Mazda RX-8 Instruction manual

Workshop Manual - General Information
2011 - RX-8
General Information
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
VEHICLE IDENTIFICATION NUMBER (VIN)
HOW TO USE THIS MANUAL
UNITS
SERVICE CAUTIONS
INSTALLATION OF RADIO SYSTEM
ELECTRICAL SYSTEM
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS
TOWING
TIEDOWN HOOK
IDENTIFICATION NUMBER LOCATIONS
SAE STANDARDS
ABBREVIATIONS
PRE-DELIVERY INSPECTION
SCHEDULED MAINTENANCE

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2011 - RX-8 - General Information
UNITS
Electric current A (ampere)
Electric power W (watt)
Electric resistanceohm
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)
Number of
revolutions rpm (revolutions per minute)
N·m (Newton meter)

Torque
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)
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 264 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.
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2011 - RX-8 - General Information
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
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2011 - RX-8 - General Information
VEHICLE IDENTIFICATION NUMBER (VIN)
JM1 FE1*2*B# 400001—
JM1 FE1*4*B# 400001—
JM1 FE1*M*B# 400001—
JM1 FE1*P*B# 400001—
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2011 - RX-8 - General Information
SAE STANDARDS
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.
SAE Standard Remark SAE Standard Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal MIL Malfunction Indicator Lamp
APP Accelerator Pedal Position MAP Manifold Absolute Pressure
ACL Air Cleaner MAF sensor Mass Air Flow Sensor
A/C Air Conditioning MFL Multiport Fuel Injection
A/F sensor Air Fuel Ratio Sensor 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
CAC Charge Air Cooler PNP Park/Neutral Position
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
pumpDLC Data Link Connector
DTM Diagnostic Test Mode #1
DTC Diagnostic Test Code(s) SAPV Secondary Air Pulse Valve
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 sensor Throttle Position Sensor
EGR Exhaust Gas Recirculation TCC Torque Converter Clutch
FC Fan Control TCM Transmission (Transaxle)
Control Module
FF Flexible Fuel
4GR Fourth Gear TR Transmission (Transaxle)
Range
GEN Generator TC Turbocharger
GND Ground VSS Vehicle Speed Sensor

HO2S Heated Oxygen Sensor With
heater
VR Voltage Regulator
VAF sensor Volume Air Flow Sensor
IAC Idle Air Control WU-TWC Warm Up Three Way
Catalytic Converter #4
IAT Intake Air Temperature
KS Knock Sensor WOT Wide Open Throttle
#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
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2011 - RX-8 - General Information
HOW TO USE THIS MANUAL
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.

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.

Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or

use of these materials during service.
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
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.
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.
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.

Using the DTC troubleshooting flow
DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC.

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.
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.