Mazda 2004 RX-8 Service manual

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
2004
Mazda
RX-8
Service
Highlights
FOREWORD
This Service Highlights is intended for use
by service training personnel of Authorized
Mazda Dealers.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book
may 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.
©2003 Mazda Motor Corporation
PRINTED IN U.S.A., MARCH 2003
Form No. 3378–1U–03C
Part No. 9999–95–102F–04

00
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
New Model Concept . . . . . . . . . . . . . . . 00–00–1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–2
HOW TO USE THIS MANUAL . . . . . . . . . 00–00–7
Vehicle Identification Number (VIN)
Code . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–7
UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–00–8
Conversion to SI Units
(Système International d'Unités) . . . . 00–00–8
Rounding Off . . . . . . . . . . . . . . . . . . . . 00–00–8
Upper and Lower Limits . . . . . . . . . . . . 00–00–8
SAE STANDARD. . . . . . . . . . . . . . . . . . . 00–00–9
End of Toc
AIM OF DEVELOPMENT CHU000000022S01
New Model Concept
"New four-door, four-passenger sports car"
•The Mazda RX-8 is an entirely new concept in a state-of-the-art sports car, combining unique sports-car
styling and excellent driving performance, together with the comfort and practicality of a four-door, four-
passenger layout.
External view
CHU0000S003

GENERAL INFORMATION
00–00–2
Outline
Exterior design
•The dynamic styling, from front to back and along the body sides, creates a sense of "motion".
•A compact cabin supported by pronounced overfenders, lowers the visual center of gravity, emphasizing a
sense of "stability".
•A pared-down body shape and a boldly contoured form gives the Mazda RX-8 an aggressive appearance.
Interior design
•Modern, high-quality design
— Vibrant styling from the dashboard to the rear.
— Tight and compact dashboard emphasizes lightness and sophistication by adopting new textures, coloring,
and metallic-look materials that add to its unique style.
— Rotor-motif shift-lever knob and sunvisors employing mesh texturing demonstrate the value and attention
to detail.
•Comfortable interior
— Front and rear console boxes with cup holders.
— Door pockets are provided for road maps or a small bag.
— Sunvisors are equipped with illuminated vanity mirrors.
— Premium audio system with nine BOSE speakers is available, offering an acoustic space of high quality.
•Center pillarless freestyle doors providing
unhindered access to the cabin have been
adopted.
•Trunk compartment with a practical capacity
— A storage capacity of approx. 290 L {306 US
qt, 255 lmp qt}, sufficient for two golf bags or
two size-67 Samsonite suitcases, has been
realized by lowering the floor thanks to the
emergency puncture repair kit which requires
no spare tire.
CHU0000S018
CHU0000S017

GENERAL INFORMATION
00–00–3
00–00
Engine - the "RENESIS" - a new-generation rotary engine
•Engine
— 13B-multi side port (MSP) (High power and Standard power), new-generation rotary engine has been
adopted.
— Side exhaust system has been adopted by transferring the exhaust ports from the rotor housing to the side
housing.
— The intake port area has been in increased by 30% over previous rotary engines. This results in reduced
intake resistance and increased air flow which makes more power.
— Cut-off seals have been provided between the oil seals and the side seals of the rotors, preventing
combustion gas from flowing into the intake air process.
— Keystone-shaped (wedge-shaped) side seals have been adopted for increased sealing performance.
— Ribs in the side housing and rotors have been decreased in thickness and weight while maintaining high
rigidity.
— Spark plugs with iridium tips have been adopted for improved heat resistance and durability.
— Flank cuts on the corners of the rotors provide improved exhaust efficiency by delaying the exhaust-port
closing timing.
•Intake and control
— Sequential dynamic air intake system (S-DAIS) has been adopted, realizing powerful output at high engine
speed provides a wide-range of torque in the low and medium-speed ranges through full use of air intake
pulsating unique to the rotary engine.
— Large, low-resistance air cleaner and variable fresh air duct (VFAD) (High power only) have been adopted.
EXHAUST PORT
EXHAUST PORT
AUXILIARY PORT
(HIGH POWER ONLY)
INTAKE PORT
SIDE EXHAUST
(RX-8)
PERIPHERAL EXHAUST
(RX-7)
EXHAUST PORT
CHU0000S020
HIGH POWER
VARIABLE DYNAMIC EFFECT
INTAKE VALVE
THROTTLE VALVE
AUXILIARY PORT VALVE
VARIABLE FRESH AIR DUCT
AIR CLEANER FRESH AIR DUCT
SECONDARY SHUTTER VALVE
INTAKE MANIFOLD
CHU0000S013

