Mazda 2007 CX-7 Instruction 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
ALPHABETICAL INDEX AI
CONTENTS
2007
Mazda
CX-7
Workshop
Manual
FOREWORD
This manual contains on-vehicle service
and/or diagnosis procedures for the Mazda
CX-7.
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.
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.
©2006 Mazda Motor Corporation
PRINTED IN U.S.A., FEBRUARY 2006
Form No. 1871–1U–06B
Part No. 9999–95–034B–07
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VEHICLE IDENTIFICATION NUMBERS (VIN)
JM3 ER29L✻7# 100001—
JM3 ER293✻7# 100001—
RELATED MATERIALS
Material Name MNAO Part No.Mazda Material No.
Mazda CX-7 2007 Service Highlights 9999–95–045F–07 3416–1U–06B
Engine Workshop Manual L3 WITH TC 9999–95–0L3T–06 1833–1U–05H
Automatic Transaxle and Transfer Workshop Manual
AW6A-EL AW6AX-EL 9999–95–0AW6–07 1874–1U–06B
Mazda CX-7 Bodyshop Manual 9999–95–093F–07 3419–1U–06C
Mazda CX-7 2007 Wiring Diagram 9999–95–068G–07 5666–1U–06B
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00
GENERAL INFORMATION
00-00–1
SECTION
00-00
Toc of S CT
GENERAL INFORMATION . . . . 00-00
Toc of S CT
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION
NUMBER (VIN) CODE . . . . . . . . . . . . . . 00-00–2
VEHICLE IDENTIFICATION
NUMBER (VIN) . . . . . . . . . . . . . . . . . . . 00-00–2
HOW TO USE THIS MANUAL . . . . . . . . . 00-00–3
Range of Topics . . . . . . . . . . . . . . . . . . 00-00–3
Service Procedure . . . . . . . . . . . . . . . . 00-00–3
Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5
Advisory Messages. . . . . . . . . . . . . . . . 00-00–5
Troubleshooting Procedure . . . . . . . . . . 00-00–6
Procedures for Use . . . . . . . . . . . . . . . . 00-00–7
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–12
Conversion to SI Units
(Système International d'Unités) . . . . . 00-00–12
Rounding Off. . . . . . . . . . . . . . . . . . . . . 00-00–12
Upper and Lower Limits . . . . . . . . . . . . 00-00–12
SERVICE CAUTIONS . . . . . . . . . . . . . . . . 00-00–13
Protection of the Vehicle . . . . . . . . . . . . 00-00–13
Preparation of Tools and
Measuring Equipment . . . . . . . . . . . . . 00-00–13
Special Service Tools . . . . . . . . . . . . . . 00-00–13
Malfunction Diagnosis System . . . . . . . 00-00–13
Disconnection of the Negative
Battery Cable . . . . . . . . . . . . . . . . . . . 00-00–13
Oil Leakage Inspection . . . . . . . . . . . . . 00-00–14
Removal of Parts. . . . . . . . . . . . . . . . . . 00-00–14
Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–15
Inspection During Removal,
Disassembly . . . . . . . . . . . . . . . . . . . . 00-00–15
Arrangement of Parts . . . . . . . . . . . . . . 00-00–15
Cleaning of Parts. . . . . . . . . . . . . . . . . . 00-00–15
Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–16
Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–16
Rubber Parts and Tubing . . . . . . . . . . . 00-00–16
Hose Clamps. . . . . . . . . . . . . . . . . . . . . 00-00–17
Torque Formulas . . . . . . . . . . . . . . . . . . 00-00–17
Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–17
Dynamometer . . . . . . . . . . . . . . . . . . . . 00-00–17
AWD inspection/service . . . . . . . . . . . . 00-00–18
SST . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–19
INSTALLATION OF
RADIO SYSTEM . . . . . . . . . . . . . . . . . . 00-00–20
ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00-00–20
Electrical Parts . . . . . . . . . . . . . . . . . . . 00-00–20
