2008 CX 9 ServiceManual

2008 Mazda CX-9 Grand Touring
2008 RESTRAINTS On-Board Diagnostic (Restraints) - Mazda CX-9
2008 RESTRAINTS
On-Board Diagnostic (Restraints) - Mazda CX-9
FOREWORD
OUTLINE
 The OBD (on-board diagnostic) system has the following functions:

 Malfunction detection function: Detects malfunctions in the air bag system and outputs DTCs.
 Data monitor function: Reads out specific input/output signals and the system status.
 Diagnostic DTCs can be read/cleared using the M-MDS.
FLOWCHART
 Use the following flowchart to verify the cause of the trouble.
NOTE:  While performing the inspection of the past malfunction code, the
applicable DTCs may be added to memory by removing or disconnecting
the related parts. Inspect only the DTCs that were indicated before
inspecting.
 When DTCs of the present malfunction are no longer output after present
or past malfunctions or both have been repaired, be sure to perform past
malfunction display cancellation to prevent repair of malfunctions that
have already been repaired.
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Sunday, November 15, 2009 10:18:53
10:18:46 AM Page 1 © 2005 Mitchell Repair Information Company, LLC.
Fig. 1: Flow Chart

Courtesy of MAZDA MOTORS CORP.
AIR BAG SYSTEM WIRING DIAGRAM (ON-BOARD DIAGNOSTIC)
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Sunday, November 15, 2009 10:18:46 AM Page 2 © 2005 Mitchell Repair Information Company, LLC.
Fig. 2: Air Bag System Wiring Diagram

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DTC DISPLAY
1. Connect the M-MDS to the DLC-2.
2. After the vehicle is identified, select the following items from the initialization screen of the M-MDS.
 When using the IDS (laptop PC)
1. Select "Self Test".

2. Select "Modules".
3. Select "RCM".
 When using the PDS (Pocket PC)
1. Select "Module Tests".

2. Select "RCM".
Fig. 3: Identifying DLC-2 Connector

3. Verify the DTC according to the directions on the screen.

 If any DTCs are displayed, perform troubleshooting according to the corresponding DTC
inspection.
4. After completion of repairs, clear all DTCs stored in the SAS control module. (See CLEARING DTC.)
CLEARING DTC

3. Select "RCM".

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2. Select "RCM".
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.

DTC TABLE
 DTCs are common for present and past malfunction diagnosis.
NOTE:  When DTCs not shown in the DTC table are displayed, replace the
SAS control module.
 If the air bag system warning light does not illuminate or remains
illuminated when the ignition switch is turned to the ON position,
inspect and repair the air bag system warning light circuit, and then
confirm that the air bag system warning light is operational.
 The air bag system warning light flashes the DTC pattern for five
cycles, and then remains illuminated until the ignition switch is
turned to the ACC or LOCK position.
DTC TABLE
DTC CHART
DTC
Air bag system warning light System malfunction
M-MDS Page
Priority location
display Flashing pattern
ranking
Seat weight sensor
B1013 16 20 (See DTC B1013.)
calibration error
Driver-side curtain air bag
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module and other air bag (See DTC B1046, B2773,

B1046 24 19
module circuits short B2774, B2775, B2776.)
Driver-side side air bag
(See DTC B1047, B1992,
B1047 22 17 module and other air bag
B1993, B1994, B1995.)
module circuits short
Passenger-side air bag
module (inflator No.1) and (See DTC B1048, B1925,
B1048 21 12
other air bag module circuits B1933, B1935, B1938.)
short
Passenger-side pre-tensioner
(See DTC B1049, B1881,
B1049 34 14 seat belt and other air bag
B1882, B1883, B1886.)
sensor No. 1 and other (See DTC B104B, B104E,
B104B 43 8
sensor circuits short to B1051, U2017.)
power supply
Passenger-side side air bag
sensor No.1 and other sensor (See DTC B104C, B104F,
B104C 44 7
circuits short to power B1050, U2018.)
supply
Crash zone sensor and other
(See DTC B104B, B104E,
B104D 42 11 sensor circuits short to
B1051, U2017.)
power supply
B104E 43 8 sensor No.1 circuit open or
B1051, U2017.)
short
B104F sensor No.1 (internal circuit
abnormal) (See DTC B104C, B104F,
44 7
Passenger-side side air bag B1050, U2018.)
B1050 sensor No.1 circuit open or
short
B1051 43 8 sensor No.1 (internal circuit
B1051, U2017.)
abnormal)
Driver-side pre-tensioner
(See DTC B1054, B1877,
B1054 33 15 seat belt and other air bag
B1878, B1879, B1885.)
(See DTC B1055, B1996,
B1055 23 16 module and other air bag
B1997, B1998, B1999.)
Passenger-side curtain air
(See DTC B1056, B2777,
B1056 25 18 bag module and other air bag
B2778, B2779, B2780.)
Driver-side air bag module (See DTC B1057, B1916,
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(inflator No.1) and other air B1932, B1934, B1936.)

B1057
bag module circuits short
19 13 Driver-side air bag module
(See DTC B1058, B2228,
B1058 (inflator No.2) and other air
B2230, B2232, B2234.)
bag module circuits short
module (inflator No.2) and (See DTC B1059, B2229,
B1059 21 12
other air bag module circuits B2231, B2233, B2235.)
short
SAS control module
Continuously
B105A - 1 activation (deployment) (See DTC B105A.)
illuminated
control frequency error
sensor No. 2 and other (See DTC B105B, B110C,
B105B 46 10
sensor circuits short to B1144, B1145.)
power supply
sensor No. 2 and other (See DTC B105F, B110D,
B105F 47 9
sensor circuits short to B1146, B1147.)
power supply
(See DTC B105B, B110C,
B110C 46 10 sensor No. 2 circuit open or
B1144, B1145.)
short
(See DTC B105F, B110D,
B110D 47 9 sensor No. 2 circuit open or
B1146, B1147.)
short
B110E 46 10
sensor No.2 ID mismatch (See DTC B110E, B110F,
Passenger-side side air bag B2856, B2886, B2887.)
B110F 47 9
sensor No.2 ID mismatch
B1144 sensor No. 2 (internal circuit
abnormal) (See DTC B105B, B110C,
46 10
Driver-side side air bag B1144, B1145.)
B1145 sensor No. 2
(communication error)
B1146 sensor No. 2 (internal circuit
abnormal) (See DTC B105F, B110D,
47 9
Passenger-side side air bag B1146, B1147.)
B1147 sensor No. 2
SAS control module
B1231 13 3 activation (deployment) (See DTC B1231.)
control freeze
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SAS control module power

B1317 supply voltage increases
Continuously (18.1 V or more)
- 1 (See DTC B1317, B1318.)
illuminated SAS control module power
B1318 supply voltage decreases
(less than 8 V)
12 2
SAS control module
B1342 (See DTC B1342, B1921.)
Continuously (internal circuit abnormal)
- 1
illuminated
Air bag system warning light
B1868 - - 1 (See DTC B1868.)
malfunction
B1877 seat belt circuit resistance
high
(See DTC B1054, B1877,
B1878 33 15 seat belt circuit short to
B1878, B1879, B1885.)
power supply
B1879 seat belt circuit short to body
ground
B1881 seat belt circuit resistance
high
(See DTC B1049, B1881,
B1882 34 14 seat belt circuit short to
B1882, B1883, B1886.)
power supply
B1883 seat belt circuit short to body
ground
Passenger air bag
deactivation (PAD) indicator
B1884 18 21 (See DTC B1884, B1890.)
circuit open or short to body
ground
(See DTC B1054, B1877,
B1885 33 15 seat belt circuit resistance
B1878, B1879, B1885.)
low
(See DTC B1049, B1881,
B1886 34 14 seat belt circuit resistance
B1882, B1883, B1886.)
low
Passenger air bag
B1890 18 21 deactivation (PAD) indicator (See DTC B1884, B1890.)
circuit short to power supply
Driver-side air bag module (See DTC B1057, B1916,

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(inflator No.1) circuit short B1932, B1934, B1936.)

B1916 19 13
to power supply
Continuously Air bag diagnostic ground
B1921 - 1 (See DTC B1342, B1921.)
illuminated circuit open
(See DTC B1048, B1925,
B1925 21 12 module (inflator No.1)
B1933, B1935, B1938.)
Driver-side air bag module
(See DTC B1057, B1916,
B1932 19 13 (inflator No.1) circuit
B1932, B1934, B1936.)
resistance high
(See DTC B1048, B1925,
B1933, B1935, B1938.)
circuit resistance high
(See DTC B1057, B1916,
B1932, B1934, B1936.)
resistance low
(See DTC B1048, B1925,
B1933, B1935, B1938.)
circuit resistance low
(See DTC B1057, B1916,
B1936 19 13 (inflator No.1) circuit short
B1932, B1934, B1936.)
to body ground
(See DTC B1048, B1925,
B1933, B1935, B1938.)
circuit short to body ground
B1992 module circuit short to
power supply
B1993 module circuit short to body
ground (See DTC B1047, B1992,
22 17
B1993, B1994, B1995.)
B1994 module circuit resistance
high
B1995
module circuit resistance low
power supply
B1997 23 16 module circuit short to body (See DTC B1055, B1996,
ground B1997, B1998, B1999.)
high
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B1999
Crash zone sensor (internal
B2226
circuit abnormal) (See DTC B104D, B2226,
42 11
Crash zone sensor B2227, B2855.)
B2227
(See DTC B1058, B2228,
B2230, B2232, B2234.)
to body ground
(See DTC B1059, B2229,
B2231, B2233, B2235.)
(See DTC B1058, B2228,
B2230, B2232, B2234.)
to power supply
(See DTC B1059, B2229,
B2231, B2233, B2235.)
(See DTC B1058, B2228,
B2230, B2232, B2234.)
resistance high
(See DTC B1059, B2229,
B2231, B2233, B2235.)
circuit resistance high
(See DTC B1058, B2228,
B2230, B2232, B2234.)
resistance low
(See DTC B1059, B2229,
B2231, B2233, B2235.)
circuit resistance low
Seat weight sensor signal
B2290 16 20 (See DTC B2290.)
malfunction
B2477 54 6 Configuration error (See DTC B2477.)
B2773
high
(See DTC B1046, B2773,
24 19 Driver-side curtain air bag B2774, B2775, B2776.)
B2775 module circuit short to body
ground
power supply
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B2777 bag module circuit resistance
low
B2778 bag module circuit resistance
high (See DTC B1056, B2777,
25 18
Passenger-side curtain air B2778, B2779, B2780.)
B2779 bag module circuit short to
body ground
B2780 bag module circuit short to
power supply
Crash zone sensor circuit (See DTC B104D, B2226,
B2855
short B2227, B2855.)
42 11
Crash zone sensor ID
B2856
mismatch
Passenger-side side air bag (See DTC B110E, B110F,
B2886 44 7
sensor No.1 ID mismatch B2856, B2886, B2887.)
B2887 43 8
sensor No.1 ID mismatch
Seat track position sensor
C1946
circuit open
C1947
(See DTC C1946, C1947,
C1948 49 22 circuit resistance not within
C1948, C1981, C1982.)
specification
C1981
circuit malfunction
C1982
U2017 43 8 sensor No. 1
B1051, U2017.)
(See DTC B104C, B104F,
U2018 44 7 sensor No. 1
B1050, U2018.)
CAN system communication
U0073 14 4
error (See DTC TABLE
Communication error to [MULTIPLEX
U0100 COMMUNICATION
PCM
- - 1 SYSTEM] .)
Communication error to
U0155
instrument cluster
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PID/DATA MONITOR DISPLAY

1. Select "DataLogger".
3. Select "RCM".

When using the PDS (Pocket PC)



2. Select "RCM".
3. Select the applicable PID from the PID table.
4. Verify the PID data according to the directions on the screen.
NOTE:  The PID data screen function is used for monitoring the calculated
value of input/output signals in the module. Therefore, if the
monitored value of the output parts is not within the specification, it
is necessary to inspect the monitored value of input parts
corresponding to the applicable output part control. In addition,
because the system does not display an output part malfunction as
an abnormality in the monitored value, it is necessary to inspect the
output parts individually.
PID/DATA MONITOR TABLE

PID/DATA MONITOR CHART
PID name Unit/Condition Operation Condition Terminal

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(definition) (Reference)
 Driver-side buckle
switch off:
BUCKLE_D
Buckled
(Driver-side buckle Unbuckled/Buckled 2W
switch status)  Driver-side buckle
switch on:
Unbuckled
 Passenger-side
BUCKLE_P buckle switch off:
(Passenger-side Buckled
Unbuckled/Buckled 2C
buckle switch  Passenger-side
status) buckle switch on:
Unbuckled
CCNT_RCM
Indicates number of
(Number of - -
DTC
continuous DTCs)
CRSH_RC
Indicates number of
(Number of - -
detected collisions
detected collisions)
DTC_CLR_ST(1) Fault information
(OCS DTC cleared Starting/Normal End/In Process/OCS Fault cleared at seat weight 2AJ
state) sensor
IGN_V (IG1 Ignition switch is at ON:
V 1D
voltage) B+
 Seat weight sensor

calibration start-
up: Starting
calibration
completed
normally: Normal
OCS_CAL_ST(2) End
Starting/Normal End/Commanding/NG
(Seat weight (Voltage)/ NG (Weight)/ Timeout/In  Seat weight sensor 2AJ
sensor calibration Process/OCS Fault calibration
status) command being
sent: Commanding
 Voltage
malfunction
during seat weight
sensor calibration:
NG (Voltage)
 Weight error
during seat weight
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sensor calibration:
NG (Weight)
calibration time
limit passed:
Timeout
calibration being
processed: In
Process
or Seat weight
sensor control
module
malfunction: OCS
Fault
OCS_SYS_ST(1) Occupant classification
(Seat weight Empty/SMALL/Indeterminate/LARGE/Invalid status determined by seat 2AJ
sensor status) weight sensor
 Sensor normal:
OCSFLT_CAL
OK
(Passenger sensing
OK/FAULT  Seat weight sensor 2AJ
system calibration
status) calibration error:
FAULT
 Sensor normal:
OCSFLT_COM
OK
(Passenger sensing
system OK/FAULT  Seat weight sensor 2AJ
communication control module
status) communication
error: FAULT
 Sensor normal:
OCSFLT_L
OK
(Passenger sensing
OK/FAULT  Seat weight sensor 2AJ
system (LH)
malfunction status) (LH) malfunction:
FAULT
 Sensor normal:
OCSFLT_MDL
OK
(Passenger sensing
system control OK/FAULT  Seat weight sensor 2AJ
module control module
malfunction status) malfunction:
FAULT
 Sensor normal:
OCSFLT_R OK
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(Passenger sensing  Seat weight sensor

system (RH) OK/FAULT (RH) malfunction: 2AJ
malfunction status) FAULT
PS_WEIGHT
(Seat weight Display of load (body
sensor measured kg weight) on front 2AJ
weight of passenger-side seat
passenger)
 Passenger-side air
bag module non-
operation (non-
deployment)
PSAB_DepSt
status: Inactive
(Passenger-side air
Inactive/Active  Passenger-side air 2AJ
bag module
deployment status) bag module
operation
(deployment)
enabled status:
Active
RES_AB_D
(Driver-side air
Under any condition:
bag module ohm 11,1M
1.5-9.7 ohms
(inflator No.1)
resistance)
RES_AB_P
(Passenger-side air
bag module ohm U, 1N
1.0-9.7 ohms
(inflator No.1)
resistance)
RES_AB2_D
(Driver-side air
bag module ohm 1Q, 1U
1.5-9.7 ohms
(inflator No.2)
resistance)
RES_AB2_P
(Passenger-side air
bag module ohm 1R, 1V
1.0-9.7 ohms
(inflator No.2)
resistance)
RES_CAB_D
(Driver-side Under any condition: 2AG,
ohm
curtain air bag 1.0-9.7 ohms 2AK
module resistance)
RES_CAB_P ohm
(Passenger-side Under any condition: 2AH,
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curtain air bag 1.0-9.7 ohms 2AL

module resistance)
RES_PT_D
(Driver-side pre- Under any condition:
ohm 2N, 2J
tensioner seat belt 1.0-9.7 ohms
resistance)
RES_PT_P
(Passenger-side Under any condition:
ohm 2A, 2E
pre-tensioner seat 1.0-9.7 ohms
belt resistance)
RES_SAB_D
(Driver-side side Under any condition:
ohm 2B, 2F
air bag module 1.0-9.7 ohms
resistance)
RES_SAB_P
Passenger-side side Under any condition:
ohm 21, 2M
air bag module 1.0-9.7 ohms
resistance)
Front seat front

TRAK_SW Seat position: Forward
2AB,
track position Forward/Rearward  Front seat rear 2AF
sensor state) position:
Rearward
(1) Used during seat weight sensor calibration setting. Not necessary for diagnostic.
(2) When the calibration error is displayed, the error can be cleared by turning the ignition switch to the
LOCK position.
DTC B1013
DTC B1013 DETECTION CONDITION AND POSSIBLE CAUSE
DTC B1013 Seat weight sensor calibration error
WARNING:
 Detection conditions are for understanding the DTC outline before
performing an inspection. Performing an inspection according to only the
DETECTION detection conditions may cause injury due to an operating error, or damage
CONDITION the system. When performing an inspection, always follow the inspection
procedure.
 Calibration set value not within valid range.

 Weight acting on front passenger-side seat during calibration
 Improperly installed front passenger-side seat part at time of calibration
 Deformed floor where attached to front passenger-side seat
POSSIBLE  Deformed front passenger-side seat under-bracket or frame
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CAUSE  Seat weight sensor deformed or malfunction

 Seat weight sensor control module malfunction
 SAS control module malfunction
 Load to or deformation of the seat belt rail
DIAGNOSTIC PROCEDURE
DTC B1013 DIAGNOSTIC PROCEDURE

STEP INSPECTION ACTION
INSPECT SEAT WEIGHT [Present malfunction diagnosis]
SENSOR
 Replace the SAS control module.
 Properly install the
passenger-side front seat. (See SAS CONTROL MODULE
Yes REMOVAL/INSTALLATION .)
1  Inspect the seat weight
sensor. (See SEAT
WEIGHT SENSOR [Past malfunction diagnosis]
CALIBRATION .)
 Is the seat weight sensor  DTC troubleshooting completed.
normal? No Go to the next step.
INSPECT PASSENGER-SIDE
FRONT SEAT
 Turn the ignition switch to

the LOCK position.
 Disconnect the negative
battery cable and wait for
1 min or more. Replace any deformed parts or remove any foreign objects.
 Remove the passenger-  After replacement, perform seat weight sensor
side seat and visually Yes
calibration and reperform the DTC inspection. If the
inspect for the following: DTC is displayed, go the next step. (See SEAT
2
 Seat under-bracket WEIGHT SENSOR CALIBRATION .)
deformation
 Seat frame
deformation
 Seat weight sensor
deformation
 Foreign objects
stuck in seat
 Are any of the parts
deformed or are any No Go to the next step.
foreign objects stuck in the
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seat?
INSPECT FLOOR Yes Go to the next step.
Visually inspect the

installation parts of the
front passenger-side seat Repair floor deformation.
for the following:
3  Abnormal floor  After repair, perform seat weight sensor calibration
deformation No and reperform the DTC inspection. If the DTC is
 Installation hole of displayed even though the floor has been repaired, go
front passenger-side the next step. (See SEAT WEIGHT SENSOR
seat is improperly CALIBRATION .)
positioned
 Is the floor normal?
INSPECT SEAT WEIGHT

SENSOR CONTROL
MODULE Replace the seat weight sensor control module. (See SEAT
WEIGHT SENSOR CONTROL MODULE
 Replace the seat weight
REMOVAL/INSTALLATION .)
sensor.
 After replacement, perform seat weight sensor
 After replacement, Yes
4 calibration and reperform the DTC inspection. If the
perform seat weight sensor DTC is displayed even though the seat weight sensor
calibration. (See SEAT control module has been replaced, replace the SAS
WEIGHT SENSOR control module. (See SAS CONTROL MODULE
CALIBRATION .) REMOVAL/INSTALLATION .)
 Reperform the DTC
inspection.
 Is DTC B1013 indicated? No DTC troubleshooting completed.
DTC B1046, B2773, B2774, B2775, B2776

DTC B1046, B2773, B2774, B2775, B2776 DETECTION CONDITION AND POSSIBLE CAUSE
B1046 Driver-side curtain air bag module and other air bag module circuits short
B2773 Driver-side curtain air bag module circuit resistance low
DTC B2774 Driver-side curtain air bag module circuit resistance high
B2775 Driver-side curtain air bag module circuit short to body ground
B2776 Driver-side curtain air bag module circuit short to power supply
WARNING:
DETECTION
CONDITION  Detection conditions are for understanding the DTC outline before performing an
inspection. Performing an inspection according to only the detection conditions
may cause injury due to an operating error, or damage the system. When
performing an inspection, always follow the inspection procedure.
Microsoft
 Resistance other than 1.0-9.7 ohms detected in driver-side curtain air bag module
circuit
 Malfunction in wiring harness between driver-side curtain air bag module and SAS
control module
 Open or short circuit in wiring harness between driver-side curtain air bag module and
POSSIBLE SAS control module
CAUSE  Driver-side curtain air bag module malfunction
DTC B1046, B2773, B2774, B2775, B2776 DIAGNOSTIC PROCEDURE

INSPECT DRIVER-SIDE CURTAIN AIR BAG
MODULE
 Using the M-MDS, verify the following Replace the SAS control module. (See
PID/DATA monitor. Yes SAS CONTROL MODULE
1 (See PID/DATA MONITOR TABLE.)
RES_CAB_D

 Is the resistance of the driver-side curtain air

bag module normal? No Go to the next step.
 Resistance: 1.0-9.7 ohms
INSPECT DRIVER-SIDE CURTAIN AIR BAG

MODULE CONNECTOR
WARNING:
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 Handling the air bag system components

improperly can accidentally deploy the air
bag modules and pre-tensioner seat belts,
which may seriously injure you. Read the
service warnings and cautions before
Yes Replace the air bag wiring harness.
handling the air bag system components.
(See AIR BAG SYSTEM SERVICE

WARNINGS .)

2 CAUTIONS .)
Turn the ignition switch to the LOCK position.


 Disconnect the negative battery cable and wait No Go to the next step.
for 1 min or more.
 Disconnect the driver-side curtain air bag
module connector. (See CURTAIN AIR BAG
MODULE REMOVAL/INSTALLATION .)
 Is there any malfunction of the driver-side
curtain air bag module connector?
VERIFY WHETHER MALFUNCTION IS IN
DRIVER-SIDE CURTAIN AIR BAG MODULE Yes Go to the next step.
OR RELATED WIRING HARNESS
 Connect the leads of the SST (Fuel and

thermometer checker) or apply 2-ohm
resistance to driver-side curtain air bag module
3 connector terminals A and B. Replace the driver-side curtain air bag
 Set the resistance of the SST (Fuel and module. (See CURTAIN AIR BAG
No
thermometer checker) to the 2-ohm position. MODULE
 Connect the negative battery cable. REMOVAL/INSTALLATION .)
 Turn the ignition switch to the ON position.
 Are DTCs B1046, B2773, B2774, B2775
and/or B2776 indicated?
INSPECT WIRING HARNESS BETWEEN
DRIVER-SIDE CURTAIN AIR BAG MODULE
AND SAS CONTROL MODULE
 Turn the ignition switch to the LOCK position.

 Disconnect the negative battery cable and wait
for 1 min or more .
 Remove the column cover. (See COLUMN
COVER REMOVAL/INSTALLATION .)
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 Disconnect the clock spring connector. (See

COMBINATION SWITCH
 Remove the glove compartment. (See GLOVE
COMPARTMENT
 Disconnect the passenger-side air bag module
connector. (See PASSENGER-SIDE AIR
BAG MODULE
 Disconnect the driver and passenger-side front Replace the SAS control module. (See
seat connectors. (See FRONT SEAT Yes SAS CONTROL MODULE
REMOVAL/INSTALLATION .) REMOVAL/INSTALLATION .)
 Disconnect the driver and passenger-side
curtain air bag module connectors. (See
CURTAIN AIR BAG MODULE
 Remove the B-pillar lower trim. (See B-
4 PILLAR LOWER TRIM
 Disconnect the driver and passenger-side pre-
tensioner seat belt connectors. (See FRONT
SEAT BELT
 Disconnect the SAS control module connectors.
(See SAS CONTROL MODULE
 Inspect the wiring harness between SAS control
module terminal 2AK and driver-side curtain
air bag module terminal A, SAS control module
terminal 2AG and driver-side curtain air bag No Replace the air bag wiring harness.
module terminal B for the following:
 Short to ground
 Short to power supply
 Open circuit
 Is the wiring harness normal?
DTC B1047, B1992, B1993, B1994, B1995

B1047 Driver-side side air bag module and other air bag module circuits short
DTC B1992 Driver-side side air bag module circuit short to power supply
B1993 Driver-side side air bag module circuit short to body ground
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B1994 Driver-side side air bag module circuit resistance high

B1995 Driver-side side air bag module circuit resistance low
WARNING:
 Detection conditions are for understanding the DTC outline before performing an
DETECTION performing an inspection, always follow the inspection procedure.
CONDITION
 Resistance other than 1.0-9.7 ohms detected in driver-side side air bag module circuit
 Malfunction in wiring harness between driver-side side air bag module and SAS
control module
 Open or short circuit in wiring harness between driver-side side air bag module and
CAUSE  Driver-side side air bag module malfunction

INSPECT DRIVER-SIDE SIDE AIR BAG

MODULE
Replace the SAS control module. (See
1 Yes SAS CONTROL MODULE
 Using the M-MDS, verify the following REMOVAL/INSTALLATION .)
PID/DATA monitor.
(See PID/DATA MONITOR TABLE.)

Microsoft
RES_SAB_D

 Is the resistance of the driver-side side air bag

No Go to the next step.
module normal?

MODULE CONNECTOR
WARNING:
bag modules and pre-tensioner seat belts, Yes Replace the air bag wiring harness.

WARNINGS .)
2
CAUTIONS .)



for 1 min or more .
 Disconnect the driver-side side air bag module
connector. (See SIDE AIR BAG MODULE
 Is there any malfunction of the driver-side side
air bag module connector?
DRIVER-SIDE SIDE AIR BAG MODULE OR Yes Go to the next step.
RELATED WIRING HARNESS

resistance to driver-side side air bag module
3 connector terminals A and B. Replace the driver-side side air bag
 Set the resistance of the SST (Fuel and module. (See SIDE AIR BAG
No
 Are DTCs B1047, B1992, B1993, B1994,
Microsoft

DRIVER-SIDE SIDE AIR BAG MODULE AND
SAS CONTROL MODULE

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
REMOVAL/INSTALLATION .) Replace the SAS control module. (See
Yes SAS CONTROL MODULE
 Disconnect the passenger-side air bag module REMOVAL/INSTALLATION .)
BAG MODULE
 Disconnect the passenger-side front seat
connector. (See FRONT SEAT
4
PILLAR LOWER TRIM
SEAT BELT
module terminal 2F and driver-side side air bag No Replace the air bag wiring harness.
module terminal A, SAS control module
terminal 2B and driver-side side air bag module
terminal B for the following:
 Short to ground
Microsoft
 Open circuit
DTC B1048, B1925, B1933, B1935, B1938

B1048 Passenger-side air bag module (inflator No.1) and other air bag module circuits short
B1925 Passenger-side air bag module (inflator No.1) circuit short to power supply
DTC B1933 Passenger-side air bag module (inflator No.1) circuit resistance high
B1935 Passenger-side air bag module (inflator No.1) circuit resistance low
B1938 Passenger-side air bag module (inflator No.1) circuit short to body ground
WARNING:
CONDITION
 Resistance other than 1.0-9.7 ohms detected in passenger-side air bag module circuit
(inflator No.1)
 Malfunction in wiring harness between passenger-side air bag module (inflator No.1)
and SAS control module
 Open or short circuit in wiring harness between passenger-side air bag module
POSSIBLE (inflator No.1) and SAS control module
CAUSE  Passenger-side air bag module malfunction
Microsoft

INSPECT PASSENGER-SIDE AIR BAG
MODULE
RES_AB_P

 Is the resistance of the passenger-side air bag

module normal? No Go to the next step.

MODULE CONNECTOR
WARNING:

WARNINGS .)
2 (See AIR BAG SYSTEM SERVICE
CAUTIONS .)

for 1 min or more . No Go to the next step.
BAG MODULE
 Is there any malfunction of the passenger-side
Yes Go to the next step.

PASSENGER-SIDE AIR BAG MODULE OR
Microsoft

thermometer checker) or apply 2-ohm resistance
to passenger-side air bag module (inflator No.1)
connector terminals 1A and 1B, and passenger-
side air bag module (inflator No.2) connector Replace the passenger-side air bag
terminals 2A and 2B. module.
3  Set the resistance of the SST (Fuel and No (See PASSENGER-SIDE AIR BAG
 Connect the negative battery cable.
 Are DTCs B1048, B1925, B1933, B1935 and/or
B1938 indicated?

PASSENGER-SIDE AIR BAG MODULE AND
SAS CONTROL MODULE

for 1 min or more .
COMBINATION SWITCH
4
 Disconnect the driver and passenger-side curtain
air bag module connectors. (See CURTAIN
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
module terminal 1J and passenger-side air bag
Microsoft
module terminal 1 A, SAS control module

terminal 1N and passenger-side air bag module
terminal 1B for the following:
 Short to ground
No Replace the air bag wiring harness.
 Open circuit
DTC B1049, B1881, B1882, B1883, B1886

B1049 Passenger-side pre-tensioner seat belt and other air bag module circuits short
B1881 Passenger-side pre-tensioner seat belt circuit resistance high
DTC B1882 Passenger-side pre-tensioner seat belt circuit short to power supply
B1883 Passenger-side pre-tensioner seat belt circuit short to body ground
B1886 Passenger-side pre-tensioner seat belt circuit resistance low
WARNING:
CONDITION
 Resistance other than 1.0-9.7 ohms detected in passenger-side pre-tensioner seat belt
circuit
 Malfunction in wiring harness between passenger-side pre-tensioner seat belt and SAS
control module
 Open or short circuit in wiring harness between passenger-side pre-tensioner seat belt
POSSIBLE and SAS control module
CAUSE  Passenger-side pre-tensioner seat belt malfunction
Microsoft

INSPECT PASSENGER-SIDE PRE-TENSIONER
SEAT BELT
RES_PT_P

 Is the resistance of the passenger-side pre-

tensioner seat belt normal? No Go to the next step.
INSPECT PASSENGER-SIDE PRE-TENSIONER

SEAT BELT CONNECTOR
WARNING:

WARNINGS .)
Microsoft

CAUTIONS .)



for 1 min or more .
2  Remove the B-pillar lower trim (RH). (See B- No Go to the next step.
PILLAR LOWER TRIM
 Disconnect the passenger-side pre-tensioner
seat belt connector. (See FRONT SEAT BELT
pre-tensioner seat belt connector?
PASSENGER-SIDE PRE-TENSIONER SEAT Yes Go to the next step.
BELT OR RELATED WIRING HARNESS

resistance to passenger-side pre-tensioner seat
3 belt connector terminals A and B. Replace the passenger-side pre-
 Set the resistance of the SST (Fuel and tensioner seat belt. (See FRONT
No
thermometer checker) to the 2-ohm position. SEAT BELT
 Are DTCs B1049, B1881, B1882, B1883,

PASSENGER-SIDE PRE-TENSIONER SEAT
BELT AND SAS CONTROL MODULE

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
Microsoft
BAG MODULE
 Disconnect the driver and passenger-side front
seat connectors. (See FRONT SEAT
PILLAR LOWER TRIM
4  Disconnect the driver and passenger-side pre-
SEAT BELT
module terminal 2E and passenger-side pre-
tensioner seat belt terminal A, SAS control
module terminal 2A and passenger-side pre-
tensioner seat belt terminal B for the following:
 Short to ground
 Open circuit
DTC B104B, B104E, B1051, U2017

DTC B104B, B104E, B1051, U2017 DETECTION CONDITION AND POSSIBLE CAUSE
B104B Driver-side side air bag sensor No.1 and other sensor circuits short to power supply
B104E Driver-side side air bag sensor No.1 circuit open or short
DTC
B1051 Driver-side side air bag sensor No.1 (internal circuit abnormal)
U2017 Driver-side side air bag sensor No.1 (communication error)
WARNING:
Microsoft
DETECTION
 Malfunction in wiring harness between driver-side side air bag sensor No.1 and SAS
CONDITION
control module
 Malfunction in driver-side side air bag sensor No.1 circuit
 Open or short circuit in wiring harness between driver-side side air bag sensor No.1
CAUSE  Driver-side side air bag sensor No.1 malfunction
DTC B104B, B104E, B1051, U2017 DIAGNOSTIC PROCEDURE

SENSOR NO.1 CONNECTOR
WARNING:
improperly can accidentally deploy the air Yes Replace the air bag wiring harness.
1 which may seriously injure you. Read the

WARNINGS .)
Microsoft

CAUTIONS .)


for 1 min or more.
 Disconnect the driver-side side air bag sensor
No.1 connector.
air bag sensor No.1 connector?
DRIVER-SIDE SIDE AIR BAG SENSOR NO.1

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
Replace the driver-side side air bag
 Disconnect the passenger-side air bag module sensor No.1, then go to the next step.
2 connector. (See PASSENGER-SIDE AIR Yes
(See SIDE AIR BAG SENSOR NO.
BAG MODULE 1 REMOVAL/INSTALLATION .)
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
Microsoft
Disconnect the SAS control module connectors.


No.1 connector.
 Inspect the wiring harnesses between SAS
control module terminal 20 and driver-side side
air bag sensor No.1 terminal A, SAS control No Replace the air bag wiring harness.
module terminal 2S and driver-side side air bag
sensor No.1 terminal B for the following:
 Short to ground
 Open circuit
INSPECT SAS CONTROL MODULE
 Connect the SAS control module connector.

 Connect the driver and passenger-side pre-
tensioner seat belt connectors.
 Connect the driver-side side air bag sensor No.1 Replace the SAS control module. (See
connector. Yes SAS CONTROL MODULE
 Connect the driver and passenger-side curtain REMOVAL/INSTALLATION .)
air bag module connectors.
3  Connect the driver and passenger-side front seat
connectors.
 Connect the passenger-side air bag module
connector.
 Connect the clock spring connector.
 Turn the ignition switch to the ON position. No DTC troubleshooting completed.
 Are DTCs B104B, B104E, B1051 and/or U2017
indicated?
DTC B104C, B104F, B1050, U2018

DTC B104C, B104F, B1050, U2018 DETECTION CONDITION AND POSSIBLE CAUSE
B104C Passenger-side side air bag sensor No.1 and other sensor circuits short to power supply
B104F Passenger-side side air bag sensor No.1 (internal circuit abnormal)
DTC
B1050 Passenger-side side air bag sensor No.1 circuit open or short
U2018 Passenger-side side air bag sensor No.1 (communication error)
WARNING:
Microsoft
CONDITION
 Malfunction in wiring harness between passenger-side side air bag sensor No.1 and
SAS control module
 Malfunction in passenger-side side air bag sensor No.1 circuit
 Open or short circuit in wiring harness between passenger-side side air bag sensor
POSSIBLE No.1 and SAS control module
CAUSE  Passenger-side side air bag sensor No.1 malfunction
DTC B104C, B104F, B1050, U2018 DIAGNOSTIC PROCEDURE

INSPECT PASSENGER-SIDE SIDE AIR BAG
WARNING:
improperly can accidentally deploy the air Yes Replace the air bag wiring harness.
Microsoft
WARNINGS .)

CAUTIONS .)

for 1 min or more.
1 No Go to the next step.
 Remove the B-pillar lower trim (RH). (See B-
PILLAR LOWER TRIM
 Disconnect the passenger-side side air bag
sensor No.1 connector. (See SIDE AIR BAG
SENSOR NO. 1
side air bag sensor No.1 connector?
PASSENGER-SIDE SIDE AIR BAG SENSOR
NO.1 AND SAS CONTROL MODULE

for 1 min or more.
COMBINATION SWITCH
REMOVAL/INSTALLATION .) Replace the passenger-side side air bag
2  Remove the glove compartment. (See GLOVE Yes sensor No.1, then go to the next step.
COMPARTMENT (See SIDE AIR BAG SENSOR NO.
REMOVAL/INSTALLATION .) 1 REMOVAL/INSTALLATION .)
BAG MODULE
AIR BAG MODULE
Microsoft
Remove the B-pillar lower trim. (See B-


PILLAR LOWER TRIM
SEAT BELT
sensor No.1 connector. No Replace the air bag wiring harness.
control module terminal 2K and passenger-side
side air bag sensor No.1 terminal A, SAS
control module terminal 2G and passenger-side
side air bag sensor No.1 terminal B for the
following:
 Short to ground
 Open circuit

 Connect the passenger-side side air bag sensor Replace the SAS control module. (See
No.1 connector. Yes SAS CONTROL MODULE
connectors.
connector.
 Are DTCs B104C, B104F, B1050 and/or U2018
indicated?
DTC B104D, B2226, B2227, B2855

Microsoft
DTC B104D, B2226, B2227, B2855 DETECTION CONDITION AND POSSIBLE CAUSE
B104D Crash zone sensor and other sensor circuits short to power supply
B2226 Crash zone sensor (internal circuit abnormal)
DTC
B2227 Crash zone sensor (communication error)
B2855 Crash zone sensor circuit short
WARNING:
DETECTION may cause injury due to an operating error, or damage the system. When
CONDITION performing an inspection, always follow the inspection procedure.
 Malfunction in wiring harness between crash zone sensor and SAS control module
 Malfunction in crash zone sensor circuit
 Open or short circuit in wiring harness between crash zone sensor and SAS control
POSSIBLE module
CAUSE  Crash zone sensor malfunction
DTC B104D, B2226, B2227, B2855 DIAGNOSTIC PROCEDURE

INSPECT CRASH ZONE SENSOR
CONNECTOR
Microsoft
WARNING:
which may seriously injure you. Read the Yes Replace the air bag wiring harness.

WARNINGS .)

1 CAUTIONS .)

for 1 min or more.
 Disconnect the crash zone sensor connector.
(See CRASH ZONE SENSOR
 Is there any malfunction of the crash zone
sensor connector?
CRASH ZONE SENSOR AND SAS CONTROL
MODULE

for 1 min or more.
 Disconnect the clock spring connector. (See Replace the crash zone sensor, then go
COMBINATION SWITCH to the next step.
Yes
REMOVAL/INSTALLATION .) (See CRASH ZONE SENSOR
COMPARTMENT
BAG MODULE
Microsoft
Disconnect the driver and passenger-side curtain


AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
2  Disconnect the SAS control module connectors. No Replace the air bag wiring harness.
control module terminal 1W and crash zone
sensor terminal A, SAS control module terminal
1S and crash zone sensor terminal B for the
following:
 Short to ground
 Open circuit

 Connect the driver and passenger-side curtain Replace the SAS control module. (See
air bag module connectors. Yes SAS CONTROL MODULE
 Connect the driver and passenger-side front seat REMOVAL/INSTALLATION .)
3 connectors.
connector.
 Connect the crash zone sensor connector.
 Is DTC B104D, B2226, B2227 and/or B2855
indicated?
DTC B1054, B1877, B1878, B1879, B1885

Microsoft
B1054 Driver-side pre-tensioner seat belt and other air bag module circuits short
B1877 Driver-side pre-tensioner seat belt circuit resistance high
DTC B1878 Driver-side pre-tensioner seat belt circuit short to power supply
B1879 Driver-side pre-tensioner seat belt circuit short to body ground
B1885 Driver-side pre-tensioner seat belt circuit resistance low
WARNING:
CONDITION
 Resistance other than 1.0-9.7 ohms detected in driver-side pre-tensioner seat belt
circuit
 Malfunction in the wiring harness between driver-side pre-tensioner seat belt and SAS
control module
 Open or short circuit in wiring harness between driver-side pre-tensioner seat belt and
CAUSE  Driver-side pre-tensioner seat belt malfunction

INSPECT DRIVER-SIDE PRE-TENSIONER

SEAT BELT
Microsoft
 Using the M-MDS, verify the following

PID/DATA monitor. Replace the SAS control module. (See
(See PID/DATA MONITOR TABLE.) REMOVAL/INSTALLATION .)
1
RES_PT_D

 Is the resistance of the driver-side pre-tensioner

seat belt normal?
INSPECT DRIVER-SIDE PRE-TENSIONER

SEAT BELT CONNECTOR
WARNING:
which may seriously injure you. Read the Yes Replace the air bag wiring harness.

WARNINGS .)

2 CAUTIONS .)

for 1 min or more.
 Remove the B-pillar lower trim (LH). (See B-
PILLAR LOWER TRIM No Go to the next step.
 Disconnect the driver-side pre-tensioner seat
belt connector. (See FRONT SEAT BELT
 Is there any malfunction of the driver-side pre-
tensioner seat belt connector?
VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.

DRIVER-SIDE PRE-TENSIONER SEAT BELT

to driver-side pre-tensioner seat belt connector
Microsoft
terminals A and B.
 Set the resistance of the SST (Fuel and
thermometer checker) to the 2-ohm position. Replace the driver-side pre-tensioner
seat belt.
3  Connect the negative battery cable. No
(See FRONT SEAT BELT
 Turn the ignition switch to the ON position. REMOVAL/INSTALLATION .)
 Are DTCs B1054, B1877, B1878, B1879,

DRIVER-SIDE PRE-TENSIONER SEAT BELT

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
 Disconnect the passenger-side air bag module Yes SAS CONTROL MODULE
connector. (See PASSENGER-SIDE AIR REMOVAL/INSTALLATION .)
4 BAG MODULE
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
Microsoft

module terminal 2J and driver-side pre-tensioner
seat belt terminal A, SAS control module
terminal 2N and driver-side pre-tensioner seat
belt terminal B for the following: No Replace the air bag wiring harness.
 Short to ground
 Open circuit
DTC B1055, B1996, B1997, B1998, B1999

B1055 Passenger-side side air bag module and other air bag module circuits short
B1996 Passenger-side side air bag module circuit short to power supply
DTC B1997 Passenger-side side air bag module circuit short to body ground
B1998 Passenger-side side air bag module circuit resistance high
B1999 Passenger-side side air bag module circuit resistance low
WARNING:
CONDITION
 Resistance other than 1.0-9.7 ohms detected in passenger-side side air bag module
circuit
 Malfunction in wiring harness between passenger-side side air bag module and SAS
control module
 Open or short circuit in wiring harness between passenger-side side air bag module
CAUSE  Passenger-side side air bag module malfunction
Microsoft

MODULE
RES_SAB_P

 Is the resistance of the passenger-side side air


MODULE CONNECTOR
WARNING:
Yes Replace the air bag wiring harness.

WARNINGS .)
Microsoft

CAUTIONS .)


2  Disconnect the negative battery cable and wait No Go to the next step.
for 1 min or more.
module connector. (See SIDE AIR BAG
side air bag module connector?
PASSENGER-SIDE SIDE AIR BAG MODULE Yes Go to the next step.

to passenger-side side air bag module connector
3 terminals A and B. Replace the passenger-side side air bag
 Set the resistance of the SST (Fuel and module.
No
thermometer checker) to the 2-ohm position. (See SIDE AIR BAG SENSOR NO.
 Connect the negative battery cable. 1 REMOVAL/INSTALLATION .)
B1999 indicated?

PASSENGER-SIDE SIDE AIR BAG MODULE

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
 Disconnect the passenger-side air bag module Replace the SAS control module. (See
Microsoft
connector. (See PASSENGER-SIDE AIR SAS CONTROL MODULE

BAG MODULE REMOVAL/INSTALLATION .)
 Disconnect the driver-side seat connector. (See
FRONT SEAT
AIR BAG MODULE Yes
PILLAR LOWER TRIM
4 tensioner seat belt connectors. (See FRONT
SEAT BELT
module terminal 21 and passenger-side side air
bag module terminal A, SAS control module
terminal 2M and passenger-side side air bag
 Short to ground
 Open circuit
DTC B1056, B2777, B2778, B2779, B2780

B1056 Passenger-side curtain air bag module and other air bag module circuits short
B2777 Passenger-side curtain air bag module circuit resistance low
DTC B2778 Passenger-side curtain air bag module circuit resistance high
B2779 Passenger-side curtain air bag module circuit short to body ground
B2780 Passenger-side curtain air bag module circuit short to power supply
WARNING:
Microsoft
CONDITION  Resistance other than 1.0-9.7 ohms detected in passenger-side curtain air bag module
circuit
 Malfunction in wiring harness between passenger-side curtain air bag module and SAS
control module
 Open or short circuit in wiring harness between passenger-side curtain air bag module
CAUSE  Passenger-side curtain air bag module malfunction

INSPECT PASSENGER-SIDE CURTAIN AIR
BAG MODULE
RES_CAB_P

 Is the resistance of the passenger-side curtain air

INSPECT PASSENGER-SIDE CURTAIN AIR

BAG MODULE CONNECTOR
WARNING:
Microsoft

service warnings and cautions before Yes Replace the air bag wiring harness.

WARNINGS .)

2 CAUTIONS .)


for 1 min or more.
 Disconnect the passenger-side curtain air bag
module connectors. (See CURTAIN AIR BAG
curtain air bag module connector?
PASSENGER-SIDE CURTAIN AIR BAG Yes Go to the next step.
MODULE OR RELATED WIRING HARNESS

to passenger-side curtain air bag module
Replace the passenger-side curtain air
3 connector terminals A and B.
bag module.
 Set the resistance of the SST (Fuel and No (See CURTAIN AIR BAG
B2780 indicated?
PASSENGER-SIDE CURTAIN AIR BAG
MODULE AND SAS CONTROL MODULE

for 1 min or more.
Microsoft

COMBINATION SWITCH
COMPARTMENT
BAG MODULE
 Disconnect the driver-side curtain air bag
module connector. (See CURTAIN AIR BAG
4 PILLAR LOWER TRIM
SEAT BELT
module terminal 2AL and passenger-side curtain
air bag module terminal A, SAS control module
terminal 2AH and passenger-side curtain air bag No Replace the air bag wiring harness.
 Short to ground
 Open circuit
DTC B1057, B1916, B1932, B1934, B1936

B1057 Driver-side air bag module (inflator No.1) and other air bag module circuits short
B1916 Driver-side air bag module (inflator No.1) circuit short to power supply
DTC
B1932 Driver-side air bag module (inflator No.1) circuit resistance high
B1934 Driver-side air bag module (inflator No.1) circuit resistance low
Microsoft
B1936 Driver-side air bag module (inflator No.1) circuit short to body ground
WARNING:
CONDITION
 Resistance other than 1.5-9.7 ohms detected in driver-side air bag module (inflator
No.1) circuit
 Malfunction in wiring harness between driver-side air bag module (inflator No.1) and
SAS control module
 Open or short circuit in wiring harness between clock spring and SAS control module
POSSIBLE  Clock spring malfunction
CAUSE  Driver-side air bag module malfunction

INSPECT DRIVER-SIDE AIR BAG MODULE

PID/DATA monitor. Replace the SAS control module. (See
(See PID/DATA MONITOR TABLE.) REMOVAL/INSTALLATION .)
1
 RES_AB_D
 Is the resistance of the driver-side air bag
module (inflator No.1) normal? No Go to the next step.
 Resistance: 1.5-9.7 ohms
Microsoft

CONNECTOR (CLOCK SPRING)
WARNING:
which may seriously injure you. Read the Replace the air bag wiring harness
service warnings and cautions before Yes
and/or clock spring.

WARNINGS .)
2
CAUTIONS .)



for 1 min or more.
 Disconnect the driver-side air bag module No Go to the next step.
connector. (See DRIVER-SIDE AIR BAG
 Is there any malfunction of the driver-side air
bag module (inflator No.1) connector?
DRIVER-SIDE AIR BAG MODULE OR Yes Go to the next step.

to driver-side air bag module (inflator No.1)
connector terminals 3A and 3B, and driver-side
3 air bag module (inflator No.2) connector Replace the driver-side air bag
terminals 4A and 4B. module.
No (See DRIVER-SIDE AIR BAG
 Set the resistance of the SST (Fuel and MODULE
thermometer checker) to the 2-ohm position. REMOVAL/INSTALLATION .)
B1936?
INSPECT CLOCK SPRING Yes Go to the next step.
 Inspect the clock spring.

Microsoft
(See CLOCK SPRING INSPECTION .) Replace the clock spring.

4 No (See CLOCK SPRING
Is the clock spring normal?
 REMOVAL/INSTALLATION .)
CLOCK SPRING AND SAS CONTROL
MODULE

for 1 min or more.
COMPARTMENT
BAG MODULE
REMOVAL/INSTALLATION .) Replace the SAS control module. (See
 Disconnect the driver and passenger-side front Yes SAS CONTROL MODULE
seat connectors. (See FRONT SEAT REMOVAL/INSTALLATION .)
5 AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
module terminal 1M and clock spring terminal
1D, SAS control module terminal 11 and clock
spring terminal 1C for the following: No Replace the air bag wiring harness.
 Short to ground
 Open circuit
Microsoft
DTC B1058, B2228, B2230, B2232, B2234

B1058 Driver-side air bag module (inflator No.2) and other air bag module circuits short
B2228 Driver-side air bag module (inflator No.2) circuit short to body ground
DTC B2230 Driver-side air bag module (inflator No.2) circuit short to power supply
B2232 Driver-side air bag module (inflator No.2) circuit resistance high
B2234 Driver-side air bag module (inflator No.2) circuit resistance low
WARNING:
CONDITION
 Resistance other than 1.5-9.7 ohms detected in driver-side air bag module (inflator
No.2) circuit
 Malfunction in wiring harness between driver-side air bag module (inflator No.2) and
SAS control module
 Open or short circuit in wiring harness between clock spring and SAS control module
POSSIBLE  Clock spring malfunction
CAUSE  Driver-side air bag module malfunction

(INFLATOR NO.2)
Microsoft
PID/DATA monitor. SAS CONTROL MODULE

(See PID/DATA MONITOR TABLE.) Yes
1 RES_AB2_D

 Is the resistance of the driver-side air bag


CONNECTOR (CLOCK SPRING)
WARNING:
improperly can accidentally deploy the air bag
modules and pre-tensioner seat belts, which Yes Replace the air bag wiring harness.
may seriously injure you. Read the air bag
system service warnings and cautions before

WARNINGS .)
2
CAUTIONS .)

for 1 min or more.
 Disconnect the driver-side air bag module
connector. (See DRIVER-SIDE AIR BAG
 Is there any malfunction of the driver-side air
bag module connector?
VERIFY WHETHER MALFUNCTION IS IN Yes Go to the next step.

DRIVER-SIDE AIR BAG MODULE (INFLATOR
NO.2) OR RELATED WIRING HARNESS

3 thermometer checker) or apply 2-ohm resistance
to driver-side air bag module (inflator No.1) No
connector terminals 3A and 3B, and driver-side Replace the driver-side air bag
air bag module (inflator No.2) connector module.
terminals 4A and 4B. (See DRIVER-SIDE AIR BAG
Microsoft


B2234 indicated?
INSPECT CLOCK SPRING Yes Go to the next step.
 Inspect the clock spring.
4 Replace the clock spring.
(See CLOCK SPRING INSPECTION .) No (See CLOCK SPRING
 Is the clock spring normal?

CLOCK SPRING AND SAS CONTROL
MODULE

for 1 min or more.
COMPARTMENT
connector. (See PASSENGER-SIDE AIR BAG
MODULE REMOVAL/INSTALLATION .) Replace the SAS control module. (See
 Disconnect the driver and passenger-side front Yes SAS CONTROL MODULE
seat connectors. (See FRONT SEAT REMOVAL/INSTALLATION .)
5 REMOVAL/INSTALLATION .)
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
Microsoft
module terminal 1Q and clock spring terminal

1B, SAS control module terminal 1U and clock
spring terminal 1A for the following:
 Short to ground
 Open circuit
DTC B1059, B2229, B2231, B2233, B2235

B1059 Passenger-side air bag module (inflator No.2) and other air bag module circuits short
B2229 Passenger-side air bag module (inflator No.2) circuit short to body ground
DTC B2231 Passenger-side air bag module (inflator No.2) circuit short to power supply
B2233 Passenger-side air bag module (inflator No.2) circuit resistance high
B2235 Passenger-side air bag module (inflator No.2) circuit resistance low
WARNING:
CONDITION
 Resistance other than 1.0-9.7 ohms detected in passenger-side side air bag module
circuit
 Malfunction in wiring harness between passenger-side air bag module (inflator No.2)
and SAS control module
 Open or short circuit in wiring harness between passenger-side air bag module
POSSIBLE (inflator No.2) and SAS control module
CAUSE  Passenger-side air bag module malfunction
Microsoft

MODULE (INFLATOR NO.2)
RES_AB2_P

 Is the resistance of the passenger-side air bag


MODULE (INFLATOR NO.2) CONNECTOR
WARNING:
improperly can accidentally deploy the air bag Yes Replace the air bag wiring harness.
modules and pre-tensioner seat belts, which
Microsoft

WARNINGS .)

CAUTIONS .)



2 for 1 min or more. No Go to the next step.
COMPARTMENT
PASSENGER-SIDE AIR BAG MODULE Yes Go to the next step.
(INFLATOR NO.2) OR RELATED WIRING
HARNESS

to passenger-side air bag module (inflator No.1)
connector terminals 1A and Replace the passenger-side air bag
3
 1B, and passenger-side air bag module (inflator module.
No.2) connector terminals 2A and 2B. No (See PASSENGER-SIDE AIR BAG
B2235 indicated?
PASSENGER-SIDE AIR BAG MODULE AND
SAS CONTROL MODULE

for 1 min or more.
Microsoft

COMBINATION SWITCH
AIR BAG MODULE Replace the SAS control module. (See
REMOVAL/INSTALLATION .) Yes SAS CONTROL MODULE
PILLAR LOWER TRIM
4 tensioner seat belt connectors. (See FRONT
SEAT BELT
module terminal 1V and passenger-side air bag
module terminal 2A, SAS control module
terminal 1R and passenger-side air bag module
terminal 2B for the following: No Replace the air bag wiring harness.
 Short to ground
 Open circuit
DTC B105A
DTC B105A DETECTION CONDITION AND POSSIBLE CAUSE
DTC B105A SAS control module activation (deployment) control frequency error
WARNING:
performing an inspection. Performing an inspection with only detection
DETECTION conditions may cause injury due to an operating error, or damage the
system. When performing an inspection, always follow the inspection
CONDITION procedure.
 The SAS control module has enabled the air bag module or pre-tensioner seat
belt to operate (deploy) five times or more.
Microsoft
POSSIBLE
CAUSE  SAS control module malfunction
DTC B105A DIAGNOSTIC PROCEDURE

ACTION
 Replace the SAS control module
(See SAS CONTROL MODULE REMOVAL/INSTALLATION .)
DTC B105B, B110C, B1144, B1145

DTC B105B, B110C, B1144, B1145 DETECTION CONDITION AND POSSIBLE CAUSE
B105B Driver-side side air bag sensor No.2 and other sensor circuits short to power supply
B110C Driver-side side air bag sensor No.2 circuit open or short
DTC
B1144 Driver-side side air bag sensor No.2 (internal circuit abnormal)
B1145 Driver-side side air bag sensor No.2 (communication error)
WARNING:
CONDITION
 Malfunction in wiring harness between driver-side side air bag sensor No.2 and SAS
control module
 Malfunction in driver-side side air bag sensor No.2 circuit
 Open or short circuit in wiring harness between driver-side side air bag sensor No.2
CAUSE  Driver-side side air bag sensor No.2 malfunction
Microsoft
DTC B105B, B110C, B1144, B1145 DIAGNOSTIC PROCEDURE

WARNING:

WARNINGS .)
1
CAUTIONS .)

for 1 min or more. No Go to the next step.
No.2 connector. (See SIDE AIR BAG
SENSOR NO. 2
Microsoft
air bag sensor No.2 connector?

DRIVER-SIDE SIDE AIR BAG SENSOR NO.2

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
connector. (See PASSENGER-SIDE AIR Replace the driver-side side air bag
BAG MODULE sensor No.2, then go to the next step.
Yes
REMOVAL/INSTALLATION .) (See SIDE AIR BAG SENSOR NO.
 Disconnect the driver and passenger-side front 2 REMOVAL/INSTALLATION .)
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
control module terminal 2AM and driver-side
side air bag sensor No.2 terminal A, SAS
control module terminal 2AI and driver-side No Replace the air bag wiring harness.
side air bag sensor No.2 terminal B for the
following:
 Short to ground
Microsoft
Short to power supply


 Open circuit

 Connect the driver-side side air bag sensor No.2 Replace the SAS control module. (See
connector. Yes SAS CONTROL MODULE
connectors.
connector.
 Are DTCs B105B, B110C, B1144 and/or B1145
indicated?
DTC B105F, B110D, B1146, B1147

DTC B105F, B110D, B1146, B1147 DETECTION CONDITION AND POSSIBLE CAUSE
B105F Passenger-side side air bag sensor No.2 and other sensor circuits short to power supply
B110D Passenger-side side air bag sensor No.2 circuit open or short
DTC
B1146 Passenger-side side air bag sensor No.2 (internal circuit abnormal)
B1147 Passenger-side side air bag sensor No.2 (communication error)
WARNING:
CONDITION
 Malfunction in wiring harness between passenger-side side air bag sensor No.2 and
SAS control module
 Malfunction in passenger-side side air bag sensor No.2 circuit
POSSIBLE  Open or short circuit in wiring harness between passenger-side side air bag sensor
CAUSE No.2 and SAS control module
 Passenger-side side air bag sensor No.2 malfunction
Microsoft
DTC B105F, B110D, B1146, B1147 DIAGNOSTIC PROCEDURE

WARNING:

1 WARNINGS .)

CAUTIONS .)

for 1 min or more.
sensor No.2 connector. (See SIDE AIR BAG
SENSOR NO. 2
Microsoft
side air bag sensor No.2 connector?
PASSENGER-SIDE SIDE AIR BAG SENSOR
NO.2 AND SAS CONTROL MODULE

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
connector. (See PASSENGER-SIDE AIR Replace the passenger-side side air bag
BAG MODULE sensor No.2, then go to the next step.
Yes
REMOVAL/INSTALLATION .) (See SIDE AIR BAG SENSOR NO.
 Disconnect the driver and passenger-side front 2 REMOVAL/INSTALLATION .)
2 seat connectors. (See FRONT SEAT
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
control module terminal 2AA and passenger-
side side air bag sensor No.2 terminal A, SAS
control module terminal 2AE and passenger-
side side air bag sensor No.2 terminal B for the
Microsoft
following:
 Short to ground
 Short to power supply No Replace the air bag wiring harness.

 Open circuit

 Connect the passenger-side side air bag sensor Replace the SAS control module. (See
No.2 connector. Yes SAS CONTROL MODULE
connectors.
connector.
 Are DTCs B105F, B110D, B1146 and/or B1147
indicated?
DTC B110E, B110F, B2856, B2886, B2887

DTC B110E, B110F, B2856, B2886, B2887 DETECTION CONDITION AND POSSIBLE CAUSE
B110E Driver-side side air bag sensor No.2 ID mismatch
B110F Passenger-side side air bag sensor No.2 ID mismatch
DTC B2856 Crash zone sensor ID mismatch
B2886 Passenger-side side air bag sensor No.1 ID mismatch
B2887 Driver-side side air bag sensor No.1 ID mismatch
WARNING:
detection conditions may cause injury due to an operating error, or damage
DETECTION the system. When performing an inspection, always follow the inspection
CONDITION procedure.
 The SAS control module detects an error of impact magnitude set in the sensor,
which occurs due to installation mismatch of the crash zone sensor or side air
bag sensors.
Microsoft
Crash zone sensor misinstalled with wrong sensor

 Driver-side side air bag sensor No.1 misinstalled with wrong sensor
POSSIBLE
 Passenger-side side air bag sensor No.1 misinstalled with wrong sensor
CAUSE
 Driver-side side air bag sensor No.2 misinstalled with wrong sensor
 Passenger-side side air bag sensor No.2 misinstalled with wrong sensor
DTC B110E, B110F, B2856, B2886, B2887 DIAGNOSTIC PROCEDURE

INSPECT EACH SENSOR FOR
INSTALLATION POSITION
WARNING:
 Handling the air bag system components Yes Go to the next step.
bag modules and pre-tensioner seat
belts, which may seriously injure you.
Read the service warnings and cautions
before handling the air bag system
components.

WARNINGS .)
1
CAUTIONS .)
Install the each sensor correctly, then go to

No
Turn the ignition switch to the LOCK
 the next step.
position.
 Disconnect the negative battery cable and
wait for 1 min or more.
 Verify that the crash zone sensor or side air
bag sensor is installed in the correct
position.
 Is each sensor installed correctly?

 Connect the negative battery cable. Yes SAS CONTROL MODULE
 Are DTCs B110E, B110F, B2856, B2886
and/or B2887 indicated? No DTC troubleshooting completed.
Microsoft
DTC B1231
DTC B1231 SAS control module activation (deployment) control freeze
WARNING:
CONDITION system. When performing an inspection, always follow the inspection
procedure.
 SAS control module determined collision

ACTION
Replace the SAS control module. (See SAS CONTROL MODULE REMOVAL/INSTALLATION .)
DTC B1317, B1318

DTC B1317, B1318 DETECTION CONDITION AND POSSIBLE CAUSE
B1317 SAS control module power supply voltage increases (18.1 V or more)
DTC
B1318 SAS control module power supply voltage decreases (less than 8 V)
WARNING:
DETECTION inspection. Performing an inspection with only detection conditions may cause
injury due to an operating error, or damage the system. When performing an
CONDITION
inspection, always follow the inspection procedure.
 When the SAS control module power supply voltage is not within 8-18 V.
 Open or short circuit in wiring harness between battery and SAS control module
POSSIBLE  SAS 7.5 A fuse malfunction
CAUSE  Battery malfunction
Microsoft
DTC B1317, B1318 DIAGNOSTIC PROCEDURE

Step Inspection Action
INSPECT FUSE
1 Remove the SAS 7.5 A fuse.

No Replace the fuse.
 Is the fuse normal?
INSPECT BATTERY Yes Go to the next step.

2  Measure the battery positive voltage. The battery has a malfunction.
No
 Is the voltage 8 V-18 V? Inspect the charge/discharge system.
Install the fuse, then go to the next

3 Yes
INSPECT WIRING HARNESS BETWEEN step.
BATTERY AND FUSE BLOCK
Microsoft

Repair the wiring harness between the
 Measure the fuse block terminal H voltage. No
battery and fuse block.
 Is the voltage 8 V-18 V?
WARNING:
improperly can control module. accidentally
deploy the air bag modules and pre-tensioner
seat belts, which may seriously injure you.
Read the service warnings before handling the
air bag system components.
(See AIR BAG SYSTEM SERVICE WARNINGS .)
(See AIR BAG SYSTEM SERVICE CAUTIONS .)

 Turn the ignition switch to the LOCK position. Yes SAS CONTROL MODULE
 Disconnect the negative battery cable and wait REMOVAL/INSTALLATION .)
for 1 min or more.
4  Disconnect the clock spring connector. (See
COMBINATION SWITCH
COMPARTMENT
air bag module connectors. (See CURTAIN AIR
BAG MODULE
REMOVAL/INSTALLATION .) No
 Remove the B-pillar lower trim. (See B-PILLAR
LOWER TRIM
tensioner seat belt connectors. (See FRONT Repair the wiring harness between the
Microsoft
SEAT BELT REMOVAL/INSTALLATION .) fuse block and SAS

 Measure the voltage at the SAS control module
terminal 1D.
DTC B1342, B1921

B1342 SAS control module (internal circuit abnormal)
DTC
B1921 Air bag diagnostic ground circuit open
WARNING:
CONDITION system. When performing an inspection, always follow the inspection
procedure.
 Malfunction in the SAS control module internal circuit

POSSIBLE

ACTION
Replace the SAS control module. (See SAS CONTROL MODULE REMOVAL/INSTALLATION .)
DTC B1868
DTC B1868 Air bag warning system light malfunction
WARNING:
DETECTION  Detection conditions are for understanding the DTC outline before
CONDITION performing an inspection. Performing an inspection with only detection
conditions may cause injury due to an operating error, or damage the
system. When performing an inspection, always follow the inspection
procedure.
Microsoft
 Air bag warning system light malfunction.

VERIFY THAT SAS CONTROL MODULE
CONNECTOR IS CONNECTED
WARNING:
air bag system service warnings and
cautions before handling the air bag
system components.
1 (See AIR BAG SYSTEM SERVICE

WARNINGS .)

CAUTIONS .) Reconnect the connector properly, then
No
go to the next step.
Turn the ignition switch to LOCK position.



 Are all SAS control module connectors
securely connected?
INSPECT DTCS IN SAS CONTROL MODULE
Perform the applicable DTC inspection.
Yes
Inspect the DTC for the SAS control module
 (See DTC TABLE.)
2 on-board diagnostic system.
 Has DTC U0155, U0073 been recorded in
memory?
INSPECT INSTRUMENT CLUSTER
 Inspect the instrument cluster warning lights Yes SAS CONTROL MODULE
using check code. REMOVAL/INSTALLATION .)
3
(See INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE .) Repair or replace the instrument cluster
No
according to inspection results.
 Are the check results okay?
Microsoft
DTC B1884, B1890

B1884 Passenger air bag deactivation (PAD) indicator circuit open or short to body ground
DTC
B1890 Passenger air bag deactivation (PAD) indicator circuit short to power supply
WARNING:
DETECTION inspection. Performing an inspection according to only the detection conditions
CONDITION
 Malfunction in PAD indicator circuit

 Open or short circuit in wiring harness between information display and SAS control
module
POSSIBLE
 Open circuit in wiring harness between battery and information display
CAUSE
 information display malfunction

INSPECT OPERATION OF PAD INDICATOR
1  Turn the ignition switch to the ON position.
No Go to Step 5.
 Does the PAD indicator illuminate?
Yes
INSPECT FUSE Install the fuse, then go to the next
Microsoft
Remove the METER 10 A fuse.


step.
2
 Is the fuse normal? No Replace the fuse.
3 Measure the battery positive voltage.
 Battery is malfunctioning Inspect the
No
charge/discharge system.
BATTERY AND PAD INDICATOR Yes Go to the next step.

 Measure the information display connector Repair the wiring harness between the
No
terminal E voltage. battery and information display.
 Is the voltage 9 V or more?
INSPECT WIRING HARNESS BETWEEN PAD

INDICATOR AND SAS CONTROL MODULE
WARNING:
bag modules and pre-tensioner front buckles,
service warnings before handling the air bag
system components.

WARNINGS .)

CAUTIONS .) Yes Go to the next step.
5

for 1 min or more.
COMBINATION SWITCH
COMPARTMENT
Microsoft
BAG MODULE
AIR BAG MODULE
PILLAR LOWER TRIM
tensioner seat belt connectors. (See FRONT No Replace the air bag wiring harness.
SEAT BELT
 Inspect the wiring harness between information
display connector terminal K and SAS control
module connector terminal 1G for the
following:
 Short to ground
 Open circuit

INSPECT PAD INDICATOR Replace the information display.
Yes (See INFORMATION DISPLAY
 Disconnect the SAS control module connector. REMOVAL/INSTALLATION .)
6
 Connect the information display connector. Replace the SAS control module. (See
No SAS CONTROL MODULE
 Does the PAD indicator illuminate? REMOVAL/INSTALLATION .)
DTC B2290
DTC B2290 Seat weight sensor signal malfunction
WARNING:
DETECTION  Detection conditions are for understanding the DTC outline before performing an
CONDITION inspection. Performing an inspection according to only the detection conditions
Microsoft
 Passenger sensing system circuit malfunction

 Seat weight sensor calibration not properly set
 Communication error between SAS control module and seat weight sensor control
POSSIBLE
module
CAUSE
 Seat weight sensor control module internal malfunction
 LH or RH seat weight sensor malfunction

INSPECT SEAT WEIGHT SENSOR
CONTROL MODULE CONNECTOR
WARNING:
 Handling the air bag system
components improperly can
accidentally operate (deploy) the air
bag modules and pre-tensioner seat
belts, which may seriously injure Repair or replace the wiring harness. After
1 you. Read the service warnings and Yes replacement, reperform the DTC inspection and
cautions before handling the air bag verify that no DTCs are displayed.
system components.

WARNINGS .)

CAUTIONS .)
Microsoft
Turn the ignition switch to the LOCK


position.
 Disconnect the negative battery cable
and wait for 1 min or more.
 Disconnect the seat weight sensor
control module connector. (See SEAT No Go to the next step.
WEIGHT SENSOR CONTROL
MODULE
 Is there any malfunction of the seat
weight sensor control module
connector?
INSPECT SEAT WEIGHT SENSOR Yes Go to the next step.
CONTROL MODULE POWER SUPPLY
CIRCUIT
If there is any malfunction in the wiring
 Turn the ignition switch to the ON harnesses, repair or replace the applicable wiring
2 position. harness.
No
 Measure voltage at terminal 3A of seat After replacement, reperform the DTC
weight sensor control module inspection and verity that no DTCs are
connector. displayed.
Is voltage more than B+?

INSPECTION WIRING HARNESS

 Disconnect the SAS control module
connector. (See SAS CONTROL
MODULE
 Verify continuity in the following
wiring harnesses: If there is any malfunction in the wiring
3 harnesses, repair or replace the applicable wiring
 Between SAS control module
harness.
terminal 2AJ and seat weight No
After replacement, reperform the DTC
sensor control module terminal inspection and verify that no DTCs are
3D displayed.
 Between seat weight sensor
control module terminal 3B and
body ground
 Is the continuity normal?
Replace the following parts according to the M-

MDS screen:
INSPECT PASSENGER SENSING
SYSTEM  If OCSFLT_CAL is displayed:
Microsoft
 Connect the seat weight sensor control Perform seat weight sensor

module connector. calibration (See SEAT WEIGHT
 Connect the SAS control module. SENSOR CALIBRATION .)
 If OCSFLT_COM or OCSFLT_MDL is
displayed:
 Verify the following PIDs using the
 Seat weight sensor control module
M-MDS. (See PID/DATA
MONITOR TABLE.) (See SEAT WEIGHT SENSOR
CONTROL MODULE
 OCSFLT_CAL
4 No REMOVAL/INSTALLATION .)
 OCSFLT_COM
 If OCSFLT_L is displayed:
 OCSFLT_L
 Seat weight sensor (LH) (See: 09-
 OCSFLT_MDL 13-3 FRONT SEAT
 OCSFLT_R DISASSEMBLY/ASSEMBLY.)
 Do all PIDs display "OK"?  If OCSFLT_R is displayed:
 Seat weight sensor (RH) (See

FRONT SEAT
DISASSEMBLY/ASSEMBLY .)
[Present malfunction diagnosis]
INSPECT SAS CONTROL MODULE (See SAS CONTROL MODULE

5  Reperform the DTC inspection.
 Is DTC B2290 indicated?
[Past malfunction diagnosis]
 DTC troubleshooting completed.

No DTC troubleshooting completed.
DTC B2477
DTC B2477 Configuration error
WARNING:
DETECTION detection conditions may cause injury due to an operating error, or damage
CONDITION the system. When performing an inspection, always follow the inspection
procedure.
 SAS control module configuration has not been performed correctly.
POSSIBLE  SAS control module configuration error

Microsoft

Replace the SAS control module. (See SAS
 Using the M-MDS, perform SAS control Yes CONTROL MODULE
1 module configuration. (See SAS REMOVAL/INSTALLATION .)
CONTROL MODULE
CONFIGURATION .)
 Is DTC B2477 indicated? No DTC troubleshooting completed.
DTC C1946, C1947, C1948, C1981, C1982

DTC C1946, C1947, C1948, C1981, C1982 DETECTION CONDITION AND POSSIBLE CAUSE
C1946 Seat track position sensor circuit open
C1947 Seat track position sensor circuit short to body ground
DTC C1948 Seat track position sensor circuit resistance not within specification
C1981 Seat track position sensor circuit malfunction
C1982 Seat track position sensor circuit short to power supply
WARNING:
DETECTION inspection. Performing an inspection according to only the detection conditions
CONDITION
 Malfunction in seat track position sensor circuit.

 Malfunction of connector between seat track position sensor and SAS control module.
 Open or short circuit in wiring harness between seat track position sensor and SAS
POSSIBLE
control module.
CAUSE
 Seat track position sensor malfunction
Microsoft
DTC C1946, C1947, C1948, C1981, C1982 DIAGNOSTIC PROCEDURE

INSPECT SEAT TRACK POSITION SENSOR
CIRCUIT

PID/DATA monitor. (See SAS CONTROL MODULE
1
(See PID/DATA MONITOR TABLE.)
 TRAK_SW
 Is the seat track position sensor circuit  DTC troubleshooting completed.
normal?
No Go to next step.
SEAT TRACK POSITION SENSOR AND SAS
CONTROL MODULE
WARNING:
air bag system service warnings and
cautions before handling the air bag
Microsoft
system components.

WARNINGS .)

CAUTIONS .)
 Turn the ignition switch to the LOCK

Replace the seat track position sensor,
position. Yes
then go to next step.
COMBINATION SWITCH
 Remove the glove compartment. (See
GLOVE COMPARTMENT
 Disconnect the passenger-side air bag
2 module connector. (See PASSENGER-
SIDE AIR BAG MODULE
front seat connectors. (See FRONT SEAT
Replace wiring harness, then go to next
 Remove the B-pillar lower trim. (See B- No
step.
PILLAR LOWER TRIM
pre-tensioner seat belt connectors. (See
FRONT SEAT BELT
 Disconnect the SAS control module
connectors. (See SAS CONTROL
MODULE
 Disconnect the seat track position sensor
Microsoft
connector
 Inspect the wiring harness between SAS
control module terminal and seat track
position sensor terminals for short to ground,
short to power supply, and open circuit:
 2AB-A
 2AF-C

 Connect the passenger-side air bag module  Replace the SAS control module.
connector.
 Connect the driver-and passenger-side front (See SAS CONTROL MODULE
seat connectors. Yes REMOVAL/INSTALLATION .)
3
 Connect the driver-and passenger-side
curtain air bag module connectors.
 Connect the driver-and passenger-side pre
tensioner seat belt connectors.  DTC troubleshooting completed.
 Connect the seat track position sensor
connector.
 Are DTCs C1946, C1947, C1948, C1981
and/or C1982 indicated? NO DTC troubleshooting completed.
Microsoft
2008 RESTRAINTS Symptom Troubleshooting (Restraints) - Mazda CX-9
2008 RESTRAINTS
Symptom Troubleshooting (Restraints) - Mazda CX-9
AIR BAG SYSTEM WIRING DIAGRAM (SYMPTOM TROUBLESHOOTING)
Microsoft
Fig. 1: Air Bag System Wiring Diagram

Microsoft
TROUBLESHOOTING INDEX
 Use the chart below verify the symptoms of the trouble in order to diagnose the appropriate area.
No. Troubleshooting item Description Page
Malfunction in air bag system (See NO.1 AIR BAG SYSTEM
Air bag system warning
1 warning light circuit (short to WARNING LIGHT DOES NOT
light does not illuminate.
ground). ILLUMINATE)
Air bag system warning Malfunction in air bag system (See NO.2 AIR BAG SYSTEM
2 light is illuminated warning light circuit (open circuit WARNING LIGHT
constantly. or short to power supply). ILLUMINATES CONSTANTLY)
NO.1 AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE

AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE - DETECTION CONDITION
AND POSSIBLE CAUSE CHART
1 Air bag system warning light does not illuminate.
DETECTION
Malfunction in air bag system warning light circuit (short to ground)
CONDITION
POSSIBLE CAUSE  Instrument cluster (circuit board) malfunction
 Short to ground circuit in wiring harness between instrument cluster and
SAS control module
INSPECT OTHER WARNING AND INDICATOR Turn the ignition switch to the LOCK
Yes
LIGHTS CIRCUIT IN INSTRUMENT CLUSTER position, then go to the next step.
1 Inspect the instrument cluster power
 Turn the ignition switch to the ON position. No supply system and ground system,
 Do other warning and indicator lights illuminate? then go to Step 4.
INSPECT DTCS IN SAS CONTROL MODULE Perform the applicable DTC
Yes inspection, then go to Step 5. (See
2 Inspect the DTC for the SAS control module on-

DTC TABLE .)
board diagnostic system.
 Have DTCs been recorded in memory? No Go to the next step.
WARNING:
Microsoft

handling the air bag system components. (See
AIR BAG SYSTEM SERVICE WARNINGS .)
(See AIR BAG SYSTEM SERVICE CAUTIONS .)
 Turn the ignition switch to LOCK position.

for 1 min or more.
COMBINATION SWITCH Replace the SAS control module, then
REMOVAL/INSTALLATION .) go to Step 5. (See SAS CONTROL
Yes
 Remove the glove compartment. (See GLOVE MODULE
COMPARTMENT REMOVAL/INSTALLATION .)
3 MODULE REMOVAL/INSTALLATION .)
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
 Turn the ignition switch to ON position.
 Does the air bag system warning light
illuminate?
Microsoft
Perform the applicable DTC

inspection, then go to the next step.
Yes
INSPECT DTCS IN INSTRUMENT CLUSTER (See DTC TABLE [INSTRUMENT
CLUSTER] .)
4  Inspect the DTC for the instrument cluster on- Inspect the instrument cluster warning
board diagnostic system. lights using check code, then go to the
next step.
 Have DTCs been recorded in memory? No
INPUT/OUTPUT CHECK
MODE .)
CONFIRM THAT MALFUNCTION SYMPTOMS
DO NOT RECUR AFTER REPAIR
 Turn the ignition switch to LOCK position. Complete troubleshooting, then

Yes
 Disconnect the negative battery cable and wait explain repairs to customer.
for 1 min or more.
 Connect all SAS control module connectors.
5  Connect the driver and passenger-side curtain air
bag module connectors. Connect the driver and
passenger-side front seat connectors.
 Connect the passenger-side air bag module Recheck malfunction symptoms, then
connector. No repeat from Step 1 if malfunction
 Connect the clock spring connector. recurs.
 Does the air bag system warning light operate
properly?
NO.2 AIR BAG SYSTEM WARNING LIGHT ILLUMINATES CONSTANTLY

AIR BAG SYSTEM WARNING LIGHT ILLUMINATES CONSTANTLY - DETECTION CONDITION
AND POSSIBLE CAUSE CHART
2 Air bag system warning light is illuminated constantly.
DETECTION Malfunction in air bag system warning light circuit (open circuit or short to
CONDITION power supply).
 Weak battery
 Instrument cluster (circuit board) malfunction
 No connection in SAS control module connector
 Poor contact in instrument cluster connector
Microsoft
 Open or short to power supply circuit in wiring harness between

instrument cluster and SAS control module
 Poor contact at terminals 1D and/or 1K of SAS control module connector
POSSIBLE CAUSE  Poor contact in wiring harness between terminal 1K of SAS control
module connector and ground
 Poor contact in wiring harness between battery and terminal 1D of SAS
control module
Battery is weak.
1  Measure the voltage of battery. Inspect charge/discharge system, then
No
go to Step 10. (See BATTERY
 Is the voltage 9 V or more ? INSPECTION [MZI-3.7] .)
WARNING: Yes Go to the next step.

handling the air bag system components.(See
AIR BAG SYSTEM SERVICE WARNINGS .)
2 (See AIR BAG SYSTEM SERVICE CAUTIONS .)

 Reconnect the connector properly,
No
then go to Step 10.
for 1 min or more.
 Remove the console. (See CONSOLE
 Are all SAS control module connectors securely
connected?
INSPECT DTCS IN INSTRUMENT CLUSTER Yes Go to the next step.
3  Inspect the DTC for the instrument cluster on- Inspect the instrument cluster. (See
board diagnostic system. No INSTRUMENT CLUSTER
 Has DTC U2064 been recorded in memory? INSPECTION .)
INSPECT DTCS IN SAS CONTROL MODULE

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Inspect the DTC for the SAS control module on-


Perform the applicable DTC
board diagnostic system. Yes inspection, then go to Step 10. (See
4 DTC TABLE .)
 Have DTCs been recorded in memory?
INSPECT DTCS IN INSTRUMENT CLUSTER Perform the applicable DTC
inspection, then go to Step 10. (See
Yes
5  Inspect the DTC for the instrument cluster on- CLEARING DTC [INSTRUMENT
board diagnostic system. CLUSTER] .)
 Have DTCs been recorded in memory? No Go to the next step.
INSPECT INSTRUMENT CLUSTER
 Inspect the instrument cluster warning lights
using check code.
6 Repair or replace the instrument
(See INSTRUMENT CLUSTER No cluster according to inspection results.
INPUT/OUTPUT CHECK MODE .) Then go to Step 10.
Are the check results okay?


INSPECT POWER SUPPLY CIRCUIT OF SAS

CONTROL MODULE (TERMINAL 1D)

 Disconnect the negative battery cable and wait Yes Go to the Step 9.
for 1 min or more.
7  Connect the driver and passenger-side curtain air
bag module connectors. Connect the driver and
passenger-side front seat connectors.
connector.
 Connect the clock spring connector. No Go to the next step.
 Inspect the voltage for PID/DATA monitor
IGN_V_2 item using M-MDS.
 Is the voltage of at least one terminal 8 V - 16
V?
BATTERY AND FUSE BLOCK Yes Go to the next step.
8  Connect the negative battery cable.

 Turn the ignition switch to ON position. No
 Measure the voltage at instrument cluster Repair the wiring harnesses, then go to
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connector terminal 1H. Step 10.


CONNECTOR TERMINAL 1D IS GROUND

for 1 min or more.
COMBINATION SWITCH
 Remove the glove compartment. (See GLOVE Replace the SAS control module, then
COMPARTMENT go to the next step. (See SAS
REMOVAL/INSTALLATION .) Yes
CONTROL MODULE
 Disconnect the passenger-side air bag module REMOVAL/INSTALLATION .)
9
AIR BAG MODULE
PILLAR LOWER TRIM
SEAT BELT
REMOVAL/INSTALLATION .) Replace the wiring harnesses, then go
No
to the next step.
module connector terminal 1D and ground for
the following:
 Open circuit

CONFIRM THAT MALFUNCTION SYMPTOMS
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DO NOT RECUR AFTER REPAIR

 Disconnect the negative battery cable and wait Yes Complete troubleshooting, then
for 1 min or more. explain repairs to customer.
 Connect the driver and passenger-side curtain air
bag module connectors.
connectors.
connector. Recheck malfunction symptoms, then
No repeat from Step 1 if malfunction
 Connect the clock spring connector. recurs.
 Connect the instrument cluster connector.
 Does the air bag system warning light operate
properly?
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2008 RESTRAINTS Air Bag System - Mazda CX-9
2008 RESTRAINTS
Air Bag System - Mazda CX-9
AIR BAG SYSTEM LOCATION INDEX
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Fig. 1: Identifying Air Bag System Location

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AIR BAG SYSTEM SERVICE WARNINGS

AIR BAG MODULE INSPECTION
 Inspecting an air bag module using a tester can operate (deploy) the air bag module, which may
cause serious injury. Do not use a tester to inspect an air bag module. Always use the on-board
diagnostic function to diagnose the air bag module for malfunctions.
Fig. 2: Precaution For Air Bag Module Inspection

AIR BAG MODULE HANDLING
 Before removing the air bag module or disconnecting the air bag module connector, always turn
the ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1
min or more to allow the backup power supply of the SAS control module to deplete its stored
power.
 Handling a live (undeployed) air bag module that is pointed toward your body could result in
serious injury if the air bag module were to accidentally operate (deploy). When carrying a live
(undeployed) air bag module, point the deployment surface away from your body to lessen the
chance of injury in case it operates (deploys).
Fig. 3: Precaution For Air Bag Module Handling
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 A live (undeployed) air bag module placed with its deployment surface to ground is dangerous. If
the air bag module were to accidentally operate (deploy), it could cause serious injury. Always
place a live (undeployed) air bag module with its deployment surface up.
Fig. 4: Precaution For Air Bag Module Handling

SIDE AIR BAG MODULE HANDLING
 Before removing the side air bag module or disconnecting the side air bag module connector,
always turn the ignition switch to the LOCK position, disconnect the negative battery cable, and
then wait for 1 min or more to allow the backup power supply of the SAS control module to deplete
its stored power.
 When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated
(deployed), always replace both the side air bag module and the seat back (pad, frame, trim) with
new parts. After servicing, verify that the seat operates normally and that the wiring harness is not
caught.
SEAT WEIGHT SENSOR HANDLING
 The front passenger-side seat and the seat weight sensor may become deformed or otherwise
damaged due to operation (deployment) of the front or side air bag in an accident. This may cause
the passenger sensing function to operate improperly and result in a serious accident. Always
replace the ' front passenger seat and seat weight sensor with new ones after the front or side air
bags have operated (deployed). After servicing, verify that the seat operates normally and that the
wiring harness is not caught. If the collision is not hard enough to cause the front or side air bags to
operate (deploy), inspect the seat weight sensor and replace it if there is any malfunction.
SAS CONTROL MODULE HANDLING
 Removing the SAS control module or disconnecting the SAS control module connector with the
ignition switch at the ON position can activate the sensor in the SAS control module and operate
(deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing
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the SAS control module or disconnecting the SAS control module connector, always turn the
ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min
or more to allow the backup power supply of the SAS control module to deplete its stored power.
 Connecting the SAS control module connector with the SAS control module not securely fixed to
the vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the
air bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-
tensioner seat belts, which may result in serious injury. Therefore, before connecting the connector,
securely fix the SAS control module to the vehicle.
 Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be
replaced with a new one even if the used one does not have any visible external damage or
deformation. The used SAS control module may have been damaged internally, which may cause
improper operation. If the SAS control module is reused, the air bags and pre-tensioner seat belts
may not operate (deploy) normally, which could result in a serious accident. Always replace the
SAS control module with a new one. The SAS control module cannot be bench-checked or self-
checked.
CRASH ZONE SENSOR HANDLING
 Removing the crash zone sensor or disconnecting the crash zone sensor connector with the ignition
switch at the ON position can activate the crash zone sensor and operate (deploy) the air bags and
pre-tensioner seat belts, which may cause serious injury. Before removing the crash zone sensor or
disconnecting the crash zone sensor connector, always turn the ignition switch to the LOCK
position, disconnect the negative battery cable, and then wait for 1 min or more to allow the backup
power supply of the SAS control module to deplete its stored power.
 If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bags and pre-
tensioner seat belts may accidentally operate (deploy) and cause injury, or the system may fail to
operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or
disassemble the sensor.
 Because a sensor is built into the crash zone sensor, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the crash zone sensor must be replaced
with a new one even if the used one does not have any visible external damage or deformation. If
the crash zone sensor is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the crash zone sensor with a new
one. The crash zone sensor cannot be bench-checked or self-checked.
SIDE AIR BAG SENSOR HANDLING
 Removing the side air bag sensor or disconnecting the side air bag sensor connector with the
ignition switch at the ON position can activate the side air bag sensor and operate (deploy) the side
air bag, which may cause serious injury. Before removing the side air bag sensor or disconnecting
the side air bag sensor connector, always turn the ignition switch to the LOCK position, disconnect
the negative battery cable, and then wait for 1 min or more to allow the backup power supply of the
SAS control module to deplete its stored power.
 If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and
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cause a serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
 Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due
to a collision or other causes, the side air bag sensor must be replaced with a new one even if the
used one does not have any visible external damage or deformation. If the side air bag sensor is
reused, the side air bag may not operate (deploy) normally, which could result in a serious accident.
Always replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-
checked or self-checked.
PRE-TENSIONER SEAT BELT INSPECTION
 Inspecting a pre-tensioner seat belt using a tester can operate (deploy) the pre-tensioner seat belt,
which may cause serious injury. Do not use a tester to inspect a pre-tensioner seat belt. Always use
the on-board diagnostic function to diagnose the pre-tensioner seat belt for malfunctions.
Fig. 5: Precaution For Pre-Tensioner Seat Belt Inspection

AIR BAG SYSTEM SERVICE CAUTIONS

AIR BAG SYSTEM COMPONENT DISASSEMBLY
 Disassembling the air bag system components could cause it to not operate (deploy) normally.
Never disassemble any air bag system components.
Fig. 6: Precaution For Air Bag System Component Disassembly

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AIR BAG MODULE, PRE-TENSIONER SEAT BELT HANDLING
 Oil, grease, or water on the air bag modules may cause the air bags and pre-tensioner seat belts to
fail to operate (deploy) in an accident. Never allow oil, grease, or water to get on the air bag
modules or pre-tensioner seat belts.
 Inserting a screwdriver or similar object into the connector of an air bag module or a pre-tensioner
seat belt may damage the connector and cause the air bag module or the pre-tensioner seat belt to
operate (deploy) improperly, which may cause serious injury. Never insert any foreign objects into
the air bag module or seat belt connectors.
Fig. 7: Precaution For Air Bag Module, Pre-Tensioner Seat Belt Handling
SEAT WEIGHT SENSOR HANDLING
 The seat weight sensor has a built-in strain gauge which may operate improperly if the sensor is
dropped by itself or when installed to the seat. If it is dropped, replace the seat weight sensor with a
new one.
 Oil, grease, or water on the seat weight sensor may cause the system to operate (deploy)
improperly. Never allow oil, grease, or water to get on the seat weight sensor.
 Foreign material in the seat weight sensor components may cause the system to operate (deploy)
improperly. Always make sure that no foreign material can get into the seat weight sensor.
 Disassembling the seat weight sensor, or tightening any of the nuts and bolts installed to the sensor
body may cause it to operate (deploy) improperly. Never disassemble the seat weight sensor or
tighten any of the nuts or bolts installed to the body of the sensor.
AIR BAG MODULE, PRE-TENSIONER SEAT BELT REUSE
 Even if an air bag module or a pre-tensioner seat belt does not operate (deploy) in a collision and
does not have any external signs of damage, it may have been damaged internally, which may cause
improper operation. Before reusing a live (undeployed) air bag module and the pre-tensioner seat
belts, always use the on-board diagnostic to diagnose the air bag module and the pre-tensioner seat
belts to verify that they have no malfunction.
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AIR BAG WIRING HARNESS REPAIR
 Incorrectly repairing an air bag wiring harness can accidentally operate (deploy) the air bag
module and pre-tensioner seat belts. If a problem is found in the air bag wiring harness, always
replace the wiring harness with a new one.
Fig. 8: Precaution For Air Bag Wiring Harness Repair

DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION
WARNING:  Handling the air bag module improperly can accidentally deploy the
air bag module, which may seriously injure you. Read the air bag
system service warnings and cautions before handling the air bag
module. (See AIR BAG SYSTEM SERVICE WARNINGS.) (See AIR
BAG SYSTEM SERVICE CAUTIONS.)
1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove in the order indicated in the table.
Fig. 9: Identifying Driver-Side Air Bag Module Components & Torque Specifications
4. Install in the reverse order of removal.
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5. Turn the ignition switch to the ON position.

6. Verify that the air bag system warning light illuminates for approx. 6 s and goes out.
 If the air bag system warning light does not operate normally, refer to the on-board diagnostic
system (air bag system) and perform inspection of the system. (See FLOWCHART .)
CONNECTOR A REMOVAL NOTE
1. Using a flathead screwdriver, pry out the connector stopper plate.

2. Disconnect the connector.
Fig. 10: Prying Out Connector Stopper Plate Using Screwdriver

PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION
 Due to the adoption of 2-step deployment control in the passenger-
side air bag module, depending on the impact force, it is possible
that inflator No.2 might not deploy. In such cases, before disposing
of the air bag module, make sure to follow the inflator deployment
procedures and verify complete deployment of inflators No.1 and 2.

2. Disconnect the negative battery cable and wait for 1 min or more .
3. Remove the following parts:
1. Decoration panel (See DECORATION PANEL REMOVAL/INSTALLATION .)
2. Front console box mat (See FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION .)
3. Indicator panel (See INDICATOR PANEL REMOVAL/INSTALLATION .)
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4. Front console box (See FRONT CONSOLE BOX REMOVAL/INSTALLATION .)

5. Center panel (See CENTER PANEL REMOVAL/INSTALLATION .)
6. Front scuff plate inner (RH) (See FRONT SCUFF PLATE REMOVAL/INSTALLATION .)
7. Front side trim (RH) (See FRONT SIDE TRIM REMOVAL/INSTALLATION .)
8. Dashboard under cover (Passenger side) (See DASHBOARD UNDER COVER
9. Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)
10. Side panel (See SIDE PANEL REMOVAL/INSTALLATION .)
11. Dashboard garnish (See DASHBOARD GARNISH REMOVAL/INSTALLATION .)
12. HF/TEL unit (See HANDS-FREE TELEPHONE (HF/TEL) UNIT
REMOVAL/INSTALLATION .) (vehicles with HF/TEL system)
4. Remove the bolts.
5. Remove the screws.
6. Remove the clips.
7. Remove the connector.
8. Remove the passenger-side air bag module in the direction of the arrow
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Fig. 11: Identifying Passenger-Side Air Bag Module, Connector & Torque Specifications
SIDE AIR BAG MODULE REMOVAL/INSTALLATION
WARNING:  Handling the air bag module improperly can accidentally operate
(deploy) the air bag module, which may seriously injure you. Read
the air bag system service warnings and cautions before handling
the air bag module. (See AIR BAG SYSTEM SERVICE WARNINGS.)
(See AIR BAG SYSTEM SERVICE CAUTIONS.)
 If the side air bag module is installed with debris in the seat back,
the foreign material may be scattered when the side air bag module
operates (deploys), causing injury. Verify that there is no foreign
material in the seat back before installing the side air bag module.

3. Slide hook A upward and remove it from hook B.
4. Open the fastener.
Fig. 12: Identifying Hooks

5. Insert a flathead screwdriver between hook C and the frame.

6. Pull the flathead screwdriver in the direction of the arrow as shown in the figure.
7. Remove the hook C.
8. Remove the hook D.
9. Remove the hook E.
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Fig. 13: Inserting Flathead Screwdriver Between Hook C & Frame

10. Remove the hook F.

11. Partially peel back the seat back trim.
Fig. 14: Identifying Hook F

12. Remove in the nuts.

13. Partially peel back the seat back pad.
14. Remove the side air bag module.
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Fig. 15: Identifying Side Air Bag Module, Connector & Torque Specifications
15. Using a flathead screwdriver, pry out the connector stopper plate.
Fig. 16: Prying Out Connector Stopper Plate Using Screwdriver

CURTAIN AIR BAG MODULE REMOVAL/INSTALLATION
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1. A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION .)
2. Front scuff plate inner (See FRONT SCUFF PLATE REMOVAL/INSTALLATION .)
3. Rear scuff plate inner (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
4. Front seat belt lower anchor installation bolt (Driver side) (See FRONT SEAT BELT
5. B-pillar lower trim (See B-PILLAR LOWER TRIM REMOVAL/INSTALLATION .)
6. Front seat belt upper anchor installation bolt (See FRONT SEAT BELT
7. B-pillar upper trim (See B-PILLAR UPPER TRIM REMOVAL/INSTALLATION .)
8. Trunk box (See TRUNK BOX REMOVAL/INSTALLATION .)
9. Seat side box (See SEAT SIDE BOX REMOVAL/INSTALLATION .)
10. Trunk end trim (See TRUNK END TRIM REMOVAL/INSTALLATION .)
11. Third-row seat (See THIRD-ROW SEAT REMOVAL/INSTALLATION .)
12. Third-row seat belt lower anchor installation bolt (See THIRD-ROW SEAT BELT
13. Trunk side trim (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
14. Roof side trim (See ROOF SIDE TRIM REMOVAL/INSTALLATION .)
15. Second-row seat belt upper anchor installation bolt (See SECOND-ROW SEAT BELT
16. C-pillar trim (See C-PILLAR TRIM REMOVAL/INSTALLATION .)
17. Third-row seat belt upper anchor installation bolt (See THIRD-ROW SEAT BELT
18. D-pillar trim (See D-PILLAR TRIM REMOVAL/INSTALLATION .)
19. Front map light (See FRONT MAP LIGHT REMOVAL/INSTALLATION .)
20. Sunvisor (See SUNVISOR REMOVAL/INSTALLATION .)
21. Assist handle (See ASSIST HANDLE REMOVAL/INSTALLATION .)
22. RES unit cover (Vehicles with RES) (See RES UNIT REMOVAL/INSTALLATION .)
23. Headliner (See HEADLINER REMOVAL/INSTALLATION .)
24. Rear speaker (See REAR SPEAKER REMOVAL/INSTALLATION .)
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Fig. 17: Identifying Curtain Air Bag Module & Torque Specifications
CAUTION:  After installing the curtain air bags, verify that the connector
and wiring harness are not caught.
6. When the ignition switch is turned to the ON position verify that the air bag system warning light
illuminates for approx. 6 s and goes out .
CRASH ZONE SENSOR REMOVAL/INSTALLATION
WARNING:  Handling the crash zone sensor improperly can accidentally deploy
the air bags and pre-tensioner seat belts, which may seriously injure
you. Read the air bag system service warnings and cautions before
handling the crash zone sensor. (See AIR BAG SYSTEM SERVICE
WARNINGS.) (See AIR BAG SYSTEM SERVICE CAUTIONS.)

3. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION .)
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Fig. 18: Identifying Bolt, Connector & Torque Specifications


system (air bag system) and perform inspection of the system. (See FLOWCHART .
SAS CONTROL MODULE REMOVAL/INSTALLATION
WARNING:  Handling the SAS control module improperly can accidentally

deploy the air bag modules and pre-tensioner seat belt, which may
seriously injure you. Read the service warnings and cautions before
handling the air bag module. (See AIR BAG SYSTEM SERVICE
 Connecting the SAS control module with the SAS control module
not securely fixed to the vehicle is dangerous. When the ignition
switch is turned to the ON position, the SAS control module could
tilt causing the SAS control module to detect that the vehicle is in a
rollover condition, which may accidentally operate (deploy) the
curtain air bag module and pre-tensioner seat belt. Therefore, before
turning the ignition switch to the ON position with the connector
connected, securely fix the SAS control module to the vehicle.
CAUTION:  Handling the SAS control module improperly can accidentally deploy
the air bag modules and pre-tensioner seat belt, which may seriously
injure you. If configuration is not completed before removing the SAS
control module, DTC B2477 will be displayed.
1. Perform SAS control module configuration when replacing it. (See SAS CONTROL MODULE
CONFIGURATION.)
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2. Side wall (See SIDE WALL REMOVAL/INSTALLATION .)
3. Console panel (Passenger side) (See CONSOLE PANEL REMOVAL/INSTALLATION .)
5. Remove the connector.
6. Remove the nuts.
7. Remove the SAS control module in the direction of the arrow
 If the SAS control module is replaced, turn the ignition switch to the ON position for 20 s or more
after completing the configuration.
 If the air bag system warning light does not operate, refer to the on-board diagnostic system (air
bag system) and perform inspection of the system. (See FLOWCHART .)
Fig. 19: Identifying SAS Control Module, Connector & Torque Specifications
SAS CONTROL MODULE CONFIGURATION.
NOTE:  Use the IDS (laptop PC) because the PDS (Pocket PC) does not support
the SAS CONTROL MODULE CONFIGURATION.

1. Select "Module Programming".
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3. Then, select items from the screen menu in the following order.
1. Select "Programmable Module Installation".
2. Select "RCM".
4. Perform the configuration according to the directions on the screen.
5. Retrieve DTCs by the M-MDS, then verify that there is no DTC present.
 If a DTC (s) is detected, perform the applicable DTC inspection. (See DTC TABLE .)
Fig. 20: Identifying DLC-2 Location

SEAT WEIGHT SENSOR CONTROL MODULE REMOVAL/INSTALLATION
CAUTION:  When the seat weight sensor control module is replaced with a new
one, perform the seat weight sensor calibration using the M-MDS.
(See SEAT WEIGHT SENSOR CALIBRATION.)

3. Remove the front passenger seat. (See FRONT SEAT REMOVAL/INSTALLATION .)
Fig. 21: Identifying Seat Weight Sensor Control Module, Connector And Fastener
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SEAT WEIGHT SENSOR CALIBRATION
CAUTION:  If any of the following work is performed, perform the seat weight
sensor calibration using the M-MDS.
 Replacement with a new seat weight sensor
 Replacement with a new seat weight sensor control module
 Replacement with new front passenger-side seat parts
 Disassembly of the front passenger-side seat
 If any of the following work is performed or when the vehicle has

been involved in a collision, perform the seat weight sensor
inspection using the M-MDS. (See SEAT WEIGHT SENSOR
INSPECTION.)
 Removal of the front passenger-side seat
 Loosening and retightening of front passenger-seat fixing bolts
1. Have two 20 kg {44 lb} weights ready to use.

1. Select "Body".
2. Select "Restraints".
1. Select "All Tests and Calibrations".

4. Then, select item from the screen menu in the following order.
1. Select "Passenger Seat Weight Sensor ReZero".
5. Perform calibration following the procedures on the M-MDS screen.

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SEAT WEIGHT SENSOR INSPECTION
CAUTION:  If any of the following work is performed or when the vehicle has
been involved in a collision, perform the seat weight sensor
inspection using the M-MDS.
 Removal of the front passenger-side seat
 Loosening and retightening of front passenger-seat fixing bolts
 If any of the following work is performed, perform the seat weight

sensor calibration using the M-MDS. (See SEAT WEIGHT SENSOR
CALIBRATION.)
 Replacement with new front passenger-side seat parts
 Disassembly of the front passenger-side seat

1. Select "Body".
2. Select "Restraints".

3. Then, select item from the screen menu in the following order.
1. Select "Passenger Seat Weight Sensor ReZero".
4. Perform inspection following the procedures on the M-MDS screen.

SIDE AIR BAG SENSOR NO. 1 REMOVAL/INSTALLATION
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WARNING:  Handling the side air bag sensor improperly can accidentally operate
the side air bag sensor. (See AIR BAG SYSTEM SERVICE

Fig. 24: Identifying Side Air Bag Sensor No. 1, Connector & Torque Specifications

6. Turn the ignition switch to the ON position and hold for 10 s or more .
SIDE AIR BAG SENSOR NO. 2 REMOVAL/INSTALLATION
WARNING:  Handling the side air bag sensor improperly can accidentally operate
the side air bag sensor. (See AIR BAG SYSTEM SERVICE

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Fig. 25: Identifying Side Air Bag Sensor No. 2, Connector & Torque Specifications

6. Turn the ignition switch to the ON position and hold for 10 s or more .
CLOCK SPRING REMOVAL/INSTALLATION

1. Driver-side air bag module (See DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
2. Steering wheel (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
3. Column cover (See COLUMN COVER REMOVAL/INSTALLATION .)
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Fig. 26: Identifying Clock Spring, Screw And Connector


CLOCK SPRING ADJUSTMENT
NOTE:  The adjustment procedure is also specified on the caution label of the
clock spring.
1. Set the front tires straight-ahead.
CAUTION:  The clock spring will break if over-wound. Do not forcibly turn
the clock spring.
2. Turn the clock spring clockwise until it stops.
Fig. 27: Turning Clock Spring Clockwise

3. From the stopped position, turn the clock spring counterclockwise 2 3/4 turns .
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Fig. 28: Turning Clock Spring Counterclockwise

4. Align the marks.
Fig. 29: Aligning Marks

CLOCK SPRING INSPECTION

1. Verify that the continuity is as indicated in the table.
 If not as indicated in the table, replace the clock spring.
NOTE:  When the vehicle-side connector for the clock spring is disconnected,
terminals 1A, 1B, 1C and 1D are shorted to prevent unexpected operatio
(deployment) of the air bag module.
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Fig. 30: Continuity Chart

Fig. 31: Identifying Vehicle-Side Connector And Air Bag Module-Side

Connector Terminals
AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT

PROCEDURES
WARNING:  A live (undeployed) air bag module or pre-tensioner seat belt may
accidentally operate (deploy) when it is disposed of and cause
serious injury. Do not dispose of a live (undeployed) air bag module
and pre-tensioner seat belt. If the SSTs (Deployment tool and
Adapter harness) are not available, consult the nearest Mazda
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representative for assistance.
CAUTION:  Deploying the air bag modules and pre-tensioner seat belts inside the
vehicle may cause damage to the vehicle interior. When the vehicle is
not to be scrapped, always deploy the air bag modules and pre-
tensioner seat belts outside the vehicle.
 If the vehicle is to be scrapped, or when disposing of any air bag modules or pre-tensioner seat belts,
operate (deploy) them inside the vehicle by following the deployment procedure below and using the SST
(Deployment tool) .
 When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to "AIR BAG
MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES".
DEPLOYMENT PROCEDURE FOR INSIDE OF VEHICLE
1. Inspect the SST (Deployment tool) . (See INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Move the vehicle to an open space, away from strong winds, and close all of the vehicle doors and
windows.
5. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat
belt.
DRIVER-SIDE AIR BAG MODULE
WARNING:  The driver-side air bag module is a dual inflator type. If one inflator
is forced to operate (deploy), the other may operate (deploy)
accidentally. To prevent injury while disposing of the air bag
module, make sure to operate (deploy) both driver-side air bag
module inflators simultaneously, following the procedure below.
NOTE:  The SSTs , two types of adopter harnesses (for inflators No.1 and No.2)
and two deployment tools are to be used to operate (deploy) the driver-
side air bag module.
1. Remove the driver-side air bag module.
(See DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.
2. Connect the SSTs (Adapter harness) to the driver-side air bag module as shown in the figure.
3. Install the driver-side air bag module.
(See DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)

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Fig. 32: Connecting SSTs To Driver-Side Air Bag Module

4. Connect the SSTs (Deployment tool) to the SSTs (Adapter harness) .
Fig. 33: Connecting SSTs (Deployment Tool) To SSTs (Adapter Harness)

5. Connect both SSTs (Deployment tool) to the battery. Connect the power supply red clip to the positive
battery terminal, and the black clip to the negative battery terminal.
6. Verify that the red lamp on both SSTs (Deployment tool) is illuminated.
7. Verify that all persons are standing at least 6 m {20 ft} away from the vehicle.
8. Press the activation switch on the SST (Deployment tool) connected with 49 L066 002 (a yellow
connector) of the SST (Adapter harness) , and after 3 s , press the activation switch on the other SST
(Deployment tool) to operate (deploy) the air bag module (both inflators).
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Fig. 34: Identifying Activation Switch

WARNING:  Verify that air bag module operation (explosive) sound occurs
twice. If no operation (explosive) sound was heard or a single
operation (explosive) sound was heard, both inflators would
not have operated (deployed) properly. This may cause serious
injury if the air bag module operates (deploy) unexpectedly. If
the two operation (explosive) sounds are not heard, perform
Step 8 again. If a total of two operation (explosive) sounds
cannot be verified even though Step 8 is performed again,
leave the air bag module alone for 30 min or more before
approaching it again.
 The air bag module is very hot immediately after it is operated
(deployed). You can get burned. Do not touch the air bag
module for at least 15 min after deployment.
9. Disconnect the SSTs (Deployment tool) form the SSTs (Adapter harness) .
PASSENGER-SIDE AIR BAG MODULE
WARNING:  The passenger-side air bag module is a dual inflator type. If one
inflator is forced to operate (deploy), the other may operate (deploy)
module, make sure to operate (deploy) both passenger-side air bag
NOTE:  The SSTs , two types of adapter harnesses (for inflators No.1 and No.2)
and two deployment tools are to be used to operate (deploy) the
passenger-side air bag module.
1. Remove the glove compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)

2. Disconnect the passenger-side air bag module connector.
3. Connect the SSTs (Adapter harness) to the passenger-side air bag module as shown in the figure.
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Fig. 35: Connecting SST (Adapter Harness) To Passenger-Side Air Bag Module

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(deployed). You can be burned. Do not touch the air bag
9. Disconnect the SSTs (Deployment tool) form the SSTs (Adapter harness) .
SIDE AIR BAG MODULE
1. Disconnect the front seat connector.

2. Connect the SST (Adapter harness) to the side air bag module and pre-tensioner seat belt connector as
shown in the figure.
Fig. 38: Connecting SST To Side Air Bag Module And Pre-Tensioner Seat Belt Connector
3. Connect the SST (Deployment tool) to the SST (Adapter harness) .

4. Connect the SST (Deployment tool) to the battery. Connect the power supply red clip to the positive
5. Verify that the red lamp on the SST (Deployment tool) is illuminated.
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Fig. 39: Connecting SST (Deployment Tool) To SST (Adapter Harness)

7. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.
8. Disconnect the SSTs (Deployment tool) from the SSTs (Adapter harness) .

1. Remove the C-pillar trim.
(See C-PILLAR TRIM REMOVAL/INSTALLATION .)
2. Remove the D-pillar trim.
(See D-PILLAR TRIM REMOVAL/INSTALLATION .)
3. Disconnect the curtain air bag module connector.

4. Connect the SST (Adapter harness) to the curtain air bag module as shown in the figure.
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Fig. 41: Connecting SST To Curtain Air Bag Module



9. Press the activation switch on the SST (Deployment tool) to operate (deploy) the curtain air bag module.
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PRE-TENSIONER SEAT BELT
1. Remove the B-pillar lower trim.
(See B-PILLAR LOWER TRIM REMOVAL/INSTALLATION .)
2. Remove the pre-tensioner seat belt and connect the SST (Adapter harness) as shown in the figure. (See
FRONT SEAT BELT REMOVAL/INSTALLATION .)
3. Install the pre-tensioner seat belt.
Fig. 44: Connecting SST To Pre-Tensioner Seat Belt


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8. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.

DEPLOYMENT PROCEDURE FOR OUTSIDE OF VEHICLE
1. Inspect the SST (Deployment tool) .
(See INSPECTION OF SST (DEPLOYMENT TOOL).)

4. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat
belt.
DRIVER-SIDE AIR BAG MODULE
WARNING:  The driver-side air bag module is a dual inflator type. If one inflator
is forced to operate (deploy), the other may operate (deploy)
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module, make sure to operate (deploy) both driver-side air bag
1. Remove the driver-side air bag module.
(See DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.
2. Connect the SSTs (Adapter harness) to the driver-side air bag module as shown in the figure.
Fig. 47: Connecting SST To Driver-Side Air Bag Module

3. Place the driver-side air bag module on the center of the tire wheel with the padded surface facing up. To
secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm2 {0.002 in2 } or more)
through the wheel and the bolt installation holes of the air bag module at least 4 times .
WARNING:  If the air bag module is not properly installed to the tire wheel,
serious injury may occur when the module is operated
(deployed). When installing the air bag module to the tire
wheel, make sure the padded surface is facing up.
Fig. 48: Placing Driver-Side Air Bag Module On Center Of Tire

Wheel
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4. Stack three tires without wheels on top of the tire with the driver-side air bag module, and then stack
another tire with a wheel on the very top.
Fig. 49: Placing Tires

5. Secure the tires with wire.
Fig. 50: Securing Tires With Wire


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connector) of the SST (Adapter harness) , and after 3 s , press the activation switch on other SST

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PASSENGER-SIDE AIR BAG MODULE
WARNING:  The passenger-side air bag module is a dual inflator type. If one
inflator is forced to operate (deploy), the other may operate (deploy)
module, make sure to operate (deploy) both passenger-side air bag
1. Remove the passenger-side air bag module.
(See PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Install the bolts to the passenger-side air bag module.
Fig. 53: Identifying Bolts And Passenger-Side Air Bag Module

3. Connect the SSTs (Adapter harness) to the passenger-side air bag module as shown in the figure.
Fig. 54: Connecting SST To Passenger-Side Air Bag Module

4. Place the padded surface of the passenger-side air bag module facing the center of the tire as shown in the
figure. To secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm2 {0.002 in2 }
or more) through the tire and around the bolts at least 4 times as shown in the figure.
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WARNING:  If the air bag module is not properly secured to the tire, the
tires may fall over by the impact of operation (deployment) and
cause serious injury. To prevent this, secure the air bag
module properly with the padded surface facing the center of
the tire
Fig. 55: Placing Passenger-Side Air Bag Module Center Of Tire

5. Stack the tire with the passenger-side air bag module on top of two tires without wheels. Stack a tire
without a wheel on top of the tire with the passenger-side air bag module, and then stack another tire with
a wheel on the very top.

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SIDE AIR BAG MODULE
1. Remove the side air bag module.
(See SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
2. Install the nuts to the side air bag module as shown in the figure, and connect the SST (Adapter
harness) .
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Fig. 60: Identifying Side Air Bag Module And Nuts

3. Place the padded surface of the side air bag module facing the center of the tire as shown in the figure. To
secure the air bag module to the tire wheel, wrap a wire (cross section 1.25 mm2 {0.002 in2 } or more)
through the tire and around the bolts at least 4 times .
WARNING:  If the air bag module is not properly secured to the tire, the
tires may fall over by the impact of operation (deployment) and
cause serious injury. To prevent this, secure the air bag
module properly with the padded surface facing the center of
the tire.
Fig. 61: Placing Side Air Bag Module Center Of Tire

4. Stack the tire with the side air bag module on top of two tires without wheels. Stack a tire without a wheel
on top of the tire with the side air bag module, and then stack another tire with a wheel on the very top.
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10. Press the activation switch on the SST (Deployment tool) to operate (deploy) the side air bag module.

1. Remove the curtain air bag module. (See CURTAIN AIR BAG MODULE
2. Remove the nuts.
3. Remove the curtain air bag module from the curtain air bracket.
Fig. 66: Identifying Curtain Air Bag Module & Nuts

4. Secure the curtain air bag module in a vise, and cut off the deployment section, as shown in the figure.
WARNING:  Be sure not to crush the pipe on the side where it is cut. If it is
crushed completely, the interior pressure of the pipe will build
up and can cause it to explode during air bag module operation
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(deployment).
Fig. 67: Identifying Curtain Air Bag Module Dimension

5. Connect the SST (Adapter harness) to the curtain air bag module as shown in the figure.
Fig. 68: Connecting SST To Curtain Air Bag Module

6. Secure the curtain air bag module to the tire, by wrapping a wire (cross section 1.25 mm2 {0.002 in2 } or
more) through the tire and the bolt installation holes at least 4 times as shown in the figure.
WARNING:  If the air bag module is not properly installed to the tire, serious
injury may occur when the module is operated (deployed).
Make sure to install the air bag module securely.
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Fig. 69: Securing Curtain Air Bag Module To Tire

7. Stack the tire with the curtain air bag module on top of two tires without wheels. Stack a tire without a
wheel on top of the tire with the curtain air bag module, and then stack another tire with a wheel on the
very top.
Fig. 70: Placing Tire

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13. Press the activation switch on the SST (Deployment tool) to operate (deploy) the curtain air bag module.
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PRE-TENSIONER SEAT BELT
1. Remove the pre-tensioner seat belt.
(See FRONT SEAT BELT REMOVAL/INSTALLATION .)
2. Connect the SST (Adapter harness) to the pre-tensioner seat belt as shown in the figure.
Fig. 74: Connecting SST To Pre-Tensioner Seat Belt

3. Put the pre-tensioner seat belt inside the tire and secure it to the tire by wrapping a wire (cross section of
1.25 mm2 {0.002 in2 } or more) through the tire and the bolt installation holes at least 4 times .
WARNING:  If the pre-tensioner seat belt is not properly installed to the tire,
serious injury may occur when the pre-tensioner part is
operated (deployed). When installing the pre-tensioner seat belt
to the tire, make sure the pre-tensioner part is inside the tire.
Fig. 75: Placing Pre-Tensioner Seat Belt Inside Tire

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4. Stack the tire with the pre-tensioner seat belt on to of two tires without wheels. Stack a tire without a
wheel on top of the tire with the pre-tensioner seat belt, and then stack another tire with a wheel on the
very top.



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10. Press the activation switch on the SST (Deployment tool) to operate (deploy) the pre-tensioner seat belt.

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL

PROCEDURES
WARNING:  A live (undeployed) air bag module or pre-tensioner seat belt may
accidentally operate (deploy) when it is disposed of and cause
serious injury. Always refer to the "AIR BAG MODULE AND PRE-
TENSIONER SEAT BELT DEPLOYMENT PROCEDURES" and dispose
of air bag modules and pre-tensioner seat belts in a deployed
condition.
 The air bag modules and the pre-tensioner seat belts are very hot
immediately after they are deployed. You can be burned. Do not
touch an air bag module and pre-tensioner seat belt for at least 15
min after deployment.
 Pouring water on the deployed air bag module and pre-tensioner
seat belt is dangerous. The water will mix with the residual gases to
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form a gas that can make breathing difficult. Do not pour water on
the deployed air bag module and pre-tensioner seat belt.
 The deployed air bag module or pre-tensioner seat belt may contain
deposits of sodium hydroxide, a caustic by product of the gas-
generated combustion. If this substance gets into your eyes or on
your hands, it can cause irritation and itching. When handling the
deployed air bag module and pre-tensioner seat belt, wear gloves
and safety glasses.
 Due to the adoption of 2-step deployment control in both the driver
and passenger-side air bag modules, depending on the impact force,
it is possible that inflator No.2 might not operate (deploy). Before
disposing of the air bag module, always follow the inflator
deployment procedures and verify the complete operation
(deployment) of inflators No.1 and 2.
1. Remove the deployed air bag module or pre-tensioner seat belt.

2. Put the air bag module or pre-tensioner seat belt in a plastic bag, seal the bag, and then dispose of it.
Fig. 80: Placing Air Bag Module Or Pre-Tensioner Seat Belt In Plastic Bag
INSPECTION OF SST (DEPLOYMENT TOOL)

1. Before using the SST (49 H066 002), inspect its operation .
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Fig. 81: Identifying SST (Deployment Tool)

INSPECTION PROCEDURE
1. Follow the steps below to inspect the SST (49 H066 002) .
 If not as indicated in the table, replace the SST (49 H066 002) because it has a malfunction .
WARNING:  Do not use a malfunctioning SST (49 H066 002), otherwise

it could cause the air bag module or pre-tensioner seat
belt to accidentally operate (deploy).
CAUTION:  Because the permissible voltage for the SST (49 H066 002)
is 12 V, do not connect a 24 V power source because it will
damage the SST. Always connect only a 12 V power
source.
DIAGNOSIS PROCEDURE
Light
Step Inspection procedure condition
Green Red
Connect the power supply red clip to the positive battery terminal, and the
1 On Off
black clip to the negative battery terminal.
2 Connect connectors A and B. Off On
3 Press the activation switch. On Off
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Fig. 82: Connecting SST To Battery

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2008 DRIVELINE/AXLE All Wheel Drive (AWD) - Mazda CX-9
2008 DRIVELINE/AXLE
All Wheel Drive (AWD) - Mazda CX-9
ELECTRONIC AWD CONTROL SYSTEM LOCATION INDEX
Fig. 1: Identifying Wheel Drive Components (AWD)

AWD CONTROL MODULE INSPECTION
NOTE:  AWD CM terminal voltage can vary depending on measuring conditions

and vehicle aging, resulting in misdiagnosis. Therefore, it is necessary to
perform an overall inspection of the input/output systems and AWD CM to
determine which part is malfunctioning.
 With the AWD CM connector connected, measure voltage by connecting
the voltmeter negative (-) lead to the body ground and positive (+) lead to
each AWD CM terminal.
1. Measure voltage or resistance at each AWD CM terminal using a voltmeter and an ohmmeter.
 If not as specified, replace the AWD CM.
TERMINAL VOLTAGE LIST (REFERENCE)
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Fig. 2: Identifying AWD Control Module Connector Terminal


Voltage Inspection
Connected Measuring
Terminal Signal Input/output Test condition (V)/ location in case
to item
Continuity of failure
Differential
oil  Inspect
temperature 3.0 differential
Differential 20°C {68°
Differential oil
oil
oil Ignition F} temperature
A temperature Input Voltage
temperature key ON Differential sensor
sensor
sensor oil  Inspect
signal
temperature 1.4 related
60°C{140° harness
F}
B - - - - - - - -
Differential
Differential
oil  Inspect
oil
C temperature - Continuity Any condition Yes related
temperature
sensor harness
sensor
GND
D - - - - - - - -
E - - - - - - - -
F - - - - - - - -
Perform measurement during DTC
G CAN_H Input/output - -
inspection.
Perform measurement during DTC
H CAN_L Input/output - -
inspection.
Ignition key ON B+  Inspect
Power
fuse
supply Ignition
I Input Voltage  Inspect
(Ignition key 1.0 or
Ignition key OFF related
switch) below
harness
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J - - - - - - - -
 Inspect
Power fuse
K supply Input Battery Voltage Any condition B+  Inspect
(Main) related
harness
L - - - - - - - -
M - - - - - - - -
 Inspect
N Ground - Ground Voltage Any condition 0 related
harness
Ignition key ON B+  AWD
AWD solenoid
AWD
O solenoid Output Voltage  Inspect
solenoid 1.0 or
(+) Ignition key OFF related
below
harness
Ignition key ON B+  AWD
solenoid
AWD AWD
P Output Voltage  Inspect
solenoid (-) solenoid 1.0 or
Ignition key OFF related
below
harness
AWD CONTROL MODULE REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the dashboard undercover (Driver side). (See DASHBOARD UNDER COVER
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Fig. 3: Identifying AWD Control Module Connector, Bolt & Torque Specifications
AWD CM REMOVAL NOTE
1. Push up the AWD CM slightly, and remove it.
Fig. 4: Pushing Up AWD CM

COUPLING COMPONENT REMOVAL/INSTALLATION

1. Drain the rear differential oil into a container.
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2. Remove the under guard (LH). (See CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.7] .)
3. Remove the presilencer. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the presilencer insulator. (See REFRIGERANT LINE REMOVAL/INSTALLATION .)
5. Remove the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
8. Add rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT .)
Fig. 5: Identifying Coupling Components & Torque Specifications

FRONT DIFFERENTIAL MOUNTING RUBBER REMOVAL NOTE
1. Detach clips as shown in the figure.
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Fig. 6: Identifying AWD Solenoid Connector

2. Support the rear differential using a jack.

3. Remove the front differential mounting rubbers.
Fig. 7: Supporting Rear Differential

COUPLING COMPONENT REMOVAL NOTE
1. Support the coupling unit with a transmission jack.

2. Cut away the coupling unit using an oil pan seal cutter.
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Fig. 8: Cutting Coupling Unit

COUPLING COMPONENT INSTALLATION NOTE
NOTE:  Clean away the old sealant before applying the new sealant.
 Install the coupling unit within 10 min after applying sealant.
 Allow the sealant to set at least 30 min after installation before filling the
differential with the specified oil.
1. Apply sealant to the coupling case surface that contacts the rear differential case.
2. Install the coupling unit to the rear differential so that the two tabs on the coupling unit engage the rear
differential grooves (two locations).
Tightening torque
22.6-26.4 N.m {2.31-2.69 kgf.m, 16.7-19.4 ft.lbf}
Fig. 9: Identifying Tabs On Coupling Unit

COUPLING COMPONENT DISASSEMBLY
WARNING:  The engine stand is equipped with a self-lock mechanism, however,

if the coupling unit is in a tilted condition, the self-lock mechanism
could become inoperative. If the coupling unit unexpectedly rotates
it could cause injury, therefore do not maintain the coupling unit in a
tilted condition. When turning the coupling unit, grasp the rotation
handle firmly.
1. Disassemble in the order indicated in the table.
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Fig. 10: Disassembling View Of Coupling Component

LOCKNUT DISASSEMBLY NOTE
1. Assemble the SSTs to the engine stand.
Fig. 11: Identifying SST

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2. Install the coupling unit to the SSTs as shown.

3. Secure the companion flange using the SST, and remove the locknut.

COMPANION FLANGE DISASSEMBLY NOTE
1. Remove the companion flange using the SST.
Fig. 14: Removing Companion Flange

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OUTPUT SHAFT DISASSEMBLY NOTE
1. Remove the coupling unit from the SST.

2. Install the coupling unit to the press as shown, and remove the output shaft together with the coupling
unit.
3. Install the companion flange to the output shaft.
Fig. 15: Installing Coupling Unit

4. Secure the companion flange using the SST , and remove the bolts.
5. Remove the output shaft.
Fig. 16: Removing Companion Flange Bolts

BEARING DISASSEMBLY NOTE
1. Remove the bearing using the SSTs and a press.
Substitution SST
 49 S033 108
Outer diameter: 33-55 mm {1.30-2.16 in}

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Height: 155 mm {6.10 in} or more

COUPLING COMPONENT ASSEMBLY
WARNING:  The engine stand is equipped With a self-lock mechanism, however,

if the coupling unit is in a tilted condition, the self-lock mechanism
could become inoperative, if the coupling unit unexpectedly rotates
it could cause injury, therefore do not maintain the coupling unit in a
tilted condition. When turning the coupling unit, grasp the rotation
handle firmly.
1. Assemble in the order indicated in the table.
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Fig. 18: View Of Coupling Components & Torque Specifications

OUTPUT SHAFT ASSEMBLY NOTE
1. Install the output shaft to the coupling unit and partially tighten the bolts.
2. Install the companion flange to the output shaft.
3. Secure the companion flange using the SST , and tighten the bolts.
Tightening torque
41.2-53.9 N.m {4.2-5.4 kgf.m, 30.4-39.7 ft.lbf}
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BEARING ASSEMBLY NOTE
1. Assemble the bearing to the coupling case using the SSTs.
Substitution SST
 49 G030 796

COUPLING CASE ASSEMBLY NOTE
CAUTION:  The coupling unit will be damaged if it is pressed directly by a press.

Always press the coupling unit into the coupling case using the SST.
1. Assemble the coupling unit to the coupling case using the SSTs and a press.
Substitution SST
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 49 S032 333
Outer diameter: 34.2-40.0 mm {1.35-1.57 in}
Inner diameter: 30.2-32.2 mm {1.19-1.26 in}
Inner depth: 65.2 mm {2.57 in} or more

OIL SEAL ASSEMBLY NOTE
1. Apply the specified oil to a new oil seal lip.

2. Install the oil seal to the coupling case using the SST.
Substitution SST
 49 W011 102
Outer diameter: 66 mm {2.60 in} or more
Inner diameter: 54-60 mm {2.13-2.36 in}
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COMPANION FLANGE ASSEMBLY NOTE
1. Install the coupling case to the SSTs as shown.

2. Install the companion flange.

LOCKNUT ASSEMBLY NOTE
1. Secure the companion flange using the SST, and tighten a new locknut.
Tightening torque
167-226 N.m {17.1-23.0 kgf.m, 124-166 ft.lbf}
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DIFFERENTIAL OIL TEMPERATURE SENSOR REMOVAL/INSTALLATION
WARNING:  Hot differential oil may cause severe burns. Do not perform
maintenance while differential oil is hot.

2. Disconnect the differential oil temperature sensor connector.
3. Remove the differential oil temperature sensor.
4. Apply differential oil to the O-ring.
5. Install the differential oil temperature sensor.
Tightening torque
12.7-17.3 N.m {1.3-1.7 kgf.m, 9.4-12.7 ft.lbf}
6. Connect the differential oil temperature sensor connector.

7. Connect the negative battery cable.
Fig. 25: Identifying Differential Oil Temperature Sensor Connector

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DIFFERENTIAL OIL TEMPERATURE SENSOR INSPECTION
WARNING:  Hot differential oil may cause severe burns. Do not perform
maintenance while differential oil is hot.

2. Disconnect the differential oil temperature sensor connector and remove the differential oil temperature
sensor.
3. Wrap the differential oil temperature sensor with plastic wrap and immerse it into a beaker filled with
water. Gradually raise the water temperature, and measure resistance between differential oil temperature
sensor terminals A and B.
 If not as specified, inspect the harness for continuity. If there is normal continuity between the
terminals, replace the differential oil temperature sensor.
Fig. 26: Inspecting Differential Oil Temperature Sensor

Differential oil temperature sensor specification
RESISTANCE SPECIFICATION
Water temperature (°C {°F}) Resistance (kirohm)
0 {32} 91-100
10 {50} 56-61
20 {68} 35-39
30 {86} 23-25
40 {104} 14-17
50 {122} 10-11
60 {140} 7.1-7.9
70 {158} 5.0-5.6
80 {176} 3.6-4.0
4. Install the differential oil temperature sensor and connect the connector.
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AWD SOLENOID INSPECTION

2. Disconnect the AWD solenoid connector.
3. Measure resistance between AWD solenoid connector terminals A and B.
 If the resistance is not within the specification, replace the coupling unit.
AWD solenoid resistance
1.5-2.0 ohms
(Rear differential oil temperature at 20°C {68°F})
4. Connect the AWD solenoid connector.

Fig. 27: Inspecting AWD Solenoid Connector

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2005-08 TRANSMISSION Automatic Transaxle Overhaul (AW6A-EL) - CX-7, CX-9 & Mazda 6
2005-08 TRANSMISSION
Automatic Transaxle Overhaul (AW6A-EL) - CX-7, CX-9 & Mazda 6
AUTOMATIC TRANSAXLE
AUTOMATIC TRANSAXLE DISASSEMBLY
Precaution
The following are precautions that must be followed when performing removal/installation.
1. Handle electronic parts with care

 Do not pull the wiring harness forcibly when disconnecting the connector. Unlock the lock first and
pull the connector.
 When connecting the connector, verify to insert it until it is properly locked. (Verify that a click
sound is heard.)
 Do not shock electronic parts. Replace with new parts if they have been dropped or subjected to
shock.
2. Prevent foreign matter from penetrating
 Be sure to remove foreign matter such as dust and sand from the automatic transaxle before
removing parts.
 Protect removed parts from dust with an object such as a vinyl sheet.
 Do not use cotton work gloves or shop rags as frayed strings might get caught in the unit. Thus
work with bare hands or use vinyl gloves.
3. Prevent scratching
 Do not pry with a screwdriver forcibly. Slightly hit the case with a plastic hammer when separating
component cases at seams.
 Do not pull the valve forcibly.
 Be careful not to get the wire harness caught between parts during installation.
4. Prevent incorrect installation and lack of or missing parts

 Be careful not to install parts incorrectly or lose parts since there are similar types of O-rings, snap
rings, bearings and races. Take great care for straightening parts and checking installation direction.
 Be careful not to drop small parts such as check balls or lose them during installation.
5. Wash parts and apply oil

 Wash each part before installing and dry using compressed air, and then apply the specified ATF
type JWS3309.
 Soak disks in ATF type JWS3309 before installing. In particular, soak new disks for 2 h or more
so that the oil seeps into the lining.
 If the thrust bearing or race falls during installation, use a small amount of yellow petrolatum
grease.
 Apply ATF type JWS3309 to contact and rotating surfaces.
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Do not apply oil or drive the vehicle immediately after installing a part applied with sealant. Leave

it for one hour or more.
 Do not wash aluminum parts or rubber parts with alkaline chemicals.
 Do not wash the rubber parts with white gasoline.
6. Handling ATF with care

 If you spill ATF on the floor, wipe it off immediately, as it is quite slippery and dangerous.
 Be sure to use JWS3309 type ATF.
Disassembly
Components
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Fig. 1: Identifying Automatic Transaxle Disassembly Components (1 Of 4)


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Disassembly procedure
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1. Remove the oil pipes and O-rings. (Refer to the appropriate article .)
CAUTION:  Do not damage the oil seal.

 Do not drop the torque converter.
2. Remove the torque converter.
Fig. 5: Identifying Torque Converter

3. Remove the drain plug and gasket.

4. Drain the ATF.
CAUTION:  Do not repair the threads using a tap or other tools.
Fig. 6: Identifying Drain Plug And Gasket

5. Remove the stud bolts.

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Fig. 7: Identifying Stud Bolts

CAUTION:  Do not touch the terminals.
Fig. 8: Caution - Do Not Touch Terminals

6. Remove the TCM.
Fig. 9: Identifying TCM Mounting Bolt

7. Set the SST as shown in the figure.

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CAUTION:  When installing the SST to the transaxle, use bolts (M12x1.25)
with a thread length of 90 mm {3.54 in}.

8. Install the SST to the position where the transaxle stud bolts were removed.
Fig. 11: Identifying SST And Transaxle Position

9. Remove the control valve body cover installation bolt.
CAUTION:  Do not damage the fitting surface of the transaxle case and the
control valve body cover.
 Do not deform the control valve body cover.
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Fig. 12: Identifying Control Valve Body Cover Bolts

10. Using a plastic hammer, tap the control valve body cover to remove it.
CAUTION:  Be careful not to damage the solenoid valves and connectors.

