL INFO RMATION

AIM OF DEVELOPMENT id000000100100

Outline

External view

ar8uun00000171

GENERAL INFORMATION

00-00–2

Suspension

!Trapezoidal front suspension tower bar adopted to improve the rigidity and handling stability. (MT)

!19-inch wheel and tire adopted for hard suspension.

FRONT SUSPENSION

TOWER BAR FRONT SUSPENSION

TOWER BAR

TRANSVERSE MEMBER

FRONT SHOCK ABSORBER

AND COIL SPRING

FRONT UPPER ARM

FRONT STABILIZER

CONTROL LINK

FRONT LOWER ARM

FRONT

STABILIZER

FRONT

CROSSMEMBER

ar8uun00000297

GENERAL INFORMATION

00-00–3

00-00

Transmission

!Manual transmission

—Six-speed P66M-D manual transmission has been adopted.

—A linked, triple-cone synchronizer mechanism has been adopted for 1st, 2nd, 3rd and 4th gears.

—A guide plate type reverse lockout mechanism has been adopted.

1ST

2ND

3RD

4TH

5TH

6TH

REV

SHIFT PATTERN

MAIN DRIVE GEAR

SHAFT

MAINSHAFT

REVERSE IDLER GEAR

1ST GEAR

2ND GEAR

3RD GEAR

4TH GEAR

5TH GEAR

6TH GEAR

ar8uun00000298

GENERAL INFORMATION

00-00–4

!Automatic transmission

—SJ6A-EL type 6-speed AT has been adopted.

—The Sport AT has been adopted.

—Newly developed direct active matic control has been adopted.

End Of Sie

TCC

OIL PUMP

CLUTCH

F1 ONE-WAY CLUTCH

TORQUE

CONVERTER

FRONT

PLANETARY GEAR

MIDDLE

PLANETARY GEAR

REAR PLANETARY GEAR

F3 ONE-WAY CLUTCH

F2 ONE-WAY CLUTCH

F4 ONE-WAY

CLUTCH

BRAKE

B1 BRAKE

B2 BRAKE

B4 BRAKE

ar8uun00000224

GENERAL INFORMATION

00-00–5

00-00

VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000100200

End Of Sie

VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300

JM1 FE172*9# 400001—

JM1 FE174*9# 400001—

JM1 FE17M*9# 400001—

JM1 FE17P*9# 400001—

End Of Sie

J M 1 F E 1 7 M * 9 # 1 2 3 4 5 6

Plant

Model year

Check Digit

Engine

Body style

Restraint system

Carline, series

World manufacturer identification

2= 13B-High power, for California

4= 13B-High power, for Federal/Canada

M= 13B-Standard power, for California

P= 13B-Standard power, for Federal/Canada

Serial No.

0= Hiroshima

1= Hofu

9=2009

*=0 to 9, X

7= Coupe

1=Driver,Passenger Air bag,

Side Airbag, Curtain Air bag

FE= Mazda RX-8

JM1= Mazda/passenger car

ar8uuw00002204

01-00–1

ENGINE

SECTION

01-00

Toc of SCT

OUTLINE[13B-MSP] . . . . . . . . .01-00

ON-BOARD DIAGNOSTIC

[13B-MSP]. . . . . . . . . . . . . . . . 01-02

MECHANICAL[13B-MSP]. . . . .01-10

LUBRICATION[13B-MSP] . . . .01-11

COOLING SYSTEM

[13B-MSP]. . . . . . . . . . . . . . . . 01-12

INTAKE-AIR SYSTEM

[13B-MSP]. . . . . . . . . . . . . . . . 01-13

FUEL SYSTEM[13B-MSP]. . . . 01-14

EMISSION SYSTEM

[13B-MSP] . . . . . . . . . . . . . . . 01-16

CHARGING SYSTEM

[13B-MSP] . . . . . . . . . . . . . . . 01-17

CRUISE CONTROL

SYSTEM[13B-MSP]. . . . . . . . 01-20

CONTROL SYSTEM

[13B-MSP] . . . . . . . . . . . . . . . 01-40

Toc of SCT

01-00 OUTLINE [13B-MSP]

ENGINE ABBREVIATIONS

[13B-MSP] . . . . . . . . . . . . . . . . . . . . . . . 01-00–1

ENGINE FEATURES [13B-MSP] . . . . . . . 01-00–2

On-board Diagnostic . . . . . . . . . . . . . . . 01-00–2

Mechanical . . . . . . . . . . . . . . . . . . . . . . 01-00–2

Lubrication . . . . . . . . . . . . . . . . . . . . . . 01-00–2

Cooling System . . . . . . . . . . . . . . . . . . 01-00–2

Charging System . . . . . . . . . . . . . . . . . 01-00–2

Cruise Control System . . . . . . . . . . . . . 01-00–2

Control System. . . . . . . . . . . . . . . . . . . 01-00–2

ENGINE SPECIFICATIONS

[13B-MSP] . . . . . . . . . . . . . . . . . . . . . . . 01-00–3

End of Toc

NG: ENGINE COMPLETE

ENGINE ABBREVIATIONS [13B-MSP] id010050100100

ABDC After Bottom Dead Center

APV Auxiliary Port Valve

AT Automatic Transmission

ATDC After Top Dead Center

BBDC Before Bottom Dead Center

BTDC Before Top Dead Center

CAN Controller Area Network

CCM Comprehensive Component Monitor

DC Drive Cycle

EX Exhaust

FP Front Primary

FS Front Secondary

F/P Fuel Pump

HI High

IC Integrated Circuit

IG Ignition

IN Intake

KAM Keep Alive Memory

KOEO Key On Engine Off

KOER Key On Engine Running

LF Left Front

LH Left Hand

LO Low

LR Left Rear

L/F Leading Front

OUTLINE [13B-MSP]

01-00–2

End Of Sie

ENGINE FEATURES [13B-MSP] id010050100200

On-board Diagnostic

Mechanical

Lubrication

Cooling System

Charging System

Cruise Control System

Control System

End Of Sie

L/R Leading Rear

MT Manual Transmission

OCV Oil Control Valve

RH Right Hand

RP Rear Primary

RR Right Rear

RS Rear Secondary

SSV Secondary Shutter Valve

SW Switch

T/F Trailing Front

T/R Trailing Rear

VDI Variable Dynamic Effect Intake

VFAD Variable Fresh Air Duct

To meet OBD-II regulations !Diagnostic test modes changed

Improved serviceability !DTCs changed

!KOEO/KOER self-test function changed

!PID/DATA monitor function changed

!Simulation test function changed

Reduced engine noise and vibration !Stationary gear changed (standard power)

Improved engine torque !Auxiliary port adopted (standard power)

Improved lubricity

!An electric type metering oil pump system adopted

!Center oil nozzles adopted which discharge oil to the center area of the rotor

housings

!Oil pump changed

!Oil pan upper block adopted

Improved serviceability !Oil filter position changed

Improved cooling performance

!Radiator changed

!Water pump changed

!Cooling fan component changed

Improved generator output !Generator changed

Improved driveability !Cruise control switch changed

Improved engine torque and output !S-DAIS control changed

!APV position sensor No.1, No.2 adopted

Improved engine reliability

!KS No.1, No.2 adopted

!Electrical fan control changed

!Fuel injection control changed

Improved lubricity

!Metering oil pump control changed

—Metering oil pump driver adopted

!Oil pressure control adopted

—Oil pressure sensor adopted

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