Mazda RX-8 Instruction manual

BODY (w)
LOCATION INDEX
1 Hood
2 Front bumper reinforcement
3 Front bumper
4 Front fender panel
5 Fuel-filler lid
6 Trunk lid
7 Rear bumper reinforcement
8 Rear bumper
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Page 1

HOOD
HOOD REMOVAL/INSTALLATION
WARNING:
•Removing the hood without proper support can be dangerous. The hood may fall and injure you. Always
perform the following procedure with at least another person.
1. Disconnect the negative battery cable.
2. To remove the hood hinge, remove the following parts:
a. Front side marker lights
b. Front bumper
c. Front combination lights
d. Front fender panel
3. Remove in the order indicated in the table.
1 Hood insulator
2 Shroud seal weatherstrip
3 Hood
4 Hood hinge
5 Hood stay
4. Install in the reverse order of removal.
5. Adjust the hood.
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Page 2

HOOD ADJUSTMENT
Gap Adjustment
1. Disconnect the negative battery cable.
2. Remove the following parts:
a. Front side marker lights
b. Front bumper
c. Front combination lights
d. Front fender panel
3. Loosen the hood hinge installation bolts and adjust the hood.
4. Tighten the bolts.
5. Verify that the gap between the hood and the body is within the specification.
Standard clearance
oa: 3.56.5 mm {0.140.25 in}
ob: 3.06.0 mm {0.120.23 in}
oc: 2.54.5 mm {0.100.17 in}
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Page 3

Height Difference Adjustment
1. Turn the stop rubber to adjust the height of the hood.
2. Verify that the height difference between the hood and the body is within the specification.
Standard clearance
oa: −1.81.2 mm {−0.070.04 in}
ob: −1.01.0 mm {−0.030.03 in}
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Page 4

TRUNK LID
TRUNK LID REMOVAL/INSTALLATION
WARNING:
•Removing the stay damper without supporting the trunk lid can be dangerous. The trunk lid may fall and
injure you. Be sure to open the trunk lid completely and support it securely before removing the stay
damper.
1. Disconnect the negative battery cable.
2. Disconnect the trunk lid wiring harness connector, then take the trunk lid harness out from the vehicle.
3. Remove the clips that secure the trunk lid wiring harness.
4. Pry off the stay damper band using a flathead screwdriver.
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Page 5

5. Pry out the connecting part of the stay damper and the hinge with a flathead screwdriver to disconnect
them, then remove the stay damper.
6. Remove nuts A, then remove the trunk lid.
7. Remove nuts B, then remove the trunk lid hinge.
8. Install in the reverse order of removal.
9. Adjust the trunk lid.
TRUNK LID ADJUSTMENT
1. Measure the gap and height difference between the trunk lid and the body.
2. Loosen the trunk lid hinge installation nuts or the trunk lid lock striker installation screws, and adjust the
trunk lid.
Standard clearance
oa: 2.54.5 mm {0.100.17 in}
ob: −1.01.0 mm {−0.030.03 in}
oc: 4.08.0 mm {0.160.31 in}
3. Tighten the bolts or screws.
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Page 6

STAY DAMPER DISPOSAL
NOTE:
•The gas in the stay damper is colorless, odorless, and non-toxic.
1. Wear protective eye wear.
2. Lay the stay damper flat.
3. Saw 2

3 mm {0.08

0.11 in} into the stay damper using a hacksaw, and allow the gas to escape from
the stay damper.
4. Verify that the gas has escaped from the stay damper.
5. Discard the stay damper.
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Page 7
Notes:

FUEL-FILLER LID
FUEL-FILLER LID REMOVAL/INSTALLATION
1. Remove the bolts.
2. Remove the fuel-filler lid.
3. Install in the reverse order of removal.
4. Adjust the fuel-filler lid.
FUEL-FILLER LID ADJUSTMENT
1. Measure the gap and height difference between the fuel-filler lid and the body.
2. Loosen the fuel-filler lid installation bolts, and adjust the fuel-filler lid.
Standard clearance
oa: 1.73.7 mm {0.070.14 in}
ob: −0.51.5 mm {−0.010.05 in}
oc: −1.01.0 mm {−0.030.03 in}
od: 1.83.8 mm {0.080.14 in}
oe: 1.73.7 mm {0.070.14 in}
of: −0.81.2 mm {−0.030.04 in}
3. Tighten the bolts.
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Page 8

