Mazda CX-9 Grand Touring 2007 User manual

2007 ENGINE PERFORMANCE
Intake-Air System (MZI-3.5) - CX-9
INTAKE-AIR SYSTEM LOCATION INDEX [MZI-3.5]
Fig. 1: Identifying Intake-Air System Components
INTAKE-AIR SYSTEM DIAGRAM [MZI-3.5]
2007 Mazda CX-9 Grand Touring
2007 ENGINE PERFORMANCE Intake-Air System (MZI-3.5) - CX-9
2007 Mazda CX-9 Grand Touring
2007 ENGINE PERFORMANCE Intake-Air System (MZI-3.5) - CX-9
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Fig. 2: Intake-Air System Diagram
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZI-3.5]
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Fig. 3: Intake-Air System Vacuum Hose Routing Diagram
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.5]
1. Complete the "BEFORE REPAIR PROCEDURE". (see BEFORE REPAIR PROCEDURE [MZI-
3.5] .)
2. Remove the batter
y
. (see BATTERY REMOVAL/INSTALLATION [MZI-3.5] .)
WARNING: When the engine and intake-air system are hot, they can badly burn.
Turn off the engine and wait until they are cool before removing the
intake-air system.
Fuel vapor is hazardous. It can easily ignite, causing serious injury
and damage. Always keep sparks and flames away from fuel.
Fuel line spills and leakage are dangerous. Fuel can ignite and cause
serious injuries or death and damage. Fuel can also irritate skin and
eyes. To prevent this, always complete the "Fuel Line Safety
Procedure".
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3. Remove the engine cover. (see ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5] .)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Complete the "AFTER REPAIR PROCEDURE". (see AFTER REPAIR PROCEDURE [MZI-3.5] .)
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Fig. 4: Identifying Intake-Air System Components With Torque Specifications
INTAKE MANIFOLD REMOVAL NOTE
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1. Drain the engine coolant. (see ENGINE COOLANT REPLACEMENT [MZI-3.5] .)
2. Disconnect the upper radiator hose.
Fig. 5: Identifying Intake Manifold Components
3. Disconnect the lower radiator hose.
4. Disconnect the two water hose from the thermostat component.
5. Disconnect the thermostat component side of the water inlet pipe which is under the intake manifold.
6. Remove the intake manifold and thermostat component as a single unit.
7. Remove the thermostat component from the intake manifold.
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Fig. 6: Identifying Thermostat Components With Torque Specifications
INTAKE MANIFOLD INSTALLATION NOTE
1. Tighten the intake manifold installation bolts in the order shown.
Intake manifold installation bolt tightening torque
8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
Fig. 7: Identifying Intake Manifold Bolt Tightening Sequence
DYNAMIC CHAMBER INSTALLATION NOTE
1. Tighten the dynamic chamber installation bolts in the order shown.
Dynamic chamber installation bolt tightening torque
8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
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Fig. 8: Identifying Dynamic Chamber Bolt Tightening Sequence
AIR CLEANER ELEMENT INSPECTION [MZI-3.5]
1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.5].)
2. Verify that the air cleaner element surface is free of dirt.
If there is dirt, use an air gun or similar tool to clean the element.
If the replacement time limit has passed, replace the element.
THROTTLE BODY INSPECTION [MZI-3.5]
RESISTANCE INSPECTION
1. Disconnect the negative battery cable. (see BATTERY REMOVAL/INSTALLATION [MZI-3.5] .)
2. Remove the engine cover. (see ENGINE COVER REMOVAL/INSTALLATION [MZI-3.5] .)
3. Disconnect the throttle body connector.
4. Measure the resistance between throttle body terminals A and B.
If not as specified, replace the throttle body. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.5].)
If as specified, carry out the "Circuit Open/Short Inspection".
Throttle body resistance
1-900 ohms
NOTE: Perform the following inspection only when directed.
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Fig. 9: Identifying Throttle Body Connector Terminals
CIRCUIT OPEN/SHORT INSPECTION
1. Disconnect the PCM connector.
2. Inspect the following wiring harnesses for open or short (continuity check).
Fig. 10: Identifying Throttle Body Connector Terminals
Fig. 11: Identifying PCM Connector Terminals
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Open circuit
If there is no continuity, the circuit is open. Repair or replace the wiring harness.
Throttle body terminal A and PCM terminal 2BO
Throttle body terminal B and PCM terminal 2BR
Short circuit
If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
Throttle body terminal A and power supply
Throttle body terminal A and ground
Throttle body terminal B and power supply
Throttle body terminal B and ground
ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZI-3.5]
1. Disconnect the negative battery cable. (see BATTERY REMOVAL/INSTALLATION [MZI-3.5] .)
2. Remove the dashboard under cover (Driver side). (see DASHBOARD UNDER COVER
REMOVAL/INSTALLATION .)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
Fig. 12: Identifying Accelerator Pedal And Electrical Connector With Torque Specifications
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2007 ELECTRICAL
Charging System (MZI-3.5) - CX-9
CHARGING SYSTEM LOCATION INDEX [MZI-3.5]
Fig. 1: Identifying Battery And Generator Location
Courtesy of MAZDA MOTORS CORP.