Wiring Harness. . . . . . . . . . . . . . . . . . . 00-00–20
Connectors. . . . . . . . . . . . . . . . . . . . . . 00-00–21
Te r mi na ls . . . . . . . . . . . . . . . . . . . . . . . 00-00–22
Sensors, Switches, and Relays . . . . . . 00-00–23
Wiring Harness. . . . . . . . . . . . . . . . . . . 00-00–23
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–24
Viewing orientation for
Connectors. . . . . . . . . . . . . . . . . . . . . 00-00–24
Electrical Troubleshooting Tools . . . . . . 00-00–25
Precautions Before Welding. . . . . . . . . 00-00–26
JACKING POSITIONS, VEHICLE LIFT
(2 SUPPORTS) AND SAFETY STAND
(RIGID RACK) POSITIONS . . . . . . . . . 00-00–27
Jacking Positions . . . . . . . . . . . . . . . . . 00-00–27
Vehicle Lift Positions. . . . . . . . . . . . . . . 00-00–28
Safety Stand Positions . . . . . . . . . . . . . 00-00–28
TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–29
Towing a 2WD Vehicle . . . . . . . . . . . . . 00-00–29
Towing a AWD Vehicle . . . . . . . . . . . . . 00-00–30
Towing/Tiedown Hooks . . . . . . . . . . . . 00-00–30
TIEDOWN HOOK. . . . . . . . . . . . . . . . . . . 00-00–31
IDENTIFICATION NUMBER
LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–32
Vehicle Identification
Number (VIN) . . . . . . . . . . . . . . . . . . . 00-00–32
Engine Identification Number . . . . . . . . 00-00–32
SAE STANDARDS. . . . . . . . . . . . . . . . . . 00-00–33
ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00-00–34
PRE-DELIVERY INSPECTION . . . . . . . . 00-00–35
Pre-Delivery Inspection Table. . . . . . . . 00-00–35
SCHEDULED MAINTENANCE . . . . . . . . 00-00–37
Scheduled Maintenance Table for U.S.A.,
CANADA and Puerto Rico . . . . . . . . . 00-00–37
End of Toc
NG: GENERAL INFORMATION
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GENERAL INFORMATION
00-00–2
VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000100200
End Of Sie
VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300
JM3 ER29L*7# 100001—
JM3 ER293*7# 100001—
End Of Sie
WM: GENERAL INFORMATION
J M 3 E R 2 9 3 * 7 # 1 2 3 4 5 6
Model year
Plant
Serial No.
0= Hiroshima
1= Hofu
7= 2007
Engine
Body, Gross vehicle weight class
9= Wagon, Gross vehicle weight class C
(1814—2267 kg)
Carline, Series ER= Mazda CX-7
JM3= Mazda/Multi-purpose vehicle category/U.S.A.
World manufacturer identification
Check digit *= 0 to 9, X
L= 2.3 L (California (L3 WITH TC))
3= 2.3 L (Federal/CANADA (L3 WITH TC))
Resraint system 2= with Curtain and Side air bags
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GENERAL INFORMATION
00-00–3
00-00
HOW TO USE THIS MANUAL id000000800100
Range of Topics
•This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
—Removal/Installation
—Disassembly/Assembly
—Replacement
—Inspection
—Adjustment
•Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
•Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.
49 H002 671
49 H032 322
49 1232 670A
SHOWS PROCEDURE ORDER
FOR SERVICE
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
Tightening torque
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Caution
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}
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GENERAL INFORMATION
00-00–4
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
GREASE
GREASE
GREASE
GREASE
INDICATES RELEVANT
REFERENCES THAT NEED
TO BE FOLLOWED DURING
INSTALLATION
SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS PROCEDURE ORDER
FOR SERVICE
SHOWS APPLICATION
POINTS OF GREASE, ETC.
