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
00–00–5
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

01–00–1
01
ENGINE
SECTION
01–00
Toc of SCT
OUTLINE . . . . . . . . . . . . . . . . . .01-00
ON-BOARD DIAGNOSTIC . . . . 01-02
MECHANICAL. . . . . . . . . . . . . .01-10
LUBRICATION . . . . . . . . . . . . .01-11
COOLING SYSTEM . . . . . . . . . 01-12
INTAKE-AIR SYSTEM . . . . . . . 01-13
FUEL SYSTEM . . . . . . . . . . . . .01-14
EXHAUST SYSTEM . . . . . . . . . 01-15
EMISSION SYSTEM. . . . . . . . . 01-16
CHARGING SYSTEM. . . . . . . . 01-17
IGNITION SYSTEM . . . . . . . . . 01-18
STARTING SYSTEM . . . . . . . . 01-19
CRUISE CONTROL SYSTEM . 01-20
CONTROL SYSTEM . . . . . . . . 01-40
Toc of SCT
01–00 OUTLINE
ENGINE ABBREVIATIONS . . . . . . . . . . . 01–00–1
ENGINE FEATURES . . . . . . . . . . . . . . . . 01–00–2
ENGINE SPECIFICATIONS . . . . . . . . . . 01–00–2
End of Toc
ENGINE ABBREVIATIONS CHU010002000S01
End Of Sie
A/C Air Conditioner
API American Petroleum Institute
APV Auxiliary Port Valve
AT Automatic Transmission
ATDC After Top Dead Center
ABDC After Bottom Dead Center
BBDC Before Bottom Dead Center
BTDC Before Top Dead Center
CAN Controller Area Network
CCM Comprehensive Component Monitor
DC Drive Cycle
DLI Distributorless Ignition
F/P Fuel Pump
FP1 Front Primary 1
FP2 Front Primary 2
FS Front Secondary
HI High
IC Integrated Circuit
IG Ignition
KAM Keep Alive Memory
KOEO Key On Engine Off
KOER Key On Engine Running
L/F Leading Front
LF Left Front
LH Left Hand
LO Low
L/R Leading Rear
LR Left Rear
MSP Multi Side Port
MT Manual Transmission
RH Right Hand
RP1 Rear Primary 1
RP2 Rear Primary 2
RR Right Rear
RS Rear Secondary
SAE Society of Automotive Engineers
SST Special Service Tool
SSV Secondary Shutter Valve
SW Switch
T/F Trailing Front
T/R Trailing Rear
VDI Variable Dynamic Effect Intake
VFAD Variable Fresh Air Duct
WDS Worldwide Diagnostic System

OUTLINE
01–00–2
ENGINE FEATURES CHU010002000S02
End Of Sie
ENGINE SPECIFICATIONS CHU010002000S03
Improved power performance
•A side intake and exhaust port system adopted
•2-piece apex seals adopted
•Keystone shaped side seals adopted
•Cut-off seal adopted
•A lightweight flywheel adopted
Improved driving performance
•Advanced front mid-ship layout adopted
•Drive-by-wire system, which opens and closes throttle valve by throttle actuator,
adopted
Improved engine torque and
output •Sequential dynamic air intake system (S-DAIS) adopted
Improved startability •A reduction type starter adopted
Reduced weight
•Thin walls on the side housings adopted
•Lightweight rotors adopted
•Aluminum rotor housings adopted
•Aluminum engine mount brackets adopted
•A compact oil filter adopted
•A thin oil pan made of steel adopted
•An oil strainer made of plastic adopted
•A down flow type radiator with aluminum core and plastic tank adopted
Miniaturization •A regulatorless generator with built-in power transistor adopted
•A built-in type water pump adopted
Improved fuel economy
•Bathtub shaped combustion chambers adopted
•By-pass valve in the eccentric shaft adopted
•Anti-wet port adopted