 Do not pull the wiring harnesses when removing the connector.
NOTE:  Disconnect the solenoid connector according to the following

procedure:
Fig. 13: Tapping Control Valve Body Cover

1. Insert a precision screwdriver from the backside into the connector as shown in the figure.
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Fig. 14: Inserting Precision Screwdriver From Backside Into Connector

2. Pry the screwdriver in the direction of the arrow and disconnect the connector.
CAUTION:  Do not damage the solenoid valves and connectors with

the screwdriver.
 When disconnecting connectors, grasp the connectors,
not the wiring harnesses. Otherwise, the wiring harnesses
may be pulled out of the connector causing poor contact.
Fig. 15: Prying Screwdriver In Direction Of Arrow

11. Disconnect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.
12. Disconnect the coupler component from the clamp.
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Fig. 16: Identifying Solenoid Connectors, VSS Connector And Input/Turbine Speed Sensor
Connector
13. Remove the lock plate, and pull out the TFT sensor from the control valve body.
14. Remove the O-ring from the TFT sensor.
NOTE:  Be sure to secure the coupler component with tape so that it will not
interfere with the control valve body component.
Fig. 17: Identifying Lock Plate And TFT Sensor

15. Fix the coupler component with tape to the transaxle case as shown in the figure.
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Fig. 18: Fixing Coupler Component With Tape To Transaxle Case

16. Remove the VSS connector and input/turbine speed sensor connector from the solenoid clamp.
Fig. 19: Identifying VSS Connector And Input/Turbine Speed Sensor Connector
NOTE:  Be sure to secure the VSS and input/turbine speed sensor with tape
so that they do not interfere with the control valve body component.
17. Secure the VSS wiring harness and input/turbine speed sensor wiring harness with tape to the transaxle
case as shown in the figure.
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Fig. 20: Securing VSS Wiring Harness And Input/Turbine Speed Sensor Wiring Harness With
Tape
18. Remove the suction cover and the gasket.
CAUTION:  Loosen the bolts evenly a little at a time in the order shown in
the figure.
Fig. 21: Identifying Suction Cover And Gasket

19. Remove the control valve body installation bolts.
CAUTION:  Do not drop the control valve body component.
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Fig. 22: Identifying Control Valve Body Bolts

20. Disconnect the manual valve link and remove the control valve body component.
Fig. 23: Identifying Manual Valve Link

21. Remove the coupler component lock plate.
CAUTION:  Do not damage the wiring harness.

 Do not pull hard on the wiring harness.
22. Remove the coupler component from the transaxle case.
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Fig. 24: Identifying Coupler Component Lock Plate

23. Remove the O-ring and the gasket from the coupler component.
CAUTION:  Do not damage the input/turbine speed sensor.
Fig. 25: Identifying O-Ring And Gasket

24. Remove the input/turbine speed sensor.

25. Remove the bolts as shown in the figure.
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Fig. 26: Identifying Bolts Of Transaxle Case (1 Of 2)

Fig. 27: Identifying Bolts Of Transaxle Case (2 Of 2)

CAUTION:  Do not damage the fitting surface of the converter housing and
the transaxle case.
26. Using a plastic hammer, tap the converter housing to remove it.
Fig. 28: Tapping Converter Housing

27. Remove the transaxle case gaskets as shown in the figure.

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Fig. 29: Identifying Transaxle Case Gaskets

28. Remove the gaskets as shown in the figure.
CAUTION:  Do not damage the oil reservoir lock plate.
Fig. 30: Identifying Gaskets

29. Remove the tube clamp and the oil reservoir lock plate.
Fig. 31: Identifying Tube Clamp And Oil Reservoir Lock Plate Bolts
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30. Remove the magnets from the oil reservoir lock plate.
CAUTION:  Do not damage the differential gear lube apply tube.
Fig. 32: Identifying Magnets Of Oil Reservoir Lock Plate

31. Using a flathead screwdriver, remove the oil pipe.
CAUTION:  Do not damage the converter housing.

 If using a screwdriver, use a wooden block or equivalent to
avoid damaging the fitting surface of the converter housing.
32. Remove the oil seal lip using a razor.
Fig. 33: Identifying Oil Pipe

33. Using a tape-wrapped flathead screwdriver, remove the oil seal (converter housing side).
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Fig. 34: Removing Oil Seal (Converter Housing Side)

34. Remove the oil pump component.
Fig. 35: Identifying Oil Pump Component Bolts

35. Remove the oil seal and the oil strainer from the oil pump component.
Fig. 36: Identifying Oil Seal And Oil Strainer

36. Remove the C3 clutch component, input shaft and the front planetary gear component.
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NOTE:  In some cases, the input shaft may be detached with the thrust roller
bearing attached.
Fig. 37: Identifying C3 Clutch Component, Input Shaft And Front

Planetary Gear Component
37. Remove the C3 clutch component from the input shaft and the front planetary gear component.
NOTE:  In some cases, the C3 clutch component may be detached with the
thrust washer attached.
Fig. 38: Identifying C3 Clutch Component

38. Remove the brake band anchor bolt.
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Fig. 39: Identifying Brake Band Anchor Bolt

39. Remove B1 the brake band.
Fig. 40: Identifying B1 Brake Band

40. Inspect the lining of the brake band.

 If the lining is flaking or has changed color, or if it is worn or the print mark is wearing away,
replace with a new brake band and C3 clutch.
When replacing, inspect the contact surfaces between the C3 clutch drum and B1 brake band. If
they are scratched or have changed color, replace with new parts.
NOTE:  Before replacing with a new B1 brake band, soak it at least 2 h in

ATF.
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Fig. 41: Inspecting Print Mark Of Brake Band

41. Remove the snap ring using snap ring pliers.
CAUTION:  The brake piston cover will fly off due to the force of the piston
return spring.
 Do not drop the brake piston cover.
 Do not drop the B1 brake piston.
Fig. 42: Removing Snap Ring

42. Remove the brake piston cover, B1 brake piston and the piston return spring.
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Fig. 43: Identifying Brake Piston Cover, B1 Brake Piston And Piston Return Spring
43. Remove the thrust bearing, bearing race and the C1 clutch component.
NOTE:  In some cases, the C1 clutch component may be detached with the
thrust bearing attached.
Fig. 44: Identifying Thrust Bearing, Bearing Race And C1 Clutch

Component
44. Remove the thrust bearing, bearing race and the sun gear input drum.
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Fig. 45: Identifying Thrust Bearing, Bearing Race And Sun Gear Input Drum
45. Remove the detent spring cover and detent spring.
CAUTION:  Be careful not to apply too much force to the pawl return spring.
Fig. 46: Identifying Detent Spring Bolt

46. Remove the pawl return spring and the parking pawl shaft.
CAUTION:  Be careful not to apply too much force to the torsion spring.
Fig. 47: Identifying Pawl Return Spring And Parking Pawl Shaft
47. Remove the torsion spring and the spring guide sleeve.
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Fig. 48: Identifying Torsion Spring And Spring Guide Sleeve

48. Remove the parking pawl and the parking pawl bracket.
Fig. 49: Identifying Parking Pawl And Parking Pawl Bracket

49. Disconnect the parking rod from the manual valve lever.
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Fig. 50: Identifying Parking Rod And Manual Valve Lever

50. Remove the manual valve lever from the transaxle case.
Fig. 51: Identifying Manual Valve Lever Of Transaxle Case

51. Remove the parking rod from the transaxle case.
Fig. 52: Identifying Parking Rod

52. Remove the parking pin from the transaxle case.
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NOTE:  Inspect the direction of the parking pin.
Fig. 53: Identifying Parking Pin

53. Remove the counter gear component.
NOTE:  For easy removal, tilt the counter gear component slightly.
Fig. 54: Identifying Counter Gear Component

54. Remove the differential component.
CAUTION:  Do not damage the VSS wiring harness.

 Do not pull hard on the VSS wiring harness.
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Fig. 55: Identifying Differential Component

55. Disconnect the VSS wiring harness from the tube wiring clamp.
CAUTION:  Do not damage the oil cooler outlet tube.
Fig. 56: Identifying Tube Wiring Clamp

56. Remove the pipe clamp, transaxle case No.1 plate, wiring harness clip and the oil cooler outlet tube.
57. Remove the O-rings from the oil cooler outlet tube.
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Fig. 57: Identifying O-Rings Of Oil Cooler Outlet Tube

58. Using a flathead screwdriver and a hammer, pry back the crimp on the lockwashers.
CAUTION:  If the lockwasher crimp is not completely pried back, the tool
cannot fit over the bolt properly and the bolt cannot be
loosened.
Fig. 58: Prying Back Crimp On Lockwashers

59. Remove the lockwashers, washers and the counter drive gear.

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 Do not damage the VSS.
Fig. 59: Identifying Bolts Of Counter Drive Gear Plate

60. Remove the VSS and spacer from the counter drive gear.
Fig. 60: Identifying VSS And Spacer

61. Using a flathead screwdriver, remove the snap ring.
CAUTION:  Do not drop the sun gear.
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62. Remove the rear planetary gear component and the one-way clutch.
NOTE:  In some cases, the sun gear may be detached with the bearing race
attached.
NOTE:  Remove the sun gear in the center while holding it.
 The thrust washer of the rear planetary gear on the rear side might
remain on the transaxle case side when removing the rear planetary
gear component.
Fig. 62: Removing Rear Planetary Gear Component And One-Way

Clutch
63. Remove the thrust bearing and the bearing races.
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Fig. 63: Identifying Thrust Bearing And Bearing Races


65. Remove the retaining plates, drive and driven plates.
NOTE:  Inspect the number of drive plates and driven plates.
Fig. 65: Identifying Retaining Plates, Drive And Driven Plates

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66. Inspect the lining of all drive plates.

replace with a new drive plate. When replacing, inspect the contact surfaces between the retaining
plate, driven plate and drive plate. If they are scratched or have changed color, replace with new
parts.
NOTE:  Before replacing with new drive plates, soak them at least 2 h in ATF.
Fig. 66: Inspecting Print Mark Of All Drive Plates

67. Remove the C2 clutch component and the thrust bearing.
Fig. 67: Identifying C2 Clutch Component And Thrust Bearing

68. Remove the seal rings from the transaxle case.
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Fig. 68: Identifying Seal Rings

69. Remove the transaxle case plate No.2.
Fig. 69: Identifying Transaxle Case Plate No.2 Bolt

70. Remove the transaxle case plate No.3.
CAUTION:  Do not damage the transaxle case.

avoid damaging the fitting surface of the transaxle case.
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72. Using a tape-wrapped flathead screwdriver, remove the oil seal (transaxle case side).

avoid damaging the fitting surface of the transaxle case.
Fig. 71: Removing Oil Seal (Transaxle Case Side)

73. Using a tape-wrapped flathead screwdriver, remove the oil seal (manual shaft).
Fig. 72: Removing Oil Seal (Manual Shaft)

OIL PUMP DISASSEMBLY/ASSEMBLY
Components
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Fig. 73: Identifying Oil Pump Components

Disassembly Procedure
1. Remove the O-ring from the oil pump.
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Fig. 74: Identifying O-Ring Of Oil Pump

2. Remove the thrust washer from the oil pump.
Fig. 75: Identifying Thrust Washer Of Oil Pump

3. Remove the seal rings from the oil pump.
CAUTION:  Do not damage the bushing on the oil pump body.
Fig. 76: Identifying Seal Rings Of Oil Pump

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4. Using a tape-wrapped flathead screwdriver, remove the oil seal from the oil pump body.
Fig. 77: Removing Oil Seal From Oil Pump Body

Assembly Procedure
1. Using the SST and a hammer, install the new oil seal to the oil pump body.
Substitution SST
 49 U027 003
Inner diameter: 54- 61 mm {2.13- 2.40 in}
Plate thickness: 2 mm {0.08 in} or more
Fig. 78: Installing Oil Seal To Oil Pump Body Using Special Tool
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2. Apply grease to the oil seal lip.

3. Apply ATF to the new seal rings and sliding surface of the oil pump component.
CAUTION:  Do not expand the seal rings too much.

 Be careful not to shorten the seal rings too much, when
installing the seal rings.
4. Compress the seal rings as shown in the figure. Then install the seal rings to the oil pump component.
NOTE:  Verify that oil seal rings rotate smoothly after installing them.
Fig. 79: Compressing Seal Rings

5. Apply grease to the thrust washer.
CAUTION:  Apply grease to the mounting surface of the thrust washer so

that it does not drop when installed.
6. Install the thrust washer to the oil pump component.
Fig. 80: Identifying Thrust Washer Of Oil Pump Component
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7. Apply ATF to a new O-ring.

8. Install the O-ring to the oil pump component.
CAUTION:  Do not damage the oil seal lip.
Fig. 81: Identifying O-Ring Of Oil Pump Component

9. Turn the drive gear with flathead screwdrivers and verify it rotates smoothly.
Fig. 82: Turning Drive Gear With Flathead Screwdrivers

B1 BRAKE PISTON DISASSEMBLY/ASSEMBLY
Components
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Fig. 83: Identifying B1 Brake Piston Components

1. Remove the O-ring from the B1 brake piston.
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Fig. 84: Identifying O-Ring Of B1 Brake Piston

2. Remove the O-rings from the brake piston cover.
Fig. 85: Identifying O-Rings Of Brake Piston Cover

Assembly Procedure
1. Apply ATF to the new O-rings.

2. Install the O-rings to the brake piston cover.
Number of O-ring
AJ:3

 L3 with TC: 2
3. Apply ATF to a new O-ring.
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Fig. 86: Identifying O-Rings Of Brake Piston Cover

4. Install the O-ring to the B1 brake piston.
Fig. 87: Identifying O-Ring Of B1 Brake Piston

C3 CLUTCH COMPONENT DISASSEMBLY
Components
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Fig. 88: Identifying C3 Clutch Disassembly Components

1. Using a flathead screwdriver, remove the snap ring from the C3 clutch drum.
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Fig. 89: Removing Snap Ring From C3 Clutch Drum

2. Remove the retaining plate, drive and driven plates from the C3 clutch drum.
NOTE:  Inspect the number of drive and driven plates.
Fig. 90: Identifying Retaining Plate, Drive And Driven Plates

3. Place the SST on the clutch balancer and compress the return spring with a press.
CAUTION:  Be careful not to expand the snap ring too much.
CAUTION:  Do not damage the seal on the clutch balancer.
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Fig. 91: Placing SST On Clutch Balancer

5. Remove the clutch balancer, return spring and the retainer from the C3 clutch drum.
Fig. 92: Identifying Clutch Balancer, Return Spring And Retainer

6. While pushing the C3 clutch piston by hand, apply compressed air into the oil passage as shown in the
figure and remove the C3 clutch piston from the C3 clutch drum.
Air pressure 392 kPa {4.0 kgf/cm2 , 57 psi}
NOTE:  When applying compressed air, shut the 3 oil passages of the C3
clutch drum as shown in the figure.
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Fig. 93: Applying Compressed Air Into Oil Passage

7. Remove the O-rings from the C3 clutch drum.
Fig. 94: Identifying O-Rings Of C3 Clutch Drum

C3 CLUTCH INSPECTION

parts.
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Fig. 95: Inspecting Lining Of All Drive Plates

2. Using vernier calipers, measure the free length of the piston return spring.
C3 clutch return spring free length Standard: 12.91 mm {0.5083 in}
 If it is less than the specification, replace the piston return spring with a new one.
Fig. 96: Measuring Free Length Of Piston Return Spring

C3 CLUTCH COMPONENT ASSEMBLY
Components
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Fig. 97: Identifying C3 Clutch Assembly Components

Assembly Procedure
1. Apply ATF to the new O-rings and the C3 clutch drum.

2. Install the O-rings to the C3 clutch drum.
3. Apply ATF to the sliding surface of the C3 clutch piston.
CAUTION:  Do not damage the seal on the piston and O-rings.

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4. Install the C3 clutch piston to the C3 clutch drum.

5. Apply ATF to the seal on the clutch balancer.
Fig. 99: Identifying C3 Clutch Piston

6. Install the retainer, return spring and the clutch balancer to the C3 clutch drum.
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Fig. 100: Identifying Retainer, Return Spring And Clutch Balancer

7. Place the SST on the clutch balancer and compress the piston return spring with a press.
CAUTION:  When installing the snap ring, set the end gap of the snap ring
as shown in the figure.
 Do not expand the snap ring too much.

8. Install the snap ring in the groove using snap ring pliers.
9. Install the driven plates, drive plates and the retaining plate in the following order to the C3 clutch drum
 Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Retaining
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Fig. 102: Identifying Drive Plates And Retaining Plate

CAUTION:  Inspect the number and order of the retaining plate, drive and
driven plates.
Fig. 103: Inspecting Number And Order Of Retaining Plate, Drive

And Driven Plates
10. Using a flathead screwdriver, install the snap ring in the groove.
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Fig. 104: Installing Snap Ring In Groove

11. Install the C3 clutch component to the oil pump and set a dial indicator as shown in the figure.
12. Apply compressed air as shown in the figure and measure the C3 clutch piston stroke.
C3 clutch piston stroke 0.6 - 0.8 mm {0.024 - 0.031 in}
 If not within the specification, select an appropriate retaining plate.
Fig. 105: Setting Dial Indicator And Measuring C3 Clutch Piston Stroke
RETAINING PLATE SIZE

Identification mark Thickness (mm {in})
1 2.8{0.110}
A 2.85{0.112}
2 2.9{0.114}
B 2.95{0.116}
3 3.0{0.118}
C 3.05{0.120}
4 3.1 {0.122}
5 3.2{0.126}
6 3.3{0.130}
7 3.4{0.134}
8 3.5{0.138}
FRONT PLANETARY GEAR COMPONENT INPUT SHAFT DISASSEMBLY/ASSEMBLY
Components
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Fig. 106: Identifying Front Planetary Gear Component Input Shaft Components
1. Remove the thrust washer from the front planetary gear component.
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Fig. 107: Identifying Thrust Washer

2. Remove the front planetary gear component from the input shaft.
Fig. 108: Identifying Front Planetary Gear Component

3. Remove the thrust washer from the front planetary gear component.
NOTE:  In some cases, the thrust washer may be detached with the input
shaft attached.
Fig. 109: Identifying Thrust Washer

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4. Remove the front planetary sun gear, thrust bearing and the bearing race from the input shaft.
NOTE:  If it is difficult to remove the bearing race, pry it off gently using a
flathead screwdriver.
Fig. 110: Identifying Front Planetary Sun Gear, Thrust Bearing And
Bearing Race
5. Remove the seal rings from the input shaft.
Fig. 111: Identifying Seal Rings Of Input Shaft

6. Remove the seal rings from the input shaft.
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Fig. 112: Identifying Seal Rings Of Input Shaft

Assembly Procedure
1. Apply ATF to the new seal rings and sliding surface of the input shaft.
CAUTION:  Do not expand the seal ring too much.

2. Compress the seal rings as shown in the figure. Then install the seal rings to the input shaft.
NOTE:  Verity that seal rings rotate smoothly after installing them.

3. Apply ATF to the bearing race.

4. Install the bearing race to the input shaft.

that it does not drop when the front planetary gear component
is installed.
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 Do not apply grease to the oil holes of the thrust washer.

 Do not drop the thrust washer.
Fig. 114: Identifying Bearing Race Of Input Shaft


6. Install the thrust washer to the front planetary gear component.
Fig. 115: Identifying Thrust Washer Of Front Planetary Gear Component

7. Install the front planetary gear component to the input shaft.
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Fig. 116: Identifying Front Planetary Gear Component Of Input Shaft

8. Apply ATF to the thrust bearing.

9. Install the thrust bearing to the input shaft as shown in the figure.
Fig. 117: Identifying Thrust Bearing Of Input Shaft

10. Install the front planetary sun gear to the input shaft as shown in the figure.
11. Apply ATF to the new seal rings and sliding surface of the input shaft.
CAUTION:  Do not expand the oil seal rings too much.

Fig. 118: Identifying Front Planetary Sun Gear Of Input Shaft

12. Compress the seal rings as shown in the figure.
Then install the seal rings to the input shaft.
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NOTE:  Verify that seal rings rotate smoothly after installing them.

that it does not drop when the front planetary gear component
is installed.
 Do not coat grease to the oil holes of the thrust washer.

14. Install the thrust washer to the front planetary gear component.
Fig. 120: Identifying Thrust Washer Of Front Planetary Gear Component

Components
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Fig. 121: Identifying C1 Clutch Disassembly Components

1. Using a flathead screwdriver, remove the snap ring from the C1 clutch drum.
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Fig. 122: Removing Snap Ring From C1 Clutch Drum

2. Remove the retaining plate, drive and driven plates from the C1 clutch drum.

CAUTION:  Do not expand the snap ring too much.
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5. Remove the clutch balancer, return spring and the retainer from the C1 clutch drum.
Fig. 125: Identifying Clutch Balancer, Return Spring And Retainer

figure and remove the forward clutch piston from the C1 clutch drum.
NOTE:  When applying compressed air, block the one oil passage of the C1
clutch drum as shown in the figure.
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7. Remove the O-rings from the C1 clutch drum.


parts.
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Components
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Fig. 130: Identifying C1 Clutch Assembly Components

Assembly Procedure
1. Apply ATF to the new O-rings and the C1 clutch drum.

2. Install the O-rings to the C1 clutch drum.
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3. Apply ATF to the sliding surface of the forward clutch piston.
CAUTION:  Do not damage the seal on the piston and O-ring.
4. Install the C1 clutch piston to the C1 clutch drum.
Fig. 132: Identifying C1 Clutch Piston Of C1 Clutch Drum

5. Apply ATF to the seal on the clutch balancer.
6. Install the retainer, return spring and the clutch balancer to the C1 clutch drum.
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Fig. 133: Identifying Retainer, Return Spring And Clutch Balancer

7. Place the SST on the clutch balancer and compress the return spring component with a press.

8. Install the snap ring in the groove using snap ring pliers.
9. Install the driven plates, drive plates and the retaining plate in the following order to the C1 clutch drum
Six drive plates type
 Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive-
Retaining
Seven drive plates type
 Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive-
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Driven- Drive- Retaining
Fig. 135: Identifying Drive Plates And Retaining Plate

driven plates.
Fig. 136: Inspecting Number And Order Of Retaining Plate, Drive

And Driven Plates
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11. Install the C1 clutch component on the input shaft and set a dial indicator as shown in the figure.
C1 clutch piston stroke 1.2-1.4 mm {0.047- 0.055 in}
Fig. 138: Applying Compressed Air And Measuring C1 Clutch Piston Stroke.

1 2.8 {0.110}
2 2.9 {0.114}
3 3.0 {0.118}
4 3.1 {0.122}
A 3.15 {0.124}
5 3.2 {0.126}
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B 3.25 {0.128}
6 3.3 {0.130}
C 3.35 {0.132}
7 3.4 {0.134}
8 3.5 {0.138}
COUNTER DRIVE GEAR DISASSEMBLY/ASSEMBLY
Components
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Fig. 139: Identifying Counter Drive Gear Components

1. Using the snap ring pliers, loosen the snap ring and remove the rear planetary ring gear.
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Fig. 140: Loosening Snap Ring

2. Using a flathead screwdriver, remove the snap ring from the rear planetary ring gear.
3. Remove the ring gear flange from the rear planetary ring gear.
Fig. 141: Removing Snap Ring From Rear Planetary Ring Gear
4. Using a flathead screwdriver and hammer, pry back the crimps locking the washer.
CAUTION:  If the lockwasher crimps are not completely pried back, the tool
cannot fit over the bolt properly and the bolt cannot be
loosened.
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Fig. 142: Prying Back Crimps Locking Washer

5. Using the SST , remove the nut and the washer.

6. Using a flathead screwdriver, remove the snap ring from the counter drive gear.
CAUTION:  Do not drop the tapered roller bearing.
Fig. 144: Identifying Snap Ring Of Counter Drive Gear

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7. Using the SST , remove the counter drive gear and tapered roller bearing.

8. Using a flathead screwdriver and hammer, remove the bearing race inner from the counter drive gear.
Fig. 146: Removing Bearing Race Inner From Counter Drive Gear
9. Using a flathead screwdriver and hammer, remove the bearing race outer from the counter drive gear.
Fig. 147: Removing Bearing Race Outer From Counter Drive Gear
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10. Using a flathead screwdriver, remove the snap ring from the counter drive gear.
Fig. 148: Removing Snap Ring From Counter Drive Gear

NOTE:  The tapered roller bearing cannot be removed from the center
support.
 The tapered roller bearing and center support must be replaced as a
set.
Fig. 149: Identifying Tapered Roller Bearing And Center Support

Assembly Procedure
NOTE:  The tapered roller bearing and bearing race outer must be replaced as a
set.
1. Using the SST and a press, install the tapered roller bearing to the center support.
Substitution SST
 49 L033 101
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Inner diameter: 68.2 mm {2.69 in} or more
Fig. 150: Installing Tapered Roller Bearing To Center Support

2. Using a flathead screwdriver, install the hole snap ring to the counter drive gear.
Fig. 151: Installing Hole Snap Ring To Counter Drive Gear

3. Using the old bearing race and the steel plate as shown in the figure, install the new bearing race outer to
the counter drive gear.
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Fig. 152: Installing Bearing Race Outer To Counter Drive Gear

4. Using the old bearing race and the steel plate as shown in the figure, install the new bearing race inner to
the counter drive gear.
CAUTION:  Do not press fit the bearing too deeply.

 Verify that the bearing is press fit to allow the installation of the
nut.
Fig. 153: Installing Bearing Race Inner To Counter Drive Gear

5. Using the SST and a press, install the counter drive gear with the tapered roller bearing.
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Substitution SST
 49 W027 001
NOTE:  Verify that the claw of the washer is fit into the groove on the center
support.
 Verify that the nut is installed in the correct direction.
Fig. 154: Installing Counter Drive Gear With Tapered Roller Bearing
6. Install the washer and nut.
Fig. 155: Identifying Washer And Nut

7. Using the SST , tighten the nut.

8. Using a spring balance, measure the starting and rotating torque of the counter drive gear.
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Fig. 156: Measuring Starting And Rotating Torque Of Counter Drive Gear
COUNTER DRIVE GEAR STARTING AND ROTATING TORQUE

N.m {kgf.cm, in.lbf}
Bearing Starting torque Rotating torque
New 0.40 - 0.50 {4.08 - 5.09, 3.55 - 4.41} 0.40 - 0.48 {4.08 - 4.89, 3.55 - 4.24}
Reused 0.20 - 0.25 {2.04 - 2.54, 1.77 - 2.20} 0.20 - 0.24 {2.04 - 2.44, 1.77 - 2.11}
Adjust the starting and rotating torque by tightening the nut.


 If the starting and rotating torque does not fall within the specification, loosen the nut and retighten
the nut to adjust torque.
9. Using a flathead screwdriver and hammer, crimp down the washer.
Fig. 157: Crimping Down Washer

10. Using a flathead screwdriver, install the hole snap ring to the counter drive gear.
11. Install the rear planetary ring gear flange to the rear planetary ring gear.
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Fig. 158: Identifying Rear Planetary Ring Gear Flange


13. Install the rear planetary ring gear to the counter drive gear.
14. Using the snap ring pliers, while loosening the snap ring, install the rear planetary ring gear.
Fig. 160: Loosening Snap Ring

ONE-WAY CLUTCH COMPONENT INSPECTION

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1. Hold the one-way clutch component in place. Verify that the rear planetary gear rotates when turned
clockwise and does not rotate when turned counterclockwise.
Fig. 161: Inspecting One-Way Clutch Component

REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT

DISASSEMBLY
Components
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Fig. 162: Identifying Rear Planetary Gear Component And One-Way Clutch Disassembly Components
1. Remove the one-way clutch component from the rear planetary gear component.
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Fig. 163: Removing One-Way Clutch Component From Rear Planetary Gear Component
2. Remove the thrust washer from the rear planetary gear component.
Fig. 164: Identifying Thrust Washer Of Rear Planetary Gear Component

3. Remove the thrust washer from the rear planetary gear component.

4. Remove the planetary sun gear and bearing races from the rear planetary gear component.
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NOTE:  If it is difficult to remove the bearing race, remove it gently using a

flathead screwdriver.
Fig. 166: Identifying Planetary Sun Gear And Bearing Races Of Rear Planetary Gear Component
REAR PLANETARY GEAR INSPECTION
NOTE:  Measure at different places and take an average.
1. Using a dial indicator, measure the inner diameter of the rear planetary gear bushings.
Rear planetary gear bushing inner diameter
Front side: 33.26 - 33.286 mm {1.3095 - 1.3104 in}
Rear side: 33.26 - 33.286 mm {1.3095 - 1.3104 in}
 If it exceeds the specification, replace the rear planetary gear component with a new one.
 When the rear planetary gear component is replaced, inspect the contact surface opposed to the
planetary sun gear.
Fig. 167: Measuring Inner Diameter Of Rear Planetary Gear Bushings

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If the surface of it is scratched or has changed color, replace the planetary sun gear with a new one.

2. Using a dial indicator, measure the inner diameter of the planetary sun gear bushings.
Rear planetary sun gear bushing inner diameter
Front side: 24.2 - 24.226 mm {0.9528 - 0.9537 in}
Rear side: 24.2 - 24.226 mm {0.9528 - 0.9537 in}
 If it exceeds the specification, replace the planetary sun gear component with a new one.
Fig. 168: Measuring Inner Diameter Of Planetary Sun Gear Bushings

 When the planetary sun gear component is replaced, inspect the contact surface opposed to the
intermediate shaft.
 If the surface of it is scratched or has changed color, replace the intermediate shaft with a new one.
REAR PLANETARY GEAR COMPONENT AND ONE-WAY CLUTCH COMPONENT ASSEMBLY
Components
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Fig. 169: Identifying Rear Planetary Gear Component And One-Way Clutch Component Assembly
Assembly Procedure
CAUTION:  Apply grease to the mounting surface of the thrust washer so that it
will not drop when the rear planetary gear component is installed.

2. Install the thrust washer to the rear planetary gear component.

that it will not drop when the rear planetary gear component is
installed.
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4. Install the thrust washer to the rear planetary gear component.

that it will not drop when the rear planetary gear component is
installed.

5. Apply ATF to the bearing races and the thrust bearing.

6. Install the bearing races to the planetary sun gear as shown in the figure.
7. Install the planetary sun gear to the rear planetary gear component.
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Fig. 172: Identifying Bearing Races Of Planetary Sun Gear

Components
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Fig. 173: Identifying C2 Clutch Component Disassembly

1. Remove the thrust bearing from the intermediate shaft.
NOTE:  If the bearing is difficult to remove, blow air between the bearing and
the intermediate shaft.
Fig. 174: Identifying Thrust Bearing Of Intermediate Shaft

2. Using a flathead screwdriver, remove the snap ring from the intermediate shaft.
Fig. 175: Removing Snap Ring From Intermediate Shaft

3. Remove the retaining plate, drive and driven plates from the intermediate shaft.
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CAUTION:  Do not contract the return spring too much.


6. Remove the clutch balancer, return spring and the spring retainer from the intermediate shaft.
CAUTION:  Do not damage the seal on the piston.
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Fig. 178: Identifying Clutch Balancer, Return Spring And Spring Retainer
figure and remove the C2 clutch piston from the intermediate shaft.
Air pressure
392 kPa {4.0 kgf/cm2 , 57 psi}
NOTE:  When applying compressed air, block the three oil passages of the
intermediate shaft as shown in the figure.

8. Remove the O-rings from the intermediate shaft.
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Fig. 180: Identifying O-Rings Of Intermediate Shaft


parts.

C2 clutch return spring free length
Standard: 14.02 mm {0.5520 in}
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Components
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Fig. 183: Identifying C2 Clutch Component Assembly

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Assembly Procedure
1. Apply ATF to the new O-rings and the intermediate shaft.

2. Install the O-rings to the intermediate shaft.
Fig. 184: Identifying O-Rings Of Intermediate Shaft

O-RING SIZE
mm {in}
Inner diameter Thickness
Upper 51.90 {2.043} 1.60 {0.0630}
Lower 50.40 {1.984} 2.62 {0.1031}
3. Apply ATF to the sliding surface of the C2 clutch piston.
4. Install the C2 clutch piston to the intermediate shaft.

5. Apply ATF to the seal on the clutch balancer and sliding surface.

 Do not damage the O-ring.
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Fig. 185: Identifying C2 Clutch Piston Of Intermediate Shaft

6. Install the spring retainer, return spring and the clutch balancer to the intermediate shaft.
CAUTION:  Be careful not to shorten the spring too much. If it is too short,
it will bite into the O-ring.
Fig. 186: Identifying Spring Retainer, Return Spring And Clutch Balancer
CAUTION:  Do not expand the snap ring too much.
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8. Install the snap ring into the groove using snap ring pliers.
9. Install the driven plates, drive plates and the retaining plate in the following order to the intermediate
shaft as shown in the figure.
Three drive plates type
 Driven- Drive- Driven- Drive- Driven- Drive- Retaining
Four drive plates type
 Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Retaining
Fig. 188: Identifying Driven Plates, Drive Plates And Retaining Plate
driven plates.
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Fig. 189: Inspecting Number And Order Of Retaining Plate, Drive And Driven Plates
10. Using a flathead screwdriver, install the snap ring into the groove.
Fig. 190: Installing Snap Ring Into Groove

11. Apply ATF to the thrust bearing.
NOTE:  Install the bearing in the correct direction as shown in the figure.
12. Install the thrust bearing to the intermediate shaft.
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Fig. 191: Identifying Thrust Bearing Of Intermediate Shaft

13. Install the intermediate shaft on the transaxle case and set a dial indicator as shown in the figure.
Air pressure
400 kPa {4.1 kgfcm2 , 58 psi}
C2 clutch piston stroke
0.45 - 0.65 mm {0.0178 - 0.0255 in}
Fig. 192: Measuring C2 Clutch Piston Stroke


1 2.5 {0.0984}
2 2.6 {0.102}
3 2.7 {0.106}
4 2.8 {0.110}
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A 2.85 {0.112}
5 2.9 {0.114}
B 2.95 {0.116}
6 3.0 {0.118}
C 3.05 {0.120}
7 3.1 {0.122}
8 3.2 {0.126}
TRANSAXLE CASE AND B2 BRAKE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in Fig. 193.

2. Assemble in the reverse order of disassembly.
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Fig. 193: Identifying Transaxle Case And B2 Brake Components

Low and Reverse Brake Piston Disassembly Note
1. Using a flathead screwdriver, remove the snap ring from the transaxle case.
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Fig. 194: Identifying Snap Ring Of Transaxle Case

2. Remove the low and reverse brake return spring from the transaxle case.
CAUTION:  Do not damage the seal on the piston.
Fig. 195: Identifying Low And Reverse Brake Return Spring

3. While pushing the low and reverse brake piston by hand, apply compressed air into the oil passage of the
transaxle case as shown in the figure and remove the low and reverse brake piston.
Air pressure
392 kPa {4.0 kgf/cm2 , 57 psi}
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Fig. 196: Applying Compressed Air Into Oil Passage Of Transaxle Case
4. Remove the O-rings from the low and reverse brake piston.
Fig. 197: Identifying O-Rings Of Low And Reverse Brake Piston

Low and Reverse Brake Piston Assembly Note

2. Install the O-ring to the low and reverse brake piston.
3. Apply ATF to the sliding surface of the transaxle case.
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Fig. 198: Identifying O-Rings Of Low And Reverse Brake Piston

4. Install the low and reverse brake piston to the transaxle case.
Fig. 199: Identifying Low And Reverse Brake Piston Of Transaxle Case
Low and Reverse Brake Return Spring Assembly Note
1. Install the low and reverse brake return spring to the transaxle case.
Fig. 200: Identifying Low And Reverse Brake Return Spring

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2. Using the SST , press the return spring into the position where the snap ring groove is visible.
Fig. 201: Pressing Return Spring Into Position


TRANSAXLE CASE AND B2 BRAKE INSPECTION
NOTE:  Measure at different places and take an average.
1. Using a dial indicator, inspect the transaxle case bushing.
Transaxle case bushing inner diameter
Standard: 21.932 - 21.953 mm {0.86347 - 0.86429 in}
 If it exceeds the specification, replace the transaxle case with a new one.
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 When the transaxle case is replaced, inspect the contact surface of the intermediate shaft bushing.
Fig. 203: Inspecting Transaxle Case Bushing

If the surface is scratched or has changed color, replace the intermediate shaft with a new one.


parts.

B2 brake return spring free length
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CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY
Components
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Fig. 206: Identifying Control Valve Body Components

CAUTION:  Do not pull the manual valve strongly.
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Fig. 207: Identifying Manual Valve Of Control Valve Body

1. Remove the manual valve from the control valve body.

2. Using a flathead screwdriver, remove the E-ring.
3. Remove the manual valve connecting rod from the manual valve.
CAUTION:  Do not damage the solenoid.
Fig. 208: Removing E-Ring

4. Remove the solenoids from the control valve body.
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Fig. 209: Locating Solenoids Bolts

Assembly Procedure
CAUTION:  Do not damage the solenoid.
1. Install the solenoids to the front control valve body.
Tightening torque
8.0-12.0 N.m {81.6-122.3 kgf.cm, 70.9 - 106.1 in.lbf}
Fig. 210: Locating Solenoids Bolts

2. Install the manual valve connecting rod to the manual valve.

3. Install the E-ring.
4. Apply ATF to the manual valve.
CAUTION:  Do not damage the manual valve.
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Fig. 211: Installing E-Ring

5. Install the manual valve to the control valve body.
Fig. 212: Identifying Manual Valve Of Control Valve Body

AUTOMATIC TRANSAXLE ASSEMBLY
Assembly
Bearing and race locations
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Fig. 213: Identifying Automatic Transaxle Assembly - Bearing And Race Locations
BEARING AND RACE SPECIFICATIONS

1 2 3 4 5 6 7 8 9 10 11
64.0 101.0 85.0 79.8 104.2
Thrust Outer - - - - - -
{2.52} {3.98} {3.35} {3.14} {4.10}
washer
(mm {in}) Inner 51.0 75.3 72.7 - - -
68.3 69.0
- - -
{2.01} {2.96} {2.86} {2.69} {2.72}
43.7
Bearing Outer - - - - - - - - - -
{1.72}
race
(front) 25.6
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(mm {in}) Inner - - - - - - - - - {1.01} -

61.3 52.6 45.6 48.7 43.8 75.0
Outer - - - - -
Bearing {2.41} {2.07} {1.80} {1.92} {1.72} {2.95}
(mm {in}) 43.7 39.2 33.2 35.0 24.25 50.5
Inner - - - - -
{1.72} {1.54} {1.31} {1.38} {0.9547} {1.99}
68.8 48.5 47.0 45.6 41.7
Bearing Outer - - -
{2.71} {1.91} {1.85}
- -
{1.80} {1.64}
-
race (rear)
(mm {in}) Inner 46.9 38.1 35.2 33.2 24.2
- - - - - -
{1.85} {1.50} {1.39} {1.31} {0.953}
Components
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Fig. 214: Identifying Automatic Transaxle Assembly - Components (1 Of 4)

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Assembly Procedure
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1. Using the SST and a hammer, install a new oil seal to the transaxle case.
Substitution SST
 49 F026 102
Fig. 218: Installing Oil Seal To Transaxle Case

2. Apply ATF to the new seal rings and sliding surface of the transaxle case.
3. Compress the seal rings as shown in the figure. Then install the seal rings in the transaxle case.
CAUTION:  Do not expand the seal rings too much.

NOTE:  Inspect that seal rings rotate smoothly after installing them.
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4. Install the transaxle case plate No.3.
Tightening torque
3.9 - 6.9 N.m {40 - 70 kgf.cm, 26 - 60 in.lbf}

5. Install the transaxle case plate No.2.
Tightening torque
3.9 - 6.9 N.m {40 - 70 kgf.cm, 26 - 60 in.lbf}
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6. Apply ATF or grease to the thrust bearing and install it to the C2 clutch component.
7. Apply ATF to the seal ring and rubbing surface of the C2 clutch component where the bushing is fit.
CAUTION:  Do not damage the seal ring.
Fig. 222: Identifying Seal Ring And Rubbing Surface Of C2 Clutch Component
8. Install the C2 clutch component to the transaxle case.
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Fig. 223: Identifying C2 Clutch Component To Transaxle Case

9. Apply ATF to the driven plates, drive plates and retaining plates.
NOTE:  Replace with new drive plates after soaking them at least 2 h in ATF.
10. Install driven plates, drive plates and the retaining plate in the following order to the transaxle case as
 Retaining- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive-
Retaining
CAUTION:  Inspect the number and order of the retaining plates, drive and
driven plates.
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Fig. 225: Inspecting Number And Order Of Retaining Plates, Drive And Driven Plates
CAUTION:  Align the opening of the snap ring with the position as shown in
the figure.

12. Apply ATF to the thrust bearing and the bearing races and install them to the transaxle case.
NOTE:  Align the spline of the C2 clutch drive plates and B2 brake drive
plates before installing the rear planetary gear component.
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Fig. 227: Identifying Thrust Bearing And Bearing Races

13. Apply ATF to each gear and the bushing, and then install the rear planetary gear component to the
transaxle case.
14. Apply ATF to the sliding surface of the one-way clutch.
NOTE:  For easy installation, while turning the rear planetary gear
component, install it.
Fig. 228: Identifying Rear Planetary Gear Component

15. Install the one-way clutch to the transaxle case.
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Fig. 229: Identifying One-Way Clutch Of Transaxle Case

CAUTION:  Align the opening of the snap ring with the position shown in
the figure.

17. While holding the one-way clutch component, inspect that the planetary gear turns to right (clockwise)
but does not turn to left (counterclockwise).
CAUTION:  Do not damage the VSS.
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Fig. 231: Inspecting Planetary Gear

18. Install the VSS and spacer to the counter drive gear.
Tightening torque 3.9 - 6.9 N.m {40 - 70 kgf.cm, 26 - 60 in.lbf}
19. Apply ATF to the spline on the counter drive gear and spline on the ring gear.

Fig. 232: Identifying VSS And Spacer Of Counter Drive Gear

20. Install the counter drive gear to the transaxle case.
NOTE:  Verify that the claws of the lockwashers are facing upward.
21. Install the new lockwashers and washers with new bolts.
Tightening torque 82.7 - 93.6 N.m {8.5 - 9.5 kgf.cm, 61.0 - 69.0 ft.lbf}
Bolt length (measured from below the head)

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A. A: 28 mm {1.102 in}
B. B: 35 mm {1.378 in}
Fig. 233: Identifying Bolts Of Lockwashers And Washers

22. Using a flathead screwdriver and a hammer, pry back the crimp locking the lockwashers.
Fig. 234: Prying Back The Crimp Locking The Lockwashers


24. Install the O-rings to the oil cooler outlet tube.
25. Install the oil cooler outlet tube, pipe clamp, transaxle case No. 1 plate and the wiring harness clip to the
converter housing.
CAUTION:
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 Do not damage the VSS wiring harness.

Fig. 235: Identifying Oil Cooler Outlet Tube, Pipe Clamp, Transaxle Case No. 1 Plate And Wiring
Harness Clip
26. Connect the VSS wiring harness to the wiring harness clip.
Fig. 236: Identifying Wiring Harness Clip

27. Apply ATF to the bearing and gear of the differential component.
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28. Install the differential component to the transaxle case.
Fig. 237: Identifying Differential Component Of Transaxle Case

29. Apply ATF to the bearing and gear of the counter gear component.
30. Install the counter gear component to the transaxle case.
NOTE:  If it is difficult to install the counter driven gear, remove the

differential component and then install the counter driven gear.
Install the differential component again.
 For easy installation, tilt the counter gear slightly.
Fig. 238: Identifying Counter Gear Component Of Transaxle Case

31. Install the parking pin to the transaxle case.
CAUTION:  Verify to install the parking pin as shown in the figure.
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Fig. 239: Identifying Parking Pin Of Transaxle Case

32. Insert the parking rod to the transaxle case.
Fig. 240: Inserting Parking Rod To Transaxle Case

33. Install the manual valve lever to the transaxle case.
Fig. 241: Installing Manual Valve Lever To Transaxle Case

34. Connect the parking rod to the manual valve lever.
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Fig. 242: Locating Parking Rod Of Manual Valve Lever

35. Install the parking pawl, parking pawl bracket and the parking rod to the transaxle case.
CAUTION:  Do not apply too much force to the torsion spring.
Fig. 243: Identifying Parking Pawl, Parking Pawl Bracket And Parking Rod
36. Install the spring guide sleeve and the torsion spring.
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NOTE:  Install the torsion spring to the position of the parking lock pawl and
parking lock pawl bracket shown in the figure together with the
spring guide sleeve and torsion spring installed.
CAUTION:  Do not apply too much force to the pawl return spring.
Fig. 244: Identifying Spring Guide Sleeve And Torsion Spring

37. Install the pawl return spring to the parking pawl shaft.
38. Install the pawl return spring and the parking pawl shaft to the transaxle case.
CAUTION:  Do not apply too much force to the detent spring.
NOTE:  When installing the pawl return spring to transaxle case, install the
parking pawl side of the spring, then install the parking pawl shaft.
Fig. 245: Identifying Pawl Return Spring And Parking Pawl Shaft
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39. Install the detent spring cover and detent spring to the transaxle case.
Fig. 246: Identifying Detent Spring Bolt

NOTE:  When installing, ensure that the center of the detent spring's roller
fits the center of the manual valve lever.
Fig. 247: Inspecting Center Of Detent Spring's Roller Fits Center Of Manual Valve Lever
40. Install the sun gear input drum to the transaxle case.
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Fig. 248: Identifying Sun Gear Input Drum Of Transaxle Case

41. Apply ATF to the bearing race and the thrust bearing, and then install them to the transaxle case.
Fig. 249: Identifying C1 Clutch Component Of Transaxle Case

43. Apply ATF to the bearing race and the thrust bearing, and then install them to the transaxle case.
CAUTION:  If the input shaft is not hold during installation, the thrust
washer might be come off.
NOTE:  Align the spline of the C1 clutch drive plates before installing the
input shaft and front planetary gear.
 Hold the C1 clutch component and install the front planetary gear
while holding the input shaft.
44. Install the input shaft and the front planetary gear to the transaxle case.
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Fig. 250: Identifying Input Shaft And Front Planetary Gear

45. Apply ATF to the bushing of the C3 clutch component.
NOTE:  Before installing the C3 clutch component, align the spline of the C3
clutch drive plates and the spline of the B1 brake drive plates.
Fig. 251: Identifying C3 Clutch Component Of Transaxle Case

NOTE:  Install the C3 clutch component so that it engages with the sun gear
drum as shown in the figure.
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Fig. 252: Inspecting C3 Clutch Component

47. Install the B1 brake band to the transaxle case.
Fig. 253: Identifying B1 Brake Band Of Transaxle Case

48. Install the brake band anchor bolt to the transaxle case.
Tightening torque 133.3 - 199.9 N.m {13.6 - 20.3 kgf.m, 98.3 - 147.4 ft.lbf}
Fig. 254: Identifying Brake Band Anchor Bolt

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49. Install the piston return spring, B1 brake piston and the brake piston cover to the transaxle case.
Fig. 255: Identifying Piston Return Spring, B1 Brake Piston And Brake Piston Cover
50. Using the SST, press the brake piston cover into the position where the snap ring groove is visible.
51. Apply ATF to the oil seal.
Fig. 256: Pressing Brake Piston Cover Into Position

52. Install the oil strainer and the oil seal to the oil pump component.
53. Apply ATF to each rubbing surface of the oil pump component.
CAUTION:  Do not drop the thrust washer.

 Do not damage the oil seal.
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Fig. 257: Identifying Oil Strainer And Oil Seal

54. Install the oil pump component to the transaxle case.
A. A: 22 mm {0.866 in}
B. B: 35 mm {1.378 in}
Fig. 258: Identifying Oil Pump Component Bolts

55. Verify that the input shaft turns smoothly.
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Fig. 259: Inspecting Input Shaft Turns Smoothly

56. Using a dial indicator, measure the input shaft end play.
Input shaft end play 0.349 - 1.081 mm {0.01374 - 0.04255 in}
Fig. 260: Measuring Input Shaft End Play

57. Put a mark on the piston rod at the point where it intersects with the case.
Fig. 261: Identifying Mark On Piston Rod

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58. Measure the stroke between the transaxle case and the mark on the piston rod when applying compressed
air into the oil hole as shown in the figure.
B1 brake piston stroke 5.50 - 6.00 mm {0.217 - 0.236 in}
 If not within the specification, select an appropriate piston rod.
Fig. 262: Measuring Stroke Between Transaxle Case And Mark On Piston Rod
PISTON ROD SIZE

Identification mark Length (mm {in})
- 102.80 {4.0473}
1 103.05 {4.0571}
2 103.30 {4.0669}
3 103.55 {4.0768}
4 103.80 {4.0866}
5 104.05 {4.0965}
6 104.30 {4.1063}
7 104.55 {4.1161}
8 104.80 {4.1260}
9 105.05 {4.1358}
10 105.30 {4.1457}
CAUTION:  Do not damage the differential gear lube apply tube.
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Fig. 263: Identifying Differential Gear Lube Apply Tube Mark

59. Install the differential gear lube apply tube to the converter housing.
Fig. 264: Identifying Differential Gear Lube Apply Tube

60. Install the magnets to the oil reservoir lock plate.
CAUTION:  Do not damage the oil reservoir lock plate.
Fig. 265: Identifying Magnets Of Oil Reservoir Lock Plate

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61. Install the oil reservoir lock plate and the tube clamp to the converter housing.
Fig. 266: Identifying Oil Reservoir Lock Plate And Tube Clamp Bolt
62. Apply ATF to the new gaskets.

63. Install the gaskets to the transaxle case as shown in the figure.
Fig. 267: Locating Gaskets Of Transaxle Case

64. Apply ATF to the new transaxle case gaskets.

65. Install the transaxle case gaskets to the transaxle case as shown in the figure.
CAUTION:  Verify to install the transaxle case gasket as shown in the

figure.
66. Remove any packing material and be careful not to get oil on the contact surface of the transaxle case and
the converter housing.
67. Clean the contact surface of the transaxle case and the converter housing and the bolt holes.
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Fig. 268: Locating Transaxle Case Gaskets

NOTE:  Completely remove sealant and oil with white gasoline or equivalent.
68. Apply ATF to a O-ring of the oil pump.

69. Apply sealant to the converter housing as shown in the figure.
NOTE:  Spread sealant over the contact surface.

 Do not apply sealant to the transaxle case.
CAUTION:  Do not damage the O-ring on the oil pump component.

 Do not damage the housing oil seal.
Fig. 269: Identifying Sealant On Converter Housing

70. Install the converter housing to the transaxle case.
NOTE:  Tap all around the contact surface with a plastic hammer during
installation.
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Fig. 270: Installing Converter Housing To Transaxle Case

71. Temporarily tighten the bolts by hand as shown in the figure.
Fig. 271: Locating Transaxle Case Bolts

TRANSAXLE CASE BOLTS IDENTIFICATION TABLE

Bolt number Bolt size Length (measured from below the head) (mm {in})
A M8 x 1.25 30 {1.18}
B M8 x 1.25 35 {1.38}
C M8 x 1.25 39 {1.54}
D M10 x 1.25 25 {0.984}
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E M10 x 1.25 40 {1.57}
72. Tighten the bolts.
Tightening torque
A, B, C: 23.5 - 35.3 N.m {2.4 - 3.5 kgf.m, 17.4 - 26.0 ft.lbf}
D, E: 29.4 - 41.2 N.m {3.0 - 4.2 kgf.m, 21.7 - 30.3 ft.lbf}
73. Install the input/turbine speed sensor to the transaxle case.
Fig. 272: Locating Input/Turbine Speed Sensor

74. Apply ATF to a new gasket as shown in the figure.

75. Install the gasket to the coupler component.
CAUTION:  Do not apply ATF to the O-ring.
76. Install a new O-ring to the coupler component.
CAUTION:  Do not apply too much force to the coupler component.

 Do not damage the coupler component.
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Fig. 273: Identifying O-Ring And Gasket

77. Install the coupler component to the transaxle case.
NOTE:  Install the coupler component to the transaxle case by engaging its
claw.
Fig. 274: Locating Coupler Component Lock Plate

78. Install a new coupler component lock plate.
CAUTION:  When installing the control valve body component, do not put
the coupler component in the open space of the separate plate
in the control valve body component.
 Do not pinch the coupler component between the separate plate
and the control valve body component.
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Fig. 275: Identifying Separate Plate

79. Connect the manual valve link and install the control valve body component.
80. Temporarily install the control valve body component with the bolts.
A. A: 31 mm {1.220 in}
B. B: 17 mm {0.669 in}
C. C: 21 mm {0.827 in}
NOTE:  Aligning the bolt holes, temporarily tighten the bolts by hand.
Fig. 276: Locating Control Valve Body Component Bolts

81. Temporarily install the suction cover and a new gasket with the bolts.
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Fig. 277: Identifying Suction Cover, Gasket And Bolts

82. Tighten the bolts in the order shown in the figure.
Tightening torque 8 - 12 N.m {82 - 122 kgf.cm, 72 - 105 in.lbf}
Fig. 278: Identifying Control Valve Body Bolts Tightening Order

83. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.
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Fig. 279: Identifying Connector Of VSS And Input/Turbine Speed Sensor

CAUTION:  If the control valve body cover is installed with the wiring
harnesses overlapped, the wiring harnesses may be pinched
between the cover and valve body causing the wiring harnesses
to be damaged. Therefore, verify that the wiring harnesses are
not overlapped when installing the control valve body cover.
Fig. 280: Caution - Wiring Harnesses Are Not Overlapped When Installing Control Valve Body
Cover
84. Apply ATF to a new O-ring and install it on the TFT sensor.
85. Install the TFT sensor with the lock plate and a bolt to the control valve body component as shown in the
figure.
Tightening torque 8 - 12 N.m {82 - 122 kgf.cm, 72 - 105 in.lbf}
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Fig. 281: Identifying TFT Sensor With Lock Plate And Bolt
86. Connect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.
87. Connect the coupler component to the clamps.
NOTE:  Completely remove sealant and oil with white gasoline or similar.
Fig. 282: Identifying Coupler Component And Clamps

88. Clean sealant and oil off the contact surface of the transaxle case with the control valve body cover and
the bolt holes.
NOTE:  Completely remove oil with white gasoline or similar.
89. Clean oil off the contact surface of the new control valve body cover with the transaxle case.
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Fig. 283: Cleaning Sealant And Oil Off Contact Surface Of Transaxle Case
90. Apply sealant to the new control valve body cover as shown in the figure.
CAUTION:  Be careful that the coupler component will not become caught
between the control valve body cover and transaxle case.
Fig. 284: Identifying Sealant On Control Valve Body Cover

91. Install the new control valve body cover with new seal bolts.
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Fig. 285: Identifying Control Valve Body Cover Seal Bolts

92. Inspect the condition of connector pin of the coupler component (foreign material, bent/broken pins) and
O-ring.
Fig. 286: Inspecting Condition Of Connector Pin Of Coupler Component (Foreign Material,
Bent/Broken Pins) And O-Ring
93. Align the transaxle case and the coupler component connector.
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Fig. 287: Aligning Transaxle Case And Coupler Component Connector

94. Be sure to match the position of the TCM marking.
CAUTION:  Do not turn more than 60° from the marking.
Fig. 288: Matching Position Of TCM Marking

95. Verify the correct positioning of the TCM and coupler component.
96. Install the TCM to the transaxle case.
CAUTION:  Do not repair the threads using a tap or other tools.

 Do not damage the transaxle case.
 Do not overtighten the stud bolts. (The stud bolts should remain
protruded from the end of the transaxle case more than 47 mm
{1.85 in}.)
 If any of the stud bolts is overtightened, the transaxle case may
be damaged (holes in the case may result).
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 If the transaxle case is damaged, the transaxle must be

replaced.
Fig. 289: Identifying TCM

97. Install the double nutted stud bolts to the transaxle case.
98. Remove the double nutted from the stud bolt.
Fig. 290: Identifying Double Nutted Stud Bolts

99. Using the SST and a hammer, tap a new oil seal so that the specified oil seal position is obtained.
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Transaxle Case Side
Substitution SST
 49 H028 202
Outer diameter: 54.5-61 mm {2.15-2.40 in}
Inner diameter: 52 mm {2.05 in} or more
Fig. 291: Tapping Oil Seal - Transaxle Case Side

Converter Housing Side
Substitution SST
 49 F027 009
Outer diameter: 76.8 mm {3.02 in}
 49 L033 101
Outer diameter: 73-76.3 mm {2.88-3.00 in}
Length: 20 mm {0.79 in} or more
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Fig. 292: Tapping Oil Seal - Converter Housing Side

100. Install a new gasket and the drain plug.

 Be careful that fingers do not get caught.
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Fig. 293: Identifying Gasket And Drain Plug

101. Using a flathead screwdriver, position the drive gear on the oil pump component in the center. Then
install the torque converter component to the transaxle.
Fig. 294: Identifying Torque Converter Component

102. To ensure that the torque converter is installed accurately, measure distance A between the end of the
torque converter and the end of the converter housing.
Distance A (between the end of the torque converter and the end of the converter housing)
Mazda6: 18 mm {0.709 in}
CX-7: 31.4 mm {1.24 in}
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Fig. 295: Measuring Distance A Between End Of Torque Converter And End Of Converter
Housing
103. Install the O-rings and oil pipes. (Refer to the appropriate article .)
104. Add the ATF.
AUTOMATIC TRANSAXLE INSPECTION
B2 Brake Inspection
1. Apply ATF to the driven plates, drive plates and retaining plates.
NOTE:  Replace with new drive plates after soaking them at least 2 h in ATF.
2. Install driven plates, drive plates and the retaining plate in the following order to the transaxle case as
 Drive- Retaining- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive- Driven- Drive-
Retaining
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CAUTION:  Inspect the number and order of the retaining plates, drive and
driven plates.
Fig. 297: Inspecting Number And Order Of Retaining Plates, Drive And Driven Plates
3. Using a flathead screwdriver, install the snap ring into the groove.
CAUTION:  Align the opening of the snap ring with the position shown in
the figure.
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Fig. 298: Installing Snap Ring Into Groove

4. Set a dial indicator as shown in the figure.

5. While applying compressed air into the oil passage as shown in the figure, measure the B2 brake
clearance and inspect the piston moves smoothly.
B2 brake clearance 1.20 - 1.40 mm {0.047 - 0.055 in}
 If not within the specification, select another retaining plate.
Fig. 299: Measuring B2 Brake Clearance


47 4.7 {0.185}
48 4.8 {0.189}
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49 4.9 {0.193}
50 5.0 {0.197}
51 5.1 {0.201}
52 5.2 {0.205}
53 5.3 {0.209}

7. Remove the retaining plates, drive and driven plates.
Fig. 301: Identifying Retaining Plates, Drive And Driven Plates

TECHNICAL DATA
TRANSMISSION/TRANSAXLE TECHNICAL DATA
TRANSMISSION/TRANSAXLE TECHNICAL DATA

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Item Specification
Front side: 33.26 - 33.286 mm {1.3095 -
1.3104 in}
Rear planetary gear bushing inner diameter
Rear side: 33.26 - 33.286 mm {1.3095 -
1.3104 in}
Front side: 24.2 - 24.226 mm {0.9528 -
0.9537 in}
Rear planetary sun gear bushing inner diameter
Rear side: 24.2 - 24.226 mm {0.9528 -
0.9537 in}
Standard: 21.932 - 21.953 mm {0.86347
Transaxle case bushing inner diameter
- 0.86429 in}
B2 brake return spring free length Standard: 19.01 mm {0.7485 in}
0.349 - 1.081 mm {0.01374 - 0.04255
Input shaft end play
in}
B1 brake piston stroke 5.50 - 6.00 mm {0.217 - 0.236 in}
Distance A (between the end of the torque converter and the Mazda6: 18 mm {0.709 in}
end of the converter housing) CX-7:31.4 mm {1.24 in}
B2 brake clearance 1.20 - 1.40 mm {0.047 - 0.055 in}
COUNTER DRIVE GEAR STARTING AND ROTATING TORQUE

N.m {kgf.cm, in.lbf}
Bearing Starting torque Rotating torque
New 0.40 - 0.50 {4.08 - 5.09, 3.55 - 4.41} 0.40 - 0.48 {4.08 - 4.89, 3.55 - 4.24}
Reused 0.20 - 0.25 {2.04 - 2.54, 1.77 - 2.20} 0.20 - 0.24 {2.04 - 2.44, 1.77 - 2.11}
SERVICE TOOLS
TRANSMISSION/TRANSAXLE SST
TRANSMISSION/TRANSAXLE SST
49 U027
49 L010 1A0
49 0107 680A 003
Engine hanger
Engine stand Oil seal
set
installer
49 G025 001 49 G019
49 G019 040
Sensor rotor 026
Wrench
installer Plate
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49 L033
49 B032 317 49 F027 009
101
Bearing & oil Attachment for
Oil seal
seal remover 68 & 77
installer
49 G030
49 W027 001 49 G019 0A9
797
Body Compressor
Handle
49 T019 0A1 49 H028
49 F026 102
Servo piston 202
Bearing installer
lifter set Block L
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2008 TRANSMISSION Automatic Transaxle (AW6A-EL, AW6AX-EL) - Mazda CX-9
2008 TRANSMISSION
Automatic Transaxle (AW6A-EL, AW6AX-EL) - Mazda CX-9
AUTOMATIC TRANSAXLE LOCATION INDEX [AW6A-EL, AW6AX-EL]
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Fig. 1: Identifying Automatic Transaxle Components Location

MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL]

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MECHANICAL SYSTEM TEST PREPARATION
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant level. (See COOLING SYSTEM SERVICE WARNINGS [MZI-3.7] .) (See
ENGINE COOLANT LEVEL INSPECTION [MZI-3.7] .)
3. Inspect the engine oil level. (See ENGINE OIL LEVEL INSPECTION [MZI-3.7] .)
4. Inspect the ATF level. (See AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AW6A-EL,
AW6AX-EL].)
5. Inspect the idle speed. (See ENGINE TUNE-UP [MZI-3.7] .)
6. Inspect the ignition timing. (See ENGINE TUNE-UP [MZI-3.7] .)
LINE PRESSURE TEST
1. Perform mechanical system test preparation. (See MECHANICAL SYSTEM TEST PREPARATION.)
WARNING:  Removing the test plug when the ATF is hot can be dangerous.
Hot ATF can come out of the opening and badly burn you.
Before removing the test plug, allow the ATF to cool.
2. Connect the SSTs (49 HD64 406A and, 49 0378 400C) to the line pressure inspection port and replace
the gauge of the SST (49 0378 400C) with the SST (49 B019 901B) .
Fig. 2: Identifying Line Pressure Inspection Port With SST

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3. Start the engine and warm it up until the ATF reaches 60-70 °C {140-158 °F}.
4. Shift the selector lever to the D range.
CAUTION:  Perform the test at least 3 times and calculate the average.
5. Read the line pressure while the engine is idling for the D range.
6. Read the line pressure while the engine is idling for the R position and M range in the same manner as in
Steps 4--5.
Line pressure
LINE PRESSURE RANGE REFERENCE

Position/range Line pressure (kPa {kgf/cm2 , psi})
D, M Idle 350-410 {3.6-4.1, 51-59}
R Idle 580-670 {6.0-6.8, 85-97}
7. Stop the engine, then replace the SST (49 B019 901B) with the gauge of the SST (49 0378 400C).
9. Measure the LPS PID value.
10. Start the engine.
11. Firmly depress the brake pedal with the left foot.
CAUTION:  If the accelerator pedal is pressed for more than 5 s while the
brake pedal is pressed, the transaxle could be damaged.
Therefore, perform Steps 14 and 15 within 5 s.

13. Gradually depress the accelerator pedal with the right foot.
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14. When the engine speed no longer increases, quickly read the line pressure and release the accelerator
pedal.
15. Shift the selector lever to the N position and idle the engine for 1 min or more to cool the ATF.
16. Verify that the line pressure and LPS PID current values change according to the following graph by
changing the shift throttle opening angle when shifting to the D range and R position with the engine
running.
 The line pressure standard other than when the engine is idling cannot be determined because the
maximum line pressure for this automatic transaxle is controlled by vehicle conditions.
Fig. 4: Line Pressure Control Solenoid Current Diagram

WARNING:  Removing the SST when the ATF is hot can be dangerous.
Hot ATF can come out of the opening and badly burn you.
Before removing the SST, allow the ATF to cool.
17. Remove the SSTs.

18. Install a test plug in the inspection port.
Tightening torque
5.9-8.8 N.m {61-89 kgf.cm, 53-77 in.lbf}
Line pressure test evaluation
LINE PRESSURE TEST EVALUATION POSSIBLE CAUSE

Condition Possible cause
 Line pressure control solenoid

Lower than specification in D range and R position
malfunction
 Primary regulator valve malfunction
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 Oil pump malfunction

 Oil leaking from D range or R
position hydraulic circuit
 Line pressure control solenoid
Constant pressure without fluctuation in hydraulic pressure malfunction
to throttle in D range and R position  Control valve body internal
malfunction
Current to throttle does not change in D range and R  TCM internal malfunction
position  Connector malfunction
Hydraulic pressure in R position is not higher than D range  Primary regulator valve malfunction
STALL TEST
3. Firmly depress the brake pedal with the left foot.
CAUTION:  If the accelerator pedal is depressed for more than 5 s while the
brake pedal is depressed, the transaxle could be damaged.
Therefore, perform Steps 5 and 6 within 5 s.
 Perform the test at least 3 times and calculate the average.
5. Gently depress the accelerator pedal with the right foot.

6. When the engine speed no longer increases, quickly read the engine speed and release the accelerator
pedal.
7. Shift the selector lever to the N position and idle the engine for 1 min or more to cool the ATF.
8. Perform a stall test of the M range and R position in the same manner as in Steps 3--7.
9. Turn off the engine.
Engine stall speed
ENGINE STALL SPEED POSSIBLE CAUSE

Position/range Engine stall speed (rpm)
D, M 2,637
R 2,555
Evaluation of stall test
EVALUATION OF STALL TEST POSSIBLE CAUSE

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 Low line pressure (Line pressure control solenoid

malfunction, primary regulator valve malfunction)
 Control valve body component malfunction (shift solenoid C
In D, M ranges
hydraulic pressure system)
 C1 clutch slipping
 One-way clutch malfunction
Above malfunction, primary regulator valve malfunction)
specification  Control valve body component malfunction (shift solenoid E
In R position
hydraulic pressure system)
 C3 clutch malfunction (slipping)
 B2 brake malfunction (slipping)
In all malfunction, primary regulator valve malfunction)
positions/ranges  Oil pump malfunction
 Oil strainer clogging
 Engine lack of power
Below specification
 Torque converter one-way clutch slipping
TIME LAG TEST
3. Warm up the engine until the ATF temperature reaches 60-70°C {140-158°F}.
4. Shift the selector lever from the N position to D range.
5. Use a stopwatch to measure the time it takes from shifting until shock is felt. Take three measurements
for each test and average from the results using the following formula.
Formula
Average time lag = (Time 1 + Time 2 + Time 3) / 3
6. Perform the test for the following shifts in the same manner as in Step 5.
 N position --> R position
Average time lag
N position --> D range: 1.5 s or less
N position --> R position: 1.5 s or less
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Evaluation of time lag test
EVALUATION OF TIME LAG TEST POSSIBLE CAUSE

 Control valve body malfunction (shift solenoid C hydraulic
pressure system)
N --> D More than  C1 clutch slipping
shift specification  One-way clutch malfunction
 Control valve body malfunction (shift solenoid E hydraulic
pressure system)
N --> R More than  C3 clutch slipping
shift specification  B2 brake slipping
ROAD TEST [AW6A-EL, AW6AX-EL]
WARNING:  When performing a road test, be aware of other vehicles, people, and
other impediments in order to avoid an accident.
NOTE:  When the legal speed limit must be exceeded, use a chassis dynamometer
instead of performing a road test.
ROAD TEST PREPARATION
1. Inspect the engine coolant level. (See COOLING SYSTEM SERVICE WARNINGS [MZI-3.7] .) (See
ENGINE COOLANT LEVEL INSPECTION [MZI-3.7] .)
2. Inspect the engine oil level. (See ENGINE OIL LEVEL INSPECTION [MZI-3.7] .)
AW6AX-EL].)
4. Inspect the idle speed. (See ENGINE TUNE-UP [MZI-3.7] .)
5. Inspect the ignition timing. (See ENGINE TUNE-UP [MZI-3.7] .)
6. Bring up the engine and transaxle to normal operating temperature.
SHIFT DIAGRAM
D range (normal mode)
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Fig. 5: Vehicle Speed & Throttle Opening Graph

D RANGE TEST
1. Perform road test preparation. (See ROAD TEST PREPARATION.)

2. Shift the selector lever to D range.
3. Accelerate with the depressing amount of accelerator pedal half and then fully depress.
4. Verify that 1-->2, 2-->3, 3-->4, 4-->5, and 5-->6 upshifts and downshifts are obtained. The shift points
must be as shown in the table below.
 If there is any malfunction, inspect the TCM and ATX. (See SYMPTOM
TROUBLESHOOTING ITEM TABLE [AW6A-EL, AW6AX-EL] .)
5. Drive the vehicle in 6GR, 5GR, 4GR, 3GR, and 2GR and verify that kickdown occurs for 6-->5, 5-->4, 4-
->3, 3-->2, 2-->1 downshifts, and that the shift points are as shown in the table below.
6. Drive the vehicle and verify that TCC operation is obtained. The operation points must be as shown in the
table below.
Vehicle speed at shift point table
VEHICLE SPEED RANGE REFERENCE

Vehicle speed (km/h Turbine speed
Range Mode Throttle condition Shift
{mph}) (rpm)
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D1 -->D2 49-55 {31-34} 5,250-5,850

D2 -->D3 95-103{59-63} 5,800-6,250
D3 -->D4 140-150{87-93} 5,600-5,950
TCC ON
(D4 ) 140-150{87-93} 4,150-4,400
Wide open throttle D4 -->D5 206-216{128-133} 6,150-6,350
TCC ON
(D5 ) 206-216{128-133} 4,550-4,750
D5 -->D6 227-237{141-146} 5,050-5,200

TCC ON
(D6 ) 227-237{141-146} 4,000-4,150
D1 -->D2 28-35{18-21} 2,900-3,800

D2 -->D3 53-69 {33-42} 3,200-4,200
D3 -->D4 83-109{52-67} 3,350-4,350
TCC ON
(D4 ) 83-109{52-67} 2,500-3,200
D NORMAL
Half throttle D4 -->D5 134-166{84-102} 4,000-4,900
TCC ON
(D5 ) 134-166{84-102} 2,950-3,650
D5 -->D6 200-226{124-140} 4,450-4,950

TCC ON
(D6 ) 200-226{124-140} 3,550-3,950
D6 -->D5 59-64 {37-39} 1,050-1,100

Closed throttle D5 -->D4 39-45 {25-27} 900-950
position D4 -->D3 25-31 {16-19} 750-900
D3 -->D1 6-12{4-7} 250-450
D6 -->D5 225-235{140-145} 4,000-4,100
D5 -->D4 145-155{90-96} 3,200-3,400
Kickdown D4 -->D3 112-122{70-75} 3,350-3,600
D3 -->D2 76-84 {48-52} 3,050-3,350
D2 -->D1 38-44 {24-27} 2,350-2,650
D1 -->D2 49-55{31-34} 5,250-5,850
Wide open throttle D2 -->D3 95-103{59-63} 5,800-6,250
D3 -->D4 140-150{87-93} 5,600-5,950
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D4 -->D5 206-216{128-133} 6,150-6,350

D5 -->D6 227-237{141-146} 5,050-5,200
D1 -->D2 28-35{18-21} 2,900-3,800
D2 -->D3 53-69 {33-42} 3,200-4,200
Half throttle D3 -->D4 83-108{52-66} 3,300-4,300
D4 -->D5 143-172{89-106} 4,250-5,050
D5 -->D6 201-226{125-140} 4,450-4,950
D6 -->D5 107-113{67-70} 1,900-1,950
D AAS
Closed throttle D5 -->D4 65-71 {41-44} 1,450-1,550
position D4 -->D3 27-33 {17-20} 800-950
D3 -->D1 6-12 {4-7} 250-450
D6 -->D5 225-235{140-145} 4,000-4,100
D5 -->D4 145-155 {90-96} 3,200-3,400
Kickdown D4 -->D3 112-122{70-75} 3,350-3,600
D3 -->D2 76-84 {48-52} 3,050-3,350
D2 -->D1 38-44 {24-27} 2,350-2,650
M RANGE TEST
1. Perform road test preparation. (See ROAD TEST PREPARATION.)

2. Shift the selector lever to M range.
3. Verify that 1-->2, 2-->3, 3-->4, 4-->5 and 5-->6 upshifts and 6-->5, 5-->4, 4-->3, 3-->2, and 2-->1
downshifts are obtained by manual shifting of the selector lever forward and back.
4. Decelerate the vehicle and verify that 6-->5, 5-->4, 4-->3, 3-->1 downshifts are obtained. The shift points
5. Decelerate the vehicle and verify that engine braking effect is felt in 1GR.
6. Drive the vehicle and verify that TCC operation is obtained in 4GR, 5GR and 6GR. The operation points
7. Drive the vehicle in 6GR, 5GR, 4GR and 3GR and verify that kickdown occurs for 6-->5, 5-->4, 4-->3, 3-
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->2 downshifts, and that the shift points are as shown in the table below.
Vehicle speed at shift point table
VEHICLE SPEED RANGE REFERENCE

Range Mode Throttle condition Shift Vehicle speed km/h {mph} Turbine speed (rpm)
Half throttle TCC ON (M6) 141-180{88-111} 2,500-3,150
M6 -->M5 44-50{28-31} 800-850
M5 -->M4 34-40 {22-24} 750-850
All round
M4 -->M3 23-29{15-17} 700-850
M Manual M3 -->M1 6-12{4-7} 250-450
M5 -->M4 85-95 {53-58} 1,900-2,050
Kickdown M4 -->M3 60-70 {38-43} 1,800-2,050
M3 -->M2 36-44 {23-27} 1,450-1,750
P POSITION TEST
1. Shift into P position on a gentle slope. Release the brake and verify that the vehicle does not roll.
 If there is any malfunction, inspect the ATX. (See SYMPTOM TROUBLESHOOTING ITEM
TABLE [AW6A-EL, AW6AX-EL] .)
AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION [AW6A-EL, AW6AX-

EL]
AUTOMATIC TRANSAXLE FLUID (ATF) CONDITION INSPECTION
1. Inspect the ATF for the following to determine whether the transaxle should be disassembled.
 The ATF is muddy.
 The ATF smells strange or unusual.
ATF Condition
ATF CONDITION POSSIBLE CAUSE

Clear dark red Normal -
Light red (pink)

 Damaged oil cooler
Contaminated  Poor filler tube installation:
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with water
Problem could occur to parts inside the transaxle due to
water contamination.
If necessary, replace the transaxle.
Defective powertrain components inside the transaxle:
Particles cause wide range of problems by clogging the
oil pipe, control valve body and oil cooler.
Has burnt smell
Deteriorated
and metal particles A large amount of metal particles are found. If
Reddish are found ATF 
brown necessary, replace the transaxle.

 Flush the system due to possible clogging of the
oil pipe or oil cooler.
Has no burnt
Normal  Discoloration by oxidation
smell
AUTOMATIC TRANSAXLE FLUID (ATF) LEVEL INSPECTION
CAUTION:  The ATF amount varies according to ATF temperature. Therefore,

when checking the ATF level or replacing the ATF, use a
thermometer to measure the temperature and adjust the ATF amount
to the specified level according to the specified temperature.
1. Place the vehicle on level ground.

2. Apply the parking brake and position wheel chocks securely to prevent the vehicle from rolling.
3. Adjust the length or thermometer probe so that the length is the same as the depth gauge, and hold the
probe with a paper holder. Insert into the filler tube and measure the temperature.
 If necessary, inspect the ATF before warming up the engine. In this case, use the ATF temperature
(15-25 °C {59-77 °F}).
4. Warm up the engine until the ATF reaches 60-70 °C {140-158 °F}.
5. Shift the selector lever and pause momentarily in each range (P--D) while depressing the brake pedal.
6. Shift the selector lever to P position.
7. Verify that the ATF level is in the HOT range (65 °C {149 °F}) while the engine is idling.
 If necessary, add ATF to the specification.
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Fig. 6: Adjusting Length Or Thermometer Probe

ATF type
JWS3309
Fig. 7: Identifying ATF Level In HOT Range

AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL,

AW6AX-EL]
WARNING:  A hot transaxle and ATF can cause severe burns. Turn off the engine
and wait until they are cool before replacing the ATF.
1. Remove the oil dipstick.

2. Remove the oil drain plug and gasket.
3. Drain the ATF into a container.
4. Install a new gasket and the drain plug.
Tightening torque
23.5-54.9 N.m {2.4-5.5 kgf.m, 17.4-40.4 ft.lbf}
5. Add the specified ATF through the oil filler tube until it reaches the lower notch of dipstick.
Microsoft
Fig. 8: Locating Oil Drain Plug

ATF
Type: JWS3309
Capacity (Approx. quantity): 7.0 L {7.4 US qt, 6.2 lmp qt}
6. Ensure that the ATF level is in the HOT range (65 °C {149 °F}).
 Add ATF to the specified level as necessary.
TRANSAXLE RANGE (TR) SWITCH INSPECTION [AW6A-EL, AW6AX-EL]
NOTE:  TR switch function is installed as one part of TCM.
1. Inspect the TCM. (See TCM INSPECTION [AW6A-EL, AW6AX-EL].)
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR INSPECTION [AW6A-

EL, AW6AX-EL]
ON-VEHICLE INSPECTION
CAUTION:  Water or foreign material entering the connector can cause a poor
connection or corrosion. Be sure not to allow water or foreign
material on the connector when disconnecting.
 Do not damage the terminals.

2. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[MZI-3.7] .)
3. Remove the TCM. (See TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
4. Verify that there is no continuity between coupler component terminals B7 and GND, or B8 and GND.
Microsoft
Fig. 9: Identifying Air Cleaner Component

If there is any malfunction, perform an off-vehicle inspection of TFT sensor. (See OFF-VEHICLE

INSPECTION.)
5. Install the TCM. (See TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
6. Install the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
Fig. 10: Identifying Air Cleaner Component Connector Terminal

OFF-VEHICLE INSPECTION
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[MZI-3.7] .)
3. Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL,
AW6AX-EL].)
4. Remove the oil cooler.
5. Remove the oil pipe. (See OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
6. Remove the control valve body. (See CONTROL VALVE BODY REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL].)
7. Remove the TFT sensor. (See TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
Fig. 11: Identifying Oil Cooler

8. Place the TFT sensor and a thermometer in ATF as shown in the figure, and heat the ATF gradually.
Fig. 12: Identifying TFT Sensor & Thermometer In ATF

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9. Measure the resistance between the coupler component terminals B7 and B8.
 If there is any malfunction, replace the TFT sensor. (See TRANSAXLE FLUID
TEMPERATURE (TFT) SENSOR REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
Transaxle fluid temperature (TFT) sensor
RESISTANCE REFERENCE
ATF temperature (°C {°F}) Resistance (kilohm)
10 {50} 5.62-7.31
25 {77} Approx. 3.5
110 {230} 0.22-0.27
10. Install the TFT sensor. (See TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR
11. Install the control valve body. (See CONTROL VALVE BODY REMOVAL/INSTALLATION
Fig. 13: Measuring Resistance Between Coupler Component Terminals B7 & B8

12. Install the oil pipe. (See OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
13. Install the oil cooler. (See OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
14. Add ATF to the specified level. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
3.7] .)
TRANSAXLE FLUID TEMPERATURE (TFT) SENSOR

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REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

[MZI-3.7] .)
AW6AX-EL].)
Fig. 14: Identifying Oil Cooler

8. Remove the coupler component lock plate.
CAUTION:  Do not damage the wiring harness.

 Do not pull hard on the wiring harness.
9. Remove the coupler component from the transaxle case.
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Fig. 15: Identifying Coupler Component Lock Plate

10. Remove the O-ring and the gasket from the coupler component.
11. Apply ATF to a new gasket and install it on the coupler component.
CAUTION:  Do not apply ATF to the O-ring.
Fig. 16: Identifying O-Ring & Gasket

12. Install a new O-ring to the coupler component.
CAUTION:  Do not apply too much force to the coupler component.

 Do not damage the coupler component.
13. Install the coupler component to the transaxle case.
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Fig. 17: Identifying O-Ring & Gasket

14. Install a new coupler component lock plate.

Fig. 18: Locating Coupler Component Lock Plate

3.7] .)
22. Perform the mechanical system test. (See MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-
EL].)
INPUT/TURBINE SPEED SENSOR INSPECTION [AW6A-EL, AW6AX-EL]
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[MZI-3.7] .)
4. Verify that there is no continuity between the coupler component terminals B12 and GND or B13 and
GND.
Fig. 19: Identifying Coupler Component

 If there is any malfunction, inspect the coupler component.

 If the coupler component is normal, perform an off-vehicle inspection of input/turbine speed
sensor. (See OFF-VEHICLE INSPECTION.)
NOTE:  Inspect with a tester that can indicate more than 10 megohms
and confirm that the value is more than 1 megohm.
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Fig. 20: Identifying Coupler Component Connector Terminal

5. Verify that there is continuity between coupler component terminals B12 and B13.

If there is any malfunction, inspect the coupler component.


 If the coupler component is normal, replace the input/turbine speed sensor. (See
INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL].)
3.7] .)
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[MZI-3.7] .)
AW6AX-EL].)
7. Remove the input/turbine speed sensor. (See INPUT/TURBINE SPEED SENSOR
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Fig. 23: Identifying Oil Cooler & Oil Pipe

8. Connect the input/turbine speed sensor terminal 2 to the battery positive terminal, connect the battery
negative terminal to input/turbine speed sensor terminal 1 through an ammeter set to a resistance of 100
ohm.
Fig. 24: Connecting Input/Turbine Speed Sensor Terminal 2 To Battery Positive Terminal
9. Measure the current while waving a magnet back and forth over the top of the input/turbine speed sensor
(less than 5 mm {0.197 in}).
 If there is any malfunction, replace the input/turbine speed sensor. (See INPUT/TURBINE
SPEED SENSOR REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
Input/turbine speed sensor
SIGNAL REFERENCE
Signal Current (mA)
High 12.0-16.0
Low 4.0-8.0
10. Install the input/turbine speed sensor. (See INPUT/TURBINE SPEED SENSOR
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Fig. 25: Measuring Current Of Input/Turbine Speed Sensor

3.7] .)
EL].)
INPUT/TURBINE SPEED SENSOR REMOVAL/INSTALLATION [AW6A-EL,

AW6AX-EL]
and wait until then are cool before replacing the ATF.

[MZI-3.7] .)
AW6AX-EL].)
Microsoft

7. Remove the input/turbine speed sensor.

8. Install the input/turbine speed sensor.
Tightening torque
3.9-6.9 N.m {40-70 kgf.cm, 26-60 in.lbf}
Fig. 27: Locating Input/Turbine Speed Sensor

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3.7] .)
EL].)
VEHICLE SPEED SENSOR (VSS) INSPECTION [AW6A-EL, AW6AX-EL]


[MZI-3.7] .)
4. Verify that there is no continuity between the coupler component terminals B19 and GND or B20 and
GND.


 If the coupler component is normal, replace the ATX. (See AUTOMATIC TRANSAXLE
NOTE:  Inspect with a tester that can indicate more than 10 megohms
and confirm that the value is more than 1 megohm.
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5. Verify that there is continuity between coupler component terminals B19 and B20.

If there is any malfunction, inspect the coupler component.


 If the coupler component is normal, replace the ATX. (See AUTOMATIC TRANSAXLE
3.7] .)
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2. Remove the VSS. (See VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
3. Connect the VSS terminal 2 to the battery positive terminal, connect the battery negative terminal to VSS
terminal 1 through an ammeter set to a resistance of 100 ohm.
Fig. 32: Connecting VSS Terminal 2 To Battery Positive Terminal

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4. Measure the current while waving a magnet back and forth over the top of the VSS (less than 5 mm
{0.197 in}).
 If there is any malfunction, replace the VSS. (See VEHICLE SPEED SENSOR (VSS)
Fig. 33: Measuring Magnet Back & Forth Over Top Of VSS
VSS
VSS SIGNAL REFERENCE

Signal Current (mA)
High 12.0-16.0
Low 4.0-8.0
5. Install the VSS. (See VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
EL].)
VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [AW6A-EL,

AW6AX-EL]
connection or corrosion. Be sure not to drop water or foreign
material on the connector when disconnecting it.
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 If foreign materials are stuck to the VSS, disturbance by magnetic

flux can cause sensor output to be abnormal and thereby negatively
affect control. Make sure that foreign materials such as iron filings
are not stuck to the VSS during installation.
1. Remove the automatic transaxle. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION

2. Remove the VSS. (See Automatic Transaxle and Transfer Workshop Manual AW6A-EL, AW6AX-EL)
SOLENOID VALVE INSPECTION [AW6A-EL, AW6AX-EL]

RESISTANCE INSPECTION (ON-VEHICLE INSPECTION)

[MZI-3.7] .)
4. Measure the resistance between the following terminals.


 If the coupler component is normal, replace the control valve body. (See CONTROL VALVE
BODY REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
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Solenoid valve resistance (ATF temperature: 20°C {68°F})
SOLENOID VALVE RESISTANCE REFERENCE

Terminal Solenoid valve Resistance (ohm)
B5-GND Shift solenoid A 11-15
B2-GND Shift solenoid B 11-15
B11-B10 Shift solenoid C 5.0-5.6
B17-B18 Shift solenoid D 5.0-5.6
B14-B22 Shift solenoid E 5.0-5.6
B21-B16 Shift solenoid F 5.0-5.6
B9-B4 TCC control solenoid 5.0-5.6
B3-B1 Line pressure control solenoid 5.0-5.6

3.7] .)
CONTINUITY INSPECTION (ON-VEHICLE INSPECTION)
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[MZI-3.7] .)
4. Verify that there is no continuity between coupler component terminals B1, B3, B4, B9, B10, B11, B14,
B17, B18, B21, B22 and GND.
 If the coupler component is normal, replace the control valve body. (See CONTROL VALVE
BODY REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL].)
3.7] .)
TCM INSPECTION [AW6A-EL, AW6AX-EL]

TR SWITCH OPERATING INSPECTION
1. Verify that the starter operates only when the ignition switch is turned to the START position with the
selector lever in P or N position.
 If there is any malfunction, neutral position learning. (See TCM REMOVAL/INSTALLATION
2. Verify that the back-up lights illuminate when shifted to R position with the ignition switch at the ON
position.
 If there is any malfunction, neutral position learning. (See TCM REMOVAL/INSTALLATION
3. Verify that the positions of the selector lever and the indicator light correspond.
 If there is any malfunction, perform the neutral position learning. (See TCM
4. Verify that the TR PID is normal.
 If there is any malfunction, perform the neutral position learning. (See TCM
Microsoft
Fig. 36: Identifying Selector Indicator Light

CONTROL MODULE INSPECTION

[MZI-3.7] .)
2. Measure the voltage at each TCM connector (wiring harness-side) terminal and refer to the TERMINAL
VOLTAGE TABLE.
 If the voltage is not as specified in the Terminal Voltage Table (Reference), inspect the parts under
"Inspection item (s)".
WARNING:  Be careful not to damage the connector waterproofing when

measuring the TCM terminal voltage. If damaged, the
waterproofing efficiency could be negatively affected.
NOTE:  Use the ground of terminal A9 of the TCM connector (wiring harness-
side) when measuring terminal voltage, as an error may occur when
connecting the negative circuit tester to ground.
Terminal Voltage Table (Reference)
Fig. 37: Identifying TCM Short Cord Connector Terminal (TCM Side)
VOLTAGE SPECIFICATION
Connected Voltage
Terminal Signal Test condition Inspection item (s)
to (V)
 Inspect battery
Battery back
A1 Battery Constant B+  Inspect related
up supply
harness
 Inspect selector lever

Below component (See
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1.0 SELECTOR
Up switch Up switch Shift up (M range) LEVER
(Selector (Selector COMPONENT
A3 INSPECTION )
lever lever
component) component) Other ranges, all positions B+  Inspect related
harness
component (See
Below
Down switch Down switch Shift down (M range) SELECTOR
1.0
(Selector (Selector LEVER
A4
lever lever COMPONENT
component) component) INSPECTION )
Other ranges, all positions B+  Inspect related
harness
Shift the Ignition
B+  Inspect PCM
Starter lock selector lever switch ON
A5 PCM  Inspect related
output signal to P or N Ignition Below
position. switch OFF 1.0 harness
Because this terminal is for
serial communication,
good/no good judgment by
A6 CAN_L PCM terminal voltage is not -  Inspect related
possible. Carry out harness
inspection according to
DTCs.
component (See
Below
M range SELECTOR
1.0
M range M range LEVER
A7
switch switch COMPONENT
INSPECTION )
Other positions, all ranges B+  Inspect related
harness
Ignition switch ON B+  Inspect Ignition
Ignition switch
A11 Power supply Below
switch Ignition switch OFF  Inspect related
1.0 harness
Shift the  Inspect back-up light
selector Below relay (See RELAY
Back-up light Back-up light Ignition lever to R 1.0
A13 INSPECTION )
relay relay switch ON position.  Inspect related
Other B+ harness

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serial communication,
good/no good judgment by
terminal voltage is not  Inspect related
A14 CAN_H PCM -
possible. Carry out harness
inspection according to
DTCs.

4. Verify that continuity or resistance at terminal is as indicated in the terminal continuity/resistance table.
 If there is any malfunction, inspect the parts under "Inspection item (s)".
 If the system does not work properly even though the parts or related wiring harnesses do not
have any malfunction, replace the TCM. (See TCM REMOVAL/INSTALLATION

Terminal Continuity/Resistance Table (Reference)
Fig. 39: Identifying Coupler Component & TCM Short Cord Connector (TCM Side)
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CONTINUITY RESISTANCE REFERENCE

Connected
Terminal Signal Test Condition Continuity/Resistance Inspection item
to
System  Inspect relate
A9 GND Constant Continuity
GND harness
 Inspect  Inspect line
resistance pressure contr
Line between solenoid (See
pressure Line couple ATF SOLENOID
control pressure component temperature: VALVE
B1 5.0-5.6 (ohms)
solenoid control terminals 20°C {68° INSPECTIO
control solenoid B3 and B1 F} [AW6A-EL,
GND (wiring AW6AX-EL]
harness-  Inspect relate
side). harness
 Inspect sh
solenoid B
SOLENO
Shift VALVE
Shift ATF temperature: 20°C {68°
B2 solenoid B 11-15 (ohms) INSPECTI
solenoid B F}
control [AW6A-E
AW6AX-E
 Inspect rela
harness
 Inspect  Inspect line
resistance pressure contr
between solenoid (See
Line
Line couple ATF SOLENOID
pressure
pressure component temperature: VALVE
B3 control 5.0-5.6 (ohms)
control terminals 20°C {68° INSPECTIO
solenoid
solenoid B3 and B1 F} [AW6A-EL,
control
(wiring AW6AX-EL]
side). harness
 Inspect  Inspect TCC
resistance control soleno
between (See SOLEN
TCC control couple ATF
VALVE
solenoid TCC control component temperature:
B4 5.0-5.6 (ohms) INSPECTIO
control solenoid terminals 20°C {68° [AW6A-EL,
GND B9 and B4 F} AW6AX-EL]
(wiring
side). harness
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 Inspect sh
solenoid A
SOLENO
Shift VALVE
Shift ATF temperature: 20°C {68°
B5 solenoid A 11-15 (ohms) INSPECTI
solenoid A F}
control [AW6A-E
AW6AX-E
 Inspect rela
harness
ATF
temperature:  Inspect TFT s
 Inspect 5.62-7.31 (kilohms) (See
resistance 10°C {50° TRANSAXL
B7
TFT sensor between F} FLUID
GND couple ATF
TEMPERAT
TFT sensor component temperature: Approx. 3.5 (kilohms) (TFT) SENS
terminals 25°C {77° INSPECTIO
B7 and B8 F} [AW6A-EL,
(wiring ATF AW6AX-EL]
harness- temperature:
B8 TFT sensor 0.22-0.27 (kilohms)  Inspect relate
side). 110°C
{230°F} harness
 Inspect  Inspect TCC

resistance control soleno
between (See SOLEN
couple ATF
TCC control VALVE
TCC control component temperature:
B9 solenoid 5.0-5.6 (ohms) INSPECTIO
solenoid terminals 20°C {68°
control [AW6A-EL,
B9 and B4 F} AW6AX-EL]
(wiring
side). harness
 Inspect
Shift resistance  Inspect shift
solenoid C between solenoid C (S
B10
control couple SOLENOID
ATF
GND component temperature: VALVE
Shift
terminals 20°C {68° 5.0-5.6 (ohms) INSPECTIO
solenoid C
B11 and F} [AW6A-EL,
Shift B10 AW6AX-EL]
B11 solenoid C (wiring  Inspect relate
control harness- harness
side).
 Inspect
B12 Input/turbine input/turbine
speed sensor sensor (See
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(-) INPUT/TUR
 Inspect for continuity SPEED SEN
between couple INSPECTIO
Input/turbine Input/turbine component terminals Continuity [AW6A-EL,
B13 speed sensor speed sensor B12 and B13 (wiring AW6AX-EL]
(+) harness-side).  Inspect relate
harness
 Inspect
resistance  Inspect shift
between solenoid E (S
couple SOLENOID
ATF
Shift component temperature: VALVE
Shift
B14 solenoid E terminals 20°C {68° 5.0-5.6 (ohms) INSPECTIO
solenoid E
control B14 and F} [AW6A-EL,
B22 AW6AX-EL]
(wiring  Inspect relate
harness- harness
side).
 Inspect
between solenoid F (Se
couple SOLENOID
Shift ATF
component temperature: VALVE
solenoid F Shift
B16 terminals 20°C {68° 5.0-5.6 (ohms) INSPECTIO
control solenoid F
GND
B16 AW6AX-EL]
harness- harness
side).
 Inspect
Shift resistance  Inspect shift
B17 solenoid D between solenoid D (S
control couple SOLENOID
ATF
Shift
terminals 20°C {68° 5.0-5.6 (ohms) INSPECTIO
solenoid D
Shift B17 and F} [AW6A-EL,
solenoid D B18 AW6AX-EL]
B18
control (wiring  Inspect relate
GND harness- harness
side).
Vehicle  Inspect VSS (

B19 VSS VEHICLE
speed (-) Continuity
 Inspect for continuity SPEED SEN
between couple (VSS)
component terminals INSPECTIO
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B19 and B20 (wiring [AW6A-EL,

Vehicle harness-side). AW6AX-EL]
B20 VSS
speed (+)  Inspect relate
harness
 Inspect
between solenoid F (Se
couple SOLENOID
ATF
Shift component temperature: VALVE
Shift
B21 solenoid F terminals 20°C {68° 5.0-5.6 (ohms) INSPECTIO
solenoid F
control B21 and F} [AW6A-EL,
B16 AW6AX-EL]
harness- harness
side).
 Inspect
between solenoid E (S
couple SOLENOID
Shift ATF
solenoid E Shift
B22 terminals 20°C {68° 5.0-5.6 (ohms) INSPECTIO
control solenoid E
GND
B22 AW6AX-EL]
harness- harness
side).
TCM REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

[MZI-3.7] .)
3. Disconnect the TCM connector.
4. Remove the clip and disconnect the selector cable.
CAUTION:  Do not use an impact wrench. Hold the manual shaft lever when
removing the manual shaft nut, or the transaxle may be
damaged.
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Fig. 40: Identifying Manual Shaft Lever & TCM Connector

5. Set the adjustable wrench as shown in the figure to hold the manual shaft lever.
Fig. 41: Identifying Manual Shaft Lever

6. Remove the manual shaft nut and washer.
Fig. 42: Identifying Manual Shaft Nut & Washer

7. Remove the TCM.

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CAUTION:  Do not touch the terminals.
Fig. 44: Identifying Air Filter

8. Inspect the condition of the connector pin of the coupler component (foreign material, bent pins, broken
pins) and O-ring after the TCM is removed.
Fig. 45: Identifying Connector Pin Of Coupler Component

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9. Align the transaxle case and coupler component connector.
Fig. 46: Locating Transaxle Case

10. Be sure to match the position of the TCM marking.
CAUTION:  Do not turn more than 60° from the marking.
11. Install the TCM.

12. Verify the correct positioning of the TCM and coupler component.
13. Tighten the TCM mounting bolts.
Tightening torque
19.6-29.4 N.m {2.0-2.9 kgf.m, 14.5-21.6 ft.lbf}
CAUTION:  Do not use an impact wrench. Hold the manual shaft lever when
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removing the manual shaft nut, or the transaxle may be

damaged.
Fig. 48: Identifying TCM Mounting Bolts

14. Install the manual shaft lever and the washer.
Fig. 49: Identifying Manual Shaft Lever & Washer

15. Set the adjustable wrench as shown in the figure to hold the manual shaft lever, and tighten the manual
shaft nut.
Tightening torque
9.8-14.7 N.m {100-142 kgf.cm, 87-123 in.lbf}
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Fig. 50: Identifying Manual Shaft Lever

16. Install the clip to the selector cable as shown in the figure.
18. Turn the manual shaft lever to P position.
Fig. 51: Identifying Clip To Selector Cable

19. Connect the selector cable and install the clip.

20. Connect the TCM connector.
3.7] .)
WARNING:  If you replace the ATX or TCM, be sure to initialize the learned
values and perform neutral position learning.
23. Perform the neutral position learning. (See NEUTRAL POSITION LEARNING.)
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Fig. 52: Identifying TCM, Manual Shaft Lever & Selector Cable
NEUTRAL POSITION LEARNING
1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
1. Select "Power train".

2. Select "Transmission".

4. Then, select the "Transmission Learning".
5. Perform the N range learning according to the directions on the screen.
 When "Operation Successful" is displayed, shift the selector lever to the P position and turn the
ignition switch to the LOCK position, then to the ON position after 5 s.
 If "Reinstall TCM properly and then try again" is displayed, perform the following inspection:

 Verify that the transaxle manual shaft is in the N position.

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If the manual shaft is in a position other than N, shaft it to the N position.
 Verify that the selector cable is adjusted properly.
 If the selector cable is not adjusted properly, adjust it. (See SELECTOR CABLE
ADJUSTMENT .)
 Inspect the manual shaft lever for deformation.
 If there is any malfunction, replace the manual shaft lever.
6. Shift the selector lever from P position to D range, then verify that the positions of the selector lever and
the indicator are aligned.
 If there is any malfunction, inspect the DTC. (See DTC TABLE [AW6A-EL, AW6AX-EL] .)
OIL SEAL (MANUAL SHAFT) REPLACEMENT [AW6A-EL, AW6AX-EL]

[MZI-3.7] .)

 Do not damage the manual shaft.
4. Remove and discard the oil seal using a tape-wrapped flathead screwdriver.
Fig. 54: Removing Oil Seal

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Substitution SST
 49 F026 102

3.7] .)
Fig. 55: Tapping Oil Seal

AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-

EL]
2. Remove the following parts.
1. Battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
2. Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
3. Engine cover
4. Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE
5. Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION .)
6. Cowl panel (See COWL PANEL REMOVAL/INSTALLATION .)
7. Front wheel
8. Splash shield
9. Side cover
10. Propeller shaft (transfer side) (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
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AW6AX-EL].)
WARNING:  Improperly jacking a transaxle is dangerous. It can slip off the

jack and may cause serious injury.
CAUTION:  To prevent the torque converter and transaxle from separating,

remove the transaxle without tilting it toward the torque
converter.
4. Remove in the order shown in the figure.

EL].)
LINE PRESSURE TEST REFERENCE

Test item
Service item
Line pressure test Stall test Time lag test Time lag test
ATX replacement X
ATX overhaul X X X X
Torque converter replacement X X
Oil pump replacement X
Control valve body component X
Clutch system replacement X X X
X : Test to be performed after the service work
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Fig. 56: View Of Automatic Transaxle Components & Torque Specifications (1 Of 2)

AWD
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Fig. 57: View Of Automatic Transaxle Components & Torque Specifications (2 Of 2)

TORQUE CONVERTER NUTS REMOVAL NOTE
1. Remove the cover as shown in the figure.

2. Align the holes by turning the torque converter.
Fig. 58: Identifying Fastener & Cover

3. Insert a flathead screwdriver through the converter housing service hole, and lock the drive plate.
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Fig. 59: Locking Drive Plate

4. Remove the torque converter nuts.
Fig. 60: Identifying Torque Converter Nuts

NO.1 ENGINE MOUNT REMOVAL NOTE
1. Remove the No.1 engine mount bracket bolts A and B as shown.
Fig. 61: Identifying No.1 Engine Mount Bracket Bolts

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2. Remove the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit.
(See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
Fig. 62: Identifying No.1 Engine Mount

NO.4 ENGINE MOUNT BRACKET REMOVAL NOTE
1. Install the SST using the following procedure.
CAUTION:  Refer to the SST instruction manual for the basic handing
procedure.
NOTE:  When installing the SST , adjust the position of each shaft so that
they do not interfere with the vehicle body.
Fig. 63: Identifying No.4 Engine Mount Bracket

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1. Install the right rear shaft of the SST to the bolt of the right shock absorber shown in the figure.
2. Install the left rear shaft of the SST to the bolt of the left shock absorber (Identical position to the
right side).
Fig. 64: View Of Right Rear Shaft Of SST

3. Install the left/right front shaft of the SST with front foot No.2 to the bolt shown in the figure.
4. Adjust the positions of the SST side bars so that they are the same height (left and right) and
horizontal.
5. Make sure each joint is securely tightened.
Fig. 65: View Of Left/Right Front Shaft Of SST

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2. Support the engine using the SSTs.
NOTE:  The SST (49 E017 5A0) can be used in place of the SST (49 C017
5A0).
3. Remove the No.4 engine mount bracket.
Fig. 66: Removing No.4 Engine Mount Bracket

TRANSAXLE REMOVAL NOTE
1. Support the transaxle on a jack.

2. Remove the transaxle mounting bolts.
3. Remove the transaxle.
Fig. 67: Supporting Transaxle On Jack

TRANSAXLE INSTALLATION NOTE
1. Set the transaxle on a jack and lift it.

2. Rotate the drive plate so that the logo mark faces upward.
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Fig. 68: Identifying Drive Plate Logo Mark Faces Upward

3. Rotate the torque converter so that the mark faces upward.
Fig. 69: Rotating Torque Converter

4. Install the transaxle mounting bolts and bracket.
Tightening torque
37-52 N.m {3.8-5.3 kgf.m, 28-38 ft.lbf}
Fig. 70: Locating Transaxle Mounting Bolts & Bracket

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NO.4 ENGINE MOUNT BRACKET INSTALLATION NOTE
1. Install the No.4 engine mount bracket to the transaxle and temporarily tighten nuts.
2. Temporarily tighten bolt.
3. Temporarily tighten bolt A and nuts B, C.
4. Tighten bolt A, nuts B and C in the order of B-->A-->C.
5. Tighten bolt D.
Tightening torque
Bolt A, Nut B, C: 66.6-93.1 N.m {6.80-9.49 kgf.m, 49.2-68.6 ft.lbf}
Bolt D: 74.5-104.9 N.m {7.60-10.69 kgf.m, 55.0-77.3 ft.lbf}

NO.1 ENGINE MOUNT INSTALLATION NOTE
1. Install the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit.

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2. Tighten the bolts on the No.1 engine mounting bracket in the order of A, B.
Tightening torque
93.1-116.6 N.m {9.50-11.8 kgf.m, 68.7-85.9 ft.lbf}
Fig. 73: Identifying Bolts On No.1 Engine Mounting Bracket

3. Tighten the No.1 engine mount bolt C at the specified torque.
Tightening torque
93.1-116.6 N.m {9.50-11.8 kgf.m, 68.7-85.9 ft.lbf}
Fig. 74: Identifying No.1 Engine Mount Bolt

TORQUE CONVERTER NUTS INSTALLATION NOTE
1. Align the holes by turning the torque converter.

2. Insert a screwdriver through the converter housing service hole, and lock the drive plate.
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CAUTION:  Loosely and equally tighten the torque converter nuts, then
further tighten them to the specified tightening torque.
Fig. 75: Locking Drive Plate

3. Tighten the torque converter mounting nuts.
Tightening torque
40.5-54.7 N.m {4.13-5.57 kgf.m, 29.9-40.3 ft.lbf}
Fig. 76: Identifying Converter Mounting Nuts

4. Install the cover as shown in the figure.
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Fig. 77: Identifying Fastener & Cover

SELECTOR CABLE INSTALLATION NOTE
1. Install the selector lever to the manual shaft lever so that no load acts on the selector cable.
NOTE:  Install the selector lever to the manual shaft lever with the clip side of
the selector cable end facing up.
2. Confirm that the tip of the manual shaft lever projects out of the end of the selector cable.
Fig. 78: Identifying Selector Lever To Manual Shaft Lever

OIL SEAL (DIFFERENTIAL) REPLACEMENT [AW6A-EL, AW6AX-EL]

TRANSAXLE CASE SIDE

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AW6AX-EL].)
CAUTION:  The oil seal is easily damaged by the sharp edges of the drive
shaft splines. Do not let the splines contact the oil seal.
3. Remove the drive shaft (left side). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)

 Do not damage the differential case.


Substitution SST
 49 H028 202
7. Install the drive shaft (left side). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
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9. Connect the negative cable.
EL].)

CONVERTER HOUSING SIDE (2WD)

AW6AX-EL].)
CAUTION:  The oil seal is easily damaged by the sharp edges of the drive
shaft splines. Do not let the splines contact the oil seal.
3. Remove the drive shaft (right side). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
4. Remove the joint shaft. (2WD) (See JOINT SHAFT REMOVAL/INSTALLATION [2WD] .)
CAUTION:  Do not damage the converter housing.


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Substitution SST
 49F027 009
Outer diameter: 76.8 mm {3.02 in}
8. Install the joint shaft. (2WD) (See JOINT SHAFT REMOVAL/INSTALLATION [2WD] .)
9. Install the drive shaft (right side). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)


EL].)
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CONVERTER HOUSING SIDE (AWD)

AW6AX-EL].)
3. Remove the transaxle. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
4. Remove the converter housing from the transaxle case. (See Automatic Transaxle Workshop Manual

Substitution SST
 49L033 101
Outer diameter: 73-76.3 mm {2.88-3.00 in}
7. Install the converter housing to the transaxle case. (See Automatic Transaxle Workshop Manual [AW6A-
EL, AW6AX-EL].)
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8. Install the transaxle (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL,

AW6AX-EL].)
EL].)

DIFFERENTIAL GEAR O-RING REPLACEMENT [AW6A-EL, AW6AX-EL]
CAUTION:  The O-ring is easily damaged by the sharp edges of the drive shaft
splines. Do not let the splines contact the O-ring.
1. Remove the drive shaft and joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [2WD] .)
(See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
CAUTION:  Do not damage the differential case.
2. Remove and discard the O-ring using a tape-wrapped flathead screwdriver.
CAUTION:  Do not damage the O-ring.

3. Apply ATF to a new O-ring and install it to the differential case.

4. Install the drive shaft and joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [2WD] .)
(See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
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Fig. 85: Removing O-ring

CONTROL VALVE BODY REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

ON-VEHICLE REMOVAL
WARNING:  Using compressed air can cause dirt and other particles to fly out,
causing injury to the eyes. Wear protective eyeglasses whenever
using compressed air.
CAUTION:  Clean the transaxle exterior throughout with a steam cleaner or

cleaning solvents before removal.
 If any old sealant gets into the transaxle during installation of the
control valve body cover, trouble may occur in the transaxle case
and control valve body cover. Clean with cleaning fluid.

[MZI-3.7] .)
AW6AX-EL].)
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6. Remove the control valve body cover installation bolt.
CAUTION:  Do not damage the fitting surface of the transaxle case and the
control valve body cover.
 Do not deform the control valve body cover.
Fig. 87: Locating Control Valve Body Cover Bolt

7. Using a plastic hammer, tap the control valve body cover to remove it.
CAUTION:  Be careful not to damage the solenoid valves and connectors.

 Do not pull the wiring harnesses when removing the connector.
NOTE:  Disconnect the solenoid connector according to the following

procedure:
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Fig. 88: Tapping Control Valve Body Cover

1. Insert a precision screwdriver from the backside into the connector as shown in the figure.
Fig. 89: Identifying Backside Into Connector

2. Pry the screwdriver in the direction of the arrow and disconnect the connector.
CAUTION:  Do not damage the solenoid valves and connectors with

the screwdriver.
 When disconnecting connectors, grasp the connectors,
not the harnesses. Otherwise, the harnesses may be
pulled out of the connector causing poor contact.
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Fig. 90: Removing Connector

8. Disconnect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.
9. Disconnect the coupler component from the clamp.
Fig. 91: Identifying Coupler Component Of Clamp

10. Remove the lock plate, and pull out the TFT sensor from the control valve body.
11. Remove the O-ring from the TFT sensor.
NOTE:  Be sure to secure the coupler component with tape so that it will not
interfere with the control valve body component.
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Fig. 92: Identifying O-ring Of TFT Sensor

12. Fix the coupler component with tape to the transaxle case as shown in the figure.
Fig. 93: Tapping To Transaxle Case

13. Remove the VSS connector and input/turbine speed sensor connector from the solenoid clamp.
Fig. 94: Identifying VSS Connector & Input/Turbine Speed Sensor Connector
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NOTE:  Be sure to secure the VSS and input/turbine speed sensor with tape
so that they will not interfere with the control valve body component.
14. Fix the VSS wiring harness and input/turbine speed sensor wiring harness with tape to the transaxle case
Fig. 95: Locating VSS Wiring Harness & Input/Turbine Speed Sensor Wiring Harness
15. Remove the suction cover and the gasket.
CAUTION:  Evenly loosen the bolts a little at a time in the order shown in
the figure.
Fig. 96: Identifying Suction Cover & Gasket

16. Remove the control valve body installation bolts.
CAUTION:  Do not drop the control valve body component.

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Fig. 97: Locating Control Valve Body Component

17. Disconnect the manual valve link and remove the control valve body component.
Fig. 98: Locating Control Valve Body Component

ON-VEHICLE INSTALLATION
CAUTION:  When installing the control valve body component, do not put the
coupler component in the open space of the separate plate in the
control valve body component.
 Do not pinch the coupler component between the separate plate and
the control valve body component.
1. Connect the manual valve link and install the control valve body component.
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Fig. 99: Locating Separate Plate

2. Temporarily install the control valve body component with the bolts.
A: 31 mm {1.220 in}
B: 17 mm {0.669 in}
C: 21 mm {0.827 in}
NOTE:  Aligning the bolt holes, temporarily tighten the bolt by hand.
Fig. 100: Locating Control Valve Body Component With Bolts

3. Temporarily install the suction cover and a new gasket with the bolts.
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Fig. 101: Identifying Suction Cover Gasket With Bolts

Tightening torque
8-12 N.m {82-122 kgf.cm, 72-105 in.lbf}
Fig. 102: Identifying Suction Cover Bolts Tighten Sequence

5. Install the connector of the VSS and input/turbine speed sensor to the solenoid clamp.
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Fig. 103: Identifying Connector Of VSS & Input/Turbine Speed Sensor

CAUTION:  If the control valve body cover is installed with the wiring harness
overlapped, the wiring harnesses may be pinched between the co
valve body causing the wiring harnesses to be damaged. Therefo
that the wiring harnesses are not overlapped when installing the
valve body cover.
Fig. 104: Precaution Of Control Valve Body Cover

6. Apply ATF to a new O-ring and install it on the TFT sensor.

7. Install the TFT sensor with the lock plate and a bolt to the control valve body component as shown in the
figure.
Tightening torque
8-12 N.m {82-122 kgf.cm, 72-105 in.lbf}
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8. Connect the solenoid connectors, VSS connector and the input/turbine speed sensor connector.
Fig. 105: Connecting Solenoid Connectors, VSS Connector & Input/Turbine Speed Sensor
Connector
9. Connect the coupler component to the clamps.
NOTE:  Completely remove sealant and oil with white gasoline or similar.
Fig. 106: Connecting Coupler Component To Clamps

10. Clean sealant and oil off the contact surface of the transaxle case with the control valve body cover and
the bolt holes.
NOTE:  Completely remove oil with white gasoline or similar.
11. Clean oil off the contact surface of the new control valve body cover with the transaxle case.
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Fig. 107: Locating Transaxle Case & Bolt Holes

12. Apply sealant to the new control valve body cover as shown in the figure.
CAUTION:  Be careful that the coupler component will not become caught
between the control valve body cover and transaxle case.
Fig. 108: Applying Sealant To Control Valve Body Cover

13. Install the new control valve body cover with new seal bolts.
Tightening torque
9.8-15.7 N.m {100-160 kgf.cm, 87-138 in.lbf}
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3.7] .)
Fig. 109: Locating Control Valve Body Cover With Seal Bolts

EL].)
OIL SEAL (OIL PUMP) REPLACEMENT [AW6A-EL, AW6AX-EL]

EL, AW6AX-EL].)
CAUTION:  The oil seal is easily damaged by the sharp edges of the torque
converter splines. Do not let the splines contact the oil seal.
 Do not pinch fingers.
2. Remove the torque converter. (See TORQUE CONVERTER REMOVAL/INSTALLATION [AW6A-

EL, AW6AX-EL].)
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CAUTION:  Do not to damage the bushing on the oil pump body.
3. Using a tape-wrapped flathead screwdriver, remove the oil seal from the oil pump body.

4. Using the SST and a hammer, install the oil seal to the oil pump body.
Substitution SST
 49U027 003
5. Coat the lip of the oil seal with grease.

6. Install the torque converter. (See TORQUE CONVERTER REMOVAL/INSTALLATION [AW6A-
EL, AW6AX-EL].)
7. Install the transaxle. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL,
AW6AX-EL].)
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EL].)
TORQUE CONVERTER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

EL, AW6AX-EL].)
CAUTION:  The oil seal is easily damaged by the sharp edges of the torque
converter splines. Do not let the splines contact the oil seal.
 Do not pinch fingers.
2. Remove the torque converter, and immediately turn it so that the hole faces upward. This will help to
keep any remaining fluid from spilling.
3. Drain any ATF remaining in the torque converter.
4. Using a flathead screwdriver, position the drive gear on the oil pump component in the center.
5. Install the torque converter to the transaxle.
Fig. 112: Identifying Torque Converter & Transaxle
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6. To ensure that the torque converter is installed accurately, measure distance A between the end of the
torque converter and the end of the converter housing.
Distance A ((between the end of the torque converter and the end of the converter housing))
20 mm {0.79 in}

AW6AX-EL].)
EL].)
Fig. 113: Identifying Torque Converter

OIL COOLER FLUSHING [AW6A-EL, AW6AX-EL]
NOTE:  If the automatic transaxle is replaced, flush and inspect the oil cooler.
 When replacing the automatic transaxle, inspect the oil cooler together
with flushing it using the following procedure, and with the oil cooler hose
removed.
1. Disconnect the oil cooler hose.

2. Set a clean oil pan up to the oil cooler hose inlet.
3. Blow 491-882 kPa {5-9 kgf/cm2 , 72-127 psi} of compressed air from the oil cooler hose outlet to drain
remaining oil.
4. Add new ATF from the oil cooler hose outlet and blow 491-882 kPa {5-9 kgf/cm2 , 72-127 psi} of
compressed air to flush. (Repeat 2 or 3 times)
5. Verify that none of the following foreign material is mixed in with the drained ATF:
 Large metal fragments of ø 0.5 mm {0.02 mm} or more that cannot pass through the oil strainer
 Fibrous clutch facing
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6. Repeat the procedures from Step 1 to 2 and flush the inside of the oil cooler.
7. If foreign material such as metal fragments or clutch facing remains even after the oil cooler is flushed
repeatedly, replace the oil cooler (radiator).
Fig. 114: Identifying Oil Cooler Flushing

OIL COOLER REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

2. Drain the ATF into a container. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT
3. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7] .)
6. Add the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7] .)
9. Inspect for oil leakage from the oil pipes and oil hoses.
10. Inspect for coolant from the hoses.
11. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZI-
3.7] .)
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12. Inspect the ATF level and condition. (See AUTOMATIC TRANSAXLE FLUID (ATF) INSPECTION
13. Perform the line pressure test. (See MECHANICAL SYSTEM TEST [AW6A-EL, AW6AX-EL].)
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Microsoft
Fig. 115: View Of Oil Cooler Components & Torque Specifications

RADIATOR (IN TANK OIL COOLER) INSTALLATION NOTE
1. The automatic transaxle oil cooler flushing must be performed whenever a transaxle is removed for
service because the existing fluid may be contaminated, and to prevent contamination of new fluid.
NOTE:  Flushing must be performed after installation of an overhauled or

replaced transaxle.
2. Follow the instructions in the manufacturer's publication for flushing operation.
OIL PIPE, HOSE CLAMP, OIL HOSE INSTALLATION NOTE
1. Apply compressed air to the cooler-side opening, and blow any remaining grime and foreign material
from the cooler pipes. Compressed air should be applied for no less than 1 min.
Fig. 116: Applying Compressed Air To Cooler-Side

2. Align the marks, and slide the oil hose onto the oil pipe until it is fully seated as shown in the figure.
NOTE:  If reusing the hose, install the new hose clamp exactly on the mark
left by the previous hose camp.
3. Install the new hose clamp onto the hose.

4. Verify that the hose clamp does not interfere with any other components.
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Fig. 117: Identifying Oil Pipe Mark

OIL COOLER DISASSEMBLY/ASSEMBLY [AW6A-EL, AW6AX-EL]

Fig. 118: Identifying Radiator Outer Tank, Mount Rubber, O-Ring, Washer, ATF Cooler &
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Torque Specifications
RADIATOR OUTER TANK (IN TANK OIL COOLER) REMOVAL NOTE
1. Inspect the height of the header tabs.

2. Insert the end of a medium tip screwdriver between the end of the header tab and the outer tank.
NOTE:  Do not open more tabs than necessary for tank removal.
Fig. 119: Identifying Radiator Outer Tank Height

3. Pivot the screwdriver to pry the tab away from the tank and repeat the procedure for each tab.
4. Remove the radiator outer tank and O-ring (gasket) from the core header when all of the tabs are opened.
NOTE:  If any header tabs are missing from the core, replace the radiator.
5. Inspect the gasket surface of the radiator core header to ensure it is clean and free of foreign material or
damage.
6. Inspect the radiator outer tank for warping. If it is warped, replace radiator tank.
Fig. 120: Removing Radiator Outer Tank

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RADIATOR OUTER TANK (IN TANK OIL COOLER) INSTALLATION NOTE
1. Install a new O-ring and ensure it is not twisted.

2. Position the radiator tank in the original direction to the core using care not to scratch the tank sealing
surface with the header tabs.
NOTE:  Step 3 will set jaw opening to the correct specification.
Fig. 121: Identifying Radiator Outer Tank

3. With the jaws of locking-type pliers (vise grips) closed and locked, turn the adjusting screw to position
the jaws against the drill bit with the diameter measured (height) in the removal procedure 1. Tighten the
lock nut on the adjusting screw against the handle to lock the adjustment in place.
Fig. 122: Identifying Jaws Of Locking-Type Pliers

4. Squeeze the header tabs down in the order as shown against the lip of the radiator outer tank base with the
locking-type pliers while rotating the pliers toward the tank.
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Fig. 123: Identifying Squeeze Of Header Tabs Down

5. Verify that the height of the header tabs is same as the height before removal.
6. Inspect for leakage from radiator. (See ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.7] .)
Fig. 124: Identifying Tab Height

DRIVE PLATE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL]

EL, AW6AX-EL].)
2. Remove in the order indicated in the figure.
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Fig. 125: Identifying Drive Plate Mounting Bolts & Torque Specifications
DRIVE PLATE MOUNTING BOLTS REMOVAL NOTE
1. Set the SST or equivalent against the drive plate.

2. Remove the bolts and the drive plate.
Fig. 126: Identifying Drive Plate With SST

DRIVE PLATE INSTALLATION NOTE
1. Remove the sealant from the bolt holes in the crankshaft and from the drive plate mounting bolts.
2. Install the drive plate.
3. Install the backing plate.
4. Set the SST or equivalent against the drive plate.
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5. Tighten the new drive plate mounting bolts in two or three steps in the order shown.
Tightening torque
73-87 N.m {7.5-8.8 kgf.m, 53.9-64.1 ft.lbf}

AW6AX-EL].)
Fig. 127: Identifying Drive Plate With SST

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2008 TRANSMISSION Automatic Transaxle Shift Mechanism - Mazda CX-9
2008 TRANSMISSION
Automatic Transaxle Shift Mechanism - Mazda CX-9
AUTOMATIC TRANSAXLE SHIFT MECHANISM LOCATION INDEX
Fig. 1: Identifying Automatic Transaxle Shift Mechanism Location Index

SHIFT-LOCK INSPECTION
2. Verify that the selector lever is in the P position.
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3. Verify that the selector lever cannot be shifted from the P position without depressing the brake pedal.
4. Depress the brake pedal and verify that the selector lever cannot be shifted from the P position.
 If there is any malfunction, inspect the interlock cable. (See INTERLOCK CABLE
INSPECTION.)
KEY INTERLOCK INSPECTION

1. Verify that the ignition key cannot be pulled out except in the P position.
 If there is any malfunction, inspect the interlock cable. (See INTERLOCK CABLE
INSPECTION.)
INTERLOCK CABLE INSPECTION

1. Turn the ignition switch to the ON position. (Engine off)
2. Remove the clip of the selector lever base plate, then remove the interlock cable from the U-groove.
3. Remove the interlock cable from the selector lever.
Fig. 2: Identifying Clip Of Selector Lever Base Plate And Interlock Cable
4. Verify that the interlock cable moves freely with the brake pedal depressed.
 If there is any malfunction, inspect the interlock cable for abnormal winding. If any abnormal
winding found, correct it.
 If the malfunction persists after correcting the interlock cable winding, replace it.
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Fig. 3: Inspecting Interlock Cable

INTERLOCK CABLE ADJUSTMENT

1. Turn the ignition switch to the ON position. (Engine off)
2. Pull up the lock piece of the interlock cable to release the lock.
Fig. 4: Identifying Lock Piece Of Interlock Cable

3. Remove the clip of the selector lever base plate, then remove the interlock cable from the U-groove.
4. Remove the interlock cable from the selector lever.
Fig. 5: Identifying Clip Of Selector Lever Base Plate And Interlock Cable
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5. Remove the lock unit from the bracket.
Fig. 6: Identifying Lock Unit And Bracket

6. Verify that the marking on the slider pin is positioned as shown in the figure.
Fig. 7: Inspecting Marking On Slider Pin Is Positioned

7. Push the interlock cable.
Fig. 8: Pushing Interlock Cable

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8. Insert the a 1.5 mm {0.059 in} round bar or similar into hole A with the slider pin fully pushed in.
Fig. 9: Identifying Hole A And Slider Pin

9. Fully pull the end of the interlock cable.
Fig. 10: Pulling End Of Interlock Cable

10. Push the a 1.5 mm {0.059 in} round bar or similar into hole B and hole C of the lock unit until it passes
through.
11. Disconnect the brake switch connector.
12. Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION .)
13. Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION .)
CAUTION:  Do not connect the brake switch connector until the interlock
cable adjustment is completed.
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Fig. 11: Identifying Hole B And Hole C Of Lock Unit

14. Install the lock unit to the bracket. (See SELECTOR LEVER COMPONENT
15. Rotate the slider pin to release the lock and verify that it slides freely.
16. Verify that the slider pin contacts the brake pedal stopper rubber and rotate the slider pin to lock.
Fig. 12: Inspecting Slider Pin Contacts Brake Pedal Stopper Rubber
17. Install the interlock cable end to the interlock link on the selector lever.
18. Fit the interlock cable in the U-groove in the selector lever base plate and install the clip.
Fig. 13: Identifying Interlock Cable And Clip Of Selector Lever Base Plate
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19. Press the interlock cable lock piece in until it is locked.
CAUTION:  Applying a load to the interlock cable while pressing the lock
piece in can affect the lock unit operation.
Fig. 14: Identifying Interlock Cable Lock Piece

20. Remove the a 1.5 mm {0.059 in} round bar or similar from the lock unit holes A, B, and C.
21. Connect the brake switch connector with the brake pedal released.
Fig. 15: Identifying Lock Unit Holes A, B, And C

CAUTION:  The clearance between the brake switch and the brake pedal is
automatically adjusted to the correct amount when the brake
switch connector is connected after the brake switch has been
properly installed. If the brake switch is not properly installed or
the connector is connected before installation, the clearance
may be incorrect, causing a brake light malfunction. Therefore,
always verify that the brake switch is properly installed before
connecting the connector.
 Once the brake switch clearance has automatically been
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adjusted, it cannot be adjusted again. Therefore, replace the

switch with a new one when replacing the power brake unit or
the pedal, or performing any procedure that changes the pedal
stroke.
22. Inspect shift lock operation. (See SHIFT-LOCK INSPECTION.)
SELECTOR LEVER INSPECTION

1. Turn the ignition switch to the ON position, (engine OFF)
2. With the brake pedal depressed, verify that there is a "click" at each range when shifted.
3. Verify that the selector lever can be shifted.
4. Verify that there is a "click" at each position when shifted from P position to M range.
Fig. 16: Inspecting Click At Each Position When Shifted From P Position To M Range
5. Verify that the positions of the selector lever and the indicator are aligned.
 If there is any malfunction, adjust the TR switch. (See TCM REMOVAL/INSTALLATION
[AW6A-EL, AW6AX-EL] .)
6. Verify that the vehicle operates in each selected range.
Fig. 17: Inspecting Positions Of Selector Lever And Indicator Are Aligned
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SELECTOR LEVER COMPONENT INSPECTION

2. Remove the center console.
3. Remove the dashboard completely. (See DASHBOARD REMOVAL/INSTALLATION .)
4. Disconnect the selector lever component connector.
5. Inspect for continuity at the selector lever component.
 If there is any malfunction, adjust the selector cable. (See SELECTOR CABLE
ADJUSTMENT.)
Fig. 18: Selector Lever Component Connector Terminals Continuity Chart

Fig. 19: Identifying Selector Lever Component Connector Terminals

SELECTOR CABLE ADJUSTMENT

1. Remove the center console.
3. Unlock the lock piece of the selector cable (selector lever side) in the order shown in the figure.
4. Verify that the manual shaft is in P position.
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Fig. 20: Unlocking Lock Piece Of Selector Cable (Selector Lever Side)
5. Lock the lock piece of the selector cable (selector lever side) in the order shown in the figure.
6. Install the center console.
7. Shift the selector lever from P position to M range, and make sure that there are no other components in
that area to interfere with the lever.
Fig. 21: Locking Lock Piece Of Selector Cable (Selector Lever Side)
SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION

2. To remove the interlock cable, remove the following parts.
2. Driver side under panel
3. Accelerator pedal (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZI-3.7] .)
3. To remove the selector cable, remove the following parts.
1. Battery and battery tray
2. Air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
3. Dashboard (See DASHBOARD REMOVAL/INSTALLATION .)
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4. Front A/C unit (See FRONT A/C UNIT REMOVAL/INSTALLATION .)

4. To remove the selector lever, remove the following parts.
1. Console (See CONSOLE REMOVAL/INSTALLATION .)
5. Remove in the order shown in the figure.
Fig. 22: Identifying Selector Lever Component Removal/Installation & Torque Specifications
SELECTOR CABLE REMOVAL NOTE
1. Remove the clip.
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2. Remove the selector cable.
Fig. 23: Identifying Selector Cable

3. Remove the selector cable from the cable bracket.
Fig. 24: Identifying Selector Cable And Cable Bracket

SELECTOR CABLE INSTALLATION NOTE
1. Install the selector cable and clip to the bracket as shown in the figure.
NOTE:  Steps 2 and 3 are for the selector cable replacement only.
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Fig. 25: Identifying Selector Cable And Cable Bracket

3. Lock the lock piece of the selector cable (selector lever side) in the order shown in the figure.
Fig. 26: Locking Lock Piece Of Selector Cable (Selector Lever Side)
4. Verify that the manual shaft is in the P position.
CAUTION:  Bending the selector cable in the manner shown in the figure
will damage the cable and it may become loose when shifted.
When installing the selector cable, hold it straight.
Fig. 27: Inspecting Manual Shaft Is In P Position

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5. Install the clip as shown in the figure.
Fig. 28: Identifying Clip

NOTE:  Install the selector lever to the manual shaft lever with the clip side of
the selector cable end facing up.
6. Install the selector lever to the manual shaft lever so that no load acts on the selector cable.
7. Confirm that the tip of the manual shaft lever projects out of the end of the selector cable.
8. Securely install the selector cable to the selector cable bracket.
Fig. 29: Inspecting Clip Side Of Selector Cable End Facing Up

INTERLOCK CABLE INSTALLATION NOTE
1. Push the interlock cable.
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Fig. 30: Pushing Interlock Cable

2. Verify that the marking on the slider pin is positioned as shown in the figure.
Fig. 31: Inspecting Marking On Slider Pin Is Positioned

3. Push the a 1.5 mm {0.059 in} round bar or similar into hole A by fully pushing the slider pin in.
Fig. 32: Identifying Hole A And Slider Pin

4. Fully pull the end of the interlock cable.
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Fig. 33: Pulling End Of Interlock Cable

5. Push the a 1.5 mm {0.059 in} round bar or similar into hole B and hole C of the lock unit until it passes
through.
7. Remove the brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION .)
8. Install a new brake switch. (See BRAKE PEDAL REMOVAL/INSTALLATION .)
CAUTION:  Do not connect the brake switch connector until the interlock
cable is installed.
Fig. 34: Identifying Hole B And Hole C Of Lock Unit

9. With the slider pin pressed, slide the lock unit to fix the lock unit hook into the bracket hole securely as
CAUTION:  Allowing the interlock cable to be bent or twisted during

installation can affect the lock unit operation.
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Fig. 35: Pressing Slider Pin

10. Rotate the slider pin to release the lock and verify that it slides freely.
11. Pull the slider pin outward until it contacts the brake pedal stopper rubber and rotate the slider pin to lock.
12. Verify that the selector lever in the P position.
Fig. 36: Pulling Slider Pin Outward Until It Contacts Brake Pedal Stopper Rubber
13. Install the interlock cable end to the cam pin on the selector lever.
14. Fit the interlock cable in the U-groove in the selector lever base plate and install the clip.
Fig. 37: Identifying Interlock Cable And Clip

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15. Press the interlock cable lock piece in until it is locked.
CAUTION:  Applying a load to the interlock cable while pressing the lock
piece in can affect the lock unit operation.
Fig. 38: Identifying Interlock Cable Lock Piece

16. Remove the a 1.5 mm {0.059 in} round bar or similar from the lock unit holes A, B, and C.
Fig. 39: Identifying Lock Unit Holes A, B, And C

17. Connect the brake switch connector with the brake pedal released.
automatically adjusted to the correct amount when the brake
switch connector is connected after the brake switch has been
properly installed. If the brake switch is not properly installed or
the connector is connected before installation, the clearance
always verify that the brake switch is properly installed before
connecting the connector.
 Once the brake switch clearance has automatically been
adjusted, it cannot be adjusted again. Therefore, replace the
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switch with a new one when replacing the power brake unit or
the pedal, or performing any procedure that changes the pedal
stroke.
18. Turn the ignition switch to ON position.

