Mazda 2009 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
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.
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.
There are explanation given only for the sections
marked with shadow ( ).
© 2008 Mazda Motor Corporation
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

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
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.
AT
MT
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
C2
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
C4
CLUTCH
C3
CLUTCH
C1
CLUTCH
B3
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
01
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