SHOWS EXPENDABLE PARTS
SHOWS DETAILS
SHOWS TIGHTENING
TORQUE UNITS
KNUCKLE
UPPER TRAILING LINK
LOWER TRAILING LINK
SST
SST
SST
SST
R
R
R
R
9
2
1
4
5
3
6
1
2
8
7
12
10
11
N·m {kgf·m, ft·lbf}
118—156 {12.0—16.0, 87—115}
94—116 {9.5—11.9, 69—86}
44—60 {4.4—6.2, 32—44}
43—56 {4.3—5.8, 32—41}
49 T028 304
49 T028 305
49 T028 303
Procedure
"Removal/Installation"
Portion
"Inspection After
Installation" Portion
INSTALL THE PARTS BY
PERFORMING STEPS
1 3 IN REVERSE ORDER
SHOWS REFERRAL
NOTES FOR SERVICE
SHOWS REFERRAL
NOTES FOR
SERVICE
LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the undercover. (See 01-10-4 Undercover Removal)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment and adjust it if necessary.
SHOWS SERVICE
ITEM (S)
1Split pin
2Nut
3Lower trailing link ball joint
4
(See 02-14-5 Lower Trailing Link Ball Joint Removal Note)
Bolt
5Lower trailing link
6Dust boot (lower trailing link)
7Split pin
8Nut
9 Upper trailing link ball joint
(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
10 Nut
11 Upper trailing link
12 Dust boot (upper trailing link)
Lower Trailing Link Ball Joint, Upper Trailing Link
Ball Joint Removal Note
Remove the ball joint using the SSTs.
—
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GENERAL INFORMATION
00-00–5
00-00
Symbols
•There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. use. These
symbols show application points or use of these materials during service.
Advisory Messages
•You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
•A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
•A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
•A Note provides added information that will help you to complete a particular procedure.
Specification
•The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits
•The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
Symbol Meaning Kind
Apply oil
New appropriate
engine oil or gear
oil
Apply brake fluid New appropriate
brake fluid
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
Apply grease Appropriate
grease
Apply sealant Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part O-ring, gasket,
etc.
Use SST or
equivalent Appropriate tools
OIL
BRAKE
FLUID
A
A
TF
TF
GREASE
GREASE
SEALANT
P
R
SST
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GENERAL INFORMATION
00-00–6
Troubleshooting Procedure
Basic flow of troubleshooting
DTC troubleshooting flow (on-board diagnostic)
•Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate.
Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
•The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a
malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic
function.
Diagnostic index
•The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely
relating to the malfunction.
Quick diagnosis chart (If mentioned)
•The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the
cause of the malfunction.
Symptom troubleshooting
•Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
CUSTOMER ARRIVES
DTC TABLE
DTC
NO WARNING LIGHT*
WITH SYMPTOM
CHECK DTC
IGNITION ON TEST, IDLING
TEST
WITHOUT DTC
DIAGNOSE BY SYMPTOM
(SYMPTOM TROUBLESHOOTING)
1. DIAGNOSTIC INDEX
2. QUICK DIAGNOSIS CHART
(IF MENTIONED)
3. SYMPTOM
TROUBLESHOOTING
*: INDICATOR LIGHTS AND WARNING
LIGHTS THAT INDICATE MALFUNCTIONS
DTC
TROUBLESHOOTING
FLOW
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC)
WARNING LIGHT*
ON/FLASHING
CHECK FOR
PRIORITIZED DTC
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GENERAL INFORMATION
00-00–7
00-00
Procedures for Use
Using the basic inspection (section 05)
•Perform the basic inspection procedure before symptom troubleshooting.
•Perform each step in the order shown.
•The reference column lists the location of the detailed procedure for each basic inspection.
•Although inspections and adjustments are performed according to the reference column procedures, if the
cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
action column.
BASIC INSPECTION
STEP INSPECTION ACTION
1
2
3
4
5Perform the stall test.
(See 05-13-4 Stall Speed Test.)
Is the stall speed normal?
Ye s
Ye s
Ye s
Ye s
Ye s
No
No
No
No
No
Go to the next step.
Go to next step.
Go to the next step.
Go to the next step.
Go to the next step.