19. Install the interlock cable to the steering lock.
20. Slide the outer casing to the steering lock and insert the clip over the convex part of the outer casing.
Fig. 40: Identifying Clip And Convex Part

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2008 ACCESSORIES & BODY, CAB Body Panels - Mazda CX-9
2008 ACCESSORIES & BODY, CAB
Body Panels - Mazda CX-9
REAR BUMPER REINFORCEMENT REMOVAL/INSTALLATION

2. Remove the rear combination light. (See REAR COMBINATION LIGHT
3. Remove the rear bumper. (See REAR BUMPER REMOVAL/INSTALLATION.)
4. Remove the fasteners, then remove the energy-absorbing foam.
5. Remove the bolts and nuts, then remove the rear bumper reinforcement.
Fig. 1: Identifying Rear Bumper Reinforcement & Torque Specifications

BODY PANELS LOCATION INDEX
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Fig. 2: Identifying Body Panels Location

HOOD REMOVAL/INSTALLATION
WARNING:  Removing the hood without supporting it could cause the hood to
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fall and cause serious injury. Always perform the procedure with at
least another person to prevent the hood from falling.

2. To remove the hood hinges, remove the following parts:
REMOVAL/INSTALLATION )
2. Side cowl grille (See COWL GRILLE REMOVAL/INSTALLATION )
Fig. 3: Identifying Hood Removing Components & Torque Specifications


5. Adjust the hood. (See HOOD ADJUSTMENT.)
HOOD ADJUSTMENT
GAP ADJUSTMENT
1. Measure the gap between the hood and body.
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Fig. 4: Measuring Gap Between Hood And Body

Standard clearance
a: -1.5-1.5 mm {-0.05-0.05 in}
b: 0.73-4.33 mm {0.03-0.17 in}
c: -1.2-1.2 mm {-0.04-0.04 in}

2. Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION )
4. Loosen the hood hinge installation bolts and adjust the hood.
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Fig. 5: Identifying Hood Hinge Bolts & Torque Specifications

HEIGHT ADJUSTMENT
1. Measure the height difference between the hood and body.
Fig. 6: Measuring Height Difference Between Hood And Body

Clearance
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a: 3.0-6.0 mm {0.11-0.23 in}
b: 2.0-5.0 mm {0.07-0.19 in}
c: 2.8-5.2 mm {0.11-0.20 in}
2. Turn the stop rubber to adjust.
Fig. 7: Turning Stop Rubber To Adjust

FUEL-FILLER LID REMOVAL/INSTALLATION

2. Remove the fuel-filler lid
4. Adjust the fuel-filler lid. (See FUEL-FILLER LID ADJUSTMENT.)
Fig. 8: Identifying Fuel-Filler Lid & Torque Specifications

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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.
Clearance
a: 1.7-3.7 mm {0.07-0.14 in}
b:-0.5-1.5 mm {-0.01-0.05 in}
Fig. 9: Measuring Gap And Height Difference Between Fuel-Filler Lid And Body
FRONT BUMPER REMOVAL/INSTALLATION

2. Remove the clip of the front over fender and put aside the front bumper.
Fig. 10: Removing Clip Of Front Over Fender


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Fig. 11: Identifying Removing Sequence Of Front Bumper Components & Torque Specifications
4. Disconnect the front fog light connector. (Vehicles with front fog lights)
6. Adjust the front fog light aiming for vehicles with front fog lights. (See FRONT FOG LIGHT
AIMING .)
FRONT BUMPER REMOVAL NOTE
1. Pull the front bumper ends (wheel arch) outward (1) to disengage from the bumper slider.
CAUTION:  When disengaging 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.
2. Remove the front bumper from the body.
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Fig. 12: Identifying Front Bumper Ends

FRONT BUMPER INSTALLATION NOTE
1. Spread the front bumper ends apart.

2. Assemble 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. Remove the front fog light. (Vehicles with front fog lights) (See FRONT FOG LIGHT
2. Remove the radiator grille. (See RADIATOR GRILLE REMOVAL/INSTALLATION .)
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Fig. 13: Identifying Front Bumper Components & Torque Specifications

FRONT OVER FENDER LOWER ASSEMBLY NOTE
1. Attach the front over fender lower to the front bumper fascia with nuts.
2. Use a soldering copper and thermally deform the tab in order to fasten the stiffening rib.
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Fig. 14: Identifying Front Over Fender Lower And Front Bumper Fascia With Nuts
FRONT BUMPER REINFORCEMENT REMOVAL/INSTALLATION

2. Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION.)
Fig. 15: Identifying Removing Sequence Of Front Bumper Reinforcement Components & Torque
Specifications
REAR BUMPER REMOVAL/INSTALLATION

3. Remove the screw and fastener.
4. Detach the tab of the splash shield to remove it.
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Fig. 16: Identifying Rear Bumper And Splash Shield With Tabs
5. Remove the clip of the rear over fender and put aside the rear bumper.
Fig. 17: Removing Clip Of Rear Over Fender


Fig. 18: Identifying Removing Sequence Of Rear Bumper Components

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REAR BUMPER REMOVAL NOTE
1. Pull the rear bumper ends (wheel arch) outward (1) to disengage from the bumper slider.
CAUTION:  When disengaging 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.
2. Remove the rear bumper (2).
Fig. 19: Identifying Rear Bumper And Bumper Slider

REAR BUMPER INSTALLATION NOTE
1. Spread the rear bumper ends apart.

2. Assemble the rear bumper to the body.
3. Press the rear bumper connecting area into the body to engage with the bumper slider.
REAR BUMPER DISASSEMBLY/ASSEMBLY

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Fig. 20: Identifying Rear Bumper Components & Torque Specifications

REFLECTOR REMOVAL NOTE
1. Pull off the reflector from the rear bumper in the direction and in the order as shown by the arrows.
Fig. 21: Identifying Rear Bumper And Reflector

REAR OVER FENDER LOWER ASSEMBLY NOTE
1. Attach the rear over fender lower to the rear bumper fascia with nuts.
2. Use a soldering copper and thermally deform the tab in order to fasten the stiffening rib.
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Fig. 22: Identifying Rear Over Fender Lower And Rear Bumper Fascia With Nuts
FRONT FENDER PANEL REMOVAL/INSTALLATION

2. Side cowl grille (See COWL GRILLE REMOVAL/INSTALLATION )
3. Front over fender (See OVER FENDER REMOVAL/INSTALLATION )
4. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION)
5. Front combination lights (See FRONT COMBINATION LIGHT
6. Sail garnish (See SAIL GARNISH REMOVAL/INSTALLATION ) '
Fig. 23: Identifying Removing Sequence Of Front Fender Panel Components & Torque
Specifications
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SHROUD PANEL REMOVAL/INSTALLATION

1. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION)
3. Front bumper reinforcement (See FRONT BUMPER REINFORCEMENT
REMOVAL/INSTALLATION)
4. Ambient temperature sensor (See AMBIENT TEMPERATURE SENSOR
5. Crash zone sensor (See CRASH ZONE SENSOR REMOVAL/INSTALLATION )
6. Hood latch (See HOOD LATCH AND RELEASE LEVER REMOVAL/INSTALLATION )
3. Put the oil cooler aside.
4. Remove the front crossmember extension. (See FRONT CROSSMEMBER
Fig. 24: Identifying Removing Sequence Of Shroud Panel Components & Torque Specifications
UPPER MOUNT RUBBER BRACKET REMOVAL NOTE
1. Remove the upper mount rubber bracket while pressing down the upper mount rubber bracket tab in the
direction of the arrow.
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Fig. 25: Identifying Upper Mount Rubber Bracket

COWL PANEL REMOVAL/INSTALLATION

2. Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION )
3. Windshield wiper motor (See WINDSHIELD WIPER MOTOR
3. Remove the bolts, then remove the cowl panel.
Fig. 26: Identifying Cowl Panel With Nuts, Bolts & Torque Specifications
Microsoft
2008 BRAKES On-Board Diagnostic (DSC/RSC) - Mazda CX-9
2008 BRAKES
On-Board Diagnostic (DSC/RSC) - Mazda CX-9
SYSTEM WIRING DIAGRAM [DSC/RSC]
Fig. 1: Brakes - System Wiring Diagram (DSC/RSC)

ON-BOARD DIAGNOSTIC [DSC/RSC]
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ON-BOARD DIAGNOSTIC (OBD) TEST DESCRIPTION
 The OBD test inspects the integrity and function of the DSC/RSC and outputs the results when requested
by the specific tests.
 On-board diagnostic test also:
 Provides a quick inspection of the DSC/RSC usually performed at the start of each diagnostic
procedure.
 Provides verification after repairs to ensure that no other faults occurred during service.
 The OBD test is divided into 3 tests:

 Read/clear diagnostic results, PID monitor and record and active command modes.
READ/CLEAR DIAGNOSTIC RESULTS
 This function allows you to read or clear DTCs in the DSC/RSC HU/CM memory.
PID/DATA MONITOR & RECORD
 This function allows you to access certain data values, input signals, calculated values, and system status
information.
ACTIVE COMMAND MODES
 This function allows you to control devices through the M-MDS.
READING DTCS PROCEDURE


3. Select "ABS".

2. Select "ABS".
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If any DTCs are displayed, perform troubleshooting according to the corresponding DTC

inspection.
4. After completion of repairs, clear all DTCs stored in the DSC/RSC. (See CLEARING DTCS
PROCEDURES.)
CLEARING DTCS PROCEDURES


3. Select "ABS".

2. Select "ABS".
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PID/DATA MONITOR AND RECORD PROCEDURE

3. Select "ABS".

2. Select "ABS".

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ACTIVE COMMAND MODES PROCEDURE

3. Select "ABS".

2. Select "ABS".
3. Select the active command modes from the PID table.

4. Perform the active command modes, inspect the operations for each parts.
 If the operation of output parts cannot be verified after the active command mode inspection is
performed, this could indicate the possibility of an open or short circuit, sticking, or operation
malfunction in the output parts.
DTC TABLE
DTC CHART
Microsoft
DTC
M- System malfunction location Page
MDS
B1317 Power supply system (See DTC B1317, B1318 [DSC/RSC].)
B1318 Power supply system (See DTC B1317, B1318 [DSC/RSC].)
B1342 DSC/RSC HU/CM system (See DTC B1342, C1730 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
B211B Combined sensor system
C1517, C2769, C2770 [DSC/RSC].)
C1095 Pump motor, motor relay system (See DTC C1095, C1096 [DSC/RSC].)
C1096 Pump motor, motor relay system (See DTC C1095, C1096 [DSC/RSC].)
C1115 Valve relay system (See DTC C1115, C1185 [DSC/RSC].)
RF ABS wheel-speed sensor (open
C1145 (See DTC C1145, C1155, C1165, C1175 [DSC/RSC].)
circuit) system
LF ABS wheel-speed sensor (open
circuit) system
RR ABS wheel-speed sensor (open
circuit) system
LR ABS wheel-speed sensor (open
circuit) system
C1185 Valve relay system (See DTC C1115, C1185 [DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1194 LF outlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1198 LF inlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1210 RF outlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1214 RF inlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
C1222 ABS wheel-speed sensor system (See DTC C1222 [DSC/RSC].)
LF ABS wheel-speed sensor/ABS
sensor rotor system
RF ABS wheel-speed sensor/ABS
sensor rotor system
RR ABS wheel-speed sensor/ABS
sensor rotor system
LR ABS wheel-speed sensor/ABS
sensor rotor system
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1242 LR outlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
Microsoft
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,

C1246 RR outlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1250 LR inlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
C1254 RR inlet solenoid valve system C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC].)
C1278 Steering angle sensor system (See DTC C1278, C1295, U2023 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1279 Combined sensor system
C1517, C2769, C2770 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
C1288 Brake fluid pressure sensor system (See DTC C1288 [DSC/RSC].)
C1295 Steering angle sensor system (See DTC C1278, C1295, U2023 [DSC/RSC].)
C1327 Brake fluid level sensor system (See DTC C1327 [DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
C1329 RF outlet solenoid valve coil system C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
LR outlet solenoid valve coil
C1330 C1335, C1336, C1527, C1528, C1530, C1531
system
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
RR outlet solenoid valve coil
C1331 C1335, C1336, C1527, C1528, C1530, C1531
system
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
C1332 LF outlet solenoid valve coil system C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
C1333 LR inlet solenoid valve coil system C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
C1334 LF inlet solenoid valve coil system C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
C1335 RF inlet solenoid valve coil system C1335, C1336, C1527, C1528, C1530, C1531
[DSC/RSC].)
C1336 RR inlet solenoid valve coil system (See DTC C1329, C1330, C1331, C1332, C1333, C1334,
C1335, C1336, C1527, C1528, C1530, C1531
Microsoft
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
RH traction control solenoid valve
C1404 C1250, C1254, C1404, C1410, C1957, C1958
system
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
LH traction control solenoid valve
C1410 C1250, C1254, C1404, C1410, C1957, C1958
system
[DSC/RSC].)
C1446 Brake switch system (See DTC C1446 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
RH traction control solenoid valve
C1527 C1335, C1336, C1527, C1528, C1530, C1531
coil system
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
LH traction control solenoid valve
C1528 C1335, C1336, C1527, C1528, C1530, C1531
coil system
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
RH stability control solenoid valve
C1530 C1335, C1336, C1527, C1528, C1530, C1531
coil system
[DSC/RSC].)
(See DTC C1329, C1330, C1331, C1332, C1333, C1334,
LH stability control solenoid valve
C1531 C1335, C1336, C1527, C1528, C1530, C1531
coil system
[DSC/RSC].)
C1730 DSC/RSC HU/CM system (See DTC B1342, C1730 [DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
RH stability control solenoid valve
C1957 C1250, C1254, C1404, C1410, C1957, C1958
system
[DSC/RSC].)
(See DTC C1194, C1198, C1210, C1214, C1242, C1246,
LH stability control solenoid valve
C1958 C1250, C1254, C1404, C1410, C1957, C1958
system
[DSC/RSC].)
Combined sensor (Yaw rate sensor
C1963 (See DTC C1963 [DSC/RSC].)
part) initial point correction error
DSC/RSC sensor (abnormal
C1991 (See DTC C1991 [DSC/RSC].)
initialization) system
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
(See DTC B211B, C1279, C1280, C1281, C1282, C1516,
C1517, C2769, C2770 [DSC/RSC].)
(See DTC TABLE [MULTIPLEX COMMUNICATION
U0073 CAN system communication error
SYSTEM] .)
(See DTC TABLE [MULTIPLEX COMMUNICATION
U0100 Communication error to PCM
SYSTEM] .)
U0140 Communication error to BCM (See DTC TABLE [MULTIPLEX COMMUNICATION
Microsoft
SYSTEM] .)
Communication error to instrument (See DTC TABLE [MULTIPLEX COMMUNICATION
U0155
cluster SYSTEM] .)
Combined sensor system (CAN2
U1901 (See DTC U1901 [DSC/RSC].)
line malfunction)
U2023 Steering angle sensor system (See DTC C1278, C1295, U2023 [DSC/RSC].)

DSC/RSC
PID name Operation condition
Unit/Condition Action HU/CM
(definition) (reference)
terminal
 Vehicle stopped
or driving at
constant speed: 0
G
 Vehicle is driving Inspect the combined sensor.
ACCLMTR G at a acceleration: (See COMBINED SENSOR -
changes 0 G- INSPECTION .)
positive
 Vehicle is driving
at a deceleration:
changes 0 G-
negative
 Brake pedal
Inspect the brake switch.
BOO_ABS (Brake depressed: On
Off/On (See BRAKE SWITCH -
pedal switch input)  Brake pedal INSPECTION .)
released: Off
CCNTABS
Indicates number of Perform the DTC inspection.
(Number of - -
DTC (See DTC TABLE.)
continuous codes)
 Vehicle stopped
or driving at
constant speed: 0
G
Inspect the combined sensor.
LAT_ACCL G  Cornering to (See COMBINED SENSOR -
right: Changes 0 INSPECTION .)
G-positive
 Cornering to left:
Changes 0 G-
negative
 Brake pedal
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released: 0 Pa, 0
psi
Inspect the brake fluid
 Brake pedal pressure sensor.
MCYLI P Pa, psi depressed: (See BRAKE FLUID -
Changes PRESSURE SENSOR
according to the INSPECTION .)
brake fluid
pressure
 Pump motor Inspect the DSC/RSC
PMP_MOTOR
activated: On HU/CM.
(Pump motor Off/On -
 Pump motor not (See DSC/RSC SYSTEM
output state)
activated: Off INSPECTION .)
 Selector lever
SHIFT_P Inspect the TCM.
position P: On
(Transaxle gear Off/On (See TCM INSPECTION -
position input)  Other than those [AW6A-EL, AW6AX-EL] .)
above: Off
 Valve relay Inspect the DSC/RSC
PWR_RLY (Valve activated: On HU/CM.
Off/On -
relay output state)  Valve relay not (See DSC/RSC SYSTEM
activated: Off INSPECTION .)
 Vehicle stopped
or driving
straight: 0 c/s
ROLL_RATE Inspect the combined sensor.
(Roll rate sensor °/s  Cornering to left: (See COMBINED SENSOR -
input) 0 °/s-positive INSPECTION .)
 Cornering to
right: 0 °/s-
negative
 Steering wheel
neutral position
(not turned): 0°
 Steering wheel Inspect the steering angle
SWA_POS turned to left: sensor.
(Steering angle ° Changes 0 °- -
(See STEERING ANGLE
sensor input) negative SENSOR INSPECTION .)
 Steering wheel
turned to right:
Changes 0 °-
positive
TCS_OFF_SW  TCS OFF switch Inspect the TCS OFF switch.
(TCS OFF switch Off/On is depressed: On (See TCS OFF SWITCH U
input) INSPECTION .)
 TCS OFF switch
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is released* Off
 Solenoid valve Inspect the DSC/RSC
V_LF_INL (Left
front inlet solenoid Off/On -
 Solenoid valve (See DSC/RSC SYSTEM
valve output state)
not activated: Off INSPECTION .)
V_LF_OTL (Left  Solenoid valve Inspect the DSC/RSC
front outlet activated: On HU/CM.
Off/On -
solenoid valve  Solenoid valve (See DSC/RSC SYSTEM
output state) not activated: Off INSPECTION .)
V_LR_INL (Left
rear inlet solenoid Off/On -
valve output state)
V_LR_OTL (Left
rear outlet solenoid Off/On -
valve output state)
V_RF_INL (Right
front inlet solenoid Off/On -
valve output state)
V_RF_OTL (Right  Solenoid valve Inspect the DSC/RSC
front outlet activated: On HU/CM.
Off/On -
V_RR_INL (Right
rear inlet solenoid Off/On -
valve output state)
V_RR_OTL (Right
rear outlet solenoid Off/On -
valve output state)
V_STB_L (LH  Solenoid valve Inspect the DSC/RSC
stability control activated: On HU/CM.
Off/On -
V_STB_R (RH  Solenoid valve Inspect the DSC/RSC

Off/On activated: On -
stability control HU/CM.
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V_TRC_L (LH  Solenoid valve Inspect the DSC/RSC
traction control activated: On HU/CM.
Off/On -
V_TRC_R (RH  Solenoid valve Inspect the DSC/RSC
traction control activated: On HU/CM.
Off/On -
Inspect the ABS wheel-speed
 Vehicle stopped:
WSPD_LF (Left sensor.
0 KPH, 0 MPH
front ABS wheel- KPH, MPH (See FRONT ABS WHEEL- AG, AD
speed sensor input)  Vehicle running: SPEED SENSOR
vehicle speed INSPECTION .)
sensor.
 Vehicle stopped: (See REAR ABS WHEEL-
WSPD_LR (Left
0 KPH, 0 MPH SPEED SENSOR
rear ABS wheel- KPH, MPH F, I
 Vehicle running: INSPECTION [2WD] .) (See
speed sensor input)
vehicle speed REAR ABS WHEEL-
SPEED SENSOR
INSPECTION [AWD] .)
 Vehicle stopped:
WSPD_RF (Right sensor.
0 KPH, 0 MPH
front ABS wheel- KPH, MPH (See FRONT ABS WHEEL- AE, AB
speed sensor input)  Vehicle running: SPEED SENSOR
vehicle speed INSPECTION .)
sensor.
 Vehicle stopped: (See REAR ABS WHEEL-
WSPD_RR (Right
0 KPH, 0 MPH SPEED SENSOR
rear ABS wheel- KPH, MPH G, J
 Vehicle running: INSPECTION [2WD] .) (See
speed sensor input)
vehicle speed REAR ABS WHEEL-
SPEED SENSOR
INSPECTION [AWD] .)
 Vehicle stopped
or driving
straight: 0 °/s
 Cornering to left: Inspect the combined sensor.
YAW_RATE °/s Changes 0 °/s- (See COMBINED SENSOR -
negative INSPECTION .)
 Cornering to
right: Changes 0
°/s-positive
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ACTIVE COMMAND MODES TABLE
ACTIVE COMMAND MODES CHART

Command name Output part Operation Operating condition
PMP_MOTOR Pump motor
PWR_RLY Valve relay
SSR_INTL DSC/RSC sensor initialization
V_LF_INL LF inlet solenoid valve
V_LF_OTL LF outlet solenoid valve
V_LR_INL LR inlet solenoid valve
V_LR_OTL LR outlet solenoid valve
V_RF_INL RF inlet solenoid valve Off/On Ignition switch at ON
V_RF_OTL RF outlet solenoid valve
V_RR_INL RR inlet solenoid valve
V_RR_OTL RR outlet solenoid valve
V_STB_L LH stability control solenoid valve
V_STB_R RH stability control solenoid valve
V_TRC_L LH traction control solenoid valve
V_TRC_R RH traction control solenoid valve
DTC B1317, B1318 [DSC/RSC]
NOTE:  DTC B1317 is output when the battery voltage is 16 V or more. If DTC
B1317 is output, inspect the battery and charging system for a malfunction
before performing the malfunction diagnosis.
DTC B1317, B1318 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE

DTC B1317, B1318 Power supply system
 B1317
 DSC/RSC HU/CM terminal X voltage of 16 V or more continues for 3 s
while driving at a vehicle speed of 8 km/h or more.
DETECTION  DSC/CM terminal X voltage of 18.5 V or more continues for 15 ms while
CONDITION driving at a vehicle speed of 8 km/h or more.
 B1318
 DSC/RSC HU/CM terminal X voltage of 10 V or less continues for 3 s
while driving at a vehicle speed of 8 km/h or more.
 SAS 7.5A fuse malfunction
 Open circuit or short to ground in the wiring harness between the DSC/RSC
POSSIBLE CAUSE HU/CM terminal X and the battery
 Open circuit or faulty ground in the wiring harness between the DSC/RSC
HU/CM terminal A and the body ground
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 Battery deterioration
 Generator malfunction
 Poor connection at connectors (female terminal)

INSPECT DSC/RSC HU/CM Yes Go to the next step.

POWER SUPPLY FOR OPEN
1 CIRCUIT
No
 Start the engine. Repair or replace the wiring harness for open circuit
 Measure the voltage between between the DSC/RSC HU/CM and ground, then go
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DSC/RSC HU/CM terminal X to Step 3.

and ground.
 Is the voltage approx. 10 V?
INSPECT DSC/RSC HU/CM If there is no continuity:
GROUND FOR POOR GROUND
OR OPEN CIRCUIT  Repair or replace the wiring harness for open
circuit between the DSC/RSC HU/CM and
 Turn the ignition switch off. ground, then go to the next step.
2
 Measure the resistance between No
ground and DSC/RSC HU/CM
terminal A. If the resistance is not within 0-1 ohm :
 Is the resistance within 0-1
ohm ?  Repair or replace the wiring harness for poor
ground, then go to the next step.
VERIFY TROUBLESHOOTING
COMPLETED
Replace the DSC/RSC HU/CM, then go to the next
 Make sure to reconnect all step.
disconnected connectors. Yes
(See DSC/RSC HU/CM
3  Clear the DTC from the memory. REMOVAL/INSTALLATION .)
(See ON-BOARD
DIAGNOSTIC [DSC/RSC].)
Is the same DTC present?

VERIFY AFTER REPAIR Go to the applicable DTC inspection.

PROCEDURE Yes
4 (See ON-BOARD DIAGNOSTIC [DSC/RSC].)
 Are any other DTCs present? No DTC troubleshooting completed.
DTC B1342, C1730 [DSC/RSC]
NOTE:  Perform the inspection of DTCs other than B1342 and C1730 first when
verifying DTCs.
DTC B1342, C1730 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE

DTC B1342, C1730 DSC/RSC HU/CM system
 B1342
 DSC/RSC HU/CM on-board diagnostic function detects control
DETECTION
module malfunction.
CONDITION
 C1730
 Sensor supply voltage is out of range.
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POSSIBLE CAUSE  DSC/RSC HU/CM internal malfunction
DTC B1342, C1730 [DSC/RSC] DIAGNOSTIC PROCEDURE

VERIFY DTC INSPECTION
Go to the applicable DTC inspection.
Turn the ignition switch off.
 Yes
(See ON-BOARD DIAGNOSTIC [DSC/RSC].)
1  Using the M-MDS, perform the
DTC inspection.
 Are any DTCs other than B1342 No Go to the next step.
and C1730 output?
VERIFY CURRENT STATUS OF
MALFUNCTION
step.
 Clear the DTC from the memory. Yes
(See DSC/RSC HU/CM
2
(See ON-BOARD


VERIFY THAT NO DTCS ARE
OUTPUT AGAIN If DTC B1342 or C1730 is output again, replace the
DSC/RSC HU/CM.
 Drive the vehicle at 32 km/h or Yes
(See DSC/RSC HU/CM
3 more. REMOVAL/INSTALLATION .)
 Stop the vehicle and verify the
DTCs.
 Are DTCs output again? No DTC troubleshooting completed.
DTC B211B, C1279, C1280, C1281, C1282, C1516, C1517, C2769, C2770
[DSC/RSC]
DTC B211B, C1279, C1280, C1281, C1282, C1516, C1517, C2769, C2770 [DSC/RSC] DETECTION
CONDITION AND POSSIBLE CAUSE
DTC B211B, C1279, C1280, C1281,
Combined sensor system
C1282, C1516, C1517, C2769, C2770
 B211B
 Combined sensor internal malfunction.
 C1279
 There is an abnormality in the signal from the
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combined sensor (yaw rate part).

 C1280
 Specified signal from combined (yaw rate part)
sensor has not output.
 C1281
combined sensor (lateral-G part).
 C1282
 Specified signal from combined (lateral-G part)
 C1516
DETECTION CONDITION
 Specified signal from combined (roll rate part)
 C1517
combined sensor (roll rate part).
 C2769
combined sensor (longitudinal-G part).
 C2770
 Specified signal from combined (longitudinal-
G part) sensor has not output.
 Combined sensor malfunction
POSSIBLE CAUSE
DTC B211B, C1279, C1280, C1281, C1282, C1516, C1517, C2769, C2770 [DSC/RSC] DIAGNOSTIC
PROCEDURE
INSPECT COMBINED SENSOR Yes Go to the next step.
 Inspect the combined sensor.
Replace the combined sensor, then go to the next
1 step.
(See COMBINED SENSOR No
INSPECTION .) (See COMBINED SENSOR
 Is the combined sensor normal?
VERIFY DTC TROUBLESHOOTING
COMPLETED. Yes
Replace the DSC/RSC HU/CM, then go to the
 Clear the DTC from the memory. next step.
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(See ON-BOARD DIAGNOSTIC (See DSC/RSC HU/CM

[DSC/RSC].) REMOVAL/INSTALLATION .)
2
 Are the same DTCs present? No Go to the next step.
PROCEDURE. Yes
DTC C1095, C1096 [DSC/RSC]

DTC C1095, C1096 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1095, C1096 Pump motor, motor relay system
 C1095
 ABS motor monitor OFF signal is input within specified time limit when the
DETECTION motor signal is switched from ON to OFF by DSC/RSC HU/CM.
CONDITION  C1096
 When pump motor monitor voltage continues for 0.05s more than 0.75V
among the pump motor ON.
 ABS 50A fuse malfunction
 Open or short to ground circuit in the wiring harness between the battery and the
DSC/RSC HU/CM terminal AK
 Open circuit in the wiring harness between the DSC/RSC HU/CM terminal B and
the body ground
POSSIBLE CAUSE
 Open or short circuit in the DSC/RSC HU/CM internal motor relay, or stuck motor
relay
 Open or short circuit in the DSC/RSC HU/CM internal motor, or frozen motor
 Motor relay malfunction
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DTC C1095, C1096 [DSC/RSC] DIAGNOSTIC PROCEDURE

INSPECT ABS FUSE CONDITION Yes Go to the next step.
1
 Is the ABS 50A fuse normal? No Replace the fuse, then go to Step 5.
INSPECT MOTOR RELAY

POWER SUPPLY FOR OPEN Yes Go to the next step.
CIRCUIT
 Turn the ignition switch off.

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Disconnect DSC/RSC HU/CM


connector.
 Turn the ignition switch to the
Repair or replace the wiring harness for open circuit
ON position (engine off).
2 No between battery positive terminal and DSC/RSC
 Measure voltage between HU/CM terminal AK, then go to Step 5.
DSC/RSC HU/CM terminal AK
(harness-side) and ground.
 Is the voltage B+?
INSPECT PUMP MOTOR

GROUND FOR OPEN CIRCUIT Yes Go to the next step.


3 Repair or replace the wiring harness for open circuit
 Inspect for continuity between
DSC/RSC HU/CM terminal B No between DSC/RSC HU/CM terminal B and ground,
(harness-side) and ground. then go to Step 5.
 Is there continuity?
VERIFY PUMP MOTOR

OPERATION Yes Go to the next step.


 Connect the M-MDS to the

DLC-2.
4 Replace the DSC/RSC HU/CM, then go to the next
step.
ON position (engine off). No
(See DSC/RSC HU/CM
 Access PMP_MOTOR active REMOVAL/INSTALLATION .)
command modes using the M-
MDS.
 Does the pump motor operate?
COMPLETED
 Make sure to reconnect all

disconnected connectors. Replace the DSC/RSC HU/CM, then go to the next
step.
 Clear the DTC from the Yes
(See DSC/RSC HU/CM
memory. REMOVAL/INSTALLATION .)
5
(See ON-BOARD
 Gradually slow down and stop

the vehicle. No Go to the next step.
 Is the same DTC present?
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PROCEDURE Yes (See ON-BOARD DIAGNOSTIC [DSC/RSC].)

6
DTC C1115, C1185 [DSC/RSC]
NOTE:  Perform the inspection of DTCs other than C1115 and C1185 first when
verifying DTCs.
DTC C1115, C1185 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE

DTC C1115, C1185 Valve relay system
 C1115
DETECTION  Short circuit in the DSC/RSC HU/CM internal value relay.
CONDITION  C1185
 Open circuit in the DSC/RSC HU/CM internal value relay.
POSSIBLE CAUSE  Open or short circuit in the DSC/RSC HU/CM internal valve relay, or
stuck valve relay
DTC C1115, C1185 [DSC/RSC] DIAGNOSTIC PROCEDURE

 Yes
1  Using the M-MDS, perform the
DTC inspection.
 Are any DTCs other than C1115 No Go to the next step.
and C1185 output?
MALFUNCTION
step.
(See DSC/RSC HU/CM
2
(See ON-BOARD
 Is the same DTC present? No Go to the next step.
VERIFY THAT NO DTCS ARE

3 OUTPUT AGAIN Yes If DTC C1115 or C1185 is output again, replace the
DSC/RSC HU/CM.
 Drive the vehicle at 32 km/h or (See DSC/RSC HU/CM
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more. REMOVAL/INSTALLATION .)
 Stop the vehicle and verify the
DTCs. No DTC troubleshooting completed.
 Are DTCs output again?
DTC C1145, C1155, C1165, C1175 [DSC/RSC]

DTC C1145, C1155, C1165, C1175 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1145 RF ABS wheel-speed sensor (open circuit) system
DTC C1155 LF ABS wheel-speed sensor (open circuit) system
DTC C1165 RR ABS wheel-speed sensor (open circuit) system
DTC C1175 LR ABS wheel-speed sensor (open circuit) system
DETECTION  Open circuit has been detected in the ABS wheel-speed sensor or the ABS wheel-
CONDITION speed sensor wiring harness on any of the four vehicle wheels.
 Open circuit in the wiring harness between the following DSC/RSC HU/CM
terminal and the ABS wheel-speed sensor terminal:
 DSC/RSC HU/CM terminal AE-RF ABS wheel-speed sensor terminal A
 DSC/RSC HU/CM terminal AB-RF ABS wheel-speed sensor terminal B
 DSC/RSC HU/CM terminal AG-LF ABS wheel-speed sensor terminal A
 DSC/RSC HU/CM terminal AD-LF ABS wheel-speed sensor terminal B

POSSIBLE CAUSE
 DSC/RSC HU/CM terminal G-RR ABS wheel-speed sensor terminal A
 DSC/RSC HU/CM terminal J-RR ABS wheel-speed sensor terminal B
 DSC/RSC HU/CM terminal F-LR ABS wheel-speed sensor terminal A
 DSC/RSC HU/CM terminal I-LR ABS wheel-speed sensor terminal B
 ABS wheel-speed sensor malfunction

Microsoft
Microsoft
DTC C1145, C1155, C1165, C1175 [DSC/RSC] DIAGNOSTIC PROCEDURE

INSPECT PID TO VERIFY THAT WHEEL
SPEED-SIGNALS ARE TRANSMITTED
FROM ABS WHEEL-SPEED SENSOR
USING M-MDS

Yes Go to Step 4.
 Connect the M-MDS to the DLC-2.
 Select the following PIDs using the M-
MDS:
WSPD_LF
1
WSPD_LR
WSPD_RF
WSPD_RR
Drive the vehicle.

 Verify that the wheel speed-signals are

transmitted from each ABS wheel-speed
sensor.
 Are the wheel-speed signals transmitted?
INSPECT FOR OPEN CIRCUIT IN WIRING

HARNESS BETWEEN DSC/RSC HU/CM
AND ABS WHEEL-SPEED SENSOR
 Turn the ignition switch off. Yes Go to the next step.

 Disconnect the DSC/RSC HU/CM
connector and ABS wheel-speed sensor.
 Inspect for continuity in the wiring harness
2 between the following ABS wheel-speed
sensor connectors on the vehicle wiring
harness-side and DSC/RSC HU/CM
connectors.
 RF ABS wheel-speed sensor: AE-A Repair or replace the wiring harness, then
No
 RF ABS wheel-speed sensor: AB-B
 LF ABS wheel-speed sensor: AG-A
 LF ABS wheel-speed sensor: AD-B
 RR ABS wheel-speed sensor: G-A
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RR ABS wheel-speed sensor: J-B


 LR ABS wheel-speed sensor: F-A
 LR ABS wheel-speed sensor: I-B
INSPECT ABS WHEEL-SPEED SENSOR

FOR MALFUNCTION
Replace the ABS wheel-speed sensor, then
 go to the next step.
 Disconnect the ABS wheel-speed sensor (See FRONT ABS WHEEL-SPEED
connector which may have a malfunction. SENSOR
 Turn the ignition switch to the ON position,
(engine off) Yes (See REAR ABS WHEEL-SPEED
3 SENSOR
 Measure the power supply voltage between
REMOVAL/INSTALLATION [2WD] .)
the ABS wheel-speed sensor connector (See REAR ABS WHEEL-SPEED
terminal A (vehicle wiring harness-side) and SENSOR
body ground on the ABS wheel-speed REMOVAL/INSTALLATION [AWD] .)
sensor which may have a malfunction.
 Is the power supply voltage of the ABS
wheel-speed sensor which may have a
malfunction more than 10 V? No Go to the next step.
VERIFY THAT THE SAME DTC IS NOT
PRESENT Repeat the inspection from Step 1.
If the malfunction recurs, replace the
 Clear the DTCs from the memory. DSC/RSC HU/CM, then go to the next
Yes
4 step.
Are the same DTCs present?

 No Go to the next step.
VERIFY THAT NO OTHER DTCS ARE Go to the applicable DTC inspection.
PRESENT Yes (See ON-BOARD DIAGNOSTIC
5 [DSC/RSC].)
 Are any other DTCs output? No DTC troubleshooting completed.
DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254, C1404,
C1410, C1957, C1958 [DSC/RSC]
DTC C1194, C1198, C1210, C1214, C1242, C1246, C1250, C1254, C1404, C1410, C1957, C1958
[DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1194 LF outlet solenoid valve system
DTC C1198 LF inlet solenoid valve system
DTC C1210 RF outlet solenoid valve system
DTC C1214 RF inlet solenoid valve system
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DTC C1242 LR outlet solenoid valve system

DTC C1246 RR outlet solenoid valve system
DTC C1250 LR inlet solenoid valve system
DTC C1254 RR inlet solenoid valve system
DTC C1404 RH traction control solenoid valve system
DTC C1410 LH traction control solenoid valve system
DTC C1957 RH stability control solenoid valve system
DTC C1958 LH stability control solenoid valve system
DETECTION  Solenoid valve operation does not correspond to solenoid ON/OFF
CONDITION commands from the DSC/RSC HU/CM.
 Open or short circuit in the DSC/RSC HU/CM internal solenoid valves
POSSIBLE CAUSE  Solenoid valve malfunction
[DSC/RSC] DIAGNOSTIC PROCEDURE
 Turn the ignition switch to the ON

position (engine off).
1  Clear the DTC from the memory.
Step 3.
(See ON-BOARD DIAGNOSTIC No
(See DSC/RSC HU/CM
Re-perform the DTC inspection.

 Is more than one solenoid valve-related

DTC output?
INSPECT DSC/RSC HU/CM POWER Replace the DSC/RSC HU/CM, then go to the
SUPPLY AND GROUND CIRCUIT FOR next step.
OPEN CIRCUIT Yes
(See DSC/RSC HU/CM
 Measure the voltage between DSC/RSC
HU/CM terminal AL and terminal A. Repair or replace the wiring harness, then go
No
 Is the voltage more than 10 V? to the next step.

COMPLETED Repeat the inspection from Step 1.
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 Clear the DTC from the memory. If the malfunction recurs, replace the
DSC/RSC HU/CM, then go to the next step.
Yes (See DSC/RSC HU/CM
3 (See ON-BOARD DIAGNOSTIC

 Are the same DTCs present?
VERIFY AFTER REPAIR PROCEDURE Yes (See ON-BOARD DIAGNOSTIC
4 [DSC/RSC].)
 Are any other DTCs present?
DTC C1222 [DSC/RSC]

DTC C1222 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1222 ABS wheel-speed sensor system
DETECTION  When the difference in the wheel speed between one tire and the others
CONDITION exceeds 25%.
 A tire of different diameter is installed.
POSSIBLE CAUSE
 An incorrect ABS sensor rotor is installed (different number of teeth).
DTC C1222 [DSC/RSC] DIAGNOSTIC PROCEDURE

INSPECT PID (WHEEL SPEED) FOR
DIFFERENCE IN EACH WHEEL
SPEED USING M-MDS

 Connect the M-MDS to the DLC-2. Yes Go to Step 4.
 Select the following PIDs using the
M-MDS:
1 WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR No Go to the next step.
 Drive the vehicle.

 Verify that the wheel speeds detected
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by the four ABS wheel speed sensors

are approximately the same.
 Are the wheel speeds approximately
the same?
INSPECT THE SIZE OF THE TIRE
THAT HAS A DIFFERENT WHEEL
SPEED Yes Go to the next step.
2  Inspect the tire for differences in the

tire diameter caused by the tire size,
wear, or tire pressure.
No Replace the tire, then go to Step 4.
 Is the tire diameter the same as the
others?
INSPECT FOR INCORRECT ABS Replace the ABS sensor rotor, then go to the
SENSOR ROTOR INSTALLATION next step.
(See FRONT ABS WHEEL-SPEED SENSOR
3  Inspect if the number of teeth on the REMOVAL/INSTALLATION .)
No
ABS sensor rotor is incorrect. (See REAR ABS WHEEL-SPEED SENSOR
 Is the number of teeth correct? (See REAR ABS WHEEL-SPEED SENSOR
REMOVAL/INSTALLATION [AWD] .)
VERIFY THAT THE SAME DTC IS
NOT PRESENT Repeat the inspection from Step 1.
If the malfunction recurs, replace the DSC/RSC
 Clear the DTC from the memory. Yes HU/CM, then go to the next step.
4 (See DSC/RSC HU/CM
(See ON-BOARD DIAGNOSTIC REMOVAL/INSTALLATION .)
[DSC/RSC].)


5 [DSC/RSC].)
DTC C1233, C1234, C1235, C1236 [DSC/RSC]

DTC C1233, C1234, C1235, C1236 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1233 LF ABS wheel-speed sensor/ABS sensor rotor system
DTC C1234 RF ABS wheel-speed sensor/ABS sensor rotor system
DTC C1235 RR ABS wheel-speed sensor/ABS sensor rotor system
DTC C1236 LR ABS wheel-speed sensor/ABS sensor rotor system
 Vehicle wheel speed signals of any of the four vehicle wheels indicate
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abnormal acceleration that exceeds specification.

DETECTION
CONDITION  Periodic abnormality is detected in the signal wave pattern from the ABS
wheel-speed sensors.
 ABS wheel-speed sensor malfunction (low output, metal shavings on
sensor)
POSSIBLE CAUSE  ABS sensor rotor malfunction (chipping of sensor rotor teeth)
 Poor installation of ABS wheel-speed sensor and/or sensor rotor
 Excessive clearance between the ABS wheel-speed sensor and sensor rotor
DTC C1233, C1234, C1235, C1236 [DSC/RSC] DIAGNOSTIC PROCEDURE

INSPECT PID FOR ABNORMAL
OUTPUT FROM ABS WHEEL-SPEED
SENSOR USING M-MDS
Yes Go to Step 4.
M-MDS:
WSPD_LF
1
WSPD_LR
WSPD_RF
If there is a difference in speeds of the four
No
WSPD_RR wheels, go to the next step.
 Start the engine and drive the vehicle.

 Verify that the PIDs of the four ABS
wheel-speed sensors correspond
approximately.
 Do the vehicle speeds correspond?

INSPECT IF MALFUNCTION
OCCURRED DUE TO IMPROPER
SENSOR CLEARANCE.
 Inspect the clearance between the

ABS wheel-speed sensor and the
ABS sensor rotor.
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(See FRONT ABS WHEEL-

SPEED SENSOR INSPECTION .)
(See REAR ABS WHEEL-SPEED

SENSOR INSPECTION [2WD] .)
(See REAR ABS WHEEL-SPEED Replace the ABS wheel-speed sensor, then go to
SENSOR INSPECTION [AWD] .) Step 4.
(See FRONT ABS WHEEL-SPEED SENSOR
 Is the clearance normal? REMOVAL/INSTALLATION .)
2 No
(See REAR ABS WHEEL-SPEED SENSOR
Clearance REMOVAL/INSTALLATION [2WD] .)
(See REAR ABS WHEEL-SPEED SENSOR
Front: 0.7-1.5 mm {0.028-0.059 in} REMOVAL/INSTALLATION [AWD] .)
Rear (2WD): 0.3-1.1 mm {0.012-

0.043 in}
Rear (AWD): 0.95-1.75 mm {0.038-

0.068 in}
Replace the front drive shaft, rear wheel hub
VISUALLY INSPECT ABS SENSOR component (2WD) or rear drive shaft (AWD),
ROTOR FOR FOREIGN MATERIAL then go to the next step.
ADHERING OR IMPROPER (See FRONT DRIVE SHAFT
3
INSTALLATION No REMOVAL/INSTALLATION .)
(See WHEEL HUB COMPONENT
 Is the result normal? REMOVAL/INSTALLATION [2WD] .)
(See REAR DRIVE SHAFT
NOT PRESENT
Repeat the inspection from Step 1.
 Clear the DTC from the memory. If the malfunction recurs, replace the DSC/RSC
Yes HU/CM, then go to the next step.
4 (See ON-BOARD DIAGNOSTIC (See DSC/RSC HU/CM
Start the engine and drive the vehicle


at 10 km/h {6.2 mph} or more.
 Are the same DTCs present?
VERIFY THAT NO OTHER DTCS Go to the applicable DTC inspection.

ARE PRESENT Yes
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DTC C1278, C1295, U2023 [DSC/RSC]

DTC C1278, C1295, U2023 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1278, C1295, U2023 Steering angle sensor system
 C1278
 The steering angle sensor detects an abnormality in the signal.
DETECTION CONDITION
 C1295, U2023
 The steering angle sensor detects an internal abnormality.
 Steering angle sensor malfunction

POSSIBLE CAUSE
DTC C1278, C1295, U2023 [DSC/RSC] DIAGNOSTIC PROCEDURE

INSPECT FOR BCM MALFUNCTION
Go to applicable DTC inspection.
Yes
(See DTC TABLE [BCM] .)
1
 Using the M-MDS, perform the DTC
inspection for the BCM.
 Are any DTCs detected?

COMPLETED
next step.
(See DSC/RSC HU/CM
2
(See ON-BOARD DIAGNOSTIC
[DSC/RSC].)
 Are the same DTCs present? No Go to the next step.

VERIFY AFTER REPAIR PROCEDURE Yes (See ON-BOARD DIAGNOSTIC
3 [DSC/RSC].)
 Are any other DTCs present?
DTC C1288 [DSC/RSC]

DTC C1288 Brake fluid pressure sensor system
DETECTION  The pressure from the brake fluid pressure sensor when the system starts
CONDITION up is not within specification.
 Open or short circuit in the brake fluid pressure sensor circuit in the
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DSC/RSC HU/CM
POSSIBLE CAUSE  Malfunction in the brake fluid pressure sensor
 Conventional brake system malfunction

INSPECT CONVENTIONAL BRAKE
SYSTEM
Inspect the conventional Drake system for

the following:
1  Normal master cylinder operation
 Brake fluid leakage between the

master cylinder and DSC/RSC Replace the malfunctioning part, then go to
No
HU/CM the next step.
 Normal brake switch operation
 Is the conventional brake system normal?
INSPECT BRAKE FLUID PRESSURE Yes Go to the next step.

SENSOR
 Inspect the brake fluid pressure sensor.

Replace the DSC/RSC HU/CM, then go to
2
the next step.
(See BRAKE FLUID PRESSURE No
(See DSC/RSC HU/CM
SENSOR INSPECTION .)
Is the brake fluid pressure sensor normal?

VERIFY NO ABNORMALITY ON BRAKE

FLUID PRESSURE SENSOR
Replace the DSC/RSC HU/CM, then go to
the next step.
 Clear the DTCs from the memory. Yes
(See DSC/RSC HU/CM
3
[DSC/RSC].)


4 [DSC/RSC].)
DTC C1327 [DSC/RSC]

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DTC C1327 Brake fluid level sensor
DETECTION CONDITION  Brake fluid level remains low
 Decrease in amount of brake fluid

POSSIBLE CAUSE
 Malfunction of brake fluid level sensor

INSPECT FOR BCM
MALFUNCTION FOR DTCs Go to applicable DTC inspection.
Yes
(See DTC TABLE [BCM] )
1  Turn the ignition switch off.
 Using the M-MDS, perform the

DTC inspection for the BCM.
 Are any DTCs detected?
INSPECT BRAKE FLUID LEVEL Yes Go to the next step.

2 Inspect the brake fluid level.
 Add brake fluid to specified level, then go to the next
No
 Is it normal?
step.
INSPECT BRAKE FLUID LEVEL
SENSOR
 Inspect the brake fluid level

sensor. Repair brake fluid level sensor, then go to the next
3
step.
(See BRAKE FLUID LEVEL No
(See MASTER CYLINDER
SENSOR INSPECTION .) REMOVAL/INSTALLATION .)
Is it normal?

VERIFY DTC
TROUBLESHOOTING
COMPLETED Repeat the inspection from Step 1.
If the malfunction occurs again, replace the
 Clear the DTC from the memory. Yes DSC/RSC HU/CM, then go to the next step.
4 (See DSC/RSC HU/CM
(See ON-BOARD
 Is the same DTC present? No Go to next step.

5 VERIFY AFTER REPAIR Yes
PROCEDURE
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DTC C1329, C1330, C1331, C1332, C1333, C1334, C1335, C1336, C1527,
C1528, C1530, C1531 [DSC/RSC]
[DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC C1329 RF outlet solenoid valve coil system
DTC C1330 LR outlet solenoid valve coil system
DTC C1331 RR outlet solenoid valve coil system
DTC C1332 LF outlet solenoid valve coil system
DTC C1333 LR inlet solenoid valve coil system
DTC C1334 LF inlet solenoid valve coil system
DTC C1335 RF inlet solenoid valve coil system
DTC C1336 RR inlet solenoid valve coil system
DTC C1527 RH traction control solenoid valve coil system
DTC C1528 LH traction control solenoid valve coil system
DTC C1530 RH stability control solenoid valve coil system
DTC C1531 LH stability control solenoid valve coil system
DETECTION
 Temperature of a solenoid valve coil exceeds specification.
CONDITION
 This does not indicate a malfunction since constant control over extended
POSSIBLE CAUSE period of time is inhibited to protect the RSC solenoid valve inside the
DSC/RSC HU.
[DSC/RSC] DIAGNOSTIC PROCEDURE
COMPLETED
next step.
(See DSC/RSC HU/CM
1
[DSC/RSC].)


PROCEDURE Yes (See ON-BOARD DIAGNOSTIC
2 [DSC/RSC].)
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DTC C1446 [DSC/RSC]

DTC C1446 Brake switch system
 Brake switch ON signal is not input when the brake fluid pressure sensor signal
DETECTION reaches the specified value.
CONDITION  Brake switch ON signal is input even if the signal from the brake fluid pressure
sensor is less than the specification.
 Open or short circuit in wiring harness between the brake switch and PCM 1T
terminal
POSSIBLE CAUSE
 Brake switch malfunction
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VERIFY OPEN OR SHORT CIRCUIT
IN BRAKE SWITCH SIGNAL
Yes Go to Step 5.
position.
 Measure the voltage between the
PCM terminal 1T and body ground
when the brake pedal is depressed
1 and released:
If it is B+ under any condition, then go to the next
Voltage No step. If it is 1 V or less under any condition, then
go to Step 3.
Brake pedal depressed: B+
Brake pedal released:
1 V or less
INSPECT BRAKE SWITCH SIGNAL
FOR SHORT TO POWER SUPPLY
Yes Go to Step 4.
CIRCUIT
Disconnect the brake switch


2 connector.
Repair or replace the wiring harness between the
brake switch connector terminal D No
PCM and brake switch, then go to Step 5
(vehicle harness-side) and body
ground.
 Is the voltage 1 V or less ?
INSPECT BRAKE SWITCH SIGNAL

FOR OPEN CIRCUIT
 Disconnect the PCM connectors.
 Disconnect the brake switch
3 connector.
 Inspect continuity between the PCM Repair or replace the wiring harness between the
connector terminal 1T (vehicle No
PCM and brake switch, then go to Step 5.
harness-side) and brake switch
terminal D:
INSPECT BRAKE SWITCH
 Inspect the brake switch.

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(See BRAKE SWITCH

Replace the brake switch, then go to the next step.
INSPECTION .)
4 No (See BRAKE PEDAL
Is the brake switch normal?


NOT PRESENT
 Reconnect all disconnected If the malfunction recurs, replace the DSC/RSC
connectors. Yes HU/CM, then go to the next step.
5  Clear the DTCs from the memory. (See DSC/RSC HU/CM
[DSC/RSC].)

VERIFY THAT NO OTHER DTCS Go to the applicable DTC inspection.

ARE PRESENT Yes
DTC C1963 [DSC/RSC]
NOTE:  The initial point of the combined sensor (yaw rate sensor part) is corrected
based on the signals from each sensor while the vehicle is driven straight,
however, the correction cannot be performed if the vehicle is continuously
driven on a curve and DTC C1963 is detected.

DTC C1963 Combined sensor (Yaw rate sensor part) initial point correction error
DETECTION  When a difference occurs between the estimated yaw rate value which is
CONDITION calculated by each sensor and the yaw rate value which is detected by the
combined sensor (yaw rate sensor part).
POSSIBLE  It occurs since the initial point correction for the combined sensor (yaw rate
CAUSE sensor part) cannot be performed due to the vehicle being continuously driven
on a curve, and does not indicate an DSC/RSC system malfunction.

PERFORM INITIALIZATION
PROCEDURE
 Perform the initialization

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procedure for the combined

sensor.
After the initialization procedure for the combined
1
(See DSC/RSC SENSOR sensor has been completed, go to the next step.
INITIALIZATION
PROCEDURE .)
VERIFY DTC
TROUBLESHOOTING
COMPLETED
 Clear the DTC from the memory. If the malfunction occurs again, replace the
Yes DSC/RSC HU/CM, then go to the next step.
2 (See ON-BOARD (See DSC/RSC HU/CM
DIAGNOSTIC [DSC/RSC].) REMOVAL/INSTALLATION .)
Start the engine and drive the


vehicle at 72 km/h {45 mph} or
more.

PROCEDURE Yes
DTC C1991 [DSC/RSC]

DTC C1991 DSC/RSC sensor (abnormal initialization) system
DETECTION  The DSC/RSC sensor detects that the initialization procedure has not
CONDITION been performed.
POSSIBLE CAUSE  The initialization procedure for the DSC/RSC sensor has not been
performed.

VERIFY INITIALIZATION Yes Go to the next step.
PROCEDURE.
1 Perform the DSC/RSC sensor initialization procedure,
 Has the DSC/RSC sensor No then go to the next step. (See DSC/RSC SENSOR
initialization procedure been INITIALIZATION PROCEDURE .)
performed?
VERIFY DTC
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TROUBLESHOOTING
COMPLETED
If the malfunction occurs again, replace the DSC/RSC
 Clear the DTC from the
Yes HU/CM, then go to the next step.
memory.
(See DSC/RSC HU/CM
2
(See ON-BOARD
DIAGNOSTIC
[DSC/RSC].)


PROCEDURE Yes
DTC U1901 [DSC/RSC]

DTC U1901 [DSC/RSC] DETECTION CONDITION AND POSSIBLE CAUSE
DTC U1901 Combined sensor system (CAN2 line malfunction)
DETECTION
 The signal from the combined sensor is not within specification.
CONDITION
 Open or short circuit in the CAN2_L wiring harness between combined sensor
terminal C and DSC/RSC HU/CM terminal M
 Open or short circuit in the CAN2_H wiring harness between combined sensor
POSSIBLE CAUSE terminal D and DSC/RSC HU/CM terminal P
 Combined sensor malfunction
 DSC/RSC HU/CM malfunction
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DTC U1901 [DSC/RSC] DIAGNOSTIC PROCEDURE

INSPECT COMBINED SENSOR SIGNAL
(CAN2 LINE) FOR OPEN CIRCUIT
 Disconnect the DSC/RSC HU/CM
connectors.
 Disconnect the combined sensor connectors.
 Inspect for continuity between the

1 DSC/RSC HU/CM connectors (vehicle
harness-side) and the following combined
sensor connector terminals (vehicle harness- No Repair or replace the wiring harness, then
side): go to Step 4.
 Combined sensor (CAN2_L): M-C
 Combined sensor (CAN2_H): P-D
INSPECT COMBINED SENSOR SIGNAL

(CAN2 LINE) FOR SHORT CIRCUIT Repair or replace the wiring harness, then
2 Yes
go to Step 4.
 Inspect for continuity between the following
DSC/RSC HU/CM connector terminals
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(vehicle harness-side) and body ground:

 Combined sensor (CAN2_L): M
 Combined sensor (CAN2_H): P
INSPECT THE COMBINED SENSOR Yes Go to the next step.

 Reconnect all disconnected connectors.
Inspect the combined sensor.
Replace the combined sensor, then go to
3
the next step.
(See COMBINED SENSOR No
(See COMBINED SENSOR
INSPECTION .)
Is the combined sensor normal?

VERIFY THAT THE SAME DTC IS NOT

PRESENT Repeat the inspection from Step 1.
If the malfunction recurs, replace the
 Clear the DTCs from the memory. DSC/RSC HU/CM, then go to the next
Yes
4 step.

5 [DSC/RSC].)
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2008 BRAKES Symptom Troubleshooting (DSC/RSC) - Mazda CX-9
2008 BRAKES
Symptom Troubleshooting (DSC/RSC) - Mazda CX-9
SYSTEM WIRING DIAGRAM [DSC/RSC]
Fig. 1: Brakes System Wiring Diagram (DSC/RSC)

FOREWORD [DSC/RSC]
 Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic Inspection.
To check the DTC, follow the DTC Inspection steps. (See ON-BOARD DIAGNOSIS [DSC/RSC] .)
PRECAUTION [DSC/RSC]
1. The ABS warning light and/or BRAKE system warning light and/or DSC indicator light and/or TCS OFF
light illuminate even when the system is normal.
PRECAUTION CHART [DSC/RSC]

Warning lights
Conditions under
that may Condition under which the ABS, EBD, TCS, DSC, and
which the light will
illuminate light may illuminate RSC control
go out
and/or flash
Under any of the following  ABS: Disables control.

conditions:  EBD:
 When the front wheels are

jacked up, stuck, or placed 1. Disable control, in cases
on a chassis roller, and where the light may
only the front wheel ABS illuminate, only when
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wheel speed sensors are DSC/RSC HU/CM

spun for 20 s or more. detects that wheel speed
sensors determine that
Parking brake is not fully After turning two or more wheels are
 ABS released while driving. malfunctioning.
warning ignition switch off,
Brake drag. vehicle is driven at 2. Enables control, if wheel
light
speed greater than speed sensors determine
 BRAKE Sudden 10 km/h {6.2 mph} three or more wheels are
system acceleration/deceleration. and normal functioning correctly.
warning operation is
light Left/right or front/rear tires are confirmed.
 DSC different. (Size, radius, tire TCS: Disables control.

indicator pressure, or wear is other than  DSC: Disables control.
light that listed on tire label.)
 RSC: Disables control.
 TCS OFF
ABS: Disables control.
light
Battery voltage at DSC/RSC Battery voltage rises EBD: Enables control.
HU/CM ignition terminal drops above approx. 10 TCS: Disables control.
below approx. 10 V. V. DSC: Disables control.
RSC: Disables control.
ABS: Enables control.
 Brake Brake fluid level
EBD: Enables control.
system lower than
Brake fluid amount is low. TCS: Enables control.
warning recommended
DSC: Disables control.
light amount.
RSC: Disables control.
2. Precautions during servicing of DSC/RSC
The DSC/RSC is composed of electrical and mechanical parts. It is necessary to categorize malfunctions
as being either electrical or hydraulic when performing troubleshooting.
1. Malfunction in electrical system

 The control module has an on-board diagnostic function. With this function, the ABS
warning light and/or BRAKE system warning light and/or DSC indicator light and/or TCS
OFF light will illuminate when there is a problem in the electrical system.
Also, past and present malfunctions are in the control module. This function can find
malfunctions that do not occur during periodic inspections. Connect the M-MDS to the DLC-
2, the stored malfunctions will be displayed in the order of occurrence. To find out the causes
of DSC/RSC malfunctions, use these on-board diagnostic results.
 If a malfunction occurred in the past but is now normal, the cause is likely a temporary poor
connection of the wiring harness.
The control module usually operates normally. Be careful when searching for the cause of
malfunction.
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 After repair, it is necessary to clear the DTC from the control module memory.
Also, if the DSC/RSC related parts have been replaced, verify that no DTC is displayed after
repairs.
 After repairing the ABS wheel-speed sensor or ABS sensor rotor, or after replacing the
control module, the ABS warning light may not go out even when the ignition switch is
turned to the ON position. In this case, drive the vehicle at a speed of more than 10 km/h
{6.2 mph} , make sure the ABS warning light goes out, and then clear the DTC.
 When repairing, if the DSC/RSC related connectors are disconnected and the ignition switch
is turned to the ON position, the control module will mistakenly detect a fault and record it as
a malfunction.
WARNING:  If the DSC/RSC sensor initialization procedure is not

completed, it could result in an unexpected accident due
to the DSC/RSC being inoperative. Therefore, after the
DSC/RSC HU/CM or combined sensor is replaced, always
perform the DSC/RSC sensor initialization precedure to
ensure proper DSC/RSC operation. (See DSC/RSC
SENSOR INITIALIZATION PROCEDURE .)
To protect the control module, make sure the ignition is off before connecting or
disconnecting the control module connector.
2. Malfunctions in hydraulic system
 Symptoms in a hydraulic system malfunction are similar to those in a conventional brake
malfunction. However, it is necessary to determine if the malfunction is in a DSC/RSC
component or the conventional brake system.
 The hydraulic unit contains delicate mechanical parts. If foreign material gets into the
component, the DSC/RSC may fail to operate. Also, it will likely become extremely difficult
to find the location of the malfunction in the event that the brakes operate but the DSC/RSC
does not. Make sure foreign material does not enter when servicing the DSC/RSC (e.g. brake
fluid replacement, pipe removal).
INTERMITTENT CONCERN TROUBLESHOOTING
Vibration method
 If a malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating,
perform the following steps.
NOTE:  There are several reasons why vehicle or engine vibration could
cause an electrical malfunction. Inspect the following:
 Connectors not fully seated.
 Wire harnesses not having full play.
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 Wires laying across brackets or moving parts.

 Wires routed too close to hot parts.
 An improperly routed, improperly clamped, or loose harness can

cause wiring to become pinched between parts.
 The connector joints, points of vibration, and places where wiring
harnesses pass through the firewall, body and other panels are the
major areas to be inspected.
Inspection method for switch connectors or wires
1. Connect the M-MDS to DLC-2.

2. Turn the ignition switch to the ON position (engine off).
NOTE:  If the engine starts and runs, perform the following steps at idle.
3. Access PIDs for the switch you are inspecting.

4. Turn the switch on manually.
5. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID.
 If the PID value is unstable, inspect for poor connection.

Inspection method for sensor connectors or wires

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 If the PID value is unstable, inspect for poor connection.
Fig. 3: Shaking Connector Or Wiring Harness

Inspection method for sensors

NOTE:  If engine starts and runs, perform the following steps at idle.

4. Vibrate the sensor slightly with your finger.
 If the PID value is unstable or a malfunction occurs, inspect for poor connection and/or poorly
mounted sensor.
Malfunction data monitor method
1. Perform the malfunction reappearance test according to malfunction reappearance mode and malfunction
data monitor. The malfunction cause is found in the malfunction data.
Inspection method for connector terminal
1. Inspect the connection condition of each female terminal.

2. Insert the male terminal, and fit the female terminal side to female terminal. Inspect if the malfunction is
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in the female terminal.
Fig. 4: Inspecting Connection

SYMPTOM TROUBLESHOOTING [DSC/RSC]

 Verify the symptoms, and perform troubleshooting according to the appropriate number.
SYMPTOM TROUBLESHOOTING [DSC/RSC]

No. Symptom
Any of the following lights do not illuminate when the ignition switch is turned to the ON position.
 ABS warning light

1  BRAKE system warning light
 DSC indicator light
 TCS OFF light
Any of the following lights remain on:
ABS warning light.


2  BRAKE system warning light
 DSC indicator light
 TCS OFF light
There is a malfunction in the system even though ABS warning light, BRAKE system warning light,
3
DSC indicator light and TCS OFF light do not illuminate.
ABS or TCS(1) operates frequently.
4
TCS does not work correctly.
DSC(1) operates frequently.
5
DSC does not work correctly.
RSC(1) operates frequently.
6
RSC does not work correctly.
(1) DSC/RSC system contains traction control, dynamic stability control and roll stability control
function; DSC indicator light illuminates and goes out while DSC/RSC is operating.
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Fig. 5: Symptom Troubleshooting Chart

NO.1 ANY OF THE FOLLOWING LIGHTS DO NOT ILLUMINATE WHEN

IGNITION SWITCH TURNED TO ON POSITION: (ABS WARNING LIGHT,
BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR TCS
OFF LIGHT) [DSC/RSC]
TROUBLESHOOTING CHART
Any of the following lights do not illuminate when the ignition switch is turned to the ON
1 position: (ABS warning light, BRAKE system warning light, DSC indicator light and/or TCS
OFF light).
[TROUBLESHOOTING HINTS]
 Inspect each light in the instrument cluster for malfunction

 Poor connection at DSC/RSC HU/CM connector
INSPECT FOR DTCS IN DSC/RSC
HU/CM Perform the applicable DTC inspection. (See
Yes
ON-BOARD DIAGNOSIS [DSC/RSC] .)
1 Inspect the DTC for the ON-BOARD
DIAGNOSTIC SYSTEM.
 Have DTCs been stored in memory?
INSPECT WHETHER MALFUNCTION

IS IN INSTRUMENT CLUSTER Yes Go to the next step.
SYSTEM OR OTHER SYSTEM
2
 Do other warning and indicator lights No Inspect or repair the instrument cluster (power
illuminate when the ignition switch is supply system, ground system).
turned to the ON position?
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VERIFY THAT DSC/RSC HU/CM Yes Go to the next step.

3 Connect the DSC/RSC HU/CM connector
Is the DSC/RSC HU/CM securely

No
securely, then go to the next step.
connected?
VERIFY THAT DSC/RSC HU/CM
CONNECTOR TERMINAL OR Yes Go to the next step.
RELATED CONNECTOR TERMINALS
ARE CONNECTED
4 Securely connect the DSC/RSC HU/CM
 Are DSC/RSC HU/CM connector No connector terminal and related connector
terminal, instrument cluster connector terminals.
terminal, or related connector terminals
securely connected?
INSPECT INSTRUMENT CLUSTER Replace the DSC/RSC HU/CM. (see DSC/RSC
Yes
HU/CM REMOVAL/INSTALLATION .)
 Inspect the instrument cluster. (See
5 ON-BOARD DIAGNOSIS Replace the instrument cluster. (See
[DSC/RSC] .) No INSTRUMENT CLUSTER
 If the instrument cluster normal
NO.2 ANY OF THE FOLLOWING LIGHTS REMAIN ON: (ABS WARNING

LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR LIGHT AND/OR
TCS OFF LIGHT) [DSC/RSC]
Any of the following lights remain on: (ABS warning light, BRAKE system warning light, DSC
2
indicator light and/or TCS OFF light)
 Brake fluid amount is low

 Parking brake does not release
 No connection at DSC/RSC HU/CM connector
(When HU/CM connector is disconnected, ABS warning light and BRAKE system warning light
illuminate)
 DSC/RSC HU/CM detected malfunction (Input and output device malfunction)

 DSC/RSC HU/CM detects low voltage in power supply
 DSC/RSC HU/CM ground malfunction
(When DSC/RSC HU/CM ground is not securely connected, ABS warning light and BRAKE
system warning light illuminate but diagnostic trouble code does not displayed)
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 DSC/RSC HU/CM does not operate (DSC/RSC HU/CM malfunction)
INSPECT BRAKE FLUID AMOUNT AND
VERIFY THAT PARKING BRAKE Yes Go to the next step.
RELEASES
1
Add brake fluid or release parking brake
 Is the brake fluid amount normal? No
pedal.
 Is the parking brake pedal released?
INSPECT DTCS IN INSTRUMENT

CLUSTER Yes Go to the next step.
Inspect the DTC for the instrument


2 cluster ON-BOARD DIAGNOSTIC Inspect the instrument cluster. (See
SYSTEM. No INSTRUMENT CLUSTER
INSPECTION .)
 Has DTC U2064 been recorded in
memory?
INSPECT DTCS IN DSC/RSC HU/CM Perform inspection using appropriate DTC.
Yes (See ON-BOARD DIAGNOSIS
3 Inspect the DTC for the ON-BOARD [DSC/RSC] .)
DIAGNOSTIC SYSTEM.
 Have DTCs been stored in memory? No Go to the next step.
INSPECT WHETHER MALFUNCTION Temporary poor connection in control module
IS IN CONTROL MODULE connector.
CONNECTOR, TERMINAL OR OTHER Inspect DSC/RSC HU/CM connector, then go
Yes
4 to Step 7.
 Do the ABS warning light and BRAKE
Inspect DSC/RSC HU/CM connector terminal,
system warning light go out after 4 s then go to Step 8.
when the ignition switch is turned to the
ON position? No Go to the next step.
INSPECT BATTERY Inspect the battery and charging system.
5 (See BATTERY INSPECTION [MZI-3.7] .)
 Is the battery voltage normal?
No
(See GENERATOR INSPECTION [MZI-
3.7] .)
INSPECT CHARGING SYSTEM Yes Go to the next step.
Inspect the charging system (drive belt
6  Is the battery voltage normal with tension, generator, etc.).
electrical load (A/C, headlight, etc.) on No (See GENERATOR INSPECTION [MZI-
and engine idling? 3.7] .)
VERIFY THAT DSC/RSC HU/CM Yes Go to the next step.
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Connect the DSC/RSC HU/CM connector
7 No
Is the DSC/RSC HU/CM securely
 securely, then go to the next step.
connected?
VERIFY THAT DSC/RSC HU/CM
CONNECTOR TERMINAL OR Replace the DSC/RSC HU/CM. (See
RELATED CONNECTOR TERMINALS Yes DSC/RSC HU/CM
ARE CONNECTED REMOVAL/INSTALLATION .)
8
 Are the DSC/RSC HU/CM connector Securely connect the DSC/RSC HU/CM
terminal or instrument cluster connector No connector terminal and related connector
terminal etc. related connector terminals terminals.
securely connected?
NO.3 THERE IS A MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS

WARNING LIGHT, BRAKE SYSTEM WARNING LIGHT, DSC INDICATOR
LIGHT AND TCS OFF LIGHT DO NOT ILLUMINATE [DSC/RSC]
There is a malfunction in the system even though the ABS warning light, BRAKE system warning
3
light, DSC indicator light and TCS OFF light do not illuminate.
 There is a mechanical malfunction in system
INSPECT DSC/RSC HU/CM FOR DTCs Perform the applicable DTC
inspection.
Yes
1  Inspect the DTC for the ON-BOARD DIAGNOSTIC (See ON-BOARD DIAGNOSIS
SYSTEM. [DSC/RSC] .)
 Have DTCs been stored in memory? No Go to the next step.
INSPECT DSC/RSC SYSTEM Inspect the conventional brake
Yes
system.
2  Perform DSC/RSC system inspection. (See
DSC/RSC SYSTEM INSPECTION .) Repair or replace any
No
 Is the system normal?
malfunctioning part.
NO.4 ABS OR TCS OPERATES FREQUENTLY/TCS DOES NOT WORK

CORRECTLY [DSC/RSC]
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ABS or TCS* operates frequently./TCS* does not work correctly.

4 *: DSC/RSC system function contains traction control function; DSC indicator light goes on and
off while DSC/RSC is operating.
 There is a difference in size or air pressure between the front and rear tires
 Incorrect ABS wheel-speed signal is input to DSC/RSC HU/CM
 There is a malfunction in the engine control system (TCS malfunction)
 Tire problem (low or high air pressure, excessive wear, different grip level by four wheels)
INSPECT DTCS IN
DSC/RSC HU/CM
Perform the applicable DTC inspection.
Yes
Inspect the DTC for the
 (See ON-BOARD DIAGNOSIS [DSC/RSC] .)
1 ON-BOARD
DIAGNOSTIC
SYSTEM.
 Have DTCs been stored No Go to the next step.
in memory?
INSPECT TIRE SIZE AND
AIR PRESSURE Yes Go to the next step.
2 Inspect the tire size and


the air pressure.
 Are size and air pressure
No Replace with specified tires and adjust tire air pressure.
as specified?
INSPECT ABS WHEEL-
SPEED SENSOR OUTPUT Yes Go to the next step.
VALUE
 Inspect the output value

from the ABS wheel-
speed sensor.
3
No  ABS wheel-speed sensor installation inspection: Inspect
(See FRONT ABS WHEEL-
SPEED SENSOR the sensor for looseness and verify that it is securely
INSPECTION .) installed.
(See REAR ABS WHEEL-  Sensor rotor installation inspection: Inspect the sensor
SPEED SENSOR rotor for poor installation and chipping of sensor rotor
INSPECTION [2WD] .) teeth. (If sensor rotor is installed poorly, it may cause
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(See REAR ABS WHEEL- output of abnormal wave form at high speed.)
SPEED SENSOR
INSPECTION [AWD] .)
Is the output value


normal?
VERIFY THAT TIRE
CONDITION
Find malfunctioning part according to "INTERMITTENT
 Verify tire condition for Yes
CONCERN TROUBLESHOOTING".
following:
4  Wear
 Grip level
(different by four
wheels) No Adjust, repair or replace tire.
 Are tires condition okay?
NO.5 DSC OPERATES FREQUENTLY/DSC DOES NOT WORK CORRECTLY

[DSC/RSC]
DSC* operates frequently. /DSC* does not work correctly.
5 *: DSC/RSC system contains dynamic stability control function; DSC indicator light illuminates
and goes out and while DSC/RSC is operating.
 DSC/RSC HU/CM detected malfunction (input and output device malfunction)

 Poor installation of combined sensor and/or steering angle sensor
(If any of the above sensors are poorly installed, DSC/RSC may operate intermittently)
 When replacing the DSC/RSC HU/CM, or combined sensor, initialization is not performed.
(If initialization is not performed correctly, DSC/RSC may not work correctly)
INSPECT DSC/RSC HU/CM FOR DTCs Perform the applicable DTC inspection. (See
Yes
1 ON-BOARD DIAGNOSIS [DSC/RSC] .)
 Inspect the DTC for the ON-BOARD
DIAGNOSTIC SYSTEM.
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Have DTCs been recorded in memory? No

 Go to the next step.
VERIFY THAT EACH SENSOR IS
INSTALLED Yes Go to the next step.
2
Are the combined sensor and steering

No Install sensor securely.
angle sensor securely installed?
VERIFY THAT EACH SENSOR IS Yes Go to the next step.
INITIALIZED
*3 Perform initialization procedure. (See
Was initialization performed after

No DSC/RSC SENSOR INITIALIZATION
replacement of the DSC/RSC HU/CM, PROCEDURE .)
or combined sensor?
VERIFY THAT TIRE CONDITION
 Verify tire condition for following: Find malfunctioning part according to

Yes "INTERMITTENT CONCERN
 Air pressure
4 TROUBLESHOOTING".
 Wear
 Grip level (different by four

wheels)
No Adjust, repair or replace tire.
 Are tires condition okay?
NO.6 RSC OPERATES FREQUENTLY/RSC DOES NOT WORK CORRECTRY

[DSC/RSC]
RSC* operates frequently/RSC* does not work correctly
6 *: DSC/RSC system contains roll stability control function; DSC indicator light illuminates and
goes out and while DSC/RSC is operating.
 DSC/RSC HU/CM detected malfunction (input and out put devise malfunction)
 Poor installation of combined sensor and/or steering angel sensor (If any of the above sensors are
poorly installed, DSC/RSC may operate intermittently)
 When replacing the DSC/RSC HU/CM, or combined sensor, initialization is not performed (If
initialization is not performed correctly, DSC/RSC may not work correctly)
 Tire problem (low or high air pressure, excessive tire wear, different grip level for four wheels)
 Poor installation or malfunction suspension parts (shock absorber, stabilizer)
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INSPECT DTC IN DSC/RSC HU/CM Perform the applicable DTC inspection (See
Yes
1 Inspect DTC for the ON-BOARD

DIAGNOSTIC SYSTEM. No Go to the next step.
 Have DTCs been stored in memory?
VERIFY THAT EACH SENSOR IS

INSTALLED Yes Go to the next step.
2
Are the combined sensor and steering

No Install the suspect sensor securely.
angle sensor securely installed?
VERIFY EACH SENSOR IS Yes Go to the next step.
INITIALIZED
3 Perform initialization procedure. (See
Was initialized performed after

No DSC/RSC SENSOR INITIALIZATION
replacement of the DSC/RSC HU/CM PROCEDURE .)
or combined sensor?
VERIFY THAT TIRE CONDITION
 Verify tire condition for following: Yes Go to the next step.
4  Air pressure
 Wear
 Grip level (different by four wheels)
No Adjust, repair or replace suspect tire.
 Are tires conditions okay?

Inspect the following suspension part:
VERIFY SUSPENTION PART
Yes  Shock absorber
5  Verify vehicle posture.
 Stabilizer
 Is there an inclination in the posture of
the vehicle right and left, left and rear? Find malfunctioning part according to
No
"intermittent concern troubleshooting".
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2008 BRAKES General Procedures (Brakes) - Mazda CX-9
2008 BRAKES
General Procedures (Brakes) - Mazda CX-9
GENERAL PROCEDURES(BRAKE)
WHEEL AND TIRE INSTALLATION
1. When installing the wheels and tires, tighten the wheel nuts in a criss-cross pattern to the following
tightening torque.
Tightening torque
107.8-147.0 N.m {11.0-14.9 Kgf.m, 79.6-108.4 ft.lbf}
Fig. 1: Identifying Wheel And Tire Nuts Tighten Sequence

BRAKE LINES DISCONNECTION
1. If any brake line has been disconnected during the procedures, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
CAUTION:  Brake fluid will damage painted surfaces. Be careful not to spill
any on painted surfaces. If it is spilled, wipe it off immediately.
BRAKE PIPE FLARE NUT TIGHTENING
1. Tighten the brake pipe flare nut using the commercially available flare nut wrench.
CONNECTOR DISCONNECTION
1. Disconnect the negative battery cable before performing any work that requires handling of connectors.
(See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
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2008 BRAKES General Procedures (Brakes) - Mazda CX-9
DSC/RSC RELATED PARTS
1. Make sure that there are no DTCs in the DSC/RSC memory after working on DSC/RSC related parts. If
there are any DTCs in the memory, clear them. (See ON-BOARD DIAGNOSIS [DSC/RSC] .)
DSC/RSC RELATED PART SENSOR INITIALIZATION PROCEDURE
WARNING:  If the initialization procedure is not completed, the DSC/RSC will not
operate properly and it might cause an unexpected accident.
Therefore, when replacing or removing the following parts, make
sure to perform the initialization procedure to insure proper RSC
operation.
1. When replacing or removing the following parts, perform the initialization procedure. (See DSC/RSC
SENSOR INITIALIZATION PROCEDURE .)
 DSC/RSC HU/CM
 Combined sensor
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2008 BRAKES Technical Data (Brakes) - Mazda CX-9
2008 BRAKES
Technical Data (Brakes) - Mazda CX-9
BRAKES TECHNICAL DATA

BRAKES TECHNICAL DATA SPECIFICATION
Item Specification
SAE J1703, FMVSS 116
Brake fluid type
DOT-3
Brake pedal height (reference value) 206.3 mm {8.122 in}
Brake pedal play 2-5 mm {0.08-0.19 in}
Brake pedal-to-floor clearance (Brake pedal when depressed at 147 N {15.0
97.6 mm {3.84 in} or more
kgf, 33.0 lbf})
Front disc plate runout limit 0.05 mm {0.002 in}
Minimum front disc plate thickness 26 mm {1.03 in}
Minimum front disc plate thickness after machining using a brake lathe on-
26.8 mm {1.06 in}
vehicle
Minimum front disc pad thickness 2.0 mm {0.08 in}
Rear disc plate runout limit 0.05 mm {0.002 in}
Minimum rear disc plate thickness 16 mm {0.63 in}
Minimum rear disc plate thickness after machining using a brake lathe on-
16.8 mm {0.66 in}
vehicle
Minimum rear disc pad thickness 2.0 mm {0.08 in}
Parking brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf} 1-3 notches
Minimum parking brake shoe thickness 1.0 mm {0.04 in}
Maximum rear disc plate inner diameter 191.0 mm {7.52 in}
Master cylinder fluid pressure
MASTER CYLINDER FLUID PRESSURE REFERENCE CHART

Vacuum amount at o kPa (0 mmHg, 0 inHg}
Pedal force Fluid pressure
200 N {20.4 kgf, 44.9 lbt} 520 kPa {5.31 kgf/cm2 , 75.5 psi} or more
MASTER CYLINDER FLUID PRESSURE REFERENCE CHART

Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}
Pedal force Fluid pressure
200 N {20.4 kgf, 44.9 lbt} 9,000 kPa {91.78 kgf/cm2 , 1,306 psi} or more
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2008 BRAKES Conventional Brake System - Mazda CX-9
2008 BRAKES
Conventional Brake System - Mazda CX-9
CONVENTIONAL BRAKE SYSTEM LOCATION INDEX
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Fig. 1: Identifying Conventional Brake System Parts Location

AIR BLEEDING
CAUTION:  Brake fluid will damage painted surfaces. Be careful not to spill any
on painted surfaces. If it is spilled, wipe it off immediately.
NOTE:  Keep the fluid level in the reserve tank at 3/4 full or more during the air
bleeding.
 Begin air bleeding with the brake caliper that is furthest from the master
cylinder.
Brake fluid type SAE J1703, FMVSS 116 DOT-3
1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air
bleeding.
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal
down.
4. While the brake pedal is depressed, the other should loosen the bleeder screw using a commercially
available flare nut wrench, drain out any fluid containing air bubbles, and tighten the bleeder screw.
Tightening torque
Front: 5.9-9.8 N.m {61-99 kgf.cm, 53-86 in.lbf}
Rear: 6.9-9.8 N.m {71-99 kgf.cm, 61-86 in.lbf}
Fig. 2: Checking Brake Pedal

5. Repeat Steps 3 and 4 until no air bubbles are seen.
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6. Perform air bleeding as described in the above procedures for all brake calipers.
7. After air bleeding, inspect the following:
 Brake operation
 Fluid leakage
 Fluid level
BRAKE PEDAL INSPECTION

PEDAL HEIGHT INSPECTION
1. Measure the distance from the center of the upper surface of the pedal pad to the insulator and verify that
it is as specified.
 If not within the specification, inspect the following items and repair or replace the applicable part
if there is any malfunction.
 Power brake unit installation condition
 Deformation of or damage to the power brake unit fork
 Brake pedal installation condition
 Clevis pin wear
 If there is no malfunction in the above items, replace the brake pedal.
Brake pedal height (reference value) 206.3 mm {8.122 in}
Fig. 3: Identifying Pedal Height

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PEDAL PLAY INSPECTION
1. Pump the pedal several times to release the vacuum in the power brake unit.
2. Gently depress the pedal by hand and measure the pedal play.
 If not within the specification, inspect the wear of the clevis pin. Replace it if there is any
malfunction.
Brake pedal play 2-5 mm {0.08-0.19 in}
NOTE:  If there is no malfunction in the clevis pin, there is a possibility

that the power brake unit has some malfunction. Verify that
there are no malfunctions, and replace it if necessary.
PEDAL-TO-FLOOR CLEARANCE INSPECTION
1. Start the engine and depress the brake pedal with a force of 147 N {15.0 kgf, 33.0 lbf}.
2. Measure the distance from the center of the upper surface of the pedal pad to the floor covering and verify
that it is as specified.
 If it is less than the specification, inspect for air in the brake line.
Brake pedal-to-floor clearance (Brake pedal when depressed at 147 N {15.0 kgf, 33.0 lbf})
97.6 mm {3.84 in} or more
Fig. 4: Identifying Pedal-To-Floor Clearance

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BRAKE PEDAL REMOVAL/INSTALLATION
automatically adjusted to the correct amount when the brake switch
is inserted into the installation hole on the brake pedal and rotated to
fix in place. If the brake switch is not properly installed, the clearance
always verify that the brake pedal is properly installed and fully
released before installing the brake switch to the pedal.
 Once the brake switch clearance has automatically been adjusted, it
cannot be adjusted again. Therefore, replace the switch with a new
one when replacing the power brake unit or the pedal, or performing
any procedure that changes the pedal stroke.

Fig. 5: Identifying Brake Pedal Components & Torque Specifications

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BRAKE PEDAL REMOVAL NOTE
1. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE
2. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
3. Remove the windshield wiper motor. (See WINDSHIELD WIPER MOTOR
4. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION .)
5. Remove the decoration panel. (See DECORATION PANEL REMOVAL/INSTALLATION .)
6. Remove the front console box mat. (See FRONT CONSOLE BOX MAT
7. Remove the indicator panel. (See INDICATOR PANEL REMOVAL/INSTALLATION .)
8. Remove the front console box. (See FRONT CONSOLE BOX REMOVAL/INSTALLATION .)
9. Remove the dashboard under cover. (See DASHBOARD UNDER COVER
10. Remove the side wall. (See SIDE WALL REMOVAL/INSTALLATION .)
11. Remove the console panel. (See CONSOLE PANEL REMOVAL/INSTALLATION .)
12. Remove the console cover. (See CONSOLE COVER REMOVAL/INSTALLATION .)
13. Remove the console. (See CONSOLE REMOVAL/INSTALLATION .)
14. Remove the front scuff plate inner. (See FRONT SCUFF PLATE REMOVAL/INSTALLATION .)
15. Remove the front side trim. (See FRONT SIDE TRIM REMOVAL/INSTALLATION .)
16. Remove the hood release lever. (See HOOD LATCH AND RELEASE LEVER
17. Remove the lower panel. (See LOWER PANEL REMOVAL/INSTALLATION .)
18. Remove the Glove Compartment. (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)
19. Remove the a-pillar trim. (See A-PILLAR TRIM REMOVAL/INSTALLATION .)
20. Remove the dashboard installation bolts as shown in the figure.
CAUTION:  Bolt A cannot be removed from the body. For this reason, a front
obstructed by the bolt when the door is opened could cause it to
scratched. When opening a front door, verify that bolt A is inserte
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Fig. 6: Identifying Dashboard Bolts & Torque Specifications

21. Lift the dashboard upward and move it 20 mm {0.78 in} to the rear of the vehicle after the locator pin for
the dashboard member is in the position shown in the figure.
Fig. 7: Identifying Dashboard & Dashboard Member

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CAUTION:  If the dashboard is moved towards the vehicle rear excessively,

the wiring harness could be damaged. Mark the position and
verify the distance when moving the dashboard.
NOTE:  When verifying the position of the dashboard member, verify visually
with the locator pin from the underside of the dashboard.
22. Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with
the brake pedal arm. dashboard
23. Remove the brake pedal. member
Fig. 8: Identifying Dashboard Member & Locator Pin

BRAKE SWITCH INSTALLATION NOTE
1. Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

2. With the brake pedal fully released, insert a new brake switch into the installation hole on the lock unit.
3. Secure the brake switch by turning it clockwise 45°.
Fig. 9: Identifying Brake Switch & Lock Nut

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BRAKE SWITCH CONNECTOR INSTALLATION NOTE
1. Inspect the brake pedal. (See BRAKE PEDAL REMOVAL/INSTALLATION.)

2. With the brake pedal in its original position, install the brake switch to the brake switch connector.
BRAKE SWITCH INSPECTION
CAUTION:  Inspect the brake switch with it installed to the brake pedal,
otherwise the brake switch may not operate normally. If the brake
switch is removed from the brake pedal, replace the brake switch
with a new one.

 If not as indicated in the table, replace the brake switch.
Fig. 10: Connector Terminal Reference

Fig. 11: Identifying Brake Switch Connector

MASTER CYLINDER REMOVAL/INSTALLATION

1. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
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2. Remove the resonance chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-

3.7] .)
3. Remove the bolt and nut as shown in the figure, and move the vacuum pipe bracket.
6. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See AIR BLEEDING.)
Fig. 12: Identifying Vacuum Pipe Bracket, Bolt, Nut & Torque Specifications
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Fig. 13: Identifying Brake Fluid Level Sensor Connector, Brake Pipe, Master Cylinder Component,
Reverse Tank, O-Ring & Torque Specifications
BRAKE FLUID LEVEL SENSOR INSPECTION

1. Disconnect the brake fluid level sensor connector from the master cylinder.
2. Inspect for continuity according to fluid level between the brake fluid level sensor terminals.
 If not as indicated in the table, replace the No.1 reserve tank. (See MASTER CYLINDER

Fig. 15: Identifying Brake Fluid Level Sensor Connector Terminal

POWER BRAKE UNIT INSPECTION
NOTE:  The following inspection methods are simple inspection methods to judge
the function of the power brake unit.
 If there is any malfunction in the power brake unit, replace the power brake
unit as a single unit.
WITHOUT USING SST
Operation inspection
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1. With the engine stopped, pump the pedal a few times.

2. With the pedal depressed, start the engine.
3. If the pedal moves down slightly immediately after starting the engine, the unit is normal.
Vacuum function inspection

2. Stop the engine after driving the vehicle for 1-2 min.
3. Depress the pedal with normal force.
4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is normal.
 If a problem is found, inspect for, damage to or improper installation of the check valve and
vacuum hose. After repairing, inspect again.
Vacuum loss function inspection

2. Depress the pedal with normal force.
3. With the pedal depressed, stop the engine.
4. Hold the pedal depressed for approx. 30 s .
5. If the pedal height does not change during this time, the unit is normal.
USING SST
Pre-inspection preparation
1. Disconnect the brake pipe flare nut area using the commercially available flare nut wrench as shown in
the figure.
2. Remove the clamp and disconnect the brake hose.
Fig. 16: Identifying Clamp, Brake Hose & Brake Pipe

3. Install the SST to the brake pipe as shown in the figure.
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4. Bleed the brake line and the SSTs of air. Bleed the air form the SSTs using bleeder screw A.
5. Install the pedal force gauge to the brake pedal.
6. Connect the vacuum gauge to the vacuum line.
Fig. 17: Installing Brake Pipe To SST

Vacuum loss inspection

2. Depress the brake pedal with a force of 200 N {20.4 kgf, 44.9 lbf}.
3. Stop the engine when the vacuum gauge reading reaches 68 kPa {510 mmHg, 20.1 inHg} with the pedal
depressed.
4. With the engine off, observe the vacuum gauge for 15 s.
5. If the gauge has dropped 3.3 kPa {25 mmHg, 1.0 inHg} or less, the unit is normal.
Lack of hydraulic pressure inspection
1. If the pedal force and fluid pressure correlation is within the specification with the engine stopped and a
vacuum amount of 0 kPa {0 mmHg, 0 inHg}, the system is normal.
MASTER CYLINDER FLUID PRESSURE SPECIFICATION

Vacuum amount at o kPa {0 mmHg, 0 inHg}
Pedal force (N {kgf, lbf}) Fluid pressure (kPa {kgf/cm2 , psi})
200 N {20.4 kgf, 44.9 lbt} 520 kPa {5.31 kgf/cm2 , 75.5 psi} or more
Hydraulic pressure inspection
1. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
2. At this time, apply the indicated pedal force and if the fluid pressure is within the specification, the unit is
normal.
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MASTER CYLINDER FLUID PRESSURE SPECIFICATION

Vacuum amount at 66.7 kPa {500 mmHg, 19.7 inHg}
Pedal force (N {kgf, lbf}) Fluid pressure (kPa {kgf/cm2 , psi})
200 N {20.4 kgf, 44.9 lbt} 9,000 kPa {91.78 kgf/cm2 , 1,306 psi} or more
After-inspection procedure
1. After the inspection, remove the SSTs, install the brake hose, clamp, and brake pipe to the original
positions, and then bleed the air from the brake line.
Fig. 18: Identifying Brake Pipe To Original Positions & Torque Specifications
POWER BRAKE UNIT REMOVAL/INSTALLATION

3.7] .)
4. Remove the cowl grill. (See COWL GRILLE REMOVAL/INSTALLATION .)
7. Remove the master cylinder component. (See MASTER CYLINDER REMOVAL/INSTALLATION.)
8. Remove the nuts as shown in the figure, and move the front heater pipe.
9. Remove the brake pipe (DSC/RSC HU/CM-master cylinder). (See DSC/RSC HU/CM
REMOVAL/INSTALLATION .).
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Fig. 19: Identifying Front Heater Pipe & Torque Specifications

10. Disconnect the brake pipe (DSC/RSC HU/CM side) as shown in the figure.
14. Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)
Fig. 20: Identifying Brake Pipe & Torque Specifications

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Fig. 21: Identifying Vacuum Hose, Snap Pin, Cleaves Pin, Power Brake Unit & Torque
Specifications
FRONT BRAKE (DISC) INSPECTION

BRAKE JUDDER REPAIR HINT
Description
Brake judder concern has the following three characteristics:
Steering wheel vibration
Steering wheel vibrates in the direction of its rotation. This characteristic is most noticeable when applying
brakes at a vehicle speed of 100-140 km/h {62-87 mph}.
Floor vibration
When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by
vehicle speed.
Brake pedal vibration
When applying brakes, a pulsating force tries to push the brake pad back. The pulsation is transmitted to the
brake pedal.
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The following are the main possible causes of brake judder:
Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.
If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge,
uneven wear occurs on the disc plate because of uneven pad/plate contact.
If the runout is less than 0.05 mm {0.002 in}, uneven wear does not occur.
The disc plate is deformed by heat.
Repeated panic braking may raise the temperature in some portions of disc plate by approx. 1,000 °C {1,832 °
F}.
This results in deformed disc plate.
Due to corrosion, the thickness and friction coefficient of disc plate change.
If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc
plate.
The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction
coefficient and causes a reaction force.
Inspection and repair procedure
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Fig. 22: Inspection & Repair Procedure Diagram

Lateral runout inspection
1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10
mm {0.39 in} with an inner diameter more than 12 mm {0.47 in}) between the hub bolt and the hub nut.
NOTE:  The component parts of the SST (49 B017 001 or 49 G019 003) can be
used as a suitable washer.
2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate
10 mm {0.39 in} from the disc plate edge.
3. Rotate the disc plate one time and measure the runout.
Front disc plate runout limit 0.05 mm {0.002 in}
Thickness variation inspection
1. Clean the disc plate-to-pad friction surface using a brake cleaner.
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2. Measure the points indicated in the illustration using a caliper (micrometer)

3. Subtract the minimum value from the maximum.
 If the result is not within specification, machine the disc plate using a lathe.
Thickness variation limit 0.015 mm {0.0005 in}
WARNING:  Do not exceed minimum disc plate thickness.
Fig. 23: Identifying Disc Plate Points

DISC PLATE THICKNESS INSPECTION
CAUTION:  Excessive runout may result if the disc plate is removed from the
vehicle then machined. Machine the disc plate while installed on the
vehicle.
1. Measure the thickness of the disc plate.

 If the thickness is not within the specification, replace the disc plate.
Minimum front disc plate thickness 26 mm {1.03 in}
Minimum front disc plate thickness after machining using a brake lathe on-vehicle 26.8 mm
{1.06 in}
DISC PAD THICKNESS INSPECTION
1. Jack up the front of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Verify the remaining thickness of the pads.
 Replace the pads as a set: right and left wheels, if either one is at or less than the minimum
thickness.
Minimum front disc pad thickness 2.0 mm {0.08 in}

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Fig. 24: Locating Disc Pad Thickness

FRONT BRAKE (DISC) REMOVAL/INSTALLATION

4. After installation, depress the brake pedal a few times, rotate the wheel by hand, and verify that the brake
does not drag.
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Fig. 25: Identifying Front Brake Components (Disc) & Torque Specifications
CALIPER INSTALLATION NOTE
1. Push the piston fully inward using the SST.

2. Install the caliper.
Fig. 26: Identifying Wood Plate With SST

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DISC PAD (FRONT) REPLACEMENT

does not drag.
Fig. 27: Identifying Disc Pad Components (Front) & Torque Specifications
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY

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Fig. 28: Identifying Caliper Components (Front) & Torque Specifications

2. Assemble in the reverse order of removal.
PISTON DISASSEMBLY NOTE
WARNING:  When compressed air is blown into the caliper body, injury to a
finger or other part from pinching could result from the piston
springing up. When blowing in compressed air, do not place your
fingers between the piston and caliper body when performing the
work.
CAUTION:  The piston could be damaged if blown out with great force. Blow the
compressed air slowly to prevent the piston from suddenly popping
out.
1. Place the SST in the caliper, then blow compressed air through the hole to force the piston out of the
caliper.
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Fig. 29: Identifying SST In Caliper

REAR BRAKE (DISC) INSPECTION

BRAKE JUDDER REPAIR HINT
Description
Brake judder concern has the following three characteristics:
Steering wheel vibration
Steering wheel vibrates in the direction of its rotation. This characteristic is most noticeable when applying
brakes at a vehicle speed of 100-140 km/h {62-87 mph} .
Floor vibration
When applying brakes, the vehicle body shakes back and forth. The seriousness of shake is not influenced by
vehicle speed.
Brake pedal vibration
When applying brakes, a pulsating force tries to push the brake pad back. The pulsation is transmitted to the
brake pedal.
The following are the main possible causes of brake judder:
Due to an excessive runout (side-to-side wobble) of disc plate, the thickness of disc plate is uneven.
If the runout is more than 0.05 mm {0.002 in} at the position 10 mm {0.39 in} from the disc plate edge,
uneven wear occurs on the disc plate because of uneven pad/plate contact.
If the runout is less than 0.05 mm {0.002 in}, uneven wear does not occur.
The disc plate is deformed by heat.
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Repeated panic braking may raise the temperature in some portions of disc plate by approx. 1,000 °C {1,832 °
F}. This results in deformed disc plate.
Due to corrosion, the thickness and friction coefficient of disc plate change.
If a vehicle is parked under damp conditions for a long time, corrosion occurs on the friction surface of disc
plate.
The thickness of corrosion is uneven and sometimes appears like a wave pattern, which changes the friction
coefficient and causes a reaction force.
Inspection and repair procedure
Fig. 30: Inspection & Repair Procedure Diagram

Lateral runout inspection
1. To secure the disc plate and the hub, tighten the hub nuts upside down or insert a washer (thickness 10
mm {0.39 in} with an inner diameter more than 12 mm {0.47 in}) between the hub bolt and the hub nut.
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NOTE:  The component parts of the SST (49 B017 001 or 49 G019 003) can be
used as a suitable washer.
2. After tightening all the hub nuts to the same torque, put the dial gauge on the friction surface of disc plate
10 mm {0.39 in} from the disc plate edge.
3. Rotate the disc plate one time and measure the runout.
Rear disc plate runout limit 0.05 mm {0.002 in}
Thickness variation inspection
1. Clean the disc plate-to-pad friction surface using a brake cleaner.

2. Measure the points indicated in the illustration using a caliper (micrometer).
3. Subtract the minimum value from the maximum.
 If the result is not within specification, machine the disc plate using a lathe.
Thickness variation limit 0.015 mm {0.0005 in}
WARNING:  Do not exceed minimum disc plate thickness.
Fig. 31: Identifying Disc Plate Points

DISC PLATE THICKNESS INSPECTION
CAUTION:  Excessive runout may result if the disc plate is removed from the
vehicle then machined. Machine the disc plate while installed on the
vehicle.
1. Measure the thickness of the disc plate.

 If the thickness is not within the specification, replace the disc plate.
Minimum rear disc plate thickness 16 mm {0.63 in}
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Minimum rear disc plate thickness after machining using a brake lathe on-vehicle 16.8 mm
{0.66 in}
DISC PAD THICKNESS INSPECTION
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheels.
3. Verify the remaining thickness of the pads.
 Replace the pads as a set: right and left wheels, if either one is at or less than the minimum
thickness.
Minimum rear disc pad thickness 2.0 mm {0.08 in}
Fig. 32: Locating Disc Pad Thickness

REAR BRAKE (DISC) REMOVAL/INSTALLATION

4. After installation, do the following.
1. Depress the brake pedal a few times. Then verify that the brakes do not drag.
2. Inspect the parking brake pedal stroke. (See PARKING BRAKE INSPECTION .)
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Fig. 33: Identifying Rear Brake Components (Disc) & Torque Specifications
DISC PLATE REMOVAL NOTE
1. If any disc plate is difficult to remove, perform the following steps to remove it.
1. Insert a flathead screwdriver into the service hole and turn the adjuster in the direction of the arrow
to compress the parking brake shoe.
2. Remove the disc plate.
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Fig. 34: Removing Disc Plate

DISC PLATE, SCREW INSTALLATION NOTE
1. Install the disc plate and the screws.

2. Perform the following steps to adjust the shoe clearance after installing the disc plate and the screws.
to expand the parking brake shoe until the disc plate cannot rotate.
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Fig. 35: Installing Disc Plate & Screws

2. Return the adjuster 13-25 notches in the direction of the arrow.
NOTE:  Shoe clearance can be adjusted to 0.15 mm {0.006 in} by

returning the adjuster 15 notches.
3. Rotate the disc plate and make sure it does not drag.
Fig. 36: Adjusting Adjuster

CALIPER INSTALLATION NOTE
1. Push the piston fully inward using the SST.

2. Install the caliper.
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Fig. 37: Pushing Piston With SST

DISC PAD (REAR) REPLACEMENT

does not drag.
Fig. 38: Identifying Disc Pad (Rear) & Torque Specifications

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CALIPER (REAR) DISASSEMBLY/ASSEMBLY

Fig. 39: Identifying Caliper Sequence (Rear) & Torque Specifications

2. Assemble in the reverse order of removal.
PISTON DISASSEMBLY NOTE
WARNING:  When compressed air is blown into the caliper body, injury to a
finger or other part from pinching could result from the piston
springing up. When blowing in compressed air, do not place your
fingers between the piston and caliper body when performing the
work.
CAUTION:  The piston could be damaged if blown out with great force. Blow the
compressed air slowly to prevent the piston from suddenly popping
out.
1. Place a piece of wood in the caliper, then blow compressed air through the hole to force the piston out of
the caliper.
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Fig. 40: Compressing Air Piston Of Caliper

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CABIN AIR FILTERS Air Filter - CX-9
CABIN AIR FILTERS
Air Filter - CX-9
REMOVAL & INSTALLATION
NOTE: Manufacturer's terminology for this filter is Air Filter.
1. Remove the glove compartment service hole cover. See Fig. 1
Fig. 1: Identifying Glove Compartment Components

2. Remove cabin air filter cover. See Fig. 1. Remove cabin air filter. See Fig. 2.
Fig. 2: Removing Cabin Air Filter

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CABIN AIR FILTERS Air Filter - CX-9
3. Install the cabin air filter in reverse order of removal.
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2008 ENGINE Charging System (MZI-3.7) - Mazda CX-9
2008 ENGINE
Charging System (MZI-3.7) - Mazda CX-9
CHARGING SYSTEM LOCATION INDEX [MZI-3.7]
Fig. 1: Identifying Battery & Generator Location

BATTERY REMOVAL/INSTALLATION [MZI-3.7]

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Fig. 2: Identifying Battery Components & Torque Specifications

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

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BATTERY INSPECTION [MZI-3.7]
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.
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-
3.7].)
Battery electrolyte specific gravity [20 C {68 °F}]
1.22-1.29
BATTERY VOLTAGE
1. Inspect the battery as follows:
12.4 V or
Go to Step 3.
more
1 Measure the battery positive voltage.
Less than Go to the
12.4 V next step.
12.4 V or Go to the
more next step.
2 Quick charge for 30 min and recheck voltage.
Less than Replace the
12.4 V battery.
Yes Normal
Using the battery load tester, apply load current (see ) and record battery
3 Replace the
voltage after 15 s. Is voltage more than the specification? No
battery.
Battery load test current
80D26L(55): 195 A
Standard specification
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Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6
BACK-UP CURRENT
1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
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.
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 .
Battery back-up current (When the ignition switch is off, the ignition key is removed, and all doors
are closed.)
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-3.7]

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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.
1. Remove the battery and then place it in a pan of water.

2. Remove the battery filler caps.
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: Identifying Battery & Battery Charger

GENERATOR REMOVAL/INSTALLATION [MZI-3.7]
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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.

3. Remove the air cleaner and fresh air duct component. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the cooling fan component. (See COOLING FAN COMPONENT
5. Remove the front splash shield (RH).
6. Remove the generator and A/C drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-
3.7] .)
9. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7] .)
3.7] .)
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Fig. 5: Identifying Generator, Generator Connector, Lower Bolt & Torque Specifications
GENERATOR LOWER BOLT REMOVAL NOTE
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.
1. Fully loosen the generator lower bolt.
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Fig. 6: Identifying Notch

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-3.7]

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-3.7] .)
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

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3. Turn off all electrical loads.
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 Connector Terminal

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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value.

4. Connect a tester, which can read 120 A or more , between generator terminal B and the wiring harness.
6. Turn off all electrical loads.
8. Increase engine speed to 2,500 rpm .
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.
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}]
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1.8-2.2 ohm
Fig. 8: Measuring Resistance Between Slip Rings With Tester

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 & Core With Tester
Stator coil
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Fig. 10: Continuity Reference Chart

Fig. 11: Identifying Stator Coil Terminal

If there is any malfunction, replace the stator.


2. Verify that there is no continuity between the stator coil leads and core using a tester.
 If there is continuity, replace the stator coil.
Fig. 12: Measuring Continuity Between Stator Coil Leads

Brush
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1. Inspect brushes for wear.

 If any brush is worn almost to or beyond the limit, replace all of the brushes.
Generator brush length
Minimum: 5.0 mm {0.20 in}
Fig. 13: Identifying Brush Length

Brush spring
1. Measure the force of the brush spring using a spring pressure gauge.
2. Read the spring pressure gauge at the brush tip projection of 2 mm {0.079 in} .
 Replace the brush spring if necessary.
Generator brush spring force
Standard: 4.1-5.3 N {0.42-0.54 kgf, 0.92-1.19 lbf}
Minimum: 1.7 N {0.17 kgf, 0.38 lbf}
Fig. 14: Measuring Force Of Brush Spring With Spring Pressure Gauge
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Rectifier (Using an analog circuit tester)
1. Inspect for continuity of the diodes using an analog circuit tester.

 If not as specified, replace the rectifier.
Specification
CONTINUITY SPECIFICATION
Negative Positive Continuity
E Yes
P1, P2, P3, P4, P5, P6
B No
E No
P1, P2, P3, P4, P5, P6
B Yes
Fig. 15: Identifying Rectifier

Rectifier (Using a digital circuit tester)
1. Inspect for continuity of the diodes using a digital circuit tester.

 If not as specified, replace the rectifier.
Specification
CONTINUITY SPECIFICATION
Negative Positive Continuity
E No
P1, P2, P3, P4, P5, P6
B Yes
E Yes
P1, P2, P3, P4, P5, P6
B No
Bearing
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1. Inspect for abnormal noise, looseness, and sticking.

 Replace the bearing if necessary.
Fig. 16: Inspecting Bearing Looseness, & Sticking

GENERATOR DISASSEMBLY/ASSEMBLY [MZI-3.7]
CAUTION:  Melt the solder quickly, otherwise the diodes (rectifier) and regulator
will be damaged by excessive heat.

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Fig. 17: Identifying Generator Components & Torque Specifications

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2008 ENGINE Cooling System (MZI-3.7) - Mazda CX-9
2008 ENGINE
Cooling System (MZI-3.7) - Mazda CX-9
COOLING SYSTEM LOCATION INDEX [MZI-3.7]
Microsoft
Microsoft
Fig. 1: Identifying Cooling System Components Location

COOLING SYSTEM SERVICE WARNINGS [MZI-3.7]
WARNING:  Never remove the cooling system cap or loosen the radiator drain
plug while the engine is running, or when the engine and radiator are
hot. Scalding engine coolant and steam may shoot out and cause
serious injury. It may also damage the engine and cooling system.
 Turn off the engine and wait until it is cool. Even then, be very
careful when removing the cap. Wrap a thick cloth around it and
slowly turn it counterclockwise to the first stop. Step back while the
pressure escapes.
 When you are sure all the pressure is gone, press down on the cap
using the cloth, turn it, and remove it.
 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.
ENGINE COOLANT LEVEL INSPECTION [MZI-3.7]
pressure escapes.
NOTE:  If the "FL22" mark is shown on or near the cooling system cap, use FL22
type engine coolant.
 FL22 type engine coolant is shipped as a diluted solution. Use the solution
as is when replacing coolant.
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Fig. 2: Identifying Cooling System Cap Mark

1. Verify that the engine coolant level in the coolant reserve tank is between the F and L marks.
 If the engine coolant level is below the L mark, add engine coolant.
Fig. 3: Identifying Engine Coolant Level In Coolant Reserve Tank

ENGINE COOLANT PROTECTION INSPECTION [MZI-3.7]

1. Measure the engine coolant temperature and specific gravity using a thermometer and a hydrometer.
CAUTION:  Use engine coolant at a concentration that meets the

environmental conditions in which the vehicle is driven,
otherwise engine damage could occur.
 The engine has aluminum parts and must be protected by an
ethylene-glycol-based coolant to prevent corrosion and
freezing.
 Do not use coolants containing Alcohol, Methanol, Borate or
Silicate. These coolants could damage the cooling system.
 Use only soft (demineralized) water in the coolant mixture.
Water that contains minerals will cut down on the coolant's
effectiveness.
 Engine coolant damages paint. If engine coolant does get on a
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painted surface, rinse it off quickly.
NOTE:  If the "FL22" mark is shown on or near the cooling system cap, use
FL22 type engine coolant.
 FL22 type engine coolant is shipped as a diluted solution. Use the
solution as is when replacing coolant.

2. Determine the engine coolant protection level by referring to the graph shown in the figure.
 If the engine coolant protection level is not correct, add water or engine coolant.
Fig. 5: Specific Gravity And Coolant Temperature Graph

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ENGINE COOLANT REPLACEMENT [MZI-3.7]
pressure escapes.
CAUTION:  Use engine coolant at a concentration that meets the environmental

conditions in which the vehicle is driven, otherwise engine damage
could occur.
 The engine has aluminum parts and must be protected by an
ethylene-glycol-based coolant to prevent corrosion and freezing.
 Do not use coolants containing Alcohol, Methanol, Borate or Silicate.
These coolants could damage the cooling system.
 Use only soft (demineralized) water in the coolant mixture. Water that
contains minerals will cut down on the coolant's effectiveness.
 Engine coolant damages paint. If engine coolant does get on a
painted surface, rinse it off quickly.
NOTE:  If the "FL22" mark is shown on or near the cooling system cap, use FL22
type engine coolant.
 FL22 type engine coolant is shipped as a diluted solution. Use the solution
as is when replacing coolant.
Engine coolant capacity (approx. quantity)
Dual fan control module: 12.2 L {12.9 US qt, 10.7 Imp qt}
Single fan control module: 11.6 L {12.3 US qt, 10.2 Imp qt}
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1. Remove the cooling system cap.
Fig. 7: View Of Cooling System Cap

2. Remove the radiator drain plug and drain the engine coolant into a container.
3. Flush the cooling system with water until all traces of color are gone.
4. Let the system drain completely.
5. Tighten the radiator drain plug.
Tightening torque
1.5-2.4 N.m {15-25 kgf.cm, 13-12 in.lbf}
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Fig. 8: Identifying Radiator Drain Plug

6. Referring to the following chart, select the correct volume peroentage of the water and engine coolant.
Antifireeze solution mixture percentage (Execpt FLI22 type engine coolant)
WATER AND COOLANT VOLUME PERCENTAGE CHART

Volume percentage (%)
Engine coolant protection Gravity at 20°C {68°F}
Water Coolant
Above - 16°C {3°C} 65 35 1.057
Above - 26°C {-15°F} 55 45 1.072
Above -40°C {40°F} 45 55 1.086
7. Refill the engine coolant into the coolant reserve tank up to the F mark on the tank.
8. Install the cooling system cap.
CAUTION:  If the water temperature gauge mises too high, stop the engine
and decrease the engine coolant temperature to prevent
overtheating. Then, verify the malfunctionining part and repair
or replace it.
 If the engine coolant level in the coolant reserve tank is below
the L mark during engine coolant air bleeding operation, stop
the engine, and after the engine coolant temperature decreases,
add engine coolant. Then, resume the engine coolant air
bleeding operation.
9. Start the engine and warm up the engine by idling.

10. After the engine warms up, perform the following steps. AT this time, be careful of the engine coolant
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temperature to prevent overheating.
NOTE:  If the accelerator pedal is depressed confiously for a speciffed time,

the engine speed may decrease to the idle speed. This is does not
indicate a malfunction.
1.Run the engine at approx. 4,000 rpm for 1 min.

2.Run the engine at idle for 1 min.
3.Repeat steps (1), (2) approx. 2 times.
4.Operate the heater at the maximum temperature and airflow, and verify that hot air blows from
werit.
11. Stop the engine, and inspect the engine coolant level after the engine temperature decrease. If it is low,
repeat steps 7 - 10.
12. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.7].)
ENGINE COOLANT LEAKAGE INSPECTION [MZI-3.7]
pressure escapes.
1. Inspect the engine coolant level. (See ENGINE COOLANT LEVEL INSPECTION [MZI-3.7].)
2. Remove the cooling system cap.
3. Install the SST and a radiator cap tester to the coolant reserve tank filler port.
4. Apply pressure using the radiator cap tester.
CAUTION:
 Applying more than 122.6 kPa {1.25 kgf/cm2 , 17.8 psi} can
damage the hoses, fittings, and other components, and cause
leakage.
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Fig. 9: Applying Pressure With Radiator Cap Tester

Engine coolant leakage inspection pressure 122.6 kPa {1.25 kgf/cm2 , 17.8 psi} [1 min]
5. When pressurizing the cooling system, verify that the pressure is maintained.
 If the gauge needle drops, it may indicate water leakage. Repair or replace the applicable part.
COOLING SYSTEM CAP INSPECTION [MZI-3.7]
pressure escapes.
1. Clean the cooling system cap and the sealed part.

2. Inspect the cooling system cap for cracks or everted seal.
 If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a radiator cap tester.
4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure is held
stable for 10 s.
 If the pressure is not held stable, replace the cooling system cap.
Cooling system cap valve opening pressure 93.2-122.6 kPa {0.95-1.25 kgf/cm2 , 13.5-17.8 psi}
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Fig. 10: Holding Cooling System Cap

COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI-3.7]
pressure escapes.
1. Drain the engine coolant until the coolant reserve tank becomes empty. (See ENGINE COOLANT
REPLACEMENT [MZI-3.7].)
4. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7].)
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Fig. 11: Identifying Coolant Reserve Tank, Hose & Torque Specifications
RADIATOR REMOVAL/INSTALLATION [MZI-3.7]
pressure escapes.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7].)
REMOVAL/INSTALLATION [MZI-3.7].)
5. Disconnect the ATF oil cooler hose from the radiator.
7. Install in the reverse order of the removal:
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AW6AX-EL] .)
Fig. 12: Identifying Coolant Reserve Tank Hose, Lower Radiator Hose, Oil Collar Water Hose And
Upper Mount Rubber Bracket
UPPER MOUNT RUBBER BRACKET REMOVAL NOTE
CAUTION:  Do not apply force excessively and in the directions that are not
specified, otherwise the upper mount rubber bracket could be
damaged.
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1. Insert a flathead screwdriver into the upper mount rubber bracket notch.
Fig. 13: Removing Upper Mount Rubber Bracket Notch

2. Apply force in the direction shown by the arrow.
Fig. 14: Applying Force In Upper Mount Rubber Bracket Notch

RADIATOR REMOVAL NOTE
1. Remove the radiator from above the engine compartment.
THERMOSTAT REMOVAL/INSTALLATION [MZI-3.7]
pressure escapes.
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Fig. 15: Identifying Thermostat Cover, Thermostat & Torque Specifications

THERMOSTAT INSTALLATION NOTE
1. Install the thermostat into the thermostat case with the jiggle pin at the top.
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Fig. 16: Identifying Jiggle Pin

O-RING INSTALLATION NOTE
1. Clean and inspect the O-ring.

 Install a new O-ring if necessary.
2. Apply clean engine coolant to the O-ring.

3. Install the O-ring.
THERMOSTAT INSPECTION [MZI-3.7]

1. Inspect the thermostat for the following.
WARNING:  During inspection, the thermostat and water are extremely hot
and can cause severe burns. Do not touch the thermostat and
water.
 The valve should not open under normal temperature.

 Opening temperature and valve lift
 If there is a malfunction, replace the thermostat.
Thermostat initial-opening temperature 79.5-83.3°C {175.2-181.9°F}
Thermostat full-open temperature 94.5°C {202.1°F}
Thermostat full-open lift More than 8.1 mm {0.32 in}
WATER PUMP REMOVAL/INSTALLATION [MZI-3.7]
WARNING:  Fuel vapor is hazardous. It can very 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
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serious injures or death and damage. Fuel can also irritate skin and
eyes. To prevent this, always complete the "Fuel Line Safety
Procedure". (See BEFORE SERVICE PRECAUTION [MZI-3.7] .)
 Continuous exposure to USED engine oil has caused skin cancer in
laboratory mice. Protect your skin by washing with soap and water
immediately after working with engine oil.
NOTE:  The following procedure "WATER PUMP REMOVAL/INSTALLATION" is

performed after the engine and transaxle component is removed from the
vehicle.
1. Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZI-3.7] .)

2. Remove the engine and transaxle component. (See ENGINE REMOVAL/INSTALLATION [MZI-
3.7] .)
3. Secure the engine and transaxle component using a hoist and the SST .
4. Remove the dynamic chamber and throttle body as a single unit. (See INTAKE-AIR SYSTEM
5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZI-3.7] .)
6. Remove the dipstick.
7. Remove the power steering oil pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION
[MZI-3.7] .)
8. Remove the power steering oil pump. (See POWER STEERING OIL PUMP
9. Remove the timing chain component. (See TIMING CHAIN REMOVAL/INSTALLATION [MZI-
3.7] .)
12. Start the engine and:
1. Inspect the runout and contact on the pulley and belt.
2. Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
3. Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZI-3.7] .)
4. Engine accessories operation.
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Fig. 17: Lifting Engine With Engine Jack

13. Perform a road test.
Fig. 18: Identifying Upper Timing Chain Guide, Water Pump, Gasket & Torque Specifications
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UPPER TIMING CHAIN GUIDE (RH) REMOVAL NOTE
1. Loosen the upper timing chain guide (RH) bolt A.

2. Remove the upper timing chain guide (RH) bolt B.
Fig. 19: Identifying Upper Timing Chain Guide And Bolts

3. Move the upper timing chain guide (RH) as shown.

4. Retighten the bolt A.
Fig. 20: Identifying Upper Timing Chain Guide And Bolts

WATER PUMP REMOVAL NOTE
NOTE:  When the water pump is removed, the engine coolant may flow through
the cylinder block and penetrate the oil pan. To prevent the engine coolant
from accumulating in the oil pan, remove the oil pan drain plug before
removing the water pump.
1. Remove the oil pan drain plug.

2. To prevent engine coolant from penetrating the oil pan, line the cylinder block with plastic sheeting as
shown in the figure before removing the water pump.
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Fig. 21: Identifying Water Pump And Plastic Sheeting

WATER PUMP INSTALLATION NOTE
1. Tighten the water pump bolts in the order shown in the figure.
Tightening torque
8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
Fig. 22: Identifying Water Pump Bolts Tighten Sequence

COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZI-3.7]
pressure escapes.
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4. Remove the engine cover.
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Fig. 23: Identifying Cooling Fan Components With Torque Specification

ATF OIL COOLER PIPE REMOVAL NOTE
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1. Remove the ATF oil cooler pipe with the hoses still connected. Position the ATF oil cooler pipe so that it
is out of the way.
COOLING FAN COMPONENT REMOVAL NOTE
1. Remove the cooling fan component from above the engine compartment.
FAN MOTOR INSPECTION [MZI-3.7]

PART INSPECTION
1. Verify that the battery is fully charged. (See BATTERY INSPECTION [MZI-3.7] .)
2. Disconnect the cooling fan motor connector (fan control module side, 2 terminals).
3. Install a tester and battery to the cooling fan motor connector as shown in the figure.
4. Verify that each fan motors operate smoothly at the standard current.
 If there is any malfunction, replace the applicable part.
Cooling fan motor standard current [Single Fan Control Module]
No.1, No.2: 11.2-15.2 A
Cooling fan motor standard current [Dual Fan Control Module]
No.1, No.2: 17-23 A
Fig. 24: Identifying Cooling Fan Motor Connector

FAN CONTROL MODULE INSPECTION [MZI-3.7]
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2. Start and warm up the engine.
3. Monitor the engine coolant temperature with the M-MDS.
Fig. 25: Connecting M-MDS To DLC-2

4. Measure the voltage at terminal A of the fan control module connector (2 terminals) as shown in the
table.
 If not within the specification, inspect the input signals from the following parts.
 Cylinder Head Temperature (CHT) sensor
 Refrigerant pressure switch (middle)
Fig. 26: Identifying Fan Control Module Connector

Single fan control module
SINGLE FAN CONTROL MODULE RESULT REFERENCE

Inspection
Result
Condition A/C Engine coolant temp.
IG SW ON or idling OFF Less than 96°C {205°F} 0 V (Fan stops.)
Idling OFF 96-106°C {205-223°F} 4.11-10.29 V
Idling ON(1) 96-106°C {205-223°F} Approx. 6.4 V
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Idling OFF More than 106°C {223°F} B+
(1) Refrigerant pressure switch (middle) is off.
(2) Refrigerant pressure switch (middle) is on.
Dual fan control module
DUAL FAN CONTROL MODULE RESULT REFERENCE

Inspection
Result
Condition A/C Engine coolant temp.
IG SW ON or idling OFF Less than 96°C {205°F} 0 V (Fan stops.)
Idling OFF 96-106°C {205-223°F} 4.11-10.29 V
Idling OFF More than 106°C {223°F} B+
(1) Refrigerant pressure switch (middle) is off.
(2) Refrigerant pressure switch (middle) is on.
5. If all the above parts are normal, replace the fan control module.
Microsoft
2008 ACCESSORIES & BODY, CAB Cruise Control System (MZI-3.7) - Mazda CX-9
Cruise Control System (MZI-3.7) - Mazda CX-9
CRUISE CONTROL SWITCH INSPECTION [MZI-3.7]

2. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE
3. Disconnect the cruise control switch connector.
4. Inspect for resistance and continuity between the cruise control switch terminals using an ohmmeter.
 If not as specified, replace the cruise control switch.
Fig. 1: Switch Position Chart

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2008 ACCESSORIES & BODY, CAB Cruise Control System (MZI-3.7) - Mazda CX-9
Fig. 2: Checking Resistance And Continuity Between Cruise Control Switch Terminals With
Ohmmeter
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2008 DRIVELINE/AXLES Differential - Mazda CX-9
2008 DRIVELINE/AXLES
Differential - Mazda CX-9
REAR DIFFERENTIAL LOCATION INDEX
Fig. 1: Identifying Rear Differential Components

DIFFERENTIAL OIL INSPECTION

2. Remove the filler plug and washer.
3. Verify that the oil is at the brim of the filler plug hole.
4. If it is low, add the specified oil.
5. Install a new washer and the filler plug, and tighten.
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Fig. 2: Identifying Filler Plug & Washer

Tightening torque 39.2-53.9 N.m {4.0-5.4 kgf.m, 29.0-39.7 ft.lbf}
DIFFERENTIAL OIL REPLACEMENT

2. Remove the filler plug.
3. Remove the drain plug and drain the differential oil into a container.
4. Install a new washer and the drain plug, and tighten.
Fig. 3: Identifying Filler Plug & Drain Plug

5. Add the specified differential oil from the filler plug until the level reaches the brim of the plug hole.
Rear differential oil
Specified oil grade: API service GL-5
Specified oil viscosity: SAE 80W-90
Capacity (approximate quantity): 1.0 L {1.1 US qt, 0.9 Imp qt}

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6. After filling with differential oil, perform oil level inspection.

OIL SEAL (SIDE GEAR) REPLACEMENT

1. Remove the drain plug and the drain differential oil into a container.
3. Remove the rear lateral link. (See REAR LATERAL LINK REMOVAL/INSTALLATION .)
4. Remove the rear coil spring. (See REAR COIL SPRING REMOVAL/INSTALLATION .)
5. Remove the rear lower arm. (See REAR LOWER ARM REMOVAL/INSTALLATION .)
6. Remove the rear trailing link and rear wheel hub component. (See WHEEL HUB COMPONENT
7. Remove the rear drive shaft. (See REAR DRIVE SHAFT REMOVAL/INSTALLATION .)
8. Remove the clip from the drive shaft.
CAUTION:  Wrap the end of a screwdriver with cloth to prevent scratches to

the inside of the differential casing.
9. Remove the oil seal from the differential casing using a screwdriver.
10. Apply differential oil to the new oil seal lip.

11. Install the new oil seal to the differential carrier using the SSTs.
Substitution SST
 49 G030 796

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12. After installing the new clip onto the drive shaft, insert the drive shaft into the differential. (See REAR
DRIVE SHAFT REMOVAL/INSTALLATION .)
13. Verify that the drive shaft cannot be pulled out.
15. Add the specified differential oil.
16. After adding the oil, perform an oil level inspection. (See DIFFERENTIAL OIL INSPECTION.)
17. Install a new washer and the oil filler plug, and tighten.
Fig. 5: Installing Washer & Oil Filler Plug

18. Inspect the rear wheel alignment and adjust it if necessary. (See REAR WHEEL ALIGNMENT
[AWD] .)
OIL SEAL (COMPANION FLANGE) REPLACEMENT

1. Drain the differential oil into a container.
2. Remove the presilencer installation nuts. (Middle pipe side) (See EXHAUST SYSTEM
3. Disconnect the hanger rubber as shown in the figure.
4. Suspend the presilencer using a cable.
5. Remove the presilencer insulator.
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Fig. 6: Identifying Hanger Rubber, Presilencer Insulator & Torque Specifications

7. Remove the locknut using the SST and a pipe.

8. Support the differential using a jack.
Fig. 7: Removing Locknut

9. After removing the front side of the differential mount, gradually lower the jack and tilt the front side of
the differential downward.
Fig. 8: Jack & Tilt Front Side Of Differential Downward

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10. Pull the companion flange off using the SST.

11. Remove the oil seal from the differential carrier using a screwdriver or similar tool.
Fig. 9: Removing Oil Seal From Differential Carrier

13. Install the new oil seal to the differential carrier using the SST.
Substitution SST
 49 W011 102
Inner diameter: 54-60 mm {2.13-2.36 in} or more
14. Install the companion flange to the drive pinion.

15. Jack up the differential and install the front side of the differential mount.
Fig. 10: Installing Oil Seal To Differential Carrier

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Tightening torque 63-85 N.m {6.5-8.6 kgf.m, 47-62 ft.lbf}
16. Install the washer and a new locknut.

17. Tighten the locknut to the specified torque using the SST and a pipe.
18. Install the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION .)

19. Add the specified differential oil from the filler plug. (See DIFFERENTIAL OIL REPLACEMENT.)
Fig. 11: Tightening Locknut

REAR DIFFERENTIAL REMOVAL/INSTALLATION

1. Drain the rear differential oil into a container.
2. Remove the under guard (LH). (See CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID
VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the presilencer insulator. (See REFRIGERANT LINE REMOVAL/INSTALLATION .)
8. Add the specified rear differential oil. (See DIFFERENTIAL OIL REPLACEMENT.)
[AWD] .)
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Fig. 12: Identifying Rear Differential Components & Torque Specifications

LOCKNUT REMOVAL NOTE
1. Lock the hub by applying the brakes.

2. Knock the crimped portion of the locknut outward using a small chisel and a hammer.
3. Loosen the locknut.
4. Temporarily tighten the locknut.
CAUTION:  Do not remove the locknut when lowering the rear differential.
Otherwise, the rear drive shaft could fall and cause injury, or
damage the part.
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Fig. 13: Loosening Locknut

REAR DIFFERENTIAL COMPONENT REMOVAL NOTE
1. Detach clips as shown in the figure.
Fig. 14: Locating Clips

2. Position the SST on the driveshaft and secure the SST with tape as shown in the figure.
CAUTION:  Always secure the SST using tape because the SST may fall off
during the operation and cause injury.
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Fig. 15: Securing SST With Tape

3. Disconnect the rear drive shaft from the rear differential side using the SST and two bars.
Fig. 16: Disconnecting Rear Drive Shaft From Rear Differential Side
CAUTION:  When lowering the rear differential, be careful not to damage the
rear differential oil seal, rear drive shaft, and surrounding parts.

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5. Remove the rear drive shaft from the rear differential while lowering the rear differential gradually.
Fig. 18: Removing Rear Drive Shaft From Rear Differential

6. Suspend the drive shaft using a cable.
Fig. 19: Identifying Drive Shaft

REAR DIFFERENTIAL COMPONENT INSTALLATION NOTE
CAUTION:  When raising the rear differential, be careful not to damage the rear
differential oil seal, rear drive shaft, and surrounding parts.
1. Install the rear drive shaft to the rear differential while raising the rear differential gradually.
2. Jack up the rear drive shaft until it is horizontal and engage the rear drive shaft (differential side) and rear
differential by tapping the wheel side.
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Fig. 20: Jacking Up Rear Drive Shaft

REAR DIFFERENTIAL DISASSEMBLY

if the rear differential is in a tilted condition, the self-lock mechanism
could become inoperative. If the rear differential unexpectedly
rotates it could cause injury, therefore do not maintain the rear
differential in a tilted condition. When turning the rear differential,
grasp the rotation handle firmly.
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Fig. 21: View Of Rear Differential Components

REAR COVER DISASSEMBLY NOTE
1. Install the SSTs to the engine stand.
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Fig. 22: Identifying SSTs To Engine Stand

2. Install the rear differential to the SSTs.

3. Remove the rear cover using an oil seal cutter.

BEARING CAP DISASSEMBLY NOTE
1. Place alignment marks on the bearing cap and carrier.
Fig. 24: Identifying Alignment Marks On Bearing Cap & Carrier

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REAR DIFFERENTIAL COMPONENT DISASSEMBLY NOTE
1. Remove the rear differential component using the SSTs.

2. Mark or otherwise distinguish between the removed left and right adjusting shims, spacers and side
bearing outer races so that they are not mixed up at the time of reassembly.
Fig. 25: Removing Rear Differential Component

LOCKNUT DISASSEMBLY NOTE
1. Remove the locknut using the SSTs.
Fig. 26: Removing Locknut

DRIVE PINION DISASSEMBLY NOTE
1. Remove the drive pinion by lightly tapping with a copper hammer.
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Fig. 27: Removing Drive Pinion

BEARING INNER RACE (REAR BEARING) DISASSEMBLY NOTE
1. Remove the bearing inner races (rear bearing) using the SST and a press.
Fig. 28: Removing Bearing Inner Races

BEARING OUTER RACE DISASSEMBLY NOTE
1. Remove the bearing outer races using the 2 grooves in the carrier and alternately tapping the sides of the
races with a brass bar.
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Fig. 29: Removing Bearing Outer Races

RING GEAR DISASSEMBLY NOTE
1. Secure the gear case in a vice and remove the bolts.

2. Lightly tap around the ring gear using a plastic hammer to remove the ring gear from the gear case.
Fig. 30: Identifying Gear Case Bolts

SIDE BEARING INNER RACE DISASSEMBLY NOTE
NOTE:  Mark or otherwise distinguish between the left and right side bearings so
that they are not mixed up at the time of reassembly.
1. Remove the side bearing inner races from the gear case using the SST and a press.
Fig. 31: Removing Side Bearing Inner Races From Gear Case
REAR DIFFERENTIAL ASSEMBLY

if the rear differential is in a tilted condition, the self-lock mechanism
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could become inoperative. If the rear differential unexpectedly

rotates it could cause injury, therefore do not maintain the rear
differential in a tilted condition. When turning the rear differential,
grasp the rotation handle firmly.
NOTE:  Clean away the old sealant before applying the new sealant.
 Install the rear cover within 10 minutes after applying sealant.
 Allow the sealant to set at least 30 minutes after installation before filling
the differential with the specified oil.
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Fig. 32: View Of Rear Differential Components & Torque Specifications

SIDE BEARING INNER RACE ASSEMBLY NOTE
CAUTION:  Do not mix up the left and right side bearing inner races.
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1. Press the side bearing inner races into the gear case using the SSTs.
Substitution SST
 49 G030 338
Inner depth: 3 mm {0.12 in} or more
Fig. 33: Pressing Side Bearing Inner Races Into Gear Case
THRUST WASHER ASSEMBLY NOTE
1. Assemble the side gears, thrust washers and pinion gears to the gear case, then assemble the knock pin.
2. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.
3. Set a dial gauge to the pinion gear as indicated in the figure.
4. Secure one of the side gears.
5. Move the pinion gear and measure the backlash at the end of the pinion gear.
 If the backlash exceeds the standard, use the thrust washers to adjust.
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Fig. 34: Setting Dial Gauge To Pinion Gear

Rear differential backlash of pinion gear and side gear 0.1 mm {0.004 in} or less
Thrust washer thickness
THRUST WASHER THICKNESS SPECIFICATION

Identification mark Thickness
0 2.0 mm {0.079 in}
1 2.1 mm {0.083 in}
2 2.2 mm {0.086 in}
05 2.05 mm {0.081 in}
15 2.15 mm {0.084 in}
RING GEAR ASSEMBLY NOTE
CAUTION:  The differential gear and ring gear could be damaged if the ring gear
is installed with old thread-locking compound remaining on the bolt
threads. Before installing the ring gear, completely remove the old
thread-locking compound from the bolt threads.
1. Apply a small amount of thread-locking compound to each of points A on the back of the ring gear, and
bolt thread areas B (around the entire ring).
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Fig. 35: Identifying Thread-Locking Compound

Application amount
Back of ring gear:
Approx. 0.4 ml {0.4 cc, 0.02 cu in}
Ring gear bolt thread points:
Approx. 0.4 ml {0.4 cc, 0.02 cu in} (0.04 ml {0.04 cc, 0.002 cu in} to each point)
2. Align the marks placed on the ring gear case at the time of disassembly and tighten the bolts in diagonal
order.
Fig. 36: Identifying Ring Gear Case

BEARING OUTER RACE ASSEMBLY NOTE
1. Press in the bearing outer race using the SSTs and a press.
Substitution SST
 49 F027 007
 49 F027 004
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Fig. 37: Pressing Bearing Outer Race

SPACER, BEARING INNER RACE ASSEMBLY NOTE
Pinion height adjustment
NOTE:  Use the same spacer.