GENERAL INFORMATION
00–00–4
—Three injectors per rotor have been provided on the High power model (2 per rotor for Standard power).
Together with the electronically controlled (drive-by-wire) throttle valves and the 32-bit powertrain control
module (PCM), the injector arrangement has realized fine control of the air-fuel ratio and reduced response
time.
—New jet air fuel mixing system that promotes
atomization, vaporization, and mixing of fuel
has been adopted on the intake port unique to
the rotary engine, realizing improved
combustion and reduced fuel consumption.
Advanced front-midship layout
•Combination of state-of-the-art technologies such as a compact rotary engine, a thin engine oil pan, a forward-
located air intake system, a compact air-conditioning unit, has produced a small and light powerplant package.
•Adoption of an advanced front-midship layout,
saddle-shaped plastic fuel tank, and an
emergency puncture repair kit requiring no spare
tire has realized a 50-50 front/rear weight
distribution, minimal yaw-inertia moment, and
high roll-rigidity.
JET AIR FUEL MIXING SYSTEM
CHU0000S014
50% 50%
ADVANCED FRONT-MIDSHIP
LAYOUT
NO SPARE TIRE DUE TO
ADOPTION OF EMERGENCY
PUNCTURE REPAIR KIT
FUEL TANK LOCATED
WITHIN WHEELBASE
RX-7
RX-8
RENESIS ENGINE
CHU0000S002

GENERAL INFORMATION
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00–00
Suspension and steering
•Tire pressure monitoring system
—The tire pressure monitoring system (TPMS) has been adopted to assist the driver in understanding the tire
status to improve the safety.
•Front suspension
—Newly developed, in-wheel type double-wishbone suspension has been adopted.
—Relatively long arms promote linear alignment changes during bounce and rebound, realizing excellent
controllability at the vehicle handling limits in diverse road and driving conditions.
•Rear suspension
—Multi-link suspension employing five links per wheel has been adopted.
—Excellent handling stability, ride comfort, and road noise performance have been realized by optimizing
each link arrangement in consideration of geometry and compliance in order to maintain the optimum tire
contact area at any time in the optimal condition against external forces during driving.
LARGE-DIAMETER MONOTUBE
SHOCK ABSORBER
FORGED-ALUMINUM
LOWER ARM
HOT-FORGED-ALUMINUM
UPPER ARM
LIGHT, RIGID SUBFRAME
CHU0000S007
LIGHT, RIGID SUBFRAME
LARGE-DIAMETER MONOTUBE
SHOCK ABSORBER
REAR KNUCKLE MADE OF LIGHTWEIGHT,
HIGHLY RIGID HOT-FORGED-ALUMINUM
FOR IMPROVED REAR TIRE RESPONSE
BY DECREASING WEIGHT UNDER SPRINGS.
LONG-LINK SUSPENSION MOUNTING POINT LAYOUT
FOR IDEAL CHANGE IN GEOMETRY
CHU0000S008

GENERAL INFORMATION
00–00–6
•Electric power steering (Rack assist type)
—To provide the driver with appropriate road
feel, the power steering system employs
computer controlled power assistance
characteristic based on vehicle speed and a
rack assist mechanism with a motor installed
on the same axis as the rack.
Brake
•Large-diameter, 17-inch type front brakes have been adopted on sport-suspension vehicles for consistent
stopping power.
•16-inch type front brakes have been adopted on standard-suspension vehicles.
•16-inch type rear brakes have been adopted on both for sport and standard-suspension vehicles.
Transmission
•Manual transmission
—Cross-ratio six-speed manual transmission has been adopted on the 13B-MSP (High power).
•Automatic transmission (13B-MSP (Standard power))
—Four-speed sport automatic transmission has been adopted that can be shifted up/down by operating the
one-touch steering-wheel-mounted switches.
—Shift patterns have been adopted that optimize the frequently used operating positions of N-D and manual
modes by reducing the shift-lever stroke.
Safety
•Lightweight and highly rigid safe body structure developed uniquely for the Mazda RX-8 has achieved high
international standards of crash safety.
•Reinforcement with high strength has been installed on the area equivalent to the center pillar on the rear
doors, realizing strength nearly equal to that of a center pillar of a standard sedan.
•Dual-inflator type air bags that control deployment of the air bags in two stages by detecting the scale of an
impact have been adopted for front-seat passengers.
•Curtain air bags have been adopted that deploy and cover the front and rear windows and protect the heads of
front and rear passengers.
•Side air bags effective in protecting the upper abdomen of passengers have been adopted and installed in the
outboard sides of the front seat backs.
•Pre-tensioner and load limiter mechanisms have been adopted for the front seat belts.
•Intrusion minimizing mechanism has been adopted for the brake pedal.
•ISO-FIX anchors and tether straps have been adopted for installing child restraint systems on the rear seats.
•Aluminum hood with a shock-absorbing cone structure has been adopted in consideration of pedestrian
protection.
End Of Sie
CHU0000S009