Improved idle fuel economy •Jet air fuel mixing system adopted
Reduced engine noise and
vibration
•Oil-filled engine mount rubber adopted
•A cooling fan with electric motor adopted
Improved reliability
•A degassing type coolant reserve tank adopted
•An independent ignition control system with distributorless ignition coil adopted
•A battery duct adopted
Improved durability •A spark plug with an iridium tip adopted
Improved lubricity •A two-rotor type trochoid oil pump adopted
•An electric type metering oil pump adopted
Improved safety •A starter interlock switch adopted (MT)
Improved serviceability •Nylon tubes adopted for fuel hoses in the engine compartment and around the fuel
tank, and quick release connectors adopted for joints
Wiring harness simplification •Controller area network (CAN) adopted
Reduction of evaporative gas •Returnless fuel system adopted
•Evaporative purge control adopted
Improved exhaust purification
•Secondary air injection (AIR) system with electric secondary air injection (AIR) pump
adopted
•TWC system adopted
Item
Specifications
13B-MSP
(Standard power)
13B-MSP
(High power)
MECHANICAL
Engine type Rotary
Rotor arrangement and number In-line 2-rotor, longitudinal
Combustion chamber type Bathtub
Displacement (ml {cc, cu in}) 654 {654, 40.0}×2
Compression ratio 10.0
Compression pressure (kPa {kgf/cm2, psi} [rpm]) 830 {8.5, 120}[250]

OUTLINE
01–00–3
2004 Mazda RX-8 Service Highlights (3378-1U-03C)
01–00
Port timing IN
Open Primary port ATDC 3° Secondary port 12°
Auxiliary port – 38°
Close Primary port ABDC 60°65° Secondary port 45°36°
Auxiliary port – 80°
EX Open BBDC 40°50°
Close BTDC 3°
LUBRICATION SYSTEM
Type Force-fed type
Oil pump Type Trochoid gear
Relief valve opening pressure
(approx. quantity) (kPa {kgf/cm2,
psi} ) 441—490 {4.5—5.0, 64.0—71.0}
Oil filter Type Full-flow
Relief valve opening pressure
(approx. quantity) (kPa {kgf/cm2,
psi} ) 78—118 {0.8—1.2, 11.4—17.1}
Oil pressure (approx. quantity)
[oil temperature 100°C {212°F}] (kPa {kgf/cm2, psi} [rpm] ) 350 {3.57, 50.8} [3,000]
Oil capacity
(approx. quantity) Oil replacement 3.3 {3.5, 2.9} Oil and oil filter replacement 3.5 {3.7, 3.1}
(L {US qt, lmp qt}) Engine overhaul 4.7 {5.0, 4.1}
Total (dry engine) 5.8 {6.1, 5.1} 6.7 {7.1, 5.9}
Recommended oil API service SL SAE viscosity 5W–20
ILSAC GF–3
COOLING SYSTEM
Type Water-cooled, forced circulation
Coolant capacity (L {US qt, lmp qt}) 9.8 {10.4, 8.6}
Water pump Centrifugal, V-ribbed belt-driven
Thermostat
Type Wax
Opening temperature (°C {F°}) 80—84 {176—183}
Full-open temperature (°C {F°}) 95 {203}
Full-open lift (mm {in}) 8.5 {0.33} or more
Radiator Type Corrugated fin
Cooling system cap Cap valve opening pressure 73.3—103.3 {0.748—1.053, 10.63—14.98}
(kPa {kgf/cm2, psi} )
Cooling fan
Type Electronic
Number of blades Cooling fan No.1: 5,
Cooling fan No.2: 7
Outer diameter (mm {in}) 300 {11.8}
FUEL SYSTEM
Injector Type Multiple hole design Type of fuel delivery Top-feed
Type of drive Electronic
Pressure regulator control pressure (kPa {kgf/cm2, psi}) Approx. 390 {3.98, 56.6}
Fuel pump type Electric
Fuel tank capacity (approx.