 Install the spacer with the chamfer on the SST side.
1. Assemble the spacer, the bearing inner race (rear bearing), and the SST O-ring to the SST (49 8531 565)
2. Insert the set assembled in Step 1 to the differential gear from the rear.
3. Assemble the bearing inner race (front bearing), SST (49 G027 005), companion flange, washer, and
locknut from the front of the differential gear.
4. Tighten the locknut to the extent that the SST (49 8531 565) can be turned by hand.
5. Place the SST (49 0305 555) on top of the SST (49 8531 565).
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6. Place the SST on the surface plate and set the dial indicator to zero.
Fig. 39: Placing SST On Surface Plate

7. Set the SST as shown in the figure.

8. Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is
installed in the carrier. Then measure the left and right side of the lower position.
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Fig. 40: Measuring Probe Of Dial Indicator

9. Add the two (left and right) values obtained by the measurements taken in Step 8 and then divide the total
by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of
the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value.
Rear differential pinion height -0.032-0.032 mm {-0.0012-0.0012 in}
Fig. 41: [Identifying Rear Differential Pinion Height]

NOTE:  For example, the measured results obtained at Step 8 and 9 are 0.06
mm {0.003 in} and 0.04 mm {0.002 in}, and the figure inscribed on the
end of the drive pinion is 2: ((0.06 mm {0.003 in}+0.04 mm {0.002 in}) /
2) - (2/100) = 0.03 mm {0.001 in} (pinion height adjustment value)
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Replace with a spacer 0.03 mm {0.001 in} thicker than the currently
used one. Spacer thickness is set at 0.015 mm {0.0006 in}
increments, therefore select the closest spacer thickness and
assemble.
 Install the spacer with the chamfer on the SST side.
Spacer thickness
SPACER THICKNESS SPECIFICATION

Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
08 3.08 {0.1213} 29 3.29 {0.1295}
09 3.095 {0.1219} 30 3.305 {0.1301}
11 3.11 {0.1224} 32 3.32 {0.1307}
12 3.125 {0.1230} 33 3.335 {0.1313}
14 3.14 {0.1236} 35 3.35 {0.1319}
15 3.155 {0.1242} 36 3.365 {0.1325}
17 3.17 {0.1248} 38 3.38 {0.1331}
18 3.185 {0.1254} 39 3.395 {0.1337}
20 3.20 {0.1260} 41 3.41 {0.1343}
21 3.215 {0.1266} 42 3.425 {0.1348}
23 3.23 {0.1272} 44 3.44 {0.1354}
24 3.245 {0.1278} 45 3.455 {0.1360}
26 3.26 {0.1283} 47 3.47 {0.1366}
27 3.275 {0.1289} - -
10. Assemble the spacer selected for the pinion height adjustment to the drive pinion.
11. Press the bearing inner race (rear bearing) into the drive pinion using the SSTs and a press.
Substitution SST
 49 V001 525
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Fig. 42: Pressing Bearing Inner Race

LOCKNUT ASSEMBLY NOTE
Drive pinion preload adjustment
1. Apply differential oil to a new locknut.

2. Assemble a new collapsible spacer, bearing inner race (front bearing), spacer and locknut to the drive
pinion, and temporarily tighten the locknut.
3. Turn the serrated part of the drive pinion by hand to seat the bearing.
4. Tighten the locknut temporarily tightened in Step 1 from the lower limit of the specified tightening torque
using the SSTs , and make this the specified preload.
 If the specified preload cannot be obtained within the specified tightening torque, replace the
collapsible spacer and inspect again.
Fig. 43: Tightening Drive Pinion Lock Nut

Rear differential drive pinion preload 1.3-1.8 N.m {13.3-18.2 kgf.cm, 11.5-15.9 in.lbf}
5. Crimp the locknut using a chisel and hammer.
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Fig. 44: Crimping Locknut

ADJUSTING SHIM ASSEMBLY NOTE
1. Assemble the differential carrier to the SSTs.

2. Assemble the spacer to the differential carrier.
3. Stack the side bearing outer race and gear case component on the surface plate as indicated in the figure,
and measure the height using a caliper and a ruler. This is value A.
Fig. 45: Measuring Height Using Caliper & Ruler

4. Measure the width of the installed differential in the differential carrier with the spacer installed.
This is value B.
5. The combined thickness of the left and right adjusting shims is obtained by the following formula.
C1 = B - A + 0.15 mm {0.006 in}
C2 = B - A + 0.44 mm {0.017 in}
6. If the combined thickness of the previously installed adjusting shims is between C1 and C2, use the shims
as they are.
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7. If the combined thickness of the previously installed adjusting shims is not between C1 and C2, or if the
adjusting shims have to be replaced, select two appropriate adjusting shims from the table below.
Fig. 46: Measuring Width Of Installed Differential

Adjusting shim thickness
ADJUSTING SHIM THICKNESS SPECIFICATION

Identification mark Thickness (mm {in}) Identification mark Thickness (mm {in})
350 3.50 {0.137} 410 4.10 {0.161}
355 3.55 {0.139} 415 4.15 {0.163}
360 3.60 {0.141} 420 4.20 {0.165}
365 3.65 {0.143} 425 4.25 {0.167}
370 3.70 {0.145} 430 4.30 {0.169}
375 3.75 {0.147} 435 4.35 {0.171}
380 3.80 {0.149} 440 4.40 {0.173}
385 3.85 {0.151} 445 4.45 {0.175}
390 3.90 {0.153} 450 4.50 {0.177}
395 3.95 {0.155} 455 4.55 {0.179}
400 4.00 {0.157} 460 4.60 {0.181}
405 4.05 {0.159} - -
CAUTION:  If adjusting shims are to be reused, do not mix up the left and
right shims.
 Do not mix up the left and right side bearing outer races and
spacers.
8. Assemble the selected adjusting shims to the differential carrier ring gear side, and the spacer to the
opposite side.
9. Assemble the differential and bearing outer race to the differential carrier.
10. Tap the selected adjusting shim between the spacer and the bearing race with a plastic hammer as shown
in the figure.
11. Align the bearing cap alignment marks to assemble the bearing cap, and temporarily tighten the bolts.
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12. Place the dial indicator so that the measuring probe contacts the top surface of one of the ring gear teeth
perpendicularly.
13. Secure the drive pinion and measure the backlash from when the ring gear moved.
Fig. 47: Tapping Adjusting Shim Between Spacer & Bearing Race
Rear differential backlash of drive pinion and ring gear
Standard: 0.09-0.11 mm {0.003-0.004 in}
Minimum value: 0.05 mm {0.002 in}
NOTE:  Measure the backlash at 4 locations around the ring gear. Make sure
one of the 4 locations is within specification, and the minimum value
for the 4 locations is 0.5 mm {0.002 in} or less.
14. If the backlash is not within the specification, adjust the gear case component by moving it in the axial
direction.
NOTE:  When moving the gear case component in the axial direction, replace
the adjusting shims. If the adjusting shim on the right side is
replaced with one that is 0.05 mm {0.002 in} thicker, replace the one
on the left with one that is 0.05 mm {0.002 in} thinner.
BEARING CAP ASSEMBLY NOTE
1. Align the bearing cap alignment marks to assemble the bearing cap.
Tightening torque 38-51 N.m {3.9-5.2 kgf.m, 28.1-37.0 ft.lbf}
2. Inspect the drive pinion and ring gear teeth contact points.
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Fig. 48: Aligning Bearing Cap Alignment Marks

1. Coat both surfaces of the ring gear uniformly with a thin red lead coating.
2. While rotating the ring gear back and forth by hand, rotate the drive pinion several times and
inspect the tooth contact.
3. Inspect the tooth contacts in four locations around the ring gear, and check that the tooth contacts
showing the red lead coating are the same as the pattern indicated in the figure.
 If the tooth contact is good, wipe off the red lead coating.
 If it is not good, adjust the pinion height, then adjust the backlash.
Fig. 49: Inspecting Tooth Contacts

4. If toe and flank contact appears as shown in the figure, replace the spacer with a thinner one, and
move the drive pinion outward.
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Fig. 50: Identifying Toe & Flank Contact

5. If heel and face contact appears as indicated in the figure, replace the spacer with a thicker one and
move the drive the pinion inward.
Fig. 51: Identifying Heel & Face Contact

REAR COVER ASSEMBLY NOTE
CAUTION:  Clean away the old sealant before applying the new sealant.
 Install the rear differential within 10 minutes after applying sealant.
 Allow the sealant to set at least 30 minutes after installation before
filling the differential with the specified oil.
1. Clean the alignment surface of the carrier and rear cover, and apply a thin coat of sealant.
2. Install the rear cover.

2. Assemble the oil seal using the SSTs.
Substitution SST
 49 G030 796

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Fig. 52: Assembling Oil Seal

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2008 BODY & ACCESSORIES Doors and Liftgate - Mazda CX-9
2008 BODY & ACCESSORIES
Doors and Liftgate - Mazda CX-9
DOOR AND LIFTGATE LOCATION INDEX
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Microsoft
Fig. 1: Identifying Door & Liftgate Components Location

FRONT DOOR REMOVAL/INSTALLATION

2. To remove the checker, remove the following parts:
1. Inner garnish (See INNER GARNISH REMOVAL/INSTALLATION .)
2. Front door trim (See FRONT DOOR TRIM REMOVAL/INSTALLATION .)
3. Front door speaker (See FRONT DOOR SPEAKER REMOVAL/INSTALLATION .)
3. To remove the front door hinges, remove the following parts:
2. Side cowl grille (See COWL GRILLE REMOVAL/INSTALLATION .)
3. Front bumper (See FRONT BUMPER REMOVAL/INSTALLATION .)
5. Sail garnish (See SAIL GARNISH REMOVAL/INSTALLATION .)
6. Front fender panel (See FRONT FENDER PANEL REMOVAL/INSTALLATION .)
Fig. 2: Identifying Front Door Components & Torque Specifications

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6. Adjust the front door. (See DOOR ADJUSTMENT.)
CONNECTOR REMOVAL NOTE
1. Pull down the lever in the direction of the arrow (1) and disconnect the connector in the direction of the
arrow (2).
Fig. 3: View Of Lever

REAR DOOR REMOVAL/INSTALLATION

1. To remove the checker, remove the following parts:
1. Inner sail garnish (See INNER SAIL GARNISH REMOVAL/INSTALLATION .)
2. Rear door trim (See REAR DOOR TRIM REMOVAL/INSTALLATION .)
3. Rear door speaker (See REAR DOOR SPEAKER REMOVAL/INSTALLATION .)
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Fig. 4: Identifying Rear Door Components & Torque Specifications


4. Adjust the front door. (See DOOR ADJUSTMENT.)
DOOR ADJUSTMENT
1. Loosen the door hinge installation bolts.
2. Adjust the gap and height difference to the standard range by moving the door back and forth, left and
right.
Clearance
a. 2.5-4.5 mm {0.10-0.17 in}

b. -1.0-1.0 mm {-0.03-0.03 in}
c. 3.0-6.0 mm {0.12-0.23 in}
d. -1.5-1.5 mm {-0.05-0.05 in}
3. Tighten the bolts or screws.
4. If the front door and rear door dose not open/close smoothly, loosen the door
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Fig. 5: Identifying Forth Door Gap Adjustment (Left And Right)

FRONT DOOR MODULE REMOVAL/INSTALLATION

1. Inner garnish (See INNER GARNISH REMOVAL/INSTALLATION )
2. Front door trim (See FRONT DOOR TRIM REMOVAL/INSTALLATION )
3. Front door speaker (See FRONT DOOR SPEAKER REMOVAL/INSTALLATION )
4. Front door glass (See FRONT DOOR GLASS REMOVAL/INSTALLATION )
3. Disconnect the power outer mirror connector.
4. Remove the clips securing the wiring harness shown in the figure and set the wiring harness out of the
way.
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Fig. 6: Identifying Front Door Module And Clip

5. Remove screws and fastener.

6. Remove the front door module.
Fig. 7: Identifying Front Door Module With Screws And Fastener

REAR DOOR MODULE REMOVAL/INSTALLATION

1. Inner sail garnish (See INNER SAIL GARNISH REMOVAL/INSTALLATION ).
4. Rear door glass (See REAR DOOR GLASS REMOVAL/INSTALLATION .)
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3. Remove the clips securing the wiring harness shown in the figure and set the wiring harness out of the
way.
Fig. 8: Identifying Rear Door Module And Clip

4. Remove screws and fastener.

5. Remove the rear door module.
Fig. 9: Identifying Rear Door Module With Screws And Fastener

LIFTGATE REMOVAL/INSTALLATION
WARNING:  When removing the stay damper, serious injury may occur if the stay
damper is removed without supporting the liftgate. Always perform
the procedure with at least another person.
CAUTION:  If replacing the rear window glass, leave the power liftgate (PLG)
unoperated for two days after the rear Window glass installation. If
the power liftgate (PLG) is operated automatically with the sealant
not hardened after the rear window glass installation, the liftgate may
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deform. It is recommended that you refrain from operating the power

liftgate (PLG) for seven days after the rear window glass installation.
Manual opening/closing will not cause liftgate deformation.

2. Disconnect the PLG arm. (Liftgate side) (Vehicles with PLG)
13. Liftgate upper trim (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION .)
14. Liftgate side trim (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION .)
15. Liftgate lower trim (See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
4. Pull down the headliner.
5. Disconnect the rear washer hose.
6. Disconnect the liftgate wiring harness connector.
7. Disconnect the stay damper band with using the flat blade screwdriver.
Fig. 10: Prying Stay Damper Band With Screwdriver

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Fig. 11: Identifying Stay Damper, Liftgate Hinge & Torque Specifications
9. If replacing with a new liftgate, the old rear window glass may be reinstalled if it is reuse able. If not,
install new rear window glass.(see REAR WINDOW GLASS INSTALLATION )
11. Adjust the liftgate. (See LIFTGATE ADJUSTMENT.)
LIFTGATE ADJUSTMENT
1. Measure the gap and height between the liftgate and the body.
2. Loosen the liftgate hinge installation bolts and adjust the gap by moving the liftgate.
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Fig. 12: Identifying Liftgate, Body Gap Adjustment & Torque Specifications
Clearance
a. 5.0-7.0 mm {0.19-0.27 in}

b. -2.0-0.0 mm {-0.08-0.00 in}
c. 1.8-6.8 mm {0.07-0.27 in}
d. -0.1-5.1 mm {-0.01-0.20 in}
e. 2.8-5.2 mm {0.11-0.20 in}
f. -0.2-2.2 mm {-0.01-0.08 in}
g. 1.5-6.5 mm {0.06-0.25 in}
h. -2.0-2.0 mm {0.08-0.08 in}
i. 4.0-8.0 mm {0.16-0.31 in}
3. Tighten the bolts or screws.
POWER LIFTGATE (PLG) ARM REMOVAL/INSTALLATION
NOTE:  If the negative battery cable is disconnected with the liftgate half opened,
the clutch cannot be disengaged resulting in difficulty in opening/closing
operation of the liftgate. Disconnect the negative battery cable with the
liftgate in the fully open/close position.
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2. Seat side box (LH) (See SEAT SIDE BOX REMOVAL/INSTALLATION .)
5. Third-row seat belt lower anchor installation bolt (LH) (See THIRD-ROW SEAT BELT
6. Rear scuff plate inner (LH) (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
7. Trunk side trim (LH) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
8. Roof side trim (LH) (See ROOF SIDE TRIM REMOVAL/INSTALLATION .)
9. Second-row seat belt upper anchor installation bolt (LH) (See SECOND-ROW SEAT BELT
10. C-pillar trim (LH) (See C-PILLAR TRIM REMOVAL/INSTALLATION .)
11. Third-row seat belt upper anchor installation bolt (LH) (See THIRD-ROW SEAT BELT
12. D-pillar trim (LH) (See D-PILLAR TRIM REMOVAL/INSTALLATION .)
3. Disconnect the PLG arm band with using the flat blade screwdriver.
4. Remove the PLG arm.
Fig. 13: Prying PLG Arm Band With Screwdriver

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POWER LIFTGATE (PLG) SLIDER REMOVAL/INSTALLATION

8. Roof side trim (LH) (See ROOF SIDE TRIM REMOVAL/INSTALLATION .)
9. Third-row seat belt upper anchor installation bolt (LH) (See THIRD-ROW SEAT BELT
10. D-pillar trim (LH) (See D-PILLAR TRIM REMOVAL/INSTALLATION .)
3. Disconnect the connection of the band that is on the PLG slider side of PLG arm with using the flat blade
screwdriver.
4. Put the PLG arm.
Fig. 14: Prying PLG Arm Band With Screwdriver

5. Revolve the outer joint in the direction of the arrow to disconnect from the PLG slider and the PLG drive
unit.
7. Remove the PLG slider.
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Fig. 15: View Of Outer Joint & Torque Specifications

POWER LIFTGATE (PLG) DRIVE UNIT REMOVAL/INSTALLATION

3. Revolve the outer joint in the direction of the arrow to disconnect from the PLG drive unit and the PLG
slider.
4. Disconnect the PLG drive unit connector.
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6. Remove the PLG drive unit.

Fig. 16: View Of PLG Drive Unit Connector & Torque Specifications
POWER LIFTGATE (PLG) CONTROL MODULE REMOVAL/INSTALLATION

3. Disconnect the PLG control module connector.
5. Remove the PLG control module.
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Fig. 17: Identifying PLG Control Module, Connector & Torque Specifications
POWER LIFTGATE (PLG) CONTROL MODULE INSPECTION

1. Measure the PLG control module terminal voltage.
2. If there is large difference between the measured value and the value in the terminal voltage table, inspect
the parts under "Inspection item(s)" and related wiring harnesses.
 If the system does not work properly even though the inspection items or related wiring harnesses
do not have any malfunction, replace the PLG control module.
Terminal Voltage Table (Reference)
Fig. 18: Identifying PLG Control Module Connector Terminal

CONNECTOR TERMINAL REFERENCE

Signal Voltage (V)/
Terminal Connected to Measurement condition Inspection item(s)
name Continuity
 Liftgate latch
and lock
Closure After opening the liftgate, actuator
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motor operate the closure motor  Latch

(Closed) with the liftgate half- position
1A Closure motor closed 0 --> B+ --> 0 switch
 Closure
motor
 Liftgate latch
and lock
actuator
 Latch
Closure
Open the fully closed position
1B motor Closure motor 0 --> B+ --> 0
liftgate by hand switch
(Open)
 Closure
motor
 Liftgate outer
handle switch
Power
1C PLG 20 A fuse Under any condition B+ PLG 20 A fuse
supply
1D GND Body ground Under any condition 1.0 or less  Related wiring
harnesses
PLG motor Open the fully closed
1E PLG motor 0 --> B+ --> 0 PLG drive unit
(Open) liftgate
PLG motor Close the fully opened
1F PLG motor 0 --> B+ --> 0 PLG drive unit
(Closed) liftgate
Ignition switch is at ON
B+
METER 10 A position
2A IG1 METER 10 A fuse
fuse Ignition switch is at LOCK
1.0 or less
or ACC position
When operating the PLG
PLG rear B+
PLG rear rear switch
2B switch PLG rear switch
switch When not operating the
signal 1.0 or less
PLG rear switch
When the PLG buzzer is
PLG buzzer B+
2C PLG buzzer sounding PLG buzzer
output
Other 1.0 or less
PLG touch  Related wiring
2D Body ground Under any condition 1.0 or less
sensor GND harnesses
When PLG is open or
Clutch 1.0 or less
2G PLG clutch closing PLG drive unit
output (-)
Other No Continuity
When PLG is open or
Clutch B+
2I PLG clutch closing PLG drive unit
output (+)
Other 1.0 or less
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PLG motor
Rotation
2J rotation Pulse signal - PLG drive unit
sensor
signal A
Rotation
Rotation
2K signal power Under any condition 5 PLG drive unit
sensor
source
PLG motor
Rotation
2L rotation Pulse signal - PLG drive unit
sensor
signal B
Rotation  Related wiring
2N Body ground Under any condition 1.0 or less
sensor GND harnesses
Power
2O BCM Under any condition B+ BCM
supply
When sensor is operating
PLG touch 0.5-4.2 or less
PLG touch normally (usually) PLG touch sensor
3A sensor
sensor (RH) Other than (RH)
signal (RH) When sensor is at fault
those above
When sensor is operating
PLG touch 0.5-4.2 or less
PLG touch normally (usually) PLG touch sensor
3B sensor
sensor (LH) Other than (LH)
signal (LH) When sensor is at fault
those above
Passenger seat side door is
locked. Check the Continuity
Passenger seat continuity with earth
Passenger seat side
3C Lock signal side lock link
Passenger seat side door is lock link switch
switch
unlocked. Check the No Continuity
continuity with earth
 Liftgate latch
After opening the liftgate,
and lock
Motor return operate the closure motor
3E Return switch 1.0 or less actuator
signal with the liftgate half-
closed  Return
switch
Liftgate is open (liftgate
Liftgate 1.0 or less
Liftgate latch latch switch is ON) Liftgate latch and lock
3F latch switch
switch Liftgate is closed (liftgate actuator
signal B+
latch switch is OFF)
 Liftgate latch
After opening the liftgate, and lock
1.0 or less --> actuator
Full latch Latch position operate the closure motor
3G B+ --> 1.0 or
switch switch with the liftgate half-  Latch
less
closed position
switch
 Closure
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motor
 Liftgate latch
and lock
After opening the liftgate, actuator
Half latch Latch position operate the closure motor 1.0 or less -->  Latch
3H
switch switch with the liftgate half- B+ position
closed switch
 Closure
motor
Passenger seat side door is
locked. Check the No Continuity
Passenger seat continuity with earth
Unlock Passenger seat side
3N(1) signal side lock link
lock link switch
switch Passenger seat side door is
unlocked. Check the Continuity
continuity with earth
When operating the
liftgate outer handle
B+
Liftgate (When the liftgate outer
outer handle Liftgate outer handle switch is ON) Liftgate outer handle
3O
switch handle switch When not operating the switch
signal liftgate outer handle
1.0 or less
(When the liftgate outer
handle switch is OFF)
PLG front PLG front switch: Switch
B+
switch PLG front is at ON
3Q PLG front switch
signal switch PLG front switch: Switch
(Input) 1.0 or less
is at OFF
Power PLG front switch: Open or
1.0 or less
supply to close switch is at ON
3R PLG switch PLG control module
PLG PLG front switch: Open or
switches B+
close switch is at OFF
3U CAN_L - communication, good/no good judgment -
by terminal voltage is not possible
3V CAN_H - communication, good/no good judgment -
by terminal voltage is not possible
(1) When checking the operation of UNLOCK signal, position the rear door lock knobs of both sides at
LOCK.
POWER LIFTGATE (PLG) TOUCH SENSOR REMOVAL/INSTALLATION

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2. PLG arm (See POWER LIFTGATE (PLG) DRIVE UNIT REMOVAL/INSTALLATION.)
3. Disconnect the PLG touch sensor connector.
5. Remove the PLG touch sensor.
Fig. 19: Identifying PLG Touch Sensor, Connector & Screw

POWER LIFTGATE (PLG) TOUCH SENSOR INSPECTION

1. Verify that the resistance is as indicated in the table.
 If no as indicated in the table, replace the PLG touch sensor.
Fig. 20: PLG Touch Sensor Resistance Chart

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Fig. 21: PLG Touch Sensor - Circuit Diagram

POWER LIFTGATE (PLG) FRONT SWITCH REMOVAL/INSTALLATION

2. Remove the dashboard under cover. (Driver's side) (See DASHBOARD UNDER COVER
Fig. 22: Identifying PLG Front Switch & Connector

POWER LIFTGATE (PLG) FRONT SWITCH INSPECTION

1. Verify that the continuity between the PLG front switch terminals is as indicated in the table.
 If not as indicated in the table, replace the PLG front switch.
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Fig. 23: PLG Front Switch Continuity Chart

Fig. 24: PLG Front Switch - Circuit Diagram

POWER LIFTGATE (PLG) REAR SWITCH REMOVAL/INSTALLATION

2. Remove the liftgate recess. (See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
3. Disconnect the connector from the PLG rear switch.
4. Remove the PLG rear switch from the recess.
Fig. 25: Identifying PLG Rear Switch & Connector

POWER LIFTGATE (PLG) REAR SWITCH INSPECTION

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1. Verify that the continuity between the PLG rear switch terminals is as indicated in the table.
 If not as indicated in the table, replace the PLG rear switch.
Fig. 26: PLG Rear Switch Continuity Chart

Fig. 27: PLG Rear Switch - Circuit Diagram

2. Apply battery voltage to PLG rear switch terminal A, and connect terminal B to ground.
3. Verify that the LED illuminates.
 If there is any malfunction, replace the PLG rear switch.
POWER LIFTGATE (PLG) BUZZER REMOVAL/INSTALLATION
CAUTION:  Do not remove the PLG buzzer except when replacing the PLG buzzer
because thread-locking compound has been applied to the screws.

2. PLG arm (See POWER LIFTGATE (PLG) DRIVE UNIT REMOVAL/INSTALLATION.)
3. Disconnect the PLG buzzer connector.
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4. Remove the bolt.

5. Remove the clip.
6. Remove the PLG buzzer.
Fig. 28: Identifying PLG Buzzer, Connector & Torque Specifications

POWER LIFTGATE (PLG) BUZZER INSPECTION

1. Connect the battery to the PLG buzzer and check if the PLG buzzer sounds.
 When the PLG buzzer does not sound, replace it.
Fig. 29: PLG Buzzer - Circuit Diagram

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 through the stay damper body using hacksaw.
4. Allow the gas to escape from the stay damper.
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5. Discard the stay damper.
Fig. 30: Cutting Stay Damper With Hacksaw

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2008 DRIVELINE/AXLES Drive Shaft - Mazda CX-9
2008 DRIVELINE/AXLES
Drive Shaft - Mazda CX-9
DRIVE SHAFT LOCATION INDEX
Fig. 1: Identifying Drive Shaft Component Location

FRONT DRIVE SHAFT PRE-INSPECTION

1. Inspect the dust boot on the drive shaft for cracks, damage, leaking grease, and looseness in the boot
band.
2. Inspect the drive shaft for bends, cracks, and wear in the joint or splines.
 Repair or replace the drive shaft or boot/band as necessary.
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Fig. 2: Locating Dust Boot

FRONT DRIVE SHAFT REMOVAL/INSTALLATION
CAUTION:  Performing the following procedures without first removing the ABS
wheel-speed sensor may possibly cause an open circuit in the
harness if it is pulled by mistake. Before performing the following
procedures, remove the ABS wheel-speed sensor (axle side) and fix it
to an appropriate place where the sensor will not be pulled by
mistake while the vehicle is being serviced.
1. Remove the side cover.

2. Remove the front ABS wheel-speed sensor. (See FRONT ABS WHEEL-SPEED SENSOR
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Fig. 3: Identifying Front Drive Shaft Components & Torque Specifications


3. Remove the locknut.
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Fig. 4: Tapping Locknut

FRONT DRIVE SHAFT REMOVAL NOTE
1. Install a spare nut onto the drive shaft so that the nut is flush with the end of the drive shaft.
2. Tap the nut with a copper hammer to loosen the drive shaft from the front wheel hub.
3. Separate the drive shaft from the wheel hub.
CAUTION:  The sharp edges of the drive shaft can slice or puncture the oil
seal. Be careful when removing the drive shaft from the
transaxle.
Fig. 5: Tapping Drive Shaft

4. Separate the left side drive shaft from the transaxle by prying with a bar inserted between the outer ring
and the transaxle, as shown in the figure.
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Fig. 6: Prying Dust Boot

5. Separate the right side drive shaft from the joint shaft by using the SSTs.
Fig. 7: Separating Right Side Drive Shaft

CLIP INSTALLATION NOTE
1. Install a new clip onto the drive shaft with the opening facing upward. Ensure that the diameter of the clip
does not exceed the specification on installation.
2. After installation, measure the outer diameter. If it exceeds the specification, repeat Steps 1-2 using a new
clip.
Clip outer diameter specification
LH: 34.0 mm {1.34 in}
RH (joint shaft): 34.0 mm {1.34 in}
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Fig. 8: Identifying Outer Diameter Clip

FRONT DRIVE SHAFT INSTALLATION NOTE
CAUTION:  The sharp edges of the drive shaft can slice or puncture the oil seal.
Be careful when installing the drive shaft to the transaxle.
 The oil seals are damaged easily if this procedure is not done
correctly.
Fig. 9: Identifying Front Drive Shaft Installation Position

Left side
1. Insert the drive shaft into the wheel hub.

2. Apply transaxle oil to the oil seal lip.
3. Push the drive shaft into the transaxle.
4. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held
by the clip.
Right side
1. Insert the drive shaft into the wheel hub.
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2. Insert the drive shaft into the joint shaft.

3. After installation, pull the transaxle side outer ring forward to confirm that the drive shaft is securely held
by the clip.
LOCKNUT INSTALLATION NOTE
1. Install a new locknut and stake it as shown.

FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY

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Fig. 11: Identifying Front Drive Shaft Components

BOOT BAND (WHEEL SIDE) DISASSEMBLY NOTE
NOTE:  The boot band does not need to be removed unless it is being replaced.
1. Remove the boot clamp with end clamp pliers as shown and discard the clamp.
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Fig. 12: Removing Boot Clamp With Clamp Pliers

BOOT BAND (TRANSAXLE SIDE) DISASSEMBLY NOTE
1. Pry up the locking clips using a screwdriver.

2. Pull back the end of the band.
Fig. 13: Prying Locking Clips

OUTER RING DISASSEMBLY NOTE
1. Mark the outer ring and the shaft for proper assembly.
Fig. 14: Aligning Mark Outer Ring And Shaft

2. Remove the clip.

3. Remove the outer ring.
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Fig. 15: Prying Outer Ring

SNAP RING, TRIPOD JOINT DISASSEMBLY NOTE
1. Mark the shaft and tripod joint for proper assembly.

2. Remove the snap ring using snap-ring pliers.
3. Remove the tripod joint from the shaft.
CAUTION:  Do not tap the tripod joint with a hammer.
Fig. 16: Removing Snap Ring With Snap-Ring Pliers

BOOT DISASSEMBLY NOTE
NOTE:  The wheel side boot does not need to be removed unless replacing it or
the ball joint and shaft component.
 Do not strip the tape until the boot is assembled.
1. Wrap the shaft splines with tape.

2. Remove the boot.
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Fig. 17: Identifying Shaft Splines With Tape

DYNAMIC DAMPER ASSEMBLY NOTE
1. Install the dynamic damper as shown in the figure.
Standard length 290.7-298.7 mm {11.45-11.75 in}
2. Install the new boot band onto the dynamic damper.
Fig. 18: Identifying Dynamic Damper Assembly Length

BOOT ASSEMBLY NOTE
NOTE:  The wheel side and transaxle side boots are different.
1. Fill the boot (wheel side) with the specified grease.
CAUTION:  Do not touch grease with your hand. Apply it from the tube to
prevent foreign matter from entering the boot.
Grease amount 110-130 g {3.89-4.58 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
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3. Remove the tape.
TRIPOD JOINT, SNAP RING ASSEMBLY NOTE
1. Align the marks and install the tripod joint using a bar and a hammer.
2. Install the new snap ring using snap-ring pliers.
CAUTION:  Be sure the snap ring engages correctly in the groove of the
shaft.
Fig. 19: Identifying Mark Location

OUTER RING ASSEMBLY NOTE
1. Fill the outer ring and boot (transaxle side) with the specified grease.
2. Install the roller cassettes.

3. Align the marks, and install the outer ring on to the shaft.
4. Install a new clip.
5. Install the boot.
6. Set the drive shaft to the standard length.
Front drive shaft standard length
LH: 658.7-668.7 mm {25.92-26.30 in}
RH: 630.7-640.7 mm {24.82-25.20 in}
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7. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth-
wrapped flathead screwdriver.
CAUTION:  Do not let grease leak.

 Do not damage the boot.
8. Verify that the drive shaft length is within the standard.
Fig. 20: Lifting Boot With Cloth

BOOT BAND (TRANSAXLE SIDE) ASSEMBLY NOTE
1. Fold the band in the direction opposite to the forward revolving direction of the drive shaft and use pliers
to pull it tight.
2. Lock the end of the band by bending the locking clips.
CAUTION:  Install the band into the groove securely.
Fig. 21: Bending Locking Clips

BOOT BAND (WHEEL SIDE) ASSEMBLY NOTE
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1. Adjust clearance A by turning the adjusting bolt of the SST.
Clearance A 2.9 mm {0.11 in}
Fig. 22: Adjusting Clearance

2. Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.
 If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot
again.
 If clearance B is less than the specification, replace the boot band, increase clearance A of the SST,
and crimp the new boot.
Clearance B 2.4-2.8 mm {0.095-0.110 in}
Fig. 23: Crimping Wheel Boot Band

3. Verify that the boot band does not protrude from the boot band installation area.
 If it does, replace the boot band and repeat Steps 2 and 3.
4. Fill the boot with the repair kit grease.

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6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
again.
 If clearance B is less than the specification, replace the boot band, increase clearance A of the SST
Clearance B 2.4-2.8 mm {0.095-0.110 in}
JOINT SHAFT PRE-INSPECTION

1. Verify that the joint shaft is not twisted or cracked.
 Replace it as necessary.
2. Turn the joint shaft by hand and verify that the bearing rotates smoothly and freely.
 Replace it as necessary.
Fig. 24: Turning Joint Shaft

JOINT SHAFT REMOVAL/INSTALLATION [2WD]
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Fig. 25: Identifying Joint Shaft Components (2WD) & Torque Specifications
JOINT SHAFT REMOVAL NOTE
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3. Pull the joint shaft straight out.
CAUTION:  The sharp edges of the joint shaft can slice or puncture the oil
seal. Be careful when removing the joint shaft from the
transaxle.

1. Install a new clip onto the joint shaft with the opening facing upward. Ensure that the diameter of the clip
2. After installation, measure the outer diameter. If it exceeds the specification, repeat Step 1 using a new
clip.
Clip outer diameter specification 34.0 mm {1.34 in} max.
Fig. 27: Identifying Clip Outer Diameter

JOINT SHAFT REMOVAL/INSTALLATION [AWD]
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3. Remove the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
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Fig. 28: Identifying Joint Shaft Components (AWD) & Torque Specifications
JOINT SHAFT REMOVAL NOTE
2. Remove the nuts.
3. Pull the joint shaft straight out.
CAUTION:  The sharp edges of the joint shaft can slice or puncture the oil
seal. Be careful when removing the joint shaft from the
transaxle.
NOTE:  If the joint shaft is removed, always replace the deflector and oil seal
of the transfer with new ones.

4. Replace the deflector and oil seal. (See TRANSFER OIL SEAL REPLACEMENT .)
2. After installation, measure the outer diameter. If it exceeds the specification, repeat Step 1 using a new
clip.
Outer diameter specification 34.0 mm {1.34 in} max.
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JOINT SHAFT DISASSEMBLY [2WD]

Fig. 31: Identifying Joint Shaft Components (2WD)

JOINT SHAFT DISASSEMBLY NOTE
1. Remove the joint shaft using a press.
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Fig. 32: Pressing Joint Shaft

DUST SEAL (AXLE SIDE) DISASSEMBLY NOTE
1. Remove the dust seal using a flathead screwdriver.
DUST SEAL (DIFFERENTIAL SIDE) DISASSEMBLY NOTE
1. Remove the bearing using a press and the SSTs.
Substitution SST
 49B014 001
 49W034 301
Inner diameter: 67.5-72 mm {2.7-2.8 in}
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Fig. 33: Pressing Bearing With SST

JOINT SHAFT DISASSEMBLY [AWD]

Fig. 34: Identifying Joint Shaft Components (AWD)

JOINT SHAFT DISASSEMBLY NOTE
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1. Remove the joint shaft using a press.
Fig. 35: Pressing Joint Shaft

DUST SEAL (AXLE SIDE) DISASSEMBLY NOTE
DUST SEAL (DIFFERENTIAL SIDE) DISASSEMBLY NOTE
1. Remove the bearing using a press and the SSTs.
Substitution SST
 49B014 001
 49W034 301
Inner diameter: 67.5-72 mm {2.7-2.8 in}
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Fig. 36: Pressing Bearing

JOINT SHAFT ASSEMBLY [2WD]

Fig. 37: Identifying Joint Shaft Components (2WD) & Torque Specifications
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1. Install the new bearing using a press and the SST.
Substitution SST
 49B025 004

DUST SEAL (DIFFERENTIAL SIDE) ASSEMBLY NOTE
1. Apply grease to the new dust seal lip.

2. Install the dust seal (differential side) using a press and the SSTs.
Substitution SST
 49B025 004
Outer diameter: 58-59.8 mm {2.2-2.3 in} or less
 49W034 301

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Fig. 39: Pressing Dust Seal (Differential Side) With SST

JOINT SHAFT ASSEMBLY NOTE
1. Install the joint shaft using a press and the SST.
Fig. 40: Pressing Joint Shaft With SST

DUST SEAL (AXLE SIDE) ASSEMBLY NOTE

2. Install the dust seal (axle side) using a press and the SST.
Substitution SST
 49B025 004
Outer diameter: 58-59.8 mm {2.2-2.3 in} or more
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Fig. 41: Pressing Dust Seal (Axle Side) With SST

JOINT SHAFT ASSEMBLY [AWD]

Fig. 42: Identifying Joint Shaft Assembly Components (AWD) & Torque Specifications
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1. Install the new bearing using a press and the SST.
Substitution SST
 49B025 004

DUST SEAL (DIFFERENTIAL SIDE) ASSEMBLY NOTE

2. Install the dust seal (differential side) using a press and the SSTs.
Substitution SST
 49B025 004
Outer diameter: 58-59.8 mm {2.2-2.3 in} or less
 49W034 301
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Fig. 44: Pressing Dust Seal (Differential Side) With SST

JOINT SHAFT ASSEMBLY NOTE
1. Install the joint shaft using a press and the SST.
Fig. 45: Pressing Joint Shaft With SST

DUST SEAL (AXLE SIDE) ASSEMBLY NOTE

2. Install the dust seal (axle side) using a press and the SST.
Substitution SST
 49B025 004
Outer diameter: 58-59.8 mm {2.2-2.3 in} or more
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Fig. 46: Pressing Dust Seal (Axle Side) With SST

REAR DRIVE SHAFT PRE-INSPECTION

1. Inspect each connecting part for looseness.
 Tighten or replace parts if necessary.
2. Inspect the dust boot on the drive shaft for cracks, damage, leaking grease, and looseness in the boot
band.
3. Inspect the drive shaft for bends, cracks, and wear in the joints or splines.
 Repair or replace the drive shaft or boot band if necessary.
Fig. 47: Locating Dust Boot

REAR DRIVE SHAFT REMOVAL/INSTALLATION
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procedures, remove the ABS wheel-speed sensor (wheel side) and fix
it to an appropriate place where the sensor will not be pulled by
1. Remove the rear ABS wheel-speed sensor. (See REAR ABS WHEEL-SPEED SENSOR
2. Drain the rear differential oil into a container. (See DIFFERENTIAL OIL REPLACEMENT .)
8. After installation, add the specified rear differential oil. (See DIFFERENTIAL OIL
REPLACEMENT .)
[AWD] .)
Fig. 48: Identifying Rear Drive Shaft Components & Torque Specifications
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REAR DRIVE SHAFT REMOVAL NOTE
1. Disengage the rear drive shaft using the SSTs.
NOTE:  Be careful not to damage the rear differential oil seal.
Fig. 49: Disengaging Rear Drive Shaft With SST

2. After installation, measure the outer diameter. If it exceeds the specification, repeat Steps 1-2 using a new
clip.
Clip outer diameter specification 29.5 mm {1.16 in} max.

REAR DRIVE SHAFT DISASSEMBLY/ASSEMBLY

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Fig. 51: Identifying Rear Drive Shaft Components

BOOT BAND (WHEEL SIDE) DISASSEMBLY NOTE
NOTE:  The boot band does not need to be removed unless it is being replaced.
1. Remove the boot clamp with end clamp pliers as shown and discard the clamp.
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Fig. 52: Crimping Boot Clamp With Clamp Pliers

BOOT BAND (DIFFERENTIAL SIDE) DISASSEMBLY NOTE
1. Pry up the locking clips using a screwdriver.

2. Pull back the end of the band.
Fig. 53: Prying Locking Clips

CLIP DISASSEMBLY NOTE
1. Mark the drive shaft and outer ring for proper assembly.
CAUTION:  Mark with paint; do not use a punch.
2. Remove the clip.
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Fig. 54: Prying Clip

SNAP RING DISASSEMBLY NOTE
1. Mark the drive shaft end and inner ring for proper reassembly.
2. Remove the snap ring using snap-ring pliers.
Fig. 55: Removing Snap Ring With Snap-Ring Pliers

BALLS, INNER RING, CAGE DISASSEMBLY NOTE
1. Mark the inner ring and cage for proper reassembly.
2. Turn the cage approx. 22.5° and pull the cage and balls from the inner ring.
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Fig. 56: Pulling Cage & Balls

BOOT ASSEMBLY NOTE
NOTE:  The wheel side and differential side boots are different.
1. Fill the wheel side boot with the specified grease.
2. With the splines of the shaft wrapped in tape, install the boot.
3. Remove the tape.
CAGE, INNER RING, BALLS, SNAP RING ASSEMBLY NOTE
1. Align the marks and install the balls and cage to the inner ring in the direction shown in the figure.
CAUTION:  Install the cage so that the major diameter is at the same side as
the snap ring groove. If incorrectly installed, the drive shaft may
become disengaged.
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Fig. 57: Aligning Marks Balls & Cage To Inner Ring

2. Align the marks and install the inner ring to the shaft.
3. Install a new snap ring.
OUTER RING, CLIP ASSEMBLY NOTE
1. Fill the outer ring and boot (differential side) with the specified grease.
2. Align the marks, and install the outer ring on to the shaft.
3. Install a new clip to the outer ring clip groove.
4. Install the boot.
Fig. 58: Installing Outer Ring Clip

5. Release any trapped air from the boots by carefully lifting up the small end of each boot with a cloth
wrapped screwdriver.
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CAUTION:  Do not let grease leak.

 Do not damage the boot.
Fig. 59: Lifting Boot With Cloth Wrapped Screwdriver

6. Set the drive shaft to the standard length.
Rear drive shaft standard length
LH: 840.3-850.3 mm {33.09-33.47 in}
RH: 895.3-905.3 mm {35.25-35.64 in}
7. Verify that the drive shaft length is within the standard.

 If not, repeat from Step 5.
BOOT BAND (DIFFERENTIAL SIDE) ASSEMBLY NOTE
1. Fold the band in the direction opposite to the forward revolving direction of the drive shaft and use pliers
to pull it tight.
2. Lock the end of the band by bending the locking clips.
CAUTION:  Install the band into the groove securely.
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Fig. 60: Bending Locking Clips

BOOT BAND (WHEEL SIDE) ASSEMBLY NOTE
Fig. 61: Adjusting Clearance

2. Crimp the wheel side small boot band using the SST. Verify that clearance B is within the specification.
again.
 If clearance B is less than the specification, replace the boot band, increase clearance A of the SST,
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Fig. 62: Crimping Wheel Side Small Boot Band

Clearance B 2.4-2.8 mm {0.095-0.110 in}
4. Fill the boot with the repair kit grease.

6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
again.
 If clearance B is less than the specification, replace the boot band, increase clearance A of the SST
Clearance B 2.4-2.8 mm {0.095-0.110 in}
Microsoft
2008 DRIVELINE/AXLE Technical Data (Driveline/Axle) - Mazda CX-9
2008 DRIVELINE/AXLE
Technical Data (Driveline/Axle) - Mazda CX-9
DRIVELINE/AXLE TECHNICAL DATA

Front and Rear Axle
FRONT AND REAR AXLE SPECIFICATION

Item Specification
Front wheel bearing maximum play 0.05 mm {0.002 in}
Rear wheel bearing maximum play 0.05 mm {0.002 in}
Drive Shaft
DRIVE SHAFT SPECIFICATION

Item Specification
LH: 658.7-668.7 mm {25.92-26.30 in}
Front drive shaft standard length
RH: 630.7-640.7 mm {24.82-25.20 in}
LH: 840.3-850.3 mm {33.09-33.47 in}
Rear drive shaft standard length
RH: 895.3-905.3 mm {35.25-35.64 in}
Differential
DIFFERENTIAL SPECIFICATION
Item Specification
Grade: API service GL-5
Viscosity: SAE 80W-90
Rear differential oil
Capacity (approximate quantity): 1.0 L {1.1 US qt, 0.9
lmp qt}
Rear differential backlash of pinion gear and
0.1 mm {0.004 in} or less
side gear
Rear differential pinion height -0.032-0.032 mm {-0.0012-0.0012 in}
Rear differential drive pinion preload 1.3-1.8 N.m {13.3-18.2 kgf.cm, 11.5-15.9 in.lbf}
Rear differential backlash of drive pinion and Standard: 0.09-0.11 mm {0.003-0.004 in}
ring gear Minimum value: 0.05 mm {0.002 in}
Propeller Shaft
PROPELLER SHAFT SPECIFICATION

Item Specification
Propeller shaft maximum runout 0.8 mm {0.031 in}
Propeller shaft starting torque 0.29-1.47 N.m {3.0-14.9 kgf.cm, 2.6-13.0 in.lbf}
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2008 DRIVELINE/AXLE Technical Data (Driveline/Axle) - Mazda CX-9
Transfer
TRANSFER SPECIFICATION
Item Specification
Grade: API service GL-5
Transfer oil Viscosity: SAE 75W-140
Capacity (approximate quantity): 0.532 L {0.562 US qt, 0.468 lmp qt}
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2008 BRAKES Dynamic Stability Control/Roll Stability Control - Mazda CX-9
2008 BRAKES
Dynamic Stability Control/Roll Stability Control - Mazda CX-9
DSC/RSC LOCATION INDEX
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Fig. 1: Identifying DSC/RSC Parts Location

DSC/RSC SYSTEM WIRING DIAGRAM

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Fig. 2: DSC/RSC System Wiring Diagram

DSC/RSC SYSTEM INSPECTION

PREPARATION
1. Verify that battery is fully charged.

2. Turn the ignition switch to the ON position, and verify that the ABS warning light goes out after approx.
3 s.
3. Turn the ignition switch off.
4. Jack up the vehicle and support it evenly on safety stands.
5. Shift to the N position.
6. Verify that all four wheels rotate.
7. Rotate the inspected wheels by hand, and verify there is no brake drag.
 If there is any brake drag, perform regular brake inspection.
 If there is no brake drag, perform DSC/RSC HU/CM operation inspection.
ABS CONTROL INSPECTION
1. Perform "Preparation".
3. Set up an active command mode inspection according to the combination of commands below.
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Brake pressure retention
BRAKE PRESSURE RETENTION REFERENCE CHART

Inspected wheels
Command name
LF RF LR RR
V_TRC_L
V_TRC_R
OFF
V_STB_L
V_STB_R
V_LF_INL ON
OFF
V_LF_OTL
OFF
V_LR_INL ON
OFF
V_LR_OTL
V_RF_INL OFF ON
V_RF_OTL OFF
V_RR_INL OFF ON
V_RR_OTL OFF
PMP_MOTOR OFF
Brake pressure reduction

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Inspected wheels
Command name
LF RF LR RR
V_TRC_L
V_TRC_R
OFF
V_STB_L
V_STB_R
V_LF_INL
ON OFF
V_LF_OTL
OFF
V_LR_INL
ON OFF
V_LR_OTL
V_RF_INL
OFF ON
V_RF_OTL
OFF
V_RR_1NL
OFF ON
V_RR_OTL
PMP_MOTOR ON
CAUTION:  To protect the DSC/RSC HU/CM, the solenoid valve and the
pump motor used during active command mode stay on for only
10 s or less each time they are switched on.
NOTE:  When working with two people, one should press on the brake pedal,
and the other should attempt to rotate the wheel being inspected.
4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being
inspected.
5. While brake pressure is maintained and a DSC/RSC HU/CM operation click sound is heard, confirm that
the wheel does not rotate. While brake pressure is being reduced and an DSC/RSC HU/CM operation
click sound is heard, confirm that the wheel rotates.
 Performing the inspection above determines the following:
 The DSC/RSC HU/CM brake lines are normal.
 The DSC/RSC HU/CM hydraulic system is not significantly abnormal (including DSC/RSC
HU/CM).
 The DSC/RSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
 The DSC/RSC unit and DSC/RSC HU/CM output system wiring harnesses (solenoid valve,
relay system) are normal.
 However, the following items cannot be verified.
 Malfunction with intermittent occurrence of the above items
 Malfunction of DSC/RSC HU/CM input system wiring harnesses and parts
 Extremely small leaks in the DSC/RSC HU/CM internal hydraulic system
DSC CONTROL INSPECTION

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1. Perform "Preparation".
3. Set up an active command mode inspection according to the combination of commands below.
CAUTION:  To protect the DSC/RSC HU/CM, the solenoid valve and the
pump motor used during active command mode stay on for only
10 s or less each time they are switched on.


Inspected wheels
Command name Understeer control inhibited Oversteer control inhibited
LF RF LR RR
V_TRC_L ON OFF ON
V_TRC_R OFF ON OFF
V_STB_L
OFF
V_STB_R
V_LF_INL ON
OFF
V_LF_OTL
OFF
V_LR_INL ON
OFF
V_LR_OTL
V_RF_INL ON OFF
V_RF_OTL OFF
V_RR_INL ON OFF
V_RR_OTL OFF
PMP_MOTOR ON
4. Send the command while rotating the wheel being inspected by hand in a forward direction.
5. Confirm that the wheel does not rotate easily while a DSC/RSC HU/CM operation click sound is heard.
 Performing the inspection above determines the following:
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The DSC/RSC HU/CM brake lines are normal.

 The DSC/RSC HU/CM hydraulic system is not significantly abnormal (including DSC/RSC
HU/CM).
 The DSC/RSC HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
 The DSC/RSC unit and DSC/RSC HU/CM output system wiring harnesses (solenoid valve,
relay system) are normal.
 However, the following items cannot be verified.
 Malfunction with intermittent occurrence of the above items
 Malfunction of DSC/RSC HU/CM input system wiring harnesses and parts
 Extremely small leaks in the DSC/RSC HU/CM internal hydraulic system
DSC/RSC HU/CM REMOVAL/INSTALLATION
WARNING:  If the DSC/RSC sensor initialization procedure is not completed, it

could result in an unexpected accident due to the DSC/RSC being
inoperative. Therefore, after the DSC/RSC HU/CM is replaced, always
perform the DSC/RSC sensor initialization procedure to ensure
proper DSC/RSC operation. (See DSC/RSC SENSOR INITIALIZATION
PROCEDURE.)
CAUTION:  The internal parts of the DSC/RSC HU/CM could be damaged if

dropped. Be careful not to drop the DSC/RSC HU/CM. Replace the
DSC/RSC HU/CM if it is subjected to an impact.
2. Remove the battery tray bracket as shown in the figure.
5. Remove the wiper motor. (See WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION .)
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Fig. 5: Identifying Battery Tray Bracket & Torque Specifications

7. Remove the nuts as shown in the figure, and move the front heater pipe.
10. After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See DSC/RSC HU AIR
BLEEDING.) (See AIR BLEEDING .)
11. After installation, perform the DSC/RSC sensor initialization procedure. (See DSC/RSC SENSOR
INITIALIZATION PROCEDURE.)
Fig. 6: Identifying Front Heater Pipe & Torque Specifications

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Fig. 7: Identifying DSC/RSC HU/CM Components & Torque Specifications

DSC/RSC HU/CM CONNECTOR REMOVAL NOTE
1. Remove the DSC/RSC HU/CM connector using the following procedure:

1. Press down the lock lever while pressing the upper tab to release the lock.
2. Press down the lock lever and lock it using the lower tab.
3. Remove the DSC/RSC HU/CM connector by pulling it in the direction of the arrow.
Fig. 8: View Of DSC/RSC HU/CM Connector

BRAKE PIPE REMOVAL NOTE
1. Place an alignment mark on the brake pipe and DSC/RSC HU/CM.
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2. Apply protective tape to the DSC/RSC HU/CM connector to prevent brake fluid from entering.
3. Remove the brake pipe.
Fig. 9: Identifying Alignment Mark On Brake Pipe & DSC/RSC HU/CM

DSC/RSC HU/CM COMPONENT INSTALLATION NOTE
1. Insert the DSC/RSC HU/CM bracket tab to the vehicle frame hole as shown in the figure.
2. Install the DSC/RSC HU/CM component.
Fig. 10: Identifying DSC/RSC HU/CM Bracket

BRAKE PIPE INSTALLATION NOTE
1. Align the marks made before removal and install the brake pipe to the DSC/RSC HU/CM and brake pipe
joint referring to the figure.
2. Tighten the brake pipe to the specified torque using the SST (49 0259 770B) and the commercially
available flare nut wrench.
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Fig. 11: Identifying Master Cylinder (Primary Side & Secondary Side)
DSC/RSC HU/CM CONNECTOR INSTALLATION NOTE
1. Install the DSC/RSC HU/CM connector using the following procedure:

1. After verifying that the lock lever is locked by the lower tab, connect the DSC/RSC HU/CM
connector to the DSC/RSC HU/CM.
2. Pull up the lock lever by pressing the lower tab, and release the lock.
3. Pull up the lock lever and lock it using the upper tab.
2. Verify that the DSC/RSC HU/CM connector is installed securely.
Fig. 12: View Of DSC/RSC HU/CM Connector

DSC/RSC HU AIR BLEEDING

1. Select "Chassis".
2. Select "Braking".
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

 Select "ABS Service Bleed"
5. Perform the air bleeding according to the directions on the screen.

DSC/RSC SENSOR INITIALIZATION PROCEDURE
WARNING:  Unless the initialization procedure of the combined sensor is

completed, the DSC/RSC will not operate, causing an unexpected
accident. Therefore, always perform the initialization procedure to
ensure DSC/RSC operation if the combined sensor and DSC/RSC
HU/CM have been removed or replaced.
1. Inspect the wheel alignment and inflation pressure.

 If there is any malfunction, adjust the applicable part.
2. Park the vehicle on level ground.

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1. Select "Chassis".
2. Select "ABS/DSC".
3. Select "Sensor Initialization".
1. Select "Module Test".

2. Select "ABS".
3. Select "Datalogger".
4. Select "SSR_INTL".
6. Perform the initialization according to the directions on the screen.

DSC/RSC HU/CM INSPECTION

1. Disconnect the DSC/RSC HU/CM connector. (See DSC/RSC HU/CM
2. Connect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
3. Attach the tester lead to the DSC/RSC HU/CM harness side connector, then inspect voltage, continuity or
resistance according to the standard (reference value) on the table.
STANDARD (REFERENCE VALUE)
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Fig. 15: Identifying DSC/RSC HU/CM Connector Terminal

CONNECTOR TERMINAL REFERENCE CHART

Measured
Connected Measured terminal
Terminal Signal name Standard Inspection item(s)
to item (measured
condition)
Ground  Wiring harness
Continuity
A (DSC/RSC Ground point Continuity A-ground point (A- ground
detected
system) point)
Ground (ABS Continuity  Wiring harness

B Ground point Continuity B-ground point (B- ground
motor) detected
point)
C - - - - - -
D - - - - - -
E - - - - - -
F-LR ABS  Wiring harness
LR wheel- LR ABS wheel-speed (F-LR ABS
Continuity
F speed sensor wheel-speed Continuity sensor wheel-speed
detected
(power supply) sensor connector sensor connector
terminal B terminal B)
G-RR ABS  Wiring harness
RR wheel- RR ABS wheel-speed (G-RR ABS
Continuity
G speed sensor wheel-speed Continuity sensor wheel-speed
detected
H - - - - - -
I-LR ABS  Wiring harness
LR wheel- LR ABS wheel-speed (I-LR ABS
Continuity
I speed sensor wheel-speed Continuity sensor wheel-speed
detected
(signal) sensor connector sensor connector
terminal A terminal A)
J-RR ABS  Wiring harness
RR wheel- RR ABS wheel-speed (J-RR ABS
Continuity
J speed sensor wheel-speed Continuity sensor wheel-speed
detected
K - - - - - -
L - - - - - -
M CAN2_L - Inspect under DTC inspection -
N - - - - - -
O - - - - - -
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P CAN2_H - Inspect under DTC inspection -

Q - - - - - -
R - - - - - -
S - - - - - -
T - - - - - -
U-TCS OFF  Wiring harness
TCS OFF TCS OFF switch Continuity (U- TCS OFF
U Continuity
switch switch connector detected switch connector
V HS_CAN_L - Inspect under DTC inspection -
W - - - - - -
Ignition switch  Wiring harness

B+ (X- ignition
Power supply Ignition at ON
X Voltage switch)
(system) switch
Ignition switch
1 V or less -
is off.
Y HS_CAN_H - Inspect under DTC inspection -
Z - - - - - -
AA - - - - - -
AB-RF ABS  Wiring harness
RF wheel- RF ABS wheel-speed (AB- RF ABS
Continuity
AB speed sensor wheel-speed Continuity sensor wheel-speed
detected
AC - - - - - -
AD-LF ABS  Wiring harness
LF ABS wheel-speed (AD-LF ABS
LF wheel-speed Continuity
AD wheel-speed Continuity sensor wheel-speed
sensor (signal) detected
sensor connector sensor connector
AE-RF ABS  Wiring harness
RF wheel- RF ABS wheel-speed (AE- RF ABS
Continuity
AE speed sensor wheel-speed Continuity sensor wheel-speed
detected
AF - - - - - -
AG-LF ABS  Wiring harness
LF wheel-speed LF ABS wheel-speed (AG-LF ABS
Continuity
AG sensor (power wheel-speed Continuity sensor wheel-speed
detected
supply) sensor connector sensor connector
AH - - - - - -
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Al - - - - - -
AJ - - - - - -
Power supply
Under any  Wiring harness
AK (ABS motor Battery Voltage B+
condition (AK- battery)
operation)
Power supply
Under any  Wiring harness
AL (solenoid Battery Voltage B+
condition (AL- battery)
operation)
FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION

1. When removing the right front ABS wheel-speed sensor, perform the following procedure.
1. Remove the coolant reserve tank installation bolts and move the coolant reserve tank. (See
COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI-3.7] .)
2. Remove the power steering reserve tank installation bolt and nut, and move the power steering
reserve tank. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION .)
2. When removing the left front ABS wheel-speed sensor, perform the following procedure:
1. Remove the air cleaner case. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[MZI-3.7] .)
Fig. 16: Identifying Front ABS Wheel Speed Sensor Connector, Front ABS Wheel Speed Sensor,
Bolt & Torque Specifications

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FRONT ABS WHEEL-SPEED SENSOR INSPECTION

INSTALLATION VISUAL INSPECTION
1. Inspect the following items:

1. Excessive play of the ABS wheel-speed sensor

2. Deformation of the ABS wheel-speed sensor
3. Deformation or damage of the ABS sensor rotor
CLEARANCE INSPECTION
1. Verify the clearance between the ABS sensor rotor and the ABS wheel-speed sensor.
 If there is any malfunction, check for improper installation, and replace if necessary.
Clearance
 0.7-1.5 mm {0.028-0.059 in}
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Fig. 17: Identifying Clearance Between ABS Sensor Rotor & ABS Wheel-Speed Sensor
SENSOR OUTPUT VALUE INSPECTION

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3. Select "ABS".

2. Select "ABS".

4. Select the following PIDs using the M-MDS:

 WSPD_LF
(LF ABS wheel-speed sensor)
 WSPD_RF
(RF ABS wheel-speed sensor)
5. Start the engine and drive the vehicle.

6. Verify that the display of the M-MDS shows the same value as the speedometer.
 If there is any malfunction, replace the front ABS wheel-speed sensor.
REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [2WD]

1. Remove the trunk box. (See TRUNK BOX REMOVAL/INSTALLATION .)
2. Remove the seat side box. (See SEAT SIDE BOX REMOVAL/INSTALLATION .)
3. Remove the third-row seat. (See THIRD-ROW SEAT REMOVAL/INSTALLATION .)
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4. Remove the rear scuff plate inner. (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
5. Remove the third-row seat belt lower anchor installation bolt. (See THIRD-ROW SEAT BELT
6. Remove the trunk side trim. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
Fig. 19: Identifying Rear ABS Wheel Speed Sensor Connector, Rear ABS Wheel Speed Sensor, Bolt
& Torque Specifications
REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [AWD]

5. Remove the third-row seat belt lower anchor installation bolt. (See THIRD-ROW SEAT BELT
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Fig. 20: Identifying Rear ABS Wheel Speed Sensor Connector, Rear ABS Wheel Speed Sensor, Bolt
REAR ABS WHEEL-SPEED SENSOR INSPECTION [2WD]



1. Remove the rear ABS wheel-speed sensor.

2. Measure the distance between the rear ABS wheel-speed sensor installation surface and the ABS sensor
rotor. This is dimension A.
3. Calculate the clearance between the front ABS wheel-speed sensor and the ABS sensor rotor using the
following formula:
Clearance (mm {in}) = A-15.0 {0.60 in}
4. Verify that the clearance between the ABS sensor rotor and the rear ABS wheel-speed sensor is as
indicated below.
 If there is any malfunction, replace it.
Clearance
 0.3-1.1 mm {0.012-0.043 in}
Fig. 21: Identifying Distance Between Rear ABS Wheel-Speed Sensor & ABS Sensor Rotor
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3. Select "ABS".

2. Select "ABS".


 WSPD_LR
(LR ABS wheel-speed sensor)
 WSPD_RR
(RR ABS wheel-speed sensor)

 If there is any malfunction, replace the rear ABS wheel-speed sensor.
REAR ABS WHEEL-SPEED SENSOR INSPECTION [AWD]

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3. Deformation or damage of the ABS sensor rotor
1. Verify the clearance between the ABS sensor rotor and the ABS wheel-speed sensor.
 If there is any malfunction, check for improper installation, and replace if necessary.
Clearance
 0.95-1.75 mm {0.038-0.068 in}
Fig. 23: Identifying Clearance Between ABS Sensor Rotor & ABS Wheel-Speed Sensor

3. Select "ABS".

2. Select "ABS".
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 WSPD_LR
(LR ABS wheel-speed sensor)
 WSPD_RR
(RR ABS wheel-speed sensor)

 If there is any malfunction, replace the rear ABS wheel-speed sensor.
COMBINED SENSOR REMOVAL/INSTALLATION
WARNING:  If the DSC/RSC sensor initialization procedure is not completed, it

could result in an unexpected accident due to the DSC/RSC being
inoperative. Therefore, after the combined sensor is replaced,
always perform the DSC/RSC sensor initialization procedure to
ensure proper DSC/RSC operation.
CAUTION:  The internal parts of the combined sensor could be damaged if

dropped. Be careful not to drop the combined sensor. Replace the
combined sensor if it is subjected to an impact. Also, do not use an
impact wrench or other similar air tools when removing/installing the
sensor.
1. Remove the second-row seat (RH). (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)

2. Remove the edge cover. (See LONG SLIDER REMOVAL/INSTALLATION .)
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3. Remove the long slider cover. (See LONG SLIDER REMOVAL/INSTALLATION .)

4. Separate the floor carpet at the area shown in the figure.
CAUTION:  When separating the floor carpet, the wiring harnesses under
the floor carpet could be damaged. Separate the floor carpet
while lifting it so as not to damage the wiring harnesses.
Fig. 25: Identifying Rear Heat Duct No.4 & Cutting Line
5. Partially peel back the floor carpet from where it is separated as shown in the figure.
6. Remove the rear heat duct No.4.
9. After installation, perform the DSC/RSC sensor initialization procedure. (See DSC/RSC SENSOR
INITIALIZATION PROCEDURE.)
Fig. 26: Identifying Rear Heat Duct No.4 & Floor Covering
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Fig. 27: Identifying Combined Sensor Cover, Combined Sensor Connector, Combined Sensor, Combined
Sensor Bracket & Torque Specifications
COMBINED SENSOR INSPECTION

2. Remove the combined sensor installation nut.
3. Select "ABS".

2. Select "ABS".

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5. Select the following PIDs, then inspect the lateral acceleration speed, longitudinal acceleration speed, roll
rate and yaw rate.
 LAT_ACCL: (lateral acceleration speed)
 ACCLMTR: (longitudinal acceleration speed)
 YAW_RATE: (yaw rate)
 ROLL_RATE (roll rate)
1. Lateral acceleration speed inspection

1. Verify the LAT_ACCL change when the combined sensor is tilted to the left and right.
 If there is any malfunction, replace the combined sensor.
Standard
When the sensor is tilted to the right (A):
LAT ACCL changes negatively.
When the sensor is tilted to the left (B):
LAT_ACCL changes positively.
Fig. 29: Tilting Sensor Right & Left

2. Longitudinal acceleration speed inspection

1. Verify the ACCLMTR change when the combined sensor is moved forward and backward.
Standard
When the sensor is tilted to forward (A):
ACCLMTR changes negatively.
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When the sensor is tilted to backward (B):
ACCLMTR changes positively.
Fig. 30: Tilting Sensor Forward & Backward

3. Yaw rate inspection

1. Verify the YAW_RATE change when the combined sensor is rotated to the left and right.
Standard
When the sensor is rotated to the right (A):
YAW_RATE changes positively.
When the sensor is rotated to the left (B):
YAW_RATE changes negatively.
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Fig. 31: Rotating Sensor Right & Left

4. Roll rate inspection

1. Verify the ROLL_RATE change when the combined sensor is tilted to the left and right.
 If there is any malfunction, replace the combined sensor
Standard
When the sensor is tilted to the right (A):
ROLL_RATE changes positively
When the sensor is tilted to the left (B):
ROLL RATE changes negatively
Fig. 32: Tilting Sensor Right & Left

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BRAKE FLUID PRESSURE SENSOR INSPECTION
NOTE:  The brake fluid pressure sensor is integrated into the DSC HU/CM and
installed to the brake line of RF- LR brake system. Therefore, perform the
brake fluid pressure sensor inspection with the SST installed to the brake
pipe on the left front wheel.

2. Disconnect the brake pipe flare nut area using a commercially available flare nut wrench.
3. Remove the clamp and disconnect the brake hose.
Fig. 33: Identifying Brake Pipe, Brake Hose & Clamp

4. Install the SSTs to the brake pipe as shown in the figure.

5. Bleed the brake line and the SSTs of air. Bleed the air from the SSTs using bleeder screw A.
Fig. 34: Identifying Brake Pipe With SST


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3. Select "ABS".
2. Select "ABS".

8. Select the "MCYLIP" PID.

10. Depress the brake pedal, and confirm that the fluid pressure value of the SST (Gauge) and the value
shown on the M-MDS are equal
 If the fluid pressures are different, replace the DSC/RSC HU/CM. (See DSC/RSC HU/CM
11. After the inspection, remove the SSTs, install the brake hose, clamp, and brake pipe to the original
positions, and then bleed the air from the brake line.
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Fig. 36: Identifying Brake Pipe & Torque Specifications

TCS OFF SWITCH REMOVAL/INSTALLATION

1. Remove the dashboard under cover (LH). (See DASHBOARD REMOVAL/INSTALLATION .)
Fig. 37: Identifying TCS OFF Switch & TCS OFF Switch Connector
TCS OFF SWITCH REMOVAL NOTE
1. Access the TCS OFF switch from behind of the dashboard, and squeeze the tabs of the switch.
2. Remove the TCS OFF switch from the dashboard.
TCS OFF SWITCH INSPECTION

1. Remove the TCS OFF switch. (See TCS OFF SWITCH REMOVAL/INSTALLATION.)
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 If not as indicated in the table, replace the TCS OFF switch.

Fig. 39: Identifying TCS OFF Switch Connector Terminal

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2008 MAZDA CX-9
2008 MAZDA
CX-9
BUZZERS, RELAYS & TIMERS

BUZZERS, RELAYS & TIMERS LOCATION
Component Location
A/C Relay In main fuse block.
BACK-UP LIGHT Relay In main fuse block.
COOLING FAN Relay No. 1 In main fuse block.
COOLING FAN Relay No. 2 In main fuse block.
FAN Relay In main fuse block.
FRONT BLOWER Relay In main fuse block.
FRONT FOG LIGHT Relay (2) In main fuse block.
FUEL PUMP Relay In main fuse block.
H/L HI Relay In main fuse block.
H/L LOW Relay In main fuse block.
HORN Relay In main fuse block.
Keyless Beeper Left rear of engine compartment.
MAIN Relay No. 1 In main fuse block.
MAIN Relay No. 2 In main fuse block.
PLG Buzzer Right side of tailgate.
REAR BLOWER Relay In main fuse block.
REAR WINDOW DEFROSTER Relay In main fuse block.
SEAT WARMER LH Relay In main fuse block.
SEAT WARMER RH Relay In main fuse block.
STARTER Relay In main fuse block.
TNS Relay In main fuse block.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
Fuse Block Behind right side of dash. See Fig. 14.
Fuse & Relay Box Center front of engine compartment. See Fig. 8.
Main Fuse Block Left rear of engine compartment. See Fig. 4.
CONTROL UNITS
CONTROL UNITS LOCATION
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2008 MAZDA CX-9
Component Location
Auto Light-Off Control Module Behind left side of dash. See Fig. 27.
Auto Light/Wiper Control Module Behind left side of dash. See Fig. 27.
AWD Control Module Behind left end of dash. See Fig. 37.
BCM Behind left kick panel. See Fig. 40.
Car-Navigation Unit Right rear of luggage compartment. See Fig. 51.
DSC/RSC HU/CM Left rear corner of engine compartment. See Fig. 5.
Fan Control Module No. 1 Behind left cooling fan assembly.
Fan Control Module No. 2 Behind right cooling fan assembly.
Hands-Free Telephone Unit Behind right side of dash. See Fig. 16.
Keyless Control Module Behind left side of dash. See Fig. 28.
Keyless Receiver Behind left side of dash. See Fig. 25.
PCM Left rear corner of engine compartment. See Fig. 7.
PLG Control Module Left side of luggage compartment. See Fig. 64.
Position Memory Control Module Under driver's seat. See Fig. 44.
PVC Valve Heater Control Center rear of engine compartment.
RES Unit Center of roof. See Fig. 53.
SAS Control Module Under front of center console. See Fig. 20.
Seat Weight Sensor Control Module Under front passenger's seat. See Fig. 46.
TCM Left front of engine compartment. See Fig. 2.
MOTORS
MOTORS LOCATION
Component Location
Air Intake Actuator Behind right side of dash.
Closer Motor Lower center of liftgate.
Cooling Fan Motor No. 1 Left front of engine compartment.
Cooling Fan Motor No. 2 Right front of engine compartment.
Door Lock Actuator (Left/Right Front) At rear of respective front door.
Door Lock Actuator (Left/Right Rear) At rear of respective rear door.
Driver Side Front Air Mix Actuator Left side of HVAC unit.
Front Airflow Mode Actuator Top left side of HVAC unit.
Front Blower Motor Under right side of dash.
Fuel Pump Unit Under rear seat, on fuel tank.
Headlight Leveling Actuator (Left/Right) In respective headlight assembly.
Liftgate Latch & Lock Actuator Lower center of liftgate.
Passenger Side Front Air Mix Actuator Right side of HVAC unit.
PLG Drive Unit Left side of luggage compartment.
Power Window Motor (Left/Right Front) In respective front door.
Power Window Motor (Left/Right Rear) In respective rear door.
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2008 MAZDA CX-9
Rear Airflow Mode Actuator Under rear of center console.

Rear Air Mix Actuator Under rear of center console.
Rear Blower Motor Under center console.
Rear Washer Motor In washer fluid reservoir.
Rear Wiper Motor Center of liftgate.
Recliner Motor In driver's seat back.
Slider Motor Under driver's seat.
Starter Rear of engine.
Sun Roof Motor Center front of roof.
Tilt Motor (Front) Under driver's seat.
Tilt Motor (Rear) Under driver's seat.
Windshield Washer Motor In washer fluid reservoir.
Windshield Wiper Motor Left rear of engine compartment.
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION
Component Location
ABS Wheel-Speed Sensor (Left/Right Front) At respective front wheelwell.
ABS Wheel-Speed Sensor (Left/Right Rear) At respective rear wheelwell.
Accelerator Pedal Position Sensor Top of accelerator pedal assembly.
Ambient Temperature Sensor Center front of engine compartment.
Left rear of engine compartment, in brake fluid
Brake Fluid Level Sensor
reservoir.
Cabin Temperature Sensor Under left side of dash.
Camshaft Position Sensor (Left) Rear of left cylinder bank.
Camshaft Position Sensor (Right) Rear of right cylinder bank.
CHT Sensor Top right front of engine.
Combined Sensor At right "C" pillar.
Crankshaft Position Sensor Left rear of engine.
Crash Zone Sensor Center front of engine compartment.
Driver-Side Side Air Bag Sensor No. 1 Near base of left "B" pillar.
Driver-Side Side Air Bag Sensor No. 2 Near base of left "C" pillar.
Fuel Gauge Sender Sub Unit Under rear seat, on fuel tank.
Fuel Tank Pressure Sensor Under rear seat, on fuel tank.
HO2S (Left Front) Left side of engine.
HO2S (Left Rear) Left rear of engine.
HO2S (Right Front) Right side of engine.
HO2S (Right Rear) Right side of engine.
Knock Sensor On right cylinder bank.
Mass Air Flow/Intake Air Temperature Sensor Rear of engine.
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2008 MAZDA CX-9
Passenger-Side Side Air Bag Sensor No. 1 Near base of right "B" pillar.
Passenger-Side Side Air Bag Sensor No. 2 Near base of right "C" pillar.
PLG Touch Sensor (Left/Right) At respective side of tailgate.
Rain Sensor Forward of interior rearview mirror.
Rear Evaporator Temperature Sensor Under center console.
Seat Recline Position Sensor In driver's seat back.
Seat Slide Position Sensor Under driver's seat.
Seat Track Position Sensor Under driver's seat.
Seat Weight Sensor (Left/Right) Under respective side of front passenger's seat.
Solar Radiation Sensor Top left side of dash.
Steering Angle Sensor In steering column.
Tilt Position Sensor (Front) Under driver's seat.
Tilt Position Sensor (Rear) Under driver's seat.
Washer Fluid-Level Sensor In washer fluid reservoir.
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
AWD Solenoid Near rear differential.
Canister Vent Solenoid Valve Under left side of vehicle, forward of fuel tank.
Fuel Injectors No. 1, 2, & 3 On right cylinder bank.
Fuel Injectors No. 4, 5 & 6 On left cylinder bank.
Magnetic Clutch Left front of engine.
Oil Control Valve (Left) Front of left cylinder bank.
Oil Control Valve (Right) Front of right cylinder bank.
Purge Solenoid Valve Rear of engine compartment.
Steering Lock Unit In steering column.
SWITCHES
SWITCHES LOCATION
Component Location
Brake Switch No. 1 On brake pedal assembly.
Brake Switch No. 2 On brake pedal assembly.
Buckle Switch (Driver/Passenger Side) Integral to respective seat belt buckle assembly.
Door Lock-Link Switch (Left/Right Front) In respective front door.
Door Lock-Link Switch (Left/Right Rear) In respective rear door.
Door Switch (Left/Right Front) At respective "B" pillar.
Door Switch (Left/Right Rear) At respective "C" pillar.
Hood Latch Switch Center front of engine compartment.
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2008 MAZDA CX-9
Horn Switch In steering wheel.

Key Reminder Switch In steering column.
Oil Pressure Switch Lower left front of engine.
Parking Brake Switch Top of parking brake assembly.
Power Steering Pressure Switch Right front side of engine.
Refrigerant Pressure Switch Right front corner of engine compartment.
MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
Audio Amplifier Right side of luggage compartment.
Audiopilot Microphone Behind left side of dash.
Capacitor (2) Right rear of roof.
Check Connector Behind right side of dash. See Fig. 15.
Clock Spring In steering column.
Coil Behind left side of dash.
Data Link Connector-2 Under lower left side of dash. See Fig. 30.
Diode Under right side of dash.
Driver-Side Air Bag Module No. 1 In steering wheel.
Driver-Side Air Bag Module No. 2 In steering wheel.
Driver-Side Curtain Air Bag Module Top of left "D" pillar.
Driver-Side Pre-Tensioner Seat Belt Base of left "B" pillar.
Driver-Side Side Air Bag Module Left side of driver's seat back.
Front Power MOS FET Near front blower motor.
Generator Left front of engine.
Horn (High) Left front of engine compartment.
Horn (Low) Right front of engine compartment.
Ignition Coils No. 1, 2 & 3 Top of right cylinder bank.
Ignition Coils No. 4, 5 & 6 Top of left cylinder bank.
Inverter Left side of luggage compartment.
Joint Connector (C-36) Behind left end of dash. See Fig. 36.
Joint Connector (C-37) Behind left center of dash. See Fig. 24.
Joint Connector (C-38) Behind center of dash. See Fig. 19.
Keyless Antenna (Exterior, Left/Right Front) In respective front door.
Keyless Antenna (Exterior, Rear) Behind center of rear bumper.
Keyless Antenna (Interior, Front Center) Under middle of dash.
Keyless Antenna (Interior, Rear) Center front of luggage compartment.
Keyless Antenna (Interior, Right Front) Under right side of dash.
Microphone Front center of roof.
Noise Filter Lower center of liftgate.
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2008 MAZDA CX-9
Passenger-Side Air Bag Module No. 1 Behind right side of dash.

Passenger-Side Air Bag Module No. 2 Behind right side of dash.
Passenger-Side Curtain Air Bag Module Top of right "C" pillar.
Passenger-Side Pre-Tensioner Seat Belt Base of right "B" pillar.
Passenger-Side Side Air Bag Module Right side of front passenger's seat back.
Power MOS FET Under center console.
PVC Valve Heater Fitting Center rear of engine compartment.
Rear Mount Camera Left side of liftgate.
Throttle Body Top rear of engine.
CONNECTORS
CONNECTORS LOCATION
Component Location
C-03 (12 Pin) Left side of engine compartment. See Fig. 6.
C-05 (14 Pin) Behind right kick panel. See Fig. 13.
C-06 (Blue, 40 Pin) Behind left side of dash. See Fig. 29.
C-07 (14 Pin) Under front of center console. See Fig. 22.
C-08 (16 Pin) Under left center of center console. See Fig. 23.
C-09 (14 Pin) Behind left kick panel. See Fig. 39.
C-11 (56 Pin) Under front of center console. See Fig. 21.
C-13 (34 Pin) Behind right kick panel. See Fig. 34.
C-14 (14 Pin) At left "B" pillar. See Fig. 54.
C-15 (14 Pin) At right "B" pillar. See Fig. 48.
C-16 (Blue, 40 Pin) Behind left kick panel. See Fig. 41.
C-19 (14 Pin) Under driver's seat. See Fig. 42.
C-20 (14 Pin) Under front passenger's seat. See Fig. 45.
C-21 (Blue, 40 Pin) At left "D" pillar. See Fig. 63.
C-23 (Light Gray, 24 Pin) Right rear corner of vehicle. See Fig. 52.
C-24 (24 Pin) Top of right "D" pillar. See Fig. 56.
C-25 (Blue, 39 Pin) Behind right kick panel. See Fig. 12.
C-26 (14 Pin) Center rear of roof. See Fig. 58.
C-27 (16 Pin) Center rear of roof. See Fig. 60.
C-28 (6 Pin) At left "D" pillar. See Fig. 57.
C-32 (14 Pin) In left rear door. See Fig. 55.
C-33 (14 Pin) In right rear door. See Fig. 49.
C-34 (16 Pin) Top front of engine. See Fig. 9.
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2008 MAZDA CX-9
C-35 (70 Pin) Right side of engine compartment. See Fig. 10.
C-39 (Yellow, 4 Pin) Behind right side of dash. See Fig. 17.
C-40 (6 Pin) Under driver's seat. See Fig. 43.
GROUNDS
GROUNDS LOCATION
Component Location
G01 (Joint Connector) Behind right kick panel. See Fig. 35.
G3 Left side of engine compartment. See Fig. 3.
G5 Behind right headlight assembly. See Fig. 11.
G7 Behind left headlight assembly. See Fig. 1.
G9 Behind right center of dash. See Fig. 18.
G10 (Joint Connector) Behind left side of dash. See Fig. 26.
G11 (Joint Connector) Behind left side of dash. See Fig. 33.
G12 (Joint Connector) At right "C" pillar. See Fig. 50.
G13 (Joint Connector) At left "C" pillar. See Fig. 61.
G14 At left "D" pillar. See Fig. 62.
G15 Center rear of roof. See Fig. 59.
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
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2008 MAZDA CX-9
Fig. 1: Engine Compartment

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2008 MAZDA CX-9

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Fig. 12: Right Kick Panel

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2008 MAZDA CX-9

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Fig. 14: Dash

Fig. 15: Dash

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Fig. 16: Dash

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Fig. 17: Dash

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Fig. 18: Dash

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Fig. 19: Dash

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Fig. 20: Center Console

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Fig. 24: Dash

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Fig. 25: Dash

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Fig. 26: Dash

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Fig. 27: Dash

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Fig. 28: Dash

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Fig. 29: Dash

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Fig. 30: Dash

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Fig. 31: Left Kick Panel

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Fig. 33: Dash

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Fig. 36: Dash

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Fig. 37: Dash

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Fig. 42: Under Driver's Seat

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Fig. 43: Under Driver's Seat

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Fig. 44: Driver's Seat

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Fig. 45: Under Front Passenger's Seat

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Fig. 46: Front Passenger's Seat

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Fig. 48: Right Side Of Vehicle

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Fig. 49: Right Rear Door


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Fig. 51: Right Rear Of Vehicle

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Fig. 52: Right Rear Of Vehicle

Fig. 53: Roof

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Fig. 54: Left Side Of Vehicle

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Fig. 55: Left Rear Door


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Fig. 58: Roof

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Fig. 59: Roof

Fig. 60: Roof

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Fig. 64: Left Rear Of Vehicle

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2008 ENGINE PERFORMANCE Emission System (MZI-3.7) - Mazda CX-9
2008 ENGINE PERFORMANCE
Emission System (MZI-3.7) - Mazda CX-9
EMISSION SYSTEM LOCATION INDEX [MZI-3.7]

ENGINE COMPARTMENT SIDE
Fig. 1: Identifying Purge Solenoid Valve, PCV Valve, PCV Valve Heater Fitting And Quick Release
Connector
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EXHAUST SYSTEM SIDE
Fig. 2: Identifying Exhaust System Side

FUEL TANK SIDE
2WD
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Fig. 3: Identifying Fuel Tank Side - 2WD

AWD
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Fig. 4: Identifying Charcoal Canister, Fuel-Filler Cap, Rollover Valve And Quick Release Connector
EMISSION SYSTEM DIAGRAM [MZI-3.7]
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Fig. 5: Emission System Diagram

FUEL-FILLER CAP INSPECTION [MZI-3.7]

LEAKAGE INSPECTION
1. Perform the following SST (Evaporative Emission System Tester 134-01049) self-test:
NOTE:  If the tester does not work correctly during self-test, refer to the
tester operators manual for more detailed procedures.
1. Verify that the gas cylinder valve is closed and the control valve located on the tester is in the
TEST position. All tester displays should be off at this time.
2. Connect the long hose (part of SST ) to the tester.
3. Connect the manifold assembly (part of SST ) to the long hose as shown.
4. Open the gas cylinder valve and verify the gas cylinder regulator left gauge reads 69-82 kPa {0.71-
0.83 kgf/cm2 , 10-12 psi}
(preset at factory).
 If not, refer to the tester operators manual to contact tester manufacturer.
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Fig. 6: Identifying Manifold Assembly And Long Hose

5. Press the ON/OFF switch to turn on the SST and make sure the left display reads 0.0.
6. Turn the control valve on the tester to the FILL position.
7. Verify the left display reading is within 13.9 to 14.0 in of water.
 If not, adjust the pressure using the regulator knob located on the right side of the tester.
8. Turn the control valve to TEST position and press the START switch.
9. After the 2-min countdown (left display) is completed, the right display shows the total pressure
loss for that period. A 0.5 in of water loss is acceptable on the self-test.
 If the loss is more than 0.5 in of water, do one or more self-test. If the failed test repeats,
check for leak using the ultrasonic leak detector (part of SST).
2. Press the RESET switch to set the left display reading to 0.0.
3. Connect the fuel cap receiver assembly (part of SST ) to the manifold assembly and fuel-filler cap from
the vehicle.
 If the fuel-filler cap is not a genuine part, replace it.
4. Turn the control valve to the FILL position.

5. Wait (maximum 20 s ) until the left display reads 13.9 to 14.0 in of water.
 If the reading is slightly below the specification, adjust it using the regulator knob.
 If the reading is far below, the fuel-filler cap has leak. Replace it.
6. Turn the control valve to the TEST position and press the START switch.
7. After the 2-min countdown (left display) is completed, check the test result (the failed/passed light on the
tester).
 If the green light turns on, the fuel-filler cap is normal.
 If the red light turns on, the fuel-filler cap has leakage. Replace it.
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Fig. 7: Identifying Fuel-Filler Cap Receiver Assembly

8. Close the gas cylinder valve.

9. Turn the control valve to the FILL position.
10. Press the ON/OFF switch to turn off the tester.
CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR

FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.7]
1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
NOTE:  Remove the charcoal canister, CV solenoid valve, and air filter as a
single unit.

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Fig. 8: Identifying Quick Release Connector, Evaporative Hose, Charcoal Canister & Torque
Specifications
CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR

FILTER COMPONENT INSPECTION [MZI-3.7]
AIRFLOW INSPECTION

2. Remove the charcoal canister, CV solenoid valve, air filter component. (See CHARCOAL CANISTER,
CANISTER VENT (CV) SOLENOID VALVE, AIR FILTER COMPONENT
3. Plug the purge solenoid valve side of the charcoal canister.
4. Pressurizing from the fuel tank side of the charcoal canister, verify that there is no leak from the charcoal
canister and that the CV solenoid valve is closed.
 If malfunction, replace the charcoal canister, CV solenoid valve, air filter component. (See
CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE, AIR FILTER
COMPONENT REMOVAL/INSTALLATION [MZI-3.7].)
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Fig. 9: Identifying Purge Solenoid Valve And Fuel Tank

5. Connect the battery positive voltage to CV solenoid valve terminal A.

6. Pressurizing from the fuel tank side of the charcoal canister, verify that the CV solenoid valve is open and
that there is airflow through the air filter.
Fig. 10: Identifying CV Solenoid Valve Wiring Harness-Side Connector

7. Pressurizing from the air filter side, verify that the CV solenoid valve is open and that there is airflow
through the air filter.
CV SOLENOID VALVE CIRCUIT OPEN/SHORT INSPECTION
1. Disconnect the PCM connector.

2. Inspect the following wiring harness for open or short circuit (continuity check).
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Fig. 11: Identifying CV Solenoid Valve Wiring Harness-Side Connector

Fig. 12: Identifying PCM Wiring Harness-Side Connector

Open circuit
 If there is no continuity, there is an open circuit. Repair or replace the wiring harness.
 CV solenoid valve terminal B and PCM terminal 1Z
 CV solenoid valve terminal A and battery
Short circuit
 If there is continuity, there is a short circuit. Repair or replace the wiring harness
 CV solenoid valve terminal B and power supply
 CV solenoid valve terminal B and body ground
PURGE SOLENOID VALVE REMOVAL/INSTALLATION [MZI-3.7]
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Fig. 13: Identifying Purge Solenoid Valve & Torque Specifications

PURGE SOLENOID VALVE INSPECTION [MZI-3.7]

AIRFLOW INSPECTION

2. Disconnect the quick release connector from the purge solenoid valve. (See QUICK RELEASE
CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7].)
3. Remove the purge solenoid valve. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION
[MZI-3.7].)
4. Verify that the airflow is as indicated in the table.
 If as specified in the table, perform the "Circuit Open/Short Inspection".
 If not as specified in the table, inspect the purge solenoid valve.
CONTINUITY CHART
Measured condition Continuity between A-B
When voltage is not applied between terminals A and B No airflow
When voltage is applied between terminals A and B Airflow detected
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Fig. 14: Identifying Purge Solenoid Valve Connector

CIRCUIT OPEN/SHORT INSPECTION

2. Inspect the following wiring harness for an open or short circuit (continuity check).
Fig. 15: Identifying Purge Solenoid Valve Wiring Harness-Side Connector


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Fig. 17: Identifying PCV Valve Heater Control

Open circuit
 If there is no continuity, the circuit is open. Repair or replace the harness.

 Purge solenoid valve terminal A and main relay No.1 terminal D
 Purge solenoid valve terminal B and PCM terminal 1 BC
Short circuit
 If there is continuity, the circuit is short. Repair or replace the harness.

 Purge solenoid valve terminal A and power supply
 Purge solenoid valve terminal A and body ground
 Purge solenoid valve terminal B and power supply
 Purge solenoid valve terminal B and body ground
POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION [MZI-3.7]
NOTE:  The PCV valve cannot be reassembled once it is removed because the
tabs will have been broken. Inspect the PCV valve without removing it
from the vehicle.
AIRFLOW INSPECTION

2. Disconnect the PCV valve hose from the PCV valve. (See POSITIVE CRANKCASE VENTILATION
(PCV) VALVE REMOVAL/INSTALLATION [MZI-3.7].)
3. Verify that there is no airflow when pressure is applied to the PCV valve using a vacuum pump.
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If there is airflow, replace the PCV valve. (See POSITIVE CRANKCASE VENTILATION

4. Verify that there is airflow when vacuum is applied to the PCV valve.
 If there is no airflow, replace the PCV valve. (See POSITIVE CRANKCASE VENTILATION
RESISTANCE INSPECTION

2. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7] .)
3. Disconnect the PCV valve heater control connector.
4. Measure the resistance between the PCV valve heater control terminals.
 If within the specification, perform out the "Circuit Open/Short Inspection".
 If not within the specification, replace the PCV valve. (See POSITIVE CRANKCASE
VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [MZI-3.7].)
PCV valve heater control resistance 10-35 ohm
Fig. 18: Identifying PCV Valve Heater Control Connector Terminals


2. Inspect the following wiring harnesses for open or short circuit (continuity check).
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Fig. 19: Identifying PCV Valve Heater Control Wiring Harness Side Connector
Fig. 20: Identifying Fuse Box (Main Relay No.1)

Fig. 21: Identifying PCM Wiring Harness Side Connector

Open circuit
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 PCV valve heater control terminal A and main relay No.1 terminal D
 PCV valve heater control terminal B and PCM terminal 2BL
Short circuit
 If there is continuity, there is a short circuit. Repair or replace the wiring harness.
 PCV valve heater control terminal A and power supply
 PCV valve heater control terminal A and body ground
 PCV valve heater control terminal B and power supply
 PCV valve heater control terminal B and body ground
POSITIVE CRANKCASE VENTILATION (PCV) VALVE

REMOVAL/INSTALLATION [MZI-3.7]
CAUTION:  A new PCV valve must be installed if removed from the cylinder head
cover.
 Upon removal, damage will occur to the locking mechanism on the
PCV valve.

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Fig. 22: Identifying PCV Valve Hose, PCV Valve Heater Control Connector, PCV Valve And O-
Ring
POSITIVE CRANKCASE VENTILATION (PCV) VALVE HEATER FITTING

INSPECTION [MZI-3.7]

2. Disconnect the PCV valve heater fitting connector.
3. Measure the resistance between the PCV valve terminals.
 If within the specification, perform out the "Circuit Open/Short Inspection".
 If not within the specification, replace the PCV valve heater fitting. (See POSITIVE
CRANKCASE VENTILATION (PCV) VALVE HEATER FITTING
PCV valve heater fitting resistance 10-35 ohms
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Fig. 23: Identifying PCV Valve Heater Connector Terminal


Fig. 24: Identifying PCV Valve Heater Control Wiring Harness Side Connector
Fig. 25: Identifying Fuse Box (Main Relay No.1)

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Fig. 26: Identifying PCM Wiring Harness Side Connector

Open circuit
 PCV valve heater fitting terminal A and main relay No.1 terminal D
 PCV valve heater fitting terminal B and PCM terminal 2AU
Short circuit
 PCV valve heater fitting terminal A and power supply
 PCV valve heater fitting terminal A and body ground
 PCV valve heater fitting terminal B and power supply
 PCV valve heater fitting terminal B and body ground
POSITIVE CRANKCASE VENTILATION (PCV) VALVE HEATER FITTING

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Fig. 27: Identifying PCV Valve Hose, PCV Valve Heater Control Connector, PCV Valve, O-Ring &
ROLLOVER VALVE REMOVAL/INSTALLATION [MZI-3.7]
NOTE:  The rollover valve cannot be removed as it is built into the fuel tank.
ROLLOVER VALVE INSPECTION [MZI-3.7]
NOTE:  The rollover valve cannot be disassembled and inspected as it is built into
the fuel tank.
1. Perform the fuel tank inspection. (See FUEL TANK INSPECTION [MZI-3.7] .)
FUEL SHUT-OFF VALVE REMOVAL/INSTALLATION [MZI-3.7]
NOTE:  The fuel shut-off valve cannot be removed as it is built into the fuel tank.
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FUEL SHUT-OFF VALVE INSPECTION [MZI-3.7]
NOTE:  The fuel shut-off valve cannot be removed and inspected as it is built into
the fuel tank.
1. Perform the fuel tank inspection. (See FUEL TANK INSPECTION [MZI-3.7] .)
QUICK RELEASE CONNECTOR (EMISSION SYSTEM)

WARNING:  Fuel is very flammable liquid. If fuel spills or leaks from the
pressurized fuel system, it will cause serious injury or death and
facility breakage. Fuel can also irritate skin and eyes. To prevent
this, always complete the "Fuel Line Safety Procedure", while
referring to the "BEFORE SERVICE PRECAUTION".
QUICK RELEASE CONNECTOR TYPE
CAUTION:  There are five types of quick release connectors. Verify the type and
location, and install/remove properly.
Fig. 28: Identifying Engine Compartment Side And Ventilation Hose

TYPE A REMOVAL
1. Release the retainer shown in the figure.

2. Disconnect the quick release connector.
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3. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to
prevent it from scratches or dirt.
Fig. 29: Identifying Quick Release Connector And Retainer

TYPE B REMOVAL NOTE
NOTE:  If the quick release connector is removed, replace the retainer with a new
one.
1. Push the retainer.
NOTE:  The quick release connector can be removed by pushing the center
of the retainer tabs.
 The retainer is attached to the pipe even after the connector is
disconnected.
2. Pull the connector side and disconnect the quick release connector.

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TYPE C REMOVAL
1. Move the retainer upward using a small flathead screwdriver or a similar tool.
2. Pull out the fuel hose straight from the fuel pipe and disconnect it.
Fig. 31: Pulling Fuel Hose Straight

TYPE D REMOVAL
CAUTION:  The quick release connector may be damaged if the release tab is
bent excessively. Do not expand the release tab over the stopper.
NOTE:  The fuel hose can be removed by pushing it to the pipe side to release the
lock.
1. Rotate the release tab on the quick release connector to the stopper position.
Fig. 32: Identifying Release Tab And Stopper

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Fig. 33: Identifying Fuel Pipe And Fuel Hose

TYPE E REMOVAL
CAUTION:  The quick release connector may be damaged if the release tab is
bent excessively. Do not expand the release tab over the stopper.
NOTE:  The fuel hose can be removed by pushing it to the pipe side to release the
lock.
1. Release the retainer shown in the figure.

2. Disconnect the quick release connector.
Fig. 34: Releasing Retainer

TYPE A INSTALLATION
1. Inspect the fuel hose and fuel pipe sealing surface for damage and deformation.
 If there is any malfunction, replace it with a new one.
2. Connect the quick release connector.

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Fig. 35: Connecting Quick Release Connector

TYPE B INSTALLATION
CAUTION:  Be sure to replace the retainer with a new one to prevent gas leakage.
 To prevent evaporative gas leakage, be sure not to damage the
connecting part between the charcoal canister and pipe, and the
locks between the quick release connector and retainer. If any of
them are damaged, replace the charcoal canister or hose with a new
one.
NOTE:  If the quick release connector O-ring is damaged or has slipped, replace
the fuel hose.
 A checker tab is integrated with the quick release connector for new fuel
hoses and evaporative hoses. Remove the checker tab from the quick
release connector after the connector is completely engaged with the fuel
pipe.
1. Remove the retainer remaining on the charcoal canister pipe.

2. Install a new retainer to the quick release connector.
3. Reconnect the hose straight to the pipe until a click is heard.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected
securely.
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Fig. 36: Identifying Checker Tab And Fuel Hose

TYPE C INSTALLATION
the fuel hose.
2. Install the quick release connector.

 Insert the fuel pipe straight to the end of the quick release connector.
 Push down the retainer using a finger.
 If the retainer cannot be pushed down, push the fuel pipe further to the quick release
connector.
securely.
Fig. 37: Installing Quick Release Connector

TYPE D INSTALLATION
the fuel hose
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 A checker tab is integrated with the quick release connector for new fuel
hoses and evaporative hoses. Remove the checker tab from the quick
release connector after the connector is completely engaged with the fuel
pipe.

2. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe.
3. Reconnect the fuel hose straight to the fuel pipe until a click is heard.
NOTE:  If the quick release connector does not move at all, disconnect it,
verify that the O-ring is not damaged or has not slipped, and then
reconnect the quick release connector.
4. Lightly pull and push the quick release connector a few times by hand, and then verify that it can move
2.0-3.0 mm {0.08-0.12 in} and is connected securely.
TYPE E INSTALLATION

connector.
securely.
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Fig. 39: Pushing Quick Release Connector

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2008 ENGINE Control System (MZI-3.7) - Mazda CX-9
2008 ENGINE
Control System (MZI-3.7) - Mazda CX-9
CONTROL SYSTEM WIRING DIAGRAM [MZI-3.7]
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Fig. 1: Control System Wiring Diagram (1 Of 3)

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CONTROL SYSTEM LOCATION INDEX [MZI-3.7]
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Fig. 4: Identifying Control System Components Location

CONTROL SYSTEM DIAGRAM [MZI-3.7]

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Fig. 5: Control System Diagram

PCM REMOVAL/INSTALLATION [MZI-3.7]
NOTE:  To replace the PCM, Setup the M-MDS and perform the PCM configuration.
(See PCM CONFIGURATION [MZI-3.7].)

NOTE:  Only 2 PCM connectors.
3. Disconnect connectors.
4. Remove PCM and bracket as and assembly.
5. Remove PCM from bracket.
6. When replacing the PCM on the vehicles, perform the following.
 PCM parameter reset. (See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING [ADVANCED KEYLESS SYSTEM] .) (See IMMOBILIZER
SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND CLEARING
[KEYLESS ENTRY SYSTEM] .)
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Fig. 6: Identifying PCM Bracket, Connector & Torque Specifications

PCM INSPECTION [MZI-3.7]
CAUTION:  The PCM terminal voltage can vary with the conditions when
measuring and changes due to aged deterioration on the vehicle,
causing false diagnosis. Therefore determine comprehensively where
the malfunction occurs among the input systems, output systems,
and the PCM.
PCM INSPECTION PREPARATION

5. Remove the windshield wiper motor. (See WINDSHIELD WASHER MOTOR
7. Remove the PCM connector still connected.
8. Install the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
TYPICAL DIAGNOSTIC REFERENCE VALUES
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VOLTAGE SENSOR SPECIFICATION CHART

Measured/PID Values
Units
Sensors/Inputs 48 KM/H 89 KM/H
KOEO Hot Idle Measured/PID
(30MPH) (55MPH)
VBAT/HIGH
PSP 0.1/LOW 0.1/LOW 0.1/LOW DCV/HIGH-LOW
(I)
GENMN
11.89/0 VBAT/50 VBAT/28 VBAT/25 DCV/%
(GFS)
APP1 3.9 3.9 3.5 3.3 DCV
APP2 1.6 1.7 1.8 2.1 DCV
APP3 1.0 1.0 1.3 1.5 DCV
FPM OFF ON ON ON ON-OFF
ACP 0.8/70 0.86/73 0.9/75 1.0/87 DCV/psi
MAF 0 0.7 1.4 1.5 DCV
MAF SIGRTN 0 0.6-1.9 1-1.6 1.3-2.3 DCV
IAT 80 (K) 50 (K) 37 (K) 34 (K) DEG F
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FTP 2.6/-0.01 2.6/-0.01 2.6/-0.01 2.6/-0.01 DCV/psi

BOO VBAT/OFF 0.1/ON (E) VBAT/OFF VBAT/OFF DCV/ON-OFF
BPA 0.1/OFF VBAT/ON (E) 0.1/OFF 0.1/OFF DCV/ON-OFF
FEPS 0.5-0.6 0.5-0.6 0.5-0.6 0.5-0.6 DCV
SCCS 5 0.1 (P) 5 5 DCV
HO2S12 (L) (D) (D) (D) DCV
HO2S22 0.1 (D) (D) (D) DCV
HO2S21 0 switching (C) switching (C) switching (C) DCV
HO2S11 (L) switching (C) switching (C) switching (C) DCV
CHT 3.6/199 3.6/199 3.58/201 3.45/208 DCV/DEG F
CMP2 0 5-7 13-16 20-23 Hz
CMP1 0 5-7 13-16 20-23 Hz
CKP 0 400-500 850-1050 1050-1150 Hz
KNOCK 1 23.99k 25.01k 25.73k 44.51k N/A
TP2 1.1/25 0.8/15 1.0/19 1.4/27 DCV/%
TP1 4.1/17 4.4/13 4.2/16 4.0/19 DCV/%
ACCS VBAT/OFF VBAT/ON (A) VBAT/OFF VBAT/OFF DCV/ON-OFF
APP 3.9 0 0 22 %
NO FAULT - NO
APP_FLT NO FAULT NO FAULT NO FAULT
FAULT FAULT
CPP/PNP NEUTRAL NEUTRAL DRIVE DRIVE NEUTRAL-DRIVE
ETC_ACT 7.56 1.27 6.22 12.74 DEG
ETC_DSD 7.62 1.31 6.19 12.73 DEG
ETC_TRIM 0.23 0.21 0.24 0.24 DEG
NO FAULT - NO
FANVAR NO FAULT NO FAULT NO FAULT
FAULT FAULT
FLI 71 (H) 72 (H) 82 (H) 81 (H) %
LOAD 51.4 (L) 16.1 35.4 34.7 %
MISFIRE NO NO NO NO YES-NO
RPM 0 600 1200 1500 RPM
VSS 0 0 30 55 MPH
NO FAULT - NO
WAC F NO FAULT NO FAULT NO FAULT
FAULT FAULT

Measured/PID Values
48 KM/H (30MPH) 89 KM/H Units
Outputs KOEO Hot Idle
Actuators/Outputs (55MPH) Measured/PID
GENFDC 3.79 0 0 0 %
SMC 0 0 0 0 DCV
CTO 0 0 0 0 Hz
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EVMV 0 337 0 847 mA

EVAPCV 0 0 0 0 %
FP 8.3/75 3.6/27 3.6/27 3.8/29 DCV/%
WAC/ACCR OFF OFF OFF OFF ON-OFF
HTR12 VBAT/OFF 0.2/ON 0.2/ON 0.2/ON DCV/ON-OFF
HTR22 VBAT/OFF 0.2/ON 0.2/ON 0.2/ON DCV/ON-OFF
CD6F (CYL 6) VBAT VBAT VBAT VBAT DCV
CD5D (CYL 5) VBAT VBAT VBAT VBAT DCV
CD4B (CYL 4) VBAT VBAT VBAT VBAT DCV
CD3E (CYL 3) VBAT VBAT VBAT VBAT DCV
CD2C (CYL 2) VBAT VBAT VBAT VBAT DCV
CD1A(CYL1) VBAT VBAT VBAT VBAT DCV
PCVHC 0 0 0 0 %
TACM (+) 3.7 VBAT VBAT VBAT DCV
INJ2 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ4 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ6 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
TACM (-) 3.7 VBAT VBAT VBAT DCV
INJ1 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ3 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
INJ5 0 2.6-3.2 2.5-5.5 3.5-8.5 mS
VCTADV 0 -.031 -27.56 -30.94 DEG
VCTADV2 0 0 -27.69 -31.06 DEG
HTR11 0.1/ON (O) 0.1/ON 0.1/ON 0.1/ON DCV/ON-OFF
HTR21 0.1/ON (O) 0.1/ON 0.1/ON 0.1/ON DCV/ON-OFF
FANVAR 0 0 0 0 %
FANDC 7.5 7.5 7.5 7.5 %
FP ON/OFF ON ON ON ON-OFF
(-)20-(+) (-)20-(+)
LONGFT1 (L) (-)20-(+)20 %
20 20
(-)20-(+) (-)20-(+)
LONGFT2 (L) (-)20-(+)20 %
20 20
MIL OFF OFF OFF OFF ON-OFF
(-)10-(+) (-)10-(+)
SHRTFT1 (L) (-)10-(+)10 %
10 10
(-)10-(+) (-)10-(+)
SHRTFT2 (U (-)10-(+)10 %
10 10
SPARKADV 10 13.25 44 45.25 DEG
VCTDC 0 0 47.32 80 %
VCTDC2 0 0 46.8 80 %
VCTADVERR 0 0.18 -0.37 -0.18 DEG
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VCTADVERR2 0 0.06 -0.43 0 DEG

Measured/PID Values
Other Units Measured/PID
KOEO Hot Idle 48 KM/H (30MPH) 89 KM/H (55MPH)
ETCVREF 5 5 5 5 DCV
VREF 5 5 5 5 DCV
VPWR VBAT VBAT VBAT VBAT DCV
KAPWR VBAT VBAT VBAT VBAT DCV
PCM CONFIGURATION [MZI-3.7]
the PCM CONFIGURATION.

1. Select the "Module Programming".

3. Then, select the "Programmable Module Installation", "PCM" from the screen menu.
4. Select "PCM" and perform procedures according to directions on the M-MDS screen.
 If a DTC(s) is detected, perform the applicable DTC inspection. (See DTC TABLE [MZI-3.7] .)

POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [MZI-3.7]

CONTINUITY INSPECTION
1. Disconnect the PSP switch connector.

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3. Verify no continuity between the PSP switch terminals while rotating the steering wheel.
 If there is continuity, verify that P/S oil pump is normal and replace the PSP switch. (See POWER
STEERING OIL PUMP DISASSEMBLY/ASSEMBLY .)
 If the monitor item condition/specification (reference) is not within the specification, even though
there is no malfunction, perform the "Circuit Open/Short Inspection".
Fig. 9: Identifying PSP Switch And Wiring Harness Side Connector

1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [MZI-3.7].)

2. Inspect the following wiring harness for open or short. (Continuity inspection)
Open circuit
 If there is no continuity, the circuit is open. Repair or replace the wiring harness.
 PSP switch terminal A and PCM terminal 21
Short circuit
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 If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
 PSP switch terminal A and body ground
MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR

2. Disconnect MAF/IAT sensor connector.
3. Remove the MAF/IAT sensor.
Fig. 10: Identifying MAF/IAT Sensor Connector, Bolts & Torque Specifications
MASS AIR FLOW (MAF) SENSOR INSPECTION [MZI-3.7]
NOTE:  Before performing the following inspection, make sure to follow the
procedure as indicated in the troubleshooting flowchart. (See HOW TO
USE THIS MANUAL .)
VISUAL INSPECTION
1. Verify the following items of the MAF sensor.

 Damage, cracks
 Rusted sensor terminal
 Bent sensor terminal
 If there is any malfunction, replace the MAF sensor. (See MASS AIR FLOW
(MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR
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VOLTAGE INSPECTION
1. Remove the MAF sensor with the connector still connected.

3. Verify that the MAF sensor output voltage (M-MDS monitor item: MAF) changes when wind is
introduced gradually to the sensor part of the MAF sensor.
 If it cannot be verified even though the related harnesses have no malfunction, replace the MAF
sensor. (See MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR
 If the monitor item status/specification (reference) is not within the specification, even though the
resistance is within the specification, perform the "Circuit Open/Short Inspection".
Fig. 11: Identifying MAF/IAT Sensor And PCM Wiring Harness Side Connector
1. Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION [MZI-3.7].

2. Disconnect the MAF/IAT sensor connector.
3. Inspect the following wiring harnesses for open or short. (Continuity inspection)
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Open circuit
 MAF/IAT sensor terminal A and main relay No.1 terminal D
 MAF/IAT sensor terminal C and PCM terminal 1AJ
 MAF/IAT sensor terminal D and PCM terminal 1 AN
 MAF/IAT sensor terminal E and PCM terminal 1AL
Short circuit
 MAF/IAT sensor terminal A and body ground
 MAF/IAT sensor terminal C and power supply
 MAF/IAT sensor terminal C and body ground
 MAF/IAT sensor terminal D and power supply
 MAF/IAT sensor terminal D and body ground
 MAF/IAT sensor terminal E and power supply
INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [MZI-3.7]
USE THIS MANUAL .)
1. Disconnect the MAF/IAT sensor connector.

2. Measure the resistance between MAF/IAT sensor terminals A and F.
Fig. 12: Identifying MAF/IAT Sensor Terminals

 If not within the specification, replace the MAF/IAT sensor. (See MASS AIR FLOW
(MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION
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[MZI-3.7].)
IAT sensor resistance
IAT SENSOR RESISTANCE SPECIFICATION CHART

IAT (°C {°F}) Resistance (kilohm)
10(50} Approx. 58.75
20 {68} Approx. 37.30
30 {86} Approx. 24.27
60 {140} Approx. 7.70
IAT sensor characteristics graph (reference)
Fig. 13: Temperature Vs Resistance Graph

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Fig. 14: Identifying MAF/IAT Sensor Connector And PCM Wiring Harness Side Connector

Open circuit
 MAF/IAT sensor terminal B and body ground
 MAF/IAT sensor terminal F and PCM terminal 1AF
Short circuit
 MAF/IAT sensor terminal B and power supply
 MAF/IAT sensor terminal F and body ground
 MAF/IAT sensor terminal F and power supply
THROTTLE POSITION (TP) SENSOR INSPECTION [MZI-3.7]

Microsoft
USE THIS MANUAL .)
VOLTAGE INSPECTION
1. Verify that no DTC related to APP sensor has been detected.

 If any DTCs related to APP sensor have been detected, perform the DTC inspection. (See DTC
TABLE [MZI-3.7] .)
4. Select TP1 or TP2 PID (voltage) on the M-MDS.

5. Operate the accelerator pedal and verify that the TP1 or TP2 PID (voltage) changes as shown in the
following graph.
 If not verified, perform the "Circuit Open/Short Inspection".
 If there is no open or short circuit, replace the throttle body. (See INTAKE-AIR SYSTEM
Fig. 16: Throttle Angle & Voltage Graph (Degrees)
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Fig. 17: Throttle Body Wiring Harness Side Connector & PCM Wiring Harness Side-Connector

2. Inspect the following wiring harnesses for open or short circuit. (Continuity inspection)
Open circuit
 Throttle body terminal C and PCM terminal 2AD
 Throttle body terminal D and PCM terminal 2D
 Throttle body terminal E and PCM terminal 2AH
 Throttle body terminal F and PCM terminal 2Z
Short circuit
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 Throttle body terminal C and power supply
 Throttle body terminal C and body ground
 Throttle body terminal D and body ground
 Throttle body terminal E and power supply
 Throttle body terminal F and body ground
 Throttle body terminal F and power supply
ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [MZI-3.7]
USE THIS MANUAL .)
VOLTAGE INSPECTION
1. Turn the ignition switch to the ON position (Engine OFF).

2. Verify that the PCM terminal 1 AC, 1 AG and 1 AK change smoothly while throttle valve is gradually
opened.
 If as verified, go to next step.
 If not as verified, perform the "Circuit Open/Short Inspection".
 If there is no open or short circuit, replace the throttle body.
3. Verify that the PCM terminal 1 AC, 1 AG and 1 AK voltages are as shown in the following table.
Fig. 18: Identifying PCM Wiring Harness Side-Connector

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 If voltage is not as following table, perform the "Circuit Open/Short Inspection".

 If there is no open or short circuit, replace accelerator pedal. (See ACCELERATOR
PEDAL REMOVAL/INSTALLATION [MZI-3.7] .)
APP sensor output voltage
APP SENSOR OUTPUT VOLTAGE SPECIFICATION CHART

PCM terminal 1AK (APP PCM terminal 1AG (APP PCM terminal 1 AC
Condition
sensor No.1) sensor No.2) (APP sensor No.3)
Accelerator pedal
Approx. 4.1 V Approx. 1.5 V Approx. 0.1 V
released
Accelerator pedal
Approx. 1.0 V Approx. 3.9 V Approx. 3.3 V
depressed
Fig. 19: Identifying Accelerator Pedal Position Sensor & PCM Wiring Harness Side Connector

2. Inspect the following wiring harnesses for open or short circuit. (Continuity inspection)
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Open circuit
 APP sensor terminal B and PCM terminal 1 AC
 APP sensor terminal C and PCM terminal 1AH
 APP sensor terminal D and PCM terminal 1Y
 APP sensor terminal E and PCM terminal 1AK
 APP sensor terminal F and PCM terminal 1BA
 APP sensor terminal G and PCM terminal 1AD
Short circuit
 APP sensor terminal B and body ground
 APP sensor terminal B and power supply
 APP sensor terminal C and power supply
 APP sensor terminal D and body ground
 APP sensor terminal E and body ground
 APP sensor terminal E and power supply
 APP sensor terminal F and body ground
 APP sensor terminal G and power supply
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZI-

3.7]
NOTE:  Disconnect the connector after the CKP sensor is removed to prevent the
CKP sensor from falling off.
 The bolt and sensor are integrated and cannot be pulled out.
 When removing the CKP sensor, be careful not to drop the tool.
 The bolt and sensor must be pulled in different directions. Pull them as
indicated in the figure.
Fig. 20: Identifying CKP Sensor

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REMOVAL

2. Remove the following part for easier access.
1. Remove the Catalytic Converter (WU-TWC) (LH).(See EXHAUST SYSTEM
Fig. 21: Identifying CKP Sensor, Cover With Insulator & Torque Specifications
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [MZI-3.7]
USE THIS MANUAL .)
VISUAL INSPECTION
1. Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR

2. Verify that there are no metal shavings on the CKP sensor.
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3. Install the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR

1. Remove the CKP sensor connector.

2. Measure the resistance between the CKP sensor terminals.
 If not within the specification, replace the CKP sensor. (See CRANKSHAFT POSITION (CKP)
SENSOR REMOVAL/INSTALLATION [MZI-3.7].)
CKP sensor resistance
250-1,000 ohms
Fig. 22: Identifying CKP Sensor And PCM Harness Side Connector
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2. Inspect the following harness for open or short circuit. (Continuity check)
Open circuit
 CKP sensor terminal A and PCM terminal 2P

 CKP sensor terminal B and PCM terminal 2T
Short circuit
 CKP sensor terminal A and power supply

 CKP sensor terminal A and body ground
 CKP sensor terminal B and power supply
 CKP sensor terminal B and body ground
CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [MZI-3.7]

2. Remove the battery.
 Remove the resonance chamber and air cleaner assy. (See INTAKE-AIR SYSTEM
4. Disconnect the CMP sensor connector
5. Remove the CMP sensor.
NOTE:  Lubricate the CMP O-ring seal with clean engine oil.
Fig. 23: Identifying CMP Sensor Connector & Torque Specifications

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CAMSHAFT POSITION (CMP) SENSOR INSPECTION [MZI-3.7]
USE THIS MANUAL .)
VISUAL INSPECTION
1. Remove the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR

2. Verify that there are no metal shavings on the CMP sensor.
3. Install the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR
1. Remove the CMP sensor connector.

2. Measure the resistance between the CMP sensor terminals.
 If not within the specification, replace the CMP sensor. (See CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/INSTALLATION [MZI-3.7].)
CMP sensor resistance
800-1,320 ohms
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Fig. 24: Identifying CMP And PCM Sensor Harness Side Connector

2. Inspect the following harness for open or short circuit. (Continuity check)
Open circuit
 CMP sensor (RH) terminal A and PCM terminal 2X

 CMP sensor (RH) terminal B and PCM terminal 2C
 CMP sensor (LH) terminal A and PCM terminal 2AB
 CMP sensor (LH) terminal B and PCM terminal 2C
Short circuit
 CMP sensor (RH) terminal A and power supply

 CMP sensor (RH) terminal A and body ground
 CMP sensor (RH) terminal B and power supply
 CMP sensor (LH) terminal A and power supply
 CMP sensor (LH) terminal A and body ground
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 CMP sensor (LH) terminal B and power supply
FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION

[MZI-3.7]
HO2S (LH) REMOVAL/INSTALLATION

3. Disconnect the HO2S (LH) connector.
NOTE:  If necessary, lubricate the HO2S with Penetrating and Lock Lubricant
loosen to aid in removal.
4. Remove the HO2S (LH) using the SST.
NOTE:  Apply a light coat of anti-seize lubricant to the threads of the HO2S.
Fig. 25: View Of HO2S (LH), SST & Torque Specifications

HO2S (RH) REMOVAL/INSTALLATION

3. Disconnect the HO2S (RH) connector.
NOTE:  If necessary, lubricate the HO2S with Penetrating and Lock Lubricant
loosen to aid in removal.
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4. Remove the HO2S (RH) using the SST.
Fig. 26: View Of HO2S, SST & Torque Specifications

FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [MZI-3.7]
USE THIS MANUAL .)
FRONT HEATED OXYGEN SENSOR (HO2S) VOLTAGE INSPECTION
1. Warm up the engine to normal operating temperature.

2. Using the M-MDS, monitor the following:
 Vehicle speed (PID: VSS)
 Engine speed (PID: RPM)
 Front HO2S voltage (PID: O2S11, O2S21)
3. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine
speed is 3,000 rpm or more.
4. Verify that the front H02S outputs a voltage of 0.6 V or more , one time or more, then verify that the
front HO2S voltage (PID: O2S11, O2S21) is 0.3 V is or less while decelerating as shown in the figure.
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Fig. 27: Output Voltage Graph

 If not within the specification, inspect the front HO2S for an open or short circuit. (See FRONT
HEATED OXYGEN SENSOR (HO2S) Voltage Inspection.) Then if there is no malfunction in
the wiring harness, replace the front HO2S. (See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [MZI-3.7].)
HO2S HEATER RESISTANCE INSPECTION
1. Disconnect the HO2S connector.

2. Measure the resistance between HO2S terminals C and A.
 If it is not within the specification, replace the HO2S. (See FRONT HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-3.7].)
HO2S heater resistance
3-30 ohms
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Fig. 28: Identifying HO2S Connector


2. Inspect the following wiring harness for open or short (continuity check).
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Fig. 29: Identifying PCM Warning Harness-Side Connector

Open circuit

 HO2S (RH) terminal A and PCM terminal 2J
 HO2S (RH) terminal B and PCM terminal 2Y
 HO2S (RH) terminal C and main relay No.2 terminal D
 HO2S (RH) terminal D and PCM terminal 2AL
 HO2S (LH) terminal A and PCM terminal 2E
 HO2S (LH) terminal B and PCM terminal 2U
 HO2S (LH) terminal C and main relay No.2 terminal D
 HO2S (LH) terminal D and PCM terminal 2AL
Short circuit
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 If there is continuity, the circuit is shorted. Repair or replace the harness.

 HO2S (RH) terminal A and power supply
 HO2S (RH) terminal A and body ground
 HO2S (RH) terminal B and power supply
 HO2S (RH) terminal B and body ground
 HO2S (RH) terminal C and body ground
 HO2S (RH) terminal D and power supply
 HO2S (LH) terminal A and power supply
 HO2S (LH) terminal A and body ground
 HO2S (LH) terminal B and power supply
 HO2S (LH) terminal B and body ground
 HO2S (LH) terminal C and body ground
 HO2S (LH) terminal D and power supply
REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-

3.7]
HO2S (LH) REMOVAL/INSTALLATION

2. Disconnect the HO2S (LH) connector.
NOTE:  If necessary, lubricate the HO2S (LH) with Penetrating and Lock
Lubricant loosen to aid in removal.
3. Remove the HO2S (LH) using the SST.
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HO2S (RH) REMOVAL/INSTALLATION

3. Disconnect the HO2S (RH) connector.
NOTE:  If necessary, lubricate the HO2S (RH) with Penetrating and Lock
Lubricant loosen to aid in removal.
4. Remove the HO2S (RH) using the SST.

REAR HEATED OXYGEN SENSOR (HO2S) INSPECTION [MZI-3.7]
USE THIS MANUAL .)
REAR HEATED OXYGEN SENSOR (HO2S) VOLTAGE INSPECTION

2. Using the M-MDS, monitor the following:
 Vehicle speed (PID: VSS)
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Engine speed (PID: RPM)


 Rear HO2S voltage (PID: O2S12, O2S22)
3. Drive the vehicle and decelerate the engine speed by releasing the accelerator pedal fully when the engine
speed is 3,000 rpm or more.
4. Verify that the rear HO2S outputs a voltage of 0.6 V or more , one time or more, then verify that the rear
HO2S voltage (PID: O2S12, O2S22) is 0.3 V is or less while decelerating as shown in the figure.
Fig. 32: Output Voltage Graph

 If not within the specification, inspect the rear HO2S for an open or short circuit. Then if there is no
malfunction in the wiring harness, replace the rear HO2S. (See REAR HEATED OXYGEN
SENSOR (HO2S) REMOVAL/INSTALLATION [MZI-3.7].)
HO2S HEATER RESISTANCE INSPECTION
1. Disconnect the HO2S connector.

2. Measure the resistance between HO2S terminals C and A.
 If it is not within the specification, replace the HO2S. (See REAR HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION [MZI-3.7].)
HO2S heater resistance
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3-30 ohms
Fig. 33: Identifying HO2S Connector


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Fig. 34: Identifying PCM Wiring Harness-Side Connector And Rear HO2S Connector
Open circuit

 HO2S (RH) terminal A and PCM terminal 2AS
 HO2S (RH) terminal B and PCM terminal 2BG
 HO2S (RH) terminal C and main relay No.2 terminal D
 HO2S (RH) terminal D and PCM terminal 2AL
 HO2S (LH) terminal A and PCM terminal 2AO
 HO2S (LH) terminal B and PCM terminal 2BC
 HO2S (LH) terminal C and main relay No.2 terminal D
 HO2S (LH) terminal D and PCM terminal 2AL
Short circuit
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 If there is continuity, the circuit is shorted. Repair or replace the harness.

 HO2S (RH) terminal A and power supply
 HO2S (RH) terminal A and body ground
 HO2S (RH) terminal B and power supply
 HO2S (RH) terminal B and body ground
 HO2S (RH) terminal C and body ground
 HO2S (RH) terminal D and power supply
 HO2S (LH) terminal A and power supply
 HO2S (LH) terminal A and body ground
 HO2S (LH) terminal B and power supply
 HO2S (LH) terminal B and body ground
 HO2S (LH) terminal C and body ground
 HO2S (LH) terminal D and power supply
KNOCK SENSOR (KS) REMOVAL/INSTALLATION [MZI-3.7]
NOTE:  Put a tray under the converter housing to receive the engine coolant.

2. Remove the following part for easier access. Perform the following procedure to remove the intake
manifold
1. Remove the ventilation hose. (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM)
2. Remove the vacuum hose (to purge solenoid valve). (See QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7] .)
3. Remove the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION
[MZI-3.7] .)
4. Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZI-
3.7] .)
5. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
[MZI-3.7] .)
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Fig. 35: Putting Tray Under Converter Housing

Fig. 36: Identifying Water Inlet Pipe, O-Ring, KS Connector & Torque Specifications
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NOTE:  Lubricate the new O-ring with clean engine coolant for installation.
KNOCK SENSOR (KS) INSPECTION [MZI-3.7]
USE THIS MANUAL .)
1. Turn the ignition switch to LOCK.

2. Disconnect the KS connector.
3. Measure the resistance between the KS terminals.
KS(RH): KS terminals A and B
KS(LH): KS terminals C and D
 If not as specified, replace the KS.

 If the KS is normal, but PID value is out of specification, perform the "Circuit Open/Short
Inspection".
KS resistance
4.39-5.35 Mohms
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Fig. 37: Identifying KS Wiring Harness Side Connector And PCM Wiring Harness Side Connector

Open circuit
 KS terminal A and PCM terminal 2Q
 KS terminal B and PCM terminal 2M
 KS terminal C and PCM terminal 2L
 KS terminal D and PCM terminal 2G
Short circuit
 KS terminal A and power supply
 KS terminal A and body ground
 KS terminal B and power supply
 KS terminal B and body ground
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 KS terminal C and power supply

 KS terminal C and body ground
 KS terminal D and power supply
 KS terminal D and body ground
CYLINDER HEAD TEMPERATURE (CHT) SENSOR

NOTE:  Do not reuse the CHT sensor, install a new sensor.

Perform the following procedure to remove the intake manifold.
2. Remove the vacuum hose (to purge solenoid valve). (See QUICK RELEASE CONNECTOR
(EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7] .)
3. Remove the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION
[MZI-3.7] .)
4. Remove the fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZI-
3.7] .)
3. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
4. Disconnect the CHT sensor connector.
5. Remove the CHT sensor using the following tools.
 Socket 3/8", 20 mm, 6 point
 Ratchet handle and torque wrench 3/8" Drive
Fig. 38: Identifying CHT Sensor Connector

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Tightening torque
8.9-10.5 N.m {90.8-107.0 kgf.cm, 78.8-92.9 in.lbf}
Fig. 39: Removing CHT Sensor Connector

CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION [MZI-3.7]
USE THIS MANUAL .)
1. Disconnect the CHT sensor connector.

2. Measure the resistance between the CHT sensor terminals.
 If it is not within the specification, replace the CHT sensor.
Measure the cylinder head temperature sensor resistance (approx.).
RESISTANCE SPECIFICATION CHART

Cylinder head temperature (°C {°F}) Resistance (kilohm)
20 {68} 37.387
80 {176} 3.775
Cylinder head temperature sensor characteristics graph (reference)
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Fig. 40: Temperature Vs Resistance Graph

Fig. 41: Identifying CHT Sensor Wiring Harness-Side Connector And PCM Wiring Harness Side
Connector

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Open circuit
 CHT sensor terminal A and PCM terminal 2AL
 CHT sensor terminal B and PCM terminal 2AN
Short circuit
 CHT sensor terminal A and power supply
 CHT sensor terminal A and body ground
 CHT sensor terminal B and power supply
FUEL TANK PRESSURE SENSOR INSPECTION [MZI-3.7]

VOLTAGE INSPECTION
1. Remove the evaporative hose component. (See FUEL TANK REMOVAL/INSTALLATION [MZI-
3.7] .)
3. Plug one end of the evaporative hose component and verify that the output voltage from the fuel tank
pressure sensor changes when pressure is applied from the other hose end.
 If it cannot be verified even though the related harnesses have no malfunction, replace the
evaporative hose component.(See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7] .)
Microsoft
Fig. 42: Identifying Fuel Tank Pressure Sensor Wiring Harness Side Connector

2. Disconnect the fuel tank pressure sensor connector.
Open circuit
 Fuel tank pressure sensor terminal A and PCM terminal 1AB
 Fuel tank pressure sensor terminal B and PCM terminal 1AL
 Fuel tank pressure sensor terminal C and PCM terminal 1U
Short circuit
 Fuel tank pressure sensor terminal A and power supply
 Fuel tank pressure sensor terminal A and body ground
 Fuel tank pressure sensor terminal B and power supply
 Fuel tank pressure sensor terminal C and body ground
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2008 ENGINE PERFORMANCE On-Board Diagnostic (MZI-3.7) - Mazda CX-9
On-Board Diagnostic (MZI-3.7) - Mazda CX-9
ON-BOARD DIAGNOSTIC WIRING DIAGRAM [MZI-3.7]
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Fig. 1: On-Board Diagnostic Wiring Diagram (1 Of 3)

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FOREWORD [MZI-3.7]
 When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication
and diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart.
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 If the DTC exists, diagnose the applicable DTC inspection. (See DTC TABLE [MZI-3.7].)
 If the DTC does not exist and the MIL does not illuminate, diagnose the applicable symptom
troubleshooting.
Fig. 4: Symptom Troubleshooting Flow Chart

ON-BOARD DIAGNOSTIC TEST [MZI-3.7]

DTC READING PROCEDURE

2. After the vehicle is identified, select the following items from the initial screen of the M-MDS.

3. Select "PCM".

2. Select "PCM".
3. Then, select the "Retrieve CMDTCs" and perform procedures according to directions on the M-MDS
screen.
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Fig. 5: Identifying DLC-2

4. Verify the DTC according to the directions on the M-MDS screen.

inspection.
5. After completion of repairs, clear all DTCs stored in the PCM, while referring to "AFTER REPAIR
PROCEDURE".
PENDING TROUBLE CODE ACCESS PROCEDURE


3. Select "PCM".

2. Select "PCM".

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screen.
4. Retrieve the pending trouble codes according to the directions on the M-MDS screen.
FREEZE FRAME PID DATA ACCESS PROCEDURE


3. Select "PCM".

2. Select "PCM".

screen.
4. Retrieve the freeze frame PID data according to the directions on the M-MDS screen.
ON-BOARD SYSTEM READINESS TESTS ACCESS PROCEDURE

1. Select "Powertrain".
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2. Select "OBD Test Modes".

3. Select "Mode 1 Powertrain Data".
4. Select "PCM".
1. Select "OBDII Modes".
2. Select "Mode 1 Powertrain Data".
3. Select "PCM".

3. Then, select the "***SUP" and "**EVAL" PIDs in the PID selection screen.
4. Monitor those PIDs and check it system monitor is completed.
NOTE:  If the on-board system readiness tests are not completed the PCM
stores DTC P1000.
NOTE:  The PID/DATA MONITOR function monitors the calculated value of the
input/output signals in the PCM. Therefore, an output device malfunction
is not directly indicated as a malfunction of the monitored value for the
output device. If a monitored value of an output device is out of
specification, inspect the monitored value of the input device related to the
output control.