REFERENCE
COLUMN
SHOWS INSPECTION
ORDER SHOWS ITEM NAMES FOR
DETAILED PROCEDURES
SHOW POINTS REQUIRING
ATTENTION BASED ON
INSPECTION RESULTS
Repair or replace any malfunctioning parts according to
the inspection result.
Repair or replace any malfunctioning parts according to
the inspection result.
Flush ATX and cooler line as necessary.
Repair or replace any malfunctioning parts according to
the inspection result.
Repair or replace any malfunctioning parts according to
the inspection result.
Perform the mechanical system test.
(See 05-13-3 MECHANICAL SYSTEM TEST.)
Is mechanical system normal?
Inspect the ATF color condition.
(See 05-13-8 AUTOMATIC TRANSMISSION
FLUID (ATF) INSPECTION.)
Are ATF color and odor normal?
Perform the line pressure test.
(See 05-13-3 Line Pressure Test.)
Is the line pressure normal?
Turn the ignition switch to the ON position.
When the selector lever is moved, does the selector
illumination indicate synchronized position to the
lever location? Also, when other ranges are selected
from N or P during idling, does the vehicle move
within 1—2 s?
Inspect the selector lever and TR switch. Repair or
replace malfunctioning parts.
(See 05-14-5 SELECTOR LEVER INSPECTION.)
(See 05-13-10 TRANSMISSION RANGE (TR) SWITCH
INSPECTION.)
If the selector lever and TR switch are normal, go to the
next step.
Inspect the voltage at the following TCM terminals.
(See 05-13-29 TCM INSPECTION.)
Terminal 2J (TFT sensor)
Terminals 1D, 2B, 2C, 2E (TR switch)
Terminal 2G (turbine sensor)
Terminal 2D (down switch)
Terminal 2I (up switch)
Terminal 1E (M range switch)
Terminal 1W (steering shift switch)
Is the voltage normal?
Ye s
No
Go to the next step.
Repair or replace any malfunctioning parts according to
the inspection result.
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GENERAL INFORMATION
00-00–8
Using the DTC troubleshooting flow
•DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each
DTC.
B
E
D36
88
4
4
47
56
6
POSSIBLE
CAUSE
1
2
4
3
ABCDE
1P
DTC P0103
DTC PO103
DETECTION
CONDITION
MAF sensor malfunction
Connector or terminal malfunction
Open circuit in wiring between MAF sensor terminal D and PCM terminal 36
Open circuit in MAF sensor ground circuit
PCM
MAF SENSOR
MAF SENSOR
HARNESS SIDE CONNECTOR
PCM
HARNESS SIDE CONNECTOR
Diagnostic procedure
STEP INSPECTION
Has FREEZE FRAME DATA been recorded?
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
Connect diagnostic tool to DLC-2.
Start engine.
Access MAF V PID using diagnostic tool.
Is MAF V PID within 0.2 - 8.3 V?
Turn ignition key to OFF.
Disconnect MAF sensor connector.
Are there any malfunctions?
ACTION
Go to next step.
Ye s
No
Ye s
No
Ye s
No
Ye s
If vehicle is not repaired, then go to next step.
Go to next step.
Go to next step.
Repair or replace terminals, then go to Step 8.
POSSIBLE
CAUSE
describes
possible
point(s) of
malfunction
Indicates the
inspection step
No. to be
performed
(01 and 05
section)
STEP shows
the order of
troubleshooting
INSPECTION
describes the
method to
quickly
determine the
malfunctioning
part(s).
Reference
item(s) to
perform
ACTION.
ACTION
describes the
appropriate
action to be taken
according to
the result
(Yes/No) of the
INSPECTION.
Indicates the
connector
related to the
inspection
Indicates the
circuit to be
inspected
(01 and 05
section)
DETECTION CONDITION
describes the condition
under which the DTC is
detected.
Check for poor connection (damaged, pulled-
out terminals, corrosion etc.).
INSPECT POOR CONNECTION OF MAF
SENSOR CONNECTOR
VERIFY CURRENT INPUT SIGNAL STATUS IS
CONCERN INTERMITTENT OR CONSTANT
Are related Service Bulletins and/or on-line
repair information available?