BUMPER
FRONT BUMPER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the front fog light connectors for vehicles with front fog lights.
3. Remove the front side marker lights.
4. Remove in the order indicated in the table.
1 Fastener A
2 Seal plate
3 Screw A
4 Screw B
5 Fastener B
6 Bolt
7 Front bumper
5. Disconnect the headlight cleaner hose for vehicles with the headlight cleaner.
6. Install in the reverse order of removal.
7. Adjust the front fog light aiming for vehicles with the front fog lights.
Front Bumper Removal Note
1. Pull the front bumper ends (wheel arch) outward to detach from the bumper slider.
CAUTION:
•When detaching the front bumper from the bumper slider, the front bumper could fall and be
damaged. Secure the front bumper so that it does not fall.
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2. Remove the front bumper from the body.
Front Bumper Installation Note
1. Spread the front bumper ends apart.
2. Attach the front bumper to the body.
3. Press the front bumper connecting area into the body to engage with the bumper slider.
FRONT BUMPER DISASSEMBLY/ASSEMBLY
1. To disassemble the front bumper, remove the following parts:
a. Front fog lights (Vehicles with the front fog lights)
b. Headlight cleaner hose (Vehicles with the headlight cleaner)
c. Headlight cleaner nozzles (Vehicles with the headlight cleaner)
d. Headlight cleaner actuator (Vehicles with the headlight cleaner)
2. Disassemble in the order indicated in the table.
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1 Screw A
2 Airdam skirt
3 Bolt A
4 License plate holder
5 Fastener
6 Front bumper mesh
7 Bolt B
8 Set plate
9 Front bumper retainer No.1
10 Screw B
11 Screw C
12 Front fog light hole cover
13 Front bumper fascia
3. Assemble in the reverse order of disassembly.
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Page 11

REAR BUMPER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the trunk end trim.
3. Remove the trunk side trim.(
4. Remove the rear combination lights.
5. Remove the fasteners.
6. Pull the rear bumper guard outward, detach tabs A, and then remove the rear bumper guard.
7. Remove in the order indicated in the table.
1 Fastener A
2 Screw A
3 Fastener B
4 Fastener C
5 Screw B
6 Rear bumper
8. Install in the reverse order of removal.
Rear Bumper Removal Note
1. Pull the rear bumper ends (wheel arch) outward to detach from the bumper slider.
CAUTION:
•When detaching the rear bumper from the bumper slider, the rear bumper could fall and be
damaged. Secure the rear bumper so that it does not fall.
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Page 12

Rear bumper Installation Note
1. Spread the rear bumper ends (wheel arches) apart.
2. Attach the rear bumper to the body.
3. Press the rear bumper connecting area into the body to engage with the bumper slider.
FRONT BUMPER REINFORCEMENT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the front side marker lights.
3. Remove the front bumper.
4. Remove fasteners A, then remove the energy-absorbing foam.
5. Remove fasteners B, then remove front bumper retainer No.2.
6. Remove the bolts, then remove the front bumper reinforcement.
7. Install in the reverse order of removal.
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Page 13

REAR BUMPER REINFORCEMENT REMOVAL/INSTALLATION
1. Remove the following parts:
a. Trunk end trim
b. Trunk side trim
c. Rear combination lights
d. Rear bumper
2. Remove the fasteners, then remove the energy-absorbing foam.
3. Remove the nuts, then remove the rear bumper reinforcement.
4. Install in the reverse order of removal.
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Page 14

FRONT FENDER PANEL
FRONT FENDER PANEL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the front side marker lights.
3. Remove the front bumper.
4. Remove the front combination lights.
5. Remove in the order indicated in the table.
1 Fastener
2 Bolt A
3 Bolt B
4 Bolt C
5 Bolt D
6 Front fender panel
6. Install in the reverse order of removal.
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Page 15

SECURITY AND LOCKS
SECURITY AND LOCKS LOCATION INDEX
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Page 16