3. Select "PCM".
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2. Select "PCM".

3. Select the PID from the PID table.

4. Verify the test results according to detections on the screen.

PID Name Description Unit
AAT Indicate the ambient air temperature °C
AC_REQ A/C request signal Off/On
ACCS A/C relay Off/On
ALTF Generator field coil control duty value %
APP Accelerator pedal position %
%
APP1 APP sensor No.1
V
%
V
%
V
ARPMDES Target engine speed RPM
AXLE Axle ratio -
BARO Barometric pressure Pa
BOO Brake switch Off/On
BPA Brake pressure applied switch Off/On
CATT11_DSD Estimated catalytic converter temperature (RH) °C
CATT21_DSD Estimated catalytic converter temperature (LH) °C
CHRGLP Generator warning light Off/On
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°C
CHT CHT sensor
V
COLP Refrigerant pressure switch (middle) Off/On
DTCCNT Number of DTCs detected -
ECT Engine coolant temperature °C
EQ_RAT11_DSD Desired equivalence ratio (lambda) -
ETC_ACT Electronic throttle control actual °
%
ETC_DSD Electronic throttle control desired
°
EVAPCP Purge solenoid valve duty value %
EVAPCV CV solenoid valve Off/On
EVMV Evaporative Emission Vapor Management valve mA
FAN_DUTY Cooling fan control %
FLI Fuel level %
FP Fuel pump relay Off/On
FPM Fuel pump monitor Off/On
FTP Fuel tank pressure sensor V
FTP_H2O Fuel tank pressure (inches of water column) -
OL/CL/OL-Drive/OL-Fault/CL-
FUELSYS1 Fuel system loop status (RH)
Fault
GENVDSD Generator voltage desired V
HTR11 Front HO2S heater (RH) Off/On
HTR12 Rear HO2S heater (RH) Off/On
HTR21 Front HO2S heater (LH) Off/On
HTR22 Rear HO2S heater (LH) Off/On
°C
IAT IAT sensor
V
INGEAR Load/no load condition Off/On
LOAD Engine load %
LONGFT1 Long term fuel trim (RH) %
LONGFT2 Long term fuel trim (LH) %
g/s
MAF MAF sensor
V
MFFJAT Intake air temperature at the time of misfire °C
MFF_LOAD Engine load at the time of misfire %
MFF_RNTM Engine running time at time of misfire ms
MFF_RPM Engine speed at the time of misfire RPM
MFF_SOAK Engine off soak time prior to misfire ms
MFF_TP Throttle position at the time of misfire V
MFF_TRIP Number of trips since the time of misfire -
MFF_VSS Vehicle speed at the time of misfire KPH
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MIL Malfunction indicator lamp Off/On

MIL_DIS Travelled distance since the MIL illuminated km
O2S11 Front HO2S (RH) V
O2S12 Rear HO2S (RH) V
O2S21 Front HO2S (LH) V
O2S22 Rear HO2S (LH) V
PCVHC PCV valve heater control %
PSP Power steering pressure switch Low/High
RO2FT1 Rear HO2S fuel trim (RH) -
RO2FT2 Rear HO2S fuel trim (LH) -
RPM Engine speed RPM
SC_CANCEL Speed control cancel switch Inactive/Active
SC_OFF Cruise control OFF switch Inactive / Active
SC_ON Cruise control ON switch Inactive / Active
SC_RES Cruise resume switch Inactive / Active
SC_SET- Cruise coast switch Inactive / Active
SC_SET+ Cruise set/acceleration switch Inactive / Active
SCCS Speed control command switch V
SHRTFT1 Short term fuel trim (RH) %
SHRTFT11 Front short term fuel trim (RH) %
SHRTFT2 Short term fuel trim (LH) %
SHRTFT21 Front short term fuel trim (LH) %
SPARKADV Ignition timing °
SPKDUR_1 Spark duration of cylinder No.1 sec
SPKDUFR_5 Spark duration of cylinder No.5 sec
SPRK_ACT Actual ignition timing °
TIRESIZE Tire revolution per mile -
TP REL Relative throttle position %
%
TP1 TP sensor No. 1
V
%
TP2 TP sensor No.2
V
VPWR Battery voltage V
VSS Vehicle speed KPH
VT ACT1 Actual valve timing (RH) °
VT ACT2 Actual valve timing (LH) °
Difference between target and actual valve timing
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VT DIFF1 (RH) °
Difference between target and actual valve timing
VT DIFF2 °
(LH)
VT DUTY1 Oil control valve duty value (RH) %
VT DUTY2 Oil control valve duty value (LH) %
DIAGNOSTIC MONITORING TEST RESULTS ACCESS PROCEDURE

1. Select "Powertrain".
2. Select "OBD Test Modes".
3. Select "Mode 6 On-Board Test Results".
1. Select "OBDII Modes".

2. Select "Mode 6 On-Board Test Results".

SIMULATION FUNCTION PROCEDURE

3. Select "PCM".
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2. Select "PCM".

3. Select the simulation items from the PID table.

4. Perform the simulation function, inspect the operations for each parts.
 If there is no operation sound from the relay, motor, and solenoid after the simulation function
inspection is performed, it is possible that there is an open or short circuit in the wiring harness,
relay, motor or solenoid, or sticking and operation malfunction.
AFTER REPAIR PROCEDURE [MZI-3.7]


3. Select "PCM".
4. Select "Retrieve CMDTCs".
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

2. Select "PCM".
4. Select "Retrieve CMDTCs".
KOEO/KOER SELF TEST [MZI-3.7]


3. Select "PCM".

2. Select "PCM".

3. Then, select the "KOEO On Demand Self Test" or "KOER On Demand Self Test" and perform
procedures according to directions on the M-MDS screen.
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If any DTCs are displayed, perform troubleshooting according to the corresponding DTC

inspection.
5. After completion of repairs, clear all DTCs stored in the PCM, while referring to "AFTER REPAIR
PROCEDURE".
OBD-II DRIVE MODE [MZI-3.7]

 The following procedure is designed to execute and complete the OBD-II monitors and to clear the DTC
P1000.
 To complete a specific monitor for repair verification, follow Steps 1 through 4, then continue using the
steps indicated by the appropriate monitor.
 The Drive Mode is performed using the M-MDS.
CAUTION:  While performing the Drive Mode, always operate the vehicle in
a safe and lawful manner.
 When the M-MDS is used to observe monitor system status
while driving, be sure to have another technician with you, or
record the data in the M-MDS using the PID/DATA MONITOR
AND RECORD function and inspect later.
NOTE:  If the OBD-II system inspection is not completed during the Drive
Mode, the following causes are considered:
 The OBD-II system detects a malfunction.
 The Drive Mode procedure is not completed correctly.
 Disconnecting the battery will reset the memory. Do not disconnect

the battery during and after Drive Mode.
 The M-MDS can be used at anytime through the course of the Drive
Mode to monitor the completion status. Monitoring can be done by
viewing the ON BOARD SYSTEM READINESS menu.
 Most OBD-II monitors will complete more readily using a "steady
foot" driving style during cruise or acceleration. Operating the
throttle in a "smooth" fashion will minimize the time required for
monitor completion.
 The fuel tank level should be between 1/2 and 3/4 full with 3/4 full
being the most desirable.
 The evaporative emission system monitor can only operate during
the first 30 min of the engine operation. When executing the
procedure for the evaporative emission system monitor, remain in
part throttle position and drive in a smooth fashion to minimize "fuel
slosh".
 When bypassing the EVAP soak times, the PCM must remain
powered (ignition switch to the ON position) after clearing the
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continuous DTCs and relearning emission diagnostic information.
OBD-II DRIVE MODE

OBD-II
monitor Step Procedure Purpose
exercised
NOTE:
 To bypass the EVAP soak timer (normally 6
hours), the PCM must remain powered after
clearing the continuous DTCs and resetting the
emission monitors information in the PCM.

 Turn the ignition switch to the ON position
(Engine off).
 Turn the ignition switch off then to the ON
position, (Engine off).
 Select the appropriate vehicle and engine
qualifier.
 Clear the continuous DTCs and reset the emission
1 monitors information in the PCM.
NOTE: Bypasses the engine soak

Drive Mode
timer. Resets the OBD-II
Preparation  The following events occur when the monitor status.
continuous DTCs and the emission
monitors information is cleared from the
PCM:
 Clears the number of DTCs and the
DTCs.
 Clears the freeze frame data.
 Clears the diagnostic monitoring

test results.
 Clears the status of the OBD-II
system monitors is reset.
 Sets DTC P1000.
2  Start the engine without turning the ignition

switch off.
 Idle the engine for 15 s.
3  Drive at 64 km/h {40 mph} until the ECT is
76.7°C {170°F} or more.
NOTE:
 When the IAT is not within 4.4-37.8°C {40-100°
F} or the altitude is above 2,438 m {8,000 ft} ,
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the EVAP monitor will not run.
Engine warm-up and

Prep for Monitor  Is the IAT within 4.4-37.8°C {40-100°F}?
4 provides IAT input to the
Entry  If not within the specification, complete the PCM.
following steps but, note that step 13 will
be required to "bypass" the EVAP monitor.
Executes the HO2S
HO2S 5  Cruise at 64 km/h {40 mph} for up to 5 min. monitor.
NOTE:
 To initiate the monitor, the throttle should be at
part throttle, Evaporative Emissions Duty Cycle
must be more than 75%, and FLI must be 15- Executes the EVAP
EVAP 6
85%, and for fuel tanks over 25 gallons Fuel emission monitor.
Level Indicator Input must be 30-85%.
 Cruise at 64-89 km/h {40-55 mpr} for 10 min.

 Stop the vehicle and go to traffic conditions.
 Include five different constant cruise speeds, Executes the catalyst
Catalyst 7
ranging from 32-89 km/h {20-55 mph} over a 10 efficiency monitor.
min period.
 Stop the vehicle. Executes the idle air
CCM (Engine) 8  Idle the engine for 2 min with the selector lever in control portion of the
the D range. CCM.
 Stop the vehicle.
 In overdrive, moderately accelerate to 81 km/h
{50 mph} and cruise for 15 s or more.
 Stop the vehicle and repeat without overdrive to
CCM 64 km/h {40 mph} cruising for 30 s or more. Executes the transaxle
9
(Transaxle)  While at 64 km/h {40 mph} , activate overdrive portion of the CCM.
and accelerate to 81 km/h {50 mph} and cruise
for 15 s or more.
 Stop the vehicle for 20 s or more.
 Repeat Step 9 five times.
 Stop the vehicle.
 Accelerate to 97 km/h {60 mph}.
Allows learning for the
Misfire and Fuel 10  Decelerate at closed throttle until reaching 64 misfire monitor.
km/h {40 mph} (no brakes).
 Repeat 3 times.
 Access the ON BOARD SYSTEM READINESS

11 to verify the OBD-II monitoring status. Determines if any
Readiness  If completed, all of the OBD-II monitoring monitor has not been
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Check status items change from non-completed to completed.

completed.
 If not completed, go to the next step.
 Verify that no pending code has been stored. If
any pending code has been stored, perform the
appropriate DTC inspection. (See DTC TABLE NOTE:
[MZI-3.7].)  The DTC P1000
will be stored if
 Otherwise, return any incomplete monitor.
Pending Code any of the OBD-II
monitors does
Check and NOTE: not complete.
12
EVAP Monitor
Bypass Check  If the EVAP monitor is not completed and
the I AT was out of the 4.4-37.8°C {40- Determines if a pending
100°F} range, or the altitude is above code is preventing the
2,438 m {8,000 ft} , the "EVAP Monitor clearing of the DTC
Bypass" procedure must be followed. P1000.
 Perform the "EVAP Monitor Bypass" procedure.
Allows the "bypass"
EVAP Monitor  Leave the vehicle for 8 h.
13 counter to increment to
Bypass  Go to Step 2 then perform from Step 2 to 11. two.
DIAGNOSTIC MONITORING TEST RESULTS [MZI-3.7]

 The purpose of this test mode is to confirm the result of OBD-II monitor diagnostic test results. The result
values stored when particular monitor is completed are displayed. If the monitor is not completed, initial
value is displayed.
DIAGNOSTIC MONITORING TEST RESULTS

OBD Monitor Test Related
Description Unit
ID ID system
01 01 Front HO2S (RH) Switchpoint V
01 80 Front HO2S (RH) Voltage Amplitude> V
01 81 Front HO2S (RH) Heater Current A
05 01 Front HO2S (LH) Switchpoint V
05 80 Front HO2S (LH) Voltage Amplitude V
HO2S
05 81 Front HO2S (LH) Heater Current A
02 01 Rear HO2S (RH) Switchpoint V
02 81 Rear HO2S (RH) Heater Current A
06 01 Rear HO2S (LH) Switchpoint V
06 81 Rear HO2S (LH) Heater Current A
21 80 -
HO2S (Front) and HO2S (Rear) switching time ratio Catalyst
22 80 -
3A 80 Phase 0 Excessive vacuum limit Pa
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3A 81 Phase 4 Purge Valve stuck open limit Pa

3A 82 Phase 0 Gross Leak Limit Pa
EVAP
Phase 2 0.040" leak check vacuum bleed up and maximum
3B 80 Pa
0.040" leak threshold
A1 80 Type A Misfire Rate (engine 200 rpm) %
A1 81 Type B Misfire Rate (engine 1000 rpm) %
A1 82 Highest Misfire Rate Type A (engine 200 rpm) %
A1 83 Highest Misfire Rate Type B (engine 1000 rpm) %
A1 84 Inferred Catalyst Mid-Bed Temperature °C
A2 0B Cylinder No.1 average misfire counts for last 10 DC -
A2 0C Cylinder No.1 misfire counts for last/current DC -
A2 80 Cylinder No.1 Type A Misfire Rate (engine 200 rpm) %
A2 81 Cylinder No.1 Type B Misfire Rate (engine 1000 rpm) %
A4 0C Cylinder No.3 misfire counts for last/current DC Misfire -
DTC TABLE [MZI-3.7]

DTC CHART (MZI-3.7)
DTC Description MIL DC Page
B1342 PCM malfunction OFF - (See DTC B1342 [MZI-3.7].)
P0010 CMP actuator circuit open (RH) ON 2 (See DTC P0010 [MZI-3.7].)
P0011 CMP timing over-advanced (RH) ON 2 (See DTC P0011 [MZI-3.7].)
Microsoft
P0012 CMP timing over-retarded (RH) ON 2 (See DTC P0012 [MZI-3.7].)

P0016 CKP-CMP sensor (RH) correlation ON 2 (See DTC P0016, P0018 [MZI-3.7].)
P0018 CKP-CMP sensor (LH) correlation ON 2 (See DTC P0016, P0018 [MZI-3.7].)
P0020 CMP actuator circuit open (LH) ON 2 (See DTC P0020 [MZI-3.7].)
P0021 CMP timing over-advanced (LH) ON 2 (See DTC P0020 [MZI-3.7].)
P0022 CMP timing over-retarded (LH) ON 2 (See DTC P0022 [MZI-3.7].)
Front HO2S (LH/RH) signals
P0040 OFF 1 (See DTC P0040, P0041 [MZI-3.7].)
swapped
Rear HO2S (LH/RH) signals
swapped
(See DTC P0053, P0054, P0059, P0060
P0053 Front HO2S (RH) heater resistance ON 2
[MZI-3.7].)
(See DTC P0053, P0054, P0059, P0060
P0054 Rear HO2S (RH) heater resistance ON 2
[MZI-3.7].)
(See DTC P0053, P0054, P0059, P0060
P0059 Front HO2S (LH) heater resistance ON 2
[MZI-3.7].)
(See DTC P0053, P0054, P0059, P0060
P0060 Rear HO2S (LH) heater resistance ON 2
[MZI-3.7].)
MAP/MAF-throttle position
P0068 ON 2 (See DTC P0068 [MZI-3.7].)
correlation
P0102 MAF circuit low input ON 2 (See DTC P0102 [MZI-3.7].)
P0103 MAF circuit high input ON 2 (See DTC P0103 [MZI-3.7].)
P0104 MAF circuit intermittent/erratic OFF 1 (See DTC P0114 [MZI-3.7].)
IAT sensor circuit
P0111 ON 2 (See DTC P0111 [MZI-3.7].)
range/performance
P0112 IAT sensor circuit low input ON 2 (See DTC P0112 [MZI-3.7].)
P0113 IAT sensor circuit high input ON 2 (See DTC P0113 [MZI-3.7].)
P0114 IAT sensor Intermittent/erratic OFF 1 (See DTC P0114 [MZI-3.7].)
CHT sensor circuit
P0116 ON 2 (See DTC P0116 [MZI-3.7].)
range/performance
CHT sensor circuit
P0119 OFF 1 (See DTC P0119 [MZI-3.7].)
intermittent/erratic
P0122 TP sensor No.1 circuit low input ON(2) 2 (See DTC P0122 [MZI-3.7].)
P0123 TP sensor No.1 circuit high input ON(2) 2 (See DTC P0123 [MZI-3.7].)
Coolant thermostat (coolant temp
P0128 below thermostat regulating ON 2 (See DTC P0128 [MZI-3.7].)
temperature)
Front HO2S (RH) circuit high (See DTC P0132, P0138, P0152, P0158
P0132 ON 2
voltage [MZI-3.7].)
Front HO2S (RH) circuit slow (See DTC P0133, P0139, P0153, P0159
P0133 ON 2
response [MZI-3.7].)
P0135 Front HO2S (RH) heater circuit ON 2
(See DTC P0135, P0141, P0155, P0161
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[MZI-3.7].)
Rear HO2S (RH) circuit high (See DTC P0132, P0138, P0152, P0158
P0138 ON 2
voltage [MZI-3.7].)
Rear HO2S (RH) circuit slow (See DTC P0133, P0139, P0153, P0159
P0139 ON 2
(See DTC P0135, P0141, P0155, P0161
P0141 Rear HO2S (RH) heater circuit ON 2
[MZI-3.7].)
P0148 Fuel delivery error OFF 1 (See DTC P0148 [MZI-3.7].)
Front HO2S (LH) circuit high (See DTC P0132, P0138, P0152, P0158
P0152 ON 2
voltage [MZI-3.7].)
Front HO2S (LH) circuit slow (See DTC P0133, P0139, P0153, P0159
P0153 ON 2
(See DTC P0135, P0141, P0155, P0161
P0155 Front HO2S (LH) heater circuit ON 2
[MZI-3.7].)
Rear HO2S (LH) circuit high (See DTC P0132, P0138, P0152, P0158
P0158 ON 2
voltage [MZI-3.7].)
Rear HO2S (LH) circuit slow (See DTC P0133, P0139, P0153, P0159
P0159 ON 2
(See DTC P0135, P0141, P0155, P0161
P0161 Rear HO2S (LH) heater circuit ON 2
[MZI-3.7].)
P0171 System too lean (RH) ON 2 (See DTC P0171, P0174 [MZI-3.7].)
P0172 System too rich (RH) ON 2 (See DTC P0172, P0175 [MZI-3.7].)
P0174 System too lean (LH) ON 2 (See DTC P0171, P0174 [MZI-3.7].)
P0175 System too rich (LH) ON 2 (See DTC P0172, P0175 [MZI-3.7].)
P0201 Injector circuit/open-cylinder No.1 ON 2 (See DTC P0201 [MZI-3.7].)
P0222 TP sensor No.2 circuit low input ON(2) 2 (See DTC P0222 [MZI-3.7].)
P0223 TP sensor No.2 circuit high input ON(2) 2 (See DTC P0223 [MZI-3.7].)
P0230 FP primary circuit OFF 1 (See DTC P0230 [MZI-3.7].)
P0231 FP secondary circuit low OFF 1 (See DTC P0231 [MZI-3.7].)
P0232 FP secondary circuit high OFF 1 (See DTC P0232 [MZI-3.7].)
P0297 Vehicle over speed condition OFF 1 (See DTC P0297 [MZI-3.7].)
P0300 Random misfire detected ON 1 (See DTC P0300 [MZI-3.7].)
(See DTC P0301, P0302, P0303, P0304,
P0301 Cylinder No.1 misfire detected ON 1
P0305, P0306, P0316 [MZI-3.7].)
(See DTC P0301, P0302, P0303, P0304,
P0305, P0306, P0316 [MZI-3.7].)
(See DTC P0301, P0302, P0303, P0304,
Microsoft
P0303 Cylinder No.3 misfire detected ON 1 P0305, P0306, P0316 [MZI-3.7].)

(See DTC P0301, P0302, P0303, P0304,
P0305, P0306, P0316 [MZI-3.7].)
(See DTC P0301, P0302, P0303, P0304,
P0305, P0306, P0316 [MZI-3.7].)
(See DTC P0301, P0302, P0303, P0304,
P0305, P0306, P0316 [MZI-3.7].)
P0315 CKP system variation not learned ON 2 (See DTC P0315 [MZI-3.7].)
Misfire detected on startup (first (See DTC P0301, P0302, P0303, P0304,
P0316 OFF 1
1000 revolutions) P0305, P0306, P0316 [MZI-3.7].)
Ignition/distributor engine speed
P0320 ON 2 (See DTC P0320 [MZI-3.7].)
input circuit
P0325 KS circuit (RH) OFF 1 (See DTC P0325 [MZI-3.7].)
P0330 KS circuit (LH) OFF 1 (See DTC P0330 [MZI-3.7].)
P0340 CMP sensor (RH) circuit ON 2 (See DTC P0340 [MZI-3.7].)
CMP sensor (RH) circuit
P0344 ON 2 (See DTC P0344 [MZI-3.7].)
intermittent
P0345 CMP sensor (LH) circuit ON 2 (See DTC P0345 [MZI-3.7].)
CMP sensor (LH) circuit
P0349 ON 2 (See DTC P0349 [MZI-3.7].)
intermittent
Ignition coil No.1 (See DTC P0351, 0352, 0353, 0354, 0355,
P0351 ON .2
primary/secondary circuit 0356 [MZI-3.7].)
P0352 ON 2
P0353 ON 2
P0354 ON 2
P0355 ON 2
P0356 ON 2
Catalyst system efficiency below
P0420 ON 2 (See DTC P0420, P0430 [MZI-3.7].)
threshold (RH)
Catalyst system efficiency below
P0430 ON 2 (See DTC P0420, P0430 [MZI-3.7].)
threshold (LH)
Evaporative emission system leak
P0442 ON 2 (See DTC P0442, P0456 [MZI-3.7].)
detected (small leak)
P0443 Purge solenoid valve circuit ON 2 (See DTC P0443 [MZI-3.7].)
P0446 CV solenoid valve control circuit ON 2 (See DTC P0446 [MZI-3.7].)
Fuel tank pressure sensor
P0451 ON 2 (See DTC P0451 [MZI-3.7].)
range/performance
P0452 Fuel tank pressure sensor low input ON 2 (See DTC P0452 [MZI-3.7].)
Microsoft
P0453 Fuel tank pressure sensor high input ON 2 (See DTC P0453 [MZI-3.7].)
Fuel tank pressure sensor
P0454 ON 2 (See DTC P0454 [MZI-3.7].)
intermittent
P0455 ON 2 (See DTC P0455 [MZI-3.7].)
detected (gross leak/no flow)
P0456 ON 1 (See DTC P0442, P0456 [MZI-3.7].)
detected (very small leak)
P0457
detected (fuel cap loose/off) OFF(1) 1 (See DTC P0457 [MZI-3.7].)
P0460 Fuel level sensor circuit ON 2 (See DTC P0460 [MZI-3.7].)
Fuel gauge sender unit
P0461 ON 2 (See DTC P0461 [MZI-3.7].)
range/performance problem
Fuel gauge sender unit circuit low
P0462 ON 2 (See DTC P0462 [MZI-3.7].)
input
Fuel gauge sender unit circuit high
P0463 ON 2 (See DTC P0463 [MZI-3.7].)
input
P0480 Fan control circuit OFF 1 (See DTC P0480 [MZI-3.7].)
P0505 Idle speed control system problem OFF 1 (See DTC P0505 [MZI-3.7].)
IAC system RPM lower than
P0506 ON 2 (See DTC P0506 [MZI-3.7].)
expected
IAC system RPM higher than
P0507 ON 2 (See DTC P0507 [MZI-3.7].)
expected
Cold start engine exhaust
P050E ON 2 (See DTC P050E [MZI-3.7].)
temperature out of range
PCV valve heater control
P053A OFF 1 (See DTC P053A [MZI-3.7].)
circuit/open
Cruise control multi-function input
P0579 OFF 1 (See DTC P0579 [MZI-3.7].)
circuit range/performance
Cruise control multi-function input
P0581 OFF 1 (See DTC P0581 [MZI-3.7].)
circuit high
P0600 Serial communication link OFF(2) 1 (See DTC P0600 [MZI-3.7].)
P0602 PCM programming error ON 2 (See DTC P0602 [MZI-3.7].)
PCM keep alive memory (KAM)
P0603 ON 2 (See DTC P0603 [MZI-3.7].)
error
Internal control module random
P0604 ON 2 (See DTC P0604 [MZI-3.7].)
access memory (RAM) error
PCM read only memory (ROM)
P0605 ON 2 (See DTC P0605 [MZI-3.7].)
error
P0606 ECM/PCM processor ON 2 (See DTC P0606 [MZI-3.7].)
P0607 Control module performance ON 2 (See DTC P0607 [MZI-3.7].)
Internal control module monitoring (See DTC P060A, P060C, P060F, P061D
P060A
processor performance OFF(2) 1 [MZI-3.7].)
Internal control module A/D

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P060B processing performance ON(2) 2 (See DTC P060B [MZI-3.7].)

Internal control module main (See DTC P060A, P060C, P060F, P061D
P060C
processor performance ON(2) 2
[MZI-3.7].)
Control module vehicle options
P0610 ON 2 (See DTC P0610 [MZI-3.7].)
error
Internal control module torque
P061B
calculation performance ON(2) 2 (See DTC P061B [MZI-3.7].)
Internal control module engine
P061C
RPM performance ON(2) 2 (See DTC P061C [MZI-3.7].)
Internal control module engine air (See DTC P060A, P060C, P060F, P061D
P061D
mass performance ON(2) 2
[MZI-3.7].)
Internal control module throttle
P061F
actuator controller performance ON(2) 2 (See DTC P061F [MZI-3.7].)
P0620 Generator control circuit OFF 1 (See DTC P0620 [MZI-3.7].)
P0625 Generator field terminal circuit low OFF 1 (See DTC P0625 [MZI-3.7].)
P0626 Generator field terminal circuit high OFF 1 (See DTC P0626 [MZI-3.7].)
P0642 Sensor reference voltage circuit low ON 2 (See DTC P0642 [MZI-3.7].)
Sensor reference voltage circuit
P0643 ON 2 (See DTC P0643 [MZI-3.7].)
high
P0645 A/C relay control circuit OFF 1 (See DTC P0645 [MZI-3.7].)
ECM/PCM power relay control
P0685 OFF 1 (See DTC P0685 [MZI-3.7].)
circuit/open
ECM/PCM power relay sense
P0689 OFF 1 (See DTC P0689 [MZI-3.7].)
circuit low
ECM/PCM power relay sense
P0690 OFF 1 (See DTC P0690 [MZI-3.7].)
circuit high
OBD II systems readiness test not
P1000 OFF 1 (See DTC P1000 [MZI-3.7].)
complete
KOER not able to complete, KOER
P1001 OFF 1 (See DTC P1001 [MZI-3.7].)
aborted
P1101 MAF sensor out of self-test range OFF 1 (See DTC P1101 [MZI-3.7].)
Exhaust temperature out of range,
P1127 OFF 1 (See DTC P1127 [MZI-3.7].)
HO2S tests not completed
Throttle actuator control throttle
P115E OFF 1 (See DTC P115E [MZI-3.7].)
body air flow trim at max limit
P1260 Theft detected, vehicle immobilized OFF 1 (See DTC P1260 [MZI-3.7].)
Cylinder head over temperature
condition
P1288 CHT sensor out of self-test range OFF 1 (See DTC P1288 [MZI-3.7].)
P1289 CHT sensor circuit high input ON 2 (See DTC P1289 [MZI-3.7].)
P1290 CHT sensor circuit low input ON 2 (See DTC P1290 [MZI-3.7].)
Cylinder head over temperature
P1299 ON 1 (See DTC P1285, P1299 [MZI-3.7].)
protection active
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CKP/CMP sensor
P1336 ON 2 (See DTC P1336 [MZI-3.7].)
range/performance
System voltage out of self-test
P1397 OFF 1 (See DTC P1397 [MZI-3.7].)
range
Unable to bleed up fuel tank
P1450 ON 2 (See DTC P1450 [MZI-3.7].)
vacuum
P145E PCV heater control circuit OFF 1 (See DTC P145E [MZI-3.7].)
P1464 A/C demand out of self-test range OFF 1 (See DTC P1464 [MZI-3.7])
P1500 Vehicle speed signal OFF 1 (See DTC P1500 [MZI-3.7])
Vehicle speed sensor (VSS) out of
P1501 OFF 1 (See DTC P1501 [MZI-3.7].)
self-test range
P1633 Keep alive power voltage too low ON 1 (See DTC P1633 [MZI-3.7].)
P1635 Tire/axle out of acceptable range OFF 1 (See DTC P1635 [MZI-3.7].)
Vehicle ID block corrupted, not
P1639 ON 2 (See DTC P1639 [MZI-3.7].)
programmed
P1650 PSP switch out of self-test range OFF 1 (See DTC P1650 [MZI-3.7].)
P1674 Control module software corrupted OFF(2) 1 (See DTC P1674 [MZI-3.7].)
P1703 Brake switch out of self-test range OFF 1 (See DTC P1703 [MZI-3.7].)
P2100 Throttle actuator circuit open OFF(2) 1 (See DTC P2100 [MZI-3.7].)
Throttle actuator circuit
P2101
range/performance ON(2) 2 (See DTC P2101 [MZI-3.7].)
Throttle actuator control system - (See DTC P2104, P2105, P2106, P2110
P2104
forced idle ON(2) 2
[MZI-3.7].)
P2105
forced engine shutdown OFF(2) 1 [MZI-3.7].)
Throttle actuator control module
P2107
processor ON(2) 2 (See DTC P2107 [MZI-3.7].)
P2110
forced limited RPM ON(2) 2
[MZI-3.7].)
Throttle actuator control system -
P2111
stuck open ON(2) 2 (See DTC P2111 [MZI-3.7].)
Throttle actuator control system -
P2112
stuck closed ON(2) 2 (See DTC P2112 [MZI-3.7].)
APP sensor No.1 circuit
P2121
range/performance OFF(2) 1 (See DTC P2121, P2126, P2131 [MZI-3.7].)
P2122 APP sensor No.1 circuit low inputOFF(2) 1 (See DTC P2122 [MZI-3.7].)
P2123 APP sensor No.1 circuit high input OFF(2) 1 (See DTC P2123 [MZI-3.7].)
P2126
range/performance OFF(2) 1 (See DTC P2121, P2126, P2131 [MZI-3.7].)
P2127 APP sensor No.2 circuit low input OFF(2) 1 (See DTC P2127 [MZI-3.7].)
Microsoft
P2131 range/performance OFF(2) 1 (See DTC P2121, P2126, P2131 [MZI-3.7].)

P2132 APP sensor No.3 circuit low input OFF(2) 1 (See DTC P2132 [MZI-3.7].)
TP sensor No.1/No.2 voltage
P2135
correlation ON(2) 2 (See DTC P2135 [MZI-3.7].)
P2195 Front HO2S (RH) signal stuck lean ON 2 (See DTC P2195, P2197 [MZI-3.7].)
P2196 Front HO2S (RH) signal stuck rich ON 2 (See DTC P2196, P2198 [MZI-3.7].)
P2197 Front HO2S (LH) signal stuck lean ON 2 (See DTC P2195, P2197 [MZI-3.7].)
P2198 Front HO2S (LH) signal stuck rich ON 2 (See DTC P2196, P2198 [MZI-3.7].)
P2270 Rear HO2S (RH) signal stuck lean ON 2 (See DTC P2270, P2272 [MZI-3.7].)
P2271 Rear HO2S (RH) signal stuck rich ON 2 (See DTC P2271, P2273 [MZI-3.7].)
P2272 Rear HO2S (LH) signal stuck lean ON 2 (See DTC P2270, P2272 [MZI-3.7].)
P2273 Rear HO2S (LH) signal stuck rich ON 2 (See DTC P2271, P2273 [MZI-3.7].)
Evaporative emission system
P260F ON 2 (See DTC P260F [MZI-3.7].)
monitoring processor performance
U0101 Communication error to TCM
Communication error to DSC/RSC
U0129
HU/CM (See PROCEDURES FOR DETERMINING THE
Communication error to instrument LOCATION OF A MALFUNCTION [MULTIPLEX
U0155
cluster COMMUNICATION SYSTEM] .)
U0300 Internal control module software
(2) incompatibility
(1) The fuel cap warning light illuminates.
(2) The electronic throttle control (ETC) warning light illuminates.
DTC B1342 [MZI-3.7]

DTC B1342 (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC B1342 PCM malfunction
DETECTION CONDITION  Malfunction in the PCM internal circuit.
 PCM EEPROM malfunction

POSSIBLE CAUSE
 PCM parameter reset has not been completed
DTC B1342 (MZI-3.7) DIAGNOSTIC PROCEDURE


MALFUNCTION
Microsoft
 Clear the DTC from the PCM memory using the

M-MDS.
 Perform the PCM parameter reset using the M-
MDS. Replace the PCM, then go to the next
step. (See PCM
Yes
(See IMMOBILIZER SYSTEM REMOVAL/INSTALLATION
COMPONENT REPLACEMENT/KEY [MZI-3.7] .)
1 ADDITION AND CLEARING [ADVANCED
KEYLESS SYSTEM] .) (See IMMOBILIZER
SYSTEM COMPONENT
REPLACEMENT/KEY ADDITION AND
CLEARING [KEYLESS ENTRY
SYSTEM] .) No Go to the next step.
Is same DTC present?


VERIFY AFTER REPAIR PROCEDURE
 Perform the "AFTER REPAIR PROCEDURE". Yes Go to the applicable DTC inspection.
(See DTC TABLE [MZI-3.7].)
2
(See AFTER REPAIR PROCEDURE [MZI-
3.7].)
No Troubleshooting completed.
 Are any DTC present?
DTC P0010 [MZI-3.7]

DTC P0010 (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P0010 CMP actuator circuit open (RH)
DETECTION  The PCM monitors the OCV (RH) circuit to the PCM for high and low voltage. The
CONDITION test fails if the voltage exceeds or falls below a calibrated limit for a calibrated
amount of time.
 OCV (RH) malfunction
 Connector or terminal malfunction
 Open circuit between OCV (RH) terminal A and main relay No.1 terminal D
POSSIBLE CAUSE
 Open circuit between OCV (RH) terminal B and PCM terminal 2BP
 Short to ground circuit between OCV (RH) terminal B and PCM terminal 2BP
 Short to power supply between OCV (RH) terminal B and PCM terminal 2BP
Microsoft
Microsoft
DTC P0010 (MZI-3.7) DIAGNOSTIC PROCEDURE

VERIFY FREEZE FRAME DATA HAS Yes Go to the next step.
BEEN RECORDED
1 Record FREEZE FRAME DATA on the repair
 Has FREEZE FRAME DATA been No
order, then go to the next step.
recorded?
VERIFY RELATED REPAIR Perform repair or diagnosis according to the
INFORMATION AVAILABILITY
available Service Bulletins.
Yes
2  Verify related Service Bulletins and/or
 If the vehicle is not repaired, go to the
on-line repair information availability.
next step.
 Is any related Service Bulletins
available? No Go to the next step.
INSPECT OCV (RH) CONNECTOR
FOR POOR CONNECTION
Repair or replace suspected part, then go to Step
Yes
 Turn the ignition switch off. 10.
3  Disconnect the OCV (RH) connector.
 Inspect for poor connection (such as

damaged/pulled-out pins, corrosion). No Go to the next step.
 Are there any malfunction?
INSPECT OCV (RH)

Replace the OCV (RH), then go to Step 10. (See
 Inspect the OCV (RH). Yes OIL CONTROL VALVE (OCV)
4 REMOVAL/INSTALLATION [MZI-3.7] .)
(See OIL CONTROL VALVE
(OCV) INSPECTION [MZI-3.7] .)
Is there any malfunction?

INSPECT OCV (RH) CIRCUIT FOR

OPEN CIRCUIT Yes Go to the next step.

5 position (Engine off).
 Measure the voltage between the OCV Repair or replace suspected part, then go to Step
(RH) connector terminal A and body No 10.
ground.
 Is the voltage B+ ?

SHORT TO POWER SUPPLY
Microsoft


 Disconnect the PCM connector. Yes
10.

 Measure the voltage between the OCV
(RH) connector terminal B (wiring No Go to the next step.
harness-side) and body ground.

SHORT TO GROUND
Yes
10.
7
 Inspect for continuity between OCV
(RH) terminal B (wiring harness-side)
and body ground. No Go to the next step.
INSPECT PCM CONNECTOR FOR

POOR CONNECTION Repair or replace suspected part, then go to Step
Yes
10.
8  Disconnect the PCM connector.

damaged/pulled-out pins, corrosion).
 Is there any malfunction?


9  Measure the resistance between the
OCV (RH) connector terminal B Repair or replace suspected part, then go to the
(wiring harness-side) and PCM No
next step.
terminal 2BP (wiring harness-side).
VERIFY TROUBLESHOOTING OF
DTC P0010 HAS BEEN COMPLETED
 Verify that all disconnected Replace the PCM, then go to the next step. (See
connectors reconnected. Yes PCM REMOVAL/INSTALLATION [MZI-
10 3.7] .)
position (Engine off).
 Clear the DTC from the PCM memory
using the M-MDS.
 Start the engine and run it at idle.
Microsoft
Retrieve DTCs using the M-MDS.


 Is the PENDING CODE for this DTC

present?
VERIFY AFTER REPAIR
PROCEDURE
Go to the applicable DTC inspection. (See DTC
 Perform the "AFTER REPAIR Yes
TABLE [MZI-3.7].)
PROCEDURE".
11
(See AFTER REPAIR
PROCEDURE [MZI-3.7].)
DTC P0011 [MZI-3.7]

DTC P0011 CMP timing over-advanced (RH)
DETECTION  The PCM monitors the variable valve timing position for an over-advanced
CONDITION camshaft timing. The test fails when the camshaft timing exceeds a maximum
calibrated value or remains in an advanced position.
POSSIBLE
CAUSE  Spool valve in OCV (RH) is stuck in advanced position
 Improper valve timing due to timing chain slippage

BEEN RECORDED
recorded?
VERIFY RELATED REPAIR
Perform repair or diagnosis according to the
Yes
next step.
VERIFY TIMING CHAIN
INSTALLATION
Microsoft
 Stop the engine.

 Remove the front cover.
 Is the camshaft timing mark at the
3 correct point?
(See TIMING CHAIN No Reinstall the timing chain, then go to Step 5.

REMOVAL/INSTALLATION
[MZI-3.7] .)
INSPECT OCV (RH)
Replace the OCV (RH), then go to the next
 Inspect the OCV (RH). Yes step. (See OIL CONTROL VALVE (OCV)

Make sure to reconnect all

 Replace the PCM, then go to the next step. (See
disconnected connectors. Yes PCM REMOVAL/INSTALLATION [MZI-
3.7] .)
5
using the M-MDS.
 Start the engine and warm it up

completely. No Go to the next step.
 Perform the "AFTER REPAIR Go to the applicable DTC inspection. (See DTC
Yes
PROCEDURE". TABLE [MZI-3.7].)
6
(See AFTER REPAIR
 Are any DTCs present?
DTC P0012 [MZI-3.7]

DTC P0012 CMP timing over-retarded (RH)
DETECTION
 The PCM monitors the variable valve timing position for over-retarded
CONDITION
camshaft timing. The test fails when the camshaft timing exceeds a maximum
Microsoft
calibrated value or remains in a retarded position.

POSSIBLE  Low engine oil pressure
CAUSE  Spool valve in the OCV (RH) is stuck in retard position

BEEN RECORDED
1 Record FREEZE FRAME DATA on the
repair order, then go to the next step.
recorded?
Yes
next step.
VERIFY ENGINE OIL PRESSURE Inspect the engine oil pressure, then go to
Yes Step 6. (See OIL PRESSURE
3 Start the engine.

 Does the oil pressure warning light
illuminate? No Go to the next step.
VERIFY TIMING CHAIN
INSTALLATION
4  Is the camshaft timing mark at the
correct point?

REMOVAL/INSTALLATION [MZI-
3.7] .)
INSPECT OCV (RH)

Replace the OCV (RH), then go to the next
5 Yes
 Inspect the OCV (RH). step.
(See OIL CONTROL VALVE (OCV)

Microsoft

VERIFY TROUBLESHOOTING OF DTC

P0012 COMPLETED
Make sure to reconnect all disconnected

 Replace the PCM, then go to the next step.
connectors. Yes (See PCM REMOVAL/INSTALLATION
 Clear the DTC from the PCM memory [MZI-3.7] .)
6 using the M-MDS.

completely.
 Is the PENDING CODE for this DTC No Go to the next step.
present?
 Perform the "AFTER REPAIR Go to the applicable DTC inspection. (See

Yes
PROCEDURE". DTC TABLE [MZI-3.7].)
7
(See AFTER REPAIR PROCEDURE
[MZI-3.7].)
DTC P0016, P0018 [MZI-3.7]

DTC P0016, P0018 (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P0016 P0016: CKP-CMP sensor (RH) correlation
DTC P0018 P0018: CKP-CMP sensor (LH) correlation
DETECTION  The PCM monitors the variable valve timing position for a misalignment
CONDITION between the camshaft and crankshaft. The test fails when the misalignment is
more than 1 tooth.
 OCV malfunction
POSSIBLE CAUSE  Camshaft advanced mechanism binding
 Improper valve timing
DTC P0016, P0018 (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
Microsoft
 Has FREEZE FRAME DATA been Record the FREEZE FRAME DATA on the
1 No
recorded? repair order, then go to the next step.
Yes
2 Verify related Service Bulletins and/or

next step.
VERIFY RELATED PENDING AND
STORED DTC
Go to the appropriate DTC troubleshooting.
Yes
Turn the ignition switch off, then to the

3 ON position (Engine off)
 Verify pending and stored DTCs using
M-MDS. No Go to the next step.
 Is other DTC present?
VERIFY CURRENT INPUT SIGNAL

STATUS Yes Go to the next step.
Start the engine and warm up


4 completely.
Replace the OCV, then go to Step 6. (See OIL
 Access VT ACT1 (P0016) or VT ACT2
No CONTROL VALVE (OCV)
(P0018) PID using the M-MDS.
 Is PID reading normal?
 -14-46°
VERIFY TIMING CHAIN

INSTALLATION
correct point? Reinstall the timing chain, then go to the next
No
step.
(See TIMING CHAIN
3.7] .)
P0016, P0018 HAS BEEN COMPLETED Replace the PCM, then go to the next step.
6 Yes (See PCM REMOVAL/INSTALLATION
 Make sure to reconnect all disconnected [MZI-3.7] .)
connectors.
 Turn the engine switch to the ON
Microsoft
position.
using the M-MDS. No Go to the next step.
 Start the engine.

Yes
7
[MZI-3.7].)
DTC P0020 [MZI-3.7]

DTC P0020 CMP actuator circuit open (LH)
DETECTION  The PCM monitors the OCV (LH) circuit to the PCM for high and low voltage. The
CONDITION test fails if the voltage exceeds or falls below a calibrated limit for a calibrated
amount of time.
 OCV (LH) malfunction
 Open circuit between OCV (LH) terminal A and main relay No.1 terminal D
POSSIBLE CAUSE
 Open circuit between OCV (LH) terminal B and PCM terminal 2BK
 Short to ground circuit between OCV (LH) terminal B and PCM terminal 2BK
 Short to power supply between OCV (LH) terminal B and PCM terminal 2BK
Microsoft

BEEN RECORDED
recorded?
INFORMATION AVAILABILITY available Service Bulletins.
2 Yes
 Verify related Service Bulletins and/or  If the vehicle is not repaired, go to the
on-line repair information availability. next step.
Microsoft

INSPECT OCV (LH) CONNECTOR
FOR POOR CONNECTION
Yes
 10.
3  Disconnect the OCV (LH) connector.

INSPECT OCV (LH)

Replace the OCV (LH), then go to Step 10. (See
 Inspect the OCV (LH). Yes OIL CONTROL VALVE (OCV)

INSPECT OCV (LH) CIRCUIT FOR

Turn the ignition switch to the ON



 Measure the voltage between the OCV Repair or replace suspected part, then go to Step
(LH) connector terminal A (wiring No
10.

Disconnect the PCM connector.
 Yes
10.
 Measure the voltage between the OCV
(LH) connector terminal B and body
ground. No Go to the next step.

SHORT TO GROUND
Yes
 Turn the ignition switch to the ON 10.
 Inspect for continuity between OCV
(LH) terminal B (wiring harness-side)
and body ground.
Microsoft
Is there continuity?
Yes
10.
8 Disconnect the PCM connector.





9  Measure the resistance between the

OCV (LH) connector terminal B Repair or replace suspected part, Then go to the
(wiring harness-side) and PCM No
next step.
terminal 2BK (wiring harness-side).
Verify that all disconnected


connectors reconnected. Replace the PCM, then go to the next step. (See
Yes PCM REMOVAL/INSTALLATION [MZI-
3.7] .)
using the M-MDS.
 Retrieve DTCs using the M-MDS.

present?
VERIFY AFTER REPAIR
PROCEDURE
 Perform the "AFTER REPAIR
Yes
TABLE [MZI-3.7].)
PROCEDURE".
11
(See AFTER REPAIR
DTC P0021 [MZI-3.7]
Microsoft

DTC P0021 CMP timing over-advanced (LH)
DETECTION  The PCM monitors the variable valve timing position for an over-advanced
calibrated value or remains in an advanced position.
POSSIBLE
CAUSE  Spool valve in OCV (LH) is stuck in advanced position

BEEN RECORDED
recorded?
Yes

next step.
VERIFY TIMING CHAIN
INSTALLATION
correct point?

[MZI-3.7] .)
INSPECT OCV (LH)
Replace the OCV (LH), then go to the next step.
 Inspect the OCV (LH). Yes (See OIL CONTROL VALVE (OCV)
Microsoft

3.7] .)
5  Clear the DTC from the PCM memory
using the M-MDS.

 Perform the "AFTER REPAIR Go to the applicable DTC inspection. (See DTC
Yes
PROCEDURE". TABLE [MZI-3.7].)
6
(See AFTER REPAIR
DTC P0022 [MZI-3.7]

DTC P0022 CMP timing over-retarded (LH)
DETECTION  The PCM monitors the variable valve timing position for over-retarded
calibrated value or remains in a retarded position.
POSSIBLE  Low engine oil pressure
CAUSE  Spool valve in the OCV (LH) is stuck in retard position

BEEN RECORDED
recorded?
Microsoft
INFORMATION AVAILABILITY Perform repair or diagnosis according to the

Verify related Service Bulletins and/or
 Yes
2 on-line repair information availability.  If the vehicle is not repaired, go to the
next step.
VERIFY ENGINE OIL PRESSURE Inspect the engine oil pressure, then go to
Yes Step 6. (See OIL PRESSURE
3 Start the engine.

 Does the oil pressure warning light
illuminate? No Go to the next step.
VERIFY TIMING CHAIN
INSTALLATION
correct point?

3.7] .)
INSPECT OCV (LH)
Inspect the OCV (LH). Replace the OCV (LH), then go to the next
 Yes
step.
5
(See OIL CONTROL VALVE (OCV)


P0022 COMPLETED
 Make sure to reconnect all disconnected Replace the PCM, then go to the next step.
6 using the M-MDS.
completely.
present?

Microsoft

PROCEDURE". Yes
DTC TABLE [MZI-3.7].)
7 (See AFTER REPAIR PROCEDURE
[MZI-3.7].)
DTC P0040, P0041 [MZI-3.7]

DTC P0040 P0040: Front HO2S (LH/RH) signals swapped
DTC P0041 P0041: Rear HO2S (LH/RH) signals swapped
 P0040 indicates that during KOER testing, the front HO2S signal(s)
DETECTION response for a fuel shift to the correct engine bank was not indicated.
CONDITION  P0041 indicates that during KOER testing, the rear HO2S signal(s)
response for a fuel shift to the correct engine bank was not indicated.
 Crossed HO2S harness connectors.
POSSIBLE CAUSE  Crossed wiring at HO2S harness connectors.
 Crossed wiring at PCM harness connector.

BEEN RECORDED
recorded?
VERIFY RELATED REPAIR Perform repair or diagnosis according to
INFORMATION AVAILABILITY the available Service Bulletins.
Yes
2  Verify related Service Bulletins and/or on-  If the vehicle is not repaired, go to
line repair information availability. the next step.
 Is any related Service Bulletins available? No Go to the next step.
INSPECT HO2S WIRING HARNESS
CONNECTORS
Yes Repair if necessary.
 For P0040, visually inspect the vehicle
3 front HO2S wiring harness connector (s) for
any indication of crossed wires (Also,
stretched or incorrectly mounted wiring
harnesses).
 For P0041, visually inspect the vehicle rear
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HO2S wiring harness connector (s) for any

indication of crossed wires (Also, stretched
or incorrectly mounted wiring harnesses). No Go to the next step.
 Are there crossed connections or wires?

P0040, P0041 HAS BEEN COMPLETED
Verify that all disconnected connectors


reconnected. Replace the PCM, then go to the next step.
(See PCM
 Turn the ignition switch to the ON position Yes
4 (Engine off). 3.7] .)
using the M-MDS.

present?
 Perform "AFTER REPAIR Go to the applicable DTC inspection. (See

Yes
5
[MZI-3.7].)
DTC P0053, P0054, P0059, P0060 [MZI-3.7]

DTC P0053, P0054, P0059, P0060 (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P0053 P0053: Front HO2S (RH) heater resistance
DTC P0054 P0054: Rear HO2S (RH) heater resistance
DTC P0059 P0059: Front HO2S (LH) heater resistance
DTC P0060 P0060: Rear HO2S (LH) heater resistance
DETECTION  Heater current requirements too low or high in the heated oxygen sensor
CONDITION (HO2S) heater control circuit.
 Open circuit between HO2S terminal C and main relay No.1 terminal E
 Short to ground circuit between HO2S terminal A and body ground
POSSIBLE CAUSE  HO2S circuits are shorted each other
 DTC P0053: Open circuit between front HO2S (RH) terminal A and PCM
terminal 2J
 DTC P0054: Open circuit between rear HO2S (RH) terminal A and PCM
Microsoft
terminal 2AS
 DTC P0059: Open circuit between front HO2S (LH) terminal A and PCM
terminal 2E
 DTC P0060: Open circuit between rear HO2S (LH) terminal A and PCM
terminal 2AO
 HO2S heater malfunction
Microsoft
DTC P0053, P0054, P0059, P0060 (MZI-3.7) DIAGNOSTIC PROCEDURE

VERIFY FREEZE FRAME DATA Yes Go to the next step.
HAS BEEN RECORDED
recorded?
 Verify related Service Bulletins Yes
2 and/or on-line repair information  If the vehicle is not repaired, go to the next
availability. step.
Is any related Service Bulletins

INSPECT FOR POWER SUPPLY IN
WIRING HARNESS
Yes Turn the ignition switch off. Go to the next step.
 Disconnect the suspect HO2S
connector.
3  Perform the KOEO self-test.
suspect HO2S connector terminal A No Repair or replace suspected part, then go to step 9.
and C, on the wiring harness side.
 Is the voltage more than 10 V?
INSPECT HO2S HEATER FOR
SHORT TO GROUND
4  Disconnect the PCM.
 Measure the resistance between
HO2S connector terminal A, the
wiring harness side, and body No Repair or replace suspected part, Go to Step 9
ground.
Microsoft
Is the resistance more than 10


kilohms?
INSPECT HO2S HEATER FOR
SHORT IN WIRING HARNESS
Measure the resistance between the


following terminals: Yes Go to the next step.
 HO2S terminal A (wiring
harness-side) and HO2S
terminal C (wiring harness-
side)
5  HO2S terminal A (wiring
harness-side) and HO2S
terminal D (wiring harness-
side)
harness-side) and HO2S No Repair or replace suspected part, Go to Step 9
terminal B (wiring harness-
side)
 Are the resistances more than 10
kilohms?
INSPECT HO2S HEATER CIRCUIT
FOR OPEN CIRCUIT IN WIRING
HARNESS
For DTC P0053 Measure resistance Yes Go to the next step.


between PCM terminal 2J and front
HO2S (RH) terminal A.
 For DTC P0054 Measure resistance
6 between PCM terminal 2AS and rear

between PCM terminal 2E and front
HO2S (LH) terminal A.
No Repair or replace suspected part, Go to Step 9.
between PCM terminal 2AO and
rear HO2S (LH) terminal A.
 Is the resistance less than 5.0 ohms?

INSPECT INTERNAL RESISTANCE
OF HO2S HEATER Replace the HO2S.
7 (See FRONT HEATED OXYGEN SENSOR
 Measure the resistance between the
No (HO2S) REMOVAL/INSTALLATION [MZI-
suspect HO2S terminal A and C on 3.7] .)
the component side. (See REAR HEATED OXYGEN SENSOR
Microsoft
Is the resistance between 3-30


(HO2S) REMOVAL/INSTALLATION [MZI-
ohms? 3.7] .) Go to Step 9.
INSPECT HO2S CASE FOR SHORT Yes Replace the PCM. Go to the next step.
TO POWER SUPPLY, HTR, AND
SIGNRTN


Replace the HO2S.
suspect HO2S terminal A and D on (See FRONT HEATED OXYGEN SENSOR
8 the component side. (HO2S) REMOVAL/INSTALLATION [MZI-
No 3.7] .)
(See REAR HEATED OXYGEN SENSOR
suspect HO2S terminal A and body (HO2S) REMOVAL/INSTALLATION [MZI-
ground. 3.7] .) Go to the next step.
 Is the resistance more than 10
kilohms?
MISFIRE DTC HAS BEEN
COMPLETED

 Turn the ignition switch to the ON 3.7] .)
 Clear the DTC from the PCM
memory using the M-MDS.

 Is the PENDING CODE for this
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Go to the applicable DTC inspection., (See DTC
 Perform "AFTER REPAIR Yes
TABLE [MZI-3.7].)
PROCEDURE".
10
(See AFTER REPAIR
DTC P0068 [MZI-3.7]

DTC P0068 MAP/MAF-throttle position correlation
Microsoft
 The PCM monitors a vehicle operation rationality check by comparing sensed

DETECTION throttle position to mass air flow readings. If during a KOER self-test, the
CONDITION comparison of the TP sensor and MAF sensor readings are not consistent with
the calibrated load values, test fails and a DTC is stored in continuous memory.
 Air leak between MAF sensor and throttle body
POSSIBLE
CAUSE  TP sensor or MAF sensor malfunction
 TP sensor not seated correctly

VERIFY FREEZE FRAME DATA HAS Yes Go to next step.
BEEN RECORDED
repair order, then go to next step.
recorded?
Perform repair or diagnosis according to
Yes
2  Verify related Service Bulletins
 If vehicle is not repaired, go to next
availability.
step.
available? No Go to next step.
VERIFY RELATED PENDING CODE OR
STORED DTC Go to appropriate DTC inspection. (See DTC
Yes
TABLE [MZI-3.7].)
3  Verify the related PENDING CODE or
stored DTCs.
No Go to next step.
 Are other DTCs present?
INSPECT FOR INLET AIR LEAKS

Yes Repair as necessary. Go to Step 8.
 Listen for air noise around the MAF
4 sensor and throttle body while the engine
is running. No Go to next step.
 Is a concern present?
INSPECT FOR TP2 SIGNAL HIGH

VERSUS LOAD WHILE DRIVING THE
Replace the malfunctioning part, then go to
CVEHICLE Yes
5 Step 8.
position (Engine running).
 Access the TP2 and LOAD PIDs using
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the M-MDS.
 Is the TP2 PID more than 2.44 V and the No Go to next step.
LOAD PID less than 30%?
INSPECT FOR TP2 SIGNAL LOW
VERSUS LOAD WHILE DRIVING THE
CVEHICLE Repair or replace the malfunctioning part, then
Yes
go to Step 8.
6 position (Engine running).
 Access the PCM and monitor the TP2
and LOAD PIDs
 Is the TP2 PID less than 0.24 V and the
No Go to next step.
LOAD PID more than 55%?
INSPECT FOR SELF-TEST DTCS
Yes
 Turn the ignition switch to the ON the next step.
7  Clear DTC from memory using M-MDS.
 Drive the vehicle while exercising the Perform the "INTERMITTENT CONCERN
throttle. No TROUBLESHOOTING". Then go to the next
 Retrieve the continuous memory DTCs. step.

P0068 HAS BEEN COMPLETED
 Verify that all disconnected connectors Yes Replace PCM, then go to next step.
reconnected.
 Clear DTC from memory using M-MDS.
8  Start engine.
 Perform "KOEO/KOER self-test"
(See KOEO/KOER SELF TEST No Go to next step.

[MZI-3.7].)
 Is same DTC present?
VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. (See

Yes
9  Perform "AFTER REPAIR
PROCEDURE".
(See AFTER REPAIR PROCEDURE No Troubleshooting completed.

[MZI-3.7].)
Microsoft
DTC P0102 [MZI-3.7]

DTC P0102 MAF circuit low input
DETECTION  The MAF sensor circuit is monitored by the PCM for low air flow (or voltage) input
CONDITION through the CCM. If during KOER the air flow (or voltage) changes below a
minimum calibrated limit, the test fails.
 Open circuit wiring harness between MAF sensor terminal A and main relay No.1
terminal D
 Open circuit wiring harness between MAF sensor terminal C and PCM terminal 1AJ
 Open circuit wiring harness between MAF sensor terminal D and PCM terminal 1
POSSIBLE AN
CAUSE
 Open circuit wiring harness between MAF sensor terminal B and body ground
 Short to ground circuit between MAF sensor terminal D and PCM terminal 1 AN
 Intake air leak (near the MAF sensor)
 A closed throttle indication
 MAF sensor malfunction
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HAS BEEN RECORDED
1 Record FREEZE FRAME DATA on the repair order,
 Has FREEZE FRAME DATA No
then go to the next step.
been recorded?

INFORMATION Perform repair or diagnosis according to the available
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AVAILABILITY Service Bulletins.

Yes
Verify related Service
  If the vehicle is not repaired, go to the next step.
2 Bulletins and/or on-line repair

information availability.
 Is any related Service Bulletins No Go to the next step.
available?
INSPECT MAF SENSOR
CONNECTOR FOR POOR
CONNECTION Yes Repair or replace suspected part, then go to Step 10.

3  Disconnect the MAF/IAT

sensor connector.
 Inspect for poor connection
(such as damaged/pulled-out No Go to the next step.
pins, corrosion).
INSPECT POWER SUPPLY

CIRCUIT FOR OPEN CIRCUIT
4 ON position (Engine off).

 Measure the voltage between
MAF sensor terminal A and No Repair or replace suspected part, then go to Step 10.
body ground.
INSPECT PCM CONNECTOR

FOR POOR CONNECTION
Yes Repair or replace suspected part, then go to Step 10.
5  Disconnect PCM connector.

pins, corrosion).
INSPECT MAF SENSOR

SIGNAL CIRCUIT FOR OPEN
CIRCUIT
 Remove PCM with PCM Yes Go to the next step.

connector connected.
the following circuits:
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MAF sensor terminal C


(wiring harness-side)
and PCM terminal 1AJ
6  MAF sensor terminal D No Repair or replace suspected part, then go to Step 10.
and PCM terminal 1AN
 Are there continuity?
INSPECT MAF SENSOR

SIGNAL CIRCUIT FOR SHORT
TO GROUND
Yes Repair or replace suspected part, then go to the Step 10.
 Disconnect the MAF/IAT
7 sensor and PCM connector.

 Inspect continuity between
following circuits:
 MAF sensor connector
terminal D and body
ground
INSPECT MAF SENSOR

GROUND CIRCUIT FOR OPEN
CIRCUIT
8 Inspect continuity between

MAF sensor terminal B and
body ground. No Repair or replace suspected part, then go to Step 10.
INSPECT THE MAF SENSOR

Replace the MAF/IAT sensor, then go to the next step.
 Inspect the MAF sensor
(See MASS AIR FLOW (MAF)/INTAKE AIR
Yes
TEMPERATURE (IAT) SENSOR
9 (See MASS AIR FLOW REMOVAL/INSTALLATION [MZI-3.7] .)
(MAF) SENSOR
 Are there any malfunction? No Go to the next step.
OF DTC P0102 HAS BEEN Replace PCM, then go to the next step. (See PCM
COMPLETED Yes
 Verify that all disconnected

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connectors reconnected.
ON position (Engine off).
 Start engine and warm it up
completely.
VERIFY AFTER REPAIR

PROCEDURE
 Perform "AFTER REPAIR Yes
TABLE [MZI-3.7].)
PROCEDURE".
11
(See AFTER REPAIR
DTC P0103 [MZI-3.7]

DTC P0103 MAF circuit high input
DETECTION  The MAF sensor circuit is monitored by the PCM for high air flow (or voltage) input
CONDITION through the CCM. If during KOEO, or KOER, the air flow (or voltage) changes
above a maximum calibrated limit, the test fails.
 Short to power supply in wiring harness between MAF sensor terminal D and PCM
POSSIBLE terminal 1AN
CAUSE  MAF sensor malfunction
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HAS BEEN RECORDED
1
No
 Has FREEZE FRAME DATA Record FREEZE FRAME DATA on the repair order,
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been recorded? then go to the next step.

INFORMATION AVAILABILITY Perform repair or diagnosis according to the available
Service Bulletins.
Verify related Service Bulletins Yes

2 and/or on-line repair  If the vehicle is not repaired, go to the next step.
information availability.
INSPECT MAF SENSOR
CONNECTOR FOR POOR

3  Disconnect the MAF/IAT

sensor connector.
pins, corrosion).
INSPECT MAF SIGNAL

CIRCUIT FOR SHORT TO
POWER SUPPLY No Repair or replace suspected part, then go to Step 7.
Turn the ignition switch to the


 Measure voltage between MAF
sensor terminal D (wiring Yes Go to the next step.
 Is voltage B+?
INSPECT PCM CONNECTOR

FOR POOR CONNECTION
No Repair or replace suspected part, then go to Step 7.

(such as damaged/pulled-out Yes Go to the next step.
pins, corrosion).
INSPECT THE MAF SENSOR Replace the MAF/IAT sensor (See MASS AIR FLOW
(MAF)/INTAKE AIR TEMPERATURE (IAT)
6  Inspect the MAF sensor. (See Yes
SENSOR REMOVAL/INSTALLATION [MZI-
MASS AIR FLOW (MAF) 3.7] .), then go to Step 7.
SENSOR INSPECTION
Microsoft
[MZI-3.7] .)
 Is there malfunction?
OF DTC P0103 HAS BEEN
COMPLETED
Replace PCM, then go to the next step. (See PCM
 Yes
7  Turn the ignition switch to the
completely.
VERIFY AFTER REPAIR

PROCEDURE
Yes
 Perform "AFTER REPAIR
TABLE [MZI-3.7].)
8 PROCEDURE". (See AFTER
REPAIR PROCEDURE
[MZI-3.7].) No Troubleshooting completed.
DTC P0104 [MZI-3.7]

DTC P0104 MAF circuit intermittent/erratic
DETECTION  A concern exists in the MAF sensor circuit, or the air tube containing the sensor,
CONDITION causing an incorrect air flow reading.
 Air leaks in the tube from the MAF to the throttle body
 Open circuit wiring harness between MAF sensor terminal C and PCM terminal
1AJ
 Open circuit wiring harness between MAF sensor terminal D and PCM terminal
1 AN
POSSIBLE CAUSE  Short to power supply in wiring harness between MAF sensor terminal C and
PCM terminal 1AJ
 Short to power supply in wiring harness between MAF sensor terminal D and
PCM terminal 1 AN
 Short to ground circuit between MAF sensor terminal C and PCM terminal 1 AJ
 Short to ground circuit between MAF sensor terminal D and PCM terminal 1
AN
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BEEN RECORDED
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Has FREEZE FRAME DATA been

 Record FREEZE FRAME DATA on the repair
1 No
recorded? order, then go to next step.
INFORMATION AVAILABILITY Perform repair or diagnosis according to
Yes
2 Verify related Service Bulletins

availability.  If vehicle is not repaired, go to next step.
VERIFY RELATED PENDING CODE
OR STORED DTC Go to appropriate DTC inspection. (See DTC
Yes
TABLE [MZI-3.7].)
3 Verify the related PENDING CODE or

stored DTCs.
No Go to next step.
INSPECT AIR SUCTIONING

BETWEEN MAF SENSOR AND TP
SENSOR Repair or replace the malfunctioning part, then
Yes
go to Step 10.
4 Inspect for major leaks, cracks and

openings between MAF sensor and
throttle body. No Go to next step.
INSPECT MAF SENSOR CONNECTOR

FOR POOR CONNECTION
Repair or replace the malfunctioning part, then
Turn the ignition switch off. Yes
 go to Step 10.
5  Disconnect the MAF/IAT sensor
connector.
damaged/pulled-out pins, corrosion). No Go to next step.
INSPECT MAF SIGNAL CIRCUIT FOR

 Turn the ignition switch to the ON Yes
go to Step 10.
6  Measure voltage between the following
terminals:
 MAF sensor terminal C (wiring
harness-side) and body ground
No Go to next step.
 MAF sensor terminal D (wiring
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Are there voltage B+?


INSPECT MAF SENSOR SIGNAL

CIRCUIT FOR SHORT TO GROUND


 Disconnect the MAF/IAT sensor and Yes
go to Step 10.
PCM connector.
7  Inspect for continuity between the
following circuits:
 MAF sensor terminal C (wiring
 MAF sensor terminal D (wiring
No Go to next step.

POOR CONNECTION
Yes
go to Step 10.
connector.
damaged/pulled-out pins, corrosion). No Go to next step.
INSPECT MAF SENSOR CIRCUIT FOR

OPEN CIRCUIT
 Disconnect the PCM connector.
 Disconnect the MAF/IAT sensor

connector.
9
following terminals:
Repair or replace suspected part, then go to the
 MAF sensor terminal C and No
next step.
PCM terminal 1AJ
 MAF sensor terminal D and
PCM terminal 1AN
Yes
 Verify that all disconnected connectors Replace the PCM, then go to next step. (See
reconnected. PCM REMOVAL/INSTALLATION [MZI-
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Clear DTC from memory using M-


3.7] .)
MDS.
10  Perform the "KOEO/KOER self-
test" (See AFTER REPAIR
PROCEDURE [MZI-3.7].) No Go to next step.

Yes
 Perform the "AFTER REPAIR TABLE [MZI-3.7].)
REPAIR PROCEDURE [MZI-3.7].)
DTC P0111 [MZI-3.7]

DTC P0111 IAT sensor circuit range/performance
 Indicates the IAT rationality test has failed. This DTC indicates that the IAT
value is higher than a calibrated value and could prevent 1 or more on-board
DETECTION diagnostic (OBD) monitors from completing. The PCM runs this logic after an
CONDITION engine off and a calibrated soak period (typically 6 hours) This soak period
allows IAT and CHT to stabilize and not differ by more than a calibrated value.
DTC P0111 is set when: the IAT at engine start exceeds the CHT by more than a
calibrated value, typically 17°C {30°F}.
POSSIBLE
CAUSE  IAT sensor malfunction

BEEN RECORDED
recorded?

Yes
2
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INSPECT IAT SENSOR Yes Go to the next step.
Inspect IAT sensor. (See INTAKE-

 Replace MAF/IAT sensor, then go to the next
3 AIR SYSTEM step. (See MASS AIR FLOW
REMOVAL/INSTALLATION No (MAF)/INTAKE AIR TEMPERATURE
[MZI-3.7] .) (IAT) SENSOR
 Is IAT sensor normal?

 Replace PCM, then go to the next step. (See
reconnected. Yes PCM REMOVAL/INSTALLATION [MZI-
3.7] .)
using the M-MDS.
 Start engine and run engine under
FREEZE FRAME DATA condition.
 Is PENDING CODE for this DTC No Go to the next step.
present?
Yes
 Perform "AFTER REPAIR TABLE [MZI-3.7].)
DTC P0112 [MZI-3.7]

DTC P0112 IAT sensor circuit low input
DETECTION  Indicates that the sensor signal is less than the self-test minimum. The IAT
CONDITION sensor minimum is 0.2 V or 121°C {250°F}.
 Short to ground circuit between MAF/IAT sensor terminal F and PCM terminal
1AF
POSSIBLE CAUSE
 IAT sensor malfunction
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BEEN RECORDED
recorded?
VERIFY RELATED REPAIR Yes Perform repair or diagnosis according to the

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  If the vehicle is not repaired, go to the
2
available?
INSPECT IAT SENSOR TERMINAL

 Repair or replace suspected part, then go to Step
Yes
6.
 Disconnect MAF/IAT sensor
3 connector.
 Inspect for bent terminal of MAF/IAT
sensor terminals E and F (part-side). No Go to the next step.
CLASSIFY IAT SENSOR

MALFUNCTION OR HARNESS
MALFUNCTION Replace MAF/IAT sensor or harness, then go to
Yes
Step 6.
 Connect M-MDS to DLC-2.
4
 Access IAT PID.
 Verify IAT value when disconnecting

MAF/IAT sensor connector. No Go to the next step.
 Does IAT value change?
INSPECT IAT SIGNAL CIRCUIT FOR

SHORT TO GROUND
Yes
next step.
 Inspect continuity between MAF/IAT

sensor terminal F (wiring harness-
side) and body ground. No Go to the next step.
using the M-MDS.
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VERIFY AFTER REPAIR

PROCEDURE Go to the applicable DTC inspection. (See DTC
Yes
TABLE [MZI-3.7].)
7  Perform the "AFTER REPAIR
PROCEDURE". (See AFTER
REPAIR PROCEDURE [MZI-3.7].) No Troubleshooting completed.
DTC P0113 [MZI-3.7]

DTC P0113 IAT sensor circuit high input
DETECTION  Indicates the sensor signal is more than the self-test maximum. The IAT sensor
CONDITION maximum is 4.6 V or -50°C {-58°F}.
 Open circuit between MAF/IAT sensor terminal E and PCM terminal 1AL
 Open circuit between MAF/IAT sensor terminal F and PCM terminal 1AF
POSSIBLE CAUSE  Short to power supply between MAF/IAT sensor terminal F and PCM terminal
1AF
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BEEN RECORDED
recorded?

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2
available?
INSPECT IAT SENSOR CONNECTOR
FOR POOR CONNECTION
Repair or replace suspected part, then go to
 Step 9.
3  Disconnect MAF/IAT sensor
connector.
CLASSIFY IAT SENSOR

MALFUNCTION OR HARNESS
MALFUNCTION
Inspect the IAT sensor. (See INTAKE AIR
Disconnect the MAF/IAT sensor
 TEMPERATURE (IAT) SENSOR
Yes
connector. INSPECTION [MZI-3.7] .)
4  Turn the ignition switch to the ON
Replace if necessary, then go to Step 9.
 Measure voltage between MAF/IAT
sensor terminal F (wiring harness-side)
 Is voltage 4.5-5.5 V?
INSPECT IAT SENSOR SIGNAL

CIRCUIT FOR SHORT TO POWER
SUPPLY Repair or replace suspected part, then go to
Yes
Step 9.
 Measure voltage between MAF/IAT
sensor terminal F (wiring harness-side)
 Is voltage B+?

POOR CONNECTION
Yes
 Turn the ignition switch off. Step 9.

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INSPECT IAT SENSOR SIGNAL

CIRCUIT FOR OPEN CIRCUIT Yes Go to the next step.
Inspect continuity between MAF/IAT


7 sensor terminal F (wiring harness-side) Repair or replace suspected part, then go to
and PCM terminal 1AF (wiring No
Step 9.
harness-side).
INSPECT IAT SENSOR GROUND

Inspect continuity between MAF/IAT


8 sensor terminal E (wiring harness-side)
and PCM terminal 1AL (wiring Repair or replace suspected part, then go to the
No
harness-side). next step.


using the M-MDS.

Go to the applicable DTC inspection. (See
Yes
 Perform the "AFTER REPAIR DTC TABLE [MZI-3.7].)
DTC P0114 [MZI-3.7]

DTC P0114 IAT sensor Intermittent/erratic
DETECTION CONDITION  Indicates the sensor signal was intermittent during the CCM.

POSSIBLE CAUSE  Harness malfunction
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BEEN RECORDED
recorded?
Yes
next step.
INSPECT CONNECTOR FOR POOR
CONNECTION Yes Go to the next step.

 Disconnect PCM connector and IAT

3 sensor connectors.
 Inspect for poor connection (such as Repair or replace suspected part, then go to
No
damaged, pulled-out pins, and Step 6.
corrosion).
INTERMITTENT INSPECTION


Inspect the IAT sensor. (See INTAKE AIR
 Access the PCM and monitor the IAT
TEMPERATURE (IAT) SENSOR
PID. Yes
4  While observing the PID, perform the Replace if necessary, then go to Step 6.
following:
 Tap on the sensor to simulate
road shock
 Wiggle the sensor connector
 Is there a large change in the voltage No Go to the next step.

reading?
INSPECT ELECTRONIC ENGINE
CONTROL WIRING HARNESS
Yes Repair if necessary, then go to Step 6.
 Access the PCM and monitor the IAT
PID.
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While observing the PID, wiggle,


shake, and bend small sections of the
wiring harness while working from the
sensor to the PCM.
 Is there a large change in the voltage
reading?


Yes (See PCM REMOVAL/INSTALLATION
[MZI-3.7] .)
using the M-MDS.

present?
Yes
DTC P0116 [MZI-3.7]

DTC P0116 CHT sensor circuit range/performance
 Indicates the engine coolant temperature logic test has failed. This DTC indicates
that the CHT value is higher than the calibrated value and could prevent 1 or
more OBD monitors from completing. The PCM runs this logic after an engine
off and a calibrated soak period (typically 6 hours). This soak period allows the
IAT and the CHT to stabilize and not differ by more than a calibrated value.
DETECTION DTC P0116 is set when all of the following conditions are met:
CONDITION
 The CHT at engine start exceeds the IAT at engine start by more than a
calibrated value, typically 17°C {30°F}.
 The CHT exceeds a calibrated value, typically 107°C {225°F}.
 The fuel system, heated oxygen and misfire monitors have not completed.
 The calibrated time to set DTC P0116 has expired.
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POSSIBLE  Cooling system malfunction

CAUSE  CHT sensor malfunction

BEEN RECORDED
recorded?
Yes available Service Bulletins.
2  Verify related Service Bulletins and/or If the vehicle is not repaired, go to next step.
Yes
TABLE [MZI-3.7].)
stored DTCs.
INSPECT CHT SENSOR

Replace the CHT sensor, then go to the next
 Inspect the CHT sensor. (See Yes
step.
4 CYLINDER HEAD
TEMPERATURE (CHT) SENSOR

Replace the PCM, then go to next step. (See
 Make sure to reconnect all disconnected Yes PCM REMOVAL/INSTALLATION [MZI-
connectors. 3.7] .)
5  Clear DTC from memory using M-
MDS.
 Perform the "KOEO/KOER self-
test" (See KOEO/KOER SELF TEST No Go to the next step.
[MZI-3.7].)
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Is same DTC present?



Yes
6 PROCEDURE". (See AFTER REPAIR
DTC P0119 [MZI-3.7]

DTC P0119 CHT sensor circuit intermittent/erratic
DETECTION  Indicates the ECT circuit became intermittently open or shorted while
CONDITION the engine was running.
 Harness malfunction
POSSIBLE CAUSE
 Low engine coolant
 CHT sensor malfunction

BEEN RECORDED
recorded?
Perform repair or diagnosis according to
Yes
 If vehicle is not repaired, go to the next
availability. step.
INSPECT CONNECTOR FOR POOR

CONNECTION
Yes
3  Turn the ignition switch off. 7.
 Disconnect PCM connector and CHT
sensor connectors.
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damaged, pulled-out pins, and

corrosion). No Go to the next step.
INTERMITTENT INSPECTION


Inspect the CHT sensor. (See CYLINDER
 Access the PCM and monitor the CHT
HEAD TEMPERATURE (CHT) SENSOR
PID. Yes
4  While observing the PID, perform the Replace if necessary, then go to Step 7.
following:
 Tap on the sensor to simulate
road shock
 Wiggle the sensor connector
 Is there a large change in the voltage No Go to the next step.

reading?
INSPECT ELECTRONIC ENGINE
CONTROL (EEC) WIRING HARNESS
Yes Repair if necessary, then go to Step 7.
Access the PCM and monitor the CHT

PID.
5  While observing the PID, wiggle,
shake, and bend small sections of the
sensor to the PCM. No Go to the next step.
 Is there a large change in the voltage
reading?
INSPECT FOR CORRECT PCM
OPERATION

 Yes Go to the next step.
 Visually inspect for:
 Pushed out pins

6
 Corrosion
 Connect all the PCM connectors and

verify that they seat correctly.
No The system is correctly. Go to the next step.

present?
 Make sure to reconnect all

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disconnected connectors.
 Clear the DTC from memory using M- Replace the PCM, then go to the next step. (See
MDS. Yes PCM REMOVAL/INSTALLATION [MZI-
3.7] .)
7
test" (See KOEO/KOER SELF TEST
[MZI-3.7].) No Go to the next step.

Yes
DTC P0122 [MZI-3.7]

DTC P0122 TP sensor No.1 circuit low input
DETECTION  The TP sensor No.1 circuit was flagged as a concern by the PCM indicating a
CONDITION low voltage or open circuit.
 TP sensor No.1 malfunction
POSSIBLE CAUSE  Open circuit between throttle body terminal F and PCM terminal 2Z
 Short to ground circuit between throttle body terminal F and PCM terminal 2Z
 Open circuit between throttle body terminal E and PCM terminal 2AH
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BEEN RECORDED
recorded?

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on-line repair information availability. Yes next step.
2
INSPECT TP SENSOR CONNECTOR
FOR POOR CONNECTION
Yes
 Step 9.
3  Disconnect the throttle body connector.

INSPECT TP SENSOR CIRCUIT FOR

SHORT TO GROUND
Yes
 Step 9.
 Inspect for continuity between TP sensor
terminal F (wiring harness-side) and
body ground No Go to the next step.
INSPECT PCM CONNECTOR FOR POOR

CONNECTION
Yes
 Step 9.

INSPECT TP SIGNAL CIRCUIT FOR

 Inspect for continuity between throttle

6 body connector terminal F (wiring
harness-side) and PCM terminal 2Z Repair or replace suspected part, then go to
No
(wiring harness-side). Step 9.
INSPECT TP GROUND CIRCUIT FOR
7
 Verify the continuity between TP sensor
terminal E (wiring harness-side) and Repair or replace suspected part, then go to
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PCM terminal 2AH (wiring harness- Step 9.

side). No
 Is the continuity?
INSPECT TP SENSOR NO.1

Replace the throttle body, then go to the next
Yes
Inspect the TP sensor No.1. (See
 step.
8 THROTTLE POSITION (TP)
SENSOR INSPECTION [MZI-3.7] .)


9 using the M-MDS.
 Perform the "KOEO/KOER self-test".

(See KOEO/KOER SELF TEST [MZI-
3.7].) No Go to the next step.

Yes
DTC P0123 [MZI-3.7]

DTC P0123 TP sensor No.1 circuit high input
CONDITION high voltage.
POSSIBLE CAUSE  Short to constant voltage supply circuit between throttle body terminal F and
PCM terminal 2Z
 TP sensor signal circuits are shorted each other
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BEEN RECORDED
recorded?

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2
available?
FOR POOR CONNECTION
Yes
 8.


POOR CONNECTION
Yes
 8.


Yes
 8.
 Measure the voltage between Throttle
body connector terminal F (wiring
harness-side) and body ground. No Go to the next step.
INSPECT TP SENSOR SIGNAL

CIRCUITS FOR SHORT EACH OTHER Yes Go to the next step.
 Disconnect the TP sensor and PCM

6 connector.
 Measure resistance between Throttle Repair or replace suspected part, then go to Step
body connector terminal D and F No
8.
kilohms?
Yes
7  Inspect the TP sensor No.1. (See step.
THROTTLE POSITION (TP)
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Are there any malfunction?


 Clear the DTC from the PCM memory 3.7] .)
8 using the M-MDS.

(See KOEO/KOER SELF TEST

Yes
DTC P0128 [MZI-3.7]

DTC P0128 Coolant thermostat (coolant temp below thermostat regulating temperature)
DETECTION  P0128 Indicates that the thermostat monitor has not achieved the required
CONDITION engine operating temperature within a specified amount of time after starting
the engine.
 Insufficient warm up time
 Low engine coolant level
POSSIBLE CAUSE
 Leaking or stuck open thermostat
 Inoperative cylinder head temperature (CHT) sensor

VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step.
RECORDED
recorded?
VERIFY RELATED REPAIR INFORMATION Perform repair or diagnosis according to
Microsoft
AVAILABILITY the available Service Bulletins.

Yes
2 Verify related Service Bulletins and/or on-
  If the vehicle is not repaired, go to
INSPECT ENGINE COOLANT LEVEL
WARNING:
 Never remove the cooling system cap or
loosen the radiator drain plug while the
engine is running, or when the engine and
radiator are hot. Scalding engine coolant
and steam may shoot out and cause
serious injury. It may also damage the
engine and cooling system.
3  Turn off the engine and wait until it is cool. Inspect for a loss of engine coolant.
Even then, be very careful when removing Repair if necessary. (See ENGINE
the cap. Wrap a thick cloth around it and
slowly turn it counterclockwise to the first No COOLANT LEVEL INSPECTION
stop. Step back while the pressure [MZI-3.7] .)
escapes. Go to Step 5.
 When you're sure all the pressure is gone,
press down on the cap using the cloth,
turn it, and remove it.
Is the engine coolant fill level correct?


INSPECT SENSOR OPERATION

Yes The test is complete. Go to the next step.
 Run the engine until the engine temperature
stabilizes.
4  Verify that the radiator hoses are hot and the
Inspect the thermostat operation. Repair
cooling system is pressurized.
No if necessary. (See THERMOSTAT
 Access the PCM and monitor the CHT PID. INSPECTION [MZI-3.7] .)
 Is the temperature more than 77°C {170.6°
F}?

Replace PCM, then go to the next step.
 Verify that all disconnected connectors are (See PCM
5 reconnected. Yes
 Turn the ignition switch to the ON position 3.7] .)
(Engine off).
 Clear the DTC from the PCM memory using
the M-MDS.
Microsoft
Start the engine and run it at idle.



present?
Yes
 Perform "AFTER REPAIR PROCEDURE". (See DTC TABLE [MZI-3.7].)
[MZI-3.7].)
DTC P0132, P0138, P0152, P0158 [MZI-3.7]

DTC P0132 P0132: Front HO2S (RH) circuit high voltage
DTC P0138 P0138: Rear HO2S (RH) circuit high voltage
DTC P0152 P0152: Front HO2S (LH) circuit high voltage
DTC P0158 P0158: Rear HO2S (LH) circuit high voltage
 The HO2S signals are monitored for an over voltage condition.
DETECTION CONDITION
 The code is set when the HO2S signal voltage is 1.5 V or more.
POSSIBLE CAUSE  Short to power supply in the wiring harness or HO2S
Microsoft

Microsoft

BEEN RECORDED
 Has FREEZE FRAME DATA been
No
recorded?
Yes
 If the vehicle is not repaired, go to the next
step.
VISUALLY INSPECT HO2S WIRING
HARNESS
NOTE:
 Disconnect the HO2S wiring Yes Repair if necessary. Go to Step 9.
harness connector.
3 Turn the ignition switch off.


 Disconnect the HO2S connector.
 Visually inspect the HO2S wiring

harness.
 Check the connector (both
halves) for contamination
 Make sure the connector pins
are fully seated
INSPECT WHETHER HO2S SIGNAL

LEVEL IS TOO HIGH
Yes Go to Step 6.
 Connect the HO2S connector.
position (Engine running)
 Access the PCM and monitor the No Go to the next step.
HO2S signal PID.
 Is the voltage less than 1.1V?
PERFORM THOROUGH WIGGLE
TEST ON HO2S WIRING HARNESS Yes Repair if necessary. Go to Step 9.

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position (Engine off)

 Access the PCM and monitor the
HO2S signal PID. Perform the "INTERMITTENT CONCERN
5  Perform a thorough wiggle test on the No TROUBLESHOOTING". Then go to the next
HO2S wiring harness. step.
 Does the voltage change during the
wiggle test?
INSPECT HO2S CIRCUIT FOR SHORT
TO POWER SUPPLY IN WIRING
HARNESS
Repair or replace suspected part, Then go to the
Yes
 next step.

 Measure the voltage between HO2S
terminal B and body ground. No Go to Step 9.
 Is any voltage present?
INSPECT HO2S
 For DTC P0132 Inspect the front

HO2S(RH)
 For DTC P0138 Inspect the rear
HO2S(RH) Replace the HO2S.
 For DTC P0152 Inspect the front (See FRONT HEATED OXYGEN SENSOR
HO2S(LH) (HO2S) REMOVAL/INSTALLATION [MZI-
3.7] .)
 For DTC P0138 Inspect the rear Yes
7 HO2S(LH) (HO2S) REMOVAL/INSTALLATION [MZI-
3.7] .)
(See FRONT HEATED OXYGEN Then go to the next step.
SENSOR (HO2S) INSPECTION
[MZI-3.7] .)
(See REAR HEATED OXYGEN

[MZI-3.7] .)

8
 Disconnect all the PCM connectors.
Microsoft
Pushed out pins


 Corrosion
No Repair if necessary. Then go to the next step.
COMPLETED

connectors are reconnected. Yes PCM REMOVAL/INSTALLATION [MZI-
using the M-MDS.

present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
10  Perform "AFTER REPAIR
DTC P0133, P0139, P0153, P0159 [MZI-3.7]

DTC P0133 P0133: Front HO2S (RH) circuit slow response
DTC P0139 P0139: Rear HO2S (RH) circuit slow response
DTC P0153 P0153: Front HO2S (LH) circuit slow response
DTC P0159 P0159: Rear HO2S (LH) circuit slow response
 The HO2S monitor checks the HO2S frequency and amplitude.
DETECTION
CONDITION  The test fails if the frequency and amplitude fall below a calibrated limit during
testing.
 Contaminated HO2S
 Exhaust leaks
 Open circuit in wiring harness between PCM terminal 2Y (wiring harness-side)
and front HO2S (RH) terminal B (wiring harness-side)
 Open circuit in wiring harness between PCM terminal 2BG (wiring harness-side)
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and rear HO2S (RH) terminal B (wiring harness-side)

 Open circuit in wiring harness between PCM terminal 2U (wiring harness-side)
and front HO2S (LH) terminal B (wiring harness-side)
 Open circuit in wiring harness between PCM terminal 2BC (wiring harness-side)
and rear HO2S (LH) terminal B (wiring harness-side)
 Open circuit in wiring harness between PCM terminal 2AL (wiring harness-side)
and HO2S terminal D (wiring harness-side)
 Short to ground in wiring harness between PCM terminal 1BJ (wiring harness-
side) and PCM terminal 2Y (wiring harness-side)
side) and PCM terminal 2BG (wiring harness-side)
side) and PCM terminal 2U (wiring harness-side)
side) and PCM terminal 2BC (wiring harness-side)
 Short to ground in wiring harness between HO2S terminal A (wiring harness-
side) and battery negative terminal
POSSIBLE CAUSE  Short to ground in wiring harness between HO2S terminal A (wiring harness-
side) and HO2S terminal C (wiring harness-side)
side) and HO2S terminal D (wiring harness-side)
side) and HO2S terminal B (wiring harness-side)
 Short to ground in wiring harness between PCM terminal 2J and front HO2S
(RH) terminal A
 Short to ground in wiring harness between PCM terminal 2E and front HO2S
(RH) terminal A
 Short to ground in wiring harness between PCM terminal 2AO and rear HO2S
(LH) terminal A
 Short to ground in wiring harness between PCM terminal 2AS and rear HO2S
(LH) terminal A
 Incorrect fueling
 Deteriorating HO2S
 Inlet air leaks
Microsoft
Microsoft

BEEN RECORDED
recorded?
Yes
next step.
PERFORM KOER SELF-TEST
 Verify that the engine is at normal Yes
3 operating temperature.
 Perform the KOER self-test.
 Are DTCs P0040, P0041 or P1127 No Go to the next step.
present?
INSPECT FOR UNMETERED AIR

LEAKS
NOTE:
 Fuel calculations can be affected by
unmetered air leaks.
Repair the source of the air leak. Then go to
Yes
Step 17.
 Carefully inspect the following areas
for potential air leaks:
4
 Hoses connecting to the MAF
sensor assembly
 Hoses connecting to the throttle
body
 Intake manifold gasket leaks
 PCV system
 The vacuum lines are

disconnected No Go to the next step.
 Improperly seated engine oil
dipstick, tube or oil filler cap
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Exhaust leaks at flanges and


gaskets
 Are any air leaks present?
INSPECT HO2S CIRCUIT (S) FOR

OPEN CIRCUIT IN WIRING HARNESS

 Remove the jumper wire (s).
 Visually inspect the HO2S wiring Yes Go to the next step.
harness for exposed wiring, water
contamination, corrosion, and proper
assembly.
 PCM terminal 2Y (wiring
harness-side) and front HO2S
(RH) terminal B (wiring harness-
side)
5
 PCM terminal 2BG (wiring
harness-side) and rear HO2S
side)
 PCM terminal 2U (wiring
Repair or replace suspected part, Then go to
harness-side) and front HO2S No
Step 17.
(LH) terminal B (wiring harness-
side)
 PCM terminal 2BC (wiring
side)
 PCM terminal 2AL (wiring
harness-side) and HO2S terminal
D (wiring harness-side)
 Are the resistances less than 5 ohms?
INSPECT HO2S CIRCUIT FOR SHORT

TO POWER SUPPLY
 Measure the resistance between the Yes Go to the next step.

 PCM terminal 1BJ (wiring
harness-side) and PCM terminal
2Y (wiring harness-side)
Microsoft
PCM terminal 1 BJ (wiring


2BG (wiring harness-side)
 PCM terminal 1 BJ (wiring
6 No Go to Step 10.
2U (wiring harness-side)
 PCM terminal 1BJ (wiring
2BC (wiring harness-side)
 Is the resistance more than 10 kilohms?
INSPECT FOR SOURCE OF

POTENTIAL HO2S CONTAMINATION
Investigate the following items as


potential sources of HO2S
contamination: Repair the source of the contamination. Change
Yes
 Use of unapproved silicon sealers the engine oil and oil filter. Then go to Step 17.
 Fuel contaminated by silicon
additives
7
 Excessive oil consumption
 Glycol leaking internally in the

engine
 Lead-contaminated fuel
 Short drive cycles in cold weather

 Use of unapproved cleaning
agents

HARNESS
Yes Repair if necessary. Then go to the next step.
 Connect the PCM connector.
8  Visually inspect the HO2S wiring

harness for exposed wiring water
contamination, corrosion, and proper No Go to the next step.
assembly.
INSPECT HO2S AND SIGRTN

CIRCUITS FOR OPEN CIRCUIT IN
WIRING HARNESS
NOTE:
 Verify the wiring harness terminals
Microsoft
are in the proper location.


 PCM terminal 2Y (wiring
side)
 PCM terminal 2BG (wiring
side) Repair or replace suspected part, Then go to
9 No
Step 17.
 PCM terminal 2U (wiring
side)
 PCM terminal 2BC (wiring
side)
 PCM terminal 2AL (wiring
INSPECT HO2S CONTROL CIRCUIT IN

WIRING HARNESS Yes Go to the next step.
10
 Perform the KOEO self-test.
 Measure the voltage between: HO2S Repair or replace suspected part, Then go to the
No
connector terminal C and D on the next step.
wiring harness side.
INSPECT HO2S HEATER FOR SHORT
IN WIRING HARNESS

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HO2S terminal A (wiring


harness-side) and battery negative
terminal
C (wiring harness-side)
 HO2S terminal A (wiring Repair or replace suspected part, Then go to
11 No
harness-side) and HO2S terminal Step 17.
B (wiring harness-side)
kilohms?
INSPECT HO2S HEATER CIRCUIT FOR
OPEN CIRCUIT IN WIRING HARNESS
Measure the resistance:


 For DTC P0133 measure
resistance between PCM terminal
2J and front HO2S (RH) terminal
A
12 2AS and rear HO2S (RH)
terminal A
resistance between PCM terminal Repair or replace suspected part, Then go to the
2E and front HO2S (LH) terminal No next step.
A
2AO and rear HO2S (LH)
terminal A
 Is the resistance less than 5 ohms?
INSPECT INTERNAL RESISTANCE OF

HO2S HEATER Yes Go to the next step.
13 Measure the resistance between the


suspect HO2S terminal A and C at
component side. No Install a new HO2S. Then go to Step 17.
 Is the resistance between 3-30 ohms?
INSPECT HO2S HEATER CIRCUIT FOR Yes Go to the next step.

INTERNAL SHORT TO SIGRTN OR
Microsoft
GROUND Replace the HO2S.

(See FRONT HEATED OXYGEN SENSOR
 Measure the resistance between:
(HO2S) REMOVAL/INSTALLATION
 HO2S terminal A and D at [MZI-3.7] .)
14 component side No
 HO2S terminal A at component (HO2S) REMOVAL/INSTALLATION
side and battery negative terminal [MZI-3.7] .)
Then go to Step 17.
INSPECT HO2S
 For DTC P0133 Inspect the front HO2S

(RH)
 For DTC P0139 Inspect the rear HO2S
(RH) Replace the HO2S.
 For DTC P0153 Inspect the front HO2S (See FRONT HEATED OXYGEN SENSOR
(LH) (HO2S) REMOVAL/INSTALLATION
[MZI-3.7] .)
 For DTC P0159 Inspect the rear HO2S Yes (See REAR HEATED OXYGEN SENSOR
15 (LH) (HO2S) REMOVAL/INSTALLATION
[MZI-3.7] .)
(See FRONT HEATED OXYGEN Then go to Step 17.
[MZI-3.7] .)

[MZI-3.7] .)


OPERATION
 Disconnect all the PCM connectors. Yes Go to the next step.

 Pushed out pins
16
 Corrosion

present?
MISFIRE DTC HAS BEEN COMPLETED
Microsoft


are reconnected. Replace PCM, then go to the next step. (See
 Turn the ignition switch to the ON Yes PCM REMOVAL/INSTALLATION [MZI-
position (Engine off). 3.7] .)
using the M-MDS.
present?
Yes
 Perform "AFTER REPAIR DTC TABLE [MZI-3.7].)
DTC P0135, P0141, P0155, P0161 [MZI-3.7]

DTC P0135 P0135: Front HO2S heater (RH) circuit
DTC P0141 P0141: Rear HO2S heater (RH) circuit
DTC P0155 P0155: Front HO2S heater (LH) circuit
DTC P0161 P0161: Rear HO2S heater (LH) circuit
 During testing the heated oxygen sensor heaters are checked for open and short
DETECTION circuits and excessive current draw.
CONDITION  The test fails when the current draw exceeds a calibrated limit or an open or
short circuit is detected.
 Short to ground between HO2S terminal A and HO2S terminal C
 Short to ground between HO2S terminal A and HO2S terminal D
 Short to ground between HO2S terminal A and HO2S terminal B
 Water in the wiring harness connector
 Open circuit between PCM terminal 2J and front HO2S (RH) terminal A
POSSIBLE CAUSE  Open circuit between PCM terminal 2AS and rear HO2S (RH) terminal A
 Open circuit between PCM terminal 2E and front HO2S (LH) terminal A
 Open circuit between PCM terminal 2AO and rear HO2S (LH) terminal A
 Low battery voltage
 Corrosion or incorrect harness connections
 HO2S heater malfunction
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Microsoft

BEEN RECORDED
recorded?
Yes
next step.
INSPECT FOR SOURCE OF
POTENTIAL HO2S CONTAMINATION
Investigate the following items as


potential sources of HO2S
contamination:
 Use of unapproved silicon sealers
Repair the source of the contamination. Change
Yes the engine oil and oil filter. Then go to the next
 Fuel contaminated by silicon
step.
additives
3  Excessive oil consumption
 Glycol leaking internally in the

engine
 Lead-contaminated fuel
 Short drive cycles in cold

weather
 Use of unapproved cleaning No Go to the next step.
agents

HARNESS
Yes
 Connect the PCM connector. Step 12.
4  Visually inspect the HO2S wiring
harness for exposed wiring water
contamination, corrosion, and proper
assembly. No Go to the next step.
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INSPECT POWER SUPPLY IN WIRING

HARNESS
Turn the ignition switch off. Go to the next
Yes
Disconnect suspect HO2S connector.
 step.
 Measure the voltage between suspect
HO2S connector terminal A and C, on
the wiring harness side.

TO GROUND

6
 Measure the resistance between HO2S
terminal A on the wiring harness side
and body ground. No Repair or replace suspected part, Go to Step 12.

IN WIRING HARNESS

following terminals: Yes Go to the next step.
C (wiring harness-side)
7
B (wiring harness-side)
kilohms?
INSPECT HO2S HEATER CIRCUIT
FOR OPEN CIRCUIT IN WIRING
HARNESS
8  For DTC P0135, measure the resistance Yes Go to the next step.
between PCM terminal 2J and front
 For DTC P0141, measure the resistance
between PCM terminal 2AS and rear
Microsoft
For DTC P0155, measure the resistance


between PCM terminal 2E and front
 For DTC P0161, measure the resistance No Repair or replace suspected part, Go to Step 12.
between PCM terminal 2AO and rear
 Is the resistance less than 5.0 ohms?

INSPECT INTERNAL RESISTANCE OF Replace HO2S.
HO2S HEATER (See FRONT HEATED OXYGEN SENSOR
(HO2S) REMOVAL/INSTALLATION
9  Measure the resistance between the [MZI-3.7] .)
suspect HO2S terminal A and C, on the No (See REAR HEATED OXYGEN SENSOR
component side. (HO2S) REMOVAL/INSTALLATION
 Is the resistance between 3-30 ohms? [MZI-3.7] .)
Go to Step 12.
INSPECT HO2S CASE FOR SHORT TO Yes Go to the next step.
POWER SUPPLY, HTR, AND SIGNRTN
Replace HO2S.
 Measure the resistance between the (See FRONT HEATED OXYGEN SENSOR
suspect HO2S terminal A and D at (HO2S) REMOVAL/INSTALLATION
10 component side. [MZI-3.7] .)
No
suspect HO2S terminal A and body (HO2S) REMOVAL/INSTALLATION
ground. [MZI-3.7] .)
Go to the next step.

OPERATION

 Pushed out pins
11
 Corrosion

present?
COMPLETED Yes
Replace PCM, then go to the next step. (See
 Verify that all disconnected connectors PCM REMOVAL/INSTALLATION [MZI-
Microsoft
are reconnected. 3.7] .)

12
using the M-MDS.
present?
Yes
DTC P0148 [MZI-3.7]

DTC P0148 Fuel delivery error
DETECTION CONDITION  At least 1 bank is lean at wide open throttle (WOT).
 Severely restricted fuel filter

 Severely restricted fuel supply line
POSSIBLE CAUSE
 Damaged or worn fuel pump
 Damaged or contaminated MAF sensor

BEEN RECORDED
recorded?
Yes
next step.
INSPECT SYSTEM INTEGRITY
Microsoft
 Visually inspect the complete fuel

delivery system for damage and
leakage.
 Check the following:
 Fuel lines and connections
 Relays
Yes Repair if necessary. Then go to Step 11.
 Fuel tank
 Fuel pump
 Fuel pressure regulator
 Fuel pulse damper
 Fuel rail at fuel injectors

3
 Damaged connector pins
 Electrical connectors not fully

engaged
 Verify that the vehicle has followed the
maintenance schedule. A new fuel filter
should have been installed within the No Go to the next step.
last 48,280 km {29,934 mph}.
 Verify that the fuse integrity.
 Verify that the battery is fully charged.
 Verify that there is clean sufficient fuel.
INSPECT ALL SYSTEM RELATED
DEVICES (SENSOR, DAMPER OR
REGULATOR) FOR LEAKAGE
 Connect the fuel pump connector.
 Check for manifold vacuum at each
4 system related component with a
vacuum line.
 Turn the ignition switch off. If the vacuum line connected to a component
 Wait 10 s. No indicates that a fuel leak is present, install a
new component. Then go to Step 11.
 Run the engine for approx. 10 s.
 Remove the vacuum hose on each
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system device connected to the fuel rail.

 Inspect for the presence of fuel in the
vacuum line of each device connected
to the fuel rail.
 Are all vacuum lines for system related
devices indicating no fuel present?
INSPECT FUEL PRESSURE


 Relieve the fuel pressure. Refer to the . Yes Go to Step 9.
 Connect the mechanical fuel pressure

gauge.
5
 Pressurize the fuel system. Refer to the
for the Fuel System Pressure Release
procedure to pressurize the fuel system. No Go to the next step.
 Compare the fuel pressure reading to
the Fuel System Specification Chart.
 Is the fuel pressure within range?
INSPECT FUEL PUMP GROUND

CIRCUIT FOR OPEN CIRCUIT IN
NOTE:
 Refer to the for schematic and
connector information.
6
 Disconnect the fuel pump connector. Repair or replace suspected part, Then go to
No
Step 11.
 Measure the resistance between fuel
pump connector terminal D (wiring
 Is the voltage less than 0.5 ohm?
INSPECT FUEL PUMP POWER SUPPLY
CIRCUIT FOR OPEN CIRCUIT IN
7  Disconnect the fuel pump connector.

 Access the PCM and control the FP
PID. Repair or replace suspected part, Then go to
Microsoft
Measure the voltage between fuel pump


Step 11.
connector terminal B (wiring harness-
No
side) and body ground.
INSPECT FUEL PRESSURE LEAK
NOTE:
 When the fuel pump is commanded
off, the fuel pressure may
substantially decrease and then
stabilize.
Yes Perform the KOEO self-test. Go to Step 10.
NOTE:
 During output state control, the fuel
pump stays commanded on for only
approx. 5 s.
Connect the mechanical fuel pressure


8 gauge.
 Access the PCM and control the FP
PID.
 Run the fuel pump to obtain maximum
fuel pressure.
 Command the fuel pump off.
 Allow the fuel pressure to stabilize.
 Record the stabilized reading.
 Monitor the fuel pressure for 1 min.
 Does the fuel pressure remain within 34

kPa {255 mmHg, 10.0 inHg} of the
recorded reading after 1 min?
INSPECT FUEL INJECTOR
9 Remove the fuel injector.

 Inspect the fuel injector operation. No Replace the fuel injector, then go to Step 11.
 Is the fuel injector normal?
INSPECT FUEL SUPPLY LINE FOR

RESTRICTION
Microsoft
NOTE:
 Observe the Warnings, Cautions, and Replace the fuel pump module. Then go to the
Notes. Yes
next step.
Disconnect the fuel supply line at the


fuel rail.
10  Disconnect the fuel supply line at the
fuel pump.
 Check the fuel supply line for Repair the cause of the restriction. Then go to
No
restriction. the next step.
 Apply 21-34 kPa {2142-3467 mmHg,
84.34-136.4 inHg} air pressure to the
fuel supply line.
 Does air flow freely through the line?



are reconnected. Replace PCM, then go to the next step. (See
3.7] .)
using the M-MDS.

present?
Yes
DTC P0171, P0174 [MZI-3.7]

DTC P0171 P0171: System too lean (RH)
DTC P0174 P0174: System too lean (LH)
 P0171 indicates that the fuel/air ratio is too lean (RH).

DETECTION  P0174 indicates that the fuel/air ratio is too lean (LH).
Microsoft
CONDITION  The adaptive fuel strategy continuously monitors the fuel delivery hardware.
The test fails when the adaptive fuel tables reach a rich calibrated limit.
Fuel System:
 Damaged or leaking fuel pulse damper

 Fuel filter plugged or dirty
 Damaged or worn fuel pump
 Leaking fuel pump check valve
 Leaking/contaminated fuel injectors
 Low fuel pressure or running out of fuel
 Purge solenoid valve is leaking when the canister is clean
 Fuel supply line restricted
 Fuel rail pressure sensor bias
POSSIBLE CAUSE
Exhaust System:
 Exhaust leaks in the exhaust manifold gasket or mating gaskets before or

near the HO2S
Intake Air System:
 Air leaks after the MAF sensor

 Vacuum leaks
 PCV system is leaking or the valve is stuck open
 Improperly seated engine oil dipstick

RECORDED
recorded?

2 AVAILABILITY Yes the available Service Bulletins.
 Verify related Service Bulletins and/or on-  If the vehicle is not repaired, go to
Microsoft

STORED DTCS
Go to the appropriate DTC
Turn the ignition switch off then to the ON

Yes troubleshooting procedures. (See DTC
position (Engine off). TABLE [MZI-3.7].)
3  Verify related PENDING CODE or stored
DTCs.
 Are any DTCs present other than the
following: No Go to the next step.
 P0171, P0174, P2195 or P2197?
PERFORM VISUAL INSPECTION ON

INTAKEAIR SYSTEM AND ALL VACUUM
HOSES


Yes Repair if necessary. Then go to Step 7.
 Check the intake air system for leaks,
obstructions, and damage.
 Inspect the entire length of all the vacuum
hoses for:
4  Proper connections
 Damage or cracks
 Damaged or cracked vacuum vacuum

hose joint
 Verify the integrity of the positive crankcase No Go to the next step.
ventilation system.
 Verify that the PCV valve part number is
correct.
INSPECT FOR PRESENCE OF VACUUM

LEAK
NOTE:
 Fuel trim values at idle are more sensitive
to a vacuum leak. The vacuum leak
(unmetered air) represents a larger portion Yes No vacuum leak is present. Go to Step 8.
of the total air flow at idle than at part
throttle.
 The BARO PID is not a commended PID to
monitor when diagnosing a vacuum leak.
BARO is calculated during high engine
load, when the vacuum leak represents a
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small portion of the total air flow

 When calculating the total fuel correction
in the following steps, if LONGFT1 equals
+13% and SHRTFT1 equals +23%, the total
fuel correction for bank 1 equals +36%. If
LONGFT2 equals +24% and SHRTFT2
equals -3% the total fuel correction for
bank 2 equals+21%.
 If the freeze frame ECT PID is available,
stabilize the engine at the temperature
recorded by the freeze frame ECT PID. If
the freeze frame ECT PID is not available,
maintain the engine coolant temperature
between 82-101°C {180-215°F} and the
intake air temperature at less than 46°C
{115°F}.
Turn the ignition switch to the ON position


(Engine running)
5  Access the PCM and monitor the ECT, CHT No Go to the next step.
and IAT PIDs.
 Access the PCM and monitor the LONGFT1,
SHRTFT1, LONGFT2 and SHRTFT2 PIDs.
 Allow the engine to stabilize at the
temperature necessary to recreate the
concern.
 Add and record the LONGFT PID value to
the SHRTFT PID value for each bank,
correction at idle.
 Increase the engine speed to 2,500 rpm for 10
s. Record the LONGFT1, SHRTFT1,
LONGFT2, and system SHRTFT2 PID
values.
 Add and record the LONGFT PID value to
the SHRTFT PID value for each bank,
correction at 2,500 rpm.
 Is the total fuel correction value difference
between idle and 2,500 rpm less than 15%?
LOCATE VACUUM LEAK
CAUTION:
Repair if necessary. Then go to the next
 Do not clamp or pinch a hard plastic hose. Yes step.
Use a vacuum cap or equivalent to restrict
the hose.
Microsoft
NOTE:
 Restricting the EVAP vapor hose while the
EVAP emission canister is purging may
shift the SHRTFT. Perform a visual
inspection if necessary.
 When monitoring for a decrease in the
SHRTFT PIDs in the following steps, if
SHRTFT1 equals +15% and the hose is
restricted, SHRTFT1 decreases to-7%. The
total decrease in the SHRTFT PIDs equals
22%.
Inspect the intake air system for a vacuum
leak in the intake manifold or intake
6 No
gaskets. Repair if necessary. Then go to
 Locate the vacuum hose joint for the intake
the next step.
air and PCV systems.
 Access the PCM and monitor the SHRTFT1
and SHRTFT2 PIDs.
 Restrict the vacuum lines one at a time for 30
s. If a vacuum leak in the intake is present,
the SHRTFT PID values decrease as the hose
is restricted.
 Is the decrease in the SHRTFT PIDs more
than 15% when one of the vacuum hoses is
restricted?
VACUUM LEAK REPAIR VERIFICATION
NOTE:
 If the freeze frame ECT PID is available,
stabilize the engine at the temperature
recorded by the freeze frame ECT PID. If
the freeze frame ECT PID is not available,
maintain the engine coolant temperature Reset the keep alive memory. Then go to
Yes
between 82-101°C {180-215°F} and the Step 13.
intake air temperature less than 46°C {115°
7 F}.

and SHRTFT2 PIDs.
concern.
 Record the SHRTFT1 and SHRTFT2 PID
values.
Microsoft
Repair the vacuum leak.



(Engine running)
concern.
A vacuum leak is still present. Go to Step
No
6.
and SHRTFT2 PIDs.
 Compare the recorded SHRTFT PID values,
prior to the no vacuum leak repair, to the
current SHRTFT PID values.
 Is the decrease in the SHRTFT PIDs more
than 15%?
WARNING:
 Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries
or death. Fuel can also irritate skin and
eyes. To prevent this, always complete the
"BEFORE REPAIR PROCEDURE".
Yes Go to Step 10.
NOTE:
 For vehicle specific fuel pressure ranges,
refer to the "FUEL LINE PRESSURE
INSPECTION ".
8  Remove the jumper wire(s).

 Relieve the fuel pressure.
 Connect the mechanical fuel pressure gauge.
 Pressurize the fuel system.
(Engine running)
 Access the PCM and control the FP PID.
 Run the fuel pump to obtain maximum fuel
pressure.
 Is the fuel pressure within the range for the
vehicle being diagnosed?
Microsoft
Replace suspected fuel line. Then go to

Yes
Step 13.
Inspect the low-pressure side fuel filter
for the following:
 Foreign materials or stain inside

INSPECT FUEL LINE FROM FUEL PUMP
fuel filter. Perform the following
TO FUEL DELIVERY PIPE
actions as a result.
9
 If foreign material or staining is
 Visually inspect fuel line for any leakage. No
found inside the fuel filter (low-
 Is fuel leakage found? pressure side), clean the fuel tank
and filter.
 If normal, replace fuel pump unit.
Then go to Step 13.

INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
10 Remove fuel injector.


Replace the fuel injector, then go to Step
 Inspect the injector operation. No
13.
INSPECT FRONT HO2S OUTPUT VOLTAGE
 Visually inspect the HO2S circuit for

exposed wiring, contamination, corrosion and Yes Go to the next step.
correct assembly. Repair if necessary.
 Measure the voltage between HO2S terminal
B and D on the component side.
11  Increase the engine speed to 2,000 rpm for 3
min.
(Engine running) No Replace the HO2S. Then go to Step 13.
 Monitor the signal voltage.
 Is the voltage more than 0.5 V at any time
during the engine running?
PERFORM THOROUGH WIGGLE TEST ON
HO2S WIRING HARNESS
 Turn the ignition switch off. Isolate the concern and repair if
12 Yes
 Connect the HO2S connector. necessary. Then go to the next step.
(Engine running)
 Verify that the engine is at normal operating
Microsoft
temperature.
 Access the PCM and monitor the HO2S
signal PID.
 Wiggle, shake, and bend small sections of the
sensor to the PCM.
 While monitoring the HO2S PID, does the
HO2S stop switching?
Verify that all disconnected connectors are


reconnected. Replace PCM, then go to the next step.
(See PCM
13 (Engine off). 3.7] .)
the M-MDS.

present?
Yes
 Perform "AFTER REPAIR PROCEDURE". (See DTC TABLE [MZI-3.7].)
[MZI-3.7].)
DTC P0172, P0175 [MZI-3.7]

DTC P0172 P0172: System too rich (RH)
DTC P0175 P0175: System too rich (LH)
 P0172 indicates that the fuel/air ratio is too rich (RH).
DETECTION  P0175 indicates that the fuel/air ratio is too rich (LH).
CONDITION  The adaptive fuel strategy continuously monitors the fuel delivery hardware.
The test fails when the adaptive fuel tables reach a rich calibrated limit.
Fuel System:
 Damaged or leaking fuel pulse damper

 Leaking fuel injectors
 Fuel return line restricted
Microsoft
 Fuel rail pressure sensor bias

 Purge solenoid valve is leaking when the canister is full
Base engine:
POSSIBLE CAUSE
 Engine oil contamination
Intake Air System:

RECORDED
recorded?
Yes
STORED DTCS
Go to the appropriate DTC
 Turn the ignition switch off then to the ON Yes troubleshooting procedures. (See DTC
position (Engine off). TABLE [MZI-3.7].)
3  Verify related PENDING CODE or stored
DTCs.
 Are any DTCs present other than the
following: No Go to the next step.
 P0172, P0175, P2196 or P2198?
INSPECT ENTIRE INTAKE AIR SYSTEM

FOR DEBRIS, BLOCKAGE OR OTHER
DAMAGE Repair if necessary.
4 Yes
Then go to Step 9.
 Check the intake air system for obstructions,
restrictions, and damage.
Microsoft
Check the throttle plate for obstructions or


sludge.
 Check the air filter element and housing for No Go to the next step.
blockage.
WARNING:
 Fuel line spills and leakage are dangerous.
Fuel can ignite and cause serious injuries
or death. Fuel can also irritate skin and Yes Go to the next step.
eyes. To prevent this, always complete the
"BEFORE REPAIR PROCEDURE".
NOTE:
 For vehicle specific fuel pressure ranges,
refer to the "FUEL LINE PRESSURE
INSPECTION ".
Remove the jumper wire(s).


5  Connect the HO2S connector.
 Relieve the fuel pressure.
 Connect the mechanical fuel pressure gauge
 Pressurize the fuel system.

Replace the fuel pump unit. Then go to
(Engine running) No
Step 9.

(Engine running)
 Access the PCM and control the FP PID.
 Run the fuel pump to obtain maximum fuel

pressure.
 Is the fuel pressure within the range for the
vehicle being diagnosed?
INSPECT FUEL INJECTOR OPERATION Yes Go to the next step.
6 Remove fuel injector.


Replace the fuel injector.
 Inspect the injector operation. No
Then go to Step 9.
INSPECT HO2S OUTPUT VOLTAGE

Microsoft
 Visually inspect the HO2S circuit for

exposed wiring, contamination, corrosion and Yes Go to the next step.
correct assembly. Repair if necessary.
 Measure the voltage between HO2S terminal
B and D on the component side.
 Increase the engine speed to 2,000 rpm for 3
7 min.
 Turn the ignition switch to the ON position Replace the HO2S.
No
(Engine running) Then go to Step 9.
 Monitor the signal voltage.
 Is the voltage more than 0.5 V at any time
during the engine running?
PERFORM THOROUGH WIGGLE TEST ON
HO2S WIRING HARNESS



Isolate the concern and repair if
Yes necessary.
(Engine running) Then go to the next step.
 Verify that the engine is at normal operating
8
temperature.
 Access the PCM and monitor the HO2S
signal PID.
 Wiggle, shake, and bend small sections of the
sensor to the PCM.
 While monitoring the HO2S PID, does the
HO2S stop switching?


reconnected. Replace the PCM, then go to the next
step. (See PCM
9 (Engine off). 3.7] .)
the M-MDS.

present?
Microsoft
 Perform "AFTER REPAIR PROCEDURE". Go to the applicable DTC inspection.

(See AFTER REPAIR PROCEDURE Yes
10 [MZI-3.7].)
 Are any DTC present? No Troubleshooting completed.
DTC P0201 [MZI-3.7]

DTC P0201 Injector circuit/open-cylinder No.1
DETECTION  The CCM monitors the operation of the fuel injector drivers in the PCM. The test
CONDITION fails if the fuel injector circuitry is inoperative.
 Fuel injector No.1 malfunction
POSSIBLE CAUSE
 Open circuit between fuel pump relay and fuel injector No.1 terminal B
 Open circuit between fuel injector No.1 terminal A and PCM terminal 2BJ
Microsoft

RECORDED Record FREEZE FRAME DATA
1
No on the repair order, then go to the
 Has FREEZE FRAME DATA been recorded? next step.
Perform repair or diagnosis
VERIFY RELATED REPAIR INFORMATION according to available Service
AVAILABILITY Bulletins.
Yes
2
 Verify related Service Bulletins availability.  If vehicle is not repaired, go
 Is any related Service Bulletins available? to the next step.
Microsoft
INSPECT FUEL INJECTOR NO.1 CONNECTOR

FOR POOR CONNECTION
Repair or replace suspected part,
Yes

then go to Step 8.
3  Disconnect the fuel injector No.1 connector.

 Are there malfunction?

CONNECTION
Yes
 then go to Step 8.

INSPECT FUEL INJECTOR NO.1 POWER SUPPLY

Turn the ignition switch to the ON position (Engine


5 off).
 Measure the voltage between fuel injector No.1 No
then go to Step 8.
connector terminal B and body ground.
INSPECT FUEL INJECTOR NO.1 SIGNAL

6 Inspect continuity between fuel injector No.1


terminal A (wiring harness-side) and PCM terminal No Repair or replace suspected part,
2BJ (wiring harness-side). then go to Step 8.
INSPECT FUEL INJECTOR NO.1

Replace the fuel injector No.1, then
Yes
 Inspect the fuel injector No.1. (See FUEL
7
INJECTOR INSPECTION [MZI-3.7] .)
VERIFY TROUBLESHOOTING OF DTC P0201

HAS BEEN COMPLETED
Replace the PCM, then go to the
8  Verify that all disconnected connectors Yes
next step.
reconnected.
Microsoft
Perform the "KOEO/KOER self-test" (See


KOEO/KOER SELF TEST [MZI-3.7].) No Go to the next step.

Go to the applicable DTC
 Perform the "AFTER REPAIR PROCEDURE". Yes inspection. (See DTC TABLE
9 (See AFTER REPAIR PROCEDURE [MZI- [MZI-3.7].)
3.7].)
 Are any DTCs present? No Troubleshooting completed.
DTC P0202 [MZI-3.7]

POSSIBLE CAUSE
 Open circuit between fuel injector No.2 terminal A and PCM terminal 2BM
Microsoft

1
Yes
2
Microsoft

FOR POOR CONNECTION
Yes

then go to Step 8.


CONNECTION
Yes




5 off).
then go to Step 8.



2BM (wiring harness-side). then go to Step 8.

Yes
7
HAS BEEN COMPLETED
 Verify that all disconnected connectors reconnected.
Yes
8 next step.
 Perform the "KOEO/KOER self-test" (See
Microsoft
KOEO/KOER SELF TEST [MZI-3.7].)


3.7].)
DTC P0203 [MZI-3.7]

POSSIBLE CAUSE
 Open circuit between fuel injector No.3 terminal A and PCM terminal 2BF
Microsoft

1
Yes
2
Microsoft

FOR POOR CONNECTION
Yes

then go to Step 8.


CONNECTION
Yes




5 off).
then go to Step 8.



2BF (wiring harness-side). then go to Step 8.

Yes
7

HAS BEEN COMPLETED
next step.
reconnected.
Microsoft



3.7].)
DTC P0204 [MZI-3.7]

POSSIBLE CAUSE
 Open circuit between fuel injector No.4 terminal A and PCM terminal 2BH
Microsoft

1
Yes
2
Microsoft

FOR POOR CONNECTION
Yes

then go to Step 8.


CONNECTION
Yes




5 off).
then go to Step 8.



2BH (wiring harness-side). then go to Step 8.

Yes
7
HAS BEEN COMPLETED
Yes
8 next step.
Microsoft


3.7].)
DTC P0205 [MZI-3.7]

POSSIBLE CAUSE
 Open circuit between fuel injector No.5 terminal A and PCM terminal 2BB
Microsoft

1
Yes
2
Microsoft

FOR POOR CONNECTION
Yes

then go to Step 8.


CONNECTION
Yes




5 off).
then go to Step 8.



2BB (wiring harness-side). then go to Step 8.

Yes
7

HAS BEEN COMPLETED
next step.
reconnected.
Microsoft



3.7].)
DTC P0206 [MZI-3.7]

POSSIBLE CAUSE
 Open circuit between fuel injector No.6 terminal A and PCM terminal 2BD
Microsoft

1
Yes
2
Microsoft

FOR POOR CONNECTION
Yes

then go to Step 8.


CONNECTION
Yes




5 off).
then go to Step 8.



2BD (wiring harness-side). then go to Step 8.

Yes
7
HAS BEEN COMPLETED
Yes
8 next step.
Microsoft


3.7].)
DTC P0222 [MZI-3.7]

DTC P0222 TP sensor No.2 circuit low input
CONDITION low voltage or open circuit.
POSSIBLE CAUSE  Open circuit between throttle body terminal C and PCM terminal 2AD
 Short to ground circuit between throttle body terminal C and PCM terminal
2AD
 Open circuit between throttle body terminal E and PCM terminal 2AH
Microsoft

BEEN RECORDED
recorded?

Microsoft

2
INSPECT TP SENSOR CONNECTOR FOR
POOR CONNECTION
Yes
 Step 9.


SHORT TO GROUND

 Repair or replace suspected part, then go to
position (Engine off). Yes
Step 9.
4 following circuits:
 TP sensor terminal D (wiring
 TP sensor terminal C (wiring

CONNECTION
Yes


 Inspect for continuity between throttle

6 body connector terminal C (wiring
harness-side) and PCM terminal 2AD Repair or replace suspected part, then go to
No
(wiring harness-side). Step 9.
INSPECT TP GROUND CIRCUIT FOR Yes Go to the next step.

OPEN CIRCUIT
Microsoft


 Verify the continuity between TP sensor Repair or replace suspected part, then go to
7 No
terminal E and body ground. Step 9.

Yes
Inspect the TP sensor No.2. (See
 step.


9 using the M-MDS.


Yes
DTC P0223 [MZI-3.7]

DTC P0223 TP sensor No.2 circuit high input
CONDITION high voltage.
POSSIBLE CAUSE  Open circuit wiring harness between throttle body terminal C and PCM
terminal 2AD
 TP sensor signal circuits are shorted each other
Microsoft

BEEN RECORDED
recorded?
Microsoft

Yes
FOR POOR CONNECTION
Yes
 8.


POOR CONNECTION
Yes
 8.


OPEN CIRCUIT

 Disconnect the throttle body connector.
5  Inspect for continuity between the

 Throttle body terminal C and Repair or replace suspected part, then go to Step
No
PCM terminal 2AD 8.
 Throttle body terminal D and
PCM terminal 2D

Yes Replace the throttle body, then go to Step 8.
 Inspect the TP sensor No.2. (See
SENSOR INSPECTION [MZI-3.7] .) No Go to the next step.
Microsoft

CIRCUITS FOR SHORT EACH OTHER Yes Go to the next step.
Disconnect the TP sensor and PCM


7 connector.
 Measure resistance between Throttle
No
body connector terminal D and C. 8.
kilohms?

8 using the M-MDS.


Yes
DTC P0230 [MZI-3.7]

DTC P0230 FP primary circuit
 The PCM monitors the fuel pump circuit output from the PCM. The test fails when the
DETECTION fuel pump output is commanded ON (grounded) and excessive current draw is detected
CONDITION on the fuel pump circuit. The test also fails when the fuel pump output is commanded
OFF and voltage is not detected on the fuel pump circuit. The PCM expects to detect
vehicle power voltage coming through the fuel pump relay coil to the fuel pump circuit.
 Fuel pump relay malfunction

POSSIBLE  Connector or terminal malfunction
CAUSE  Open circuit wiring harness between fuel pump relay terminal E and PCM terminal 1V
 Short to ground circuit between fuel pump relay terminal E and PCM terminal 1V
 Open circuit wiring harness between ignition switch and fuel pump relay terminal A
Microsoft
 PCM malfunction

RECORDED Record FREEZE FRAME DATA on
1
No the repair order, then go to the next
 Has FREEZE FRAME DATA been recorded? step.
VERIFY RELATED REPAIR INFORMATION Perform repair or diagnosis according
AVAILABILITY to available Service Bulletins.
Yes
2  If vehicle is not repaired, go to
 Verify related Service Bulletins availability.
the next step.
Microsoft

STORED DTC Go to appropriate DTC inspection.
Yes
3 Verify the related PENDING CODE or stored

DTCs.
INSPECT FUEL PUMP RELAY CONNECTOR

FOR POOR CONNECTION
Repair or replace suspected part, then
Yes
 go to Step 10.
4  Disconnect the fuel pump relay.


CONNECTION
Yes
 go to Step 10.

INSPECT FUEL PUMP RELAY POWER

SUPPLY CIRCUIT FOR OPEN CIRCUIT Yes Go to the next step.


6 (Engine off).
 Measure voltage between fuel pump relay Repair or replace suspected part, then
connector terminal A (harness-side) and body No
go to Step 10.
ground.
 Is voltage B+?
INSPECT FUEL PUMP CONTROL CIRCUIT

FOR SHORT TO GROUND
Yes
 Turn the ignition switch to the ON position go to Step 10.
7 (Engine off).
 Inspect for continuity between fuel pump relay
connector terminal E (harness-side) and body

INSPECT FUEL PUMP CONTROL CIRCUIT
FOR OPEN CIRCUIT
Microsoft


 Inspect for continuity between fuel pump relay Repair or replace suspected part, then
8 No
terminal E and PCM terminal 1V. go to Step 10.
INSPECT FUEL PUMP RELAY

Replace the fuel pump relay, then go
Yes
Inspect the fuel pump relay. (See RELAY to the next step.
9 
INSPECTION .)
HAS BEEN COMPLETED
Replace the PCM, then go to the next
 Yes
step.
reconnected.


Yes
 Perform the "AFTER REPAIR PROCEDURE". (See DTC TABLE [MZI-3.7].)
11 (See AFTER REPAIR PROCEDURE [MZI-
3.7].)
DTC P0231 [MZI-3.7]

DTC P0231 FP secondary circuit low
DETECTION  The PCM monitors the fuel pump monitor circuit. The test fails if the PCM
CONDITION commands the fuel pump ON and B+ voltage is not detected on the FPM circuit.
POSSIBLE CAUSE
 Open circuit between battery and fuel pump relay terminal C
 Open circuit between fuel pump relay terminal D and PCM terminal 1Q
Microsoft

1
2 Yes
Microsoft

VERIFY RELATED PENDING CODE OR STORED
DTC Go to appropriate DTC inspection.
Yes

DTCs.
INSPECT FUEL PUMP RELAY CONNECTOR FOR

POOR CONNECTION
Yes


CONNECTION
Yes

INSPECT FUEL PUMP RELAY POWER SUPPLY



6 off).
 Measure voltage between fuel pump relay Repair or replace suspected part,
connector terminal C (wiring harness-side) and No
then go to Step 9.
body ground.
 Is voltage B+?
INSPECT FUEL PUMP MONITOR CIRCUIT FOR


7
 Inspect continuity between fuel pump relay
terminal D (wiring harness-side) and PCM terminal No
then go to Step 9.
1Q (wiring harness-side).
INSPECT FUEL PUMP RELAY Replace the fuel pump relay, then
8 Yes
 Inspect the fuel pump relay. (See RELAY
Microsoft
INSPECTION .)

HAS BEEN COMPLETED
 Yes
next step.
reconnected.


3.7].)
DTC P0232 [MZI-3.7]

DTC P0232 FP secondary circuit high
 The PCM monitors the fuel pump monitor circuit. This test fails when the PCM detects
voltage on the fuel pump monitor circuit while the fuel pump is commanded OFF. The
DETECTION fuel pump monitor circuit is wired to a pull-up voltage inside the PCM. The fuel pump
CONDITION monitor circuit goes high if, with the key ON, engine OFF and the fuel pump
commanded OFF, the fuel pump monitor/fuel pump power circuit loses its path to
ground through the fuel pump. The fuel pump monitor circuit also goes high if the fuel
pump monitor/fuel pump power circuit is short to voltage.
 Fuel pump malfunction
POSSIBLE
CAUSE  Open circuit between fuel pump terminal B and PCM terminal 1Q
 Fuel pump connector for poor connection
 Short to power supply between fuel pump terminal B and PCM terminal 1Q
 Short to power supply between fuel pump relay terminal D and PCM terminal 1Q
Microsoft

1
VERIFY RELATED REPAIR INFORMATION
according to available Service
AVAILABILITY
Bulletins.
2 Yes
 Verify related Service Bulletins availability.
 If vehicle is not repaired, go
Microsoft

VERIFY RELATED PENDING CODE OR STORED
DTC Go to appropriate DTC inspection.
Yes

DTCs.
INSPECT FUEL PUMP RELAY CONNECTOR

FOR POOR CONNECTION
Yes


CONNECTION
Yes



 Repair or replace suspected part,
Yes
(Engine off). then go to Step 10.
6  Measure voltage between the following terminals:
 Fuel pump relay terminal D (wiring harness-

side) and body ground
 fuel pump terminal B (wiring harness-side)
and body ground No Go to the next step.
 Is voltage B+?


7
 Inspect continuity between fuel pump terminal B
(wiring harness-side) and PCM terminal 1Q No
then go to Step 10.
(wiring harness-side).
Microsoft
INSPECT FUEL PUMP RELAY Replace the fuel pump relay, then
Yes
go to Step 10.
8 Inspect the fuel pump relay. (See RELAY

INSPECTION .) No Go to the next step.
INSPECT FUEL PUMP

Replace the fuel pump unit, then go
Yes
Inspect the fuel pump. (See FUEL PUMP UNIT to the next step.
9 
HAS BEEN COMPLETED
Verify that all disconnected connectors Replace the PCM, then go to the
 Yes
next step.
reconnected.


3.7].)
DTC P0297 [MZI-3.7]

DTC P0297 Vehicle over speed condition
DETECTION  P0297 indicates that the vehicle has been operated in a manner which
CONDITION caused the engine or vehicle to exceed a calibration limit.
 Wheel slippage (water, ice, mud and snow).
POSSIBLE CAUSE  Excessive engine rpm in neutral.
 Vehicle drive at a high rate of speed.

Microsoft
HAS BEEN RECORDED

Record FREEZE FRAME DATA on the repair order,
1 No
Has FREEZE FRAME DATA
 then go to the next step.
been recorded?
INFORMATION AVAILABILITY Perform repair or diagnosis according to the available
Service Bulletins.
Verify related Service Bulletins Yes

availability. step.
INSPECT VEHICLE OPERATION
Yes Vehicle is normal. Then go to the next step.
 Check for:
 Water, ice, mud and snow

causing wheel slippage.
 Excessive engine speed in
3
N (Neutral). Clear DTCs and refer to "DIAGNOSTIC INDEX "
 Check whether the vehicle No if customer had any drive ability concerns. (See
way driven at a high rate of QUICK DIAGNOSTIC CHART [MZI-3.7] .)
speed.
 Was the vehicle driven under any
of the above conditions?
DTC P0297 HAS BEEN
COMPLETED


connectors are reconnected. Yes

 Retrieve DTCs using the M-

MDS. No Go to the next step.
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
5 Yes
TABLE [MZI-3.7].)
Microsoft
REPAIR PROCEDURE [MZI-

3.7].) No Troubleshooting completed.
DTC P0300 [MZI-3.7]

DTC P0300 Random misfire detected
 The PCM monitors the crankshaft position sensor input signal interval time. The
PCM calculates the change of the interval time for each cylinder. If the change of
interval time exceeds the pre-programmed criteria, the PCM detects a misfire in
DETECTION the corresponding cylinder. When the engine is running, the PCM counts the
CONDITION number of misfires that occurred at 200 crankshaft revolutions and 1,000
crankshaft revolutions and calculates the misfire ratio for each crankshaft
revolution. If the ratio exceeds the pre-programmed criteria, the PCM determines
that a misfire, which can damage the catalytic converter or affect emission
performance, has occurred.
 CMP sensor malfunction
 CKP sensor malfunction
 Ignition coil malfunction
 Ignition system malfunction
 MAF sensor contamination
 Excess air suction in intake air system (between MAF/IAT sensor and dynamic
chamber)
 Vacuum hoses damages or improper connection
 Fuel pressure regulator malfunction
POSSIBLE
 Fuel line clogged
CAUSE
 Fuel filter clogged
 Fuel runout
 Poor quality fuel
 Fuel leakage in fuel line
 Insufficient compression
 Variable valve timing control system improper operation
 Purge solenoid valve malfunction
 PCV valve malfunction
 Related connector and terminal malfunction
 Related wiring harness malfunction
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BEEN RECORDED
recorded?
availability. step.
OR STORED DTCs
Go to the appropriate DTC troubleshooting. (See
Yes
Turn the ignition switch off then to

3 the ON position (Engine off).
 Verify related pending code or stored
DTCs. No Go to the next step.