quantity) (L {US gal, lmp gal}) 60 {15.9, 13.2}
Fuel type Unleaded premium (unleaded high-octane) gasoline
EMISSION SYSTEM
AIR system Air pump, air control valve
Catalyst type Three-way catalyst (monolithic)
EVAP control system Canister design
Item Specifications
13B-MSP
(Standard power) 13B-MSP (High power)

OUTLINE
01–00–4
2004 Mazda RX-8 Service Highlights (3378-1U-03C)
Revised 3/2004 (Ref. No. R014/04)
*1 : MT
*2 : AT
*3 : Cold area
*4 : Standard equipment
*5 : Hot type plug: Available only for customers who often drive their car at very low speed which causes the plugs
to foul easily.
End Of Sie
PCV system Closed design
CHARGING SYSTEM
Battery Voltage (V) 12
Type and capacity
(5 hour rate) (A·h) 50D20L (40)*1, 55D23L (48)*2
75D23L (52)*3, 75D26L (52)*3
Generator Out-put (V–A) 12—100 Regulated voltage (V) Controlled by PCM
Self diagnosis function
IGNITION SYSTEM
Ignition system
Type Distributorless ignition (DLI)
Spark advance Electric
Firing order When idling:T/F-L/F-T/R-L/R Except for idling: L/F-T/F-L/R-T/R
(Independent ignition control)
Spark plug Type NGK Leading side RE7A-L*4, (RE6A-L)*5
Trailing side RE9B-T*4
STARTING SYSTEM
Starter Type Coaxial reduction
Output (kW) AT: 1.8, MT: 1.4
CONTROL SYSTEM
Neutral switch (MT) ON/OFF
CPP switch (MT) ON/OFF
SSV switch ON/OFF
APV position sensor – Hall element
ECT sensor Thermistor
IAT sensor Thermistor
TP sensor Hall element
APP sensor Hall element
MAF sensor (Inside MAF) Hot-wire
Front HO2S Zirconia element (all range air/fuel ratio sensor)
Rear HO2S Zirconia element (Stoichiometric air/fuel ratio sensor)
BARO sensor Piezoelectric element
KS Piezoelectric element
Eccentric shaft position sensor Magnetic pickup
Metering oil pump switch ON/OFF
Brake switch ON/OFF
Throttle valve actuator DC motor
APV motor –DCmotor
Fuel injector (primary 1) Multiple hole type (12 holes)
Fuel injector (secondary) Multiple hole type (4 holes)
Fuel injector (primary 2) – Multiple hole type
(4 holes)
Stepping motor (in metering oil pump) Stepping motor
Item Specifications
13B-MSP
(Standard power) 13B-MSP (High power)

ON-BOARD DIAGNOSTIC
01–02–1
01–02
01–02 ON-BOARD DIAGNOSTIC
ON-BOARD DIAGNOSTIC OUTLINE . . . 01–02–1
Features. . . . . . . . . . . . . . . . . . . . . . . . 01–02–1
Block Diagram . . . . . . . . . . . . . . . . . . . 01–02–1
DIAGNOSTIC TEST MODE. . . . . . . . . . . 01–02–2
Sending Diagnostic Data . . . . . . . . . . . 01–02–2
Sending Freeze Frame Data . . . . . . . . 01–02–3
Sending Emission-related
Malfunction Code . . . . . . . . . . . . . . . . 01–02–4
Sending Intermittent Monitoring System
Test Results . . . . . . . . . . . . . . . . . . . . 01–02–6
Sending Continuous Monitoring System
Test Results . . . . . . . . . . . . . . . . . . . . 01–02–6
On-board Device Control . . . . . . . . . . . 01–02–7
DLC-2 Outline . . . . . . . . . . . . . . . . . . . . 01–02–7
DTC DETECTION LOGIC AND
CONDITIONS . . . . . . . . . . . . . . . . . . . . . 01–02–7
KOEO/KOER SELF-TEST . . . . . . . . . . . . 01–02–15
KOEO (Key ON, Engine Off)
Self-test . . . . . . . . . . . . . . . . . . . . . . . . 01–02–15
KOER (Key ON, Engine Running)
Self-test . . . . . . . . . . . . . . . . . . . . . . . . 01–02–15