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED Record FREEZE FRAME DATA on repair order, then go
to next step.
Perform repair or diagnosis according to available repair
information.
Intermittent concern is existing. Go to INTERMITTENT
CONCERNS TROUBLESHOOTING procedure.
(See 01-03-33 INTERMITTENT CONCERN
TROUBLESHOOTING)
FROM
MAIN RELAY
TERMINAL D
MIL illuminates if PCM detects the above malfunction during first drive cycle. Therefore,
PENDING CODE is not available.
FREEZE FRAME DATE is available.
DTC is stored in the PCM memory.
This is a continuous monitor (CCM).
Diagnostic support note
PCM monitors input voltage from TP sensor after ignition key is turned on. If input voltage at PCM terminal 68 is
above 8.25 V, PCM determines that TP circuit has malfunction.
MAF circuit high input
TROUBLE CONDITION
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GENERAL INFORMATION
00-00–9
00-00
Using the diagnostic index
•Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting.
•The exact malfunction symptoms can be selected by following the index.
No. TROUBLESHOOTING ITEM DESCRIPTION Page
1 Melting of main or other fuses
MIL comes on (See 01-03-7 NO.2 MIL COMES ON)
(See 01-03-8 NO. 3 WILL NOT CRANK)
5 Engine stalls. After start/at idle
6 Cranks normally but will not start
7 Slow return to idle
8 Engine runs rough/rotling
9 Fast idle/runs on
10 Low idle/stalls during deceleration
2
Will not crank3
4Hard start/long crank/erratic start/erratic
crank
Starter cranks engine at normal
speed but engine requires excessive
cranking time before starting.
Engine stops unexpectedly at idle
and/or after start.
(See 01-03-6 MELT NO.1 MAIN OR
OTHER FUSE)
(See 01-03-9 NO. 4 HARD START/
LONG CRANK/ERRATIC CRANK)
(See 01-03-11 NO. 5 ENGINE-STALLS
AFTER START/AT IDLE)
(See 01-03-15 NO.6 CRANKS
NORMALLY BUT WILL NOT START)
(See 01-03-19 NO. 7 SLOW RERUN
TO IDLE)
(See 01-03-20 NO. 8 ENGINE RUNS
ROUGH/ROLLING IDLE )
(See 01-03-23 NO. 9 FAST IDLE/RUNS
ON)
(See 01-03-24 NO. 10 LOW IDLE/
STALLS DURING DECELERATION)
Starter cranks engine at normal
speed but engine will not run.
Engine takes more time than normal
to return to idle speed.
Engine speed fluctuates between
specified idle speed and lower
speed and engine shakes
excessively.
Engine speed continues at fast idle
after warm-up.
Engine runs after ignition key is
turned to OFF.
Engine stops unexpectedly at begin-
ning of deceleration or recovery
from deceleration.
MIL is illuminated incorrectly.
Starter does not work.
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GENERAL INFORMATION
00-00–10
Using the quick diagnosis chart
•The chart lists the relation between the symptom and the cause of the malfunction.
•The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It
also specifies a range of common causes when multiple malfunction symptoms occur.
•The appropriate diagnostic inspection relating to a malfunction cause as specified by the symptoms can be
selected by looking down the diagnostic inspection column of the chart.