STATUS (KEY TO ON/IDLE)
Inspect the suspected circuit or part or both
Access APP1, APP2, APP3, ECT,

IAT, MAF, RPM, TP_REL and VSS Yes (See PCM INSPECTION [MZI-3.7] .)
4 PIDs using the M-MDS. (See PCM Then go to Step 18.
 Is there any signal that is far out of
specification when the ignition
switch is in the ON position and No Go to the next step.
engine runs at idle?
STATUS UNDER TROUBLE
CONDITION Inspect the suspected circuit or part or both
Yes
 Inspect the same PIDs as in Step 4
(See PCM INSPECTION [MZI-3.7] .)
5
when simulating the FREEZE Then go to Step 18.
FRAME DATA condition.
 Is there any signal which causes
drastic changes?
Inspect the installation condition for damage to
the timing belt and gears, and repair
Microsoft
malfunctioning parts.
INSPECT CMP SENSOR
 If it is normal, replace CMP sensor. (See
CRANKSHAFT POSITION (CKP)
 Inspect the CMP sensor. (See
Yes SENSOR REMOVAL/INSTALLATION
6 CRANKSHAFT POSITION
[MZI-3.7] .)
(CKP) SENSOR INSPECTION
[MZI-3.7] .)
 Is there any malfunction? Then go to Step 18.
VERIFY CKP SENSOR Retighten the CKP sensor, then go to Step 18.
INSTALLATION CONDITION (See CRANKSHAFT POSITION (CKP)
Yes
7 SENSOR REMOVAL/INSTALLATION
Inspect for CKP sensor looseness.
 [MZI-3.7] .)
 Is the CKP sensor loose? No Go to the next step.
INSPECT IGNITION SYSTEM
Perform the spark test. (See


8 ENGINE CONTROL SYSTEM Repair or replace the malfunctioning part

OPERATION INSPECTION No according to the spark test results, then go to Step
[MZI-3.7] .) 18.
 Are the results of the spark test
normal?
INSPECT MAF PID
Start the engine.

 Access the MAF PID using the M-
9 MDS.
Replace the MAF/IAT sensor, then go to Step 18.
 Verify that the MAF PID changes No (See INTAKE-AIR SYSTEM
quickly according to the engine speed REMOVAL/INSTALLATION [MZI-3.7] .)
when the engine is raced.
 Is the MAF PID response normal?
INSPECT FOR EXCESSIVE AIR

SUCTION IN INTAKE AIR SYSTEM
Repair or replace the suspected part, then go to
 Inspect for air leakage at the Yes
Step 18.
following:
10  Between the MAF/IAT sensor
and the throttle body
 Between the throttle body and
the dynamic chamber No Go to the next step.
If the fuel line pressure is too low, go to the next
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step. If the fuel line pressure is excessively high,

check as follows:
INSPECT FUEL LINE PRESSURE  Fuel pump maximum pressure

 Fuel return line for clogging
Yes  If all of the above are normal, replace
11  Inspect the fuel line pressure. (See the pressure regulator. (See
FUEL LINE PRESSURE PRESSURE REGULATOR
INSPECTION [MZI-3.7] .) INSPECTION [MZI-3.7] .)
Then go to Step 18.

No Go to Step 18.
Yes Replace suspected fuel line, then go to Step 18.
Inspect the low-pressure side fuel filter for the
following:
 Foreign material or staining inside the fuel

filter
INSPECT FUEL LINE FROM FUEL

PUMP TO FUEL DELIVERY PIPE Perform the following actions as a result:
12 Visually inspect the fuel line for any No
  If foreign material or staining is found
leakage. inside the fuel filter (low-pressure side),
 Is any fuel leakage found? clean the fuel tank and filter.
 If normal, replace the fuel pump unit. (See
FUEL PUMP UNIT
3.7] .)
Then, go to Step 18.

INSPECT ENGINE COMPRESSION
 Inspect the engine compression. (See
13 COMPRESSION INSPECTION Perform an engine overhaul for repairs, then go to
[MZI-3.7] .) No
Step 18.
 Is it normal?
INSPECT VARIABLE VALVE
TIMING CONTROL SYSTEM
14 OPERATION
 Inspect the variable valve timing
control system operation. (See
Microsoft
ENGINE CONTROL SYSTEM

OPERATION INSPECTION Repair or replace the malfunctioning part
[MZI-3.7] .) No according to the variable valve timing control
 Does the variable timing control system inspection results, then go to Step 18.
system work properly?
INSPECT OPERATION OF PURGE
SOLENOID VALVE Yes Go to the next step.
Inspect the purge control system


operation. (See ENGINE
15 CONTROL SYSTEM Repair or replace the malfunctioning part
OPERATION INSPECTION No according to the purge control system inspection
[MZI-3.7] .) results, then go to Step 18.
 Does the purge control system work
properly?
INSPECT PCV VALVE OPERATION

 Yes Replace the PCV valve, then go to Step 18.
 Remove the PCV valve and check
16 the valve operation. (See POSITIVE
CRANKCASE VENTILATION
(PCV) VALVE INSPECTION No Go to the next step.
[MZI-3.7] .)
 Is the PCV valve operation normal?
INSPECT SEALING OF ENGINE

COOLANT PASSAGE
WARNING:
 Never remove the cooling system
cap or loosen the radiator drain
plug while the engine is running, or
when the engine and radiator are
hot. Scalding engine coolant and
steam may shoot out and cause Air penetrates due to poor sealing of the head
serious injury. It may also damage gasket or other areas between the combustion
17 the engine and cooling system. Yes chamber and the engine coolant passage. Repair
 Turn off the engine and wait until it or replace malfunctioning parts, then go to the
is cool. Even then, be very careful next step.
when removing the cap. Wrap a
thick cloth around it and slowly
turn it counterclockwise to the first
stop. Step back while the pressure
escapes
 When you are sure all the pressure
is gone, press down on the cap
using the cloth, turn it, and remove
it.
Microsoft
 Remove the radiator cap.

 Implement the procedure to bleed air
from the engine coolant, then run the
engine at idle
 Are there any small bubbles which
make the engine coolant white at the No Go to the next step.
filling opening?
NOTE:
 Large bubbles are normal
since they are remaining air
coming from the engine
coolant passage.


Replace the PCM, then go to the next step. (See
connectors are reconnected.
 Clear the DTC from the PCM 3.7] .)
18 memory using the M-MDS.
 Perform the KOER SELF TEST
using the M-MDS. (See
KOEO/KOER SELF TEST [MZI-
3.7].)
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0301, P0302, P0303, P0304, P0305, P0306, P0316 [MZI-3.7]

DTC P0301, P0302, P0303, P0304, P0305, P0306, P0316 (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
DTC P0301 P0301: Cylinder No.1 misfire detected
Microsoft

DTC P0316 P0316: Misfire detected on startup (first 1000 revolutions)
 The PCM monitors the crankshaft position sensor input signal interval time. The
PCM calculates the change of the interval time for each cylinder. If the change of
interval time exceeds the pre-programmed criteria, the PCM detects a misfire in
DETECTION the corresponding cylinder, when the engine is running, the PCM counts the
CONDITION number of misfires that occurred at 200 crankshaft revolutions and 1,000
crankshaft revolutions and calculates the misfire ratio for each crankshaft
revolution. If the ratio exceeds the pre-programmed criteria, the PCM determines
that a misfire, which can damage the catalytic converter or affect emission
performance, has occurred.
 Spark plug malfunction
POSSIBLE  Fuel injector malfunction
CAUSE  Air suction in intake air system (between dynamic chamber and cylinder head)
 Inadequate engine compression due to engine internal malfunction
 Related connector or terminal malfunction
 Related wiring harness malfunction
DTC P0301, P0302, P0303, P0304, P0305, P0306, P0316 (MZI-3.7) DIAGNOSTIC PROCEDURE
RECORDED
No
 Has FREEZE FRAME DATA been recorded?
Yes
2  Verify related Service Bulletins and/or on-line  If the vehicle is not repaired, go to
repair information availability. the next step.
STORED DTCs Go to the appropriate DTC
Yes troubleshooting. (See DTC TABLE
3  Turn the ignition switch off then to the ON [MZI-3.7].)
 Verify related pending code or stored DTCs.
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VERIFY CURRENT INPUT SIGNAL STATUS

(KEY TO ON/IDLE)
Inspect the suspected circuit or part or
 Access APP1, APP2, APP3, ECT, IAT, MAF, Yes both according to inspection results.
Then go to Step 13. (See PCM
RPM TP_REL and VSS PIDs using the M-
4 MDS. (See PCM INSPECTION [MZI- INSPECTION [MZI-3.7] .)
3.7] .)
 Is there any signal that is far out of
specification when the ignition switch is in No Go to the next step.
the ON position and the engine runs at idle?
VERIFY CURRENT INPUT SIGNAL STATUS
UNDER TROUBLE CONDITION Inspect the suspected circuit or part or
both according inspection results. Then
 Inspect the same PIDs as in Step 4 when
Yes
5 go to Step 13. (See PCM INSPECTION
simulating the FREEZE FRAME DATA [MZI-3.7] .)
condition.
 Is there any signal which causes drastic
changes? No Go to the next step.
INSPECT SPARK PLUG CONDITION  If the spark plug is wet, fuel
flooding is suspected. Go to Step

9.
 Remove the spark plug from the suspected
 If the spark plug has a crack,
cylinder. excess wear or improper gap,
 Check the spark plug condition: Yes replace the malfunctioning spark
6
 Cracks plug. Then go to Step 13.
 Excess wear
(See CRUISE CONTROL
 Gap SWITCH INSPECTION [MZI-
 Wet 3.7] .)
 Is any problem found on the spark plug? No Go to the next step.
INSPECT IGNITION SYSTEM OPERATION
FOR SUSPECTED CYLINDER Yes Go to the next step.
 Perform the spark test for the suspected

7 cylinder. (See ENGINE CONTROL Replace or replace the malfunctioning
SYSTEM OPERATION INSPECTION No part according to the spark test results,
[MZI-3.7] .) then go to Step 13.
 Are the results of the spark test normal?
INSPECT FUEL INJECTOR WIRING Yes Go to the next step.

HARNESS
8
 Remove the intake air system parts.
 Disconnect the fuel injector connector on the
suspected cylinder. Inspect the fuel injector wiring harnesses.
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Connect the noid light to the fuel injector


Repair or replace if necessary, then go to
connector terminals. Step 13.
No
 Verify the light dimness during cranking.
 Does the noid light illuminate?
INSPECT FUEL INJECTOR OPERATION
Remove fuel injector from the suspected

 Replace fuel injector, then go to Step 13.
cylinder. (See FUEL INJECTOR (See FUEL INJECTOR
REMOVAL/INSTALLATION [MZI-3.7] .) Yes REMOVAL/INSTALLATION [MZI-
9  Swap the fuel injector with one from another 3.7] .)
cylinder.
 Is there the misfire DTC for the cylinder

which has a suspected fuel injector?
INSPECT FOR AIR SUCTION AT INTAKE
AIR SYSTEM
Repair or replace the suspected part, then
 Inspect for air leakage at the following:
Yes
go to Step 13.
10  Around the connection of the dynamic
chamber and the intake manifold
 Around the connection of the intake
manifold and the cylinder head No Go to the next step.
 Is air leakage found?
INSPECT SEALING OF ENGINE COOLANT

PASSAGE
WARNING:
engine is running, or when the engine and
and steam may shoot out and cause Air penetrates due to poor sealing of the
serious injury. It may also damage the head gasket or other areas between the
11 engine and cooling system. Yes combustion chamber and the engine
 Turn off the engine and wait until it is cool. coolant passage. Repair or replace
Even then, be very careful when removing malfunctioning parts, then go to Step 13.
slowly turn it counterclockwise to the first
stop. Step back while the pressure
escapes.
 When you are sure all the pressure is gone,
press down on the cap using the cloth, turn
it, and remove it.
Microsoft
 Remove the radiator cap.

 Implement the procedure to bleed air from the
engine coolant, then run the engine at idle.
 Are there any small bubbles which make the
engine coolant white at filling opening? No Go to the next step.
NOTE:
 Large bubbles are normal since they
are remaining air coming from the
engine coolant passage.
Inspect the engine compression. (See

12 COMPRESSION INSPECTION [MZI- Overhaul the engine, then go to the next
3.7] .) No
step.
 Is the engine compression normal?
VERIFY TROUBLESHOOTING OF MISFIRE

DTC HAS BEEN COMPLETED


step. (See PCM
13 (Engine off). 3.7] .)
the M-MDS.

present?
Yes
 Perform the "AFTER REPAIR (See DTC TABLE [MZI-3.7].)
DTC P0315 [MZI-3.7]

DTC P0315 CKP system variation not learned
DETECTION
 The PCM is unable to learn and correct for mechanical inaccuracies in the
CONDITION
crankshaft pulse wheel tooth spacing. This DTC disables the misfire
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monitor.
 Crankshaft pulse wheel teeth malfunction
POSSIBLE CAUSE

BEEN RECORDED
recorded?
Yes
next step.
OR STORED DTCs
Yes
 Turn the ignition switch off then to the
INSPECT PHYSICAL CONDITION OF

CRANKSHAFT PULSE WHEEL
NOTE:
 DTC P0315 is set when the PCM is Yes Go to the next step.
unable to learn and correct for the
mechanical variations in the
4 crankshaft pulse wheel tooth spacing
(the allowable correction tolerances
are exceeded).
 Inspect the crankshaft pulse wheel for

damaged teeth.
 Inspect the crankshaft pulse wheel for
wobble.
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Check for a loose crankshaft pulse


wheel.
 Check the CKP sensor for damage. No Repair if necessary. Then go to Step 6.
 Are the CKP sensor and crankshaft
pulse wheel normal?
INSPECT DAMPER AND PULLEY
ASSEMBLY
NOTE:
 This step is for engines that have Disconnect the negative battery terminal for 5
damper mounted pulse rings. min to allow the PCM to learn the new profile.
Yes
Remove the front cover if necessary Install a new pulley or damper assembly. Then
5 to observe the crank pulley. go to the next step.
Observe the crank pulley for wobble.


 Examine the El pulse ring fastened to

the harmonic dampener.
 Does the crank pulley wobble or is the No Go to the next step.
pulse ring loose or damaged?


are reconnected. Replace the PCM, then go to the next step. (See
3.7] .)
using the M-MDS.

present?
Yes
DTC P0320 [MZI-3.7]

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DTC P0320 Ignition/distributor engine speed input circuit

 The ignition engine speed sensor input signal to the PCM is continuously
DETECTION monitored.
CONDITION  The test fails when the signal indicates that 2 successive erratic PIP pulses
occurred.
 Loose wires/connectors.
POSSIBLE CAUSE  Arcing secondary ignition components (coil, wires or plugs).
 On-board transmitter (2-way radio).

VERIFY FREEZE FRAME DATA HAS
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BEEN RECORDED
Record FREEZE FRAME DATA on the
1 No
 repair order, then go to the next step.
recorded?
Yes
line repair information availability. next step.
STORED DTCs
Yes
 Turn the ignition switch off then to the ON
INSPECT CKP SENSOR SIGNAL SENT TO

PCM
NOTE:
Yes Go to Step 13.
 The battery should be fully charged and
the starting system should be
functioning properly.
4
Disable the inertia switch.


(Engine off)
 Access the PCM and monitor the RPM
PID.
 Crank the engine.
 Is the engine speed more than 150 rpm?
INSPECT TIMING COVER, CKP SENSOR

AND EXTERNAL TRIGGER WHEEL
(OUTSIDE TIMING COVER) FOR Yes Repair if necessary. Then go to Step 13.
OBVIOUS PHYSICAL DAMAGE
5  Visually check the timing cover, CKP
sensor and external trigger wheel (outside
the timing cover) for obvious physical No Go to Step.
damage.
 Do any parts appear physically damaged?
Microsoft
INSPECT FOR PROPER CKP BIAS

VOLTAGES IN PCM
Disconnect the CKP sensor connector.


(Engine off)
6  Measure the voltage between:
 CKP sensor terminal A on the wiring

harness side and battery negative
No Go to Step 8.
 CKP sensor terminal B on the wiring
harness side and battery negative
 Are the voltages between 1-3 V?
INSPECT CKP SENSOR RESISTANCE

7  Measure the resistance between CKP

sensor terminal A and B on the component No Replace the CKP sensor. Then go to Step
side. 13.
 Is the resistance between 0.25-1 kilohms?
INSPECT CKP WIRING HARNESS SHIELD

NOTE: Yes Go to the next step.

 The wiring harness shield protects the
CKP signal from electrical noise and is
grounded at one end, typically near the
PCM.
8 NOTE:
 Perform the following resistance
measurement between the CKP shield
and the ground. Repair the short circuit. Check for a poor
No
ground. Then go to Step 13.
 Measure the resistance between:

 CKP_SHLD assembly connector
wiring harness side and ground
 Is the resistance less than 5 ohms?
INSPECT FOR SHORT BETWEEN CKP (+)
AND CKP (-) IN WIRING HARNESS Yes Go to the next step.
9
Microsoft
Measure the resistance between:


 CKP sensor terminal A and B on the Repair or replace suspected part, Then go to
No
wiring harness side Step 13.
INSPECT CKP CIRCUIT(S) FOR OPEN

CIRCUIT IN WIRING HARNESS

 CKP sensor connector A on the
10 wiring harness side and PCM

terminal 2P
 CKP sensor connector B on the No
Step 13.
wiring harness side and PCM
terminal 2T
INSPECT CKP CIRCUIT(S) FOR SHORT

TO GROUND IN WIRING HARNESS

 CKP sensor connector A on the
11 wiring harness side and battery

negative
 CKP sensor connector B on the No
Step 13.
wiring harness side and battery
negative
 Are the resistances more than 10 kilohms?
INSPECT CKP CIRCUIT FOR SHORT TO

VOLTAGE IN WIRING HARNESS

(Engine off) Yes
Step 13.
 Measure the voltage between:
12  CKP sensor connector A on the
wiring harness side and battery
negative
 CKP sensor connector B on the
wiring harness side and battery No Go to the next step.
negative
 Are any voltage present?
 Verify that all disconnected connectors are

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reconnected.
 Turn the ignition switch to the ON position Replace the PCM, then go to the next step.
(Engine off). Yes (See PCM REMOVAL/INSTALLATION
13 using the M-MDS.

present?
Yes
DTC P0325 [MZI-3.7]

DTC P0325 KS circuit (RH)
DETECTION  The KS detects vibrations upon increase and decrease in engine RPM. The KS
CONDITION generates a voltage based on this vibration. A DTC is set if the voltage goes outside
a calibrated level.
 Open circuit wiring harness between KS terminal C and PCM terminal 2L
 Short to power supply in wiring harness between KS terminal C and PCM terminal
2L
 Short to ground circuit between KS terminal C and PCM terminal 2L
 Open circuit wiring harness between KS terminal D and PCM terminal 2G
POSSIBLE CAUSE
 Short to power supply in wiring harness between KS terminal D and PCM terminal
2G
 Short to ground circuit between KS terminal D and PCM terminal 2G
 KS malfunction
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BEEN RECORDED
recorded?

2 Yes
 Verify related Service Bulletins  If the vehicle is not repaired, go to the next
and/or on-line repair information step.
availability.
Microsoft


available?
INSPECT KS CONNECTOR FOR
POOR CONNECTION
Yes
 9.
3  Disconnect the KS connector.

INSPECT KS (RH) SIGNAL CIRCUIT


9.
4 following terminals:
 KS terminal C and body
ground.
 KS terminal D and body
ground.
 Are the voltage B+?
INSPECT KS (RH) CIRCUIT FOR

SHORT TO GROUND
 Turn the ignition switch to the ON Repair or replace suspected part, then go to Step
9.
 KS terminal C and body
ground.
 KS terminal D and body
ground.

Yes
9.
 Disconnect the PCM sensor
connector.
 Inspect for poor connection (such as No Go to the next step.
Microsoft


INSPECT KS (RH) CIRCUIT FOR

OPEN CIRCUIT

 KS terminal C and PCM
terminal 2L Repair or replace suspected part, then go to Step
No
9.
 KS terminal D and PCM
terminal 2G
INSPECT THE KS (RH)

Replace the KS, then go to the next step. (See
 Inspect the KS (RH). (See KNOCK
Yes KNOCK SENSOR (KS)
8 SENSOR (KS) INSPECTION REMOVAL/INSTALLATION [MZI-3.7] .)
[MZI-3.7] .)


 Perform the "KOEO or KOER self-
test" using the M-MDS. (See
3.7].)
 Is the PENDING CODE for the DTC
present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0330 [MZI-3.7]

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DTC P0330 KS circuit (LH)
DETECTION  The KS detects vibrations upon increase and decrease in engine RPM. The KS
CONDITION generates a voltage based on this vibration. A DTC is set if the voltage goes outside
a calibrated level.
 Open circuit wiring harness between KS terminal A and PCM terminal 2Q
 Short to power supply in wiring harness between KS terminal A and PCM terminal
2Q
 Short to ground circuit between KS terminal A and PCM terminal 2Q
 Open circuit wiring harness between KS terminal B and PCM terminal 2M
POSSIBLE CAUSE
 Short to power supply in wiring harness between KS terminal B and PCM terminal
2M
 Short to ground circuit between KS terminal B and PCM terminal 2M
 KS malfunction
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BEEN RECORDED
recorded?
availability. step.
INSPECT KS CONNECTOR FOR
POOR CONNECTION
Yes
 9.
3  Disconnect the KS connector.

INSPECT KS (LH) SIGNAL CIRCUIT


9.
 KS terminal A and body
ground.
 KS terminal B and body
ground.
 Are there voltage B+?
INSPECT KS (LH) CIRCUIT FOR

SHORT TO GROUND
5  Turn the ignition switch to the ON Yes
9.
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KS terminal A and body


ground.
 KS terminal B and body No Go to the next step.
ground.

POOR CONNECTION
 9.
6  Disconnect the PCM sensor
connector.
INSPECT KS (LH) CIRCUIT FOR

OPEN CIRCUIT

 KS terminal A and PCM
terminal 2Q Repair or replace suspected part, then go to Step
No
9.
 KS terminal B and PCM
terminal 2M
 Are there continuity?
INSPECT THE KS (LH)

Replace the KS, then go to the next step.(See
 Inspect the KS (LH). (See KNOCK Yes KNOCK SENSOR (KS)
8 SENSOR (KS) INSPECTION REMOVAL/INSTALLATION [MZI-3.7] .)
[MZI-3.7] .)

Microsoft
present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P0340 [MZI-3.7]

DTC P0340 CMP sensor (RH) circuit
DETECTION  The test fails when the PCM can no longer detect the signal from the CMP
CONDITION sensor (RH),
 CMP sensor (RH) malfunction
 Short to ground circuit between CMP sensor (RH) terminal A and PCM
terminal 2X
POSSIBLE CAUSE  Short to power supply between CMP sensor (RH) terminal A and PCM
terminal 2X
 Open circuit between CMP sensor (RH) terminal A and PCM terminal 2X
 Open circuit between CMP sensor (RH) terminal B and PCM terminal 2C
 PCM malfunction
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BEEN RECORDED
recorded?
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Verify related Service Bulletins and/or Yes

next step.
CLEAR AND ATTEMPT TO RETRIEVE
THE DTC

 If DTCs P0340, P0344, P0345 or
P0349 are present, ignition,
alternator noise, radio frequency
interference and CKP concerns
should be considered.
3
using the M-MDS.
position (Engine running). Perform the "INTERMITTENT CONCERN
No
TROUBLESHOOTING". Then go to Step 11.
 Increase engine speed to more than
1,500 rpm for 10 s. Repeat this 3
times .
 Retrieve the continuous memory
DTCs.
 The same DTC present?
CHECK THE GENERATOR FOR
EXCESSIVE ELECTRICAL NOISE Yes Go to the next step.
NOTE:
 If the generator/regulator is
electrically noisy, the noise
decreases when the terminal B is
disconnected.  Inspect the charging system, then go to
4 Step 11.
 Drive belt damaged and
 Turn the ignition switch to the ON No
misinstallation
 Generator pulley or generator
 Monitor the generator for an audible misinstallation
electric noise.
 Generator/regulator terminal B
disconnected.
Microsoft


 With the engine running, determine if
the generator is still noisy.
 Does the noise remain constant when
the terminal B is disconnected?
INSPECT CMP SENSOR (RH)
CONNECTOR FOR POOR
CONNECTION
Yes
11.

5  Disconnect the CMP sensor (RH)
connector.
INSPECT CMP SENSOR SIGANAL

SUPPLY Repair or replace suspected part, then go to Step
Yes
11.

 Measure voltage between CMP sensor
(RH) terminal A (wiring harness-side)
INSPECT CMP SENSOR (RH) SIGNAL

CIRCUIT FOR SHORT TO GROUND Repair or replace suspected part, then go to Step
Yes
11.
 Check continuity between CMP sensor

(RH) terminal A and body ground.

POOR CONNECTION
Yes
11.
 Check for poor connection (such as

INSPECT CMP SENSOR (RH) CIRCUIT

Microsoft
FOR OPEN CIRCUIT


 Check continuity between the

following circuits:
9
 CMP sensor (RH) terminal A
and PCM terminal 2X No
11.
 CMP sensor (RH) terminal B
and PCM terminal 2C

Replace CMP sensor (RH), then go to the next
Inspect CMP sensor (RH). (See
 step. (See CRANKSHAFT POSITION (CKP)
10 CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION
SENSOR INSPECTION [MZI- [MZI-3.7] .)
3.7] .)
 Is there any malfunction? No Go to the next step.
DTC P0340 COMPLETED


 Turn ignition switch to the ON
3.7] .)
using the M-MDS.

VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
DTC P0344 [MZI-3.7]

DTC P0344 CMP sensor (RH) circuit intermittent
DETECTION
Microsoft
CONDITION  The test fails when the PCM detects an intermittent signal from the CMP
sensor.
 CMP sensor (RH) malfunction
 Sensor shielding malfunction
 Short to ground circuit between CMP sensor (RH) terminal A and PCM
POSSIBLE CAUSE terminal 2X
 Short to power supply between CMP sensor (RH) terminal A and PCM
terminal 2X
 Open circuit between CMP sensor (RH) terminal A and PCM terminal 2X
 Open circuit between CMP sensor (RH) terminal B and PCM terminal 2C
Microsoft

BEEN RECORDED
recorded?
Microsoft


next step.
THE DTC

 If DTCs P0340, P0344, P0345 or
3
using the M-MDS.
No
1,500 rpm for 10 s . Repeat this 3
times.
DTCs.
NOTE:
4 Step 11.
misinstallation
electric noise.
disconnected.
Microsoft


CONNECTOR FOR POOR
CONNECTION
Yes
11.

5  Disconnect the CMP sensor (RH)
connector.

Yes
11.

(RH) terminal A (wiring harness-side)
INSPECT CMP SENSOR (RH) SIGNAL

Yes
11.

(RH) terminal A and body ground.

POOR CONNECTION
Yes
11.

INSPECT CMP SENSOR (RH) CIRCUIT

Microsoft
FOR OPEN CIRCUIT



following circuits:
9
 CMP sensor (RH) terminal A
and PCM terminal 2X No
11.
 CMP sensor (RH) terminal B
and PCM terminal 2C

Replace CMP sensor (RH), then go to the next
 Inspect CMP sensor (RH). (See step. (See CRANKSHAFT POSITION (CKP)
Yes
3.7] .)
DTC P0344 COMPLETED


3.7] .)
using the M-MDS.

VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
DTC P0345 [MZI-3.7]

DTC P0345 CMP sensor (LH) circuit
DETECTION
Microsoft
CONDITION  The test fails when the PCM can no longer detect the signal from the CMP
sensor (LH).
 CMP sensor (LH) malfunction
 Short to ground circuit between CMP sensor (LH) terminal A and PCM
terminal 2AB
POSSIBLE CAUSE  Short to power supply between CMP sensor (LH) terminal A and PCM
terminal 2AB
 Open circuit between CMP sensor (LH) terminal A and PCM terminal 2AB
 Open circuit between CMP sensor (LH) terminal B and PCM terminal 2C
 PCM malfunction
Microsoft

BEEN RECORDED
recorded?
Microsoft


next step.
THE DTC

 If DTCs P0340, P0344, P0345 or
3
using the M-MDS.
No
1,500 rpm for 10 s . Repeat this 3
times.
DTCs.
NOTE:
4 Step 11.
misinstallation
electric noise.
disconnected.
Microsoft


INSPECT CMP SENSOR (LH)
CONNECTOR FOR POOR
CONNECTION
Yes
11.

5  Disconnect the CMP sensor (LH)
connector.

Yes
11.

(LH) terminal A (wiring harness-side)
INSPECT CMP SENSOR (LH) SIGNAL

Yes
11.

(LH) terminal A and body ground.

POOR CONNECTION
Yes
11.

INSPECT CMP SENSOR (LH) CIRCUIT

Microsoft
FOR OPEN CIRCUIT



following circuits:
9
 CMP sensor (LH) terminal A
and PCM terminal 2AB No
11.
 CMP sensor (LH) terminal B
and PCM terminal 2C

Replace CMP sensor (LH), then go to the next
 Inspect CMP sensor (LH). (See step. (See CRANKSHAFT POSITION (CKP)
Yes
3.7] .)
DTC P0345 COMPLETED


3.7] .)
using the M-MDS.
 Access the MAF PI D using the M-

VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
DTC P0349 [MZI-3.7]

DTC P0349 CMP sensor (LH) circuit intermittent
DETECTION
Microsoft
CONDITION  The test fails when the PCM detects an intermittent signal from the CMP
sensor (LH).
 CMP sensor (LH) malfunction
 Sensor shielding malfunction
 Short to ground circuit between CMP sensor (LH) terminal A and PCM
POSSIBLE CAUSE terminal 2AB
 Short to power supply between CMP sensor (LH) terminal A and PCM
terminal 2AB
 Open circuit between CMP sensor (LH) terminal A and PCM terminal 2AB
 Open circuit between CMP sensor (LH) terminal B and PCM terminal 2C
Microsoft

BEEN RECORDED
recorded?
Microsoft


next step.
THE DTC

 If DTCs P0340, P0344, P0345 or
3
using the M-MDS.
No
1,500 rpm for 10 s. Repeat this 3
times.
DTCs.
NOTE:
4 Step 11.
misinstallation
electric noise.
disconnected.
Microsoft


CONNECTOR FOR POOR
CONNECTION
Yes
11.

5  Disconnect the CMP sensor (LH)
connector.

Yes
11.

(LH) terminal A (wiring harness-side)
INSPECT CMP SENSOR (LH) SIGNAL

Yes
11.

(LH) terminal A and body ground.

POOR CONNECTION
Yes
11.

INSPECT CMP SENSOR (LH) CIRCUIT

Microsoft
FOR OPEN CIRCUIT



following circuits:
9
 CMP sensor (LH) terminal A
and PCM terminal 2AB No
11.
 CMP sensor (LH) terminal B
and PCM terminal 2C

Replace CMP sensor (LH), then go to the next
 Inspect CMP sensor (LH). (See step. (See CRANKSHAFT POSITION (CKP)
Yes
3.7] .)
DTC P0349 COMPLETED


3.7] .)
using the M-MDS.

VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
DTC P0351, 0352, 0353, 0354, 0355, 0356 [MZI-3.7]

DTC P0351, 0352, 0353, 0354, 0355, 0356 (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE
CAUSES
DTC P0351 P0351: Ignition coil No.1 primary/secondary circuit
Microsoft

DETECTION  Each ignition primary circuit is continuously monitored. The test fails when the
CONDITION PCM does not receive a valid ignition diagnostic monitor pulse signal from the
ignition module (integrated in the PCM).
 Open circuit between ignition coil No.1 terminal C and PCM terminal 2A
 Open circuit between ignition coil No.2 terminal C and PCM terminal 2F
 Open circuit between ignition coil No.3 terminal C and PCM terminal 2K
 Open circuit between ignition coil No.4 terminal C and PCM terminal 2W
 Open circuit between ignition coil No.5 terminal C and PCM terminal 2AA
 Open circuit between ignition coil No.6 terminal C and PCM terminal 2AE
 Short to power supply between ignition coil No.1 terminal C and PCM terminal 2A
 Short to power supply between ignition coil No.2 terminal C and PCM terminal 2F
 Short to power supply between ignition coil No.3 terminal C and PCM terminal 2K
 Short to power supply between ignition coil No.4 terminal C and PCM terminal 2W
POSSIBLE  Short to power supply between ignition coil No.5 terminal C and PCM terminal
CAUSE 2AA
 Short to power supply between ignition coil No.6 terminal C and PCM terminal
2AE
 Short to ground circuit between ignition coil No.1 terminal C and PCM terminal 2A
 Short to ground circuit between ignition coil No.2 terminal C and PCM terminal 2F
 Short to ground circuit between ignition coil No.3 terminal C and PCM terminal 2K
 Short to ground circuit between ignition coil No.4 terminal C and PCM terminal 2W
 Short to ground circuit between ignition coil No.5 terminal C and PCM terminal
2AA
 Short to ground circuit between ignition coil No.6 terminal C and PCM terminal
2AE
 Open circuit between ignition coil terminal A and main relay No.2 terminal D
Microsoft
DTC P0351, 0352, 0353, 0354, 0355, 0356 (MZI-3.7) DIAGNOSTIC PROCEDURE
Microsoft

BEEN RECORDED
Has FREEZE FRAME DATA been No
 order, then go to the next step.
recorded?
Yes

next step.
INSPECT IGNITION COIL
CONNECTOR FOR POOR
CONNECTION Repair or replace suspected part, then go to Step
Yes
10.
3
 Disconnect the ignition coil connector.

INSPECT IGNITION COIL POWER

SUPPLY CIRCUIT FOR OPEN
CIRCUIT
Disconnect the ignition coil connector.



 Measure the voltage between ignition No
10.
coil terminal A (wiring harness-side)
and body ground.
INSPECT IGNITION COIL SIGNAL

Yes
10.
 Measure the voltage between ignition
coil terminal C (wiring harness-side)

Microsoft

position (Engine off). Repair or replace suspected part, then go to Step
Yes
10.
 Inspect continuity between ignition
6
coil terminal C (wiring harness-side)
and body ground.
POOR CONNECTION
Yes
 10.


 Inspect continuity between the

following circuits:
 Ignition coil No.1 terminal C
(wiring harness-side) and PCM
terminal 2A (wiring harness-
side)
terminal 2F (wiring harness-side)
8 terminal 2K (wiring harness-
side)
terminal 2W (wiring harness-
side) Repair or replace suspected part, then go to Step
No
10.
terminal 2AA (wiring harness-
side)
terminal 2AE (wiring harness-
side)
Microsoft
INSPECT IGNITION COIL Yes Go to the next step.
9 Inspect ignition coil. (See IGNITION


Replace the ignition coil, then go to the next
COIL INSPECTION [MZI-3.7] .) No
step.
 Are there ignition coil normal?
DTC P0351, P0352, P0353, P0354, P0355
and P0356 COMPLETED

3.7] .)
10 using the M-MDS.
3.7].)
present?
Yes
DTC P0420, P0430 [MZI-3.7]

DTC P0420 P0420: Catalyst system efficiency below threshold (RH)
DTC P0430 P0430: Catalyst system efficiency below threshold (LH)
 P0420 indicates right bank catalyst system efficiency is below the acceptable
DETECTION threshold.
CONDITION  P0430 indicates left bank catalyst system efficiency is below the acceptable
threshold.
 Use of leaded fuel.
 Oil contamination
 Cylinder misfiring.
 Damaged HO2S.
 Malfunctioning CHT sensor.
 Downstream HO2S wires improperly connected.
 Fuel pressure too high.
Microsoft
 Damaged exhaust system pipe.

 Damaged exhaust manifold.
 Damaged muffler/tailpipe ass
NOTE:
POSSIBLE  Internal deterioration of a catalytic converter is usually caused by
CAUSE abnormal engine operation front of the catalyst. Events that can
produce higher than normal temperatures in the catalyst are particularly
suspect, such as misfiring. Incorrect HO2S signal input (e.g., rich/lean
signal when engine is operating under rich/lean conditions) can cause
an abnormal temperature increase in the catalyst. CHT sensor DTCs can
indicate that the thermostat is not operating correctly or that the engine
coolant level is not filled to specification, producing above normal
operating temperatures.

BEEN RECORDED
recorded?
Yes
next step.
OR STORED DTCs
Yes
 Is other DTCs present?
INSPECT GAS LEAKAGE OF Repair or replace malfunctioning exhaust parts,

Yes
EXHAUST SYSTEM then go to Step 7.
4
 Visually inspect for exhaust gas
leakage in exhaust system.
Microsoft
Are there gas leakage?


INSPECT INSTALLATION OF FRONT

AND REAR HO2S Yes Go to the next step.
5 Inspect for looseness of front and rear

HO2Ss. No Retighten sensor, then go to Step 7.
 Are they it normal?
INSPECT TWC
Clear the DTC using the M-MDS.

6  Cycle the ignition switch off then back

to the ON position.
 Inspect the TWC. No Replace the TWC, then go to the next step.
 Is it normal?
DTC P0420, P0430 HAS BEEN
COMPLETED

using the M-MDS.

present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P0442, P0456 [MZI-3.7]

DTC P0442 P0442: Evaporative emission system leak detected (small leak)
DTC P0456 P0456: Evaporative emission system leak detected (very small leak)
 P0442 indicates that a leak has been detected as small as 1 mm (0.04 in) in the
Microsoft
EVAP vapor management valve solenoid system when there is less than 0.625
kPa (PID FTP_H2O displays "2.5") bleed-up over 15 s at 75% fuel fill. Bleed-up
DETECTION and evaluation time vary as a function of fuel fill level. The vapor generation
CONDITION limit is more than 0.625 kPa (PID FTP_H2O displays "2.5") over 120 s.
 P0456 indicates that a fuel vapor leak from an opening as small as 0.508 mm
{0.020 in} has been detected by the EVAP running loss monitor test.
 After-market EVAP hardware (such as fuel-filler cap) nonconforming to
required specifications.
POSSIBLE  Small holes or cuts in fuel vapor hoses/tubes (P0442, P0456).
CAUSE  CV solenoid stays partially open on closed command.
 Damaged, cross-threaded or loosely installed fuel-filler cap.
 EVAP system component seals leaking.

RECORDED
recorded?
INFORMATION AVAILABILITY the available Service Bulletins.
Yes
STORED DTCs Go to the appropriate DTC
Yes troubleshooting. (See DTC TABLE
3  Turn the ignition switch off then to the ON [MZI-3.7].)
 Verify related pending code or stored DTCs.
EVAP SYSTEM LEAK TEST

 Carry out the EVAP system leak inspection
4 using the M-MDS. (See ENGINE

CONTROL SYSTEM OPERATION
INSPECTION [MZI-3.7] .) No Go to Step 6.
 Is small or large leakage detected?

Microsoft
 Re-tighten the fuel-filler cap then carry out

the EVAP system leak inspection using the
M-MDS again. (See ENGINE CONTROL
5 SYSTEM OPERATION INSPECTION
[MZI-3.7] .) No Go to Step 14.
 Is small or large leakage detected?
VISUALLY INSPECT COMPONENTS FOR
SMALL LEAKS
Verify that the CV solenoid valve is


properly seated on the charcoal canister.
 Visually inspect for cut or loose connections Repair or install a new component if
to the fuel vapor hoses/tubes in the Yes
necessary. Go to Step 13.
following locations:
 Charcoal canister to CV solenoid
6 valve.
 Charcoal canister to evaporative
emission valve component.
 Evaporative emission valve
component to the fuel tank (if
applicable).
 Check for fuel-filler pipe damage.
 Is a concern with a hose, tube, connection,

or valve visually evident?
INSPECT FOR SMALL LEAKS AT FUEL-
FILLER CAP
(Engine off)
7  Close CV solenoid valve using the
EVAPCV PID.
 Using the EVAP system tester, check for No Go to Step 9.
leaks around the fuel-filler cap.
 Is a leak detected?
VISUALLY INSPECT FUEL-FILLER CAP

AND FUEL-FILLER PIPE Replace the malfunctioning parts, then go
Yes
to Step 13.
8  Visually inspect the fuel-filler cap and fuel-
filler pipe for damage.
 Is the fuel-filler cap or fuel-filler pipe
damaged?
INSPECT FOR SMALL LEAK WITH
TESTER SET AT FILL POSITION
Microsoft


(Engine off) Yes Go to Step 13.
 Close CV solenoid valve using the
EVAPCV PID from the output test mode.
9  Pressurize EVAP system to 3.48 kPa (PID
FTP_H2O displays "14").
No Go to Step 10.
 Does the pressure hold between 3.43 and
3.53 kPa (PID FTP_H2O displays "13.80"
and "14.20")?
INSPECT FOR LEAKS IN COMPLETE
EVAP SYSTEM
Verify CV solenoid valve is closed.


Repair or replace the component if
 Verify system is pressurized to 3.48 kPa Yes
(PID FTP_H2O displays "14").
 Using the ultrasonic leak detector, check the
following EVAP system locations:
10  EVAP return tube to CV solenoid
valve.
 CV solenoid valve to charcoal
canister-CV solenoid valve
component. Discontinue pressurizing the system. Go to
No
 Charcoal canister-CV solenoid valve the next step.
component to fuel tank.
 fuel-filler cap and fuel-filler pipe.
INSPECT FOR SMALL LEAK FROM EVAP

RETURN TUBE TO CHARCOAL CANISTER
 Disconnect the fuel tank vapor tube at the Repair or replace the component if
fuel fuel vapor hose joint and plug the Yes
opening in the hose joint.
(Engine off)
11  Close CV solenoid valve using the
EVAPCV PID from the output test mode.
 Pressurize the EVAP system to 3.48 kPa
(PID FTP_H2O displays "14"). Open the CV solenoid valve. Go to the
No
 Using the ultrasonic leak detector, check the next step.
EVAP system from the intake manifold to
the CV solenoid valve.
Microsoft
INSPECT FOR SMALL LEAK BETWEEN

FUEL TANK VAPOR TUBE AND FUEL
TANK FILLER PIPE Repair or install a new component. Go to
Yes
the next step.
Transfer the plug from the fuel vapor hose

joint to the fuel tank vapor tube.
12  Pressurize EVAP system to 3.48 kPa (PID
FTP_H2O displays "14").
 Using the ultrasonic leak detector, check the
Reconnect the fuel vapor tube to the fuel
fuel tank vapor tube to the fuel tank for No
vapor hose joint. Go to Step 13.
leaks. Check the FTP sensor, fuel tank vapor
tube and the fuel-filler pipe.

 Connect all disconnected connectors and
hoses.
13
 Perform the EVAP System Leak Test. (See
Leakage still exists. Locate leak point and
ENGINE CONTROL SYSTEM No
repair. Repeat this step.
OPERATION INSPECTION [MZI-3.7] .)
 Are the test results normal?

 Verify that all disconnected connectors are

(See PCM
 Turn the ignition switch to the ON position Yes REMOVAL/INSTALLATION [MZI-
14 (Engine off). 3.7] .)
the M-MDS.
present?
DTC P0443 [MZI-3.7]

DTC P0443 Purge solenoid valve circuit
DETECTION  The PCM monitors the state of the purge solenoid valve circuit output driver. The
CONDITION test fails when the signal moves outside the minimum or maximum limit for the
commanded state.
Microsoft

 Short to ground between purge solenoid valve terminal B and PCM terminal 1 BC
 Open circuit between main relay No.1 terminal D and purge solenoid valve terminal
POSSIBLE CAUSE A
 Short to power supply between purge solenoid valve terminal B and PCM terminal
1 BC
 Open circuit between purge solenoid valve terminal B and PCM terminal 1 BC
 PCM malfunction

HAS BEEN RECORDED
Microsoft
 Has FREEZE FRAME DATA been Record FREEZE FRAME DATA on the repair
1 No
recorded? order, then go to the next step.
Verify related Service Bulletins
 Yes
availability. step.
INSPECT PURGE SOLENOID
VALVE CONNECTOR FOR POOR
CONNECTION
Yes
 10.
3  Disconnect purge solenoid valve
connector.
 Inspect for poor connection (such
as damaged/pulled-out pins,




 Measure voltage between purge Repair or replace suspected part, then go to Step
solenoid valve terminal A and body No 10.
ground.
 Is voltage B+?

VALVE CONTROL CIRCUIT FOR
SHORT TO POWER SUPPLY Repair or replace suspected part, then go to Step
Yes
10.
 Measure the voltage between purge
solenoid valve control terminal B
 Is voltage B+?

Yes
VALVE CONTROL CIRCUIT FOR
SHORT TO GROUND Repair or replace suspected part, then go to the
Microsoft


Step 10.
6 purge solenoid valve control
terminal B and body ground. No Go to the next step.

POOR CONNECTION
 10.

as damaged/pulled-out pins,
 Is there any malfunction? v

VALVE CONTROL CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT


 Inspect continuity between purge Repair or replace suspected part, then go to the
solenoid valve terminal B and PCM No Step 10.
terminal 1BC.

VALVE Replace purge solenoid valve (See PURGE
SOLENOID VALVE
 Inspect the purge solenoid valve.
Yes
9 REMOVAL/INSTALLATION [MZI-3.7] .), then
(See PURGE SOLENOID go to Step 10.
VALVE INSPECTION [MZI-
3.7] .)
DTC P0443 COMPLETED
 Make sure to reconnect all Replace PCM, then go to the next step. (See PCM
Yes
disconnected connectors. REMOVAL/INSTALLATION [MZI-3.7] .)
10  Clear DTC from PCM memory
using M-MDS.
KOEO/KOER SELF TEST
 Is the PENDING CODE same DTC
Microsoft
present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P0446 [MZI-3.7]

DTC P0446 CV solenoid valve control circuit
DETECTION  Monitors the CV solenoid valve circuit for an electrical failure. The test fails when
CONDITION the signal moves outside the minimum or maximum allowable calibrated parameters
for a specified canister vent duty cycle by PCM command.
 CV solenoid valve malfunction
 Short to ground between CV solenoid valve terminal B and PCM terminal 1Z
POSSIBLE
CAUSE  Open circuit between battery and CV solenoid valve terminal A
 Short to power supply between CV solenoid valve terminal B and PCM terminal 1Z
 Open circuit between CV solenoid valve terminal B and PCM terminal 1Z
 PCM malfunction
Microsoft

HAS BEEN RECORDED
recorded?
Yes
and/or on-line repair information
step.
availability.
Microsoft

INSPECT CV SOLENOID VALVE
CONNECTOR FOR POOR
CONNECTION
Yes
 10.
3  Disconnect CV solenoid valve
connector.
damaged/pulled-out pins,




 Measure voltage between CV Repair or replace suspected part, then go to Step
solenoid valve terminal A and body No 10.
ground.
 Is voltage B+ ?

CONTROL CIRCUIT FOR SHORT
TO POWER SUPPLY Repair or replace suspected part, then go to Step
Yes
10.
 Measure the voltage between CV
 Is voltage B+?

TO GROUND Repair or replace suspected part, then go to the
Yes
Step 10.
 Inspect for continuity between CV


Yes
10.
Microsoft
Disconnect PCM connector.



7 damaged/pulled-out pins, No Go to the next step.
corrosion).

CONTROL CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT


 Inspect continuity between CV Repair or replace suspected part, then go to the

solenoid valve terminal B and PCM No Step 10.
terminal 1Z.

Replace CV solenoid valve (See CHARCOAL
Inspect the CV solenoid valve. (See
 CANISTER, CANISTER VENT (CV)
CHARCOAL CANISTER, Yes SOLENOID VALVE, AIR FILTER
9 CANISTER VENT (CV) COMPONENT REMOVAL/INSTALLATION
SOLENOID VALVE, AIR [MZI-3.7] .), then go to Step 10.
FILTER COMPONENT
DTC P0446 COMPLETED


disconnected connectors. Yes
 Clear DTC from PCM memory
10 using M-MDS.
KOEO/KOER SELF TEST
 Is the PENDING CODE same DTC
present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
Microsoft
DTC P0451 [MZI-3.7]

DTC P0451 Fuel tank pressure sensor range/performance
NOTE:
 For some vehicle applications, DTC P0451 is set for a fuel tank pressure
sensor range (offset) concern. The DTC P0454 replaces the original P0451
DETECTION for intermittent (noisy) sensor concerns. Until the phase in process is
complete, noisy or offset fuel tank pressure sensor concerns may set DTC
CONDITION P0451.
 The fuel tank pressure changes more than 14 inches of water in 0.10 s. Fuel tank
pressure sensor output is offset by + /-1.7 inches of water.
 Intermittent open or short in the fuel tank pressure sensor or the fuel tank
pressure sensor signal
POSSIBLE
 Fuel tank pressure sensor malfunction
CAUSE
 PCM malfunction

HAS BEEN RECORDED
 Has the FREEZE FRAME DATA No
been recorded?
INFORMATION AVAILABILITY Perform the repair or diagnosis according to the
available repair information.
availability. step.
 Is any related repair information

OR STORED DTCs Yes
3
 Turn the ignition switch off then to
the ON position (Engine off).
 Verify related pending code or No Go to the next step.
stored DTCs.
Microsoft
Is other DTCs present?


CLEAR AND ATTEMPT TO

RETRIEVE THE DTC
Clear the DTC from the PCM

 Run the engine for approx. 10 s .
 Check for continuous memory No DTC troubleshooting completed.

DTCs.
INSPECT FUEL TANK PRESSURE

AND PCM SENSOR CONNECTOR
FOR POOR CONNECTION Yes Repair or replace suspected part, then go to Step 8.


connector.
INSPECT THE FUEL TANK

PRESSURE Replace evaporative hose component, then go to
Yes Step 8. (See FUEL TANK
6  Inspect the MAF sensor. (See FUEL REMOVAL/INSTALLATION [MZI-3.7] .)
TANK PRESSURE SENSOR
OPERATION

 Pushed out pins
7
 Corrosion

DTC present?
Microsoft
DTC P0451 COMPLETED


 Clear the DTC from the PCM Yes PCM REMOVAL/INSTALLATION [MZI-
memory using the M-MDS. 3.7] .)
8
3.7].)
 Start the engine and wait for
approx. 10s. No Go to the next step.
 Is the PENDING CODE for the
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7])
3.7]) No DTC troubleshooting completed.
DTC P0452 [MZI-3.7]

DTC P0452 Fuel tank pressure sensor low input
DETECTION  The PCM monitors the evaporative emission (EVAP) control system fuel tank
CONDITION pressure sensor input signal to the PCM. The test fails when the signal average drops
below a minimum allowable calibrated parameter.
POSSIBLE
CAUSE  Short to ground between fuel tank pressure sensor terminal A and PCM terminal 1
AB
 Fuel tank pressure sensor signal circuit and ground circuit for short each other
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BEEN RECORDED
been recorded?

Microsoft

 Yes
availability. step.
available?
INSPECT FUEL TANKE PRESSURE
SENSOR CONNECTOR FOR POOR
CONNECTION
Yes
7.

3  Disconnect the fuel tank pressure
sensor connector.
VERIFY FUEL TANK PRESSURE

SIGNAL CIRCUIT FOR SHORT TO
GROUND Repair or replace suspected part, then go to Step
Yes
7.
4
 Inspect for continuity between fuel
tank pressure sensor terminal A
(wiring harness-side) and body

SENSOR SIGNAL CIRCUIT AND
GROUND CIRCUIT FOR SHORT Yes Go to the next step.
EACH OTHER

 Disconnect the fuel tank pressure
 Measure resistance between PCM
terminal 1AB (wiring harness-side) No
7.
and PCM terminal 1AL (wiring
harness-side)
kilohms?

SENSOR
Microsoft
Perform the fuel tank pressure sensor


inspection. (See FUEL TANK
Replace the evaporative hose component, then go
PRESSURE SENSOR
6 No to the next step. (See FUEL TANK
 Is the fuel tank pressure sensor
normal?
DTC P0452 COMPLETED

 Turn ignition switch to the ON 3.7] .)
VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
8  Perform the "After Repair
Procedure". (See AFTER REPAIR
DTC P0453 [MZI-3.7]

DTC P0453 Fuel tank pressure sensor high input
DETECTION  The PCM monitors the evaporative emission (EVAP) control system fuel tank
CONDITION pressure sensor input signal to the PCM. The test fails when the signal average
jumps above a minimum allowable calibrated parameter.
 Open circuit between fuel tank pressure sensor terminal A and PCM terminal 1AB
POSSIBLE  Open circuit between fuel tank pressure sensor terminal B and PCM terminal 1AL
CAUSE  Short to the constant voltage supply circuit between fuel tank pressure sensor
terminal A and PCM terminal 1AB
 Short to power supply between fuel tank pressure sensor terminal C and PCM
terminal 1U
 Fuel tank pressure sensor power circuit and signal circuit are shorted each other
Microsoft

BEEN RECORDED
been recorded?
Microsoft

 Yes
availability. step.
available?
SENSOR CONNECTION FOR POOR
CONNECTION
Yes
9.

3  Disconnect fuel tank pressure sensor
connector.

SENSOR SIGNAL CIRCUIT FOR

9.
 Fuel tank pressure sensor
terminal A (wiring harness-
terminal C (wiring harness- No Go to the next step.

POOR CONNECTION
 9.
sensor and PCM connector.

SENSOR CIRCUIT FOR OPEN
Microsoft
CIRCUIT
Inspect for continuity between the

following circuits:
connector terminal A (harness-
6 side) and PCM connector
terminal 1AB. Repair or replace suspected part, then go to Step
No
9.
connector terminal B (harness-
side) and PCM connector
terminal 1AL

SENSOR SIGNAL CIRCUIT AND
POWER CIRCUIT FOR SHORT EACH Yes Go to the next step.
OTHER


 Disconnect the fuel tank pressure

 Measure resistance between PCM
connector terminal 1U (harness-side) No
9.
and CM connector terminal 1AB
(harness-side).
kilohms?
SENSOR Yes Go to the next step.
 Inspect the fuel tank pressure sensor.

8 (See FUEL TANK PRESSURE Replace the evaporative hose component, then go
SENSOR INSPECTION [MZI- No to the next step. (See FUEL TANK
3.7] .) REMOVAL/INSTALLATION [MZI-3.7] .)
 Is the fuel tank pressure sensor
normal?
DTC P0453 COMPLETED
9  Make sure to reconnect all Yes PCM REMOVAL/INSTALLATION [MZI-
disconnected connectors. 3.7] .)
Microsoft

completely.
VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
DTC P0454 [MZI-3.7]

DTC P0454 Fuel tank pressure sensor intermittent
DETECTION
 The fuel tank pressure changes more than 14 inches of water in 0.10 s.
CONDITION
 Intermittent open or short in the fuel tank pressure sensor or the fuel
POSSIBLE CAUSE tank pressure sensor signal

BEEN RECORDED
recorded?
Yes
next step.
VERIFY RELATED PENDING CODE Go to the appropriate DTC troubleshooting. (See

Yes
OR STORED DTCs DTC TABLE [MZI-3.7].)
3
ON position (Engine off). Perform the "INTERMITTENT CONCERN
Microsoft
Verify related pending code or stored


TROUBLESHOOTING". Then go to the next
DTCs. No step.

 Clear the DTC from the PCM memory Yes PCM REMOVAL/INSTALLATION [MZI-
using the M-MDS. 3.7] .)
4  Perform the "KOEO or KOER self-
test" using the M-MDS.

[MZI-3.7].)
Is the PENDING CODE for the DTC

present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P0455 [MZI-3.7]

DTC P0455 Evaporative emission system leak detected (gross leak/no flow)
DETECTION  P0455 indicates that a substantial leak or blockage has been detected in the
CONDITION EVAP system when there is - 1.74 kPa (PID FTP_H2O displays "-7.0") or less
vacuum for a 30 seconds evaluation time.
 After-market EVAP hardware (such as fuel-filler cap) not conforming to

required specifications.
 Disconnected or cracked fuel chopping timer tube, CV solenoid valve outlet
tube or EVAP return tube.
POSSIBLE
CAUSE  CV solenoid valve stuck closed
 Damaged or missing fuel-filler cap.
 Insufficient fuel-filler cap installation.
 Loose fuel vapor hose/tube connections to EVAP system components.
 Blockages or restrictions in fuel vapor hoses/tubes.
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 Rollover valve blocked or fuel shut-off valve.

 CV solenoid valve stuck open.
 Mechanically inoperative Fuel tank pressure sensor.
 Damaged charcoal canister.

HAS BEEN RECORDED
1 Record FREEZE FRAME DATA on the repair order,
been recorded?
availability. step.

VERIFY RELATED PENDING
CODE OR STORED DTCs
Yes
Turn the ignition switch off then

3 to the ON position (Engine off).
 Verify related pending code or
stored DTCs. No Go to the next step.
VISUALLY INSPECT FOR LARGE

EVAP SYSTEM LEAK
 Check for the presence of a fuel-

filler cap. Do not tighten or check
for correct installation at this
time.
4 Yes
 Verify that both the input port Repair or replace the EVAP components if
vacuum hose and EVAP return necessary. (See FUEL TANK INSPECTION
tube are attached to the CV [MZI-3.7] .)
solenoid valve. (See FUEL TANK PRESSURE SENSOR
 Verify that the CV solenoid valve INSPECTION [MZI-3.7] .)
is properly attached to the (See CHARCOAL CANISTER, CANISTER
charcoal canister. VENT (CV) SOLENOID VALVE, AIR FILTER
Microsoft
Visually inspect for disconnected


COMPONENT REMOVAL/INSTALLATION
or cracked fuel vapor hoses/tubes [MZI-3.7] .)
between the intake manifold and Go to Step 7.
the following components:
 CV solenoid valve
 Charcoal canister
 Fuel shut-off valve
 Check for damage to the fuel-

filler pipe and the fuel tank. No Go to the next step.
 Is a concern visually evident?
INSPECT FOR EVAP SYSTEM

LEAKS
 Disconnect the EVAP return tube
from the intake manifold and plug
the EVAP return tube.
 Connect the EVAP System Leak
5 Tester to the EVAP test port.
 Perform the EVAP System Leak Verify that the fuel-filler cap is installed correctly.
Test. (See ENGINE CONTROL No Repair or install a new components if necessary. Go
SYSTEM OPERATION to Step 8.
 Does the pressure stay above 1.99
kPa (PID FTP_H2O displays
"8")?
INSPECT FOR BLOCKAGE

BETWEEN CV SOLENOID VALVE
AND FUEL VAPOR HOSE JOINT
 Turn the ignition switch to the Yes Go to the next step.

ON position (Engine off)
 Using M-MDS tester, select the
Diagnostic Data Link.
6  Select the PCM.
 Select the Active Command
Modes.
 Select the Output Test Mode.
 Close the CV solenoid valve
using the EVMV PID. No Replace the fuel tank vapor line(s). Go to Step 8.
 Pressurize the EVAP system to
3.48 kPa (PID FTP_H2O displays
"14").
Microsoft
 Press STOP (#4) on M-MDS

tester to open the EVMV.
 Does the pressure drop
immediately?
Replace the CV solenoid valve.
INSPECT FOR (See CHARCOAL CANISTER, CANISTER
MALFUNCTIONING CV Yes VENT (CV) SOLENOID VALVE, AIR FILTER
SOLENOID VALVE OR FUEL COMPONENT REMOVAL/INSTALLATION
7 TANK PRESSURE SENSOR [MZI-3.7] .) .) Go to the next step.
Replace the evaporative hose component.
 Were both P0455 and P1443 (See FUEL TANK REMOVAL/INSTALLATION
present at Step 1? No
[MZI-3.7] .)
Connect all disconnected

connectors and hoses.
8  Perform the EVAP System Leak
Test. (See ENGINE CONTROL Leakage still exists. Locate leak point and repair.
SYSTEM OPERATION No
Repeat this step.
DTC P0455 HAS BEEN
COMPLETED
connectors are reconnected. Yes
PCM REMOVAL/INSTALLATION [MZI-3.7] .)
 Retrieve DTCs using the M-
DTC present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
3.7].)
Microsoft
 Are any DTC present? No Troubleshooting completed.
DTC P0457 [MZI-3.7]

DTC P0457 Evaporative emission system leak detected (fuel cap loose/off)
DETECTION  P0457 indicates that the initial vacuum could not be achieved after a
CONDITION refueling event and the purge vapor flow is excessive (gross leak).
POSSIBLE CAUSE  Missing or loose fuel filler cap.

BEEN RECORDED
recorded?
availability. step.
OR STORED DTCs

the ON position (Engine off). Go to the appropriate DTC troubleshooting. (See
Yes
 Verify related pending code or stored DTC TABLE [MZI-3.7].)
DTCs.
3  Are other DTCs present?
NOTE:
 If DTC P0455 is present,
diagnose that DTC first. (See
ENGINE CONTROL SYSTEM No Go to the next step.
OPERATION INSPECTION
[MZI-3.7] .)
INSPECT FOR MISSING OR

Microsoft
LEAKING FUEL FILLER CAP

Repair or replace if necessary. Go to the next
Yes
Check for missing or loose fuel filler
 step.
4 cap.
 Check for possible cross-threaded
fuel filler cap. No Go to Step 6.
EVAP SYSTEM LEAK TEST Yes Go to Step 6.
Perform the EVAP system leak test.


Leakage still exists. Go to the P0455
5 (See ENGINE CONTROL Troubleshooting. (See ENGINE CONTROL
SYSTEM OPERATION No
SYSTEM OPERATION INSPECTION [MZI-
INSPECTION [MZI-3.7] .) 3.7] .)


connectors are reconnected. Replace the PCM, then go to the next step. (See
3.7] .)

present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0460 [MZI-3.7]

DTC P0460 Fuel level sensor circuit
DETECTION  The PCM monitors the fuel level input communications network message for a
CONDITION concern. The test fails when the PCM determines that the value of the fuel level
input signal is stuck. The PCM calculates the amount of fuel used during
Microsoft
operation. If the fuel level input signal does not change or does not correspond
with the calculated fuel usage, the DTC is set.
 Empty fuel tank
 Incorrectly installed fuel gauge
POSSIBLE  Instrument cluster malfunction
CAUSE  Fuel level input signal circuit malfunction
 Overfilled fuel tank
 Fuel gauge malfunction
 Stuck float arm

HAS BEEN RECORDED
1 Record the FREEZE FRAME DATA on the repair
recorded?
VERIFY REPAIR INFORMATION
AVAILABILITY Perform repair or diagnosis according to the
Yes available Service Bulletins. If the vehicle is not
2  Verify related Service Bulletins repaired, go to the next step.
availability.
OR STORED DTCs
Yes
VERIFY STORED DTC IN

INSTRUMENT CLUSTER Go to the appropriate DTC inspection. (See DTC
Yes
TABLE [INSTRUMENT CLUSTER] .)
4  Turn the ignition switch off then to
 Verify stored DTCs in instrument No Go to the next step.
cluster.
Microsoft
Is other DTCs present?



test". (See KOEO/KOER SELF
TEST [MZI-3.7].)
 Is the PENDING CODE for the No Go to the next step.
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P0461 [MZI-3.7]

DTC P0461 Fuel gauge sender unit range/performance problem
 The PCM monitors the fuel level input communications network message for a
DETECTION concern. The test fails when the fuel level input signal repeatedly moves in and
CONDITION out of range, exceeding the minimum or maximum allowable calibrated
parameters for a specified fuel fill percentage in the fuel tank.
POSSIBLE  Excessive electrical noise

HAS BEEN RECORDED
recorded?
Microsoft


repaired, go to the next step.
2 availability.
available?
OR STORED DTCs
Yes

INSTRUMENT CLUSTER
Go to the appropriate DTC inspection. (See DTC
Yes
 Verify stored DTCs in instrument
cluster. No Go to the next step.

TEST [MZI-3.7].)
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P0462 [MZI-3.7]

Microsoft

DTC P0462 Fuel gauge sender unit circuit low input
 The PCM) monitors the fuel level input communications network message for
DETECTION a concern. The test fails if the fuel level input signal is less than the minimum
CONDITION allowable calibrated parameter for a specified fuel-fill percentage in the fuel
tank.
 Empty fuel tank
POSSIBLE  Incorrectly installed fuel gauge
CAUSE  Instrument cluster malfunction
 Fuel level input signal circuit malfunction

HAS BEEN RECORDED
recorded?
availability.
OR STORED DTCs
Yes

INSTRUMENT CLUSTER
Yes
Microsoft
cluster.

TEST [MZI-3.7].)
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P0463 [MZI-3.7]

DTC P0463 Fuel gauge sender unit circuit high input
 The PCM monitors the fuel level input communications network message-for a
DETECTION concern. The test fails if the fuel level input signal is more than the maximum
CONDITION allowable calibrated parameter for a specified fuel-fill percentage in the fuel
tank.
 Incorrectly installed fuel gauge
POSSIBLE  Instrument cluster malfunction
 Overfilled fuel tank

Microsoft

HAS BEEN RECORDED
recorded?
availability.
OR STORED DTCs
Yes

INSTRUMENT CLUSTER
Yes
cluster. No Go to the next step.
TEST [MZI-3.7].)
DTC present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
Microsoft

6 3.7].) No Troubleshooting completed.
DTC P0480 [MZI-3.7]

DTC P0480 Fan control circuit
DETECTION  This test inspect the fan control circuit. The DTC sets if the PCM detects the
CONDITION voltage on the fan control variable circuit is not within the expected range.

 Fan control module malfunction
 Open circuit between fan control module No.1 terminal 1B and PCM
terminal 1AM
 Short to power supply between fan control module No.1 terminal 1B and
PCM terminal 1AM
 Short to ground circuit between fan control module No.1 terminal 1B and
PCM terminal 1AM
 Open circuit between fan control module No.2 terminal B and PCM
terminal 1AM
 Short to power supply between fan control module No.2 terminal B and
PCM terminal 1AM
POSSIBLE CAUSE  Short to ground circuit between fan control module No.2 terminal B and
PCM terminal 1AM
 Open circuit between fan control module No.1 terminal 1A and cooling fan
relay No.1 terminal E
 Open circuit between fan control module No.1 terminal 1C and body ground
 Open circuit between fan control module No.2 terminal A and cooling fan
relay No.2 terminal E
 Open circuit between fan control module No.2 terminal C and body ground
 Open circuit between fan control module terminal 1B and PCM terminal 1
AM
 Short to power supply between fan control module terminal 1B and PCM
terminal 1AM
 Short to ground circuit between fan control module terminal 1B and PCM
Microsoft
terminal 1AM
 Open circuit between fan control module terminal 1C and cooling fan relay
terminal E
 Open circuit between fan control module terminal 1A and body ground
Microsoft

BEEN RECORDED
recorded?
Yes

next step.
INSPECT FAN CONTROL MODULE
CONNECTOR FOR POOR
CONNECTION
Yes
3  Disconnect fan control module
connector.
damaged, pulled-out pins, corrosion,
etc.). No Go to the next step.

POWER SUPPLY CIRCUIT FOR OPEN
CIRCUIT Yes Go to the next step.

 Measure voltage between the following
circuits:

Microsoft
 Fan control module No.1

terminal 1A (wiring harness-side)
and body ground.
terminal A (wiring harness-side)
and body ground. Repair or replace suspected part, then go to
4 No
Step 10.
Fan control module terminal 1C


ground.

GROUND CIRCUIT FOR OPEN
CIRCUIT

 inspect for continuity between the
following circuits:

5 terminal 1C (wiring harness-side)
and body ground.
terminal C (wiring harness-side)
and body ground. Repair or replace suspected part, then go to
No
Step 10.
Fan control module terminal 1A


ground.
INSPECT FAN CONTROL CIRCUIT

FOR SHORT TO POWER

position (Engine off). Repair or replace suspected part, then go to
Yes
Step 10.
following circuits:

Microsoft

terminal 1B (wiring harness-side)
and body ground.
terminal B (wiring harness-side)
and body ground.
Fan control module terminal 1B


ground.

FOR SHORT TO GROUND

following circuits:
Dual fan control module Yes
Step 10.

7 and body ground.
and body ground.
Fan control module terminal 1B No

 Go to the next step.
ground.

POOR CONNECTION
Yes
Microsoft
FOR OPEN CIRCUIT

following circuits: Yes Go to the next step.

and PCM terminal 1AM (wiring
harness-side).
9  Fan control module No.2
and PCM terminal 1AM (wiring
harness-side). Repair or replace suspected part, then go to the
No
next step.
Fan control module terminal 1B


terminal 1AM (wiring harness-
side).


3.7] .)
using the M-MDS.
TEST [MZI-3.7].) No Go to the next step.

Yes
DTC P0505 [MZI-3.7]

Microsoft
DTC P0505 Idle speed control system problem
DETECTION  The PCM attempts to control engine speed during the KOER self-test. The test
CONDITION fails when the desired engine speed could not be reached or controlled during
the self-test.
 Failure mode effects management condition is present
 Intake air restriction
 Exhaust restriction
 Sludged throttle body
 Vacuum leakage
POSSIBLE  Throttle body malfunction
CAUSE  PCM malfunction
NOTE:
 This DTC is informational only and it may be accompanied by other
DTCs. Diagnose other DTCs first. If other DTCs are not present inspect
the intake air system for air restrictions, vacuum leaks, and damage. If
no concerns are present, clear the DTC and repeat the self-test.

HAS BEEN RECORDED
recorded?
availability. step.

OR STORED DTCs
Yes
Microsoft
INSPECT AIR CLEANER ELEMENT

Yes Replace the air cleaner element, then go to Step 9.
4 Remove air cleaner element with the

engine running.
 Is the engine speed increased?
INSPECT FOR AIR SUCTION AT

INTAKE AIR SYSTEM
Inspect for air leakage at the

 Repair or replace the suspected part, then go to
Yes
following: Step 9.
5  Around connection of
dynamic chamber and intake
manifold
 Around connection of intake
manifold and cylinder head No Go to the next step.
 Is air leakage found?
INSPECT THROTTLE BODY Clean or replace the throttle body passage, then go
PASSAGE Yes
6 to Step 9.
Is the throttle body clogged?

7 COMPRESSION INSPECTION
[MZI-3.7] .) No Overhaul the engine, then go to the next step.
INSPECT FOR RESTRICTION IN Replace malfunctioning part, then go to the next

EXHAUST SYSTEM AND TWC Yes
8 step.
 Is there any restriction? No Go to the next step.
 Perform the KOEO and KOER self-
test.
 Retrieve the DTCs using the M- No Go to the next step.
MDS.
Microsoft
Is the PENDING CODE for this


DTC present?
VERIFY AFTER REPAIR
PROCEDURE
TABLE [MZI-3.7].)
PROCEDURE".
10
(See AFTER REPAIR
DTC P0506 [MZI-3.7]

DTC P0506 IAC system RPM lower than expected
DETECTION  This DTC is set when the PCM detects an engine idle speed that is less
CONDITION than the desired engine speed.
 Engine mechanical concern
POSSIBLE CAUSE  Sludged throttle body
 Vacuum leakage
 Throttle body malfunction
 PCM malfunction

HAS BEEN RECORDED
recorded?

2 Yes
 Verify related Service Bulletins  If the vehicle is not repaired, then go to the
and/or on-line repair information next step.
availability.
Microsoft


available?
VERIFY RELATED PENDING OR
STORED DTCS
Repair applicable DTCs. (See DTC TABLE [MZI-
Yes
Turn the ignition switch off then to

3.7].)
 Verify pending code or stored
DTCs using the M-MDS. No Go to the next step.

Yes Replace the air cleaner element, then go to Step 7.
4  Remove air cleaner element with
the engine running.
INSPECT INTAKE AIR SYSTEM

FOR EXCESSIVE AIR SUCTION Repair or replace the malfunctioning part, then go
Yes
to Step 7.
5  Visually inspect the hose in intake
air system for damages.
INSPECT THROTTLE BODY Clean or replace the throttle body passage, then go
PASSAGE Yes
6 to the next step.
DTC P0506 HAS BEEN
COMPLETED
3.7] .)
7  Start the engine.
 Depress brake pedal for 14 s or
more.
present?
VERIFY AFTER REPAIR

8 Yes
TABLE [MZI-3.7].)
PROCEDURE".
Microsoft
(See AFTER REPAIR

DTC P0507 [MZI-3.7]

DTC P0507 IAC system RPM higher than expected
DETECTION  This DTC is set when the PCM detects an engine idle speed that is more
CONDITION than the desired engine speed.
 Intake air leak after throttle body
 Vacuum leakage
POSSIBLE CAUSE  EVAP system malfunction
 PCM malfunction

BEEN RECORDED
recorded?
Yes
 If the vehicle is not repaired, then go to
on-line repair information availability. the next step.
VERIFY RELATED PENDING OR
STORED DTCS
Repair applicable DTCs. (See DTC TABLE
Yes
[MZI-3.7].)
 Verify pending code or stored DTCs
using the M-MDS. No Go to the next step.
INSPECT AIR CLEANER ELEMENT Replace the air cleaner element, then go to Step
Microsoft
Remove air cleaner element with the Yes 7.


4 engine running.
INSPECT INTAKE AIR SYSTEM FOR

EXCESSIVE AIR SUCTION Repair or replace the malfunctioning part, then
Yes
go to Step 7.
5  Visually inspect the hose in intake air
system for looseness or damages.
INSPECT THROTTLE BODY Clean or replace the throttle body passage, then
PASSAGE Yes
6 go to Step 7.

3.7] .)
7
using the M-MDS.
 Depress brake pedal for 14 s or more.

present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P050E [MZI-3.7]

DTC P050E (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P050E Cold start engine exhaust temperature out of range
 The PCM calculates the actual catalyst warm up temperature during a cold start.
DETECTION The PCM then compares the actual temperature to the expected catalyst
CONDITION temperature model. The difference between the actual and expected temperatures
is a ratio. When this ratio exceeds the calibrated value this DTC is set and the
malfunction indicator lamp (MIL) illuminates.

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 Mechanical concern with the engine
POSSIBLE
CAUSE  Throttle body malfunction
 Vacuum leakage
 PCM malfunction
DTC P050E (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
Yes
next step.
OR STORED DTCs
Yes

Replace the air cleaner element, then go to Step
Yes
 Remove air cleaner element with the
9.
4
engine running.
Yes
go to Step 9.
5  Visually inspect the hose in intake air
system for looseness or damages.
INSPECT THROTTLE BODY Clean or replace the throttle body passage, then
Yes
PASSAGE go to Step 9.
Microsoft
6 Is the throttle body clogged?


7 COMPRESSION INSPECTION
[MZI-3.7] .) No Overhaul the engine, then go to Step 9.
INSPECT FOR RESTRICTION IN Replace malfunctioning part, then go to the next

EXHAUST SYSTEM AND TWC Yes
8 step.
Is there any restriction?
DTC P050E HAS BEEN COMPLETED


using the M-MDS.
 Perform the "KOEO and KOER self-
TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P053A [MZI-3.7]

DTC P053A (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P053A PCV valve heater control circuit/open
DETECTION  This DTC is set when the PCM detects a PCV valve heater circuit
CONDITION malfunction.
 Open circuit between PCV valve heater control terminal A and main relay
No.1
Microsoft
 Open circuit between PCV valve heater fitting terminal A and main relay
No.1
 Short to ground circuit between PCV valve heater control terminal B and
PCM terminal 2BL
 Short to ground circuit between PCV valve heater fitting terminal B and PCM
terminal 2AU
 Short to power circuit between PCV valve heater control terminal B and PCM
POSSIBLE CAUSE terminal 2BL
 Short to power circuit between PCV valve heater fitting terminal B and PCM
terminal 2AU
 Open circuit between PCV valve heater control terminal B and PCM terminal
2BL
 Open circuit between PCV valve heater fitting B and PCM terminal 2AU
 Damaged PCV heater assembly
Microsoft
Microsoft
DTC P053A (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
Yes
2  Verify related Service Bulletins and/or  If the vehicle is not repaired, go to the
INSPECT PCV VALVE HEATER
CONTROL AND PCV VALVE HEATER
FITTING CONNECTOR FOR POOR
CONNECTION Repair or replace suspected part, then go to
Yes
Step 10.
3
 Disconnect PCV valve heater control and
PCV valve heater fitting connector.

INSPECT POWER SUPPLY CIRCUIT

FOR OPEN CIRCUIT
 Inspect the voltage between the following
circuit:
4
 PCV valve heater control terminal
A (wiring harness-side) and body
ground Repair or replace suspected part, then go to
No
Step 10.
 PCV valve heater fitting terminal A
ground
FITTING CIRCUIT FOR SHORT TO
POWER SUPPLY
Microsoft


Yes
following circuit: Step 10.
5 B (wiring harness-side) and body
ground
 PCV valve heater fitting terminal B
(wiring harness-side) and body No Go to the next step.
ground

GROUND
Yes
 Inspect for continuity between the Step 10.
following circuit:
6  PCV valve heater control terminal
B (wiring harness-side) and body
ground
ground

CONNECTION
Yes


CONTROL AND PCV VALVE HEATER Yes Go to the next step.
FITTING FOR OPEN CIRCUIT

8
following circuit:
 PCV valve heater control terminal Repair or replace suspected part, then go to
B (wiring harness-side) and PCM No Step 10.
terminal 2BL (wiring harness-side)
 PCV valve heater fitting B (wiring
Microsoft

2AU (wiring harness-side)

FITTING
 Inspect the PCV valve heater control and

PCV valve heater fitting. Yes
the next step.
(See POSITIVE CRANKCASE
9 VENTILATION (PCV) VALVE

VENTILATION (PCV) VALVE
HEATER FITTING INSPECTION
[MZI-3.7] .) No Go to the next step.



P053A HAS BEEN COMPLETED

reconnected. Yes (See PCM REMOVAL/INSTALLATION
10 using the M-MDS.
 Perform the "KOEO or KOER self-test"
using the M-MDS. (See KOEO/KOER
SELF TEST [MZI-3.7].)
 Is the PENDING CODE for the DTC No Go to the next step.
present?
Yes
DTC P0579 [MZI-3.7]

DTC P0579 Cruise control multi-function input circuit range/performance
DETECTION  P0579 may set when the cruise control switch circuits are open, shorted to
Microsoft
CONDITION voltage or ground.

 Open circuit between cruise control switch terminal B and PCM terminal
1AT
 Open circuit between cruise control switch terminal C and PCM terminal 1AP
 Short to power supply between cruise control switch terminal B and PCM
terminal 1AT
POSSIBLE CAUSE  Short to power supply between cruise control switch terminal C and PCM
terminal 1 AP
 Short to ground circuit between cruise control switch terminal B and PCM
terminal 1AT
 Short to ground circuit between cruise control switch terminal C and PCM
terminal 1AP
 Cruise control switch malfunction
 PCM malfunction
Microsoft

BEEN RECORDED
recorded?
2 Yes
Microsoft

INSPECT CRUISE CONTROL SWITCH
CONNECTOR FOR POOR
CONNECTION
Yes
9.
 Turn the ignition switch to off.
3  Disconnect the cruise control switch
connector.
IINSPECT CRUISE CONTROL SWITCH

SUPPLY
 Yes
9.
4  Measure the voltage between the
 Cruise control switch terminal B
and body ground
 Cruise control switch terminal C
and body ground


Yes
9.
and body ground
and body ground No Go to the next step.

POOR CONNECTION
Yes

damaged/pulled-out pins, corrosion). No Go to the next Step.
Microsoft

CIRCUIT FOR OPEN

and PCM terminal 1AT Repair or replace suspected part, then go to Step
No
9.
and PCM terminal 1AP

Replace the cruise control switch, then go to the
Yes
 Inspect the cruise control switch. (See next step.
8 CRUISE CONTROL SWITCH


using the M-MDS.
TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P0581 [MZI-3.7]

Microsoft
DTC P0581 Cruise control multi-function input circuit high

DETECTION  P0581 sets when the cruise control switch circuits are shorted to voltage or
CONDITION open.
 Open circuit between cruise control switch terminal B and PCM terminal
1AT
 Open circuit between cruise control switch terminal C and PCM terminal
1AP
POSSIBLE CAUSE  Short to power supply between cruise control switch terminal B and PCM
terminal 1 AT
 Short to power supply between cruise control switch terminal C and PCM
terminal 1 AP
 Cruise control switch malfunction
 PCM malfunction
Microsoft

BEEN RECORDED
recorded?
Yes
next step.
CONNECTOR FOR POOR
CONNECTION
Yes
8.
 Turn the ignition switch to off.
3  Disconnect the cruise control switch
connector.
IINSPECT CRUISE CONTROL

SWITCH CIRCUIT FOR SHORT TO
POWER SUPPLY
 Yes
8.
and body ground
and body ground

POOR CONNECTION
5 Yes
8.
Microsoft
Inspect for poor connection (such as



CIRCUIT FOR OPEN

and PCM terminal 1AT Repair or replace suspected part, then go to Step
No
8.
and PCM terminal 1AP

Replace the cruise control switch, then go to the
Yes
 Inspect the cruise control switch. (See next step.
7 CRUISE CONTROL SWITCH


using the M-MDS.
TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
Microsoft
DTC P0600 [MZI-3.7]

DTC P0600 Serial communication link
DETECTION  Indicates an error occurred in the PCM. This DTC may be set alone or in
CONDITION combination with P2105.
POSSIBLE CAUSE  PCM malfunction

BEEN RECORDED
recorded?
availability. step.
OPERATION
Disconnect all the PCM connectors. Yes Go to the next step.


 Pushed out pins

3
 Corrosion


present?
 Verify that all disconnected Yes

 Turn the ignition switch to the ON PCM REMOVAL/INSTALLATION [MZI-
Microsoft

4
test.
present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0602 [MZI-3.7]

DTC P0602 PCM programming error
DETECTION
 This DTC indicates a programming error within the vehicle ID block.
CONDITION
POSSIBLE CAUSE  Vehicle ID data corrupted by the M-MDS during vehicle ID

reprogramming

BEEN RECORDED
recorded?
Yes
2 and/or on-line repair information step.
availability.
 Is any related Service Bulletins Reprogram the vehicle ID using the M-MDS,
No
available? then go to the next step.
Microsoft


3  Clear the DTC from the PCM
TEST [MZI-3.7].)
 Retrieve DTCs using the M-MDS. No Go to the next step.
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P0603 [MZI-3.7]

DTC P0603 PCM keep alive memory (KAM) error
DETECTION  Indicates the PCM has experienced an internal memory concern. However, there
CONDITION are external items that can cause this DTC.
 Reprogramming
 Battery terminal corrosion
POSSIBLE CAUSE  Open circuit between battery positive terminal and PCM terminal 1 BB
 Loose battery connection
Microsoft

1 BEEN RECORDED
Record FREEZE FRAME DATA on the
No
Microsoft
recorded?
Yes
  If vehicle is not repaired, go to the next
on-line repair information availability. step.
 Is any Service Bulletins available? No Go to the next step.
INSPECT BATTERY TERMINALS FOR
POOR CONNECTION Repair or replace suspected part, then go to
Yes
Step 7.

 Inspect for poor connection and

corrosion.

POOR CONNECTION
Yes
 Step 7.

INSPECT MONITOR CIRCUIT FOR

OPEN CIRCUIT
 Disconnect the battery cables.
 Inspect the continuity between battery Repair or replace suspected part, then go to
positive terminal (wiring harness-side) No Step 7.
and PCM terminal 1BB (wiring harness-
side).

OPERATION
6  Visually inspect for:
 Pushed out pins
 Corrosion
Microsoft



present?


are reconnected. Replace the PCM, then go to the next step.
 Turn the ignition switch to the ON Yes (See PCM REMOVAL/INSTALLATION
position (Engine off). [MZI-3.7] .)
using the M-MDS.
test". (See KOEO/KOER SELF TEST
[MZI-3.7].)
present?
Yes
8 PRECAUTION". (See AFTER
DTC P0604 [MZI-3.7]

DTC P0604 Internal control module random access memory (RAM) error
DETECTION CONDITION  Indicates the PCM RAM has been corrupted.
 Module reprogramming
POSSIBLE CAUSE  Aftermarket performance products.
 PCM malfunction

1 BEEN RECORDED
No
Microsoft

Yes

availability.
 Is any related Service Bulletins Perform PCM reprograming using the M-MDS,
No
available? then go to next step.


connectors are reconnected. Replace the PCM, go to the next step. (See PCM
Yes
 Turn the ignition switch to the ON REMOVAL/INSTALLATION [MZI-3.7] .)
TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
4  Perform the "After Repair Procedure".
(See AFTER REPAIR
DTC P0605 [MZI-3.7]

DTC P0605 PCM read only memory (ROM) error
DETECTION CONDITION  The PCM ROM has been corrupted.
 An attempt was made to change the calibration

POSSIBLE CAUSE  Module programming error
 PCM malfunction
Microsoft

BEEN RECORDED
order, then go to next step.
recorded?
Yes
 If vehicle is not repaired, go to next step.
No


are reconnected. Replace the PCM, then go to next step. (See
using the M-MDS.
TEST [MZI-3.7].)
No Go to next step.
present?
Yes
DTC P0606 [MZI-3.7]

DTC P0606 ECM/PCM processor
DETECTION  This DTC indicates a register hardback (PCM internal
CONDITION communications) error.
Microsoft

BEEN RECORDED
recorded?
Yes

availability.
No


connectors are reconnected. Replace the PCM, go to the next step. (See PCM
Yes
 Turn the ignition switch to the ON REMOVAL/INSTALLATION [MZI-3.7] .)
TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
4  Perform the "After Repair Procedure".
(See AFTER REPAIR
DTC P0607 [MZI-3.7]

DTC P0607 Control module performance
Microsoft
DETECTION  Indicates that the PCM internal CPU has encountered an error. The PCM
CONDITION monitors itself and carries out internal checks of its own CPU. If any of these
checks returns an incorrect value, the DTC is set.
POSSIBLE
CAUSE  PCM malfunction

BEEN RECORDED
recorded?
Yes
No


using the M-MDS.
 Perform "KOEO and KOER self-test".
[MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
Microsoft
DTC P060A, P060C, P060F, P061D [MZI-3.7]

DTC P060A, P060C, P060F, P061D (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P060A P060A: Internal control module monitoring processor performance
DTC P060C P060C: Internal control module main processor performance
DTC P061D P061D: Internal control module engine air mass performance
DETECTION CONDITION  Indicates an error occurred in the PCM.
 Software incompatibility issue

POSSIBLE CAUSE
 PCM malfunction
DTC P060A, P060C, P060F, P061D (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
Yes
next step.
INSPECT PCM FOR LATEST
CALIBRATION
 Program the PCM to the latest Yes Go to the next step.

calibration.
 Perform the KOEO self-test.
 Use the customer information to
recreate the concern. No Go to Step 5.
 Perform the self-test.
 Are DTCs P060A, P060C or P060D
present?
OPERATION
Microsoft
Disconnect all the PCM connectors.



 Pushed out pins Yes PCM REMOVAL/INSTALLATION [MZI-
 Corrosion 3.7] .)
4  Connect all the PCM connectors and

present?
MISFIRE DTC P060A, P060C AND
P061D HAS BEEN COMPLETED


reconnected. Replace the PCM, then go to the next step. (See
3.7] .)
using the M-MDS.
TEST [MZI-3.7].)
present?
Yes
DTC P060B [MZI-3.7]

DTC P060B (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P060B Internal control module A/D processing performance
DETECTION CONDITION  Indicates that an error occurred in the PCM.
DTC P060B (MZI-3.7) DIAGNOSTIC PROCEDURE

Microsoft

BEEN RECORDED
No
recorded?
Yes
next step.
OR STORED DTCs
Yes
INSPECT FOR REFERENCE

VOLTAGE CONCERNS
 Inspect the PCM wiring harness for
4 damage.
 Verify the correct operation of the
sensors using ETCREF, VREF and No Go to Step 6.
related circuits.

OPERATION
 Disconnect all the PCM connectors. Replace the PCM, then go to the next step. (See
 Visually inspect for: Yes PCM REMOVAL/INSTALLATION [MZI-
 Pushed out pins 3.7] .)
5
 Corrosion

present?
DTC P060B HAS BEEN COMPLETED
Microsoft


using the M-MDS.
6
TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P0610 [MZI-3.7]

DTC P0610 Control module vehicle options error
DETECTION CONDITION  Indicates a PCM vehicle options error.
 Module reprogramming
POSSIBLE CAUSE  Aftermarket performance products.
 PCM malfunction.

BEEN RECORDED
recorded?
2 INFORMATION AVAILABILITY Yes available Service Bulletins.
Microsoft

availability.
Perform PCM reprograming using the M-MDS,
 Is any related Service Bulletins No
then go to next step.
available?


TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P061B [MZI-3.7]

DTC P061B (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P061B Internal control module torque calculation performance
DETECTION
 Indicates that a calculation error occurred in the PCM.
CONDITION
POSSIBLE NOTE:
CAUSE  This DTC is an informational DTC and may be set in combination
with a number of other DTCs which are causing the FMEM.
Diagnose other DTCs first.
DTC P061B (MZI-3.7) DIAGNOSTIC PROCEDURE

Microsoft

BEEN RECORDED
 No
recorded?
Yes

next step.
OR STORED DTCs
Yes

OPERATION
 Disconnect all the PCM connectors. Replace the PCM, then go to the next step. (See
4
 Corrosion

present?
DTC P061B HAS BEEN COMPLETED

5 Yes PCM REMOVAL/INSTALLATION [MZI-
using the M-MDS.
Microsoft

TEST [MZI-3.7].)
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P061F [MZI-3.7]

DTC P061F (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P061F Internal control module throttle actuator controller performance
DETECTION
 Indicates that a calculation error occurred in the PCM.
CONDITION
NOTE:
POSSIBLE CAUSE  This DTC is an informational DTC and may be set in combination with a
number of other DTCs which are causing the FMEM. Diagnose other
DTCs first.
DTC P061F (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
Yes
next step.
OR STORED DTCs Go to the appropriate DTC troubleshooting. (See
Yes
Microsoft

DTCs.

OPERATION


4
 Corrosion


present?
DTC P061F HAS BEEN COMPLETED


using the M-MDS.
test.
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P061C [MZI-3.7]

DTC P061C (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P061C Internal control module engine RPM performance
Microsoft
DETECTION CONDITION  Indicates that a calculation error occurred in the PCM.

 CKP sensor circuit is open or short.
 CKP sensor circuit intermittent
POSSIBLE CAUSE  CMP sensor circuit is open or short.
 CMP sensor circuit intermittent
 PCM malfunction
DTC P061C (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
Yes
OR STORED DTCs
Yes
INSPECT CKP SENSOR SIGNAL SENT

TO PCM Yes Go to the next step.
NOTE:
4
 The battery should be fully charged
and the starting system should be
functioning properly.
Microsoft
Disable the inertia switch.



position (Engine off) Inspect the CKP sensor or related harness.
 Access the PCM and monitor the RPM No Repair or replace suspected part, then go to the
PID. next step.
 Is the RPM greater than 150 rpm?

OPERATION


5
 Corrosion


present?
DTC P061C HAS BEEN COMPLETED


using the M-MDS.
TEST [MZI-3.7].)
 Retrieve the DTCs using the M-MDS.
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
Microsoft
DTC P0620 [MZI-3.7]

DTC P0620 Generator control circuit
DETECTION  The PCM reads the generator and sends a DTC through the network when the
CONDITION generator indicates a concern.
 Drive belt misadjustment
 Open circuit between generator terminal LI and PCM terminal 2AG
 Open circuit between generator terminal B and battery positive terminal
POSSIBLE CAUSE
 Short to ground between generator terminal LI and PCM terminal 2AG
 Short to power supply between generator terminal LI and PCM terminal 2AG
 PCM malfunction
Microsoft

BEEN RECORDED
1
No
Microsoft

Yes

INSPECT DRIVE BELT CONDITION Yes Go to the next step.
3 Verify that drive belt auto tensioner

 Replace and/or adjust drive belt, then go to Step
indicator mark does not exceed limit. No 12. (See DRIVE BELT INSPECTION [MZI-
 Is drive belt normal?
3.7] .)
INSPECT GENERATOR TERMINAL
FOR POOR INSTALLATION Connect generator terminal B correctly, then go
Yes
to Step 12.
4 Turn the engine switch off.

 Inspect generator terminal B for

looseness.
INSPECT GENERATOR CIRCUIT FOR

Yes
 12.
 Measure voltage between generator
terminal LI (wiring harness-side) and
body ground. No Go to the next step.
 Is voltage B+?

SHORT TO GROUND Repair or replace suspected part, then go to the
Yes
next step.
6  Inspect for continuity between
generator terminal LI (wiring harness-

POOR CONNECTION
Yes
 Turn the engine switch off.
12.
7
damaged/pulled-out terminals,
Microsoft

Inspect for continuity between


8 generator terminal LI (wiring harness-
side) and PCM terminal 2AG (wiring No Repair or replace suspected part, then go to Step
harness-side) 12.
INSPECT BATTERY POSITIVE

TERMINAL FOR POOR
INSTALLATION Connect the battery positive terminal correctly,
Yes
then go to Step 12.
9  Turn the engine switch off.
 Inspect the battery positive terminal

for looseness. No Go to the next step.

Inspect continuity between generator


10 terminal B (wiring harness-side) and
battery positive terminal (wiring Repair or replace suspected part, then go to Step
No
harness-side). 12.
INSPECT GENERATOR
Replace the generator, then go to the next step.
Inspect the generator. (See
 Yes (See GENERATOR
11 GENERATOR INSPECTION REMOVAL/INSTALLATION [MZI-3.7] .)
[MZI-3.7] .)
 Verify that all disconnected connectors

reconnected.
12 using the M-MDS.
3.7].)
present?
Microsoft

TABLE [MZI-3.7].)
REPAIR PROCEDURE [MZI-3.7].) No Troubleshooting completed.
DTC P0625 [MZI-3.7]

DTC P0625 Generator field terminal circuit low
DETECTION  The PCM monitors generator load from the generator/regulator in the form of
CONDITION frequency. The concern indicates the input is lower than the load should be in normal
operation. The load input could be low when no generator output exists.
 Drive belt damaged
 Short to ground between generator terminal RC and PCM terminal 2S
POSSIBLE
CAUSE  Short to ground between generator terminal LI and PCM terminal 2AG
 Open circuit between terminal B and battery positive terminal
 Low system voltage
Microsoft

BEEN RECORDED
1
No
Microsoft

Yes

INSPECT DRIVE BELT DAMAGED Yes Go to the next step.
3 Verify inspect the drive belt for

damage. Replace the drive belt, then go to Step 10. (See
No
DRIVE BELT INSPECTION [MZI-3.7] .)
 Is the drive belt normal?

FOR POOR INSTALLATION Connect generator terminal B correctly, then go
Yes
to Step 10.


looseness.

SHORT TO GROUND
Inspect for continuity between the
 Yes
Step 10.
following terminal:
5  Generator terminal RC (wiring
 Generator terminal LI (wiring
harness-side) and body ground. No Go to the next step.

TERMINAL FOR POOR
INSTALLATION Connect the battery positive terminal correctly,
Yes
then go to Step 10.

 Inspect the battery positive terminal for

looseness. No Go to the next step.

7
 Inspect the continuity between
generator terminal B (wiring harness-
side) and battery positive terminal Repair or replace suspected part, then go to
Microsoft
(wiring harness-side) Step 10.

No

POOR CONNECTION
Yes
Turn the engine switch off.

Step 10.
8
INSPECT GENERATOR
Replace the generator, then go to Step 10. (See
 Inspect the generator. (See Yes GENERATOR
9 GENERATOR INSPECTION [MZI- REMOVAL/INSTALLATION [MZI-3.7] .)
3.7] .)


reconnected.
10 using the M-MDS.
3.7].)
present?
Yes
DTC P0626 [MZI-3.7]

DTC P0626 Generator field terminal circuit high
DETECTION  The PCM monitors generator load from the generator/regulator in the form of
CONDITION frequency. The concern indicates the input is higher than the load should be in normal
operation. The load input could be high when a battery short to ground exists.
Microsoft
 Open circuit in wiring harness between generator terminal RC and PCM terminal 2S
POSSIBLE  Short to power supply between generator terminal RC and PCM terminal 2S
CAUSE  Short to power supply between generator terminal LI and PCM terminal 2AG

Microsoft

BEEN RECORDED
 No
recorded?
Yes

next step.
FOR POOR INSTALLATION Connect generator terminal B correctly, then
Yes
go to Step 9.


looseness.


 Repair or replace suspected part, then go to
Step 9.
 Generator terminal RC (wiring
 Generator terminal LI (wiring

POOR CONNECTION
Yes
Turn the engine switch off.

Step 9.
5

 Inspect for continuity between generator

Microsoft
terminal RC (wiring harness-side) and

6 PCM terminal 2S (wiring harness-side). No Repair or replace suspected part, then go to
Step 9.

TERMINAL FOR POOR INSTALLATION Connect the battery positive terminal
Yes
correctly, then go to Step 9.
7  Turn the engine switch off.
 Inspect the battery positive terminal for

looseness.

Inspect the continuity between generator


8 terminal B (wiring harness-side) and
battery positive terminal (wiring Repair or replace suspected part, then go to
No
harness-side) the next step.


9 using the M-MDS.
 Perform the KOEO or KOER self-test
present?
Yes
DTC P0642 [MZI-3.7]

DTC P0642 Sensor reference voltage circuit low
DETECTION  Indicates the reference voltage circuit is lower than reference voltage
CONDITION minimum.
Microsoft
 Short to ground between fuel tank pressure sensor terminal C and PCM
terminal 1U
POSSIBLE CAUSE

VERIFY FREEZE FRAME DATA
Microsoft
HAS BEEN RECORDED

Record FREEZE FRAME DATA on the repair
1 No
recorded?
 Yes
availability. step.


sensor connector.
damaged/pulled-out pins, No Go to the next step.
corrosion).

POOR CONNECTION

corrosion).

SENSOR CIRCUIT FOR SHORT TO
GROUND Yes Repair or replace suspected part, then go to Step 7.

5
 Inspect the continuity between fuel
tank pressure sensor terminal C
ground.
SENSOR
Microsoft
 Inspect the fuel tank pressure Replace the evaporative hose component, then go
sensor. (See FUEL TANK Yes to the next step. (See FUEL TANK
6 PRESSURE SENSOR REMOVAL/INSTALLATION [MZI-3.7] .)


KOEO/KOER SELF TEST
[MZI-3.7].)
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0643 [MZI-3.7]

DTC P0643 Sensor reference voltage circuit high
DETECTION  Indicates the reference voltage circuit is higher than reference voltage
CONDITION maximum.
 Short to power supply between fuel tank pressure sensor terminal C and PCM
terminal 1U
POSSIBLE CAUSE
Microsoft

HAS BEEN RECORDED
recorded?
Microsoft

 Yes
availability. step.
available?


sensor connector.

POOR CONNECTION



SENSOR CIRCUIT FOR SHORT TO
POWER SUPPLY Yes Repair or replace suspected part, then go to Step 7.


 Measure the voltage continuity
between fuel tank pressure sensor
terminal C (wiring harness-side) and No Go to the next step.
body ground.

SENSOR
Replace the evaporative hose component, then go
Yes to the next step. (See FUEL TANK
 Inspect the fuel tank pressure sensor.
(See FUEL TANK PRESSURE
SENSOR INSPECTION [MZI-
3.7] .)
Microsoft


3.7].)
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0645 [MZI-3.7]

DTC P0645 A/C relay control circuit
 Monitors the A/C relay control circuit output from the PCM. The test fails when the
DETECTION PCM grounds the A/C relay control circuit, excessive current draw is detected on the
CONDITION A/C relay control circuit; or, with the A/C relay control circuit not grounded by the
PCM, voltage is not detected on the A/C relay control circuit (the PCM expects to
detect vehicle power voltage coming through the A/C relay coil to the A/C circuit).
 A/C relay malfunction
POSSIBLE  Open circuit in wiring between main relay terminal No.1 D and A/C relay terminal A
CAUSE  Open circuit in wiring between A/C relay terminal E and PCM terminal IN
 Short to ground in wiring between A/C relay terminal E and PCM terminal 1N
 Short to power supply between A/C relay terminal E and PCM terminal 1N
Microsoft
Microsoft

BEEN RECORDED
recorded?
availability. step.
INSPECT THAT THE ACCS PID IS Yes Go to the next step.
OFF
Turn ignition key to ON (Engine


ACCS input to PCM is requesting A/C. Inspect
3 running). A/C system operation, then go to Step 12.
 A/C switch and defroster switch off. No (See DIAGNOSTIC TROUBLE CODE
 Access the ACCS PID uesing M- NUMBER INSPECTION .)
MDS. (See TROUBLESHOOTING INDEX .)
 Is the PID state off?
INSPECT A/C RELAY CONNECTOR

FOR POOR CONNECTOR
 12.
4  Disconnect the A/C relay connector.

damaged, pulled-out pins, corrosion,
etc.). No Go to the next step.
INSPECT A/C RELAY POWER

SUPPLY CIRCUIT FOR OPEN Yes Go to the next step.
CIRCUIT


 Measure voltage between A/C relay Repair or replace suspected part, then go to Step
No
terminal A (wiring harness-side) and 12.
body ground.
 Is voltage B+?
INSPECT A/C RELAY CONTROL

Microsoft

SUPPLY

Yes
12.
6  Remove the A/C relay.
 Measure voltage between A/C relay

terminal E (wiring harness-side) and
 Is voltage B+?

 Install the A/C relay.
Yes
12.
 Inspect continuity between A/C relay

terminal E (wiring harness-side) and

POOR CONNECTION
Yes
 Turn ignition switch to off. 12.

damaged, pulled-out pins, corrosion). No Go to the next step.



9  Inspect continuity between A/C relay

terminal E (wiring harness-side) and Repair or replace suspected part, then go to Step
PCM terminal 1N (wiring harness- No 12.
side).
INSPECT A/C RELAY Yes Go to the next step.
10  Inspect A/C relay. (See RELAY Replace the A/C relay. Start the engine. Turn on
INSPECTION .) No the A/C switch. Wait for 15 s. Turn off the A/C
 Is A/C relay normal? switch, then go to Step 12.

OPERATION
Microsoft

 Visually inspect for: Yes Go to the next step.
 Pushed out pins
 Corrosion
11  Connect all the PCM connectors and
 Retrieve DTCs using the M-MDS. No The system is correctly. Go to the next step.
DTC present?


3.7].)
present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P0685 [MZI-3.7]

DTC P0685 ECM/PCM power relay control circuit/open
DETECTION  This DTC sets when the ignition switch position run circuit indicates the key is in the
CONDITION off, ACC, or LOCK position, and the amount of time the PCM remains powered
through the PCM power relay exceeds a predetermined amount of time.
 Short to ground circuit between main relay No.1 terminal A and PCM terminal 1BM
POSSIBLE
CAUSE  Main relay No.1 malfunction
 PCM malfunction
Microsoft
Microsoft

BEEN RECORDED
recorded?
Yes
next step.
INSPECT MAIN RELAY NO.1
CONTROL CIRCUIT FOR SHORT TO
GROUND Repair or replace suspected part, then go to Step
Yes
5.
 Inspect for continuity between main
relay No.1 terminal A (wiring harness-
side) and body ground. No Go to the next step.

OPERATION

 Pushed out pins
4
 Corrosion

present?
DTC P0685 HAS BEEN COMPLETED Replace the PCM, then go to the next step. (See
 Verify that all disconnected connectors 3.7] .)
reconnected.
Microsoft
using the M-MDS.

5 KOEO/KOER SELF TEST [MZI- No Go to the next step.
3.7].)
present?
Yes
DTC P0689 [MZI-3.7]

DTC P0689 ECM/PCM power relay sense circuit low
DETECTION  This DTC sets when the passive anti theft system (PATS) system indicates the key
CONDITION is in ON or START position and the ignition switch position run circuit indicates
OFF, ACC, or LOCK position.
 Ignition circuit fuse (MAIN, IG KEY 1, IG KEY 2)
 Open circuit between battery positive terminal and PCM terminal 1 BD
POSSIBLE
CAUSE  Short to ground circuit between battery positive terminal and PCM terminal 1 BD
 Ignition switch malfunction
 PATS system malfunction
Microsoft
Microsoft

BEEN RECORDED
 No
recorded?
Yes
INSPECT ALL OTHER PATS DTCs Yes Go to the next step.
 Repair all other PATS DTCs before
P0689. (See IMMOBILIZER SYSTEM
COMPONENT REPLACEMENT/KEY
(See IMMOBILIZER SYSTEM
ADDITION AND CLEARING
[ADVANCED KEYLESS SYSTEM] .)
3
(See IMMOBILIZER SYSTEM No
COMPONENT REPLACEMENT/KEY COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING ADDITION AND CLEARING
[KEYLESS ENTRY SYSTEM] .) [KEYLESS ENTRY SYSTEM] .)
Have all other PATS DTCs been

diagnosed?
CONNECTION
Yes
 Step 7.

damaged, pulled-out pins, corrosion). No Go to the next step.
INSPECT BATTERY POSITIVE CIRCUIT

FOR OPEN CIRCUIT Yes Go to the next step.

 Measure the voltage between PCM Repair or replace suspected part, then go to
terminal 1BD (wiring harness-side) and No
Step 7.
body ground.
Microsoft

OPERATION

 Pushed out pins

6
 Corrosion

verify that they seat correctly. No The system is correctly. Go to the next step.

present?

7 using the M-MDS.
present?
Yes
DTC P0690 [MZI-3.7]

DTC P0690 ECM/PCM power relay sense circuit high
DETECTION  This DTC sets when the passive anti theft system (PATS) system indicates the key
CONDITION is in the OFF, ACC, or LOCK position and the ignition switch position run circuit
indicates ON or START position.
 Short to power supply between battery positive terminal and PCM terminal 1BD
POSSIBLE
CAUSE  PATS system malfunction
 Ignition switch malfunction
Microsoft
Microsoft

BEEN RECORDED
 No
recorded?
Yes
P0690. (See IMMOBILIZER SYSTEM
3
(See IMMOBILIZER SYSTEM No
COMPONENT REPLACEMENT/KEY COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING ADDITION AND CLEARING
[KEYLESS ENTRY SYSTEM] .) [KEYLESS ENTRY SYSTEM] .)

diagnosed?
INSPECT IGNITION SWITCH POSITION
RUN CIRCUIT SHORT TO POWER
Yes
Step 6.
 Measure the voltage between PCM
terminal 1BD (wiring harness-side) and

OPERATION
5
 Pushed out pins
 Corrosion

Microsoft

present?


using the M-MDS. [MZI-3.7] .)
6
using the M-MDS.
present?
Yes
DTC P1000 [MZI-3.7]

DTC P1000 OBD-II systems readiness test not complete
DETECTION
 P1000 indicates that the OBD-II monitor testing is not complete.
CONDITION
 The vehicle is new from the factory and has not yet completed an OBD-
II Drive Cycle.
 The battery or the PCM has been disconnected.
POSSIBLE CAUSE  OBD-II monitor malfunction had occurred before completion of an
OBD-II Drive Cycle.
 The PCM DTCs have been cleared with an M-MDS tester as part of a
service process.
Microsoft

BEEN RECORDED
 No
recorded?
Yes

next step.
DTC P1000: INSPECT FOR OTHER DTCS
 This test should be used only if DTC

P1000 was received in Continuous
Memory. Ignore any DTC P1000s in Repair other DTCs. Go to the applicable DTC
Yes
KOEO or KOER. Troubleshooting.
3 NOTE:
 DTC P1000 indicates that all of
the OBD-II monitors have not
yet been successfully tested to
clear DTC P1000.
 Were any other DTCs received with
P1000?
Perform the Drive Mode.
Yes
(See OBD-II DRIVE MODE [MZI-3.7].)
REQUEST TO CLEAR DTC P1000
Inform customer that if the law in the state
4 requires additional driving in order to clear
 Has the customer requested DTC P1000
be cleared from the PCM memory? No DTC P1000 from the PCM memory, it must be
performed before an inspection maintenance
test.
Yes
DTC P1001 [MZI-3.7]

Microsoft
DTC P1001 KOER not able to complete, KOER aborted

 P1001 indicates any of the following
 Unable to access Continuous Memory DTCs.
 Unable to activate KOEO or KOER Self-Test.
DETECTION CONDITION
 M-MDS tester communication problem.
 DTC displayed by M-MDS tester not listed.
 KOER Self-Test cannot be completed.
 Damaged DLC-2.
 Incorrect Self-Test procedure.
 VREF is not in specification.
POSSIBLE CAUSE  Idle RPM out of specification.
 Open in DLC-2 wiring harness circuit.
 Short in DLC-2 circuit or associated modules.
 Damaged PCM power relay circuit

BEEN RECORDED
recorded?
availability. step.

OR STORED DTCs
Yes

Microsoft
OPERATION


4  Corrosion

present?


3.7] .)

present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P1101 [MZI-3.7]

DTC P1101 MAF sensor out of self-test range
 The MAF sensor circuit is monitored by the PCM for an out of range air flow (or
DETECTION voltage) input. If, during KOEO, the air flow voltage signal is more than 0.27 V with
CONDITION the ignition switch in the ON position (Engine off). Likewise, the test fails if the
airflow voltage signal is not within 0.46 to 2.44 V with the ignition switch in the ON
position (Engine running) (KOER).
 Low battery charge

Microsoft
 Open circuit wiring harness between MAF sensor terminal B (wiring harness-side) and
body ground
POSSIBLE  Open circuit wiring harness between MAF sensor terminal C (wiring harness-side) and
CAUSE PCM terminal 1AJ (wiring harness-side)

Microsoft

BEEN RECORDED
 repair order, then go to next step.
recorded?
Yes

 If vehicle is not repaired, go to next
availability.
step.
Yes
TABLE [MZI-3.7].)
stored DTCs.
INSPECT MAF SIGNAL SENT TO PCM

Perform the "INTERMITTENT CONCERN
Yes
4 position (Engine running).
 Access MAF PID using the M-MDS
 Is the voltage between 0.46-2.44 V
INSPECT MAF SENSOR AND PCM

CONNECTOR FOR POOR
CONNECTION
Yes
Step 10.
5  Disconnect the MAF/IAT sensor and
PCM connector.
INSPECT MAF SENSOR GROUND



6
 Inspect continuity between MAF sensor
terminal B (wiring harness-side) and No
Step 10.
body ground.
INSPECT MAF SENSOR SIGNAL

Microsoft

 Inspect continuity between MAF sensor
terminal C (wiring harness-side) and
7 PCM terminal 1AJ (wiring harness- Repair or replace suspected part, then go to
No
side). Step 10.
INSPECT MAF SENSOR
Replace the MAF/IAT sensor, then go to Step
Yes
Inspect the MAF sensor. (See MASS
 10.
8 AIR FLOW (MAF) SENSOR

OPERATION

 Pushed out pins

9
 Corrosion


present?

3.7] .)
10
 Start engine.
 Perform "KOEO/KOER self-test" (See


Yes
Microsoft
DTC P1127 [MZI-3.7]

DTC P1127 Exhaust temperature out of range, HO2S tests not completed
DETECTION  The HO2S monitor uses an exhaust temperature model to determine when the
CONDITION HO2S heaters are cycled ON. The test fails when the inferred exhaust
temperature is below a minimum calibrated value.
POSSIBLE  Engine not operating long enough prior to carrying out the KOER self-test
CAUSE  Exhaust system too cool

BEEN RECORDED
recorded?
Yes

EXHAUST TEMPERATURE OUT OF
RANGE
Perform the KOER self-test, then go to the next
NOTE: Yes step. (See KOEO/KOER SELF TEST [MZI-
3.7].)
 Address all other DTCs before
proceeding.
3
position (Engine running) Run the engine until the PID indicates ON.
 Verify that the engine is at normal Perform the KOER self-test, then go to the next
No
operating temperature. step.
 Access the PCM and monitor the (See KOEO/KOER SELF TEST [MZI-3.7].)
HO2S heater PID.
 Is the PID state ON?
Microsoft


Replace PCM, then go to the next step. (See
 Clear DTC from memory using M-
MDS. 3.7] .)
4  Start engine.
 Perform "KOEO/KOER self-

test" (See KOEO/KOER SELF
VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P115E [MZI-3.7]

DTC P115E Throttle actuator control throttle body air flow trim at max limit
 During idle, the PCM monitors the throttle angle and air flow. If the air flow is
DETECTION determined to be less than expected, the PCM adjusts the throttle angle to
CONDITION compensate. The air flow reduction is typically the result of sludge buildup
around the throttle plate. This DTC indicates the PCM has reached the maximum
allowed compensation and is no longer able to compensate for the build up.
POSSIBLE
CAUSE  Sludge around the throttle plate

BEEN RECORDED
recorded?
INFORMATION AVAILABILITY Yes
 Verify related Service Bulletins available Service Bulletins.
Microsoft
and/or on-line repair information  If the vehicle is not repaired, go to the next
availability. step.
2
INSPECT FOR OTHER POWERTRAIN
DTCs Yes Go to the next step.
3 Repair all other powertrain DTCs


before P115E.
 Have all other powertrain DTCs been
No Go to the appropriate DTC Troubleshooting.
diagnosed?
INSPECT THROTTLE BODY
Yes Replace the throttle body. Then go to the Step 6.
 Remove the air duct from the throttle
4 valve body.
 Check around the throttle plate for Clean the throttle plate and throttle valve body.
No
sludge. Then go to the next step.
 Is the throttle valve normal?
PERFORM KOER SELF-TEST

 Yes Replace the throttle body then go to the step.

present?
DTC P115E HAS BEEN COMPLETED


3.7] .)

present?
VERIFY AFTER REPAIR
PROCEDURE
Microsoft
 Perform "AFTER REPAIR Go to the applicable DTC inspection. (See DTC

PROCEDURE". (See AFTER Yes
TABLE [MZI-3.7].)
7 REPAIR PROCEDURE [MZI-
3.7].)
DTC P1260 [MZI-3.7]

DTC P1260 Theft detected, vehicle immobilized
DETECTION Indicates that the RATS determined a theft condition existed and the engine is
CONDITION disabled. This DTC is a good indicator to check the PATS for DTCs.
 Previous theft condition
POSSIBLE CAUSE  Anti-theft system failure Theft indicator flashing rapidly or on solid when the
ignition switch is in the ON position.
 Check the anti-theft system for DTCs.

HAS BEEN RECORDED
recorded?
availability. step.

P1260.

COMPONENT
REPLACEMENT/KEY (See IMMOBILIZER SYSTEM
ADDITION AND CLEARING COMPONENT REPLACEMENT/KEY
Microsoft
[ADVANCED KEYLESS ADDITION AND CLEARING [ADVANCED

SYSTEM] .) KEYLESS SYSTEM] .)
(See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY
COMPONENT ADDITION AND CLEARING [KEYLESS
3 REPLACEMENT/KEY No ENTRY SYSTEM] .)


diagnosed?
INSPECT FOR OTHER
POWERTRAIN DTCs Yes Go to the next step.
4  Repair all other powertrain DTCs

before P1260.
 Have all other powertrain DTCs No Go to the appropriate DTC troubleshooting.
been diagnosed?
No system malfunctions exists at this time.
For intermittent No Starts or Start Stalls, verify
intermittent PATS faults.
Then go to the next step.
NOTE:
ATTEMPT TO START ENGINE
 PATS cannot stall the engine after 1
 Complete the keep alive memory. second of operation. For intermittent
Stalls while driving, verify the M-MDS
 Reset to clear DTC 1260. Yes tester to PCM communication during
5 concern. If a PCM communication error
 This reset initializes the PCM to
occurs, possible causes are:
communicate with the PATS.
 Loss of PWRS or grounds to the
 Attempt to start the engine. PCM.
 Does the engine start?  Malfunctioning PCM PWR relay.
 Malfunctioning EEC PWR diode.
 Repair if necessary and return the vehicle

to customer.
DTC P1260 is not the cause of the No Start. (See
No
QUICK DIAGNOSTIC CHART [MZI-3.7] .)
6  Verify that all disconnected Yes PCM REMOVAL/INSTALLATION [MZI-
connectors are reconnected. 3.7] .)
Microsoft
Clear the DTC from the PCM



DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P1285, P1299 [MZI-3.7]

DTC P1285 P1285: Cylinder head over temperature condition
DCT P1299 P1299: Cylinder head over temperature protection active
 P1285 indicates that an engine overheat condition was sensed by the
CHT sensor.
DETECTION
CONDITION  P1299 indicates that an engine overheat condition was detected by the
CHT sensor.
 Fail-safe function was activated to cool the engine.
 Base engine malfunction
POSSIBLE CAUSE
 Engine cooling system malfunction

RECORDED Record FREEZE FRAME DATA on
1
No the repair order, then go to the next
 Has FREEZE FRAME DATA been recorded? step.
VERIFY RELATED REPAIR INFORMATION Perform repair or diagnosis according
AVAILABILITY to the available Service Bulletins.
2 Yes
 Verify related Service Bulletins and/or on-line  If the vehicle is not repaired, go
Microsoft
repair information availability. to the next step.

INSPECT COOLING SYSTEM
WARNING:
engine is running, or when the engine and Yes Go to the next step.
and steam may shoot out and cause serious
injury. It may also damage the engine and
cooling system.
 Turn off the engine and wait until it is cool.
Even then, be very careful when removing
slowly turn it counterclockwise to the first
stop. Step back while the pressure escapes.
 When you are sure all the pressure is gone,
press down on the cap using the cloth, turn
3 it, and remove it.
NOTE:
 If the electric cooling fan does not operate,
go to the applicable DTC inspection. (See
DTC TABLE [MZI-3.7].) Repair if necessary. Then go to the next
No
step.
An engine overheat condition is sensed by the

CHT sensor.
 Check the cooling system for:
 Correct coolant level
 Internal or external coolant leaks
 Blockage of the radiator
 Cooling fan operation
 Is the cooling system normal?
INSPECT OPERATION OF THE CHT SENSOR

 Run the engine until the engine temperature
stabilizes.
4  Verify the radiator hoses are hot and the An engine overheat temperature was
cooling system is pressurized. No not detected. Repair any other DTCs if
 Verify self-test DTCs. necessary.
 Is DTC P1285 present?
INSPECT CHT SENSOR Replace the CHT sensor, then go to the

Microsoft
Inspect the CHT sensor. (See CYLINDER

 Yes next step.
HEAD TEMPERATURE (CHT) SENSOR
5
INSPECTION [MZI-3.7] .) No Go to the next step.
VERIFY TROUBLESHOOTING OF DTC P1285,


 Replace the PCM, then go to the next
reconnected. step. (See PCM
Yes
 Turn the ignition switch to the ON position REMOVAL/INSTALLATION [MZI-
6 (Engine off). 3.7] .)
the M-MDS.

 Is the PENDING CODE for this DTC present?

Yes
DTC P1288 [MZI-3.7]

DTC P1288 CHT sensor out of self-test range
DETECTION  Indicates the CHT sensor is out of self-test range. The engine is not at a
CONDITION normal operating temperature.
 Cold engine
 Engine overheating
POSSIBLE CAUSE  Connector or terminal malfunction

Yes Go to next step.
BEEN RECORDED
Microsoft

 Record FREEZE FRAME DATA on the repair
1 No
recorded? order, then go to next step.
Yes


Yes
TABLE [MZI-3.7].)
stored DTCs.
INSPECT THE COOLING SYSTEM Yes Go to the next step.

4 Inspect the vehicle coolant level.
 Inspect the cooling system (overheat), the go
No
 Is the cooling system normal?
to Step 7.
INSPECT CHT SENSOR
Yes Replace the CHT sensor, then go to Step 7.
Inspect the CHT sensor. (See

5 CYLINDER HEAD

OPERATION

 Pushed out pins
6
 Corrosion

present?
Yes
 Verify that all disconnected connectors Replace the PCM, then go to the next step.
reconnected. (See PCM REMOVAL/INSTALLATION
Microsoft
Clear the DTC from the PCM memory


[MZI-3.7] .)
using the M-MDS.
7 using the M-MDS. (See KOEO/KOER
present?
Yes
DTC P1289 [MZI-3.7]

DTC P1289 CHT sensor circuit high input
DETECTION
 Indicates a CHT sensor circuit open.
CONDITION
 Open circuit in wiring harness between CHT sensor terminal A and PCM
terminal 2AL
 Open circuit in wiring harness between CHT sensor terminal B and PCM
terminal 2AN
POSSIBLE CAUSE
 Short to power supply in wiring harness between CHT sensor terminal B and
PCM terminal 2AN
Microsoft

BEEN RECORDED
recorded?
Microsoft

2
INSPECT POOR CONNECTION OF CHT
SENSOR CONNECTOR
Yes
 Step 8.
3  Disconnect CHT sensor connector.

INSPECT CHT SENSOR SIGNAL

Yes
Step 8.

 Measure the voltage between CHT
sensor terminal B (wiring harness-side)

POOR CONNECTION Repair or replace suspected part, then go to
Yes
Step 8.

INSPECT CHT SENSOR CIRCUIT FOR

OPEN CIRCUIT
 Inspect the continuity between the
following circuit:
 CHT sensor terminal A (wiring
6 harness-side) and PCM terminal
2AL (wiring harness-side). Repair or replace suspected part, then go to
 CHT sensor terminal B (wiring
No
Step 8.
2AN (wiring harness-side).
INSPECT CHT SENSOR

Microsoft

 Replace the CHT sensor, then go to the next
Yes
CYLINDER HEAD step.
7 TEMPERATURE (CHT) SENSOR


 Clear the DTC from the PCM memory Yes (See PCM REMOVAL/INSTALLATION
8  Perform the KOEO or KOER self-test
using the M-MDS.

[MZI-3.7].)

present?
Yes
DTC P1290 [MZI-3.7]

DTC P1290 CHT sensor circuit low input
DETECTION
 Indicates a CHT sensor circuit short to ground.
CONDITION
 Short to ground in wiring harness between CHT sensor terminal B and PCM
terminal 2AN
POSSIBLE CAUSE
Microsoft

BEEN RECORDED
recorded?
Microsoft

2
INSPECT TERMINAL BENT
Repair or replace the terminal, then go to Step
 Yes
6.
3  Disconnect the CHT sensor connector.
 Inspect for bent of CHT sensor

terminals A and B (part-side).
INSPECT CHT SENSOR SIGNAL

Yes

Step 6.
4
 Inspect for continuity between CHT
sensor terminal B (wiring harness-side)
INSPECT CHT SENSOR

Replace the CHT sensor, then go to the next
 Yes
step.
5 CYLINDER HEAD

6 using the M-MDS.
present?
VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. (See

Yes
7 DTC TABLE [MZI-3.7].)
Microsoft
DTC P1336 [MZI-3.7]

DTC P1336 CKP/CMP sensor range/performance
DETECTION  The input signal to the PCM from the CKP sensor or the CMP sensor
CONDITION is erratic.
POSSIBLE CAUSE
 Base engine malfunction

BEEN RECORDED
recorded?
availability. step.

OR STORED DTC Go to appropriate DTC inspection. (See DTC
Yes
TABLE [MZI-3.7].)
3  Verify the related PENDING CODE
or stored DTCs.
INSPECT THE CKP SENSOR SIGNAL

SENT TO THE PCM
4 Yes Go to Step 8.
NOTE:
 The battery should be fully
charged and the starting system
Microsoft
should be functioning properly.
Connect the M-MDS to the DLC-2.


 Access RPM PID.
 Is the reading more than 150 rpm?
INSPECT THE FRONT COVER, CKP

SENSOR AND CKP SENSOR PULSE
WHEEL FOR OBVIOUS PHYSICAL Yes Repair if necessary, then go to Step 11.
DAMAGE


 Visually inspect the front cover,

CKP sensor and CKP sensor pulse
wheel for obvious physical damage. No Go to the next step.
 Do any parts appear physically
damaged?
INSPECT CKP SENSOR
CONNECTOR FOR POOR
Yes
11.
6  Disconnect the CKP sensor
connector.
INSPECT CKP SENSOR

Replace the CKP sensor, then go to Step 11. (See
 Inspect the CKP sensor. (See Yes CRANKSHAFT POSITION (CKP) SENSOR
7 CRANKSHAFT POSITION REMOVAL/INSTALLATION [MZI-3.7] .)
(CKP) SENSOR INSPECTION
[MZI-3.7] .)
INSPECT CMP SENSOR
CONNECTOR FOR POOR
Yes
11.
8  Disconnect the CMP sensor
connector.
INSPECT CMP SENSOR

Microsoft
Inspect the CMP sensor. (See

 Replace the CMP sensor, then go to Step 11. (See
CAMSHAFT POSITION (CMP) Yes CAMSHAFT POSITION (CMP) SENSOR
9 SENSOR INSPECTION [MZI- REMOVAL/INSTALLATION [MZI-3.7] .)
3.7] .)

POOR CONNECTION Repair or replace suspected part, then go to the
Yes
next step.
10 Disconnect the PCM connector.


 Are any malfunction?
 Yes PCM REMOVAL/INSTALLATION [MZI-
11 disconnected connectors. 3.7] .)
VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P1397 [MZI-3.7]

DTC P1397 System voltage out of self-test range
 This DTC indicates that the 12-volt system voltage is too high or too low
DETECTION during the KOEO or KOER self-test. It sets if the system voltage falls below or
CONDITION exceeds the calibrated threshold at any time during the KOEO or KOER self-
test.
POSSIBLE
CAUSE  Battery or charging system concern.
Microsoft

BEEN RECORDED
recorded?
Yes
Inspect charging system. (See QUICK
INSPECT THE BATTERY DIAGNOSTIC CHART [MZI-3.7] .)
 Turn the ignition switch off. Yes

3 If there is any malfunction, repair or

 Inspect the battery. replace malfunctioning part, then go to

 Is the battery normal? the next step.
No Replace the battery, then go to the next step.


reconnected.
4 using the M-MDS.
3.7].)
present?
Yes
DTC P1450 [MZI-3.7]

Microsoft
DTC P1450 Unable to bleed up fuel tank vacuum

DETECTION  P1450 indicates the Self-Test has detected that the EVAP system is unable to
CONDITION bleed up fuel tank vacuum.
 Blockages or kinks in the charcoal canister tube or purge solenoid valve
outlet tube (between fuel tank, CV solenoid valve and charcoal canister).
 Fuel filler cap is stuck closed (no vacuum relief).
 Contaminated fuel vapor elbow on charcoal canister.
 Restricted charcoal canister.
POSSIBLE CAUSE  CV solenoid valve stuck open (partially or fully).
 Plugged CV solenoid valve filter.
 CV solenoid valve is stuck open.
 Power supply open (wiring harness near Fuel tank pressure sensor, Fuel tank
pressure sensor or PCM).

HAS BEEN RECORDED
recorded?
availability. step.

OR STORED DTCs
Yes
INSPECT FOR VISUAL CAUSES OF

EXCESSIVE FUEL TANK VACUUM
Microsoft
Verify kinks or bends in the fuel


vapor hoses and tubes. Remove any contamination or foreign material
 Visually inspect the charcoal
around fuel vapor hoses and tubes.
Yes
canister inlet port, CV solenoid Repair the hoses, tubes or components if
4 necessary. Go to Step 9.
valve, EVAP dust separator or the
outlet hose for contamination or
foreign material.
 Is a concern evident?
PERFORM EVAP LEAK TEST Yes Go to the next step.
Connect the EVAP Leak Tester to


the fuel filler pipe. Check to see if the CV solenoid valve is stuck
open. Replace if necessary.
 Close the purge solenoid valve using
5 (See CHARCOAL CANISTER, CANISTER
the EVMV PID. No VENT (CV) SOLENOID VALVE, AIR
 Pressurize the EVAP system to 3.48 FILTER COMPONENT
kPa (PID FTP_H2O displays "14"). REMOVAL/INSTALLATION [MZI-3.7] .)
 Does the pressure reach 3.48 kPa Go to Step 9.
(PID FTP_H2O displays "14")?
INSPECT WHETHER CV SOLENOID Yes Go to the next step.
VALVE IS STUCK CLOSED Check to see if the CV solenoid valve is stuck
closed. Replace if necessary.
6  Open the purge solenoid valve using
(See CHARCOAL CANISTER, CANISTER
the EVMV PID. No VENT (CV) SOLENOID VALVE, AIR
FILTER COMPONENT
 Does the pressure drop
immediately? Go to Step 9.
INSPECT FOR FUEL TANK
PRESSURE SENSOR PID WITHOUT Yes Go to the next step.
PRESSURE APPLIED
 Disconnect the charcoal canister

outlet tube at the charcoal canister.
7  Using M-MDS tester, select Replace the evaporative hose component.
Diagnostic Data Link. (See FUEL TANK PRESSURE SENSOR
No
 Select PCM. INSPECTION [MZI-3.7] .)
 Select Active Command Modes. Go to the next step.
 Access FTP V PID and record the
reading.
 Is the reading between 2.40 to 2.80
V?
Microsoft
Connect all disconnected connectors Yes Go to the next step.


and hoses.
 Perform the EVAP system leak test.
8 (See ENGINE CONTROL Leakage still exists. Locate leak point and repair.
SYSTEM OPERATION No
Repeat this step.


 Start the engine and the perform
"EVAP system monitor drive cycle"
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
10 PROCEDURE".
 (See AFTER REPAIR
PROCEDURE [MZI-3.7].) No Troubleshooting completed.
DTC P145E [MZI-3.7]

DTC P145E PCV heater control circuit
DETECTION
 This DTC sets when the PCM detects a PCV valve heater circuit malfunction.
CONDITION
 Open circuit between PCV valve heater control terminal A and main relay
No.1
 Open circuit between PCV valve heater fitting terminal A and main relay
No.1
 Short to ground circuit between PCV valve heater control terminal B and
PCM terminal 2BL
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 Short to ground circuit between PCV valve heater fitting terminal B and PCM
terminal 2AU
 Open circuit between PCV valve heater control terminal B and PCM terminal
2BL
POSSIBLE CAUSE
 Open circuit between PCV valve heater fitting B and PCM terminal 2AU
 PCV valve heater control malfunction
 PCV valve heater fitting malfunction
Microsoft
Microsoft

BEEN RECORDED
recorded?
Yes
FITTING CONNECTOR FOR POOR
CONNECTION Repair or replace suspected part, then go to
Yes
Step 9.
3
 Disconnect PCV valve heater control and
PCV valve heater fitting connector.

INSPECT POWER SUPPLY CIRCUIT

FOR OPEN CIRCUIT
 Inspect the voltage between the following
circuit:
4
A (wiring harness-side) and body
ground Repair or replace suspected part, then go to
No
Step 9.
 PCV valve heater fitting terminal A
ground
GROUND
Microsoft



following circuit: Yes
Step 9.
5 B (wiring harness-side) and body

ground
ground

CONNECTION
Yes
6 Disconnect PCM connector.


damaged/pulled-out pins, corrosion). No Go to the next step

FITTING FOR OPEN CIRCUIT Yes Go to the next step.

following circuit:
7  PCV valve heater control terminal
B (wiring harness-side) and PCM
terminal 2BL (wiring harness-side) Repair or replace suspected part, then go to
No
 PCV valve heater fitting B (wiring Step 9.
2AU (wiring harness-side)

FITTING
 Inspect the PCV valve heater control and Yes Replace the malfunctioning part, then go to
PCV valve heater fitting. the next step.
8


Microsoft

HEATER FITTING INSPECTION



P145E HAS BEEN COMPLETED

9 using the M-MDS.
present?
Yes
DTC P1464 [MZI-3.7]

DTC P1464 A/C demand out of self-test range
DETECTION  The DTC sets when the PCM receives a request for A/C during the
CONDITION self-test.
 A/C or defrost on during self-test
 A/C relay circuit short to voltage
POSSIBLE CAUSE
 A/C switch malfunction
 A/C relay malfunction

BEEN RECORDED
1
No
Microsoft

Yes

VERIFY A/C AND DEFROST ARE OFF
DURING SELF-TEST
Perform the "KOEO/KOER self-test".

3 (See KOEO/KOER SELF TEST
[MZI-3.7].)
No Turn the A/C and defrost off. Then go to Step 5.
 Are the A/C and defrost off during the
self-test?
INSPECT ACCS PID The ACCS PID indicates that the PCM is being
requested to turn on the A/C. Inspect the A/C
 Turn the ignition switch to the ON system.
(See DIAGNOSTIC TROUBLE CODE
4  A/C and defroster OFF. NUMBER INSPECTION .) Then go to the
 Access the PCM and monitor the
next step.
ACCS PID. The ACCS PID indicates that the ACCS input to
No
 Is the PID state ON? the PCM is low. Go to the next step.


reconnected.
5 using the M-MDS.
3.7].)
present?
Yes
Microsoft
DTC P1500 [MZI-3.7]

DTC P1500 Vehicle speed signal
DETECTION  Indicates the VSS input signal was intermittent. This DTC is set when a VSS
CONDITION concern interferes with other OBD tests, such as the catalyst efficiency
monitor, the EVAP monitor, or the HO2S monitor.
 Intermittent sensor connections
POSSIBLE  Intermittent open in the sensor wiring harness circuit(s)
CAUSE  Intermittent short in the sensor wiring harness circuit(s)
 Sensor malfunction

BEEN RECORDED
recorded?
Yes
next step.
VERIFY STORED DTC IN DSC/RSC
HU/CM
Go to the appropriate DTC inspection. (See ON-
Yes
BOARD DIAGNOSIS [DSC/RSC] .)
 Verify stored DTCs in DSC/RSC
HU/CM. No Go to the next step.
 Are DTCs stored?
 Verify that all disconnected Yes PCM REMOVAL/INSTALLATION [MZI-
connectors reconnected. 3.7] .)
using the M-MDS.
Microsoft

test" using the M-MDS.
4 (See KOEO/KOER SELF TEST No Go to the next step.