BATTERY REMOVAL/INSTALLATION [MZI-3.5]
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
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2007 ELECTRICAL Charging System (MZI-3.5) - CX-9
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Fig. 2: Identifying Battery Components With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
BATTERY BOX INSTALLATION NOTE
1. Install the battery box so that the side with the notch points toward the front fender (LH).
Fig. 3: Identifying Battery Box
Courtesy of MAZDA MOTORS CORP.
BATTERY INSPECTION [MZI-3.5]
WARNING: Since battery acid is toxic, be careful when handling the battery.
Since battery acid is highly corrosive, be careful not to allow it to
contact clothing or the vehicle.
In case battery acid contacts skin, eyes, or clothing, flush it
immediately with running water. Especially if the acid gets in the
eyes, flush with water for more than 15 min and get prompt medical
attention.
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ELECTROLYTE SPECIFIC GRAVITY
1. Measure the electrolyte specific gravity using a hydrometer.
If it is less than the specification, recharge the battery. (See BATTERY RECHARGING [MZI-
3.5].)
Battery electrolyte specific gravity [20 °C {68 °F}]
1.22-1.29
BATTERY VOLTAGE
1. Inspect the battery as follows:
DIAGNOSIS PROCEDURE
Battery load test current
80D26L (55): 195 A
Standard specification
BATTERY SPECIFICATION
BACK-UP CURRENT
1. Verif
y
that the i
g
nition switch is off (ke
y
has been removed) and that all doors are closed.
Step Inspection Action
1 Measure the battery positive voltage.
12.4 V or
more Go to Step 3.
Less than
12.4 V
Go to the
next step.
2 Quick charge for 30 min and recheck voltage.
12.4 V or
more
Go to the
next step.
Less than
12.4 V
Replace the
battery.
3Using the battery load tester, apply load current (80D26L (55): 195 A) and
record battery voltage after 15 s . Is voltage more than the specification?
Yes Normal
No Replace the
battery.
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6
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2. Disconnect the negative battery cable.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 30 min , and then measure the back-up current.
If not within the specification, measure the back-up current while removing the fuses one by one
from the inside of the main fuse block and the inside of the fuse block.
Battery back-up current
Vehicles with immobilizer system: 50-60 mA
Vehicles without immobilizer system: 55 mA or less
4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
BATTERY RECHARGING [MZI-3.5]
1. Remove the battery and then place it in a pan of water.
2. Remove the battery filler caps.
NOTE: If the battery is not left undisturbed for 30 min , the tester will indicate
a high value (approx. 300 mA ).
If the key or any electrical accessory is operated within approx. 30
min after the tester is connected, the battery must be left undisturbed
for approx. 30 min from that point.
CAUTION: Operating electrical loads while the back-up current is being
measured can damage the tester.
NOTE: For vehicles with the immobilizer system, the system periodically
shifts synchronization of the security light flashing. Therefore, 60 mA
(0.1 s) current is supplied when the security light is illuminated, and
50 mA (2 s) current is supplied when the security light is not
illuminated. In addition, the measuring instrument, which shows the
average value, indicates around 55 mA .
WARNING: Keep all flames away from the battery, otherwise evaporated gas
from the battery fluid may catch fire, and cause serious injury.
Remove the battery filler caps when recharging to prevent battery
deformation or damage.
CAUTION: Do not quick charge for more than 30 min. It will damage the battery.
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3. Connect a battery charger to the battery and adjust the charging current as follows.
Battery slow charge current
80D26L (55): 5.5-6.5 A
Battery quick charge current [30 min]
80D26L (55): 35 A
4. After the battery is recharged, verify that the voltage is within the specification and remains at the same
value for 1 h or more after the recharging has been completed.
If not within the specification, replace the battery.
Standard voltage
12.4 V or more
Fig. 4: Connecting Battery Charger To Battery
Courtesy of MAZDA MOTORS CORP.
GENERATOR REMOVAL/INSTALLATION [MZI-3.5]
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (see ENGINE COOLANT REPLACEMENT [MZI-3.5] .)
3. Remove the air cleaner and fresh air duct component. (see INTAKE-AIR SYSTEM
WARNING: Remove and install all parts when the engine is cold, otherwise they
can cause severe burns or serious injury.
When the battery cables are connected, touching the vehicle body
with generator terminal B will generate sparks. This can cause
personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the
following operation.
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REMOVAL/INSTALLATION [MZI-3.5] .)