XX XX
XXX
XX
XX
XX
XX
XX
XX
XX
XX
X
X
X
XX
X
X
X
XXX X
X
XXX
X
XX
X
XX
XX
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
XX
X
XX
X
X
X
X
X
X
XX
Troubleshooting item
1Melts of main or other fuse
2
Will not crank
Hard to start/long crank/erratic start/erratic
crank
4
Cranks normally but will not start
5Engine stalls After start/at idle
6
Slow return to idle
7
Engine runs rough/rolling idle
8
9
Engine stalls/quits Acceleration/cruise
Acceleration/cruise
Acceleration/cruise
Acceleration
Acceleration/cruise
Acceleration/cruise
Acceleration/cruise
Engine runs rough
Acceleration/cruise/
deceleration
Misses
Buck/jerk
Hesitation/stumble
Surges
Lack/loss of power
10
11
Poor fuel economy
12
High oil consumption/leakage
13
Cooling system concerns
Cooling system concerns
Overheating
Runs cold
14
15
16
Engine noise
17
Vibration concerns (engine)
18
A/C always on/ A/C compressor runs
continuously
A/C does not work sufficiently
19
20
Intermittent concerns
21
Constant voltage
22
Possible factor
MIL comes on
3
Fast idle/runs on
Low idle/stalls during deceleration
Knocking/pinging
Emissions compliance
Exhaust smoke
Fuel odor (in engine compartment)
23
24
25 A/C does not cut off under wide open throttle
conditions
26 Exhaust sulphur smell
27 Fuel refill concerns
28 Fuel filling shut off issues
29
30
31 Spark plug condition
32 Automatic transaxle
concerns
Upshift/downshift/
engagement (See 05-01 AUTOMATIC TRANSAXLE SYMPTOM TROUBLESOOTING)
Starter motor malfunction (Mechanical or electrical)
Starter circuit including ignition switch open
Improper engine oil level
Low or dead battery
Charging system malfunction
Improper engine compression
Improper valve timing
Hydrolocked engine
Improper engine oil viscosity
Improper dipstick
Base engine malfunction
Drive plate or flywheel seized
Improper tension or damaged drive belts Improper engine coolant level
Water and anti-freeze mixture improperly
Cooling system malfunction (Radiator, hoses, overflow system, thermostat, etc.)
Cooling fan system malfunction
Engine or transaxle mounts improperly installed
Cooling fan or condenser fan seat improperly
Accelerator cable free play mis-adjustment
Fuel quality
PARTS WHICH MAY BE THE
CAUSE OF PROBLEMS
SYMPTOM QUICK DIAGNOSTIC CHART
PART WHICH MAY BE
THE SYMPTOM
CHOOSE THE
ACTUALSYMPTOM
1
2
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GENERAL INFORMATION
00-00–11
00-00
Using the symptom troubleshooting
•Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for
each trouble symptom.
End Of Sie
NG: GENERAL INFORMATION
TROUBLE SYMPTOM
14 Engine flares up or slips when upshifting or down shifting
DESCRIPTION
POSSIBLE
CAUSE
When accelerator is depressed while driving, engine speed increases but vehicle not.
There is clutch slip because clutch is stuck or line pressure is low.
Clutch stuck, slippage (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch 1, one-way clutch 2)
Line pressure low
Malfunction or mis-adjustment of TP sensor
Malfunction of VSS
Malfunction of input/turbine speed sensor
Malfunction of sensor ground
Malfunction of shift solenoid A, B or C
Malfunction of TCC solenoid valve
Malfunction of body ground
Malfunction of throttle cable
Malfunction of throttle valve body
Poor operating of mechanical pressure
Selector lever position disparity
TR switch position disparity
Note
Diagnostic procedure
STEP INSPECTION ACTION
Is line pressure okay? Ye s
Ye s
Ye s
2Is shift point okay?
(See 05-17-5 ROAD TEST)
3Stop engine and turn ignition switch on.
Is operating sound of shift solenoids heard?
Go to next step.
No
No
No
Go to next step
Go to symptom troubleshooting No.9 "Abnormal shift".
(See ATX Workshop Manual GF4A-EL (1666-1A-99F))
Inspect for shift solenoid mechanical stuck.
(See 05-17-14 Inspection of Operation)
4Verify test results.
If okay, return to diagnostic index to service any additional symptoms.
If vehicle is repaired, troubleshooting completed.
1
DESCRIPTION
describes what
kind of TROUBLE
SYMPTOM
POSSIBLE
CAUSE
describes
possible
point of
malfunction
STEP shows
the order of
troubleshooting.
Reference
item(s) for
additional
information
to perform
INSPECTION.
Reference
item(s) to
perform
ACTION.
How to
perform
ACTION is
described in
the relative
material
shown.