GENERAL INFORMATION
00–00–7
00–00
HOW TO USE THIS MANUAL CHU000000001S02
Vehicle Identification Number (VIN) Code
End Of Sie
J M 1 F E 1 7 N * 4 # 1 2 3 4 5 6
Serial No.
0= Hiroshima
1= Hofu
4=2004, 5=2005...
N= 13B-Standard power
3= 13B-High power
FE= Mazda RX-8
1=Drv. & Pass.-A/B,
Side A/B, Curtain A/B
7= Coupe
JM1= Mazda/passenger car
*=0 to 9, X
Plant
Model year
Check Digit
Engine type
Body style
Restraint system
Vehicle type
World manufacturer identification
CHU0000S001

GENERAL INFORMATION
00–00–8
UNITS CHU000000002S01
Conversion to SI Units (Système International d'Unités)
•All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted
from these values.
Rounding Off
•Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit
value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8.
Upper and Lower Limits
•When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is
an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI
unit value may differ after conversion. For example, consider 2.7 kgf/cm2in the following specifications:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}
270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
•The actual converted values for 2.7 kgf/cm2are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
End Of Sie
Electrical current A (ampere)
Electric power W (watt)
Electric resistance ohm
Electric voltage V (volt)
Length mm (millimeter)
in (inch)
Negative pressure
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
Positive pressure
kPa (kilo pascal)
kgf/cm2(kilogram force per square
centimeter)
psi (pounds per square inch)
Torque
N·m (Newton meter)
kgf·m (kilogram force meter)
kgf·cm (kilogram force centimeter)
ft·lbf (foot pound force)
in·lbf (inch pound force)
Volume
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight g (gram)
oz (ounce)

GENERAL INFORMATION
00–00–9
00–00
SAE STANDARD CHU000000003S01
•In accordance with new regulations, SAE (Society of Automotive Engineers) standard names and
abbreviations are now used in this manual. The table below lists the names and abbreviations that have been
used in Mazda manuals up to now and their SAE equivalents.
#1 : Diagnostic trouble codes depend on the diagnostic test mode.
#2 : Controlled by the PCM
#3 : Device that controls engine and powertrain
#4 : Directly connected to exhaust manifold
End Of Sie
SAE Standard Remark SAE Standard Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MAP Manifold Absolute Pressure
APP Accelerator Pedal Position MAF Mass Air Flow
ACL Air Cleaner MAF sensor Mass Air Flow Sensor
A/C Air Conditioning MFL Multiport Fuel Injection
A/F Air Fuel Ratio OBD On-board Diagnostic System
BARO Barometric Pressure OL Open Loop
B+ Battery Positive Voltage OC Oxidation Catalytic Converter
CMP sensor Camshaft Position Sensor O2S Oxygen Sensor
LOAD Calculated Load Value PNP Park/Neutral Position
CAC Charge Air Cooler PID Parameter Identification
CLS Closed Loop System PSP Power Steering Pressure
CTP Closed Throttle Position PCM Powertrain Control Module #3
CPP Clutch Pedal Position
PAIR Pulsed Secondary Air Injection Pulsed
injection
CIS Continuous Fuel Injection
System
CKP sensor Crankshaft Position Sensor
AIR Secondary Air Injection
Injection
with air
pump
DLC Data Link Connector
DTM Diagnostic Test Mode #1
DTC DiagnosticTrouble Code(s)SAPV Secondary Air PulseValve
DI Distributor Ignition SFI Sequential Multiport Fuel
Injection
DLI Distributorless Ignition
EI Electronic Ignition #2 3GR Third Gear
ECT Engine Coolant Temperature TWC Three Way Catalytic Converter
EM Engine Modification TB Throttle Body
EVAP Evaporative Emission TP Throttle Position
EGR Exhaust Gas Recirculation TP sensor Throttle Position Sensor
FC Fan Control TCC Torque Converter Clutch
FF Flexible Fuel TCM Transmission (Transaxle) Control
Module
4GR Fourth Gear
GEN Generator TR Transmission (Transaxle) Range
GND Ground TC Turbocharger
HO2S Heated Oxygen Sensor With
heater
VSS Vehicle Speed Sensor
VR Voltage Regulator
IAC Idle Air Control VAF sensor Volume Air Flow Sensor
IAT Intake Air Temperature WU-TWC Warm Up Three Way Catalytic
Converter #4
KS Knock Sensor
MIL Malfunction Indicator Lamp WOP Wide Open Throttle