PID/DATA MONITOR AND RECORD . . . 01–02–18
SIMULATION TEST . . . . . . . . . . . . . . . . . 01–02–20
End of Toc
ON-BOARD DIAGNOSTIC OUTLINE CHU010200102S01
Features
Block Diagram
End Of Sie
To meet the OBD-II regulations •Diagnostic test modes adopted
Improved serviceability •DTCs adopted
•KOEO/KOER self-test function adopted
•PID/DATA monitor function adopted
•Simulation test function adopted
INPUT DEVICE OUTPUT DEVICEENGINE CONTROL SYSTEM
FAIL-SAFE
FUNCTION
DETECTION
FUNCTION
PID DATA
MONITOR
FUNCTION
SIMULATION
TEST
FUNCTION
MEMORY
FUNCTION
MALFUNCTION
INDICATION
FUNCTION
TESTER
COMMUNICATION
FUNCTION
MIL
DLC-2
CAN
WDS OR
EQUIVALENT
OBD SYSTEM
PCM
CHU0102S001

ON-BOARD DIAGNOSTIC
01–02–2
DIAGNOSTIC TEST MODE CHU010200102S02
•To meet OBD-II regulations, the following diagnostic test modes have been adopted.
Sending Diagnostic Data
PID data monitor
•The PID data monitor items are shown below.
PID data monitor table
—: Not applicable
Diagnostic test mode Item
Mode 01 Sending diagnostic data (PID data monitor/On-board system readiness test)
Mode 02 Sending freeze frame data
Mode 03 Sending emission-related malfunction code (DTC)
Mode 04 Clearing/resetting emission-related malfunction information
Mode 06 Sending intermittent monitoring system test results (DMTR)
Mode 07 Sending continuous monitoring system test results (pending code)
Mode 08 On-board device control (simulation test, active command mode)
Mode 09 Request vehicle information
Full names Unit
Fuel system loop status Refer to list below.
LOAD %
ECT °C°F
Short term fuel trim %
Long term fuel trim %
Engine speed rpm
Vehicle speed km/h mph
Spark advance °
IAT °C°F
MAF g/s
Absolute TP %
AIR control status —
O2S location —
Input voltage from rear HO2S V
Target A/F fuel trim %
OBD requirement according to vehicle design —
Time since engine start s
Distance travelled while MIL is activated km miles
Purge solenoid valve control signal %
Fuel tank level %
Number of warm-ups since DTCs cleared —
Distance travelled since DTCs cleared km miles
BARO kPa
Lambda —
Front HO2S output current mA
Estimated catalyst converter temperature °C°F
PCM power supply voltage V
Absolute load value %
Relative TP %
TP from TP sensor No.2 %
APP from APP sensor No.1 %
APP from APP sensor No.2 %
Throttle actuator control signal %

ON-BOARD DIAGNOSTIC
01–02–3
01–02
Meaning of fuel system loop status
•The following information is displayed on the tester.
—Feedback operating: HO2S being used for feedback is normal.
—Feedback stops: ECT is lower than the determined feedback zone.
—Feedback stops: Open loop due to driving condition.
—Feedback stops: Open loop due to detected system fault.
On-board system readiness test
•The items supported by the on-board system readiness test are shown below.
Continuous monitoring system
—HO2S heater
—Thermostat
—Fuel system
—Misfire
—CCM
Intermittent monitoring system
—HO2S
—AIR system
—Catalyst
—EVAP system
Sending Freeze Frame Data
•The Freeze Frame Data monitor items are shown below.
Freeze Frame Data monitor table
—: Not applicable
Full names Unit
DTC that caused required Freeze Frame Data storage —
Fuel system loop status Refer to list below.