When accelerator pedal is depressed for driveway, engine speed increase but vehicle speed increase
slowly.
Before following troubleshooting steps, make sure that Automatic Transaxle On-board Diagnostic and
Automatic Transaxle Basic Inspection are conducted.
If vehicle is not repaired or additional diagnostic information is not available, replace or reprogram PCM.
If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or
diagnosis.
If shift solenoids are okay, inspect for open or short
circuit between PCM connector terminal A, B or C.
Inspect for bend, damage, corrosion or loose
connection if shift solenoid A, B, or C terminal on ATX.
(See 05-17-15 AUTOMATIC TRANSAXLE
REMOVEVAL/INSTALLATION)
If problem remains, replace or overhaul transaxle and
repair or replace defective parts.
Overhaul control valve body and repair or replace any
defective parts.
Repair or replace any defective parts according to
inspection results.
Simulate SHIFT A, SHIFT B and SHIFT C PIDs
for ON.
ACTION
describes the
appropriate
action to be
taken according
to the result
(Yes/No) of the
INSPECTION.
INSPECTION
describes the
method to
quickly
determine the
malfunctioning
part(s).
Connect diagnostic tool to DLC-2.
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GENERAL INFORMATION
00-00–12
UNITS id000000100400
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
WM: GENERAL INFORMATION
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)
Tor qu e
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)
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GENERAL INFORMATION
00-00–13
00-00
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
Revised 7/2006 (Ref. No. R065/06)
SERVICE CAUTIONS id000000800200
Injury/damage Prevention Precautions
•Depending on the vehicle, the cooling fan may operate suddenly even when the ignition switch is turned off.
Therefore, keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent
injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing
the cooling fan or parts near the cooling fan.
Protection of the Vehicle
•Always be sure to cover fenders, seats and floor
areas before starting work.
Preparation of Tools and Measuring Equipment
•Be sure that all necessary tools and measuring
equipment are available before starting any work.
Special Service Tools
•Use special service tools or the equivalent when
they are required.
Malfunction Diagnosis System
•Use the Mazda modular diagnostic system (M-MDS) for malfunction diagnosis.
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GENERAL INFORMATION
00-00–14
2007 Mazda CX-7 Workshop Manual (1871–1U–06B)
Disconnection of the Negative Battery Cable
•When working with the negative battery cable disconnected, wait for 1 min or more to allow the back up power
supply of the SAS control module to deplete its stored power after the cable is disconnected.
•Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is
necessary to note down the information stored in those memories before disconnecting the cable.
•If the battery had been disconnected during vehicle maintenance or for other reasons, the window will not fully
close automatically. Initialize the power window system for the power window main switch and the sub switch
(FR).
(See 09-12-13 POWER WINDOW INITIALIZATION PROCEDURE)
Warning
•When the negative battery cable is disconnected, the initialization setting of the steering angle
sensor is cleared. Therefore, perform the initialization procedure after connecting the negative
battery cable. (See 09-40-8 STEERING ANGLE SENSOR INITIALIZATION PROCEDURE.)
Oil Leakage Inspection
•Use either of the following procedures to identify the type of oil that is leaking:
Using UV light (black light)
1. Remove any oil on the engine or transaxle/transmission.
Note
•Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or
ATF (or transaxle/transmission oil).
2. Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission oil).
3. Allow the engine to run for 30 min.
4. Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs.
Note
•To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the
fluorescent dye instruction manual.
Not using UV light (black light)
1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle/transmission oil), both from the dipstick, and place them next
to the leaked oil already on the tissue.
3. Compare the appearance and smell, and identify
the type of oil that is leaking.
4. Remove any oil on the engine or transaxle/
transmission.
5. Allow the engine to run for 30 min.
6. Check the area where the oil is leaking, then
make necessary repairs.
Removal of Parts
•While correcting a problem, also try to determine
its cause. Begin work only after first learning
which parts and sub-components must be
removed and disassembled for replacement or
repair. After removing the part, plug all holes and
ports to prevent foreign material from entering.