[MZI-3.7].)


present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P1501 [MZI-3.7]

DTC P1501 Vehicle speed sensor (VSS) out of self-test range
DETECTION  Indicates that the vehicle speed input signal is out of the self-test range. If the
CONDITION PCM detects a vehicle speed input signal any time during the self-test, DTC
P1501 is set and the test aborts.
 Noise on the vehicle speed input signal from radio frequency
POSSIBLE interference/electro magnetic interference
CAUSE  External sources, such as ignition wires, the charging circuit, or aftermarket
equipment

BEEN RECORDED
recorded?
Yes
2  If the vehicle is not repaired, go to the
 Verify related Service Bulletins and/or
next step.
 Is any related Service Bulletins No Go to the next step.
Microsoft
available?
VERIFY STORED DTC IN DSC/RSC
HU/CM
Go to the appropriate DTC inspection. (See
Yes

 Verify stored DTCs in DSC/RSC
HU/CM. No Go to the next step.
 Are DTCs stored?


reconnected.
4 using the M-MDS.
3.7].)
present?
Yes
DTC P1633 [MZI-3.7]

DTC P1633 Keep alive power voltage too low
DETECTION CONDITION  Indicates the keep alive power circuit has experienced a voltage
interrupt.
POSSIBLE CAUSE  Open circuit between battery positive terminal and PCM terminal 1
BB
Microsoft

1
VERIFY FREEZE FRAME DATA HAS No
BEEN RECORDED Record FREEZE FRAME DATA on the repair
Microsoft


recorded?
Yes

next step.
INSPECT BATTERY TERMINAL AND
PCM CONNECTOR FOR POOR
CONNECTION
Yes
Step 5.
3  Disconnect battery terminal and PCM
connector.
INSPECT KEEP ALIVE POWER


 Disconnect battery cables.
 Check continuity between battery

positive terminal (harness-side) and No
next step.
PCM terminal 1BB (wiring harness-
side).

 Make sure to reconnect all Yes PCM REMOVAL/INSTALLATION [MZI-
5 disconnected connectors. 3.7] .)
using the M-MDS.

6 Yes
Microsoft

DTC P1635 [MZI-3.7]

DTC P1635 Tire/axle out of acceptable range
DETECTION  This DTC indicates the tire and axle information contained in the vehicle
CONDITION identification block does not match the vehicle hardware.
 Incorrect tire size
POSSIBLE CAUSE  Incorrect axle ratio
 Incorrect vehicle identification configuration parameters

BEEN RECORDED
recorded?
2 and/or on-line repair information  If vehicle is not repaired, go to the next
availability. step.

VERIFY VEHICLE IDENTIFICATION
TIRE DATA Yes Go to the next step.


3 position. Perform PCM configuration procedure, then go
 Connect the M-MDS to the DLC-2. No to Step 5. (See PCM CONFIGURATION
 Access the data of the tire size.
[MZI-3.7] .)
 Is it the same as a equipped tire?
VERIFY GENUINE TIRES ARE Yes Go to the next step.

INSTALLED
4 Change to the genuine tire, then go to the next
No
 Is genuine tires are equipped? step.
Microsoft

3.7] .)
 Clear DTC from PCM memory using
M-MDS.
 Start engine and warm up it
VERIFY AFTER REPAIR

PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P1639 [MZI-3.7]

DTC P1639 Vehicle ID block corrupted, that not programmed
DETECTION  This DTC indicates that the VID block is not programmed or the
CONDITION information within is corrupt.
 New PCM
POSSIBLE CAUSE  Incorrect PCM
 Incorrect VID configuration

BEEN RECORDED
recorded?

Microsoft
 Verify related Service Bulletins and/or If the vehicle is not repaired, go to the
2  Is any related Service Bulletins Perform the PCM reprogramming procedure.
available? No (See PCM CONFIGURATION [MZI-3.7] .)


using the M-MDS.
 Start the engine and perform the
KOEO and KOER self-test.
present?
VERIFY AFTER REPAIR
Yes
TABLE [MZI-3.7].)
DTC P1650 [MZI-3.7]

DTC P1650 PSP switch out of self-test range
DETECTION  In the KOEO self-test, this DTC indicates the PSP input to the PCM is high. In the
CONDITION KOER self-test, this DTC indicates the PSP input did not change state.
 The steering wheel must be turned during KOER self-test
 PSP switch malfunction
POSSIBLE CAUSE
 Open circuit between PSP switch terminal A and PCM terminal 2I
 Short to ground circuit between PSP switch terminal A and PCM terminal 2I
Microsoft

BEEN RECORDED
recorded?
Yes
on-line repair information availability.  If vehicle is not repaired, go to next step.

Microsoft
INSPECT PSP SWITCH CONNECTOR

FOR POOR CONNECTION
Yes
Step 8.


INSPECT PSP SWITCH CIRCUIT FOR

SHORT TO GROUND
Yes

Step 8.
4
 Inspect for continuity between PSP
switch terminal A (wiring harness-side)

POOR CONNECTION
Yes
 Step 8.

INSPECT PSP SWITCH CIRCUIT FOR

 Inspect for continuity between PSP

6 switch terminal A (wiring harness-side)
and PCM terminal 21 (wiring harness- No Repair or replace suspected part, then go to
side) Step 8.

OPERATION
7  Visually inspect for:
 Pushed out pins
 Corrosion
 Connect all the PCM connectors and No The system is correctly. Go to the next step.
Microsoft
Is the PENDING CODE for this DTC


present?

 Start the engine. [MZI-3.7] .)
8
M-MDS.
 Perform the "KOEO/KOER Self-Test".

Yes
DTC P1674 [MZI-3.7]

DTC P1674 Control module software corrupted
DETECTION  Indicates that an error occurred in the PCM. This DTC is set in
CONDITION combination with P2105.
 Software incompatibility issue
POSSIBLE CAUSE
 PCM malfunction

HAS BEEN RECORDED
recorded?
Yes
Microsoft

  If the vehicle is not repaired, go to the next
2 availability. Perform the PCM reprogramming procedure. (See
 Is any related Service Bulletins No PCM CONFIGURATION [MZI-3.7] .)Then go
available? to the next step.


 Start the engine and perform the
KOEO and KOER self-test.
DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
DTC P1703 [MZI-3.7]

DTC P1703 Brake switch out of self-test range
DETECTION  Indicates that during the KOEO self-test, the brake pedal position signal was high,
CONDITION or during the KOER self-test, the BPP signal did not cycle high and low.
 Brake switch No.1 malfunction
POSSIBLE CAUSE
 Brake switch No.1 misinstallation
 Brake switch No.1 circuit malfunction
Microsoft

VERIFY FREEZE FRAME DATA Yes Go to next step.
HAS BEEN RECORDED
been recorded?
VERIFY RELATED REPAIR Yes Perform repair or diagnosis according to available

INFORMATION AVAILABILITY Service Bulletins.
Microsoft

  If vehicle is not repaired, go to next step.
availability.
2
 Is any related Service Bulletins No Go to next step.
available?
VERIFY THE BRAKE PEDAL WAS Yes Go to next step.
APPLIED
Perform the KOER self-test.
3 Apply and release the brake pedal during the KORE
 Was the brake pedal applied and No
released during the KOEO self- test, then go to Step 10 (See KOEO/KOER SELF
test? TEST [MZI-3.7].)
INSPECT THE OPERATION OF
THE BLAKE/TAILLIGHT Yes Go to next step.

4
 Depress and release the brake
pedal and check the blake/taillight No Repair or replace harness or blake/taillight, then go
operation. to Step 10.
 Do the blake/taillight operate
correctly?
INSPECT THE CRUISE CONTROL
OPERATION Yes Go to next step.
5 Check for cruise control


operation.
 Does the cruise control operate
correctly?
INSPECT BRAKE SWITCH AND
6  Disconnect the throttle body
connector.
as damaged/pulled-out pins, No Go to the next step.
corrosion).
INSPECT BRAKE SWITCH NO.1
CIRCUIT MALFUNCTION
Yes Go to next step.
Microsoft
PCM terminal 1T (wiring harness-

 Verify the following values when
the brake pedal to the floor and
releasing.
7 No Repair or replace suspected part, then go to Step 10.
 Brake pedal fully depressed:
more than 10 V
 Brake pedal fully released:
less than 1.0 V
 Is the voltage normal?
INSPECT BRAKE SWITCH

 Inspect the brake switch. (See
8 BRAKE SWITCH

OPERATION
Disconnect all the PCM

connectors.
9  Pushed out pins
 Corrosion
 Connect all the PCM connectors

and verify that they seat correctly. No The system is correctly. Go to the next step.

DTC present?
DTC P1703 HAS BEEN
COMPLETED
Replace the PCM, then go to next step. (See PCM
Yes
 Verify that all disconnected REMOVAL/INSTALLATION [MZI-3.7] .)
10 connectors reconnected.
 Clear DTC from memory using
M-MDS.
 Perform KOEO/KOER Self-Test.
No Go to next step.
 Is PENDING CODE same as
DTC present?
VERIFY AFTER REPAIR

PROCEDURE
Microsoft
 Perform "AFTER REPAIR Go to the applicable DTC inspection. (See DTC

PROCEDURE". Yes
TABLE [MZI-3.7].)
11 (See AFTER REPAIR
DTC P2100 [MZI-3.7]

DTC P2100 Throttle actuator circuit open
DETECTION
 A PCM malfunction flag is set indicating the motor circuit is open.
CONDITION
 Throttle actuator malfunction
 Open circuit wiring harness between throttle body terminal A and PCM
terminal 2BO
 Short to power supply in wiring harness between throttle body terminal A and
POSSIBLE CAUSE PCM terminal 2BO
 Open circuit wiring harness between throttle body terminal B and PCM
terminal 2BR
 Short to power supply in wiring harness between throttle body terminal B and
PCM terminal 2BR
 Throttle actuator circuits are shorted each other
Microsoft

HAS BEEN RECORDED
recorded?
2 Yes available Service Bulletins.
 Verify related Service Bulletins
Microsoft
availability. step.
INSPECT THROTTLE BODY
CONNECTOR FOR POOR
CONNECTION

3  Disconnect the throttle body
connector.
corrosion).
INSPECT THE THROTTLE

ACTUATOR Replace the throttle body, then go to Step 9. (See
Yes INTAKE-AIR SYSTEM
4  Inspect the throttle actuator. (See REMOVAL/INSTALLATION [MZI-3.7] .)
THROTTLE BODY
POOR CONNECTION

corrosion).
INSPECT THROTTLE ACTUATOR

CONTROL CIRCUIT FOR OPEN
 Throttle body terminal A and
PCM terminal 2BO
 Throttle body terminal B and No Repair or replace suspected part, then go to Step 9.
PCM terminal 2BR
Microsoft
CIRCUITS FOR SHORT EACH

OTHER

 Disconnect the throttle body and

7 PCM connector.
 Measure resistance between throttle
body terminal A and B.
kilohms?
INSPECT HROTTLE ACTUATOR
TO POWER SUPPLY
Repair or replace suspected part, then go to the next
Turn the ignition switch to the ON Yes

step.
 Throttle body terminal A and
body ground.
 Throttle body terminal B and
body ground.

9  Perform the KOEO or KOER self-
test using the M-MDS.

[MZI-3.7].)
DTC present?
VERIFY AFTER REPAIR
Yes
10 TABLE [MZI-3.7].)
Microsoft
3.7].)
DTC P2101 [MZI-3.7]

DTC P2101 Throttle actuator circuit range/performance
DETECTION  A PCM malfunction flag is set indicating the motor circuit is open, and may
CONDITION require cycling the key.
POSSIBLE CAUSE  Throttel actuator circuit are cross-wired
Microsoft

BEEN RECORDED
recorded?
Yes
OR STORED DTCs FOR ALL OF
VEHICLE MODULE Go to the appropriate DTC troubleshooting. (See
Yes
3  Turn the ignition switch off then to the
INSPECT THROTTLE BODY AND

CONNECTION
Yes
6.
4  Disconnect the throttle body and PCM
connector.

OPERATION
5
 Pushed out pins
 Corrosion
 Connect all the PCM connectors and No The system is correctly. Go to the next step.
Microsoft


present?

 Start the engine. 3.7] .)
6
M-MDS.
 Perform the "KOEO/KOER Self-
Test". (See KOEO/KOER SELF
VERIFY AFTER REPAIR

Yes
TABLE [MZI-3.7].)
DTC P2104, P2105, P2106, P2110 [MZI-3.7]

DTC P2104 P2104: Throttle actuator control system - forced idle
DTC P2105 P2105: Throttle actuator control system - forced engine shutdown
DTC P2110 P2110: Throttle actuator control system - forced limited RPM
DETECTION
 The TAC system is in the failure mode effects management (FMEM) mode.
CONDITION
 This DTC is an informational DTC and may be set in combination with a
POSSIBLE CAUSE number of other DTCs which are causing the FMEM. Diagnose other DTCs
first.

BEEN RECORDED
recorded?
Microsoft

Yes
Verify related Service Bulletins and/or If the vehicle is not repaired, go to the

2 
next step.
Perform the PCM reprogramming procedure.
 Is any related Service Bulletins No (See PCM CONFIGURATION [MZI-3.7] .)
available? Then go to the next step.
STORED DTCs FOR ALL OF VEHICLE
MODULE Go to the appropriate DTC troubleshooting.
Yes
3 Turn the ignition switch off then to the

PERFORM VISUAL INSPECTION

 Isolate the concern and repair if necessary.
Yes
 Visually inspect the following for
Then go to Step 6.
4 obvious signs of damage:
 Throttle body
 PCM No Go to the next step.

INSPECT ACCELERATOR PEDAL

POSITION (APP) SENSOR
Repair or replace if necessary. Then go to the
Yes
 Perform the APP sensor inspection (See next step.
5 ACCELERATOR PEDAL POSITION
(APP) SENSOR INSPECTION [MZI-
3.7] .) No Go to the next step.
MISFIRE DTC HAS BEEN COMPLETED
are reconnected. Yes (See PCM REMOVAL/INSTALLATION
6 [MZI-3.7] .)
using the M-MDS.
 Perform the KOEO and KOER self test.
Microsoft



present?
Yes
DTC P2107 [MZI-3.7]

DTC P2107 Throttle actuator control module processor
DETECTION
 The throttle actuator control area of the PCM failed the self-test.
CONDITION
 Throttle actuator control circuits are shorted each other
 Short to power supply between throttle actuator terminal A and PCM
POSSIBLE CAUSE terminal 2BO
 Short to power supply between throttle actuator terminal B and PCM
terminal 2BR
 PCM malfunction
Microsoft

HAS BEEN RECORDED
recorded?
2 Yes available Service Bulletins.
 Verify related Service Bulletins
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availability. step.
INSPECT MAF SENSOR
CONNECTOR FOR POOR


connector.
corrosion).

TO POWER SUPPLY

 Measure voltage between the
4 following circuits:
 Throttle actuator terminal A
(wiring harness-side) and
body ground.
 Throttle actuator terminal B No Go to the next step.
body ground.

CONTROL CIRCUITS FOR SHORT
EACH OTHER Yes Go to the next step.
5  Disconnect the throttle body and
PCM connector.
 Measure resistance between throttle
actuator terminal A and B. No Repair or replace suspected part, then go to Step 8.
kilohms?
INSPECT THROTTLE ACTUATOR Replace the throttle body, then go to Step 8. (See
6 Yes INTAKE-AIR SYSTEM
 Inspect the throttle actuator. (See
Microsoft
THROTTLE BODY

OPERATION
Disconnect all the PCM connectors. Yes Go to the next step.


 Pushed out pins

7
 Corrosion
 Connect all the PCM connectors

and verify that they seat correctly.

DTC present?

 Start the engine. 3.7] .)
8
 Clear DTC from PCM memory
using M-MDS.
 Perform the "KOEO/KOER Self-
Test". (See KOEO/KOER SELF
VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P2111 [MZI-3.7]

DTC P2111 Throttle actuator control system - stuck open
DETECTION  This PCM fault status indicates the throttle plate is at a more angle than
CONDITION commanded.
Microsoft
 Binding throttle body, stuck open

 Throttle actuator control circuits are cross-wired
POSSIBLE CAUSE
 PCM malfunction

Microsoft

RECORDED
No
 Has FREEZE FRAME DATA been recorded?
Yes
2  Verify related Service Bulletins and/or on-line  If the vehicle is not repaired, go to
INSPECT THROTTLE POSITION OPEN
CIRCUIT AND CLOSED VOLTAGES

(Engine off). Yes Go to the Step 5.
 Access the PCM and monitor the TP1 and
TP2 PIDs.
3  Verify the following values of the PIDs when
depressing the accelerator pedal to the floor
and releasing.
 Pedal fully released: TP1 is 3.7-4.7 V
 Pedal fully released: TP2 is 0.3-1.9 V No Go to the next step.

 Pedal fully depressed: TP1 is 0.7-2.9 V
 Are both PIDs within the specification?
INSPECT FOR OBSTRUCTION OF

THROTTLE BODY
Yes Go to the Step 7.
WARNING:
 Substantial opening and closing torque is
applied by this system. To prevent injury,
be careful to keep fingers away from
throttle mechanism when actuated. Failure
4 to follow these instructions may result in
personal injury.
Isolate and repair the obstruction. Then

 Turn the ignition switch off. No
go to Step 9.
 Remove the air hose from the throttle body.
 Visually inspect for throttle plate obstructions
or sludge.
 Slowly, push the throttle plate to wide open
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and release.
 Does the throttle plate move freely to wide
open and back?
INSPECT TP SENSOR OPERATION


(Engine off).
TP2 PIDs.
 Slowly press the accelerator pedal from fully
5 released to fully depressed while observing

the voltage readings.
 Use the chart as a reference. Replace the throttle body. Then go to
No
 Inspect the TP sensor. (See THROTTLE Step 9.
POSITION (TP) SENSOR INSPECTION
[MZI-3.7] .)
 Do all signal values smoothly change when
the accelerator is depressed?
INTERMITTENT CONCERN Yes Go to the next step.
Access the PCM and monitor the TP1 and


6 TP2 PIDs.
Repair or replace suspected part, then go
 Wiggle, shake, and bend the wiring harness No
to Step 9.
from the TP to the PCM.
 Are the voltages between 0.49-4.65 V?

CONTROL MOTOR VISUALLY
NOTE:
Replace the throttle body. Then go to
 Make sure the throttle body connector is Yes
Step 9.
properly connected.
7
 Inspect the throttle actuator control motor for
damaged housing, wiring harness connector,
and wiring harness. No Go to the next step.
 Are there any concerns with the throttle
actuator control motor hardware?

CONTROL CIRCUITS FOR SHORT EACH Yes Go to the next step.
OTHER
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
 Disconnect the throttle body and PCM

connector. Repair or replace suspected part, then go
8 No
 Measure resistance between throttle actuator
to the next step.
terminal A and B.


step. (See PCM
 Clear the DTC from the PCM memory using Yes REMOVAL/INSTALLATION [MZI-
the M-MDS. 3.7] .)
9
 Perform the "KOEO or KOER self-test" using
the M-MDS.

3.7].)
Is the PENDING CODE for the DTC present?


Yes
DTC P2112 [MZI-3.7]

DTC P2112 Throttle actuator control system - stuck closed
DETECTION  This PCM fault status indicates the throttle plate is at a lower angle than
CONDITION commanded.
 Binding throttle body, stuck open
 Throttle actuator control circuits are cross-wired
POSSIBLE CAUSE
 PCM malfunction
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1 VERIFY FREEZE FRAME DATA HAS BEEN No Record FREEZE FRAME DATA on the
RECORDED repair order, then go to the next step.
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Has FREEZE FRAME DATA been recorded?



Yes
2 Verify related Service Bulletins and/or on-line
  If the vehicle is not repaired, go to
INSPECT THROTTLE POSITION OPEN
CIRCUIT AND CLOSED VOLTAGES


(Engine off). Yes Go to the Step 5.
TP2 PIDs.
 Verify the following values of the PIDs when
3
depressing the accelerator pedal to the floor
and releasing.
 Pedal fully released: TP1 is 3.7-4.7 V
 Pedal fully released: TP2 is 0.3-1.9 V No Go to the next step.

 Are both PIDs within the specification?
INSPECT FOR OBSTRUCTION OF

THROTTLE BODY
WARNING: Yes Go to the Step 7.

 Substantial opening and closing torque is
applied by this system. To prevent injury,
be careful to keep fingers away from
throttle mechanism when actuated. Failure
to follow these instructions may result in
personal injury.
4

 Remove the air hose from the throttle body. Isolate and repair the obstruction. Then
No
 Visually inspect for throttle plate obstructions go to Step 9.
or sludge.
 Slowly, push the throttle plate to wide open
and release.
 Does the throttle plate move freely to wide
open and back?
INSPECT TP SENSOR OPERATION
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(Engine off).
TP2 PIDs.
 Slowly press the accelerator pedal from fully
released to fully depressed while observing
the voltage readings.
5  Use the chart as a reference.
 Inspect the TP sensor.
No
Step 9.
(See THROTTLE POSITION (TP)
 Do all signal values smoothly change when

the accelerator is depressed?
INTERMITTENT CONCERN Yes Go to the next step.
Access the PCM and monitor the TP1 and


6 TP2 PIDs.
Repair or replace suspected part, then go
 Wiggle, shake, and bend the wiring harness No
to Step 9.
from the TP to the PCM.
 Are the voltages between 0.49-4.65 V?

CONTROL MOTOR VISUALLY
NOTE:
 Make sure the throttle body connector is Yes
Step 9.
properly connected.
7
 Inspect the throttle actuator control motor for
damaged housing, wiring harness connector,
and wiring harness. No Go to the next step.
 Are there any concerns with the throttle
actuator control motor hardware?
CONTROL CIRCUITS FOR SHORT EACH
8 OTHER
 Turn the ignition switch off. No

 Measure resistance between throttle actuator Repair or replace suspected part, then go
Microsoft
terminal A and B. to the next step.



step. (See PCM
 Clear the DTC from the PCM memory using Yes REMOVAL/INSTALLATION [MZI-
the M-MDS. 3.7] .)
9
 Perform the "KOEO or KOER self-test" using
the M-MDS.

3.7].)
Is the PENDING CODE for the DTC present?


Yes
DTC P2121, P2126, P2131 [MZI-3.7]

DTC P2121, P2126, P2131 (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P2121 APP sensor No.1 circuit range/performance
DETECTION  APP sensor fault flag is set for sensor No.1, No.2 and No.3 by the PCM,
CONDITION indicating the signal is out of the normal self-test operating range.
 APP sensor signal circuits are shorted each other
 APP sensor malfunction
 PCM malfunction
P2121
 Open circuit wiring harness between APP sensor terminal E and PCM
terminal 1AK
 Short to ground circuit between APP sensor terminal E and PCM terminal 1
AK
 Short to power supply in wiring harness between APP sensor terminal E
and PCM terminal 1 AK
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P2126
 Open circuit wiring harness between APP sensor terminal H and PCM
terminal 1AG
 Short to ground circuit between APP sensor terminal H and PCM terminal
1 AG
 Short to power supply in wiring harness between APP sensor terminal H
and PCM terminal 1 AG
POSSIBLE CAUSE
P2131
 Open circuit wiring harness between APP sensor terminal B and PCM
terminal 1 AC
 Short to ground circuit between APP sensor terminal B and PCM terminal 1
AC
 Short to power supply in wiring harness between APP sensor terminal B
and PCM terminal 1 AC
Microsoft
DTC P2121, P2126, P2131 (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
Microsoft

Yes
INSPECT ACCELERATOR PEDAL FOR
OBSTRUCTION Yes Go to the next step.


3 (Engine off).
 Depress the accelerator pedal fully to the Isolate and repair the obstruction. Then go
floor and release. No
to Step 12.
 Does the pedal move freely to the floor and
back?
INSPECT APP SENSOR SIGNAL
VOLTAGE RANGES FOR ACCELERATOR
PEDAL FULLY APPLIED AND DEPRESS
POSITIONS
 Access the PCM and monitor the APP1, Yes Go to the next step.
APP2 and APP3 PIDs.
 Verify the following values of the PIDs
when depressing the accelerator pedal fully
to the floor.
 APP1: 0.48-1.79 V
4
 APP2: 2.95-4.62 V
 APP3: 2.43-4.02 V
 Verify the following values of the PIDs

when press the accelerator pedal release.
 APP1: 3.43-4.69 V
No Go to Step 6.
 APP2: 1.13-1.88V
 APP3: 0.64-1.28 V
 Are all PIDs signals out of range for the

pedal fully depressing and released
positions?
INSPECT REFERENCE VOLTAGE TO APP

SENSOR
 Disconnect the APP sensor connector.
(Engine off).
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Measure the voltage between the APP


sensor connector D or F terminal (wiring
harness side) and the APP sensor connector No Repair if necessary. Then go to Step 12.
C or G terminal (wiring harness side)
 Is the voltage between 4-6 V?
INSPECT FUNCTIONALITY OF APP

CIRCUITS
Yes Go to the next Step.
NOTE:
6  Use the voltage measurements from
Step 4.
No Go to Step 11.
Are APP1, APP2 or APP3 out of range?


INSPECT FUNCTIONALITY OF APP

SENSOR

Yes Go to next Step.
 Disconnect the APP sensor connector.
following APP sensor terminals (APP
sensor component side).
 E and D or F: 600-1,370 ohms
 E and C or G: 720-1,660 ohms
7  E and H: 1,300-2,960 ohms
 E and B: 1,250-2,860 ohms
 H and D or F: 750-1,720 ohms
 H and C or G: 660-1,520 ohms

Replace the accelerator pedal. Then go to
No
Step 12.
 H and B: 1,230-2,810 ohms
 B and D or F: 710-1,640 ohms
 B and C or G: 580-1,340 ohms
 D or F and C or G: 200-470 ohms
 Are all the resistances within

specifications?
INSPECT APP SENSOR SIGNAL CIRCUIT

 P2121: APP sensor terminal E and
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PCM terminal 1AK

 P2126: APP sensor terminal H and
PCM terminal 1AG Repair or replace suspected part, then go to
No
 P2131: APP sensor terminal B and Step 12.
PCM terminal 1AC

FOR SHORT TO GROUND


 Inspect for continuity between the Yes
Step 12.
9  P2121: APP sensor terminal E and
body ground
body ground
 P2131: APP sensor terminal B and
No Go to the next Step.
body ground


(Engine off). Repair or replace suspected part, then go to
Yes
 Measure the voltage between the following Step 12.
terminals:
10  P2121: APP sensor terminal E and
body ground
body ground
 P2131: APP sensor terminal B and No Go to the next Step.
body ground
 Are the voltage B+?

FOR SHORT EACH OTHER

 Disconnect PCM connector. Yes Go to the next step.
 Disconnect APP sensor connector.
following APP sensor terminals (wiring
harness-side)
Microsoft
 P2121
E and H
E and B
E and D or F
E and C or G
 P2126
H and E
H and B
11 No
H and D or F the next step.
H and C or G
 P2131
Band E
B and H
B and D or F
B and C or G
 Are there resistance greater than 10

kilohms?

P2121, P2126 or P2131 HAS BEEN
COMPLETED
12 [MZI-3.7] .)
using the M-MDS.
using the M-MDS.

3.7].)
Microsoft


present?
Yes
DTC P2122 [MZI-3.7]

DTC P2122 APP sensor No.1 circuit low input
DETECTION
 APP sensor No.1 is out of self-test range low.
CONDITION
 Short to ground circuit between APP sensor terminal F and PCM terminal
1BA
 Short to ground circuit between APP sensor terminal D and PCM terminal
1Y
 Short to ground circuit between APP sensor terminal G and PCM terminal 1
AD
POSSIBLE CAUSE
 Short to ground circuit between APP sensor terminal C and PCM terminal
1AH
 Short to ground circuit between APP sensor terminal E and PCM terminal
1AK
Microsoft

BEEN RECORDED
recorded?
Microsoft

 Yes
availability. step.
INSPECT APP SENSOR CONNECTOR
FOR POOR CONNECTION
 7.
3  Disconnect the APP sensor
connector.
INSPECT APP SENSOR NO.1




following terminals: Repair or replace suspected part, then go to Step
Yes
7.
 APP sensor terminal F and
body ground.
4  APP sensor terminal D and
body ground.
 APP sensor terminal G and
body ground.
 APP sensor terminal C and
body ground.
 APP sensor terminal E and
body ground.

Replace the accelerator pedal, then go to Step 7.
 Inspect APP sensor No.1. (See Yes (See ACCELERATOR PEDAL
5 ACCELERATOR PEDAL REMOVAL/INSTALLATION [MZI-3.7] .)
INSPECT PCM CONNECTOR FOR Yes

Microsoft


7.
6  Inspect for poor connection (such as
7 connectors reconnected. 3.7] .)
VERIFY AFTER REPAIR

PROCEDURE
Yes
TABLE [MZI-3.7].)
3.7].) No DTC troubleshooting completed.
DTC P2123 [MZI-3.7]

DTC P2123 APP sensor No.1 circuit high input
DETECTION
 APP sensor No.1 is out of self-test range high.
CONDITION
 Open circuit wiring harness between APP sensor terminal F and PCM
terminal 1BA
 Open circuit wiring harness between APP sensor terminal D and PCM
terminal 1Y
 Open circuit wiring harness between APP sensor terminal G and PCM
terminal 1AD
POSSIBLE CAUSE  Open circuit wiring harness between APP sensor terminal C and PCM
terminal 1 AH
 Open circuit wiring harness between APP sensor terminal E and PCM
terminal 1AK
 Short to power supply in wiring harness between APP sensor terminal F and
PCM terminal 1 BA
 Short to power supply in wiring harness between APP sensor terminal D and
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PCM terminal 1Y
 Short to power supply in wiring harness between APP sensor terminal G and
PCM terminal 1 AD
 Short to power supply in wiring harness between APP sensor terminal C and
PCM terminal 1 AH
 Short to power supply in wiring harness between APP sensor terminal E and
PCM terminal 1 AK
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BEEN RECORDED
recorded?
availability. step.
FOR POOR CONNECTION
 8.
connector.

POOR CONNECTION
Yes


Microsoft



following terminals (wiring harness-
side).
PCM terminal 1BA.
 APP sensor terminal D and
6 PCM terminal 1Y.
 APP sensor terminal G and Repair or replace suspected part, then go to Step
No
PCM terminal 1AD. 8.
PCM terminal 1AH.
PCM terminal 1AK.
INSPECT APP SENSOR NO.1 SIGNAL

SUPPLY

 Measure the voltage between the Repair or replace suspected part, then go to Step
Yes
following terminals (wiring harness- 8.
side).
7 body ground.
body ground.
body ground.
body ground.
8 Verify that all disconnected
 3.7] .)
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Start the engine.


VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P2127 [MZI-3.7]

DETECTION
CONDITION
1BA
1Y
 Short to ground circuit between APP sensor terminal G and PCM terminal
1AD
POSSIBLE CAUSE
 Short to ground circuit between APP sensor terminal C and PCM terminal
1AH
 Short to ground circuit between APP sensor terminal H and PCM terminal 1
AG
Microsoft

BEEN RECORDED
recorded?
Microsoft

 Yes
availability. step.
FOR POOR CONNECTION
 7.
connector.




Yes
7.
body ground.
body ground.
body ground.
body ground.
 APP sensor terminal H and
body ground.


Microsoft


7.
VERIFY AFTER REPAIR

PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P2128 [MZI-3.7]

DETECTION
CONDITION
terminal 1BA
terminal 1Y
terminal 1 AD
terminal 1 AH
 Open circuit wiring harness between APP sensor terminal H and PCM
terminal 1 AG
 Snort to power supply in wiring harness between APP sensor terminal F and
PCM terminal 1BA
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PCM terminal 1Y
PCM terminal 1 AD
PCM terminal 1AH
 Short to power supply in wiring harness between APP sensor terminal H and
PCM terminal 1 AG
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BEEN RECORDED
recorded?
availability. step.
FOR POOR CONNECTION
 8.
connector.

POOR CONNECTION
Yes


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

side).
PCM terminal 1BA.
6 PCM terminal 1Y.
No
PCM terminal 1AH.
PCM terminal 1AG.

SUPPLY

Yes
side).
7 body ground.
body ground.
body ground.
body ground.
 3.7] .)
Microsoft
Start the engine.


VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P2132 [MZI-3.7]

DETECTION
CONDITION
1BA
1Y
 Short to ground circuit between APP sensor terminal G and PCM terminal 1
AD
POSSIBLE CAUSE
 Short to ground circuit between APP sensor terminal C and PCM terminal 1
AH
 Short to ground circuit between APP sensor terminal B and PCM terminal 1
AC
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BEEN RECORDED
recorded?
Microsoft

 Yes
availability. step.
FOR POOR CONNECTION
 7.
connector.




Yes
7.
body ground.
body ground.
body ground.
body ground.
 APP sensor terminal B and
body ground.


Microsoft


7.
VERIFY AFTER REPAIR

PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P2133 [MZI-3.7]

DETECTION
CONDITION
terminal 1BA
terminal 1Y
terminal 1 AD
terminal 1 AH
 Open circuit wiring harness between APP sensor terminal B and PCM
terminal 1 AC
 Short to power supply in wiring harness between APP sensor terminal F and
PCM terminal 1BA
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PCM terminal 1Y
PCM terminal 1 AD
PCM terminal 1 AH
 Short to power supply in wiring harness between APP sensor terminal B and
PCM terminal 1 AC
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BEEN RECORDED
recorded?
availability. step.
FOR POOR CONNECTION
 8.
connector.

POOR CONNECTION
Yes


Microsoft



side).
PCM terminal 1BA.
6 PCM terminal 1Y.
No
PCM terminal 1AH.
PCM terminal 1AC.

SUPPLY

Yes
side).
7 body ground.
body ground.
body ground.
body ground.
 3.7] .)
Microsoft
Start the engine.


VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P2135 [MZI-3.7]

DTC P2135 TP sensor No.1/No.2 voltage correlation
DETECTION  The PCM flagged a concern indicating that TP sensor No.1 and TP sensor No.2
CONDITION disagree by more than a calibrated limit.
 Short to power supply between TP sensor No.1 terminal F and PCM terminal 2Z
 Short to power supply between TP sensor No.2 terminal C and PCM terminal
POSSIBLE CAUSE 2AD
 TP sensor circuits are shorted each other
 TP sensor malfunction
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HAS BEEN RECORDED
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1 Has FREEZE FRAME DATA been No Record the FREEZE FRAME DATA on the repair

availability. step.
INSPECT TP SENSOR RESISTANCE

 Disconnect the throttle body
connector.
following terminals (throttle body
component side).
 Throttle body terminal F and
D: 700-1,800 ohms
3
 Throttle body terminal F and
E: 1,300-2,800 ohms
Replace the throttle body, then go to Step 6. (See
 Throttle body terminal C and No INTAKE-AIR SYSTEM
D: 1,000-2,400 ohms REMOVAL/INSTALLATION [MZI-3.7] .)
 Throttle body terminal C and
E: 500-1,500 ohms
 Throttle body terminal D and
E: 700-2,100 ohms
 Are all the resistances within
specifications?
SUPPLY
following circuits:
 Throttle body terminal F
 Throttle body terminal C
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body ground.

CIRCUITS FOR SHORT EACH
OTHER


5  Disconnect the throttle body and

PCM connector.
 Measure resistance between throttle No
next step.
body terminal F and C.
kilohms?
 Yes PCM REMOVAL/INSTALLATION [MZI-
VERIFY AFTER REPAIR

PROCEDURE
Yes
DTC P2195, P2197 [MZI-3.7]

DTC P2195 P2195: Front HO2S (RH) signal stuck lean
DTC P2197 P2197: Front HO2S (LH) signal stuck lean
DETECTION  A HO2S indicating lean at the end of a test is trying to correct for an over-rich
CONDITION condition. The test fails when the fuel control system no longer detects
switching for a calibrated amount of time.
 Front HO2S malfunction

 Fuel injector malfunction
 Insufficient fuel line pressure
Microsoft
 Leakage exhaust gas

 Air suction at intake-air system malfunction
POSSIBLE  Leakage fuel
CAUSE  MAF sensor malfunction
 ECT sensor malfunction
 PCM malfunction

BEEN RECORDED
recorded?
VERIFY RELATED REPAIR Yes
2 next step.
available? Perform the PCM reprogramming procedure.
No (See PCM CONFIGURATION [MZI-3.7] .)
OR STORED DTCs Go to the appropriate DTC troubleshooting.
Yes
3  Turn the ignition switch off then to the
 Verify the related PENDING CODE or
stored DTCs using the M-MDS.
IDENTIFY TRIGGER DTC FOR Yes Go to the next step.
FREEZE FRAME DATA
4 Go to the troubleshooting for the DTC on the
 Is DTC P2195 or P2197 on the
No FREEZE FRAME DATA. (See DTC TABLE
FREEZE FRAME DATA? [MZI-3.7].)

STATUS
 Verify the following PIDs.
 (See PCM INSPECTION [MZI-3.7] .)
 APP1
Microsoft
APP2

 APP3
 ECT
Inspect the malfunctioning part according to
5  MAF No
the inspection results. Then go to Step 13.
 TP_REL
 VSS
 Are the PIDs normal?

STATUS UNDER FREEZE FRAME
DATA CONDITION

 Verify the following PIDs under the

FREEZE FRAME DATA condition.
6
 APP1
 APP2
Inspect the malfunctioning part according to
 APP3 No
the inspection results. Then go to Step 13.
 ECT
 MAF
 TP_REL

Yes
go to Step 13.
7  Visually inspect for looseness, cracks or
damage to the hoses in the intake-air
system.

STATUS OF MAF SENSOR Yes Go to the next step.

 Access the MAF PID. Replace the MAF/IAT sensor, then go to Step
No
 Verify that the MAF PID changes 13.
quickly according to the engine speed.
 Is the PID normal?
INSPECT FRONT HO2S
 Inspect the front HO2S (RH) (with

Microsoft
DTC P2195) or the front HO2S (LH)

(with DTC P2197). Inspect the related wiring harnesses
Yes If there is no malfunction
(See FRONT HEATED OXYGEN Replace the HO2S, then go to Step 13.
9
[MZI-3.7] .)


Replace the suspected fuel injector, then go to
Inspect the fuel injector for the right

Yes Step 13. (See FUEL INJECTOR
bank (with DTC P2195) or the left bank
(with DTC P2197). (See FUEL
INJECTOR INSPECTION [MZI-
3.7] .)
INSPECT FUEL LINE PRESSURE

 Perform the "FUEL LINE PRESSURE
11 INSPECTION". (See FUEL LINE

PRESSURE INSPECTION [MZI-
3.7] .) No Go to Step 13.
INSPECT FUEL SYSTEM FOR FUEL Repair or replace the malfunctioning part, then
LEAKAGE Yes
12  Visually inspect for fuel leakage in the Replace the fuel pump unit, then go to the next
fuel system. No step. (See FUEL PUMP UNIT
 Is there fuel leakage? REMOVAL/INSTALLATION [MZI-3.7] .)


are reconnected.
Replace the PCM, then go to the next step.
 Turn the ignition switch to the ON Yes (See PCM REMOVAL/INSTALLATION
position (Engine off). [MZI-3.7] .)
using the M-MDS.
 Perform no load racing at the engine
speed of 2,500-3,500 rpm for 60s or
more, then idle the engine for 60s or
more.
 Perform the KOEO and KOER self-test. No Go to the next step.
Microsoft


present?
Yes
DTC P2196, P2198 [MZI-3.7]

DTC P2196 P2196: Front HO2S (RH) signal stuck rich
DTC P2198 P2198: Front HO2S (LH) signal stuck rich
DETECTION  A HO2S indicating rich at the end of a test is trying to correct for an over-rich
CONDITION condition. The test fails when the fuel control system no longer detects
switching for a calibrated amount of time
 Front HO2S malfunction
 Fuel injector malfunction
 Insufficient fuel line pressure
POSSIBLE
CAUSE  Air suction at intake-air system malfunction
 Leakage fuel
 ECT sensor malfunction
 PCM malfunction

BEEN RECORDED
recorded?
2 Yes
and/or online repair information step.
availability.
Microsoft

 Perform the PCM reprogramming procedure.
No
OR STORED DTCs Go to the appropriate DTC troubleshooting. (See
Yes
 Verify the related PENDING CODE
or stored DTCs using the M-MDS.
FREEZE FRAME DATA
 Is DTC P2196 or P2198 on the
STATUS
 Verify the following PIDs. (See
PCM INSPECTION [MZI-3.7] .)
 APP1
5  APP2
 APP3 Inspect the malfunctioning part according to the

 ECT
No inspection results.
Then go to Step 11.
 MAF
 TP_REL
 VSS

STATUS UNDER FREEZE FRAME
DATA CONDITION Yes Go to the next step.
 Verify the following PIDs under the
6 FREEZE FRAME DATA condition.
(See PCM INSPECTION [MZI-

3.7] .) Inspect the malfunctioning part according to the
No
inspection results. Then go to Step 11.
 APP1
 APP2
 APP3
Microsoft
ECT
 MAF
 TP_REL
 VSS

STATUS OF MAF SENSOR

 Access the MAF PID.
 Verify that the MAF PID changes

No Replace the MAF/IAT sensor, then go to Step 11.
quickly according to engine speed.
 Is the PID normal?
INSPECT FRONT HO2S
 Inspect the front HO2S (RH) (with

Inspect the related wiring harnesses
DTC P2195) or the front HO2S (LH)
Yes If there is no malfunction
(with DTC P2197).
Replace the HO2S, then go to Step 11.
8
(See FRONT HEATED OXYGEN
[MZI-3.7] .)
 Inspect the fuel injector for the right Replace the suspected fuel injector, then go to
bank (with DTC P2196) or the left Yes Step 11. (See FUEL INJECTOR
bank (with DTC P2198). REMOVAL/INSTALLATION [MZI-3.7] .)
9
(See FUEL INJECTOR

INSPECT FUEL LINE PRESSURE
 Perform the "FUEL LINE Replace the malfunctioning part. Go to the next
Yes
PRESSURE INSPECTION". step.
10
(See FUEL LINE PRESSURE
Microsoft
COMPLETED


more.
 Perform KOEO and KOER self-test.

DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
DTC P2270, P2272 [MZI-3.7]

DTC P2270 P2270: Rear HO2S (RH) signal stuck lean
DTC P2272 P2272: Rear HO2S (LH) signal stuck lean
DETECTION  The downstream HO2S is forced rich and monitored by the PCM. The test
CONDITION fails if the PCM does not detect the output of the HO2S in a calibrated
amount of time
 Rear HO2S malfunction
POSSIBLE CAUSE

Microsoft
BEEN RECORDED Yes Go to the next step.

1  Has FREEZE FRAME DATA been Record FREEZE FRAME DATA on the repair
No

Yes
Verify related Service Bulletins and/or If the vehicle is not repaired, go to the

2 
next step.
Perform the PCM reprogramming procedure.
 Is any related Service Bulletins No (See PCM CONFIGURATION [MZI-3.7] .)
STORED DTCs Go to the appropriate DTC troubleshooting.
Yes
3 Turn the ignition switch off then to the

 Verify the related PENDING CODE or
stored DTCs using the M-MDS.
IDENTIFY TRIGGER DTC FOR FREEZE Yes Go to the next step.
FRAME DATA
 Is DTC P2270 or P2272 on the FREEZE
FRAME DATA? [MZI-3.7].)
INSPECT FOR EXHAUST GAS
LEAKAGE Visually inspect for exhaust gas Yes Repair or replace the malfunctioning parts.
leakage between the TWC and the rear Then go to the next step.
5
HO2S.

INSPECT REAR HO2S
 For DTC P02270 Inspect the rear HO2S

(RH) Repair or replace the malfunctioning parts.
Yes
 For DTC P02272 Inspect the rear HO2S Then go to the next step.
6 (LH)


Microsoft


are reconnected.
position (Engine off). Replace the PCM, then go to the next step.
7
more.
 Perform the KOEO and KOER self-test.

present?
 Perform "AFTER REPAIR Go to the applicable DTC inspection. (See

Yes
8
[MZI-3.7].)
DTC P2271, P2273 [MZI-3.7]

DTC P2271 P2271: Rear HO2S (RH) signal stuck rich
DTC P2273 P2273: Rear HO2S (LH) signal stuck rich
DETECTION  The downstream HO2S is forced rich and monitored by the PCM. The test
CONDITION fails if the PCM does not detect the output of the HO2S in a calibrated
amount of time.
POSSIBLE CAUSE  Rear HO2S malfunction

HAS BEEN RECORDED
recorded?
Microsoft

Yes
  If the vehicle is not repaired, go to the next
availability. Perform the PCM reprogramming procedure. (See
 Is any related Service Bulletins No PCM CONFIGURATION [MZI-3.7] .)
OR STORED DTCs
Yes
 Verify the related PENDING
CODE or stored DTCs using the M- No Go to the next step.
MDS.
FREEZE FRAME DATA
 Is DTC P2271 or P2273 on
INSPECT REAR HO2S
 For DTC P2271 Inspect the rear

HO2S(RH) Inspect the related wiring harnesses.
If there is no malfunction, replace the HO2S. (See
 For DTC P2273 Inspect the rear Yes
REAR HEATED OXYGEN SENSOR (HO2S)
5 HO2S(LH)
[MZI-3.7] .)

COMPLETED

6 Yes PCM REMOVAL/INSTALLATION [MZI-
3.7] .)
Microsoft

more.
test. No Go to the next step.

DTC present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
TABLE [MZI-3.7].)
7 PROCEDURE" (See AFTER
DTC P260F [MZI-3.7]

DTC P260F (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
DTC P260F Evaporative emission system monitoring processor performance
DETECTION  This DTC sets when a concern is detected internal to the PCM. The
CONDITION microprocessor that controls the engine off natural vacuum (EONV) leak
check monitor is separate from the main processor within the PCM.
 Module communications network concerns
POSSIBLE
CAUSE  PCM calibration level
 PCM malfunction
DTC P260F (MZI-3.7) DIAGNOSTIC PROCEDURE

BEEN RECORDED
recorded?
2  Verify related Service Bulletins Yes
availability. step.
Microsoft

OR STORED DTCs Go to the appropriate DTC troubleshooting.(See
Yes
3 Turn the ignition switch off then to

 Verify the related PENDING CODE
No Go to the next step
or stored DTCs using the M-MDS.
INSPECT THE PERFORMANCE OF
THE PROCESSOR

 Yes Go to Step 6.
 Disconnect the battery and wait for 1
min.
 Connect the battery.
4
completely.
 Allow the engine idle to stabilize.
 Access FTP PID.
 Is the pressure equal to 0 kPa {0
kgf/cm2 , 2.0 psi}.

INSPECT FOR SELF-TEST DTC P260F
5  Idle the engine 2 min.
 Perform the KOEO/KOER self-test.

 Is DTC P260F present?
INSPECT PCM FOR THE LATEST

CALIBRATION
 Program the PCM to the latest
calibration.
 Idle the engine for 2 min.
 Perform the KOEO/KOER self-test.
 Is DTC P260F present?

OPERATION
 Pushed out pins
Microsoft
Corrosion


7 No The system is correctly. Go to the next step.

present?
DTC P260F HAS BEEN COMPLETED

8  Perform the KOEO or KOER self-test
using the M-MDS.

[MZI-3.7].)

present?
VERIFY AFTER REPAIR
PROCEDURE
Yes
Microsoft
2008 ENGINE Service Tools (MZI-3.7) - Mazda CX-9
2008 ENGINE
Service Tools (MZI-3.7) - Mazda CX-9
ENGINE SST [MZI-3.7]

1. Mazda SST number
2. Global SST number
Example
Fig. 1: Identifying Service Tools (1 Of 2)

Microsoft
2008 ENGINE Service Tools (MZI-3.7) - Mazda CX-9
Fig. 2: Identifying Service Tools (2 Of 2)

Microsoft
2008 ENGINE Technical Data (MZI-3.7) - Mazda CX-9
2008 ENGINE
Technical Data (MZI-3.7) - Mazda CX-9
ENGINE TECHNICAL DATA [MZI-3.7]

ENGINE TECHNICAL DATA SPECIFICATION
Item Specification
IN: 0.150-0.250 mm {0.00591-0.00984 in}
Standard valve clearance [Engine cold]
EX: 0.300-0.400 mm {0.0119-0.0157 in}
Oil control valve resistance 5-14 ohms
Ignition timing Approx. BTDC 13°
No load: 570-670 rpm
Electrical load on: 630-730 rpm
Idle speed (P position) Power steering oil pump operation: 600-700 rpm
A/C and heater operation: 570-850 rpm [-40-49 °C {-40-120°
F}]
HC concentration: Within the regulation
Idle mixture
CO concentration: Within the regulation
Oil replacement: 4.7 L {5.0 US qt, 4.2 lmp qt}
Engine oil capacity (approx. quantity) Oil and oil filter replacement: 5.2 L {5.5 US qt, 4.6 lmp qt}
Total (dry engine): 5.9 L {6.2 US qt, 5.2 lmp qt}
Oil pressure (reference value) [oil
temperature: 93.3°C {200°F}] 310-621 kPa {3.17-6.33 kgf/cm2 , 45.0-90.0 psi} [2,000 rpm]
Engine coolant capacity (approx. Dual fan control module: 12.2 L {12.9 US qt, 10.7 lmp qt}
quantity) Single fan control module: 11.6 L {12.3 US qt, 10.2 lmp qt}
Cooling system cap valve opening
pressure 93.2-122.6 kPa {0.95-1.25 kgf/cm2 , 13.5-17.8 psi}
Thermostat initial-opening temperature 79.5-83.3°C {175.2-181.9°F}
Thermostat full-open temperature 94.5°C {202.1°F}
Thermostat full-open lift More than 8.1 mm {0.32 in}
Cooling fan motor standard current
No.1, No.2: 11.2-15.2 A
[Single fan control module]
Cooling fan motor standard current
No.1, No.2: 17-23 A
[Dual fan control module]
Fuel line pressure 331-85 kPa {3.38-4.94 kgf/cm2 , 48.1-70.3 psi}
Fuel injector resistance 11-18 ohms
Battery electrolyte specific gravity [20°
1.22-1.29
C {68°F}]
Battery load test current 80D26L (55): 195 A
Battery back-up current (When the
Vehicles with immobilizer system: 50-60 mA
ignition switch is off, the ignition key is
Vehicles without immobilizer system: 55 mA or less
removed, and all doors are closed.)
Microsoft
Battery slow charge current 80D26L (55): 5.5-6.5 A

Battery quick charge current [30 min] 80D26L (55): 35 A
Terminal B: B+
Terminal A: B+
Generator standard voltage [IG-ON]
Terminal RC: Approx. 1 V or less
Terminal LI: Approx. 1 V
Terminal B: 12-16 V
Generator standard voltage [Idle, 20°C Terminal A: 12-16 V
{68°F}] Terminal RC: 0-16 V
Terminal LI: 1-16 V
70 % of the nominal output current (nominal output current: 110
Generator generated current minimum A)
value [Ambient temp. 20°C {68°F}, voltage 13.0-15.0 V, both engine
and generator are hot]
Generator rotor resistance (between slip
1.8-2.2 ohm
rings) [20°C {68°F}]
Generator brush length
Generator brush spring force
Minimum: 1.7 N {0.17 kgf, 0.38 lbf}
Ignition coil secondary coil resistance 5-6 kilohms
1-4-2-5-3-6
Firing order
Spark plug type CY01 18 110

Spark plug gap 1.29-1.45 mm {0.051-0.057 in}
Spark plug resistance 2-20 kilohms
Microsoft
Starter no-load test voltage 11 V

Starter no-load test current 90 A or less
Starter pinion gap 0 mm {0 in}
Starter armature runout 0.1 mm {0.004 in} max.
Starter commutator diameter
Segment groove depth of starter Standard: 0.5 mm {0.02 in}
commutator Minimum: 0.2 mm {0.008 in}
Starter brush length
Starter brush spring force
Minimum: 2.75 N {0.28 kgf, 0.62 lbf}
Engine oil specification
ENGINE OIL SPECIFICATION

Item U.S.A. and CANADA Except U.S.A. and CANADA
Engine oil grade
Engine oil viscosity 5W-20
Microsoft
2008 ENGINE Symptom Troubleshooting (MZI-3.7) - Mazda CX-9
2008 ENGINE
Symptom Troubleshooting (MZI-3.7) - Mazda CX-9
SYMPTOM TROUBLESHOOTING WIRING DIAGRAM [MZI-3.7]
Microsoft
Fig. 1: Symptom Troubleshooting Wiring Diagram (1 Of 3)

Microsoft

Microsoft

FOREWORD [MZI-3.7]
 When the customer reports a vehicle malfunction, check the malfunction indicator lamp (MIL) indication
and diagnostic trouble code (DTC), then diagnose the malfunction according to the following flowchart:
Microsoft
 If a DTC exists, diagnose the applicable DTC inspection. (See DTC TABLE [MZI-3.7] .)
 If no DTC exists and the MIL does not illuminate or flash, diagnose the applicable symptom
troubleshooting. (See QUICK DIAGNOSTIC CHART [MZI-3.7].)
Fig. 4: Symptom Troubleshooting Flow Chart

SYMPTOM DIAGNOSTIC INDEX [MZI-3.7]

 Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting
chart.
Diagnostic Index
DIAGNOSTIC INDEX
No. TROUBLESHOOTING ITEM DESCRIPTION PAGE
( NO.1 MELTING OF MAIN
1 Melting of main or other fuses - OR OTHER FUSES [MZI-
3.7].)
The MIL is
(See NO.2 MIL
2 MIL illuminates illuminated
ILLUMINATES [MZI-3.7].)
incorrectly.
The starter does not (See NO.3 WILL NOT
3 Will not crank
work. CRANK [MZI-3.7].)
The starter cranks the (See NO.4 HARD TO

4 Hard to start/long crank/erratic start/erratic crank engine at normal START/LONG
speed but the engine CRANK/ERRATIC
requires excessive START/ERRATIC CRANK
Microsoft
cranking time before [MZI-3.7].)

starting.
The engine stops
(See NO.5 ENGINE
unexpectedly at idle
5 Engine stalls. After start/at idle STALLS-AFTER START/AT
and/or after start or
IDLE [MZI-3.7].)
both.
The starter cranks
(See NO.6 CRANKS
engine at normal
6 Cranks normally but will not start NORMALLY BUT WILL
speed but the engine
NOT START [MZI-3.7].)
will not run.
The engine takes more
(See NO.7 SLOW RETURN
7 Slow return to idle time than normal to
TO IDLE [MZI-3.7].)
return to idle speed.
The engine speed
fluctuates between the
(See NO.8 ENGINE RUNS
specified idle speed
8 Engine runs rough/rolling idle. ROUGH/ROLLING IDLE
and lower speed and
[MZI-3.7].)
the engine shakes
excessively.
The engine speed
continues at fast idle
after warm-up. (See NO.9 FAST IDLE/RUNS
9 Fast idle/runs on
The engine runs after ON [MZI-3.7].)
the ignition switch is
turned off.
The engine stops
unexpectedly at the (See NO.10 LOW
beginning of IDLE/STALLS DURING
10 Low idle/stalls during deceleration
deceleration or DECELERATION [MZI-
recovery from 3.7].)
deceleration.
The engine stops
unexpectedly at the
beginning of
Engine acceleration or during
Acceleration/cruise
stalls/quits. acceleration.
The engine stops
unexpectedly while
11 cruising.
The engine speed
Engine runs fluctuates during
Acceleration/cruise
rough. acceleration or
(See NO.11 ENGINE
cruising.
STALLS/QUITS, ENGINE
The engine misses RUNS ROUGH, MISSES,
Misses Acceleration/cruise during acceleration or BUCK/JERK,
cruising. HESITATION/STUMBLE,
Microsoft
The vehicle SURGES [MZI-3.7].)

bucks/jerks during
Buck/jerk Acceleration/cruise/deceleration
acceleration, cruising,
or deceleration.
A momentary pause at
the beginning of
Hesitation/stumble Acceleration
acceleration or during
acceleration.
A momentary minor
Surges Acceleration/cruise irregularity in engine
output.
The performance is (See NO.12 LACK/LOSS OF
Lack/loss of poor under load (such POWER-
12 Acceleration/cruise
power as power down when ACCELERATION/CRUISE
climbing hills). [MZI-3.7].)
Sound is produced
when the air/fuel
(See NO.13
mixture is ignited by
KNOCKING/PINGING-
13 Knocking/pinging Acceleration/cruise something other than
ACCELERATION/CRUISE
the spark plug (such
[MZI-3.7].)
as hot spot in
combustion chamber).
The fuel economy is (See NO.14 POOR FUEL
14 Poor fuel economy
unsatisfactory. ECONOMY [MZI-3.7].)
(See NO.15 EMISSION
15 Emission compliance Fails emissions test.
COMPLIANCE [MZI-3.7].)
(See NO.16 HIGH OIL
The oil consumption
16 High oil consumption/leakage CONSUMPTION/LEAKAGE
is excessive.
[MZI-3.7].)
The engine runs at (See NO.17 COOLING
Cooling system
17 Overheating higher than normal SYSTEM CONCERNS-
concerns
temperature/overheats. OVERHEATING [MZI-3.7].)
The engine does not (See NO.18 COOLING
Cooling system
18 Runs cold reach normal SYSTEM CONCERNS-
concerns
operating temperature. RUNS COLD [MZI-3.7].)
Blue, black, or white
(See NO.19 EXHAUST
19 Exhaust smoke smoke from exhaust
SMOKE [MZI-3.7].)
system
(See NO.20 FUEL ODOR (IN
Gasoline fuel smell or
20 Fuel odor (in engine compartment) ENGINE COMPARTMENT)
visible leakage
[MZI-3.7].)
Engine noise from (See NO.21 ENGINE NOISE
21 Engine noise
under hood [MZI-3.7].)
Vibration from under (See NO.22 VIBRATION
22 Vibration concerns (engine)
hood or driveline CONCERNS (ENGINE)
Microsoft
[MZI-3.7].)
The A/C compressor
(See NO.23 A/C DOES NOT
magnetic clutch does
23 A/C does not work sufficiently. WORK SUFFICIENTLY
not engage when A/C
[MZI-3.7].)
is turned on.
(See NO.24 A/C IS ALWAYS
The A/C compressor
A/C is always on or A/C compressor runs ON OR A/C COMPRESSOR
24 magnetic clutch does
continuously. RUNS CONTINUOUSLY
not disengage.
[MZI-3.7].)
The A/C compressor (See NO.25 A/C DOES NOT
A/C does not cut off under wide open throttle magnetic clutch does CUT OFF UNDER WIDE
25
conditions. not disengage under OPEN THROTTLE
wide open throttle. CONDITIONS [MZI-3.7].)
Rotten egg smell (See NO.26 EXHAUST
26 Exhaust sulphur smell (sulphur) from SULPHUR SMELL [MZI-
exhaust 3.7].)
The fuel tank does not (See NO.27 FUEL REFILL
27 Fuel refill concerns
fill smoothly. CONCERNS [MZI-3.7].)
(See NO.28 FUEL FILLING
The fuel does not shut
28 Fuel filling shut off concerns SHUT OFF CONCERNS
off properly.
[MZI-3.7].)
An incorrect spark (See NO.29 SPARK PLUG
29 Spark plug condition
plug condition. CONDITION [MZI-3.7].)
(See SYMPTOM
AT concerns not
TROUBLESHOOTING
30 AT concerns Upshift/downshift engagement related to engine
ITEM TABLE [AW6A-EL,
performance.
AW6AX-EL] .)
QUICK DIAGNOSTIC CHART [MZI-3.7]
Microsoft
Fig. 5: Quick Diagnostic Chart (1 Of 4)

Microsoft

Microsoft

Microsoft

NO.1 MELTING OF MAIN OR OTHER FUSES [MZI-3.7]

TROUBLESHOOTING HINTS - NO.1 MELTING OF MAIN OR OTHER FUSES
1 MELTING OF MAIN OR OTHER FUSES
Microsoft
Inspect condition of fuse
TROUBLESHOOTING HINTS FOR FUSES

Damaged fuse Related wiring harness
MAIN fuse
 IGKEY2 fuse
 Ignition switch
 Generator
 FUEL PUMP fuse
 FAN1 fuse
 Cooling fan relay (Single fan control module)
MAIN  Fan control module (Single fan control module)
 Cooling fan relay No.1 (Dual fan control module)
 Fan control module No.1 (Dual fan control module)
 FAN2 fuse
 Cooling fan relay (Single fan control module)
 Fan control module (Single fan control module)
 Cooling fan relay No.2 (Dual fan control module)
Microsoft
IGKEY1 fuse
IGKEY1 Ignition switch
 ENG. IGA fuse
IGKEY2 fuse
Ignition switch
IG KEY2  STA fuse
 Starter relay
 Starter
 PCM
ENG.IGA fuse
Fuel pump relay

 PCM
ENG.IGA  Diode
 Fan relay (Single fan control module)
 Cooling fan relay No.1 (Dual fan control module)
FUEL PUMP fuse
Fuel pump relay

 Fuel pump
 PCM
 INJ fuse
FUEL PUMP  PCM
 Fuel injector No.1
FAN 1 fuse
 Fan relay
FAN1  Fan control module (Single fan control module)

FAN 2 fuse
Microsoft
Fan relay
 Fan control module (Single fan control module)
FAN 2
ENG+B fuse
ENG+B  Generator
 CV solenoid valve
 PCM
STA fuse
STA Starter relay
 PCM
ENG BAR fuse
Front HO2S (RH)

 Front HO2S (LH)
 Rear HO2S (RH)
ENG BAR  Rear HO2S (LH)
 Oil control valve (RH)
 Oil control valve (LH)
 Mass air flow/intake air temperature sensor
 Purge solenoid valve
 Brake switch No.2
ENG BAR2 fuse
ENG BAR2 A/C relay

 PCV valve heater fitting
 PCV valve heater control
ENG INJ fuse

ENG INJ
 PCM
INJ fuse
 PCM
 Fuel injector No.1
INJ
Microsoft
Fuel injector No.6


IG COIL fuse
 Condenser
 Ignition coil No.1
IG COIL  Ignition coil No.2
NO.2 MIL ILLUMINATES [MZI-3.7]

NO.2 MIL ILLUMINATES (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
2 MIL ILLUMINATES
DESCRIPTION The MIL is illuminated incorrectly.
 The PCM illuminates for emission-related concern (DTC is stored in PCM)
 Instrument cluster malfunction
POSSIBLE
CAUSE NOTE:
 If the MIL blinks at steady rate, misfire condition could possibly
exist.
NO.2 MIL ILLUMINATES (MZI-3.7) DIAGNOSTIC PROCEDURE

STEP INSPECTION RESULTS ACTION
DTC is displayed:
Yes  Go to appropriate the DTC inspection.

Turn the ignition switch to the ON (See DTC TABLE [MZI-3.7] .)
1 position (Engine off). No DTC is displayed:
Retrieve any DTCs.
Are there any DTCs displayed?  Inspect instrument cluster operation.
No
INSPECTION .)
 Verify test results.

 If normal, return to diagnostic index to service any additional symptoms.
Microsoft
(See SYMPTOM DIAGNOSTIC INDEX [MZI-3.7].)
 If malfunction remains, inspect related Service Bulletins and/or On-line Repair

Information and perform repair or diagnosis.
2  If vehicle is repaired, troubleshooting completed.
 If vehicle is not repaired or additional diagnostic information is not available,

replace the PCM.
NO.3 WILL NOT CRANK [MZI-3.7]

NO.3 WILL NOT CRANK (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
3 WILL NOT CRANK
DESCRIPTION The starter does not work.
 Open starter circuit between ignition switch and starter
 TR switch malfunction
 TR switch misadjustment
 Low or dead battery
 Charging system malfunction.
POSSIBLE CAUSE
 Starter malfunction
 Seized/hydrolocked engine, drive plate
 Immobilizer system and/or circuit malfunction
 Immobilizer system operating properly. (Ignition key is not registered)
 Advanced keyless entry system malfunction
NO.3 WILL NOT CRANK (MZI-3.7) DIAGNOSTIC PROCEDURE

NOTE:
Inspect advanced keyless entry system and
 The following test should be repair or replace according to inspection
performed on the advanced result.
keyless entry system. If not Yes
1 (See SYMPTOM
equipped, go to the next step. TROUBLESHOOTING CHART
Start the engine using the mechanical
ignition key.Does the engine start? No Go to the next step.
Connect the M-MDS to the DLC-2. Both conditions appear:
Do the following conditions appear? Yes
2 Go to Step 4.
 The engine is not completely
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started. Either or other condition appears:

No
 DTC P1260 is displayed. Go to the next step.
Is the coil antenna connector securely Connect the coil antenna connector
3
connected to the coil antenna? No securely.
Return to Step 1.
Inspect and repair or replace the following:
 Wiring harnesses and connectors

from keyless control module terminal
3W and instrument cluster terminal
1W
4 Does the security light flush?
No  Wiring harness and connectors from
keyless control module terminal 3X
and instrument cluster terminal 1X
 Instrument cluster

INSPECTION .)
Connect the M-MDS to the DLC-2 and
retrieve DTC for PCM, instrument cluster
and keyless control module.
Go to appropriate DTC inspection.
DTC Yes
(See DTC TABLE [MZI-3.7] .)
PCM: B1342, U0073, U0155
5 Instrument cluster: B1213, B1600,
B1601, B1602, B1681, B2103, B2139,
B2431, U0100, U0214
Keyless control module (with advanced
keyless entry system): B1681, B2103, No Go to the next step.
B1213
Inspect for the following wiring harnesses
and connectors:
With advanced keyless entry system Repair or replace suspected wiring harness
Yes
and connector.
 Between coil terminal A and
keyless control module terminal 3V
6  Between coil terminal B and
keyless control module terminal 3U
No
Without advanced keyless entry system
Go to the next step, (with advanced keyless
 Between coil terminal A and entry system)
instrument cluster terminal 1E Go to the Step 8. (without advanced keyless
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 Between coil terminal B and entry system)

instrument cluster terminal 1G

Inspect the following wiring harnesses
and connectors for an open or short
circuit:
Repair or replace wiring harness and
 Between keyless control module Yes
connectors.
terminal 3W and instrument cluster
7 terminal 1W
 Between keyless control module
terminal 3X and instrument cluster
terminal 1X
and connectors:
Repair or replace suspected wiring harness
 Between PCM terminal 1BG and Yes
and connector.
instrument cluster terminal 1W
8
 Between PCM terminal 1BL and
instrument cluster terminal 1X
Inspect the following:

 Battery connection
 Battery condition
(See: 01-17-2 BATTERY

INSPECTION [MZI-3.7])
9
 Fuses
Service if necessary.
(See: 01-03-12 NO.1 MELTING No
Repeat Step 9.
OF MAIN OR OTHER FUSES
[MZI-3.7])
 Transmission in Park or Neutral

(AT)
Microsoft
Are all items normal?

Connect the M-MDS to the DLC-2. Yes Go to the next step.
Turn ignition switch to the ON position. Inspect TR switch is adjusted properly,
(Engine off) inspect for open or short circuit between TR
10
Access TR PID. No switch and TCM.
Is TR PID indicated P/N when selecting P Repair or replace components as required.
or N position Then go to the next step.
Is clicking sound heard from starter relay Yes Go to step 14.
11 when the ignition switch is turned to
START? No Go to the next step.
Inspect the starter relay and following
harnesses.
Between starter relay and PCM
12
Between starter relay and ignition switch Repair or replace components as required.
(See: 09-21-6 RELAY INSPECTION) No
Then go to step 11.
Are they normal?
Inspect IGNITION switch and related Yes Go to the next step.
harnesses.
13 (See: 09-21-2 IGNITION SWITCH Repair or replace components as required.
INSPECTION) No
Then go to step 11.
Are they normal?
Inspect the following harnesses. Yes Go to the next step.
Between starter relay and Battery
14 Repair or replace as required.
Between starter relay and Starter No
Are they normal? Then go to next step.
Inspect the starting system.
(See: 01-19-2 STARTER INSPECTION
15
[MZI-3.7])
No Repair or replace components as required.
Is starting system normal?
Inspect for seized/hydro locked engine or Yes Repair or replace components as required.
16 flywheel.
Is ENGINE seized or hydro locked? No Go to the next step.
DTC is displayed:
Communication error message is
displayed:
Inspect for the following:
17 Yes
 Open circuit in wiring harness
between main relay and PCM
terminal 1BO or 1BJ
Connect the M-MDS to the DLC-2.  Open circuit in wiring harness
Retrieve any continuous memory DTCs. between main relay terminal E and
Are there any continuous memory DTCs PCM terminal 1BM
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displayed?  Main relay is stuck open.

 Open or short circuit in wiring
harness between the DLC-2 and PCM
terminals 1BL or 1BG
 Open or poor GND circuit (PCM
terminal 1D, 1J, 1BP, 1BK)
 Poor connection of vehicle body
GND
No DTC is displayed:
No
DTC is displayed:
Retrieve any KOEO DTCs using M- Yes Go to appropriate DTC inspection.
MDS. (See DTC TABLE [MZI-3.7] .)
18
Are there DTCs displayed during KOEO
inspection? No DTC is displayed:
No

19
 If vehicle is repaired, troubleshooting completed.

replace the PCM.
(See PCM REMOVAL/INSTALLATION [MZI-3.7] .)
NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK

[MZI-3.7]
NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK (MZI-3.7)
DETECTION CONDITIONS AND POSSIBLE CAUSES
4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK
 The starter cranks engine at normal speed but engine requires excessive cranking
DESCRIPTION time before starting.
 The battery is in normal condition.
 Erratic signal to ignition coil

 Vacuum leakage
 Poor fuel quality
 Starting system malfunction
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 Air leakage from intake-air system
 Erratic signal from CKP sensor
 Erratic signal from CMP sensor
 Improper air/fuel mixture ratio control
 Air cleaner restriction
 Improper operation of electronic throttle control system
 Inadequate fuel pressure
 MAF sensor contamination
 Incorrect MAF sensor GND voltage
 Restriction in exhaust system
 Pressure regulator malfunction (built-in fuel pump unit)
WARNING:
POSSIBLE The following troubleshooting flow chart contains the fuel system diagnosis
CAUSE and repair procedures. Read the following warnings before servicing the fuel
system:
 Fuel vapor is hazardous. It can easily ignite, causing serious injury

and damage. Always keep sparks and flames away from fuel.
serious injuries or death and damage. Fuel can also irritate skin and
eyes. To prevent this, always complete "BEFORE SERVICE
PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this
manual.
(See BEFORE SERVICE PRECAUTION [MZI-3.7] .)
(See AFTER SERVICE PRECAUTION [MZI-3.7] .)
CAUTION:
 Disconnecting/connecting quick release connector without cleaning it
may cause damage to fuel pipe and quick release connector. Always
clean quick release connector joint area before
disconnecting/connecting, and make sure that it is free of foreign
material.
NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK (MZI-3.7)

Microsoft

 Vacuum leakage Yes Go to the next step.

 Proper fuel quality (such as proper
octane, contamination,
winter/summer blend)
 Loose bands on intake-air system
1
 Cracks on intake-air system parts
 Intake-air system restriction (such Service if necessary.
as air cleaner element, fresh air No
Repeat Step 1.
duct.)

Connect the M-MDS to the DLC-2. DTC is displayed:
Turn the ignition switch to the ON Yes Go to the appropriate DTC inspection.
2 position (Engine off). (See DTC TABLE [MZI-3.7] .)
Retrieve any DTCs. No DTC is displayed:
Are there any DTCs displayed? No
Go to symptom troubleshooting "No. 17
Cooling system concerns-Overheating".
Yes (See NO.17 COOLING SYSTEM
3 Is engine overheating? CONCERNS-OVERHEATING [MZI-
3.7].)
Inspect the ignition coil related wiring
harness condition (intermittent open or
4
short circuit) for all cylinders.
No Repair the wiring harnesses.
Are wiring harness conditions normal?
Spark plug is wet or covered with carbon:
Inspect the spark plug conditions. Yes Inspect for fuel leakage from fuel injector.
5 Is spark plug wet, covered with carbon or Spark plug is grayish white:
grayish white? Inspect the fuel injector for clogging.
Install the spark plugs on original cylinders.
No
Visually inspect the CKP sensor and
teeth of crankshaft pulley.
6
Are the CKP sensor and teeth of
No Replace the malfunctioning part.
crankshaft pulley normal?
Remove and shake the PCV valve. Yes Go to the next step.
7
Does the PCV valve rattle? No Replace the PCV valve.
Inspect the electronic throttle control system
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operation.
Attempt to start engine at part throttle. Yes (See ENGINE CONTROL SYSTEM
8 Does engine run smoothly at part OPERATION INSPECTION [MZI-3.7].)
throttle?
Zero or low:
Install the fuel pressure gauge between Inspect the fuel pump relay and the fuel
the fuel pipe and fuel distributor. pump circuit.
Short check connector terminal F/P to Inspect the fuel line for clogging.
body GND using a jumper wiring. If there is no malfunction, replace the fuel
Turn the ignition switch to the ON pump unit.
9 (See FUEL PUMP UNIT
position. No
Is fuel line pressure correct with ignition REMOVAL/INSTALLATION [MZI-
switch ON? 3.7] .)
(See FUEL LINE PRESSURE High:
INSPECTION [MZI-3.7] .) Replace the fuel pump unit.
(See FUEL PUMP UNIT
3.7] .)
Inspect the fuel injector.
Is the fuel line pressure held after ignition (See FUEL INJECTOR INSPECTION
switch is turned off? [MZI-3.7] .)
10 If the fuel injector is normal, replace the fuel
(See FUEL LINE PRESSURE No
INSPECTION [MZI-3.7] .) pump unit.
(See FUEL PUMP UNIT
3.7] .)
Disconnect a vacuum hose from purge
solenoid valve and plug opening end of Inspect if the purge solenoid valve is stuck
Yes
11 vacuum hose. open.
Start engine.
Is starting condition improved? No Go to the next step.
Inspect the MAF sensor for following:
Yes Repair or replace the malfunctioning part.
 Contamination
12  MAF sensor terminal B voltage
(GND circuit)
Is there any contamination?
Visually inspect the exhaust system part. Yes Replace the suspected part.
13 Is there any deformed exhaust system
part? No Go to the next step.
Yes
Inspect the starting system. Inspect for loose connectors or poor
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(See STARTER INSPECTION [MZI- terminal contact.

14 3.7] .)
Is starting system normal? No Repair or replace components as required.


15

Replace the PCM.
NO.5 ENGINE STALLS-AFTER START/AT IDLE [MZI-3.7]

NO.5 ENGINE STALLS-AFTER START/AT IDLE (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
5 ENGINE STALLS-AFTER START/AT IDLE
DESCRIPTION  Engine stops unexpectedly.
 A/C system operation is improper

 Air leakage from intake-air system parts
 No signal from CKP sensor due to sensor, related wire or wrong installation
 Vacuum leakage
 Low engine compression
 Electrical connector disconnection
 Open or short circuit in fuel pump body and related wiring harness
 No battery power supply to PCM or poor GND
 Fuel pump body mechanical malfunction
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 Fuel leakage from fuel injector

 Fuel injector clogging
 Improper operation variable valve timing control system
 Immobilizer system operating property. (Ignition key is not registered.)
WARNING:
The following troubleshooting flow chart contains the fuel system diagnosis
and repair procedures. Read the following warnings before servicing the fuel
system:
POSSIBLE
CAUSE  Fuel vapor is hazardous. It can easily ignite, causing serious injury
manual.
CAUTION:
material.
NO.5 ENGINE STALLS-AFTER START/AT IDLE (MZI-3.7) DIAGNOSTIC PROCEDURE

Connect the M-MDS to the DLC-2. Both conditions appear:
Do the following conditions appear? Yes
Go to Step 3.
1
 The engine is not completely started. Either or other condition appears:
No
 DTC P1260 is displayed.
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Does the engine stall after approx. 2 s Immobilizer system is normal.

2 No
since the engine is started? Go to Step 9.
Is coil connector securely connected to
3 Connect the coil connector securely.
coil? No
Return to Step 2.
Wiring harnesses and connectors

from keyless control module
terminal 3W and instrument cluster
terminal 1W
4 Does the security light flush?  Wiring harness and connectors from
No
and instrument cluster terminal 1X

INSPECTION .)
retrieve DTC for PCM, instrument cluster
and keyless control module (with advanced
keyless entry system). Go to the appropriate DTC inspection.
Are any of the following DTCs displayed? Yes
DTC
5 PCM: B1342, U0073, U0155
Instrument cluster: B1213, B1600,
B1601, B1602, B1681, B2103, 2139,
B2431, U0110, U0214
Keyless control module (with advanced No Go to the next step.
keyless entry system): B1681, B2103,
B1213

Repair or replace the suspected wiring
and connectors: Yes
harness and connector.
With advanced keyless entry system:
6  Between coil terminal A and keyless

control module terminal 3V
 Between coil terminal B and keyless
control module terminal 3U
Without advanced keyless entry system: Go to the next step, (with advanced
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 Between coil terminal A and keyless entry system.)

instrument cluster terminal 1G Go to Step 8. (without advanced keyless
entry system.)
 Between coil terminal B and
instrument cluster terminal 1E No

Inspect the following wiring harnesses and
connectors for an open or short circuit:
 Between keyless control module Repair or replace wiring harness and

Yes
terminal 3W and instrument cluster connectors.
terminal 1W
7
terminal 1X
and connectors:
8
Verify the following:
 Vacuum connection Yes Go to the next step.

 Air cleaner element
 No air leakage from intake-air
system
9  No restriction of intake-air system
 Proper sealing of intake manifold
and components attached to intake
manifold Service if necessary.
No
 Ignition wiring Repeat Step 9.
 Fuel quality: proper octane,
contamination, winter/summer blend
 Electrical connections
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 Smooth operation of throttle valve

 APP sensor
 Wiring harnesses and connectors for
following:
 PCM terminal 1AC-APP
Connect the M-MDS to the DLC-2. sensor terminal B
Access the APP1 and APP2, APP3 PIDs.  PCM terminal 1 AH-APP
Crank the engine with accelerator pedal sensor terminal C
10 released.
Are the APP1 and APP2, APP3 PIDs No  PCM terminal 1Y-APP sensor
indicating that the accelerator pedal is in terminal D

the released position?  PCM terminal 1AK-APP
sensor terminal E
 PCM terminal 1BA-APP
sensor terminal F
 PCM terminal 1 AD-APP
sensor terminal G
 PCM terminal 1AG-APP
sensor terminal H
 TP sensor
following:
 PCM terminal 2BO-TP sensor
Connect the M-MDS to the DLC-2. terminal A
Access the TP1, TP2 PID. Crank the
 PCM terminal 2BR-TP sensor
11 engine with accelerator pedal released.
terminal B
Are the TP1, TP2 PID indicates the closed No
throttle position?  PCM terminal 2AD-TP sensor
terminal C
 PCM terminal 2D-TP sensor
terminal D
 PCM terminal 2AH-TP sensor
terminal E
 PCM terminal 2Z-TP sensor
terminal F
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DTC is displayed:
displayed:

between main relay and PCM
Connect the M-MDS to the DLC-2. terminal 1 BO or 1BJ
Turn the ignition switch to the ON position Yes
 Open main relay GND circuit
12 (Engine off).
Retrieve any DTCs.  Main relay is stuck open.
Are there any DTCs displayed?  Open or short circuit in wiring

harness between the DLC-2 and
PCM terminals 1BL or 1BG
 Poor connection of vehicle body
GND
No
Inspect electronic throttle control system
operation.
Attempt to start engine at part throttle. Yes (See ENGINE CONTROL SYSTEM
13 OPERATION INSPECTION [MZI-
Does engine run smoothly at part throttle?
3.7].)
 Open or short circuit in CKP sensor

 Open or short circuit in wiring
harness between CKP sensor
Connect the M-MDS to the DLC-2. terminal A and PCM terminal 2P
Access RPM PID.  Open or short circuit in wiring
14
Is RPM PID indicating engine speed No harness between CKP sensor
during engine cranking? terminal B and PCM terminal 2T
wiring harnesses
If CKP sensor and wiring harness are

normal, go to the next step.
Visually inspect CKP sensor and teeth of
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crankshaft pulley. Yes Go to the next step.

15 Are CKP sensor and teeth of crankshaft
pulley normal? No Replace the malfunctioning part.
16
short circuit) for all cylinders. Are wiring
harness conditions normal?
Perform the spark test. Go to the next step.
(See ENGINE CONTROL SYSTEM Yes If symptoms occurs with the A/C on, go to
OPERATION INSPECTION [MZI- Step 23.
17
3.7].)
Is strong blue spark visible at each Repair or replace the malfunctioning part
No
cylinder? according to spark test result.
Spark plug is wet or covered with
carbon:
Inspect the spark plug condition. Yes Inspect for fuel leakage from injector.
Install spark plugs on original cylinders.
No
19
visually inspect the exhaust system part. Yes Replace the suspected part.
20
Is there any deformed exhaust system part? No Go to the next step.
Zero or low:
Install the fuel pressure gauge between the Inspect the fuel pump relay and fuel pump
fuel pipe and the fuel distributor. circuit.
Short check connector terminal F/P to body Inspect the fuel line for clogging.
GND using a jumper wiring. If there is no malfunction, replace the fuel
position. No
switch ON? 3.7] .)
(See FUEL PUMP UNIT
3.7] .)
Visually inspect for fuel leakage at fuel
injector O-ring and fuel line. Inspect the fuel injector.
22 Service if necessary. If the fuel injector is normal, replace the
Is fuel line pressure held after ignition No fuel pump unit.
switch is turned off? (See FUEL PUMP UNIT
(See FUEL LINE PRESSURE REMOVAL/INSTALLATION [MZI-
Microsoft

 The following test is for stall If A/C is always on, go to symptom
concerns with the A/C on. If other troubleshooting "No.24 A/C is always on
symptoms exist, go to the next or A/C compressor runs continuously".
step.
(See NO.24 A/C IS ALWAYS ON OR
23 A/C COMPRESSOR RUNS
Connect pressure gauges to A/C low and No CONTINUOUSLY [MZI-3.7].)
high pressure side lines.Turn A/C on and For other symptoms, inspect the following:
measure low side and high side
pressures.Are pressures within  Refrigerant charging amount
specifications?(See REFRIGERANT
 Condenser fan operation
PRESSURE CHECK .)
Disconnect the vacuum hose between the Inspect if purge solenoid valve is stuck
purge solenoid valve and the intake open.
manifold from purge solenoid side. Yes
24 Inspect evaporative emission control
Plug opening end of vacuum hose. system.
Start the engine.
Is the engine stall now eliminated? No Go to the next step.
Is air leakage felt or heard at intake-air Yes Repair or replace the malfunctioning part.
25 system components while racing the
engine to higher speed? No Go to the next step.
Inspect variable valve timing control Yes Go to the next step.
system operation.
(See ENGINE CONTROL SYSTEM
26 OPERATION INSPECTION [MZI- Repair or replace the malfunctioning parts
3.7].) No according to variable valve timing control
Does variable valve timing control system operation inspection results.
function properly?
Yes Inspect the valve timing.
27 Is the engine compression correct?
No Inspect for cause.

28

replace the PCM.
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NO.6 CRANKS NORMALLY BUT WILL NOT START [MZI-3.7]

NO.6 CRANKS NORMALLY BUT WILL NOT START (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
6 CRANKS NORMALLY BUT WILL NOT START
 The starter cranks engine at normal speed but the engine will not run.
 Refer to symptom troubleshooting "NO.5 ENGINE STALLS" if this symptom
DESCRIPTION appears after engine stall.
 Fuel is in tank.
 Battery is in normal condition.
 No battery power supply to PCM
 Open PCM GND or vehicle body GND
 No signal from CKP sensor due to sensor, related wire or incorrect installation
 No signal from CMP sensor due to sensor, related wire or incorrect installation
 Vacuum leakage
POSSIBLE  Restriction in intake-air system
CAUSE  Restriction in exhaust system
 Disconnected electrical connector
 Open or short circuit in fuel pump body and related wiring harness
 Fuel pump mechanical malfunction
 Fuel leakage from injector
 Fuel injector is clogged.
 Improper variable valve timing control system operation
 Immobilizer system operating properly. (Ignition key is not registered.)
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WARNING:
system:

manual.
CAUTION:
material.
NO.6 CRANKS NORMALLY BUT WILL NOT START (MZI-3.7) DIAGNOSTIC PROCEDURE
Both conditions appear:
Do any of the following conditions Yes
Go to Step 3.
appear?
1
 Engine does not completely start. No Either or other condition appears:
 DTC P1260 is displayed.

Does engine stall after approx. 2 s from
2 Immobilizer system is normal.
when it is started? No
Go to Step 9.
Is the coil connector securely connected
3 Connect the coil connector securely.
to the coil? No
Return to Step 2.

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 Wiring harnesses and connectors from

keyless control module terminal 3W
and instrument cluster terminal 1W
 Wiring harness and connectors from
4 Does the security light flush? No and instrument cluster terminal 1X

INSPECTION .)
retrieve the DTC for PCM, instrument
cluster and keyless control module (with
advanced keyless entry system).
Go to the appropriate DTC inspection.
Are any of the following DTCs Yes
displayed?
DTC
5
PCM: B1342, U0073, U0155
Instrument cluster: B1213, B1600,
B1601, B1602, B1681, B2103, B2139,
B2431, U0100, U0214
Keyless control module (with No Go to the next step.
advanced keyless entry system):
B1681, B2103, B1213

and connectors:
With advanced keyless entry system: Repair or replace the suspected wiring
Yes
 Between coil terminal A and
keyless control module terminal
3V
keyless control module terminal
6 3U
Go to the next step, (with advanced keyless

Without advanced keyless entry system: entry system.)
No
Go to Step 8. (without advanced keyless
 Between coil terminal A and entry system.)
instrument cluster terminal 1G
instrument cluster terminal 1E
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and connectors for an open or short
circuit:
Repair or replace wiring harness and
 Between keyless control module Yes
connectors.
terminal 3W and instrument
7 cluster terminal 1W
terminal 1X
and connectors:
8
 Vacuum connection
 External fuel shut off or accessory
(such as kill switch, alarm) Yes Go to the next step.
 Fuel quality: proper octane,
contamination, winter/summer
blend
system
9  Intake-air system restriction (such
as air cleaner element, fresh air
duct)
 Proper sealing of intake manifold Service if necessary.
and components attached to intake No Repeat Step 9.
manifold
 Ignition wiring
 Fuses
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DTC is displayed:
 Go to the appropriate DTC inspection.

displayed:
Turn the ignition switch to the ON Yes  Open circuit in wiring harness between
10 position (Engine off). main relay and PCM terminal 1 BO or
Retrieve any DTCs. 1BJ
Are there any DTCs displayed?  Open main relay GND circuit
 Open or short circuit in wiring harness

between the DLC-2 and PCM terminal
1BL or 1BG
 Main relay is stuck open.

 Poor connection of vehicle body GND
No
 APP sensor
following:
Access the APP1 and APP2, APP3
PIDs. Crank the engine with accelerator  PCM terminal 1 AC-APP sensor
11 pedal released. terminal B

Are the APP1 and APP2, APP3 PIDs No
 PCM terminal 1 AH-APP sensor
indicating that the accelerator pedal is in terminal C
the released position?  PCM terminal 1Y-APP sensor
terminal D
 PCM terminal 1AK-APP sensor
terminal E
 PCM terminal 1BA-APP sensor
terminal F
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 PCM terminal 1AD-APP sensor

terminal G
 PCM terminal 1AG-APP sensor
terminal H
 TP sensor
following:
 PCM terminal 2BO-TP sensor
Connect the M-MDS to the DLC-2. terminal A
Access the TP1, TP2 PID. Crank the
 PCM terminal 2BR-TP sensor
12 engine with accelerator pedal released.
No terminal B
Are the TP1, TP2 PID indicates the
closed throttle position?  PCM terminal 2AD-TP sensor
terminal C
 PCM terminal 2D-TP sensor
terminal D
 PCM terminal 2AH-TP sensor
terminal E
 PCM terminal 2Z-TP sensor
terminal F
Does the engine start with the throttle Yes Go to Step 28.
13
valve closed? No Go to the next step.
Inspect the electronic throttle control system
operation.
Will the engine start and run smoothly at Yes
14 (See ENGINE CONTROL SYSTEM
part throttle? OPERATION INSPECTION [MZI-3.7].)
Connect the M-MDS to the DLC-2.  Open or short circuit in CKP sensor
Access RPM PID.  Open or short circuit in wiring harness
15
Is RPM PID indicating the engine speed No between CKP sensor terminal A and
when cranking the engine? PCM terminal 2P
between CKP sensor terminal B and
PCM terminal 2T
wiring harnesses
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If CKP sensor and wiring harness are normal,

Visually inspect the CKP sensor and
teeth of crankshaft pulley.
16
Are CKP sensor and teeth of crankshaft
pulley normal?
17
short circuit) for all cylinders. Are
wiring harness conditions normal?
Perform the spark test.
OPERATION INSPECTION [MZI-
18
3.7].) Repair or replace the malfunctioning part
Is strong blue spark visible at each No
according to spark test result.
cylinder?
Spark plug is wet or covered with carbon:
Inspect for fuel leakage from injector.
Inspect the spark plug conditions. Yes
Spark plug is grayish white:
19 Is spark plug wet, covered with carbon Inspect the fuel injector for clogging.
or grayish white?
Install the spark plugs on original cylinders.
No
20
visually inspect the exhaust system part. Yes Replace the suspected part.
21 Is there any deformed exhaust system
part? No Go to the next step.
Zero or low:
Install the fuel pressure gauge between Inspect the fuel pump relay and fuel pump
the fuel pipe and the fuel distributor. circuit.
Short check connector terminal F/P to Inspect the fuel line for clogging.
body GND using a jumper wiring. If there is no malfunction, replace the fuel
22 position. (See FUEL PUMP UNIT
Is fuel line pressure correct when No
ignition switch is turned on/off five 3.7] .)
times? High:
(See FUEL LINE PRESSURE Replace the fuel pump unit.
INSPECTION [MZI-3.7] .) (See FUEL PUMP UNIT
3.7] .)
Visually inspect the fuel injector O-ring
and fuel line for fuel leakage. Inspect the fuel injector.
Microsoft
Service if necessary. If the fuel injector is normal, replace the fuel

Is the fuel line pressure held after the pump unit.
23 ignition switch is turned off? No (See FUEL PUMP UNIT
Disconnect the vacuum hose between
the purge solenoid valve and the intake Inspect if the purge solenoid valve is stuck
manifold from purge solenoid valve open mechanically.
Yes
24 side. Inspect the evaporative emission control
Start the engine.
Is starting condition improved? No Go to the next step.
Is air leakage felt or heard at intake-air Yes Repair or replace the malfunctioning part.
25 system components while racing engine
to higher speed? No Go to the next step.
Inspect the variable valve timing control
system operation. Yes Go to the next step.
3.7].)
Does variable valve timing control No Repair or replace the malfunctioning part.
function properly?
No Inspect for causes.

28

replace the PCM.
NO.7 SLOW RETURN TO IDLE [MZI-3.7]

NO.7 SLOW RETURN TO IDLE (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
7 SLOW RETURN TO IDLE
DESCRIPTION Engine takes more time than normal to return to idle speed.

Microsoft
 Thermostat is stuck open.

POSSIBLE CAUSE  Throttle body malfunction
NO.7 SLOW RETURN TO IDLE (MZI-3.7) DIAGNOSTIC PROCEDURE

ECT and thermostat are normal.
Yes
Access ECT PID on the M-MDS.
Remove thermostat and inspect operation. Inspect for both ECT PID and temperature
(See THERMOSTAT gauge on instrument cluster readings.
REMOVAL/INSTALLATION [MZI- If temperature gauge on instrument cluster
2 3.7] .) indicates normal range but ECT PID is not
(See THERMOSTAT INSPECTION No same as temperature gauge reading, inspect
[MZI-3.7] .) CHT sensor.
Is thermostat normal? If temperature gauge on instrument cluster
indicates cold range but ECT PID is normal,
inspect temperature gauge and heat gauge
unit.
Inspect for air leakage from the intake-air
Yes system components while racing the engine
3 Is throttle body free of contamination? to higher speed.
No Clean or replace throttle body.

4

replace the PCM.
Microsoft
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [MZI-3.7]

NO.8 ENGINE RUNS ROUGH/ROLLING IDLE (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
8 ENGINE RUNS ROUGH/ROLLING IDLE
 Engine speed fluctuates between specified idle speed and lower speed and
DESCRIPTION engine shakes excessively.
 Idle speed is too slow and engine shakes excessively.

 Idle learning of electronic throttle control system is not completed
 Erratic or no signal from CMP sensor
 Improper air / fuel mixture ratio control operation (abnormal signal form MAF
sensor or HO2S)
POSSIBLE  Open or short circuit in PCM GND circuit
CAUSE  Poor fuel quality
 Disconnected electrical connectors
 Fuel pump body mechanical malfunction
 Improper load signal input
 Fuel line restriction or clogging
 Improper fuel injection control operation
 Vacuum leakage
Microsoft
WARNING:
The following troubleshooting flow chart contains fuel system diagnosis and
repair procedures. Read following warnings before servicing the fuel
system:

manual.
CAUTION:
material.
NO.8 ENGINE RUNS ROUGH/ROLLING IDLE (MZI-3.7) DIAGNOSTIC PROCEDURE

Troubleshooting completed. (Cause of this
Warm up the engine. symptom is that the idle learning of
Yes
1 Idle the engine for 5 min. electronic throttle control system is not
Is the symptom disappeared? completed.)
 External fuel shut off or accessory

(such as kill switch, alarm)
 Fuel quality (such as proper octane,
2 contamination, winter/summer
blend)
system
manifold
Microsoft
 Ignition wiring
 Fuses
 Smooth operation of throttle valve Service if necessary.
No
 PCM GND circuit (1D, U, 1BP, Repeat Step 2.
1BK)

Turn the ignition switch to the ON position Yes Go to the appropriate DTC inspection.
3 (Engine off). (See DTC TABLE [MZI-3.7] .)
Go to symptom troubleshooting "No.17
Cooling system concerns - Overheating".
Yes (See NO.17 COOLING SYSTEM
4 Is the engine overheating? CONCERNS-OVERHEATING [MZI-
3.7].)
Access MAF PID.
5 Inspect for open or short circuit of MAF
Drive vehicle with monitoring PID. Is No
MAF PID within specification? sensor and related wiring harness.
 The following test is for engine If the A/C is always on, go to symptom
running at rough idle with A/C on. troubleshooting "No.24 A/C is always on
If other symptoms exist, go to the or A/C compressor runs continuously".
next step.
(See NO.24 A/C IS ALWAYS ON OR
A/C COMPRESSOR RUNS
6 Connect pressure gauge to A/C low and
No CONTINUOUSLY [MZI-3.7].)
high pressure side lines.Start engine and For other symptoms, inspect the
idle it.Turn the A/C switch on.Measure low following:
side and high side pressures.Are pressures
within specifications?(See  Refrigerant charging amount
REFRIGERANT PRESSURE
 Condenser fan operation
CHECK .)

 The following test is for engine
running rough with P/S on. If other
7 symptoms exist, go to the next Inspect power steering pressure switch
step. No operation and wiring harness between P/S
pressure switch and PCM terminal 21.
Connect the M-MDS to the DLC-2.Start
Microsoft
the engine and idle it.Access PSP PID.Is

PSP PID within specification?
Visually inspect the CKP sensor and teeth
of crankshaft pulley.
8
Are the CKP sensor and teeth of crankshaft
pulley normal?
9
short circuit) for all cylinders. Are wiring
harness conditions normal?
carbon:
Yes Inspect for fuel leakage from injector.
Inspect the spark plug condition. Spark plug is grayish white:
10 Is the spark plug wet, covered with carbon Inspect the fuel injector for clogging.
or grayish white?
Install the spark plugs on original
No cylinders.
Perform the electronic throttle control Yes Go to the next step.
system operation inspection.
11 OPERATION INSPECTION [MZI- Repair or replace the malfunctioning part
3.7].) No according to electronic throttle control
Does the electronic throttle control system system operation inspection results.
function properly?
Low:
Inspect the fuel line for clogging.
Install fuel pressure gauge between fuel If there is no malfunction, replace fuel
pipe and fuel distributor. pump unit.
Start the engine and run it at idle. (See FUEL PUMP UNIT
12 Measure fuel line pressure during idle. REMOVAL/INSTALLATION [MZI-
Is fuel line pressure correct during idle? No
3.7] .)
(See FUEL PUMP UNIT
3.7] .)
Visually inspect for fuel leakage at fuel Yes Go to the next step.
injector, O-ring, and fuel line. Inspect fuel injector.
Service if necessary. If fuel injector is normal, replace fuel
13 Does fuel line pressure hold after ignition pump unit.
switch is turned off? No
(See FUEL PUMP UNIT
Microsoft
LONG FT1 PID, LONG FT2 PID is out of

specification.
Less than specification (too rich):
Connect the M-MDS to the DLC-2.  Inspect EVAP control system.
Start the engine and idle it.
Access LONG FT1 PID, LONG FT2 PID.
14 No
Measure LONG FT1 PID, LONG FT2 PID Greater than specification (too lean):
at idle.
Is PID value normal?  Inspect for air leakage at intake-air
system components.
 If system is normal, go to the
next step.
Disconnect the vacuum hose between the
purge solenoid valve and the intake Check if purge solenoid valve is stuck
manifold from purge solenoid valve side. Yes open mechanically.
15 Inspect EVAP control system.
Plug opening end of vacuum hose.
Start the engine.
Does the engine condition improve? No Go to the next step.
16
Visually inspect the exhaust system part. Yes Replace the suspected part.
17
Visually inspect the CMP sensor and teeth
of camshaft.
18
Are the CMP sensor and teeth of camshaft
normal?
Inspect variable valve timing control
system operation. Yes Go to the next step.
3.7].)
Does variable valve timing control system No Repair or replace the malfunctioning part.
function properly?
20 Is engine compression correct?
No Inspect for causes.

21 (See SYMPTOM DIAGNOSTIC INDEX [MZI-3.7].)

Microsoft

replace the PCM.
NO.9 FAST IDLE/RUNS ON [MZI-3.7]

NO.9 FAST IDLE/RUNS ON (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
9 FAST IDLE/RUNS ON
 The engine speed continues at fast idle after warm-up.
DESCRIPTION
 The engine runs after the ignition switch is turned off.
POSSIBLE CAUSE  Accelerator pedal position sensor misadjustment
 Cruise control system operation improperly
 Improper load signal input
NO.9 FAST IDLE/RUNS ON (MZI-3.7) DIAGNOSTIC PROCEDURE

Access ECT PID. ECT PID is higher than 112°C {234°F}:
Start and warm up engine to normal Go to symptom troubleshooting "No.17 Cooling
1 system concerns - Overheating".
operating temperature. No
Is ECT PID between 82-112°C ECT PID is less than 82°C {180°F}:
{180-234°F}? Go to symptom troubleshooting "No.18 Cooling
system concerns - Runs cold".
If the AC_REQ PID is not normal:
 Inspect A/C switch, refrigerant pressure

switch, and fan switch, and related wiring
harness for vibration or intermittent
open/short circuit.
Microsoft
If the TR PID is not normal:
 Inspect TR switch and related wiring

Access and monitor PSP and TR harness for vibration or intermittent
PIDs. open/short circuit.
3 Are PIDs values normal? No
3.7] .) If the PSP PID is not normal:
 Inspect power steering switch and related

wiring harness for vibration or intermittent
open/short circuit.
Yes Repair or replace parts if necessary.
Is there air leakage felt or heard at
4 intake-air system components while
No  Electronic throttle control system
racing engine to higher speed?
operation
 Accelerator pedal position sensor

5

replace the PCM.
NO.10 LOW IDLE/STALLS DURING DECELERATION [MZI-3.7]

NO.10 LOW IDLE/STALLS DURING DECELERATION (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
10 LOW IDLE/STALLS DURING DECELERATION
DESCRIPTION  Engine stops unexpectedly at the beginning of deceleration or recovery from

deceleration.
 Vacuum leakage
Microsoft

 Evaporative emission control system malfunction
 Accelerator pedal position sensor or related circuit malfunction
 Accelerator pedal position sensor misadjustment
POSSIBLE
CAUSE  TP sensor or related circuit malfunction
 MAF sensor or related circuit malfunction
 Brake switch or related circuit malfunction
 TR switch or related circuit malfunction
 Improper A/C magnetic clutch operation
NO.10 LOW IDLE/STALLS DURING DECELERATION (MZI-3.7) DIAGNOSTIC PROCEDURE

Engine runs rough/rolling idle".
Yes
1 Does the engine idle roughly? (See NO.8 ENGINE RUNS
ROUGH/ROLLING IDLE [MZI-3.7].)
Go to symptom troubleshooting "No.24 A/C
is always on or A/C compressor runs
continuously."
Turn off the A/C switch and fan switch. Yes
2 (See NO.24 A/C IS ALWAYS ON OR A/C
Does the A/C magnetic clutch engage? COMPRESSOR RUNS
CONTINUOUSLY [MZI-3.7].)
 Proper routing of and no damage
to vacuum lines
3  No air leakage from intake-air
system Service if necessary.
No
Repeat Step 3.

Microsoft

Repair or replace the malfunctioning part
3.7].)
5 No according to electronic throttle control
Does the electronic throttle control
system operation inspection results.
system function properly?
Disconnect the vacuum hose between the
purge solenoid valve and the intake Inspect the evaporative emission control
Yes
manifold from purge solenoid valve side. system.
6
Drive the vehicle.
Does the engine condition improve?
Connect the M-MDS to the DLC-2. APP1, APP2, APP3 PIDs:
Access APP1, APP2, APP3, TP1, TP2, Inspect the accelerator pedal position sensor.
MAF and VSS PIDs. TP1, TP2 PID:
7 Inspect TP sensor.
Monitor each PID while driving vehicle. No
(See PCM INSPECTION [MZI-3.7] .) MAF PID:
Are PIDs normal? Inspect MAF sensor.
VSS PID:
Inspect VSS.
If the BOO PID is not normal:
 Inspect brake switch, and related

wiring harness for vibration or
Access and monitor BOO, TR PIDs. intermittent open/short circuit.
8 Are PIDs values normal?
(See PCM INSPECTION [MZI-3.7] .) No
If the TR PID is not normal:
 Inspect TR switch and related wiring

open/short circuit.

9

replace the PCM.
Microsoft
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES,

BUCK/JERK, HESITATION/STUMBLE, SURGES [MZI-3.7]
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK,
HESITATION/STUMBLE, SURGES (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE
CAUSES
ENGINE STALLS/QUITS-ACCELERATION/CRUISE
ENGINE RUNS ROUGH-ACCELERATION/CRUISE
MISSES-ACCELERATION/CRUISE
11
BUCK/JERK-ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE-ACCELERATION
SURGES-ACCELERATION/CRUISE
 Engine stops unexpectedly at the beginning of acceleration or during
acceleration.
 Engine stops unexpectedly while cruising.
 Engine speed fluctuates during acceleration or cruising.
DESCRIPTION
 Engine misses during acceleration or cruising.
 Vehicle bucks/jerks during acceleration, cruising, or deceleration.
 Momentary pause at beginning of acceleration or during acceleration
 Momentary minor irregularity in engine output
 Improper A/C system operation

 Erratic signal or no signal from CMP sensor
 Vacuum leakage
 Main relay intermittent malfunction
 Improper air/fuel mixture ratio control operation
 Fuel flow into evaporative purge hose
 Improper valve timing due to jumping out timing chain
Microsoft

 Intermittent open or short circuit in fuel body pump circuit
 Check valve (two-way) malfunction integrated with fuel tank
 Erratic signal form APP sensor
 Erratic signal form TP sensor
 Intermittent open or short circuit of MAF sensor, TP sensor, APP sensor and
VSS
 ATX malfunction
 Loose attaching bolts or worn engine mounts
POSSIBLE WARNING:
CAUSE The following troubleshooting flow chart contains the fuel system diagnosis
system:
 Fuel vapor is hazardous. It can easily ignite, causing serious injury and
damage. Always keep sparks and flames away from fuel.
manual.
CAUTION:
material.
NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK,

HESITATION/STUMBLE, SURGES (MZI-3.7) DIAGNOSTIC PROCEDURE
Microsoft

 Vacuum connection
 Air cleaner element Yes Go to the next step.
system
 No restriction of intake-air system
1 manifold
 Ignition wiring
 Fuel quality (such as proper octane,
contamination, winter/summer Service if necessary.
No
blend) Repeat Step 1.

Yes
3 Is engine overheating? Cooling system concerns - Overheating".
APP1, APP2, APP3 PIDs:
Inspect if output signal from APP sensor
changes smoothly.
RPM PID:
Connect the M-MDS to the DLC-2. Inspect the CKP sensor and related wiring
Access APP1, APP2, APP3, RPM, VPWR, harness for vibration or intermittent
MAF, TP1, TP2 and VSS PIDs. open/short circuit.
4
Drive the vehicle with monitoring PIDs. No VPWR PID:
Are PIDs within specifications? Inspect for open circuit intermittently.
(See PCM INSPECTION [MZI-3.7] .) MAF PID:
Inspect for open circuit of the MAF sensor
and related wiring harness intermittently.
TP1, TP2 PID:
Inspect if output signal from TP sensor
changes smoothly.
Microsoft
VSS PID:
Inspect for open circuit of VSS and related
wiring harness intermittently.
5
Are CKP sensor and teeth of crankshaft
pulley normal?
carbon:
Yes Inspect for fuel leakage from fuel injector.
Inspect the spark plug conditions. Spark plug is grayish white:
6 Is spark plug wet, covered with carbon or Inspect the fuel injector for clogging.
grayish white?
No cylinders.
7
8 OPERATION INSPECTION [MZI- Repair or replace the malfunctioning part
3.7].) No according to electronic throttle system
Does the electronic throttle control system operation inspection results.
function properly?
Visually inspect deformed exhaust system Yes Replace the suspected part.
9 part.
Zero or low:
Install fuel pressure gauge between the fuel Inspect the fuel pump relay and fuel pump
pipe and fuel distributor. circuit.
Short check connector terminal F/P to body Inspect the fuel line for clogging.
GND using a jumper wiring. If there is no malfunction, replace the fuel
position. No
switch to ON position? 3.7] .)
(See FUEL PUMP UNIT
3.7] .)
11 injector O-ring and fuel line. Inspect the fuel injector.
Service if necessary. If the fuel injector is normal, replace the
Is fuel line pressure held after ignition fuel pump unit.
Microsoft
switch is turned off? (See FUEL PUMP UNIT

(See FUEL LINE PRESSURE No REMOVAL/INSTALLATION [MZI-
If the A/C is always on, go to symptom
stall with the A/C on. If other troubleshooting "No.24 A/C is always on
symptom exists, go to the next or A/C compressor runs continuously".
step. (See NO.24 A/C IS ALWAYS ON OR
A/C COMPRESSOR RUNS
12 CONTINUOUSLY [MZI-3.7].)
Connect a pressure gauge to A/C low and No
high pressure side lines.Turn the A/C on For other symptoms, inspect the
and measure low side and high side following:
pressure.Are pressures within
specifications?(See REFRIGERANT  Refrigerant charging amount
PRESSURE CHECK .)  Condenser fan operation
NOTE:
 The following test should be Yes Go to the next step.
performed for symptom with
cruise control ON. If other
13 symptoms exist, go to the next
step.
No Repair or replace the malfunctioning part.
Inspect cruise control system.Is cruise
control system normal?
Inspect the front HO2S.
(See FRONT HEATED OXYGEN Replace the front HO2S.
14 SENSOR (HO2S) INSPECTION [MZI- (See REAR HEATED OXYGEN
3.7] .) No SENSOR (HO2S)
Is the front HO2S normal? REMOVAL/INSTALLATION [MZI-
3.7] .)
Inspect the evaporative purge hose between Inspect the check valve (two-way).
the fuel tank and the purge valve. Yes (See FUEL TANK INSPECTION [MZI-
15 3.7] .)
Does fuel flow into evaporative purge
hose? No Go to the next step.
Disconnect the vacuum hose between the Go to the next step.
purge solenoid valve and the intake Inspect if the purge solenoid valve is stuck
manifold from the purge solenoid valve Yes open mechanically.
16 side. Inspect the evaporative emission control
Drive the vehicle.
Does the engine condition improve? No Go to the next step.
Visually inspect the CMP sensor and
projections of camshaft pulley.
17
Are CMP sensor and projections of
camshaft pulley normal?
Microsoft
 Valve timing
Yes  Internal transaxle part
 Engine mounts
 Check valve (two-way)

19

replace the PCM.
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [MZI-3.7]

NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE (MZI-3.7) DETECTION CONDITIONS
AND POSSIBLE CAUSES
12 LACK/LOSS OF POWER-ACCELERATION/CRUISE
DESCRIPTION Performance is poor under load (such as power down when climbing hills).
 Improper A/C system operation

 Erratic signal or no signal from CMP sensor
 Restriction in intake-air system
 Intake air temperature too hot
 Purge control solenoid malfunction
 Brake dragging
 Vacuum leakage
Microsoft

 Improper valve timing due to jumping out of timing chain
 Improper variable valve timing control operation
 Intermittent open or short in fuel pump related circuit
 Erratic signal from accelerator pedal position sensor
 Erratic signal from TP sensor
 Intermittent open or short circuit in MAF sensor, Accelerator pedal position
sensor, TP sensor, IAT sensor and VSS
 ATX malfunction
POSSIBLE
CAUSE WARNING:
system:

manual.
CAUTION:
material.
Microsoft
NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE (MZI-3.7) DIAGNOSTIC PROCEDURE

 Vacuum connection Yes Go to the next step.

 Restriction in intake-air system (such
as air cleaner element, fresh air duct)
 No air leakage from intake-air system
 No restriction of intake-air system
1  Proper sealing of intake manifold and
components attached to intake
manifold Service if necessary.
No
 Fuel quality (such as proper octane, Repeat Step 1.
contamination, winter/summer blend)

Yes
3 Is the engine overheating? Cooling system concerns-Overheating".
APP1, APP2, APP3 PIDs:
Inspect if output signal accelerator pedal
position sensor changes smoothly.
RPM PID:
Inspect CKP sensor and related wiring
Connect the M-MDS to the DLC-2. open/short circuit or both.
Access APP1, APP2, APP3, RPM, MAF, MAF PID:
TP1, TP2, IAT and VSS PIDs. Inspect for intermittent open circuit of
4
Drive vehicle while monitoring PIDs. No MAF sensor and related wiring harness.
Are PIDs within specifications? TP1, TP2 PID:
(See PCM INSPECTION [MZI-3.7] .) Inspect if output signal TP sensor changes
smoothly.
IAT PID:
Inspect for air suction in intake-air
system.
If normal, inspect intermittent short circuit
of IAT sensor and related wiring
harnesses.
Microsoft
VSS PID:
Inspect for intermittent open circuit of
VSS and related wiring harness.
5
Are the CKP sensor and teeth of crankshaft
pulley normal?
carbon:
Inspect the fuel injector for fuel leakage.
Yes
Inspect the spark plug condition. Inspect spark plug and high-tension lead.
No cylinders.
7
Does the PCV valve rattle? No Replace PCV valve.
Perform electronic throttle control system Yes Go to the next step.
operation inspection.
(See ENGINE CONTROL SYSTEM Repair or replace the malfunctioning part
8
OPERATION INSPECTION [MZI-3.7].) No according to electronic throttle control
Does electronic throttle control system system operation inspection results.
function properly?
visually inspect deformed exhaust system Yes Replace the suspected part.
9 part.
Zero or low:
Inspect the fuel pump relay and fuel pump
Install the fuel pressure gauge between the circuit.
fuel pipe and the fuel distributor. Inspect the fuel line for clogging.
Short check connector terminal F/P to body If there is no malfunction, replace the fuel
GND using a jumper wiring. pump unit.
10 Turn the ignition switch to the ON position. (See FUEL PUMP UNIT
Is fuel line pressure correct with ignition No
switch to ON position? 3.7] .)
(See FUEL PUMP UNIT
3.7] .)
If A/C is always on, go to symptom
stalling with the A/C on concern. If troubleshooting "No.24 A/C is always on
or A/C compressor runs continuously".
Microsoft
other symptoms exist, go to the (See NO.24 A/C IS ALWAYS ON OR

next step. A/C COMPRESSOR RUNS
CONTINUOUSLY [MZI-3.7].)
Connect pressure gauge to the A/C low and For other symptoms, inspect the
11 high side pressure lines.Turn the A/C on No following:
and measure low side and high side
pressures.Are pressures within  Refrigerant charging amount
specifications?(See REFRIGERANT  Condenser fan operation
PRESSURE CHECK .)
Inspect for A/C cut-off operation.
12
OPERATION INSPECTION [MZI-3.7].)
No Inspect A/C cut-off system components.
Does the A/C cut-off function properly?
Inspect if purge solenoid valve is stuck
Disconnect the vacuum hose between the open mechanically.
purge solenoid valve and the intake Inspect the evaporative emission control
manifold from purge solenoid valve side. Yes system.
13 (See ENGINE CONTROL SYSTEM
Drive the vehicle. OPERATION INSPECTION [MZI-
Does the engine condition improve? 3.7].)
Visually inspect the CMP sensor and
projections of camshaft pulley.
14
Are the CMP sensor and projections of
camshaft pulley normal?
Inspect the variable valve timing control Yes Go to the next step.
system operation.
(See ENGINE CONTROL SYSTEM Repair or replace the malfunctioning part
15
OPERATION INSPECTION [MZI-3.7].) No according to variable valve timing control
Does the variable valve timing control system inspection results.
system function properly?
Yes  Valve timing

16 Is the engine compression correct?  Internal transaxle components
 Brake system for dragging

17

Microsoft

replace the PCM.
NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE [MZI-3.7]

NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE (MZI-3.7) DETECTION CONDITIONS
AND POSSIBLE CAUSES
13 KNOCKING/PINGING - ACCELERATION/CRUISE
Sound is heard when air/fuel mixture is ignited by something other than spark plug
DESCRIPTION
(such as hot spot in combustion chamber).
 Engine overheating due to cooling system malfunction
 Knock sensor malfunction
 Erratic signal from CMP sensor
 Inadequate engine compression
WARNING:
system:
POSSIBLE
CAUSE  Fuel vapor is hazardous. It can easily ignite, causing serious injury
manual.
CAUTION:
Microsoft
material.
NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE (MZI-3.7) DIAGNOSTIC PROCEDURE

Access ECT PID.
1 Verify ECT PID is less than 116°C Inspect the cooling system for cause of
{241°F} during driving. No
overheating.
Is ECT PID less than specification?
Access IAT and MAF PIDs.
Monitor each PID. IAT PID:
2 Inspect IAT sensor
(See PCM INSPECTION [MZI- No
3.7] .) MAF PID:
Are PIDs normal? Inspect MAF sensor
DTC is displayed:
Connect the M-MDS to the DLC-2. Yes Go to the appropriate DTC inspection.
3
position (engine off).
Are there any DTCs displayed? No DTC is displayed:
No
Yes Inspect the ignition timing.
Install fuel pressure gauge between Low:
fuel pipe and fuel distributor. Inspect the fuel pump relay and fuel pump circuit.
Start the engine and idle it. Inspect the fuel line for clogging.
Measure fuel line pressure during If there is no malfunction, replace the fuel pump
5 idle. unit.
Is fuel line pressure correct during No (See FUEL PUMP UNIT
idle? REMOVAL/INSTALLATION [MZI-3.7] .)
(See FUEL PUMP UNIT
Inspect the knock sensor. Yes Inspect ignition timing.
6
Is the knock sensor normal? No Replace the knock sensor.

7

Microsoft


replace the PCM.
NO.14 POOR FUEL ECONOMY [MZI-3.7]

NO.14 POOR FUEL ECONOMY (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
14 POOR FUEL ECONOMY
DESCRIPTION Fuel economy is unsatisfactory.
 Contaminated air cleaner element
 Engine cooling system malfunction
 Improper ATF level
 Weak spark
 Improper coolant level
 Brake dragging
POSSIBLE  Improper valve timing due to jumping out of timing chain
CAUSE  Contaminated MAF sensor
 Improper engine compression
 Exhaust system clogging
WARNING:
repair procedures. Read following warnings before servicing fuel system:

manual.
Microsoft
CAUTION:
material.
NO.14 POOR FUEL ECONOMY (MZI-3.7) DIAGNOSTIC PROCEDURE

 Air cleaner element for
contamination
 ATF level
1  Fuel quality
 Coolant level Service if necessary.
Brake dragging No
 Repeat Step 1.

Access ECT PID. Yes Go to the next step.
Drive vehicle while monitoring PID.
3 (See PCM INSPECTION [MZI- Inspect for coolant leakage, cooling fan and
3.7] .) No condenser fan operations or thermostat
Is PID within specification? operation.
(See ENGINE CONTROL
SYSTEM OPERATION
4
INSPECTION [MZI-3.7].) Repair or replace the malfunctioning part
Is strong blue spark visible at each No according to spark test result.
cylinder?
Install the fuel pressure gauge Low:

Microsoft
between the fuel pipe and the fuel Inspect the fuel pump relay and fuel pump
distributor. circuit.
Start the engine and idle it. Inspect the fuel line for clogging.
Measure fuel line pressure during If there is no malfunction, replace the fuel pump
idle. unit
5 Is fuel line pressure correct during No (See FUEL PUMP UNIT
(See FUEL PUMP UNIT
Inspect for variable valve timing
control system operation. Yes Go to the next step.
(See ENGINE CONTROL
6 SYSTEM OPERATION
INSPECTION [MZI-3.7].)
Does the variable valve timing No Repair or replace the malfunctioning part.
control system function properly?
7
Visually inspect the exhaust system
Yes Replace the suspected part.
part.
8
Is there any deformed exhaust
system?
Inspect for contaminated MAF Yes Go to the next step.
9 sensor.
Is there any contamination? No Inspect for cause.
Inspect the MAF sensor for Yes Replace MAF sensor.
10 contamination.
Is there any contamination? No Go to the next step.

12

replace the PCM.
Microsoft
NO.15 EMISSION COMPLIANCE [MZI-3.7]

NO.15 EMISSION COMPLIANCE (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
15 EMISSION COMPLIANCE
DESCRIPTION Fails emissions test.
 Vacuum lines leakage or blockage
 Cooling system malfunction
 Leakage from intake manifold
 PCV valve malfunction or incorrect valve installation
 Exhaust system clogging
 Fuel tank ventilation system malfunction
 Fuel-filler cap malfunction
 Charcoal canister damage
 Air cleaner element clogging or restriction
 Improper air/fuel mixture ratio control operation
 Bend or open circuit HO2S wiring harness
POSSIBLE
CAUSE  Catalyst converter malfunction
 Engine internal parts malfunction
 Excessive carbon is built up in combustion chamber
 Improper engine compression
WARNING:

manual.
Microsoft
CAUTION:
material.
NO.15 EMISSION COMPLIANCE (MZI-3.7) DIAGNOSTIC PROCEDURE

 Vacuum lines for leakage or Yes Go to the next step.

blockage
 Proper maintenance schedule
1 followed
 Intake-air system and air
cleaner element concerns: Service if necessary.
obstructions, leakage or No
Repeat Step 1.
dirtiness

Turn the ignition switch to the ON Yes Go to appropriate DTC inspection.
Is any other driveability concern Yes Go to appropriate symptom troubleshooting.
3
present? No Go to the next step.
Access ECT PID. Yes Go to the next step.
Warm up the engine and idle it.
4 Verify ECT PID is correct.
(See PCM INSPECTION [MZI- No Inspect for coolant leakage, cooling fan and
3.7] .) condenser fan operation or thermostat operation.
Is ECT PID correct?
Inspect fuel-filler cap. Yes Replace the fuel-filler cap.

5 (See FUEL-FILLER CAP
Microsoft
Is there any leakage at fuel-filler

cap?
Inspect the front HO2S. Yes Go to the next step.
(See FRONT HEATED OXYGEN Replace the front HO2S.
6 SENSOR (HO2S) INSPECTION (See FRONT HEATED OXYGEN SENSOR
[MZI-3.7] .) No
(HO2S) REMOVAL/INSTALLATION [MZI-
Is front HO2S normal? 3.7] .)
Perform spark test.
(See ENGINE CONTROL
SYSTEM OPERATION
7
INSPECTION [MZI-3.7].) Repair or replace the malfunctioning part
Is strong blue spark visible at each No according to spark test result.
cylinder?
Install the fuel pressure gauge
between the fuel pipe and the fuel Low:
distributor. Inspect the fuel line for clogging.
Start the engine and idle it. If there is no malfunction, replace the fuel pump
Measure fuel line pressure during unit.
idle. No
Is fuel line pressure correct during REMOVAL/INSTALLATION [MZI-3.7] .)
idle? High:
9
Inspect for fuel saturation inside Yes Replace the charcoal canister.
charcoal canister. Inspect the fuel tank vent system.
10
Is excess amount of liquid fuel No Then, go to the next step.
present in canister? (See FUEL TANK INSPECTION [MZI-3.7] .)
visually inspect the exhaust system
Yes Replace the part.
part.
11
Is there any deformed exhaust
system part?
Inspect the three-way catalytic
converter. Yes Go to the next step.
(See EXHAUST SYSTEM
12
Is the three-way catalytic converter No Replace the three-way catalytic converter.
normal?


Microsoft

13  If vehicle is not repaired or additional diagnostic information is not available,
replace the PCM.
NO.16 HIGH OIL CONSUMPTION/LEAKAGE [MZI-3.7]

NO.16 HIGH OIL CONSUMPTION/LEAKAGE (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
16 HIGH OIL CONSUMPTION/LEAKAGE
DESCRIPTION Oil consumption is excessive.
 Improper dipstick
POSSIBLE CAUSE
 Improper engine oil viscosity
 Engine internal parts malfunction
NO.16 HIGH OIL CONSUMPTION/LEAKAGE (MZI-3.7) DIAGNOSTIC PROCEDURE

Remove and shake the
PCV valve.
1
Does the PCV valve
No Replace the PCV valve.
rattle?
Inspect for the
following:
Inspect the internal engine parts such as valves, valve guides,
 External leakage
Yes valve stem seals, cylinder head drain passage, and piston
rings.
 Proper dipstick
2
 Proper engine oil
viscosity
No
Repeat Step 2.


Microsoft

replace the PCM.
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [MZI-3.7]

NO.17 COOLING SYSTEM CONCERNS-OVERHEATING (MZI-3.7) DETECTION CONDITIONS
AND POSSIBLE CAUSES
17 COOLING SYSTEM CONCERNS-OVERHEATING
DESCRIPTION Engine runs at higher than normal temperature/overheats.
 Improper coolant level
 Blown fuses
 Coolant leakage
 Excessive A/C system pressure
 Improper water/anti-freeze mixture
 Fans reverse rotation
POSSIBLE CAUSE  Poor radiator condition
 Thermostat malfunction
 Radiator hoses damage
 Improper or damaged radiator cap
 Cooling fan is inoperative.
 Coolant overflow system malfunction
 Improper tension of drive belt
 Drive belt damage
NO.17 COOLING SYSTEM CONCERNS-OVERHEATING (MZI-3.7) DIAGNOSTIC PROCEDURE

 Engine coolant level Yes Go to the next step.

 Coolant leakage
 Water and anti-freeze mixture
 Radiator condition
Microsoft
 Collapsed or restricted radiator

hoses
 Radiator pressure cap
 Overflow system Service if necessary.
1 Fan rotational direction No
 Repeat Step 1.
 Fuses

Yes Go to Step 5.
Inspect for the following and repair or
replace if necessary:
 Refrigerant charging amount

Start the engine and idle it.  Open circuit in wiring harness
Turn the A/C switch on and set blower fan between A/C relay and PCM
3
to any speed. No terminal 1N
Does the A/C compressor engage?
 Seized A/C magnetic clutch
 A/C magnetic clutch malfunction
If all items are normal, go to the next step.

 Refrigerant pressure switch

operation
Connect the M-MDS to the DLC-2.  The A/C switch is stuck open.
Access AC_REQ PID.
 Open or short circuit between
4 Start the engine and idle it.
Turn the A/C switch and fan switch on. No refrigerant pressure switch and PCM
Does AC_REQ PID read on? terminal 1R
 Open circuit of blower motor fan
switch and resistor (if blower motor
does not operate)
 The evaporator temperature sensor
and A/C amplifier
Inspect cooling fan control system
operation.
Microsoft
(See ENGINE CONTROL SYSTEM Yes Go to the next step.

5 3.7].)
Does the cooling fan control system No Repair or replace the malfunctioning part.
function properly?
6 Is the drive belt normal?
No Replace the drive belt.
Is there leakage around the heater unit in Yes Inspect and service heater for leakage.
7
passenger compartment? No Go to the next step.
Is there leakage at the coolant hoses and/or Yes Replace the malfunctioning part.
8
radiator? No Go to the next step.
The engine coolant temperature and
Yes thermostat are normal, inspect engine
block for leakage or blockage.
Cool down the engine. Access ECT PID.
Remove thermostat and inspect operation. Inspect for both ECT PID and temperature
(See THERMOSTAT gauge readings.
REMOVAL/INSTALLATION [MZI- If temperature gauge on instrument cluster
9
3.7] .) indicates normal range but ECT PID is not
(See THERMOSTAT INSPECTION No same as temperature gauge reading, inspect
[MZI-3.7] .) CHT sensor.
Is thermostat normal? If temperature gauge on instrument cluster
indicates overheating but ECT PID is
normal, inspect temperature gauge and heat
gauge unit.

10

replace the PCM.
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [MZI-3.7]

NO.18 COOLING SYSTEM CONCERNS-RUNS COLD (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
18 COOLING SYSTEM CONCERNS-RUNS COLD
DESCRIPTION Engine takes excessive time to reach normal operating temperature.
Microsoft
 Thermostat malfunction
POSSIBLE CAUSE
 Cooling fan system malfunction
NO.18 COOLING SYSTEM CONCERNS-RUNS COLD (MZI-3.7) DIAGNOSTIC PROCEDURE

Is customer complaint "Lack of passenger Yes Inspect A/C and heater system.
1
compartment heat" only? No Go to the next step.
Go to symptom troubleshooting "No.9 Fast
idle/runs on".
Does the engine speed continue at fast Yes
2 (See NO.9 FAST IDLE/RUNS ON [MZI-
idle? 3.7].)
Remove the thermostat and inspect
operation.
(See THERMOSTAT
3
3.7] .)
(See THERMOSTAT INSPECTION
No Replace the thermostat.
[MZI-3.7] .)
Is thermostat normal?
Access ECT PID.
Inspect for both ECT PID and temperature
gauge on instrument cluster readings.
Inspect cooling fan control system If the temperature gauge on the instrument
operation. cluster indicates normal range but ECT PID
(See ENGINE CONTROL SYSTEM Yes is not the same as temperature gauge
4 OPERATION INSPECTION [MZI- reading, inspect the CHT sensor.
3.7].) If the temperature gauge on the instrument
Does the cooling fan control system cluster indicates cold range but ECT PID is
function properly? normal, inspect the temperature gauge and
heat gauge unit.

5

replace PCM.
Microsoft
NO.19 EXHAUST SMOKE [MZI-3.7]

NO.19 EXHAUST SMOKE (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
19 EXHAUST SMOKE
DESCRIPTION Blue, black, or white smoke from exhaust system
Blue smoke (Burning oil):

 Engine internal oil leakage
White smoke (Water in combustion):
 Cooling system malfunction (coolant loss)

 Engine internal coolant leakage
Black smoke (Rich fuel mixture):

 Intake-air system is collapsed or restricted.
 Fuel return line is restricted.
POSSIBLE  Excessive fuel pressure
CAUSE  Improper engine compression
 Injector fuel leakage
WARNING:

manual.

Microsoft
CAUTION:
material.
NO.19 EXHAUST SMOKE (MZI-3.7) DIAGNOSTIC PROCEDURE

Burning oil is indicated.
Blue
What color is smoke coming from Water in combustion is indicated.
1 White
the exhaust system? Go to Step 3.
Rich fuel mixture is indicated.
Black
Go to Step 4.
 Damaged valve guide, stems or valve seals

 Blocked oil drain passage in cylinder head
Remove and shake the PCV  Piston ring is not seated, seized or worn.
Yes  Damaged cylinder bore
2 valve.
Does the PCV valve rattle?
If other driveability symptoms are present, return to

diagnostic index to service any additional
symptoms.
No Replace the PCV valve.
 Cylinder head gasket leakage

 Intake manifold gasket leakage
Does the cooling system hold Yes  Cracked or porous engine block
3
pressure?
If other driveability symptoms are present, return to
diagnostic index to service any additional
symptoms.
Microsoft
 Collapsed or restricted
intake-air system
 Restricted fuel return line Service if necessary.
4 No
Repeat Step 4.

Connect the M-MDS to the DLC- DTC is displayed:
2. Yes Go to the appropriate DTC inspection.
Turn the ignition switch to the (See DTC TABLE [MZI-3.7] .)
5
No
Are there any DTCs displayed? Go to the next step.
Install the fuel pressure gauge
between the fuel pipe and the fuel Low:
distributor. Inspect the fuel line for clogging.
Start the engine and idle it. If there is no malfunction, replace the fuel pump
Measure fuel line pressure during unit.
idle. No
Is fuel line pressure correct during REMOVAL/INSTALLATION [MZI-3.7] .)
idle? High:
Perform the spark test. Inspect the CMP sensor.
(See ENGINE CONTROL Yes (See CAMSHAFT POSITION (CMP) SENSOR
SYSTEM OPERATION INSPECTION [MZI-3.7] .)
7
Is strong blue spark visible at Repair or replace the malfunctioning part according
No
each cylinder? to spark test result.

8

replace the PCM.
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [MZI-3.7]
Microsoft
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
20 FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTION Gasoline fuel smell or visible leakage
 Excessive fuel pressure
 Fuel tank vent system blockage
 Charcoal canister malfunction
 Fuel leakage from fuel system
WARNING:

POSSIBLE  Fuel line spills and leakage are dangerous. Fuel can ignite and cause
CAUSE serious injuries or death and damage. Fuel can also irritate skin and
manual.
CAUTION:
material.
NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) (MZI-3.7) DIAGNOSTIC PROCEDURE

injector O-ring and fuel line.
1 Install the fuel pressure gauge between the Replace the fuel pump unit.
fuel pipe and the fuel distributor. (See FUEL PUMP UNIT
No
Start engine and idle it. REMOVAL/INSTALLATION [MZI-
Measure fuel line pressure during idle. 3.7] .)
Is fuel line pressure correct during idle?
Microsoft
(See FUEL LINE PRESSURE

Inspect for blockage/restriction or open
circuit in wiring harness between the Yes Replace vacuum hose.
engine vacuum port and the charcoal
2 canister.
Inspect for blockage in fuel tank vent
system. No Go to the next step.
Is malfunction indicated?
Inspect the purge solenoid valve.
(See PURGE SOLENOID VALVE Replace the purge solenoid valve.
3 (See PURGE SOLENOID VALVE
INSPECTION [MZI-3.7] .) No
Is the solenoid operating properly? REMOVAL/INSTALLATION [MZI-
3.7] .)
DTC is displayed:
Connect the M-MDS to the DLC-2. Yes Go to the appropriate DTC inspection.
4 position (Engine off). No DTC is displayed:
Retrieve any DTCs. Inspect charcoal canister for fuel saturation.
If excess amount of liquid fuel is present,
replace the charcoal canister.
(See ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZI-3.7].)