LOAD %
ECT °C°F
Short term fuel trim %
Long term fuel trim %
Engine speed rpm
Vehicle speed km/h mph
Spark advance °
IAT °C°F
MAF g/s
Absolute TP %
AIR control status —
Time since engine start s
Purge solenoid valve control signal %
Fuel tank level %
Number of warm-ups since DTCs cleared —
Distance travelled since DTCs cleared km miles
BARO kPa
Estimated catalyst converter temperature °C°F
PCM power supply voltage V
Lambda —
Absolute load value %
Relative TP %
TP from TP sensor No.2 %
APP from APP sensor No.1 %
APP from APP sensor No.2 %
Throttle actuator control signal %

ON-BOARD DIAGNOSTIC
01–02–4
Meaning of fuel system loop status
•The following information is displayed on the tester.
—Feedback operating: HO2S being used for feedback is normal.
—Feedback stops: ECT is lower than the determined feedback zone.
—Feedback stops: Open loop due to driving condition.
—Feedback stops: Open loop due to detected system fault.
Sending Emission-related Malfunction Code
•The DTCs are shown below.
DTC table
×: Applicable
—: Not applicable
DTC No. Condition MIL DC Monitor item*Memory
function
P0030 Front HO2S heater control circuit problem ON 2 HO2S heater ×
P0031 Front HO2S heater control circuit low ON 2 HO2S heater ×
P0032 Front HO2S heater control circuit high ON 2 HO2S heater ×
P0037 Rear HO2S heater control circuit low ON 2 HO2S heater ×
P0038 Rear HO2S heater control circuit high ON 2 HO2S heater ×
P0076 VDI solenoid valve control circuit low OFF 2 CCM ×
P0077 VDI solenoid valve control circuit high OFF 2 CCM ×
P0101 MAF sensor circuit range/performance problem ON 2 CCM ×
P0102 MAF sensor circuit low input ON 1 CCM ×
P0103 MAF sensor circuit high input ON 1 CCM ×
P0107 BARO sensor circuit low input ON 1 CCM ×
P0108 BARO sensor circuit high input ON 1 CCM ×
P0111 IAT sensor circuit range/performance problem ON 2 CCM ×
P0112 IAT sensor circuit low input ON 1 CCM ×
P0113 IAT sensor circuit high input ON 1 CCM ×
P0117 ECT sensor circuit low input ON 1 CCM ×
P0118 ECT sensor circuit high input ON 1 CCM ×
P0122 TP sensor No.1 circuit low input ON 1 CCM ×
P0123 TP sensor No.1 circuit high input ON 1 CCM ×
P0125 Insufficient coolant temperature for closed loop fuel control ON 2 CCM ×
P0126 Insufficient coolant temperature for stable operation ON 2 Thermostat ×
P0128 Coolant thermostat problem ON 2 Thermostat ×
P0130 Front HO2S circuit problem ON 2 HO2S ×
P0131 Front HO2S circuit low voltage ON 2 HO2S ×
P0132 Front HO2S circuit high voltage ON 2 HO2S ×
P0133 Front HO2S circuit slow response ON 2 HO2S ×
P0138 Rear HO2S circuit high voltage ON 2 HO2S ×
P0139 Rear HO2S circuit slow response ON 2 HO2S ×
P0171 System too lean ON 2 Fuel system ×
P0172 System too rich ON 2 Fuel system ×
P0222 TP sensor No.2 circuit low input ON 1 CCM ×
P0223 TP sensor No.2 circuit high input ON 1 CCM ×
P0300 Random misfire detected Flash/ON 1 or 2 Misfire ×
P0301 Front rotor misfire detected Flash/ON 1 or 2 Misfire ×
P0302 Rear rotor misfire detected Flash/ON 1 or 2 Misfire ×
P0327 KS circuit low input ON 1 CCM ×
P0328 KS circuit high input ON 1 CCM ×
P0335 Eccentric shaft position sensor circuit problem ON 1 CCM ×
P0336 Eccentric shaft position sensor circuit range/performance
problem ON 1 CCM ×