4. Remove the cooling fan component. (see FAN MOTOR REMOVAL/INSTALLATION [MZI-3.5] .)
5. Remove the front splash shield (RH).
6. Remove the generator and A/C drive belt. (see DRIVE BELT REMOVAL/INSTALLATION [MZI-
3.5] .)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Refill the engine coolant. (see ENGINE COOLANT REPLACEMENT [MZI-3.5] .)
10. Inspect for engine coolant leakage. (see ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.5] .)
Fig. 5: Identifying Generator And Connector With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
GENERATOR LOWER BOLT REMOVAL NOTE
1. Fully loosen the generator lower bolt.
NOTE: The generator lower bolt cannot be fully removed from the engine because
it contacts the body frame. However, the generator can be
removed/installed without fully removing the lower bolt because there is a
notch at the lower bolt installation part of the generator.
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Fig. 6: Identifying Generator Lower Bolt
Courtesy of MAZDA MOTORS CORP.
GENERATOR REMOVAL NOTE
1. Remove the generator from above the engine compartment.
GENERATOR INSTALLATION NOTE
1. Tighten the upper and lower bolts temporarily.
2. Tighten the upper bolt to the specified tightening torque.
3. Tighten the lower bolt to the specified tightening torque.
GENERATOR INSPECTION [MZI-3.5]
GENERATOR WARNING LIGHT
1. Verify that the battery is fully charged.
2. Verify that the generator and A/C drive belt deflection/tension is correct. (see DRIVE BELT
INSPECTION [MZI-3.5] .)
3. With the ignition switch turned to the ON position, verify that the generator warning light illuminates.
If it does not illuminate, inspect the generator warning light and the wiring harness.
If the generator warning light and the wiring harness are normal, inspect the PCM.
4. Verify that the generator warning light goes out after the engine is started.
If it does not go out, inspect if any DTCs are displayed.
If any DTCs are displayed, carry out troubleshooting according to the corresponding DTC
inspection.
GENERATOR
Voltage
1. Verify that the battery is fully charged.
2. Verify that the generator and A/C drive belt deflection/tension is correct. (see DRIVE BELT
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INSPECTION [MZI-3.5] .)
3. Turn off all electrical loads.
4. Start the engine.
5. Verify that the generator rotates smoothly without any noise while the engine is running.
If there is any noise, find the cause and repair or replace the generator.
6. Measure the voltage at each terminal using a tester.
If it is not as specified, find the cause and repair or replace the applicable part.
Generator standard voltage [IG-ON]
Terminal B: B+
Terminal A: B+
Terminal RC: Approx. 1 V or less
Terminal LI: Approx. 1 V
Generator standard voltage [Idle, 20 °C {68 °F}]
Terminal B: 12-16 V
Terminal A: 12-16 V
Terminal RC: 0-16 V
Terminal LI: 1-16 V
Fig. 7: Identifying Generator Connector Terminals
Courtesy of MAZDA MOTORS CORP.
Current
NOTE: Since the charging current decreases rapidly after starting the engine,
carry out the following procedure quickly, and read the maximum current
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1. Verify that the battery is fully charged.
2. Verify that the generator and A/C drive belt deflection/tension is correct. (see DRIVE BELT
INSPECTION [MZI-3.5] .)
3. Disconnect the negative battery cable.
4. Connect a tester, which can read 120 A or more , between generator terminal B and the wiring harness.
5. Connect the negative battery cable.
6. Turn off all electrical loads.
7. Start the engine.
8. Increase engine speed to 2,500 rpm.
9. Turn the following electrical loads on and verify that the current reading increases more than the
minimum value indicated below.
Headlights (high-beam)
Blower motor (HI)
Rear window defroster
Brake lights
Generator generated current minimum value
70 % of the nominal output current (nominal output current: 110 A)
[Ambient temp. 20 °C {68 °F}, voltage 13.0-15.0 V, both engine and generator are hot]
GENERATOR INNER PARTS
Rotor
1. Measure the resistance between the slip rings using a tester.
If not within the specification, replace the rotor.
Generator rotor resistance (between slip rings) [20 °C {68 °F}]
value.
NOTE: When the electrical load on the vehicle is low, the specified current
cannot be verified although the generator is normal. In this case,
increase the electrical load (Leave the headlights turned on for a
while, then discharge the battery, or use a similar method.) and
recheck.
When the generator itself or the ambient temperature are too high,
the specified current also cannot be verified. In this case, cool down
the generator and recheck.
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1.8-2.2 ohm
Fig. 8: Measuring Resistance Between Slip Rings Using With Tester
Courtesy of MAZDA MOTORS CORP.
2. Verify that there is no continuity between the slip ring and core using a tester.
If there is continuity, replace the rotor.
3. Inspect the slip ring surface condition.
If the slip ring surface is rough, use a lathe or fine sandpaper to smooth it.
Fig. 9: Measuring Continuity Between Slip Ring And Core Using With Tester
Courtesy of MAZDA MOTORS CORP.
Stator coil
1. Verif
y
that the continuit
y
is as indicated in the table.
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