1
Keyless control module
(See KEYLESS CONTROL MODULE REMOVAL/INSTALLATION .)
(See KEYLESS CONTROL MODULE INSPECTION .)
2
Keyless receiver
(See KEYLESS RECEIVER REMOVAL/INSTALLATION .)
(See KEYLESS RECEIVER INSPECTION .)
3
Front inner handle
(See FRONT INNER HANDLE REMOVAL/INSTALLATION .)
4
Coil
(See COIL REMOVAL/INSTALLATION .)
5
Hood release lever
(See HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION .)
(See HOOD LATCH SWITCH INSPECTION .)
6
Trunk lid opener switch
(See TRUNK LID OPENER SWITCH REMOVAL/INSTALLATION .)
(See TRUNK LID OPENER SWITCH INSPECTION .)
7
Trunk lid striker
(See TRUNK LID STRIKER REMOVAL/INSTALLATION .)
8
Trunk lid latch and opener
(See TRUNK LID LATCH AND OPENER REMOVAL/INSTALLATION .)
(See TRUNK LID OPENER INSPECTION .)
9
Trunk key cylinder
(See TRUNK KEY CYLINDER REMOVAL/INSTALLATION .)
(See TRUNK KEY CYLINDER SWITCH INSPECTION .)
10
Rear door lock striker (lower)
(See REAR DOOR LOCK STRIKER REMOVAL/INSTALLATION .)
11
Rear door lower latch
(See REAR DOOR LOWER LATCH REMOVAL/INSTALLATION .)
(See REAR DOOR LOWER LATCH SWITCH INSPECTION .)
12
Front door lock striker
(See FRONT DOOR LOCK STRIKER REMOVAL/INSTALLATION .)
13 Front door latch and lock actuator
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(See FRONT DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION .)
(See FRONT DOOR LOCK ACTUATOR INSPECTION .)
14
Rear door lock striker (upper)
(See REAR DOOR LOCK STRIKER REMOVAL/INSTALLATION .)
15
Rear door upper latch
(See REAR DOOR UPPER LATCH REMOVAL/INSTALLATION .)
(See REAR DOOR UPPER LATCH SWITCH INSPECTION .)
16
Rear door release handle
(See REAR DOOR RELEASE HANDLE REMOVAL/INSTALLATION .)
17
Front door key cylinder
(See FRONT DOOR KEY CYLINDER REMOVAL/INSTALLATION .)
18
Front outer handle
(See FRONT OUTER HANDLE REMOVAL/INSTALLATION .)
19
Hood latch
(See HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION .)
20
Hood striker
(See HOOD STRIKER REMOVAL/INSTALLATION .)
21
Trunk lid opener relay
(See RELAY INSPECTION .)
22
Transmitter
(See TRANSMITTER BATTERY REPLACEMENT .)
(See TRANSMITTER BATTERY INSPECTION .)
(See TRANSMITTER ID CODE CHANGE .)
23
Door lock switch
(See DOOR LOCK SWITCH REMOVAL/INSTALLATION .)
(See DOOR LOCK SWITCH INSPECTION .)
24
Trunk opener cancel switch
(See TRUNK LID OPENER CANCEL SWITCH REMOVAL/INSTALLATION .)
(See TRUNK LID OPENER CANCEL SWITCH INSPECTION .)
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Page 18

DOORS AND LIFTGATE
DOOR
DOOR LOCATION INDEX
1
Front door
(See FRONT DOOR REMOVAL/INSTALLATION .)
(See DOOR ADJUSTMENT .)
2
Rear door
(See REAR DOOR REMOVAL/INSTALLATION .)
(See REAR DOOR ASSEMBLY/DISASSEMBLY .)
(See DOOR ADJUSTMENT .)
3
Front door unit
(See FRONT DOOR UNIT REMOVAL/INSTALLATION .)
FRONT DOOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. To remove the checker, remove the following parts:
a. Inner garnish (See INNER GARNISH REMOVAL/INSTALLATION .)
b. Front door trim (See FRONT DOOR TRIM REMOVAL/INSTALLATION .)
c. Front door speaker (See FRONT DOOR SPEAKER REMOVAL/INSTALLATION .)
3. To remove the front door hinge, remove the following parts:
a. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION .)
b. Front fender panel (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)
4. Remove in the order indicated in the table.
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Page 19

1
Connector
(See Connector Removal Note .)
2 Bolt A
3 Bolt B
4 Front door
5 Nut
6 Checker
7 Bolt C
8 Front door hinge
5. Install in the reverse order of removal.
6. Adjust the front door. (See DOOR ADJUSTMENT .)
Connector Removal Note
1. Pull the rubber boot outward.
2. Pull down the lever in the direction indicated by the arrow and disconnect the connector.
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Page 20