P0410 AIR system problem ON 2 AIR system ×
P0420 Catalyst system efficiency below threshold ON 2 Catalyst ×
P0441 EVAP system incorrect purge flow ON 2 EVAP system ×

ON-BOARD DIAGNOSTIC
01–02–5
01–02
P0442 EVAP system leak detected (small leak) ON 2 EVAP system ×
P0443 Purge solenoid valve circuit problem ON 2 CCM ×
P0446 EVAP system vent control circuit problem ON 2 EVAP system ×
P0455 EVAP system leak detected (large leak) ON 2 EVAP system ×
P0456 EVAP system leak detected (very small leak) ON 2 EVAP system ×
P0461 Fuel gauge sender unit circuit range/performance problem ON 2 CCM ×
P0462 Fuel gauge sender unit circuit low input ON 2 CCM ×
P0463 Fuel gauge sender unit circuit high input ON 2 CCM ×
P0480 Cooling fan No.1 control circuit problem OFF 2 Other ×
P0481 Cooling fan No.2 control circuit problem OFF 2 Other ×
P0500 VSS circuit problem ON 2 CCM ×
P0505 Idle air control system problem OFF ———
P0506 Idle air control system RPM lower than expected ON 2 CCM ×
P0507 Idle air control system RPM higher than expected ON 2 CCM ×
P0562 System voltage low (KAM) ON 1 CCM ×
P0564 Cruise control switch input circuit problem OFF 1 Other ×
P0571 Brake switch input circuit problem OFF 1 Other ×
P0601 PCM memory check sum error ON 1 CCM ×
P0602 PCM programming error ON 1 CCM ×
P0604 PCM random access memory error ON 1 CCM ×
P0610 PCM vehicle options error ON 1 CCM ×
P0638 Throttle actuator control circuit range/performance problem ON 1 CCM ×
P0661 SSV solenoid valve control circuit low ON 2 CCM ×
P0662 SSV solenoid valve control circuit high ON 2 CCM ×
P0703 Brake switch No.1 input circuit problem ON 2 CCM ×
P0704 CPP switch input circuit problem ON 2 CCM ×
P0850 Neutral switch input circuit problem ON 2 CCM ×
P1260 Immobilizer system problem OFF 1 Other —
P1574 TP sensor output incongruent ON 1 CCM ×
P1577 APP sensor output incongruent ON 1 CCM ×
P1686 Metering oil pump control circuit low flow side problem ON 1 Other ×
P1687 Metering oil pump control circuit high flow side problem ON 1 Other ×
P1688 Metering oil pump control circuit initial check problem ON 1 Other ×
P2004 APV stuck open ON 2 CCM ×
P2006 APV motor control circuit IC problem ON 2 CCM ×
P2008 APV motor control circuit/open ON 2 CCM ×
P2017 APV position sensor circuit problem ON 2 CCM ×
P2070 SSV stuck open ON 2 CCM ×
P2096 Target A/F feedback system too lean ON 2 Fuel system ×
P2097 Target A/F feedback system too rich ON 2 Fuel system ×
P2101 Drive-by-wire relay control circuit problem ON 1 CCM ×
P2106 Throttle actuator control system-forced limited power ON 1 CCM ×
P2107 Throttle actuator control module processor error ON 1 CCM ×
P2108 Throttle actuator control module performance error ON 1 CCM ×
P2109 TP sensor minimum stop range/performance problem ON 1 CCM ×
P2112 Throttle actuator control system range/performance problem ON 1 CCM ×
P2119 Throttle actuator control throttle body range/performance
problem ON 2 CCM ×
P2122 APP sensor No.1 circuit low input ON 1 CCM ×
P2123 APP sensor No.1 circuit high input ON 1 CCM ×
P2127 APP sensor No.2 circuit low input ON 1 CCM ×
P2128 APP sensor No.2 circuit high input ON 1 CCM ×
P2135 TP sensor No.1/No.2 voltage correlation problem ON 1 CCM ×
DTC No. Condition MIL DC Monitor item*Memory
function