ATF OR
TRANSAXLE/
TRANSMISSION OIL
LEAKED OIL
ENGINE OIL
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GENERAL INFORMATION
00-00–15
00-00
Disassembly
•If the disassembly procedure is complex,
requiring many parts to be disassembled, all parts
should be marked in a place that will not affect
their performance or external appearance, and
identified so that reassembly can be performed
easily and efficiently.
Inspection During Removal, Disassembly
•When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
Arrangement of Parts
•All disassembled parts should be carefully
arranged for reassembly.
•Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
Cleaning of Parts
•All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
Warning
•Using compressed air can cause dirt and
other particles to fly out causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
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GENERAL INFORMATION
00-00–16
Reassembly
•Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
•If removed, these parts should be replaced with
new ones:
—Oil seals
—Gaskets
—O-rings
—Lock washers
—Cotter pins
—Nylon nuts
•Depending on location:
—Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
—Oil should be applied to the moving
components of parts.
—Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
Adjustment
•Use suitable gauges and testers when making
adjustments.
Rubber Parts and Tubing
•Prevent gasoline or oil from getting on rubber
parts or tubing.
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GENERAL INFORMATION
00-00–17
00-00
Hose Clamps
•When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
Torque Formulas
•When using a torque wrench-SST or equivalent
combination, the specified torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
A : The length of the SST past the torque wrench drive.
L : The length of the torque wrench.
Vise
•When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
Dynamometer
•When inspecting and servicing the power train on the dynamometer or speedometer tester, pay attention to the
following:
—Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
—Make sure the vehicle is in a facility with an exhaust gas ventilation system.
—Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be
below70°C {158°F} degrees.)
—Keep the area around the vehicle uncluttered so that heat does not build up.
—Watch the water temperature gauge and do not overheat the engine.
—Avoid added load to the engine and maintain normal driving conditions as much as possible.
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Torque Unit Formula
N·m N·m ×[L/(L+A)]
kgf·m kgf·m ×[L/(L+A)]
kgf·cm kgf·cm ×[L/(L+A)]
ft·lbf ft·lbf ×[L/(L+A)]
in·lbf in·lbf ×[L/(L+A)]
0
1
1
2
2
3
3
SST
AL
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PROTECTIVE PLATES
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GENERAL INFORMATION
00-00–18
Note
•When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the DSC CM
determines that there is a malfunction in the DSC and illuminates the following lights:
—ABS warning light
—Brake system warning light
—DSC indicator light
•If the above lights are illuminated, dismount the vehicle from the chassis dynamometer and turn the
ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, run the vehicle
at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the
memory. Clear the DTC from the memory by following the memory clearing procedure [DSC] in the on-
board diagnostic system. (See04-02-3 ON-BOARD DIAGNOSIS.)
AWD inspection/service
Speedometer tester measurement
Caution
•Install the tension bar (chain wire) to the tie down hook and secure the vehicle to prevent it from
rolling and running off.
•Do not accelerate suddenly from a standstill or accelerate/decelerate rapidly.
Free roller type
1. Align the free rollers with the wheel base and tread, then set them on the floor properly.
2. Drive the vehicle slowly onto the tester roller and
free rollers.
3. Start the engine and accelerate gradually to
inspect the speedometer.
4. After inspection, decelerate gradually with gentle
braking.
Propeller shaft removal type
1. Remove the propeller shaft.
(See03-15-3 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
2. Place the front wheels on the tester roller.
3. Accelerate gradually and inspect the
speedometer.
4. After inspection, decelerate gradually with gentle
braking.
5. Install the propeller shaft.
(See03-15-3 PROPELLER SHAFT REMOVAL/
INSTALLATION.)
Brake tester measurement
1. Place the wheels (front or rear) to be measured
on the tester roller.
2. Shift to the N position/neutral.
3. Activate the tester roller and measure braking
force. If there is a large amount of brake drag
force, the electronic control system coupling may
be affected. Jack up all four wheels to eliminate
the effect of the coupling and rotate each wheel
by hand to verify the rotation condition.
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