5

replace the PCM.
NO.21 ENGINE NOISE [MZI-3.7]

NO.21 ENGINE NOISE (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
21 ENGINE NOISE
DESCRIPTION Engine noise from under hood
Squeal, click or chirp noise:
 Improper engine oil level

 Improper drive belt tension
Microsoft
 Generator installation (alignment)

 Splash shield or under cover looseness (splashed water to drive belts)
Rattle sound noise:
 Loose parts
Hiss sound noise:
 vacuum leakage
 Loose spark plug
POSSIBLE CAUSE Rumble or grind noise:
 Improper drive belt tension

 Improper P/S fluid level
Rap or roar noise:
 Dynamic dumper looseness

 Exhaust system looseness
 Intake-air system looseness
Other noise:
 Camshaft friction gear noise or MLA noise

 Timing chain noise
NO.21 ENGINE NOISE (MZI-3.7) DIAGNOSTIC PROCEDURE

Inspect for the followings:

Is a squealing, click or
1 Yes  Engine oil level
chirping sound present?
 Drive belt tension
 Splash shield or under cover looseness
Microsoft
 Generator installation (alignment)

Inspect for the followings:
Is a rumbling or grinding Yes  Drive belt tension
2
noise present?
 P/S fluid level

Yes Inspect rattling location for loose parts.
3 Is a rattling noise present?
Yes  Vacuum leakage

4 Is a hissing noise present?  Spark plug looseness
 Intake-air system leakage

Inspect looseness for followings:
Is a rapping or roar noise Yes  Dynamic dumper

5  Intake-air system
present?
 Exhaust system

Knocking/pinging".
Yes
(See NO.13 KNOCKING/PINGING-
6 Is a knocking noise present? ACCELERATION/CRUISE [MZI-3.7].)
If the noise comes from the engine internal, inspect for
No
friction gear, timing chain or MLA noise.

7

replace the PCM.
NO.22 VIBRATION CONCERNS (ENGINE) [MZI-3.7]
Microsoft
NO.22 VIBRATION CONCERNS (ENGINE) (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE

CAUSES
22 VIBRATION CONCERNS (ENGINE)
DESCRIPTION  Vibration from under hood or driveline
 Loose attaching bolts or worn parts

POSSIBLE CAUSE
 Components malfunction such as worn parts
NO.22 VIBRATION CONCERNS (ENGINE) (MZI-3.7) DIAGNOSTIC PROCEDURE

Inspect the following components for loose
attaching bolts or worn parts: Inspect the following systems:
 Cooling fan  Wheels

Yes  ATX
 Drive belt and pulleys
1  Generator  Driveline
 Engine mounts  Suspension
 Exhaust system mounts
Readjust or retighten engine mount
No installation position.
All items normal? Service if necessary for other parts.

2

replace the PCM.
NO.23 A/C DOES NOT WORK SUFFICIENTLY [MZI-3.7]

NO.23 A/C DOES NOT WORK SUFFICIENTLY (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
23 A/C DOES NOT WORK SUFFICIENTLY.
DESCRIPTION A/C compressor magnetic clutch does not engage when the A/C switch is turned on.
 Improper refrigerant charging amount
Microsoft
 Open the A/C magnetic clutch

 Open circuit in wiring harness between A/C relay and A/C magnetic clutch
 Poor GND of A/C magnetic clutch
POSSIBLE  Refrigerant pressure switch is stuck open.
CAUSE  A/C relay is stuck open.
 Seized A/C compressor
 Open circuit in wiring harness between A/C switch and PCM through both
refrigerant pressure switch and A/C amplifier
NO.23 A/C DOES NOT WORK SUFFICIENTLY (MZI-3.7) DIAGNOSTIC PROCEDURE

Connect the M-MDS to the DLC- DTC is displayed:
2. Yes Go to the appropriate DTC inspection.
1
No
Disconnect A/C compressor
connector.
Inspect for GND condition of magnetic clutch on
Start engine and turn A/C switch
A/C compressor.
on. Yes
If GND condition is normal, inspect for open circuit
2 Is there correct voltage at A/C
magnetic clutch coil.
compressor magnetic clutch
terminal?
Specification
10.5 V or more No Go to the next step.
Inspect refrigerant pressure switch operation.
Disconnect refrigerant pressure Yes
If switch is normal, go to the next step.
switch connector.
Connect jumper wiring between Inspect for the following:
A/C high pressure switch
terminal.  A/C switch is stuck open.
Connect jumper wiring between  Open circuit in wiring harness between
3 refrigerant pressure switch refrigerant pressure switch and PCM terminal
terminal. No 1R
Turn the ignition switch to the  Open circuit in wiring harness between
ON position. blower motor fan switch and resistor (if
Turn A/C switch on and set blower motor does not operate)
blower fan to any speed.
 Evaporator temperature sensor and A/C
Does A/C work?
amplifier
Inspect whether A/C relay is stuck open.
Remove jumper wiring from the Yes
Replace if necessary.
switch connector.
Microsoft
Reconnect connector to Inspect the following and repair or replace if

refrigerant pressure switch. necessary:
4 Start the engine and turn the A/C No
switch on.  Refrigerant charging amount
Does the fan operate?  A/C compressor for seizure


5

replace the PCM.
NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY

[MZI-3.7]
NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY (MZI-3.7) DETECTION
CONDITIONS AND POSSIBLE CAUSES
24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION A/C compressor magnetic clutch does not disengage.
 A/C compressor magnetic clutch engagement is stuck.
 A/C relay is stuck closed.
POSSIBLE CAUSE  Short to GND in wiring harness between A/C switch and PCM
 Short to GND in wiring harness between A/C relay and PCM
 Short circuit to battery power in A/C relay to magnetic clutch
NO.24 A/C ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY (MZI-3.7) DIAGNOSTIC

PROCEDURE
Microsoft
 A/C relay is stuck closed.

 Short to GND in wiring harness
between A/C relay and PCM
Yes terminal 1N.
Start the engine and idle it.

Turn the A/C switch on. If both items normal, go to the next
2
Remove the A/C relay. step.
Does the A/C magnetic clutch disengage?
Inspect if circuit between the A/C
relay and magnetic clutch shorts to
battery power circuit.
No
If the circuit is normal, inspect the
magnetic clutch for stuck engagement
or clearance.
Disconnect refrigerant pressure switch
connector.
Start the engine and turn A/C switch on.
Inspect for short to GND in wiring
NOTE: Yes harness between refrigerant pressure
switch and PCM terminal 1R.
3  A/C should not work when
disconnecting connector. If A/C
remains working, short to GND circuit
may be present.

Does the A/C remain working?
Reconnect refrigerant pressure switch Inspect following:
connector.
Turn off A/C switch.  Short to GND in wiring harness
between A/C switch and A/C
NOTE: Yes amplifier
4  A/C should not work when turning A/C  Short to GND circuit between
switch off. If A/C remains working, A/C amplifier and refrigerant
short to GND circuit may be present.
pressure switch
Inspect whether A/C switch is stuck
No
Does A/C remain working? closed.

5

Microsoft

replace the PCM.
NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE
CONDITIONS [MZI-3.7]
NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS (MZI-3.7)
25 A/C DOES NOT CUT OFF UNDER WOT CONDITIONS.
DESCRIPTION A/C compressor magnetic clutch does not disengage under WOT.
 Accelerator pedal position sensor malfunction
POSSIBLE CAUSE  Accelerator pedal position sensor misadjustment
 Loosely installed accelerator pedal position sensor
NO.25 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS (MZI-3.7)
Does A/C compressor
1 disengage when the A/C switch Go to symptom troubleshooting "NO.24 A/C IS
is turned off? No ALWAYS ON OR A/C COMPRESSOR RUNS
CONTINUOUSLY".
Connect the M-MDS to the DTC is displayed:
DLC-2. Yes Go to the appropriate DTC inspection.
2
No
Are there any DTCs displayed? Inspect accelerator pedal position sensor.


3

replace the PCM.
Microsoft
NO.26 EXHAUST SULPHUR SMELL [MZI-3.7]S

NO.26 EXHAUST SULPHUR SMELL (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE
CAUSES
26 EXHAUST SULPHUR SMELL
DESCRIPTION Rotten egg smell (sulphur) from exhaust
 Electrical connectors are disconnected or connected poorly
 Charcoal canister malfunction
 Vacuum lines are disconnected or connected improperly.
 Improper fuel pressure
WARNING:

POSSIBLE  Fuel line spills and leakage are dangerous. Fuel can ignite and cause
CAUSE serious injuries or death and damage. Fuel can also irritate skin and
manual.
CAUTION:
material.
NO.26 EXHAUST SULPHUR SMELL (MZI-3.7) DIAGNOSTIC PROCEDURE

Are any driveability or exhaust Yes Go to the appropriate flow chart.
1
smoke concerns present? No Go to the next step.
Microsoft
 Electrical connections Yes Go to the next step.

 Vacuum lines
2  Fuel quality Service if necessary.
No
Repeat Step 2.
Connect the M-MDS to the DTC is displayed:
DLC-2. Yes Go to the appropriate DTC inspection.
3
No
Install the fuel pressure gauge Low:
between the fuel pipe and the Inspect fuel pump relay and fuel pump circuit.
fuel distributor. Inspect the fuel line for clogging.
Start engine and idle it. If there is no malfunction, replace the fuel pump unit.
Is fuel line pressure correct at No
(See FUEL PUMP UNIT
Yes Replace the charcoal canister.
Inspect the charcoal canister for Inspect the fuel tank vent system.
fuel saturation. If the fuel tank vent system is normal, suggest trying
5 a different brand since sulphur content can vary in
Is excess amount of liquid fuel No
present in canister? different fuels.
If the fuel tank vent system is not normal, repair or
replace the malfunctioning part.

6

replace the PCM.
NO.27 FUEL REFILL CONCERNS [MZI-3.7]

Microsoft
NO.27 FUEL REFILL CONCERNS (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
27 FUEL REFILL CONCERNS
DESCRIPTION  Fuel tank is not filled smoothly.
 Clogged EVAP pipes

 Nonreturn valve malfunction
 Improper use of fuel nozzle
 Inadequate fuel filling speed
WARNING:
 The following troubleshooting flow chart contains the fuel system
diagnosis and repair procedures. Read the following warnings before
servicing the fuel system:
 Fuel vapor is hazardous. It can easily ignite, causing serious
injury and damage. Always keep sparks and flames away from
fuel.
POSSIBLE  Fuel line spills and leakage are dangerous. Fuel can ignite and
CAUSE cause serious injuries or death and damage. Fuel can also
irritate skin and eyes. To prevent this, always complete
"BEFORE SERVICE PRECAUTION" and "AFTER SERVICE
PRECAUTION" described in this manual.
CAUTION:
material.
NO.27 FUEL REFILL CONCERNS (MZI-3.7) DIAGNOSTIC PROCEDURE


Yes
 Improper use of fuel nozzle
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 Inadequate fuel filling speed

Nonreturn valve is installed improperly:
Remove the fuel-filler pipe.  Reinstall nonreturn valve to proper

Make sure the nonreturn valve is installed position.
2 properly.
Inspect nonreturn valve operation. No
Is the nonreturn valve normal? Nonreturn valve does not operate
properly:
 Replace nonreturn valve.


3

replace the PCM.
NO.28 FUEL FILLING SHUT OFF CONCERNS [MZI-3.7]

NO.28 FUEL FILLING SHUT OFF CONCERNS (MZI-3.7) DETECTION CONDITIONS AND
POSSIBLE CAUSES
28 FUEL FILLING SHUT OFF CONCERNS
DESCRIPTION  Fuel does not shut off properly.
 Clogged EVAP pipes

 Nonreturn valve malfunction
 Fuel shut-off valve malfunction
 Fuel nozzle malfunction
 Fuel nozzle is not inserted correctly.
WARNING:
 The following troubleshooting flow chart contains the fuel system
diagnosis and repair procedures. Read the following warnings before
servicing the fuel system:
 Fuel vapor is hazardous. It can easily ignite, causing serious
injury and damage. Always keep sparks and flames away from
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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
"BEFORE SERVICE PRECAUTION" and "AFTER SERVICE
PRECAUTION" described in this manual.

POSSIBLE
CAUSE (See AFTER SERVICE PRECAUTION [MZI-3.7] .)
CAUTION:
material.
NO.28 FUEL FILLING SHUT OFF CONCERNS (MZI-3.7) DIAGNOSTIC PROCEDURE

Yes  Improper use of fuel nozzle

 Fuel is not inserted correctly.
 Inspect fuel shut-off valve.

Remove the fuel-filler pipe.
Make sure the nonreturn valve is installed Nonreturn valve is installed improperly:
2 properly.
Inspect nonreturn valve operation.  Reinstall the nonreturn valve to proper
Is the nonreturn valve normal? position.
No
Nonreturn valve does not operate properly:
 Replace the nonreturn valve.


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replace the PCM.
NO.29 SPARK PLUG CONDITION [MZI-3.7]

NO.29 SPARK PLUG CONDITION (MZI-3.7) DETECTION CONDITIONS AND POSSIBLE CAUSES
29 SPARK PLUG CONDITION
DESCRIPTION Incorrect spark plug condition
NOTE:
 Inspecting spark plugs condition can determine whether problem is related
to a specific cylinder or possibly all cylinders.
Wet/carbon stuck on specific plug:
 Spark-Weak, not visible

 Air/fuel mixture-Excessive fuel injection volume
 Compression-No compression, low compression
 Malfunction spark plug
Grayish white with specific plug:
 Air/fuel mixture-Insufficient fuel injection volume

POSSIBLE
CAUSE  Malfunction spark plug
Wet/carbon is stuck on all plugs:
 Spark-Spark weak
 Air/fuel mixture-Too rich
 Compression-Low compression
 Clogging in intake/exhaust system
Grayish white with all plugs:
 Air/fuel mixture-Too lean
WARNING:
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system:

manual.
CAUTION:
material.
NO.29 SPARK PLUG CONDITION (MZI-3.7) DIAGNOSTIC PROCEDURE

Yes Troubleshooting completed.
Specific plug is wet or covered with carbon:
Remove all the spark plugs. Specific plug looks grayish white:
1 Inspect spark plug condition. Go to Step 7.
Is spark plug condition normal? No All plugs are wet or covered with carbon:
Go to Step 9.
All plugs look grayish white:
Go to Step 15.
Inspect all areas related to oil, working up and
Are the spark plug wet/covered Yes
2 down.
with carbon by the engine oil?
Inspect the spark plug for the Yes Go to the next step.
following:
3  Cracked insulator Replace the spark plug.

 Heat range No (See SPARK PLUG
 Air gap REMOVAL/INSTALLATION [MZI-3.7] .)
 Worn electrode
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Is the spark plug normal?

Inspect compression pressure at
suspected malfunctioning Yes Go to the next step.
cylinder.
4
Is compression pressure correct?
(See COMPRESSION No Repair or replace the malfunctioning part.
Install all spark plugs.
Perform the spark test at suspected Yes Go to the next step.
5 malfunctioning cylinder.
Is strong blue spark visible? No Repair or replace the malfunctioning part.
(Compare with normal cylinder.)
Inspect fuel injector for the following:
Install the fuel pressure gauge Yes  Open or short circuit in injector
between fuel filter and fuel  Leakage
distributor.  Injection volume
Short check connector terminal Zero or low:
F/P to body GND using a jumper Inspect the fuel pump relay and fuel pump circuit.
wiring. Inspect the fuel line for clogging.
6
Turn the ignition switch to the ON If there is no malfunction, replace the fuel pump
position (Engine off). unit.
Is the fuel line pressure correct No (See FUEL PUMP UNIT
with the ignition switch at ON? REMOVAL/INSTALLATION [MZI-3.7] .)
(See FUEL PUMP UNIT
Inspect the spark plug for the
following. Yes Go to the next step.
 Heat range
7 Replace the spark plug.
 Air gap
No (See SPARK PLUG
Is the spark plug normal?
Remove the suspected fuel
injector. Inspect for open circuit in wiring harness between
Inspect the following: fuel injector connector terminal A and PCM at the
8 Yes
 Resistance
 For No.1 cylinder: 2BJ
 Fuel injection volume
 For No.2 cylinder: 2BM
(See FUEL INJECTOR  For No.3 cylinder: 2BF
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INSPECTION [MZI-  For No.4 cylinder: 2BH

3.7] .)
 For No.5 cylinder: 2BB
 For No.6 cylinder: 2BD
Are all above items normal? No Replace the fuel injector.

Is the air cleaner element free of Yes Go to the next step.
9
clogging? No Replace the air cleaner element.
(See ENGINE CONTROL Yes Go to the next step.
SYSTEM OPERATION
10
Is strong blue spark visible at each No Repair or replace the malfunctioning part.
cylinder?
Install the fuel pressure gauge Yes Go to the next step.
between the fuel filter and fuel Zero or low:
distributor. Inspect the fuel pump relay and fuel pump circuit.
Short check connector terminal Inspect the fuel line for clogging.
F/P to body GND using a jumper If there is no malfunction, replace the fuel pump
wiring. unit.
11
Turn the ignition switch to the ON No (See FUEL PUMP UNIT
position (Engine off). REMOVAL/INSTALLATION [MZI-3.7] .)
Is the fuel line pressure correct High:
with ignition switch at ON? Replace the fuel pump unit.
(See FUEL LINE PRESSURE (See FUEL PUMP UNIT
INSPECTION [MZI-3.7] .) REMOVAL/INSTALLATION [MZI-3.7] .)
Inspect the following PIDs:
 ECT
 O2S11 (When engine can be
started.) Yes Go to the next step.
started.)
12 started.)
started.)
 MAF

3.7] .)
Are PIDs normal?
Perform the purge control
inspection. Yes Go to the next step.
(When engine can be started.)
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(See ENGINE CONTROL

SYSTEM OPERATION
13 No Repair or replace the malfunctioning part.
Is the purge control correct?
Perform compression inspection.
Yes Visually inspect for deformed exhaust system part.
(See COMPRESSION
14
Is compression correct?
When the engine cannot be
started, inspect the intake-air
Yes Repair or replace the malfunctioning part.
system for air leakage.
When the engine can be started,
15
perform intake manifold vacuum
inspection.
Is air sucked in from intake-air
system?
Inspect the following PIDs:
 ECT
 O2S11
 O2S12
 O2S21
Install the fuel pressure gauge Yes  O2S22
Between the fuel filter and the fuel
distributor.  MAF
Short check connector terminal
F/P to body GND using a jumper (See PCM INSPECTION [MZI-3.7] .)
wiring.
16
position (Engine off). Inspect PCM GND condition.
Is fuel line pressure correct with Zero or low:
the ignition switch at ON? Inspect the fuel pump relay and fuel pump circuit.
(See FUEL LINE PRESSURE Inspect the fuel line for clogging.
INSPECTION [MZI-3.7] .) If there is no malfunction, replace the fuel pump
unit.
No (See FUEL PUMP UNIT
High:
Replace the fuel pump unit.
(See FUEL PUMP UNIT


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replace the PCM.
INTERMITTENT CONCERN TROUBLESHOOTING [MZI-3.7]

VIBRATION METHOD
 If malfunction occurs or becomes worse while driving on a rough road or when the engine is vibrating,
perform the steps below.
NOTE:  There are several reasons vehicle or engine vibration could cause an
electrical malfunction. Inspect the following:
 Connectors not fully seated
 Wiring harnesses not having full play
 Wiring harnesses laying across brackets or moving parts
 Wiring harnesses routed too close to hot parts
 An improperly routed, improperly clamped, or loose wiring harness

can cause wiring to become pinched between parts.
 The connector joints, points of vibration, and places where wiring
harnesses pass such as through the firewall and body panels are the
major areas to be checked.
Inspection Method for Switch Connectors or Wiring Harnesses

2. Turn the ignition switch to the ON position (Engine off).
NOTE:  If the engine starts and runs, perform the following steps during idle.

4. Turn the switch on manually.
 If PID value is unstable, inspect for poor connection.
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Fig. 9: Inspection Method For Wiring Harnesses

Inspection Method for Sensor Connectors or Wiring Harnesses


 If PID value is unstable, inspect for poor connection.
Fig. 10: Inspection Method For Sensor Connectors

Inspection Method for Sensors

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4. Vibrate the sensor slightly with your finger.
 If PID value is unstable or malfunction occurs, check for poor connection or poorly mounted sensor
or both.
Inspection Method for Actuators or Relays

3. Prepare the output state control function for actuators or relays that you are inspecting.
4. Vibrate the actuator or relay with your finger for 3 s after output state control function is activated.
 If variable click sound is heard, check for poor connection or poorly mounted actuator or both, or
the relay.
NOTE:  Vibrating relays too strongly may result in open relays.
Fig. 11: Inspection Method For Relays

WATER SPRINKLING METHOD
If malfunction occurs only under high humidity or rainy/snowy weather, perform the following steps:
CAUTION:  Indirectly change the temperature and humidity by spraying water

onto the front of the radiator.
 If a vehicle is subject to water leakage, the leakage may damage the
control module. When testing a vehicle with a water leakage problem,
special caution must be used.
1. Connect the M-MDS to the DLC-2 if you are inspecting sensors or switches.
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3. Access PIDs for sensor or switch if you are inspecting sensors or switches.
4. If you are inspecting the switch, turn it on manually.
5. Spray water onto the vehicle or run it through a car wash.
 If PID value is unstable or malfunction occurs, repair or replace part if necessary.
Fig. 12: Water Sprinkling Method

ENGINE CONTROL SYSTEM OPERATION INSPECTION [MZI-3.7]

INPUT SIGNAL SYSTEM INSPECTION PROCEDURE
1. Find an irregular signal. (See FINDING IRREGULAR SIGNALS.)

2. Locate source. (See LOCATING THE SOURCE OF UNUSUAL SIGNALS.)
3. Repair or replace the malfunctioning part.
4. Confirm that the irregular signal is no longer detected.
Finding irregular signals
While referring to, use the PID/DATA monitor and record function to inspect the input signal system relating to
the problem.
1. Start the engine and idle the vehicle. You can assume that any signals that are out of specification by a
wide margin are irregular.
2. When recreating the problem, any sudden change in monitor input signals that is not intentionally created
by the driver can be determined as irregular.
Locating the source of unusual signals
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CAUTION:  Compare the M-MDS monitor voltage with the measurement voltage
using the digital measurement system function. If you use another
tester, misreading may occur.
 When measuring voltage, attach the tester GND to the GND of the
PCM that is being tested, or to the engine itself. If this is not
performed, the measured voltage and actual voltage may differ.
 After connecting the pin to a waterproof coupler, confirming
continuity and measuring the voltage, inspect the waterproof
connector for cracks. If there are any, use sealant to fix them. Failure
to do this may result in deterioration of the wiring harness or terminal
from water damage, leading to problems with the vehicle.
Variable resistance type 1 (TP sensor)
Fig. 13: Variable Resistance Type 1 (TP Sensor)

Input signal system inspection for variable resistance type 1
1. When an irregular signal is detected, measure the #1 PCM terminal voltage.

 If the #1 terminal voltage and the M-MDS monitor voltage are the same, proceed to the next step.
 If there is a difference of 0.5 V or more , inspect for the following points concerning the PCM
connector:
 Female terminal opening is loose.
 Coupler (pin holder) damage
 Pin discoloration (blackness)
 Harness/pin crimp is loose or disconnected.
2. Measure the #2 sensor terminal voltage.

 If there is a 0.5 V or more difference between the sensor and the M-MDS voltages, inspect the
wiring harness for open or short circuits.
 If the sensor and the M-MDS voltages are the same, inspect for the following points concerning the
sensor connector:

Microsoft

 If there are no problems, proceed to next investigation below.
Standard power supply system inspection for variable resistance type 1
 Confirm that the #3 terminal is at 5 V.

 If the measured voltage on the #3 terminal is 5 V , inspect the following points on the sensor
connector.
 If there is no problem, inspect for the following:
 Female terminal opening is loose.
 Coupler (pin holder) damage
 Pin discoloration (blackness)
 If the #3 terminal measures other than 5 V , inspect for the following:
 Harness/pin crimp is loose or disconnected.
GND system inspection for variable resistance type 1
 Confirm that terminal sensor #5 is at 0 V.

 If it is at 0 V , inspect the sensor.
 If necessary, replace the sensor.
 If not, inspect for the following:
 Female terminal opening is loose causing an open or short circuit in wiring harness
Variable resistance type 2 (mass air flow (MAF) sensor & VSS)
Fig. 14: Variable Resistance Type 2 (Mass Air Flow Sensor & VSS)
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GND system inspection for variable resistance type 2

 If it is at 0 V , inspect the sensor.
 If necessary, replace the sensor.
 If not at 0 V , inspect for the following:
Input signal system inspection for variable resistance type 2

 If there is a difference of 0.5 V or more , inspect for the following points concerning the PCM
connector:

 If the sensor and the M-MDS voltages are the same, inspect the following points concerning the
sensor connector:
Electrical supply system inspection for variable resistance type 2
 Confirm that the sensor #3 terminal is B+.

 If the measured voltage on the #3 terminal is B+ , inspect the following points on the sensor
connector.
 If there is no problem, inspect for the following:
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 If the #3 terminal measures other than B+ , inspect the following:
Thermistor type (IAT sensor & CHT sensor)
Fig. 15: Thermistor Resistance Type (IAT Sensor & CHT Sensor)
Input signal system inspection for thermistor type

 If there is a difference of 0.5 V or more , inspect the following points concerning the PCM
connector:
 Female terminal opening loose

 If the sensor and the M-MDS voltages are the same, inspect the following points concerning the
sensor connector:
GND system inspection for thermistor type

Microsoft
 If it is at 0 V , inspect the sensor. If necessary, replace the sensor.

 If not, inspect for the following:
MAIN RELAY OPERATION INSPECTION
1. Verify that the main relay clicks when the ignition switch is turned to ON position and off.
 If there is no operation sound, inspect the following:
 Main relay (See RELAY INSPECTION .)
 Harness and connector between battery and main relay terminal A.
 Harness and connector between PCM terminal 1Q and main relay terminal E.
ELECTRONIC THROTTLE CONTROL SYSTEM INSPECTION
Engine coolant temperature compensation inspection

2. Access the following PIDs:
 ECT
 IAT
 RPM
3. Verify that the engine is cold, then start the engine.

4. Verify that the engine speed decreases as the engine warms up.
 If the engine speed does not decrease or decreases slowly, inspect the following:
 CHT sensor and related wiring harness
(See CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION [MZI-

3.7] .)
 Electronic throttle body and related wiring harness
(See THROTTLE BODY INSPECTION [MZI-3.7] .)
Load compensation inspection
1. Start the engine and idle it.

3. Verify that P0506, P0507 is not displayed.
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 If P0506, P0507 are displayed, perform DTC inspection.
4. Access the RPM PID.
NOTE:  Excludes temporary idle speed drop just after the loads are turned
on.
5. Verify that the engine speed is within the specification under each load condition.
 If load condition is not as specified, inspect the following:
 A/C switch and related wiring harness
(See FRONT CLIMATE CONTROL UNIT INSPECTION .)
 Fan switch and related wiring harness
(See FRONT CLIMATE CONTROL UNIT INSPECTION .)
Throttle position (TP) sweep inspection

3. Verify that none of the following DTC are displayed:
 P0122, P0123, P0222, P0223, P2101, P2107, P2112, P2122, P2123, P2127, P2128, P2135
 If any one DTC is displayed, perform DTC inspection.
4. Access TP1, TP2 PID.

5. Verify that the PID reading is within the CTP value. (See PCM INSPECTION [MZI-3.7] .)
 If the PID reading is out of range, perform the following:
 Remove the air duct from the throttle valve body.
 Verify that the throttle valve opens when the accelerator pedal is depressed.
 If the throttle valve opens, inspect the throttle position sensor and related wiring
harness.
 If the throttle valve does not open, inspect the throttle actuator control motor and
related wiring harness.
6. Gradually depress the throttle pedal and verify that the PID reading increases accordingly.
 If the PID reading drops momentarily, inspect the following:
 Throttle position sensor
7. Fully depress the throttle pedal and verify that the PID reading is within WOT value. (See PCM
 If the PID reading is out of range, perform the followings:
Microsoft
 Remove the air duct from throttle valve body.

 Verify that the throttle valve opens when throttle pedal is depressed.
 If the throttle valve opens, inspect the throttle position sensor and related wiring
harness.
 If the throttle valve does not open, inspect the throttle actuator control motor and
FUEL INJECTOR OPERATION INSPECTION
FUEL INJECTOR OPERATION INSPECTION CHART

Yes Fuel injector operation is normal.
While cranking the engine, inspect for fuel
injector operation sound at each cylinder using a All cylinders not heard:
1 Go to the next step.
soundscope. No
Is operation sound heard? Some cylinders not heard:
Go to Step 3.
 Fuel injector power system

related wiring harness and
Yes connectors
Perform main relay operation inspection.
2  PCM connectors
Is main relay operation normal?
 Fuel injector GND and related
wiring harness and connectors
Repair or replace malfunctioning
No
parts.
Switch fuel injector connector of not operating Yes Go to the next step.
3 fuel injector with operating fuel injector.
Is operation sound heard? No Replace the fuel injector.
Inspect PCM terminal voltage of fuel
Yes
Are wiring harness and connectors of not injector signal.
4
operation fuel injector normal? (Open or short) Repair or replace malfunctioning
No
parts.
FUEL CUT CONTROL SYSTEM INSPECTION
NOTE:  This inspection has to perform after the Fuel Injector Operation Inspection.
If simulation function of the M-MDS is used:
1. Warm up the engine and idle it.

3. Select the RPM and FUELSYS1 PIDs.
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4. Monitor the both PIDs while performing the following steps.

1. Depress the accelerator pedal and increase the RPM PID to 4,000 rpm.
2. Quickly release the accelerator pedal (brake pedal is not depressed) and verify that the FUELSYS1
PID is OL, and CL. when the RPM PID drops below 1,200 rpm.
 If not as specified, inspect the following.
 CHT sensor and related harness
(See CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION

[MZI-3.7] .)
 TR switch and related wiring harness
(See TRANSAXLE RANGE (TR) SWITCH INSPECTION [AW6A-EL, AW6AX-

EL] .)
If simulation function of the M-MDS is not used:
1. Warm up the engine and idle it.

2. Measure the fuel injector control signal wave profile using the oscilloscope while performing the
following steps.
1. Depress the accelerator pedal and increase the engine speed to 4,000 rpm.
2. Quickly release the accelerator pedal (brake pedal is not depressed) and verify that the wave profile
constant B+ , and appears wave, when the engine speed drops below 2,200 rpm.
 If not as specified, inspect the following.
 CHT sensor and related harness
(See CYLINDER HEAD TEMPERATURE (CHT) SENSOR INSPECTION

[MZI-3.7] .)
 TR switch and related wiring harness
(See TRANSAXLE RANGE (TR) SWITCH INSPECTION [AW6A-EL, AW6AX-

EL] .)
FUEL PUMP OPERATION INSPECTION
1. Remove the fuel-filler cap.

3. Turn the fuel pump relay from off to on using the FP PID and inspect if the operation sound is heard.
 If no operation sounds is heard, proceed to next step.
4. Measure voltage at wiring harness side fuel pump connector terminal B.
Specification
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B+ (Ignition switch at on)
 If the voltage is as specified, inspect the following:

 Fuel pump continuity
 Fuel pump GND
 Wiring harness between fuel pump relay and PCM terminal 1V
 If not as specified, inspect the following:

 Fuel pump relay
 Wiring harness connector (Main relay-fuel pump relay-fuel pump)
FUEL PUMP CONTROL SYSTEM INSPECTION
1. Crank the engine and verify that fuel pump relay operation sound is heard.
2. If operation sound is not heard, inspect the following:
 Fuel pump relay
(See RELAY INSPECTION .)
 Wiring harness and connectors (Main relay-fuel pump relay-PCM terminal 1V)
SPARK TEST
1. Disconnect the fuel pump relay.

2. Verify that each ignition coil and connector is connected properly.
3. Inspect the ignition system in the following procedure.
WARNING:  High voltage in the ignition system can cause strong electrical
shock which can result in serious injury. Avoid direct contact
to the vehicle body during the following spark test.
FUEL PUMP CONTROL SYSTEM INSPECTION CHART

 Disconnect the ignition coil from the Yes Go to the next step.
spark plugs.
 Remove the spark plugs.
1 Perform 2 times of no-load racing at 4000
 Ensure that the spark plugs don't No rpm for 2 min to burn off the carbon deposits.
have carbon deposits. Then repeat this step.
 Are the spark plugs OK?
 Inspect the spark plugs for damage, wear, Yes Go to the next step.
2 and proper plug gap.
 Are the spark plugs normal? No Replace spark plugs, then go to the next step.
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Yes Ignition system is normal.

Some cylinders do not spark:
 Reconnect the spark plugs to the ignition
coil.  Go to the next step.
3  Ground the spark plugs to the engine. No
 Is a strong blue spark visible at each
cylinder while cranking? All cylinders do not spark:
 Go to Step 5.
 Inspect the following wiring harnesses
for open or short:
 Ignition coil No.1 terminal C-PCM
terminal 2A Inspect and replace the ignition coil.
 Ignition coil No.2 terminal C-PCM Yes (See IGNITION COIL INSPECTION
terminal 2F [MZI-3.7] .)
4 terminal 2K
terminal 2W
terminal 2AA Repair or replace the malfunctioning part,
No
 Ignition coil No.6 terminal C-PCM then go to Step 1.
terminal 2AE
 Are the wiring harnesses normal?
Measure the voltage at terminal A in each Yes Go to the next step.
5 ignition coils.
No Inspect power supply circuit of ignition coils.
Verify continuity between each ignition coils Yes Go to the next step.
6 terminal B and battery negative post.
Is there any continuity? No Inspect GND circuit of ignition coils.
Repair or replace the connector, then go to
 Does the PCM connector or ignition coil Yes
7 Step 1.
connectors have poor connection? No Go to the next step.
Inspect for open or short circuit in wiring
Yes
 Are the following parts normal? harness and connector of CKP sensor.
8
 CKP sensor and crankshaft pulley Repair or replace the malfunctioning part,
No
then go to Step 1.
PURGE CONTROL SYSTEM INSPECTION
If simulation function of the M-MDS is used:

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2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
3. Put the finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is
cold.
 If there is a vacuum, inspect the following:
 Wiring harness and connectors (Purge solenoid valve-PCM terminal 1BC)
 Purge solenoid vale (stuck open)
4. Connect the M-MDS to the DLC-2 and verify that the DTC P0443 is shown. Perform the DTC
inspection. (See DTC TABLE [MZI-3.7] .)
5. Select EVAPCP PID.
6. Increase the duty value of the purge valve to 50 % and inspect if the operation sound of the valve is
heard.
 If the operation sound is heard, inspect for the loose or damaged vacuum hose. (Intake manifold-
purge solenoid valve-charcoal canister)
 If the operation sound is not heard, perform the purge solenoid valve inspection.
(See PURGE SOLENOID VALVE INSPECTION [MZI-3.7] .)

8. Monitor the EVAPCP PID using the M-MDS, and drive the vehicle approx. 2,000 rpm for 30 sec. or
more.
 If the EVAPCP PID is 0 % , inspect the following.
 MAF, APP1, APP2, APP3, TP_REL and LOAD PIDs.
If simulation function of the M-MDS is not used:

2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.
3. Put the finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is
cold.
 If there is a vacuum, inspect the following:
 Wiring harness and connectors (Purge solenoid valve-PCM terminal 1BC)
 Purge solenoid vale (stuck open)
4. Connect the M-MDS to the DLC-2 and verify that the DTC P0443 is shown. Perform the DTC
inspection.
5. Access EVAPCP and ECT PIDs.

6. Verify that the ECT PID is more than 78°C {173°F}.
 If the ECT PID reading indicates less than 78°C {173°F} , perform the ECT inspection.
7. Set the vehicle on the dynamometer or chassis roller.

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WARNING:  When the dynamometer or chassis roller is operating, there is a

possibility that the operator may come into contact with or be
caught up in the rotating parts, leading to serious injuries or
death. When performing work while the dynamometer or
chassis roller is operating, be careful not to come into contact
with or caught up in any of the rotating parts.
8. Drive the vehicle approx. 2,000 rpm for 30 sec. or more.

 If there is no vacuum, inspect the following:
 Wiring harness and connector (Main relay-purge solenoid valve-PCM terminal 1BC)
 Purge solenoid valve
 MAF, APP1, APP2, APP3, TP_REL and LOAD PISs
 If there is vacuum, inspect the following:
 Vacuum hose (Purge solenoid valve-charcoal canister)
A/C CUT-OFF CONTROL SYSTEM INSPECTION

2. Turn the A/C switch and the fan switch on.
3. Verify that the A/C compressor magnetic clutch actuates.
 If it does not actuate, go to symptom troubleshooting "No.23 A/C does not work sufficiently".
4. Fully open the throttle valve and verify that the A/C compressor magnetic clutch does not actuate for 2-5
s.
 If it actuates, inspect as follows:
 A/C relay
 Open or short to GND circuit in wiring harness and connectors (Ignition switch-A/C relay-
PCM terminal 1N)
 A/C related parts
 APP1, APP2, APP3 PIDs
COOLING FAN CONTROL SYSTEM INSPECTION

2. Start the engine and warm it up to normal operating temperature.
3. Perform the KOER self-test. (See KOEO/KOER SELF TEST [MZI-3.7] .)
4. Verify that the DTC P0480 is not shown and the cooling fan operates during the KOER self-test.
 If DTC P0480 is shown, perform the DTC troubleshooting procedure.
 If the cooling fans do not operate, proceed to the following:

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1. Verify the clicking sound of the cooling fan relay when the ignition switch is turned from the
off to the ON position.
2. If there is no the clicking sound, inspect the cooling fan relay for an open circuit between the
ignition switch and the cooling fan relay.
 If there is a clicking sound, go to the next step.
 Inspect the following parts in the indicated order in accordance with fan operation conditions.
Cooling fans do not operate
 Open circuit between the fan control module and the cooling fan relay
 Open circuit between fan control module and ground
 Poor connection of the fan control module connector
 Fan control module (See FAN CONTROL MODULE INSPECTION [MZI-3.7] .)
Cooling fan motor No.1 does not operate
 Open or short to ground circuit between the fan control module and cooling fan motor No.1
 Poor connection of the fan control module connector or cooling fan motor No.1 connector
 Cooling fan motor No.1 (See FAN MOTOR INSPECTION [MZI-3.7] .)
Cooling fan motor No.2 does not operate
 Open or short to ground circuit between the fan control module and the cooling fan motor No.2
 Poor connection of the fan control module connector or the cooling fan motor No.1 connector
 Cooling fan motor No.2 (See FAN MOTOR INSPECTION [MZI-3.7] .)
VARIABLE VALVE TIMING CONTROL SYSTEM OPERATION INSPECTION
When idling cannot be continued
NOTE:  Inspect for each bank
1. Remove the OCV and verify that the spool valve is at maximum retard position.
 If the spool valve is stuck in advance direction, replace the OCV. (See OIL CONTROL VALVE
(OCV) REMOVAL/INSTALLATION [MZI-3.7] .)
2. Connect the OCV.
3. Turn the ignition switch to ON position.
4. Verify that the spool valve is at max. retard position.
 If the spool valve is stuck in advance direction, inspect the following:
 Short circuit in harnesses or connectors between the OCV and the PCM.
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5. Inspect the variable valve timing actuator.
When idling can be continued
For right bank
1. Disconnect OCV (RH) connector.

2. Warm up the engine and it at idle.
3. Apply the battery voltage to the OCV and verify that the engine idles roughly or stalls.
 If the engine idles roughly or stalls, inspect the timing belt component (valve timing deviation).
 If the engine does not idle roughly or stall, go to the next step.
4. Remove the OCV (RH) and perform spool valve operation inspection. (See OIL CONTROL VALVE
 OCV (RH)
 Harnesses and connectors between OCV (RH) and PCM have an open or short circuit.
 If as specified, inspect the following right bank hydraulic passages for clogging or leakage, or both.
 Oil pressure switch - OCV
 OCV - camshaft
 Camshaft internal passage
5. If they are normal, replace the right bank camshaft pulley (with built-in variable valve timing actuator).
For left bank
1. Disconnect OCV (LH) connector.

2. Warm up the engine to idle.
3. Apply the battery voltage to the OCV and verify that the engine idles roughly or stalls.
 If the engine idles roughly or stalls, inspect the timing belt component (valve timing deviation).
 If the engine does not idle roughly or stall, go to the next step.
4. Remove the OCV (LH) and perform spool valve operation inspection. (See OIL CONTROL VALVE
 OCV (LH)
 Harnesses and connectors between OCV (LH) and PCM have an open or short circuit.
 If as specified, inspect the following left bank hydraulic passages for clogging or leakage or both.
 Oil pressure switch - OCV
 OCV - camshaft
 Camshaft internal passage
5. If they are normal, replace the left bank camshaft pulley (with built-in variable valve timing actuator).
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EVAPORATIVE EMISSION (EVAP) SYSTEM LEAK INSPECTION
 To verify that the problem has been fixed properly after repairs, the run drive cycle or EVAP system leak
inspection must be performed.
EVAP system leak inspection using the M-MDS
the EVAP system test.
EVAP system test out line
 The EVAP system test, which can substituted for the run drive cycle as an EVAP control system repair
confirmation method, can detect the small / large leak or blockage without run-drive cycle.
NOTE:  M-MDS can not detect "VERY SMALL LEAK". To identify the leak
point, please use the leak tester or ultrasonic leak detector.
EVAP system test description
 The EVAP system test finds gas leaks or blockage of EVAP system using the changes of the fuel tank
pressure.
 This test starts after sending an on-demand test signal from the M-MDS to the PCM.
 This test consists of three stages, and each stage is performed automatically as follows:
Stage 1 test. (Test for large leak or blockage)
 M-MDS send the stage 1 test start signal to the PCM.

 PCM controls the CV solenoid valve and purge solenoid valve to control the tank pressure to
the targeted value.
 M-MDS detect the large leak or the purge line blockage if the tank pressure does not arrive at
the target vacuum in specified period.
Stage 2 test. (Test for small leak)
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Fig. 16: Stage 1 Test For Large Leak Or Blockage

 When fuel tank pressure arrived at the targeted pressure at stage 1 test, M-MDS send the
stage 2 test signal to the PCM to turn off the purge solenoid to keep the tank pressure.
 M-MDS detect the small leak if the tank pressure can not keep within the target in specified
period.
Stage 3 test. (Test for blockage)
Fig. 17: Stage 2 Test For Small Leak

 M-MDS send the stage 3 test signal to the PCM to turn off the CV solenoid for check the
blockage of EVAP system.
 M-MDS detect blockage of the CV solenoid valve or air filter if the tank pressure does not
arrive at the target (atmosphere).
Fig. 18: Stage 3 Test For Blockage

EVAP system malfunction judgment
 M-MDS detect the small / large leak or blockage based on fuel tank pressure at the end of EVAP Test.
The EVAP Test could not obtain the target vacuum. A large leak or blockage is suspect.
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 This judgment means tank pressure could not arrive at target pressure at stage 1 test.
 Check for the large leakage or inspect the purge solenoid valve operation and related hoses.
 Repair or replace any malfunctioning parts.
The EVAP Test could not maintain the target vacuum. A small leak is suspect.
 This judgment means tank pressure could not stay in target pressure at stage 2 test.
 Run the EVAP Test again after Re-tighten the fuel filler cap.
 If small leak is suspected again, use the leak tester or ultrasonic leak detector for identify the leak
point.
 Repair or replace any malfunctioning parts.
Blockage in EVAP system.
 This judgment means tank pressure could not return to atmosphere at stage 3 test.
 Inspect the CV solenoid, Air filter, Charcoal canister and related hoses for blockage.
No large leaks or blockage have been detected in the EVAP system at this time.
 M-MDS can not detect "VERY SMALL LEAK".

 To identify the leak point, please use the leak tester or ultrasonic leak detector.
Evaporative system test procedure
1. Verify that all PIDs within the following specifications.
NOTE:  To successfully perform this procedure, all PIDs must be within the
specifications before proceeding to the next step.
2. Select the following items from the initialization screen of the M-MDS.
1. Select the "Powertrain".
2. Select the "Fuel".
3. Select the "EVAP Test".
 Verify that ECT and IAT are within the specifications at the confirmation screen. To
successfully perform this procedure, ECT and IAT must be within the spec before proceeding
to the next step.
 Fuel Level must be maintained within 15%-85%. PCM will cancel the EVAP Test If the
Fuel Level is lower than 15% or higher than 85%.
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Fig. 19: Evaporative System Test Procedure

3. Verify the test results described on the M-MDS and follow the instructions.
EVAP system leak inspection using leak tester
1. Perform the following SST (EVAP System Tester 134-01049) self-test:
NOTE:  If the tester does not work correctly during the self-test, refer to the
tester operators manua for a more detailed self-test procedure.
1. Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle
valve.
2. Connect the vehicle interface hose (part of the SST ) to the SELF-TEST port located on the control
panel. Hand tighten the fitting. (Do not overtighten.)
3. Turn the control valve to the TEST position.
4. The gauge should read 331-381 mm {13-15 in} of water.
 If the gauge is not reading in this range, adjust the pressure by turning the black knob on the
low pressure regulator at the nitrogen bottle.
5. Turn the control valve to the HOLD position.
6. Verify that the gauge holds pressure and that the flow meter reads no flow.
 If there is no drop in pressure and no flow, the tester passes the self-test.
 If the gauge leaks down, refer to the tester operators manual.
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Fig. 20: EVAP System Leak Inspection Using Leak Tester

2. Connect the SST to the vehicle.

1. Verify that the control valve on the panel is in the HOLD position then open the nitrogen bottle
valve.
2. Remove the fuel-filler cap from the vehicle.
 If the fuel-filler cap is not a MAZDA part or equivalent, replace it.
NOTE:  INSPECT FUEL FILLER CAP AND FILLER NECK

 Visually inspect for damage, insufficient sealing, rust,
cracks or warps for filler cap and filler neck.
 Repair or replace if necessary.
3. Connect the receiver assembly (SST: 134-01059) to the vehicle cap test hose assembly (part of the
SST ) and the fuel-filler cap from the vehicle.
4. Connect the cap adaptor (SST: 134-01058) to the vehicle cap test hose assembly (part of the SST )
and to the fuel-filler neck.
5. Connect the vehicle interface hose (part of the SST ) to the center fitting of the vehicle cap test
hose assembly (part of the SST ).
5. Request the PCM on-board device control (Mode 08) using the M-MDS to close the canister vent value.
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Fig. 21: Inspecting Fuel Filler Cap & Filler Neck

NOTE:  The canister vent value is closed for 10 min unless the following any
actions are done:
 The engine is started.
 The ignition switch is turned off position.
6. Make sure the control valve on the 134-01049 is in the HOLD position and that the valve on the cylinder
of nitrogen gas is open.
7. Turn the control valve to the open position and let the system fill. You should note a drop in the gauge
pressure along with the flow meter being pegged at maximum flow for several minutes depending on how
full or empty the fuel tank is, and how long it takes to completely fill and pressurize the evaporative
emissions system hoses.
8. If the gauge and the flow meter do not settle to a measurable level after 2-3 min, then refer to the Mazda
Workshop Manual to verify that the canister vent valve is properly closed. If canister vent valve is
properly closed. The EVAP system has large leakage. Check for leakage and repair as necessary.
9. Verify the pressure gauge and flow meter reading to determine if there is an evaporative emissions leak:
NO EVAPORATIVE LEAK:
 The flow meter registers "zero flow" and the pressure gauge returns to the pre-set pressure of 356
mm {14 in} of water (H2O).
EVAPORATIVE LEAK:
 The pressure does not return to the preset level of 356 mm {14 in} of water (H2O) when measuring
the flow. See "SETTING LEAK STANDARD FOR TESTING" (.020 to .040 inch H2O) of the
Evaporative Emissions Tester operators manual (134-01067).
NOTE:  Turn the control valve to the HOLD position then disconnect the SST.
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2008 ENGINE Mechanical (MZI-3.7) - Mazda CX-9
2008 ENGINE
Mechanical (MZI-3.7) - Mazda CX-9
ENGINE LOCATION INDEX [MZI-3.7]
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Fig. 1: Exploded View Of Engine Components

ENGINE TUNE-UP [MZI-3.7]

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NOTE:  If the accelerator pedal is depressed continuously for a specified time, the
engine speed may decrease to the idle speed. This is due to the fuel cut
control operation, which prevents overheating, and it does not indicate a
malfunction.
ENGINE TUNE-UP PREPARATION

3. Turn off the electrical loads.
4. Verify that no DTCs are available.
5. Warm up the engine as follows.
2. Perform no-load racing at 2,500-3,000 rpm for 3 min. (ECT is approx. 80 °C {176 °F} or more)
3. Release the accelerator pedal.
4. Wait until the cooling fans stop.
Fig. 2: Identifying DLC-2 Part Location

IGNITION TIMING INSPECTION
1. Perform "Engine Tune-up Preparation". (See ENGINE TUNE-UP PREPARATION.)
NOTE:  The ignition timing cannot be adjusted.

 The M-MDS is required to verify the ignition timing.
2. Verify that the ignition timing (M-MDS: SPARKADV) is within the specification using M-MDS
function.
Ignition timing Approx. BTDC 13°
3. Verify that ignition timing advances when the engine speed increases gradually.
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 If it is not within the specification, refer to "ENGINE SYMPTOM TROUBLESHOOTING". (See

SYMPTOM DIAGNOSTIC INDEX [MZI-3.7] .)
IDLE SPEED INSPECTION
NOTE:  The idle speed cannot be adjusted.

 The M-MDS is required to verify the idle speed.
2. Verify that the idle speed (M-MDS: RPM) is within the specification using M-MDS.
Idle speed (P position)
No load: 570-670 rpm
Electrical load on: 630-730 rpm
Power steering oil pump operation: 600-700 rpm
A/C and heater operation: 570-850 rpm [-40-49 °C {-40-120 °F}]
IDLE MIXTURE INSPECTION

2. Verify that the idle speed and ignition timing are within the specification. (See IGNITION TIMING
INSPECTION.) (See IDLE SPEED INSPECTION.)
3. Insert an exhaust gas analyzer into the tailpipe.
4. Verify that the CO and HC concentrations are within the specified regulation.
 If not within the regulation, refer to "ENGINE SYMPTOM TROUBLESHOOTING". (See
SYMPTOM DIAGNOSTIC INDEX [MZI-3.7] .)
Idle mixture
HC concentration: Within the regulation
CO concentration: Within the regulation
DRIVE BELT INSPECTION [MZI-3.7]

GENERATOR & A/C DRIVE BELT
NOTE:  The generator and A/C drive belt deflection/tension inspection is not
necessary because of the use of the drive belt auto tensioner.
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1. Verify that the drive belt auto tensioner indicator mark does not exceed the maximum belt length.
 If it exceeds the maximum belt length, replace the generator and A/C drive belt. (See DRIVE
BELT REMOVAL/INSTALLATION [MZI-3.7].)
2. Visually inspect the generator and A/C drive belt for damage and cracks.
 If there is generator and A/C drive belt damage and cracks, replace the generator and A/C drive
belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7].)
Fig. 3: Identifying Belt Length

POWER STEERING OIL PUMP DRIVE BELT
1. Visually inspect the power steering oil pump drive belt for damage and cracks.
 If there is power steering oil pump drive belt damage and cracks, replace the power steering oil
pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7].)
DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7]

GENERATOR & A/C DRIVE BELT
NOTE:  When removing the generator and A/C drive belt, perform the procedure
with two people, one releasing the belt tension and the other removing the
belt.
1. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)

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2. Remove the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
3. Remove the splash shield (RH).
4. Set a breaker bar on the center of the tensioner pulley as shown.
5. Using the breaker bar, turn the center of the tensioner pulley clockwise to release the tension on the
generator and A/C drive belt.
6. Remove the generator and A/C drive belt.
7. Install the generator and A/C drive belt.
NOTE:  When the generator and A/C drive belt is replaced with a new one, the
drive belt auto tensioner indicator mark is aligned with the nominal
belt length mark.
Fig. 4: Turning Center Of Tensioner Pulley

8. Verify that the drive belt auto tensioner indicator mark is within the maximum and minimum belt length.
(See DRIVE BELT INSPECTION [MZI-3.7].)
 If the drive belt auto tensioner indicator mark is not within the limit, replace the generator and A/C
drive belt.
9. Install the splash shield (RH).
10. Install the front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
11. Install the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)
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Fig. 5: Identifying Belt Length

POWER STEERING OIL PUMP DRIVE BELT
1. Remove the generator and A/C drive belt. (See GENERATOR AND A/C DRIVE BELT.)
2. Remove the power steering oil pump drive belt.
1. Install the SST between the power steering oil pump drive belt and the power steering oil pump
pulley.
NOTE:  Hold the SST by hand until it is lodges between the power
steering oil pump pulley and power steering oil pump drive belt.
Fig. 6: View Of SST Between Power Steering Oil Pump Drive

Belt & Power Steering Oil Pump Pulley
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2. Turn the crankshaft clockwise to remove the power steering oil pump drive belt.
NOTE:  If there is power steering oil pump drive belt damage and
cracks, replace the power steering oil pump drive belt.
3. Install the power steering oil pump drive belt.

1. Install the SST according to the following steps.
1. Loosen the clamp adapter nut of the SST.
NOTE:  There is no need to remove the clamp adapter nut

completely when positioning the SST on the power
steering oil pump pulley.
2. Position the SST on the power steering oil pump pulley with the clamp adapter in one of the
holes of the pulley.
3. Tighten the clamp adapter nut by hand.
NOTE:  Hand tightening of the clamp adapter nut is sufficient.
Fig. 7: Positioning SST On Power Steering Oil Pump Pulley

2. Position the power steering oil pump drive belt around the SST and the power steering oil pump
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pulley.
NOTE:  Hold the SST and power steering oil pump drive belt by hand
until the power steering oil pump drive belt is properly seated.
3. Turn the crankshaft clockwise to install the power steering oil pump drive belt.
Fig. 8: Positioning Power Steering Oil Pump Drive Belt

NOTE:  Verify that the power steering oil pump drive belt is firmly attached to
the pulleys.
4. Install the generator and A/C drive belt. (See GENERATOR AND A/C DRIVE BELT.)
5. Verify that the drive belt auto tensioner indicator mark does not exceeds the maximum belt length. (See
DRIVE BELT INSPECTION [MZI-3.7].)
 If it exceeds the maximum belt length, replace the generator and A/C drive belt.
Fig. 9: Identifying Power Steering Oil Pump Drive Belt With Pulleys
DRIVE BELT AUTO TENSIONER INSPECTION [MZI-3.7]

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3.7].)
5. Verify that the drive belt auto tensioner moves smoothly in the operational direction.
 Replace the drive belt auto tensioner if necessary.
Tightening torque: 8.9-12.1 N.m {91-123 kgf.cm, 79-107 in.lbf}
6. Turn the drive belt auto tensioner pulley by hand and verify that it rotates smoothly.
 Replace the drive belt auto tensioner if necessary.
Fig. 10: Turning Drive Belt Auto Tensioner Pulley

Fig. 11: Identifying Drive Belt Auto Tensioner Pulley

ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7]

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1. Remove the engine cover in the order indicated in the figure.
NOTE:  Firmly pull the engine cover near the locations shown to disengage
the retainers.
Fig. 12: View Of Engine Cover Side

VALVE CLEARANCE INSPECTION/ADJUSTMENT [MZI-3.7]

VALVE CLEARANCE INSPECTION

3. Remove the ventilation hose.
3.7] .)
6. Disconnect the wiring harness.
9. Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7].)
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12. Measure the valve clearance.
1. Rotate the crankshaft clockwise and verify that the timing mark of the intake side camshaft
sprocket is in the position shown in the figure. In this position, the No.1 cylinder is at the TDC of
the compression stroke.
2. Measure the valve clearance of location A shown in the figure.
 If it is not within the specification, replace the tappet and adjust the valve clearance to the
median value of the standard.
Fig. 13: Identifying Valve Clearance Gap

IN: 0.150-0.250 mm {0.00591-0.00984 in}
EX: 0.300-0.400 mm {0.0119-0.0157 in}
NOTE:  Make sure to note down the measured values for choosing the
suitable replacement tappets.
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Fig. 14: Identifying Engine Front Side

3. Mark the crank pulley and engine front cover as shown in the figure.
4. Rotate the crankshaft clockwise 360 ° so that the No.5 cylinder is at TDC of the compression
stroke.
5. Measure the valve clearance of location B shown in the figure.
 If it is not within the specification, replace the tappet and adjust the valve clearance to the
median value of the standard.
Fig. 15: Locating Crank Pulley Mark

IN: 0.150-0.250 mm {0.00591-0.00984 in}

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EX: 0.300-0.400 mm {0.0119-0.0157 in}
NOTE:  Make sure to note down the measured values for choosing the
suitable replacement tappets.
VALVE CLEARANCE ADJUSTMENT
1. Follow the cylinder head gasket replacement procedure and remove the camshafts and camshaft sprocket
as a single unit. (See CYLINDER HEAD GASKET REPLACEMENT [MZI-3.7].)
2. Remove the tappet.
3. Install an appropriate tappet based on the results of the valve clearance inspection.
Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance
IN: 0.150-0.250 mm {0.00591-0.00984 in}
EX: 0.300-0.400 mm {0.0119-0.0157 in}
VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [MZI-3.7]
CAUTION:  The variable valve timing actuator cannot be disassembled because

it is a precision unit.
NOTE:  The following procedure "VARIABLE VALVE TIMING ACTUATOR

REMOVAL/INSTALLATION" is performed after the engine and transaxle
component is removed from the vehicle. (See ENGINE
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3.7].)
3. Secure the engine and transaxle component using a hoist and the SST.
[MZI-3.7].)
CAUTION:  When removing the timing chain and marking the timing marks
on the chain, mark the camshaft timing chain as well.
Fig. 16: View Of Engine & Transaxle Component With SST

9. Follow the "TIMING CHAIN REMOVAL/INSTALLATION" procedure and removal the timing chain.
(See TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7].)
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3. Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZI-3.7].
Fig. 17: Identifying Engine Components With SST & Torque Specifications
VARIABLE VALVE TIMING ACTUATOR COMPONENT REMOVAL NOTE
CAUTION:  Do not rotate the crankshaft counterclockwise. The timing chains

may bind, causing engine damage.
1. Turn the crankshaft clockwise so that the crankshaft keyway is in the 11 o'clock position. (This will
position the No.1 cylinder at TDC.)
NOTE:  Verify that there are timing marks in three locations (Yellow 1, Black
2) on the timing chain. If any timing marks are missing, mark the
timing chain.
 When marking the crankshaft sprocket side timing chain, change the
mark color.
 If replacing with a new timing chain, place alignment marks in the
same positions as those prior to the replacement.
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Fig. 18: Turning Crankshaft Clockwise

2. Mark the timing chain at the position of each timing sprocket timing mark.
CAUTION:  Verify that there are timing marks in two locations on the
camshaft timing chain. If any timing marks are missing, mark
the camshaft timing chain.
 If replacing with a new variable valve timing actuator, place
alignment marks in the same positions as those prior to the
replacement.
3. Mark the camshaft timing chain at the positions where it is aligned with each of the camshaft sprocket on
both banks.
Fig. 19: Locating Camshaft Timing Chain Mark

LH
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Fig. 20: Locating Camshaft Timing Chain Mark (LH)

RH
4. Remove the timing chain in the following order.

1. Chain tensioner
2. Timing chain
3. Tensioner arm
4. Chain guide
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Fig. 21: Locating Timing Chain Mark Location

5. Crankshaft sprocket
Fig. 22: Identifying Crankshaft Sprocket

5. Rotate the crankshaft counterclockwise until the keyway is in the 9 o'clock position.
6. Slowly compress the camshaft timing chain tensioner (LH) piston by hand.
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Fig. 23: Rotating Crankshaft Counterclockwise

7. Insert an approx. 1.0 mm {0.039 in} thin wire or paper clip into the camshaft timing chain tensioner
(LH) shown in the figure to hold the tensioner piston.
Fig. 24: Inserting Paper Clip Into Camshaft Timing Chain Tensioner (LH)
8. Install the SST onto the camshafts (LH).
NOTE:  The camshaft sprocket is integrated with the variable valve timing
actuator and cannot be disassembled.
Fig. 25: Identifying SST Onto Camshafts (LH)

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9. Remove the variable valve timing actuator, camshaft timing chain and the exhaust camshaft sprocket of
the LH bank as a single unit.
10. Slowly compress the camshaft timing chain tensioner (RH) piston by hand.
(RH) shown in the figure to hold the tensioner piston.
Fig. 26: Inserting Thin Wire Or Paper Clip Into Camshaft Timing Chain Tensioner (RH)
12. Install the SST onto the camshafts (RH).
NOTE:  The camshaft sprocket is integrated with the variable valve timing
actuator and cannot be disassembled.
13. Remove the variable valve timing actuator, camshaft timing chain and the exhaust camshaft sprocket of
the RH bank as a single unit.
Fig. 27: Identifying SST Onto Camshafts (RH)

VARIABLE VALVE TIMING ACTUATOR COMPONENT INSTALLATION NOTE
1. Align the alignment marks on the camshaft timing chain and both intake and exhaust side camshaft
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sprockets of both banks.
RH
Fig. 28: Locating Alignment Marks On Camshaft Timing Chain (RH)

LH
2. Install the variable valve timing actuator, camshaft timing chain and the exhaust camshaft sprocket of the
RH bank as a single unit.
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Fig. 29: Locating Alignment Marks On Camshaft Timing Chain (LH)

3. Remove the retaining wire inserted into the camshaft timing chain tensioner (RH).
4. Tighten the new camshaft sprocket (RH) installation bolts using the following 4 steps.
1. Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}.
2. Loosen 360 ° (one full turn) in reverse order.
3. Tighten to 10 N.m {102 kgf.cm, 89 in.lbf}.
4. Tighten to 90 °
5. Install the variable valve timing actuator, camshaft timing chain and the exhaust camshaft sprocket of the
LH bank as a single unit.
Fig. 30: Locating Retaining Wire Into Camshaft Timing Chain Tensioner
6. Remove the retaining wire inserted into the camshaft timing chain tensioner (LH).
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7. Tighten the new camshaft sprocket (LH) installation bolts using the following 4 steps.
1. Tighten to 40 N.m {4.1 kgf.m, 30 ft.lbf}.
4. Tighten to 90 °
Fig. 31: Locating Retaining Wire Into Camshaft Timing Chain Tensioner
8. Rotate the crankshaft clockwise until the keyway is in the 11 o'clock position. (This will position the No.1
cylinder at TDC.)
9. Follow the "TIMING CHAIN REMOVAL/INSTALLATION" procedure and install the timing chain.
10. Remove the SSTs installed to the camshaft components on both banks.
Fig. 32: Rotating Crankshaft Clockwise

OIL CONTROL VALVE (OCV) INSPECTION [MZI-3.7]

COIL RESISTANCE INSPECTION
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3. Disconnect the OCV connector.
4. Measure the coil resistance between terminals A and B using a tester.
 If it is not within the specification, replace the OCV.
Oil control valve resistance 5-14 ohms
Fig. 33: Locating OCV Connector

SPOOL VALVE OPERATION INSPECTION

2. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZI-3.7].)
3. Verify that the spool valve in the OCV is in the maximum valve timing retard position as indicated in the
figure.
 If not as specified, replace the OCV.

 If not as specified, recharge the battery.
Fig. 34: Identifying Maximum Valve Timing Retard Position (Spool Valve)
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5. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and
moves to the maximum valve timing advance position.
Fig. 35: Locating OCV Connector

 If not as specified, replace the OCV.
NOTE:  When applying battery positive voltage between the OCV terminals,
the connection can be either of the following:
 Positive battery cable to terminal A, Negative battery cable to
terminal B
 Positive battery cable to terminal B, Negative battery cable to
terminal A
Fig. 36: Identifying Maximum Valve Timing Advance Position

(Spool Valve)
6. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve
timing retard position.
 If not as specified, replace the OCV. (See OIL CONTROL VALVE (OCV)
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OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [MZI-3.7]

4. Disconnect the vacuum hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
3.7] .)
10. Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7].)
11. Remove the OCV.
NOTE:  The LH side is shown, however, the RH side is the same.
Fig. 37: Identifying OCV & Bolt

COMPRESSION INSPECTION [MZI-3.7]
WARNING:  Hot engines and oil can cause severe burns. Turn off the engine and
wait until they are cool.
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 Fuel vapor is hazardous. It can very easily ignite, causing serious


 Recharge it if necessary. (See BATTERY INSPECTION [MZI-3.7] .)
2. Warm up the engine to the normal operating temperature.

3. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (See BEFORE SERVICE
PRECAUTION [MZI-3.7] .)
7. Remove the spark plugs.
8. Measure the compression pressure using the following procedure.
1. Connect the compression gauge into the spark plug hole.
2. Crank the engine a minimum of five compression strokes and record the highest reading.
Fig. 38: Measuring Compression Pressure

NOTE:  Note the approximate number of compression strokes required

to obtain the highest reading.
3. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
4. The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75% of the highest reading. Refer to the COMPRESSION PRESSURE LIMIT
CHART.
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 If the compression in one or more cylinders is low or the compression difference between
cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder
and recheck the compression.
 If the compression increases, the piston, the piston rings, or cylinder wall may be worn
and overhaul is required.
 If the compression stays low, a valve may be stuck or improperly seated and overhaul
is required.
 If two adjacent cylinders indicate low compression pressures, and squirting oil on the
piston does not increase compression, the head gasket may be leaking between
cylinders. Engine oil and/or coolant in the cylinders could result from this condition.
Compression Pressure Limit Chart kPa
COMPRESSION PRESSURE LIMIT CHART

{kgf/cm2 , psi}
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum
pressure pressure pressure pressure pressure pressure pressure pressure
1,000
924 {9.41, 696 {7.10, 1,131 848 {8.65, 1,338 1,544 1,158
{10.20,
134} 101} {11.52, 164} 123} {13.63, 194} {15.73, 224} {11.81, 168}
146}
1,014
938 {9.56, 703 {7.17, 1,145 855 {8.72, 1,351 1,558 1,165
{10.34,
136} 102} {11.67, 166} 124} {13.77, 196} {15.88,226} {11.88, 169}
147}
1,020
952 {9.70, 717 {7.31, 1,158 869 {8.86, 1,365 1,572 1,179
{10.40,
138} 104} {11.80, 168} 126} {13.91, 198} {16.02,228} {12.02,171}
148}
1,034
965 {9.83, 724 {7.38, 1,172 876 {8.93, 1,379 1,586 1,186
{10.54,
140} 106} {11.94, 170} 127} {14.05, 200} {16.16,230} {12.09, 172}
150}
1,041
979 {9.97, 738 {7.53, 1,186 889 {9.07, 1,303 1,600 1,200
{10.62,
142} 107} {12.08, 172} 129} {13.28,202} {16.30,232} {12.24, 174}
151}
1,055
933 {9.51, 745 {7.60, 1,200 903 {9.21, 1,407 1,055 1,207
{10.76,
144} 109} {12.23,174} 131} {14.34, 204} {10.75,153} {12.31,175}
153}
1,007 1,062
758 {7.73, 1,214 910 1,420 1,627 1,220
{10.26, {10.83,
110} {12.37, 176} {9.28,132} {14.47,206} {16.58, 154} {12.44, 177}
146} 154}
1,020 1,075
765 {7.80, 1,227 917 1,434 1,641 1,227
{10.39, {10.96,
111} {12.50,178} {9.35,133} {14.61,208} {16.72,238} {12.51, 178}
148} 156}
1,034 1,083
779 {7.94, 1,241 931 {9.49, 1,448 1,655 1,241
{10.54, {10.04,
113} {12.65, 180} 135} {14.76,210} {16.87,240} {12.65, 180}
150} 157}
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1,048 1,089
786 {8.02, 1,255 936 {9.54, 1,462 1,669 1,248
{10.68, {11.10,
114} {12.79, 182} 136} {14.90,212} {17.01,242} {12.73, 181}
152} 158}
1,062 1,103
793 {8.09, 1,269 952 1,476 1,682 1,262
{10.82, {11.25,
115} {12.93, 184} {9.70,138} {15.04,214} {17.14,244} {12.87, 183}
154} 160}
1,076 1,117
807 {8.23, 1,282 965 {9.84, 1,489 1,696 1,269
{10.96, {11.39,
117,} {13.06,186} 140} {15.17,216} {17.28,246} {12.94, 184}
156} 162}
1,089 1,124
814 {8.30, 1,296 972 {9.91, 1,503 1,710 1,202
{11.10, {11.46,
118} {13.21,188} 141} {15.32,218} {17.43,248} {12.26, 186}
158} 163}
1,103 1,138
827 {8.43, 1,310 979 {9.98, 1,517 1,724 1,289
{11.24, {11.60,
120} {13.35, 190} 142} {15.46,220} {17.57,250} {13.14, 187}
160} 165}
1,110 1,145
834 {8.50, 1,324 993 {10.2, 1,631
{11.31, {11.67, - -
121} {13.49, 192} 144} {16.62,222}
161} 166}
9. Remove the compression gauge.

10. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION [MZI-3.7] .)
11. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZI-3.7] .)
12. Install the dynamic chamber and throttle body as a single unit. (See INTAKE-AIR SYSTEM
13. Install the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)
14. Install the fuel pump relay.
15. Complete the "AFTER REPAIR PROCEDURE". (See AFTER SERVICE PRECAUTION [MZI-
3.7] .)
TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7]
NOTE:  The following procedure "TIMING CHAIN REMOVAL/INSTALLATION" is
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vehicle. (See ENGINE REMOVAL/INSTALLATION [MZI-3.7].)

3.7].)
Fig. 39: Identifying Engine & Transaxle Component With SST

[MZI-3.7].)
3. Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZI-3.7].)
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Fig. 40: Identifying Engine Components With Torque Specifications

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CRANKSHAFT PULLEY LOCK BOLT REMOVAL NOTE
1. Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZI-3.7] .)

2. Set a flathead screwdriver to the drive plate in the position indicated in the figure to lock the crankshaft
rotation.
3. Remove the crankshaft pulley lock bolt and washer.
Fig. 41: Locking Crankshaft Rotation

CRANKSHAFT PULLEY REMOVAL NOTE
1. Remove the washer from the crankshaft pulley lock bolt, install a suitable spacer (thickness: approx. 14
mm {0.55 in} , diameter: approx. 30 mm {1.18 in} ), (similar to front shock absorber lower nut) to the
crankshaft pulley lock bolt, and install the crankshaft pulley lock bolt to the crankshaft.
Fig. 42: Identifying Crankshaft Pulley Lock Bolt & Spacer

2. Remove the crankshaft pulley using the SST.

3. Remove the crankshaft pulley lock bolt and spacer.
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Fig. 43: Removing Crankshaft Pulley With SST

FRONT OIL SEAL REMOVAL NOTE
1. Remove the front oil seal using a flathead screwdriver as shown.
Fig. 44: Removing Front Oil Seal

CYLINDER HEAD COVER REMOVAL NOTE
1. Remove the cylinder head cover bolts in the order shown.
RH
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Fig. 45: Identifying Cylinder Head Cover Bolts (RH)

LH
Fig. 46: Identifying Cylinder Head Cover Bolts (LH)

CYLINDER HEAD COVER OIL SEAL REMOVAL NOTE
NOTE:  Inspect the OCV attachment hole seals and spark plug tube attachment
hole seals. Remove the any damaged seals.
 The OCV attachment hole seals removal is shown, the spark plug tube
attachment hole seals removal procedure is the same.
1. Tap the OCV attachment hole seals and spark plug tube attachment hole seals using the SSTs and
hammer.
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Fig. 47: View Of Cylinder Head Cover Oil Seal & SST
ENGINE FRONT COVER AND NO.3 ENGINE MOUNT BRACKET REMOVAL NOTE
1. Loosen the engine front cover and No.3 engine mount bracket installation bolts in the order shown in the
figure.
2. Install 4 of the engine front cover bolts (finger tightened) into the 4 threaded holes in the engine front
cover.
Fig. 48: Identifying Engine Front Cover & No.3 Engine Mount Bracket
1. Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder
block seal is released.
2. Remove the engine front cover.
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Fig. 49: Locating Engine Front Cover Bolts

OCV COMPONENT REMOVAL NOTE
1. Loosen the OCV component installation bolts in the order shown in the figure.
RH
Fig. 50: Identifying OCV Component Bolts (RH)

LH
Fig. 51: Identifying OCV Component Bolts (LH)

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TIMING CHAIN COMPONENT REMOVAL NOTE

timing chain.
mark color.
 When the timing chain is replaced with a new one, mark the new
timing chain at the same positions as the removed timing chain.

1. Chain tensioner
2. Timing chain
3. Tensioner arm
4. Chain guide
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Fig. 53: Identifying Timing Sprocket Timing Mark

Fig. 54: Identifying Crankshaft Sprocket

OCV COMPONENT INSTALLATION NOTE
1. Tighten the OCV component installation bolts in the order shown in the figure.
RH
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Fig. 55: Identifying OCV Component Bolts (RH)

LH
Fig. 56: Identifying OCV Component Bolts (LH)

TIMING CHAIN COMPONENT INSTALLATION NOTE
1. Verify that the crankshaft keyway is at 11 o'clock position.
NOTE:  Of the three marked locations on the timing chain, align the mark that
has a different color to the crankshaft sprocket side timing mark.
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Fig. 57: Identifying Timing Chain Component

2. Place alignment marks on the timing chain corresponding to each of the alignment marks on the timing
sprocket.
Fig. 58: View Of Alignment Marks On Timing Chain

3. Push down the link plate of the timing chain tensioner and release the plunger lock.
NOTE:  The plunger should retract with minimal force. If binding occurs,
remove the chain tensioner from the vise and reset it in the vise.
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Fig. 59: Pushing Link Plate Of Timing Chain Tensioner

4. Secure the chain tensioner using a vice attached with a soft base, and slowly press the plunger back
shown in the figure while pressing down the link plate.
5. Release the pressure slightly from the plunger, and move the plunger back and forth 2-3 mm {0.08-0.11
in).
Fig. 60: Pressing Plunger

6. Insert an approx. 1.5 mm {0.059 in} thick wire or paper clip where the link plate hole and the tensioner
body hole overlap to fix the link plate and lock the plunger.
7. Install the timing chain in the following order.
2. Chain guide
3. Tensioner arm
4. Timing chain
5. Chain tensioner
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Fig. 61: Identifying Link Plate Hole & Tensioner Body Hole
Fig. 62: Identifying Crankshaft Sprocket, Tensioner Arm, Timing Chain & Chain Tensioner
8. Remove the retaining wire.
Fig. 63: View Of Retaining Wire

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ENGINE FRONT COVER & NO.3 ENGINE MOUNT BRACKET INSTALLATION NOTE
1. Apply the silicon sealant (Loctite 5900) to the engine front cover shown in the figure.
Silicon sealant thickness
A: 5.0-6.0 mm {0.197-0.236 in}
B: 2.5-3.5 mm {0.099-0.137 in}
2. Install the engine front cover and No.3 engine mount bracket.
1. Tighten the engine front cover and No.3 engine mount bracket installation bolts in 4 steps in the
order shown in the figure.
Fig. 64: Identifying Engine Front Cover Sealant Area

CAUTION:  Install the engine front cover and No.3 engine mount
bracket installation bolts within 10 min of applying the
silicone sealant.
Tightening Torque
TIGHTENING TORQUE SPECIFICATION

Step Installation position Tightening torque
1 1-6 10 N.m {102 kgf.cm, 89 in.lbf}
2 7-9 15 N.m {1.5 kgf.m, 11 ft.lbf}
3 1-6 20-28 N.m {2.1-2.8 kgf.m, 15-20 ft.lbf}
4 7-9 70-80 N.m {7.2-8.1 kgf.m, 52-59 ft.lbf}
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2. Tighten the engine front cover installation bolts in the order in 2 steps in the order shown in the
figure.
Fig. 65: Identifying Engine Front Cover Bolts Tightening Sequence

CAUTION:  Install the engine front cover installation bolts within 60

min of applying the silicone sealant.
Tightening torque

2. Tighten to 20-28 N.m {2.1-2.8 kgf.m, 15-20 ft.lbf}.
Fig. 66: Identifying Engine Front Cover Bolts Tightening Sequence

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CYLINDER HEAD COVER OIL SEAL NOTE
NOTE:  Installation of new seals is only required if damaged seals were removed
during disassembly of the engine.
1. Push the OCV attachment hole seals and spark plug tube attachment hole seals slightly in by hand.
2. Tap the OCV attachment hole seals and spark plug tube attachment hole seals using the SST and hammer.
Fig. 67: Identifying Cylinder Head Cover With SST

CYLINDER HEAD COVER INSTALLATION NOTE
1. Apply silicone sealant (Loctite 5900) to the mating faces as shown.
RH
Fig. 68: Applying Silicone Sealant To Mating Faces (RH)

LH
2. Install the cylinder head cover with a new gasket.

3. Tighten the bolts in the order as shown.
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CAUTION:  Install the cylinder head cover installation bolt and studs within
5 min of applying the silicone sealant.
Fig. 69: Applying Silicone Sealant To Mating Faces (LH)

RH
Fig. 70: Identifying Cylinder Head Cover Bolts Tightening Sequence (RH)
LH
Tightening torque
8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
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Fig. 71: Identifying Cylinder Head Cover Bolts Tightening Sequence (LH)
FRONT OIL SEAL INSTALLATION NOTE
NOTE:  Apply clean engine oil to the front oil seal bore in the engine front cover.
1. Push the front oil seal slightly in by hand.

2. Tap the front oil seal in evenly using the SST and a hammer.
Substitution SST
 49G028 203
Tube with board thickness 2 mm {0.079 in} or more
Fig. 72: Tapping Front Oil Seal With SST

CRANKSHAFT PULLEY INSTALLATION NOTE
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NOTE:  Lubricate the contact surface (exterior area of inner diameter) of the front
oil seal with clean engine oil.
1. Install the crankshaft pulley, washer, and SST to the crankshaft.
Fig. 73: View Of Crankshaft Pulley & Washer

2. Tighten the SST nut and install the crankshaft pulley.
Fig. 74: Installing Crankshaft Pulley With SST

CRANKSHAFT PULLEY LOCK BOLT INSTALLATION NOTE
1. Set a flathead screwdriver to the drive plate in the position indicated in the figure to lock the crankshaft
rotation.
2. Tighten the new crankshaft pulley lock bolt in four steps.
1. Tighten to 140 N.m {14 kgf.m, 103 ft.lbf}.
4. Tighten 85 °--95 °.
3. Install the starter. (See STARTER REMOVAL/INSTALLATION [MZI-3.7] .)
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Fig. 75: Locking Crankshaft Rotation

CYLINDER HEAD GASKET REPLACEMENT [MZI-3.7]
NOTE:  The following procedure "CYLINDER HEAD GASKET REPLACEMENT" is

vehicle. (See ENGINE REMOVAL/INSTALLATION [MZI-3.7].)

3.7].)
3. Using a hoist, lower the engine and transaxle component on a level surface.
WARNING:  Protect and stabilize the lowered engine and transaxle

component with creosotes to prevent injury or damage due to
roll over.
5. Remove the fuel injector and fuel distributor together as a single unit. (See FUEL INJECTOR
6. Remove the thermostat and thermostat housing together as a single unit. (See THERMOSTAT
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7. Remove the Intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
8. Remove both WU-TWCs together with both exhaust manifolds as a single unit. (See EXHAUST
SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
[MZI-3.7].)
13. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZI-3.7] .)
CAUTION:  When removing the timing chain and marking the timing marks
on the chain, mark the camshaft timing chain as well.
14. Follow the "TIMING CHAIN REMOVAL/INSTALLATION" procedure and removal the timing chain.
4. Engine accessories operation
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Fig. 76: Identifying Engine Components & Torque Specifications

CAMSHAFT COMPONENT REMOVAL NOTE

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timing chain.
mark color.
 When the timing chain is replaced with a new one, mark the new
timing chain at the same positions as the removed timing chain.

NOTE:  Verify that there are timing marks in two locations on the camshaft
timing chain. If any timing marks are missing, mark the camshaft
timing chain.
 If replacing with a new camshaft timing chain, place alignment marks
in the same positions as those prior to the replacement.
Fig. 78: Identifying Timing Chain Marks Location

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3. Mark the camshaft timing chain at the positions where it is aligned with each of the camshaft sprocket on
both banks.
LH
Fig. 79: Identifying Mark Of Camshaft Timing Chain

RH

1. Chain tensioner
2. Timing chain
3. Tensioner arm
4. Chain guide
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Fig. 80: Locating Timing Chain Mark

Fig. 81: Identifying Crankshaft Sprocket Bolts

5. Rotate the crankshaft counterclockwise until the keyway is in the 9 o'clock position.
6. Slowly compress the camshaft timing chain tensioner (LH) piston by hand.
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Fig. 82: Rotating Crankshaft Counterclockwise

(LH) shown in the figure to hold the tensioner piston.
NOTE:  When the timing chain removed, valve spring pressure will rotate the
camshaft (LH) approx. 3 ° to a neutral position.
Fig. 83: Inserting Wire Or Paper Clip Into Camshaft Timing Chain
Tensioner (LH)
8. Verify that the camshafts (LH) are in the neutral position.
NOTE:  The cylinder head and the camshaft bearing caps are numbered to
make sure they are reassembled in their original position. When
removed, keep the bearing caps with the cylinder head they were
removed from. Do not mix the caps.
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Fig. 84: Identifying Camshafts Timing Mark

9. Loosen the LH bank camshaft cap bolts in several passes in the order shown in the figure and remove the
camshaft cap.
10. Remove the camshaft, camshaft sprocket, camshaft timing chain, and camshaft timing chain tensioner of
the LH bank as a single unit.
11. Slowly compress the camshaft timing chain tensioner (RH) piston by hand.
Fig. 85: Identifying Camshaft Cap Bolts Loosen Sequence

(RH) shown in the figure to hold the tensioner piston.
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Fig. 86: Inserting Wire Or Paper Clip Into Camshaft Timing Chain Tensioner (RH)
13. Put a wrench to the position shown in the figure on the RH bank camshaft, rotate the RH bank camshaft
counterclockwise, and set the camshaft to the neutral position.
Fig. 87: Rotating RH Bank Camshaft Counterclockwise

NOTE:  The cylinder head and the camshaft bearing caps are numbered to
make sure they are reassembled in their original position. When
removed, keep the bearing caps with the cylinder head they were
removed from. Do not mix the caps.
Fig. 88: Identifying Timing Mark Of Crankshaft

14. Loosen the RH bank camshaft cap bolts in several passes in the order shown in the figure and remove the
camshaft cap.
15. Remove the camshaft, camshaft sprocket, camshaft timing chain, and camshaft timing chain tensioner of
the RH bank as a single unit.
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Fig. 89: Identifying RH Bank Camshaft Cap Bolts Loosening Sequence

CYLINDER HEAD REMOVAL NOTE
1. Loosen the cylinder head bolts in several passes in the order shown.
Fig. 90: Identifying Cylinder Head Bolts Loosening Sequence (Engine Front Side)
CYLINDER HEAD INSTALLATION NOTE
NOTE:  The cylinder head bolts must be replaced with new bolts. The bolts are
torque-to-yield designed and cannot be reused.
1. Tighten the cylinder head bolts in the order in 6 steps in the order shown in the figure.
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Tightening Torque

Step Installation position Tightening torque
1 1-16 20 N.m {2.0 kgf.m, 15 ft.lbf}
2 1-16 35 N.m {3.6 kgf.m, 26 ft.lbf}
3 1-16 90°
4 1-16 90°
5 1-16 90°
6 17, 18 8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
Fig. 91: Identifying Cylinder Head Bolts Tightening Sequence (Engine Front Side)
CAMSHAFT COMPONENT INSTALLATION NOTE
1. Assemble the camshaft timing chain tensioners on both sides.
NOTE:  Install the camshaft, camshaft sprocket and camshaft timing chain of
the both bank as a single unit.
2. Install the camshaft component (RH).

1. Install the camshaft timing chain by aligning the colored links on the camshaft timing chain with
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the marks on the camshaft sprockets (RH).
RH
Fig. 92: Locating Camshaft Timing Chain Mark

2. Position the camshaft component onto the cylinder head (RH) in the neutral position as shown.
Fig. 93: Identifying Timing Mark Of Crankshaft

3. Install the RH bank camshaft caps and temporarily tighten the camshaft cap bolts evenly in the
order shown in several passes.
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Fig. 94: Identifying Camshaft Cap Bolts Tightening Sequence

4. Remove the retaining wire inserted into the camshaft timing chain tensioner (RH).
Fig. 95: Identifying Retaining Wire Into Camshaft Timing Chain Tensioner (RH)
5. Using the RH bank camshaft sprocket installation bolt at the position shown in the figure, rotate the
RH bank camshaft clockwise.
Fig. 96: Rotating RH Bank Camshaft Clockwise

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3. Install the camshaft component (LH).

1. Install the camshaft timing chain by aligning the colored links on the camshaft timing chain with
the marks on the camshaft spockets (LH).
Fig. 97: Installing Camshaft Component (LH)

LH
Fig. 98: Locating Camshaft Timing Chain Marks

2. Position the camshafts onto the cylinder head (LH) in the neutral position as shown.
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Fig. 99: Positioning Camshafts Onto Cylinder Head (LH)

3. Install the LH bank camshaft caps and temporarily tighten the camshaft cap bolts evenly in the
order shown in several passes.
Tightening torque: 8.5-11.5 N-m {87-117 kgf-cm 76-101 in-lbf}
Fig. 100: Identifying Camshaft Cap Bolts Tightening Sequence

4. Remove the retaining wire inserted into the camshaft timing chain tensioner (LH).
Fig. 101: Identifying Retaining Wire Into Camshaft Timing Chain Tensioner (LH)
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5. Follow the TIMING CHAIN REMOVAL/INSTALLATION" procedure and install the timing chain. (See
TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7].)

FRONT OIL SEAL REPLACEMENT [MZI-3.7]

3. Position the power steering reserve tank out of the way. (See POWER STEERING OIL PUMP
4. Remove the both front wheels and tires. (See GENERAL PROCEDURES (SUSPENSION) .)
6. Position the both ABS wheel-speed sensor out of the way. (See FRONT ABS WHEEL-SPEED
SENSOR REMOVAL/INSTALLATION .)
7. Position the front stabilizer control link (lower side) (RH) out of the way. (See FRONT STABILIZER
8. Position the tie-rod end ball joint (RH) out of the way. (See FRONT CROSSMEMBER
9. Remove the front shock absorber (LH) lower side bolts, position and secure the wheel hub and steering
knuckle component (LH) out of the way with a rope or wire. (See FRONT SHOCK ABSORBER AND
COIL SPRING REMOVAL/INSTALLATION .)
10. Disconnect the front drive shaft (RH) from the joint shaft side. (See FRONT DRIVE SHAFT
11. Remove the front pipe and middle pipe as a single unit. (See EXHAUST SYSTEM
12. Position the propeller shaft out of the way. (AWD) (See PROPELLER SHAFT
3.7].)
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[MZI-3.7].)
Fig. 103: Identifying Crankshaft Pulley Lock Bolt, Crankshaft Pulley, Oil Seal & Torque
Specifications
CRANKSHAFT PULLEY LOCK BOLT REMOVAL NOTE
1. Remove the cover as shown in the figure.
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Fig. 104: Identifying Crankshaft Pulley Lock Bolt, Cover & Fastener
2. Set a wrench to the drive plate bolt at the position shown in the figure to lock the crankshaft rotation.
3. Remove the crankshaft pulley lock bolt and washer.
Fig. 105: Removing Crankshaft Pulley Lock Bolt

1. Loosen the No.1 engine mount bolt C.
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Fig. 106: View Of No.1 Engine Mount Bolt C

NOTE:  Do not remove the No.1 engine mount rubber from the front
crossmember.

3. Position the coolant reserve tank out of the way. (See COOLANT RESERVE TANK
4. Remove the following parts to install the SST.
1. The windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE
2. The cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
3. The cowl panel. (See COWL PANEL REMOVAL/INSTALLATION .)
4. The air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
5. The front cooler pipe installation bolt (position the front cooler pipe out of the way.).
5. Install the SST using the following procedure.
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Fig. 108: Identifying Front Cooler Pipe & Bolt

CAUTION:  Refer to the SST instruction manual for the basic handing
procedure.
NOTE:  When installing the SST, adjust the position of each shaft so that
they do not interfere with the vehicle body.
Fig. 109: Identifying Main Frame, Rear Shaft, Side Bar & Front Shaft
1. Install the right rear shaft of the SST to the bolt of the right shock absorber shown in the figure.
2. Install the left rear shaft of the SST to the bolt of the left shock absorber (Identical position to the
right side).
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Fig. 110: View Of Right Rear Shaft Of SST

3. Install the left/right front shaft of the SST with front foot No.2 to the bolt shown in the figure.
4. Adjust the positions of the SST side bars so that they are the same height (left and right) and
horizontal.
5. Make sure each joint is securely tightened.
Fig. 111: View Of Left/Right Front Shaft Of SST

6. Support the engine using the SSTs.

7. Remove the No.3 engine mount.
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CRANKSHAFT PULLEY REMOVAL NOTE
1. Slightly loosen the SST (49 C017 5A0) support and tilt the engine to the lower side slightly.
2. Remove the washer from the crankshaft pulley lock bolt, install a suitable spacer (thickness: approx. 14
mm {0.55 in} , diameter: approx. 30 mm {1.18 in}) , (similar to front shock absorber lower nut) to the
crankshaft pulley lock bolt, and install the crankshaft pulley lock bolt to the crankshaft.
Fig. 113: Identifying Crankshaft Pulley Lock Bolt & Spacer

3. Remove the crankshaft pulley using the SST.

4. Remove the crankshaft pulley lock bolt and spacer.
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Fig. 114: Removing Crankshaft Pulley With SST

FRONT OIL SEAL REMOVAL NOTE
1. Remove the front oil seal using a flathead screwdriver as shown.
Fig. 115: Identifying Front Oil Seal & RAG

FRONT OIL SEAL INSTALLATION NOTE
NOTE:  Apply clean engine oil to the front oil seal bore in the engine front cover.
1. Push the front oil seal slightly in by hand.

2. Tap the front oil seal in evenly using the SST and a hammer.
Substitution SST
 49G028 203

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Fig. 116: Identifying Front Oil Seal With SST

CRANKSHAFT PULLEY INSTALLATION NOTE
NOTE:  Lubricate the contact surface (exterior area of inner diameter) of the front
oil seal with clean engine oil.
1. Install the crankshaft pulley, washer, and SST to the crankshaft.
Fig. 117: Identifying Crankshaft Pulley, Washer & SST

2. Tighten the SST nut and install the crankshaft pulley.
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Fig. 118: Installing Crankshaft Pulley

NO.3 ENGINE MOUNT INSTALLATION NOTE
1. Using the SST (49 C017 5A0) , tilt up the engine until it is vertical.
2. Tighten the bolts on the No.1 engine mount bracket in the order of A, B.

3. Tighten the No.1 engine mount bolt C at the specified torque.
No.1 engine mount through-bolt tightening torque 93.1-116.6 N.m {9.50-11.8 kgf.m, 68.7-85.9 ft.lbf}
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4. Temporarily tighten the No.3 engine mount bolt and nuts in the order shown in the figure.
Fig. 121: Identifying No.3 Engine Mount Bolt & Nuts Tightening Sequence
5. Tighten the No.3 engine mount in the order shown in the figure.
Tightening Torque

Installation Position Tightening Torque
1, 2, 7 74.5-104.9 N.m {7.60-10.6 kgf.m, 55.0-77.3 ft.lbf}
3, 4, 5, 6 43.1-74 N.m {4.40-7.54 kgf.m, 31.8-54.5 ft.lbf}
Fig. 122: Identifying No.3 Engine Mount Bolt & Nuts Tightening Sequence
6. Remove the SST (49 C017 5A0).

7. Install the following parts.
1. Install the front cooler pipe installation bolt.
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Tightening torque: 8-12 N.m {82-122 kgf.cm, 71-106 in.lbf}
Fig. 123: Identifying Front Cooler Pipe Installation Bolt & Front Cooler Pipe
2. The air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)

3. The cowl panel. (See COWL PANEL REMOVAL/INSTALLATION .)
4. The cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION .)
5. Tthe windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE
8. Install the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION
[MZI-3.7] .)
CRANKSHAFT PULLEY LOCK BOLT INSTALLATION NOTE
1. Rotate the crankshaft clockwise, and set a wrench to the drive plate bolt at the position shown in the
figure to lock the crankshaft rotation.
2. Tighten the new crankshaft pulley lock bolt in 4 steps.
1. Tighten to 140 N.m {14 kgf.m, 103 ft.lbf}.
4. Tighten 85 °--95 °.
3. Verify the tightening torque for the drive plate installation bolt to which the wrench has been set. (See
COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZI-3.7] .)
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Fig. 124: Setting Drive Plate Bolt

4. Install the cover as shown in the figure.
Fig. 125: Identifying Crankshaft Pulley Lock Bolt, Cover & Fastener
REAR OIL SEAL REPLACEMENT [MZI-3.7]

2. Remove the drive plate. (See DRIVE PLATE REMOVAL/INSTALLATION [AW6A-EL, AW6AX-
EL] .)
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Fig. 126: Identifying CKP Sensor Pulse Wheel & Rear Oil Seal
REAR OIL SEAL REMOVAL NOTE
1. Using a flathead screwdriver, remove the rear oil seal.
Fig. 127: Removing Rear Oil Seal

REAR OIL SEAL INSTALLATION NOTE
NOTE:  Lubricate the rear oil seal lips and bore with clean engine oil.
1. Push the rear oil seal slightly in by hand.

2. Tap the rear oil seal in evenly using the SST and a hammer.
Substitution SST
 49W011 101
Outer diameter: 105 mm {4.13 in} or more Inner diameter: 93-105 mm {3.7-4.1 in} Tube with
board thickness 2 mm {0.079 in} or more
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Fig. 128: Identifying Rear Oil Seal

ENGINE REMOVAL/INSTALLATION [MZI-3.7]
1. Perform "Fuel Line Safety Procedures". Leave the fuel pump relay removed. (See BEFORE SERVICE
PRECAUTION [MZI-3.7] .)
2. Disconnect both battery cables.
4. Drain the power steering fluid. (See POWER STEERING FLUID INSPECTION .)
8. Disconnect the vacuum hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
9. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
3.7] .)
11. Remove the both front wheels and tires. (See GENERAL PROCEDURES (SUSPENSION) .)
3.7].)
14. Disconnect the front drive shaft (RH) from the joint shaft side. (See FRONT DRIVE SHAFT
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15. Disconnect the front drive shaft (LH) from the transaxle side. (See FRONT DRIVE SHAFT
16. Remove the front pipe and middle pipe as a single unit. (See EXHAUST SYSTEM
17. Position the propeller shaft out of the way. (AWD) (See PROPELLER SHAFT
18. Disconnect the selector cable from the transaxle side. (See AUTOMATIC TRANSAXLE
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL] .)
19. Disconnect the heater hose. (See HEATER PIPE AND HOSE COMPONENT
20. Disconnect the power steering return hose. (See POWER STEERING OIL PUMP
21. Disconnect the radiator hose. (See RADIATOR REMOVAL/INSTALLATION [MZI-3.7] .)
22. Disconnect the water hose. (See OIL COOLER REMOVAL/INSTALLATION [MZI-3.7] .)
23. Disconnect the ATF oil cooler hose.
24. Disconnect the plastic fuel hose. (See BEFORE SERVICE PRECAUTION [MZI-3.7] .) (See QUICK
RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7] .)
NOTE:  Do not disconnect the engine side of this wiring harness.
26. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope
so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION .)
27. Remove the engine and transaxle component using an engine jack in the order indicated in the figure.
4. Engine accessories operation
NOTE:  If the engine is overhauled and installed to the vehicle, perform the
road test and verify that there is no malfunction.
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Fig. 129: Identifying Engine, Transaxle, Engine Mount Bracket, Engine Mount Rubber & Torque
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Specifications
1. Remove the front under cover A and front under cover B. (See FRONT UNDER COVER
2. Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)
3. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See STEERING
WHEEL AND COLUMN REMOVAL/INSTALLATION .)

5. Remove the No.1 engine mount No.1 engine mount bracket and the front crossmember as a single unit

NO.3 ENGINE MOUNT RUBBER AND NO.4 ENGINE MOUNT BRACKET REMOVAL NOTE
1. Secure the engine and transaxle using an engine jack and attachment.
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CAUTION:  Remove the engine and transaxle carefully, holding it steady. If

the transaxle falls it could be damaged or cause injury.
2. Secure the engine, transaxle, and crossmember component using a hoist.
Fig. 132: Lifting Engine & Transaxle With Engine Jack

ENGINE & TRANSAXLE REMOVAL NOTE
NOTE:  When lowering the engine, slightly move it to the left side of the vehicle to
set the A/C compressor out of the way.
Fig. 133: Setting A/C Compressor

ENGINE MOUNT INSTALLATION NOTE
1. Tighten the No.3 engine mount stud bolts.
Tightening torque: 15.7-23.5 N.m {1.61-2.39 kgf.m, 11.6-17.3 ft.lbf}
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Fig. 134: Identifying No.3 Engine Mount Stud Bolts

2. Secure the engine and the transaxle using an engine jack and attachment as shown.
Fig. 135: Lifting Engine & Transaxle With Engine Jack

3. Temporarily tighten the No.3 engine mount bolts and nuts in the order shown in the figure.
4. Temporarily tighten the No. 4 engine mount bracket in two passes.
Fig. 136: Identifying No.3 Engine Mount Bolts & Nuts

1. Temporarily tighten the No.4 engine mount bracket in the order shown in the figure until the flange
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surface does not adhere.

2. Temporarily tighten the No.4 engine mount bracket in the order shown in the figure until the flange
surface firmly adheres.

5. Install the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit.

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Fig. 140: Identifying Bolts On No.1 Engine Mounting Bracket

7. Teighten the No.1 engine mount bolt C at the specified torque.
8. Install the intermediate shaft installation bolt, and disconnect the steering shaft. (See STEERING

9. Install the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)

10. Install the front under cover A and front under cover B. (See FRONT UNDER COVER
11. Temporarily tighten the No.3 engine mount bolt and nuts in the order shown in the figure.
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Fig. 142: Identifying No.3 Engine Mount Bolt & Nuts

Tightening Torque

1, 2, 7 74.5-104.9 N.m {7.60-10.6 kgf.m, 55.0-77.3 ft.lbf}
3, 4, 5, 6 43.1-74 N.m {4.40-7.54 kgf.m, 31.8-54.5 ft.lbf}

Tightening Torque

1, 2, 3 66.6-93.1 N.m {6.80-9.49 kgf.m, 49.2-68.6 ft.lbf}
4 74.5-104.9 N.m {7.60-10.6 kgf.m, 55.0-77.3 ft.lbf}
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ENGINE DISASSEMBLY/ASSEMBLY [MZI-3.7]

1. Remove the transaxle from the engine. (See AUTOMATIC TRANSAXLE
REMOVAL/INSTALLATION [AW6A-EL, AW6AX-EL] .)
EL] .)
4. Remove the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR
6. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZI-3.7] .)
7. Remove the fuel injector and fuel distributor. (See FUEL INJECTOR REMOVAL/INSTALLATION
[MZI-3.7] .)
8. Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
9. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
10. Remove the thermostat case and water hose component. (See THERMOSTAT
11. Remove the CHT sensor. (See CYLINDER HEAD TEMPERATURE (CHT) SENSOR
12. Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR
13. Remove the oil pressure switch. (See OIL PRESSURE INSPECTION [MZI-3.7] .)
14. Remove the oil cooler. (See OIL COOLER REMOVAL/INSTALLATION [MZI-3.7] .)
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Fig. 145: Identifying Engine Bolts With Torque Specifications

NO.3 ENGINE MOUNT STAY (ENGINE FRONT COVER SIDE) INSTALLATION NOTE
1. Tighten the No.3 engine mount stay (engine front cover side) in the order shown in the figure.
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Fig. 146: Identifying No.3 Engine Mount Stay

WATER INLET PIPE INSTALLATION NOTE
1. Apply clean engine coolant to the O-ring.
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2008 BODY & ACCESSORIES Entertainment - Mazda CX-9
Entertainment - Mazda CX-9
ENTERTAINMENT LOCATION INDEX

AUDIO SYSTEM
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Fig. 1: Identifying Audio System Components Location

CAR-NAVIGATION SYSTEM, REAR ENTERTAINMENT SYSTEM

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Fig. 2: Identifying Car-Navigation System Components Location

REAR VIEW MONITOR
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Fig. 3: Identifying Rear Mount Camera

ANTENNA FEEDER
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Fig. 4: Identifying Antenna Feeder

AUDIO UNIT REMOVAL/INSTALLATION

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Fig. 5: Identifying Audio Unit Remove/Install Components

CAUTION:  When installing the Audio unit, make sure that the wiring
harness and antenna feeder are not caught between the unit
and dashboard. If the wiring harness or the antenna feeder is
caught between the unit and dashboard, it may cause
malfunctions.
AUDIO UNIT REMOVAL NOTE
1. Pull the audio unit outward, detach clip A from the dashboard, and then remove the audio unit.
Fig. 6: Identifying Audio Unit

AUDIO UNIT DISASSEMBLY/ASSEMBLY

STANDARD AUDIO
CAUTION:  Before disassembling the audio unit, spread a cloth on the floor to
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put the disassembled parts on. This protects the surface of the panel
from scratches or dirt.
Fig. 7: Exploded View Of Audio Unit

ACTION ILLUMINATION ON/OFF SWITCHING

STANDARD AUDIO
NOTE:  The action illumination* can be switched on and off by performing the
following procedure.

2. Turn the audio on.
3. Press the audio control dial 7 times.
4. Turn the audio control dial to the left and right to switch the action illumination ON/OFF.
* : May or may not be equipped, depends on the vehicle.
Fig. 8: Turning Audio Control Dial To Left & Right

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CAR-NAVIGATION UNIT REMOVAL/INSTALLATION
NOTE:  Car-navigation unit is located on the right side of the trunk box under the
trunk board.

Fig. 9: Identifying Car-Navigation Unit Components & Torque Specifications

AUDIO AMPLIFIER REMOVAL/INSTALLATION

2. Seat side box (RH) (See SEAT SIDE BOX REMOVAL/INSTALLATION .)
4. Third-row seat (RH) (See THIRD-ROW SEAT REMOVAL/INSTALLATION .)
5. Rear scuff plate inner (RH) (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
6. Third-row seat belt lower anchor installation bolt (Passenger Side) (See THIRD-ROW SEAT
BELT REMOVAL/INSTALLATION .)
7. Trunk side trim (RH) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
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Fig. 10: Identifying Audio Amplifier Components & Torque Specifications

AUDIO AMPLIFIER CONFIGURATION
the AUDIO AMPLIFIER CONFIGURATION.


2. Select "AM".
 If a DTC (s) is detected, perform the applicable DTC inspection. (See DTC TABLE [AUDIO
AMPLIFIER] .)
Fig. 11: Identifying Data Link Connector 2

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FRONT DOOR SPEAKER REMOVAL/INSTALLATION

2. Remove the inner garnish. (See INNER GARNISH REMOVAL/INSTALLATION .)
3. Remove the front door trim. (See FRONT DOOR TRIM REMOVAL/INSTALLATION .)
Fig. 12: Identifying Front Door Speaker Components

FRONT DOOR SPEAKER INSTALLATION NOTE
1. Remove the speaker with the wiring harness passing through the groove of the front door module.
CAUTION:  If the speaker is installed with the wiring harness out of the
groove, an open circuit in the wiring harness could occur.
Fig. 13: Identifying Front Door Module & Wiring Harness

FRONT DOOR SPEAKER INSPECTION

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1. Verify the resistance between front door speaker terminals.

 If the resistance is not within the specification, replace the front door speaker.
Resistance
Standard: 4 ohms
Bose®: 2 ohms
2. Connect a 1.5 V battery to the front door speaker and verify that noise is heard from the front door
speaker.
 If no noise is heard, replace the front door speaker.
Fig. 14: Identifying Front Door Speaker Terminals

REAR DOOR SPEAKER REMOVAL/INSTALLATION

2. Remove the inner sail garnish. (See INNER SAIL GARNISH REMOVAL/INSTALLATION .)
3. Remove the rear door trim. (See REAR DOOR TRIM REMOVAL/INSTALLATION .)
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Fig. 15: Identifying Rear Door Speaker Components

REAR DOOR SPEAKER INSTALLATION NOTE
1. Remove the speaker with the wiring harness passing through the groove of the rear door module.
CAUTION:  If the speaker is installed with the wiring harness out of the
groove, an open circuit in the wiring harness could occur.
Fig. 16: Identifying Rear Door Module & Wiring Harness

REAR DOOR SPEAKER INSPECTION

1. Verify the resistance between rear door speaker terminals.
 If the resistance is not within the specification, replace the rear door speaker.
Resistance
Standard: 4 ohms
Bose®: 2 ohms
2. Connect a 1.5 V battery to the rear door speaker and verify that noise is heard from the rear door speaker.
 If no noise is heard, replace the rear door speaker.
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Fig. 17: Identifying Rear Door Speaker Terminals

FRONT SPEAKER REMOVAL/INSTALLATION

2. Remove the cover from the dashboard using a flathead screwdriver wrapped with protective tape.
3. Remove the solar radiation sensor. (LH) (See SOLAR RADIATION SENSOR
Fig. 18: Identifying Front Speaker Components

FRONT SPEAKER INSPECTION

1. Verify the resistance between front speaker terminals.
 If the resistance is not within the specification, replace the front speaker.
Resistance 3.6 ohms
2. Connect a 1.5 V battery to the front speaker and verify that noise is heard from the front speaker.
 If no noise is heard, replace the front speaker.
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Fig. 19: Identifying Front Speaker Terminals

CENTER SPEAKER REMOVAL/INSTALLATION

Fig. 20: Identifying Center Speaker Components

CENTER SPEAKER INSPECTION

1. Verify the resistance between center speaker terminals.
 If the resistance is not within the specification, replace the center speaker.
Resistance 3.6 ohms
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2. Connect a 1.5 V battery to the center speaker and verify that noise is heard from the center speaker.
 If no noise is heard, replace the center speaker.
Fig. 21: Identifying Center Speaker Terminals

REAR SPEAKER REMOVAL/INSTALLATION

Fig. 22: Identifying Rear Speaker Components

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REAR SPEAKER INSPECTION

1. Verify the resistance between rear speaker terminals.
 If the resistance is not within the specification, replace the rear speaker.
Resistance 3.6 ohms
2. Connect a 1.5 V battery to the rear speaker and verify that noise is heard from the rear speaker.
 If no noise is heard, replace the rear speaker.
Fig. 23: Identifying Rear Speaker Terminals

ROOF SPEAKER REMOVAL/INSTALLATION

2. Remove the RES unit cover. (See RES UNIT REMOVAL/INSTALLATION.)
Fig. 24: Identifying Roof Speaker Components


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ROOF SPEAKER INSPECTION

1. Verify the resistance between roof speaker terminals.
 If the resistance is not within the specification, replace the roof speaker.
Resistance 3.6 ohms
2. Connect a 1.5 V battery to the roof speaker and verify that noise is heard from the roof speaker.
 If no noise is heard, replace the roof speaker.
Fig. 25: Identifying Roof Speaker Terminals

TWEETER REMOVAL/INSTALLATION
2. Remove the cover from the dashboard using a flathead screwdriver wrapped with protective tape.
3. Remove the solar radiation sensor. (LH) (See SOLAR RADIATION SENSOR
Fig. 26: Identifying Tweeter Components

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TWEETER INSPECTION
1. Verify the resistance between tweeter terminals.
 If the resistance is not within the specification, replace the tweeter.
Fig. 27: Tweeter Terminals Resistance Chart

Fig. 28: Identifying Tweeter Terminals

SPEAKER CONNECTION INSPECTION [WITH BOSE®]

1. Turn the ignition switch to the ACC or ON position.
2. While pressing the POWER button, simultaneously press the AUDIO button for 2 s or more.
3. Input diagnosis code "03" and select the "ENTER".
4. Verify that each speaker outputs sound in the following order.
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Fig. 29: Identifying Speaker Outputs Sound Order

* : Setting depends on the model.
NOTE:  If the sound is not output normally, inspect the following parts:
 Malfunctioning speaker
 Wiring harness between audio unit and malfunctioning speaker
5. Turn the audio off or the ignition switch to the LOCK position to end the connection inspection.
BASS-BOX REMOVAL/INSTALLATION
4. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)
Fig. 30: Identifying Bass-Box Components & Torque Specifications
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BASS-BOX INSPECTION
1. Verify the resistance between bass-box terminals.
 If the resistance is not within the specification, replace the bass-box.
Resistance 4 ohms
2. Connect a 1.5 V battery to the bass-box and verify that noise is heard from the bass-box.
 If no noise is heard, replace the bass-box.
Fig. 31: Identifying Bass-Box Terminals

CONDENSER REMOVAL/INSTALLATION
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3. Slightly bend back the headliner.

Fig. 32: Identifying Condenser Components & Torque Specifications

AUDIOPILOT MICROPHONE REMOVAL/INSTALLATION
NOTE:  "AudioPilot" is a registered trademark of Bose® Corporation.

Fig. 33: View Of Audiopilot Microphone

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NOISE FILTER REMOVAL/INSTALLATION

2. Remove the liftgate upper trim. (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION .)
3. Remove the liftgate side trim. (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION .)
4. Remove the liftgate lower trim. (See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
Fig. 34: Identifying Noise Filter Remove/Install Components

NOISE FILTER INSPECTION

1. Verify the resistance and continuity between the noise filter terminals.
 If the resistance is not as indicated in the table, replace the noise filter.
Fig. 35: Identifying Noise Filter Terminals Continuity Chart

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Fig. 36: Identifying Noise Filter Terminals

GLASS ANTENNA INSPECTION

AM/FM
1. Inspect the glass antenna for damage visually.

2. Inspect for continuity between the glass antenna terminals using an ohmmeter.
 If not as specified, replace the glass antenna. (See FILAMENT REPAIR .)
Fig. 37: Glass Antenna Terminals Continuity Chart

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Fig. 38: Identifying Glass Antenna Terminals

ANTENNA FEEDER LOCATION
NOTE:  GPS antenna feeder No.1 is integrated in the instrument panel wiring
harness.
 GPS antenna feeder No.2 is integrated in the rear wiring harness.
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Fig. 39: Identifying Antenna Feeder Location

FRONT ANTENNA FEEDER INSPECTION

 If not as indicated in the table, replace the front antenna feeder.
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Fig. 40: Front Antenna Feeder Terminals Continuity Chart

Fig. 41: Identifying Front Antenna Feeder Terminals

REAR ANTENNA FEEDER INSPECTION

 If not as indicated in the table, replace the rear antenna feeder.
Fig. 42: Rear Antenna Feeder Terminals Continuity Chart

Fig. 43: Identifying Rear Antenna Feeder Terminals

GPS ANTENNA FEEDER INSPECTION

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 If not as indicated in the table, replace the GPS antenna feeder.
Fig. 44: GPS Antenna Feeder Terminals Continuity Chart

Fig. 45: Identifying GPS Antenna Feeder Terminals

GPS ANTENNA REMOVAL/INSTALLATION

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Fig. 46: Identifying GPS Antenna Components

AUDIO CONTROL SWITCH REMOVAL/INSTALLATION

2. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE
3. Remove the steering wheel. (See STEERING WHEEL AND COLUMN
Fig. 47: Identifying Audio Control Switch Components

AUDIO CONTROL SWITCH INSPECTION

WITHOUT HF/TEL SYSTEM
1. Verify the resistance and continuity between the audio control switch terminals.
 If the resistance and continuity are not as indicated in the tables, replace the audio control switch.
Fig. 48: Audio Control Switch Terminals Continuity Chart (Without HF/TEL System)
Microsoft
R : Resistance. See the table.
Switch position Resistance (ohm)
VOL- button ON 51-56
VOL+ button ON 140-154
SEEK+ button ON 286-315
SEEK- button ON 534-589
MODE button ON 985-1,088
VOICE/MUTE button ON 1,935-2,138
OFF 4,795-5,299
Fig. 49: Identifying Audio Control Switch Terminals (Without HF/TEL System)
WITH HF/TEL SYSTEM
1. Verify the resistance and continuity between the audio control switch terminals.
 If the resistance and continuity are not as indicated in the tables, replace the audio control switch.
HF/TEL SWITCH
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Fig. 50: Audio Control Switch Terminals Continuity Chart (With HF/TEL System)
Fig. 51: Audio Control Switch Terminals Continuity Chart (With HF/TEL System)
Fig. 52: Identifying Audio Control Switch Terminals (With HF/TEL System)
R : Resistance. See the table.
Switch position Resistance (ohm)
VOL- button ON 51-56
VOL+ button ON 140-154
SEEK+ button ON 286-315
SEEK- button ON 534-589
MODE button ON 985-1,088
VOICE/MUTE button ON 1,935-2,138
OFF 4,795-5,299
MICROPHONE REMOVAL/INSTALLATION
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2. Remove the map light. (See FRONT MAP LIGHT REMOVAL/INSTALLATION .)

3. Press the microphone in the direction indicated by the arrow and remove the microphone.
Fig. 53: View Of Microphone

RES UNIT REMOVAL/INSTALLATION

Fig. 54: Identifying RES Unit Components & Torque Specifications

RES UNIT COVER REMOVAL NOTE

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1. Pull the cover outward and detach clips A and B.
Fig. 55: Identifying RES Unit Cover Clips

HEADPHONE BATTERY REPLACEMENT

1. Remove the screw, then remove the headphone battery cover.
2. Remove the old batteries.
3. Insert 2 AAA-size batteries with the positive pole (+) and negative pole (-) as shown in the figure.
4. Install the headphone battery cover and screw.
Fig. 56: Inserting AAA-Size Batteries

REMOTE CONTROLLER BATTERY REPLACEMENT

1. Push the tab, and pull the battery case out.
2. Remove the old battery.
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Fig. 57: View Of Battery Case

3. Insert a new battery (CR2023) with the positive pole (+) facing up.
Used battery
Lithium battery CR2023


4. Slide the battery case back into the remote controller until the tab clicks into place.
Fig. 58: Identifying Battery

AUXILIARY TERMINAL UNIT REMOVAL/INSTALLATION

2. Remove auxiliary terminal unit panel. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
Microsoft
Fig. 59: Identifying Auxiliary Terminal Unit Screws

POWER SUPPLY SOCKET REMOVAL/INSTALLATION

2. Remove auxiliary terminal unit panel. (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
3. Press the tabs, pull the power supply socket outward, and then remove it.
Fig. 60: View Of Power Supply Socket

INVERTER REMOVAL/INSTALLATION
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7. Trunk side trim (Driver side) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
Fig. 61: Identifying Inverter Components & Torque Specifications

INVERTER INSPECTION
1. Measure the voltage at each terminal.
WARNING:  The AC voltage is extremely high voltage. Be careful when

measuring the voltage.
If the voltage is not as specified in the Terminal Voltage Table, inspect the parts under "inspection

item(s)" and related wiring harnesses.
3. If the system does not work properly even though the inspection items or related wiring harnesses do not
have any malfunction, replace the inverter.
Microsoft
Fig. 62: Identifying Inverter Unit Connector Terminals

TERMINAL VOLTAGE TABLE
Signal Voltage (V)/
Terminal Connected to Measured condition Inspection item (s)
name Continuity
Ignition switch is at AC 103-5-  Power supply
AC power socket (AC
Power supply ACC or ON position 126.5
A, B supply 115V)
socket (AC 115 V) Ignition switch is at
output 1.0 or less  Related wiring
LOCK position harnesses
Ignition switch is at  MIRROR 7.5 A
B+
MIRROR 7.5 A ACC or ON position fuse
E ACC
fuse Ignition switch is at  Related wiring
1.0 or less
LOCK position harnesses
 AC PWR 15 A
Power AC PWR 15 A fuse
M Under any condition B+
supply fuse  Related wiring
harnesses
N GND Body ground Under any condition 1.0 or less  Related wiring
harnesses
REAR MOUNT CAMERA REMOVAL/INSTALLATION

4. Remove the rear finisher. (See REAR FINISHER REMOVAL/INSTALLATION .)
Fig. 63: Identifying Rear Mount Camera Screws

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HANDS-FREE TELEPHONE (HF/TEL) UNIT REMOVAL/INSTALLATION

2. Remove the dashboard under cover (Passenger side). (See DASHBOARD UNDER COVER
Fig. 64: Identifying Hands-Free Telephone (HF/TEL) Unit Components & Torque Specifications
ACCESSORY SOCKET REMOVAL/INSTALLATION

FRONT

3. Indicator panel (See SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION .)
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Fig. 65: Identifying Accessory Socket & Cap (Front)

CENTER

Fig. 66: Identifying Accessory Socket & Cap (Center)

REAR

5. Rear scuff plate inner (RH) (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
6. Third-row seat belt lower anchor installation bolt (RH) (See THIRD-ROW SEAT BELT
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7. Trunk side trim (Passenger side) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
Fig. 67: Identifying Accessory Socket & Cap (Rear)

ACCESSORY SOCKET REMOVAL NOTE
1. While pressing a tape-wrapped flathead screwdriver against the cap projection, pull the accessory socket
outward.
Fig. 68: View Of Accessory Socket

CAP REMOVAL NOTE
1. While pressing the tabs, pull the cap outwards.
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Fig. 69: View Of Cap

ACCESSORY SOCKET INSPECTION

1. Connect a tester as shown in the figure and verify that there is continuity.
 If the continuity cannot be verified, replace the accessory socket.
Fig. 70: Identifying Accessory Socket Terminals

AUXILIARY JACK REMOVAL/INSTALLATION

3. Disconnect the auxiliary jack connector.
4. Squeeze the tabs of auxiliary jack and pull it outward to remove it.
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Fig. 71: View Of Auxiliary Jack

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2008 ENGINE Exhaust System (MZI-3.7) - Mazda CX-9
2008 ENGINE
Exhaust System (MZI-3.7) - Mazda CX-9
EXHAUST SYSTEM INSPECTION [MZI-3.7]

1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
 If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7]
WARNING:  When the engine and exhaust system are hot, they can badly burn.
Turn off the engine and wait until they are cool before removing the
exhaust system.

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Fig. 1: Exploded View Of Exhaust Components & Torque Specifications

WARM UP THREE WAY CATALYTIC CONVERTER (WU-TWC) (RH) REMOVAL NOTE

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2WD
1. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [2WD] .)

2. Remove the WU-TWC (RH).
AWD
1. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [AWD] .)

2. Remove the insulator. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION .)
3. Remove the No.1 engine mount (transaxle side). (See ENGINE REMOVAL/INSTALLATION [MZI-
3.7] .)
4. Push up the engine.
5. Remove the WU-TWC (RH).
EXHAUST MANIFOLD INSULATOR (LH) REMOVAL NOTE
1. Set the fan control module out of the way. (See COOLING FAN COMPONENT
2. Remove the exhaust manifold Insulator (LH).
WARM UP THREE WAY CATALYTIC CONVERTER (WU-TWC) (LH) INSTALLATION NOTE
1. Install the WU-TWC (LH) insulator.

2. Temporarily tighten WU-TWC (LH) bracket.
3. Temporarily tighten WU-TWC (LH) bracket (L type) (engine side).
4. Install the WU-TWC (LH).
5. Install the WU-TWC (LH) bracket.
6. Install the WU-TWC (LH) bracket (L type).
WARM UP THREE WAY CATALYTIC CONVERTER (WU-TWC) (RH) INSTALLATION NOTE
2WD
1. Install the WU-TWC (RH) insulator.

2. Temporarily tighten WU-TWC (RH) bracket.
3. Temporarily tighten WU-TWC (RH) bracket (L type) (engine side).
4. Install the WU-TWC (RH).
5. Install the WU-TWC (RH) bracket.
6. Install the WU-TWC (RH) bracket (L type).
AWD
1. Install the WU-TWC (RH) insulator.

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2. Temporarily tighten WU-TWC (RH) bracket.

3. Temporarily tighten WU-TWC (RH) bracket (L type) (engine side).
4. Push up the engine.
5. Install the WU-TWC (RH).
6. Install the No.1 engine mount (transaxle side). (See ENGINE REMOVAL/INSTALLATION [MZI-
3.7] .)
7. Install the insulator. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION .)
8. Install the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [AWD] .)
9. Install the WU-TWC (RH) bracket.
Microsoft
2008 ACCESSORIES & BODY, CAB Exterior Trim - Mazda CX-9
Exterior Trim - Mazda CX-9
EXTERIOR TRIM LOCATION INDEX
Microsoft
Microsoft
Fig. 1: Identifying Exterior Trim Location

RADIATOR GRILLE REMOVAL/INSTALLATION

1. Set the front over fender out of the way. (See OVER FENDER REMOVAL/INSTALLATION.)
Fig. 2: Identifying Radiator Grille Components & Torque Specifications

4. Remove the front bumper retainers.

5. Remove the fasteners.
6. Remove the screws A.
7. Remove the grille bracket.
8. Remove the screws B.
9. Remove the tabs D.
10. Remove the ornament.
11. Remove the radiator grille.
12. Press tabs C in the direction of the arrow, pull the radiator grille inward, and remove it from the front
bumper.
COWL GRILLE REMOVAL/INSTALLATION

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2. Remove the front fender molding.
Fig. 3: Identifying Cowl Grille Components

3. Remove the weatherstrip.

4. Remove the fastener.
5. Remove the side cowl grille.
6. Pull the cowl grille in the direction of arrow (1) so that it is free from the pins, pull tabs A in the direction
of arrow (2), and then remove the windshield.
7. Disconnect the windshield washer hose.
8. Remove the cowl grille.
9. Install in the reverse order of removal. joint pipe
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Fig. 4: Identifying Cowl Grille, Windshield Washer Hose And Joint Pipe
FRONT BELTLINE MOLDING REMOVAL/INSTALLATION

REMOVAL
1. Fully open the front door glass.

5. Remove the power outer mirror. (See POWER OUTER MIRROR REMOVAL/INSTALLATION .)
6. Remove clip A using a protective tape-wrapped flathead screwdriver.
7. Lift (partially peeling back) the front beltline molding in the direction of the arrow and then remove tabs
B.
8. Remove the clip C.
9. Remove the front beltline molding.
Fig. 5: Identifying Front Beltline Molding With Clips And Tab

INSTALLATION
1. Install the clip A.

2. Install the tabs B.
3. Install the clip C.
4. Install the front beltline molding.
5. Install the power outer mirror. (See POWER OUTER MIRROR REMOVAL/INSTALLATION .)
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6. Install the front door trim. (See FRONT DOOR TRIM REMOVAL/INSTALLATION .)
7. Install the inner garnish. (See INNER GARNISH REMOVAL/INSTALLATION .)
Fig. 6: Identifying Front Beltline Molding With Clips And Tab

REAR BELTLINE MOLDING REMOVAL/INSTALLATION

REMOVAL
1. Fully lower the rear door glass.

2. Remove the clip A using a protective tape-wrapped flathead screwdriver.
3. Lift (partially peeling back) the rear beltline molding in the direction of the arrow and then remove tabs
B.
5. Remove the rear beltline molding.
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Fig. 7: Identifying Rear Beltline Molding With Clips And Tab

INSTALLATION
1. Install the clip A.

2. Install the tabs B.
3. Install the clip C.
4. Install the rear beltline molding.
Fig. 8: Identifying Rear Beltline Molding With Clips And Tab

ROOF MOLDING REMOVAL
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1. Detach the T-stud which secure sections A of roof molding, using a flat head screwdriver or equivalent
tool.
2. While pulling the roof molding up, detach it from the clips at section B, C, and then remove the roof
molding.
Fig. 9: Identifying Roof Molding With T-Stud And Clips

ROOF MOLDING INSTALLATION

1. Attach the roof molding to the T-stud at the front portion of section A.
2. Hook the roof molding to clips B, C and press it in to attach.
3. Attach the roof molding to the T-stud at the rear portion of section A.
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Fig. 10: Identifying Roof Molding With T-Stud And Clips

ROOF CARRIER BRACKET REMOVAL/INSTALLATION

2. Partially peel back the seaming welt.
4. Remove the nuts.
5. Remove the roof carrier bracket.
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NOTE:  Install the roof carrier bracket so that the arrow on it faces inward.
Fig. 11: Identifying Roof Carrier Bracket With Nuts & Torque
Specifications
REAR FINISHER REMOVAL/INSTALLATION

1. Remove the liftgate upper trim. (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION )
2. Remove the liftgate side trim. (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION )
4. Set the noise filter out of the way. (See NOISE FILTER REMOVAL/INSTALLATION .)
6. Remove the dynamic damper.
Fig. 12: Identifying Dynamic Damper With Bolts & Torque Specifications
7. Disconnect the request switch connector and the rear mount camera connector.
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8. Remove the nuts.

9. Pull the rear finisher outward, then disengage clip A, B, and C from the body.
10. Remove the rear finisher.
11. Remove the request switch. (See REQUEST SWITCH REMOVAL/INSTALLATION [ADVANCED
KEYLESS SYSTEM] .)(Vehicles with advanced keyless system)
12. Remove the rear mount camera. (See REAR MOUNT CAMERA REMOVAL/INSTALLATION .)
(Vehicles with rear mount camera)
Fig. 13: Identifying Request Switch Connector, Rear Mount Camera Connector & Torque
Specifications
REAR SASH MOLDING INSTALLATION
NOTE:  Double-sided adhesive tape has already been attached to the new rear
sash molding.
WARNING:  Using a razor with bare hands can cause injury. Always wear gloves
when using a razor.
1. When installing a new rear sash molding, follow the procedure below:
1. Remove the adhesive remaining on the body using razor.
2. Remove any grease or dirt from the adhesion surface of the body.
2. When reusing the rear sash molding, follow the procedure below:
1. Remove the adhesive remaining on the rear sash molding and the body using a razor.
2. Remove any grease or dirt from the adhesion surface of the rear sash molding and the body.
3. Apply primer to the bonding area of the rear sash molding.
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4. Affix double-sided adhesive tape A to the rear sash molding as shown in the figure.
Fig. 14: Identifying Double-Sided Adhesive Tape Applying To Rear Sash Molding
5. Affix double-sided adhesive tape B to the rear sash molding as shown in the figure.
NOTE:  As for the double-sided adhesive tape, use beta tape B 5078 (1
mm {0.04 in} thickness) or equivalent.
3. Peel off the backing of the double-sided
Fig. 15: Identifying Double-Sided Adhesive Tape Applying To Rear Sash Molding
4. Hook tab B to the body in the position where tabs A and D align with the sash holes.
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5. Press the rear sash molding in the direction of the arrow and install tabs A and D to the body.
CAUTION:  Do not press the rear sash molding in any place other than the
rubber areas.
6. Press the rear sash molding from the vehicle front in the direction of the arrow and install tab C.
NOTE:  After installing the front sash molding, verify that tabs B and C are
connected properly to the body.
Fig. 16: Identifying Double-Sided Adhesive Tape And Rear Sash

Molding
REAR SPOILER REMOVAL/INSTALLATION

3. Disconnect the high-mount brake light connector.
4. Remove the nuts.
5. Detach the clips and remove the rear spoiler.
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Fig. 17: Identifying Rear Spoiler With Nut, Clip & Torque Specifications
REAR DOOR GARNISH REMOVAL/INSTALLATION

3. Remove the pin A.
4. Slide the rear door garnish in the direction shown by the arrow and remove it.
Fig. 18: Identifying Rear Door Garnish With Screw

OVER FENDER REMOVAL/INSTALLATION

FRONT

2. Remove the clips A.
3. Remove the clip B.
5. Remove the front over fender.
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Fig. 19: Identifying Front Over Fender With Clips

REAR

2. Remove the clips A.
3. Remove the clips B.
5. Remove the rear over fender.
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Fig. 20: Identifying Rear Over Fender With Clips

FRONT UNDER COVER REMOVAL/INSTALLATION

FRONT UNDER COVER A

3. Remove the front under cover A.
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Fig. 21: Identifying Front Under Cover A With Screws, Bolts & Torque Specifications
FRONT UNDER COVER B

3. Remove the front under cover B.
Fig. 22: Identifying Front Under Cover B With Screws And Bolts
SPLASH SHIELD REMOVAL/INSTALLATION

1. Remove the front over fender. (See OVER FENDER REMOVAL/INSTALLATION.)
3. Remove the fasteners A.
4. Remove the splash shield.
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Fig. 23: Identifying Splash Shield, Fasteners & Torque Specifications

SAIL GARNISH REMOVAL/INSTALLATION

1. Pull the sail garnish outward and detach clips A from the body.
2. Remove the sail garnish.
Fig. 24: Identifying Sail Garnish With Clips

SIDE GARNISH REMOVAL

FRONT
1. Pull the side garnish and remove clip A from the vehicle body.
2. Slide the side garnish to the vehicle rear and remove clips B and C from the side garnish.
3. Remove the side garnish.
4. Remove clips B and C from the body, then install it to the side garnish.
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Fig. 25: Identifying Front Side Garnish With Clips

REAR
1. Pull the side garnish and remove clip A from the vehicle body.
2. Slide the side garnish to the vehicle rear and remove clips B and C from the side garnish.
3. Remove the side garnish.
4. Remove clips B and C from the body, then install it to the side garnish.
Fig. 26: Identifying Rear Side Garnish With Clips

SIDE GARNISH INSTALLATION

FRONT
1. Install clips A and then B to the vehicle from the front side.
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Fig. 27: Identifying Front Side Garnish With Clips

REAR
1. Install clips A and then B to the vehicle from the rear side.
Fig. 28: Identifying Rear Side Garnish With Clips

SIDE STEP MOLDING REMOVAL

1. Set the over fender out of the way
2. Remove the tow fasteners shown in the figure and set the front over fender out of the way.
3. Slide the side step molding in the direction of the arrow and detach clips A and B.
4. Remove the side step molding.
5. Remove clips A and B from the body, then install it to the side step molding.
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Fig. 29: Identifying Side Step Molding With Clips

SIDE STEP MOLDING INSTALLATION

1. Install the clips A and B.
2. Return the over fender to its original position.
Fig. 30: Identifying Side Step Molding With Clips

FRONT SASH MOLDING REMOVAL
when using a razor.
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2. Press tab A in the direction of the arrow and remove it.

3. While cutting the double-sided adhesive tape using a flathead screwdriver or a razor, separate the front
sash molding from the body.
4. Rotate the front sash molding at the pivot of tab B in the direction of arrow D and remove it.
5. Remove the tab C.
6. Remove the front sash molding.
Fig. 31: Identifying Front Sash Molding With Tab

DOOR SASH FILM REMOVAL

1. Partially peel back the glass run channel.
2. Partially peel back the door weatherstrip.
5. Front beltline molding (See FRONT BELTLINE MOLDING REMOVAL/INSTALLATION.)
6. Rear beltline molding (See REAR BELTLINE MOLDING REMOVAL/INSTALLATION.)
7. Front sash molding (See FRONT SASH MOLDING REMOVAL.)
8. Rear sash molding (See REAR SASH MOLDING REMOVAL.)
9. Rear door garnish (See REAR DOOR GARNISH REMOVAL/INSTALLATION.)
4. Peel off the rear sash film by pulling it outward from one end.
NOTE:  Slowly remove the door sash film since it may tear easily.
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Fig. 32: Peeling Off Rear Sash Film

FRONT SASH MOLDING INSTALLATION
NOTE:  Double-sided adhesive tape has already been attached to the new front
sash molding.
when using a razor.
1. When installing a new front sash molding, follow the procedure below:
1. Remove the adhesive remaining on the body using razor.
2. Remove any grease or dirt from the adhesion surface of the body.
2. When reusing the front sash molding, follow the procedure below:
1. Remove the adhesive remaining on the front sash molding and the body using a razor.
2. Remove any grease or dirt from the adhesion surface of the front sash molding and the body.
3. Apply primer to the bonding area of the front sash molding.
4. Affix double-sided adhesive tape A to the front sash molding as shown in the figure.
Microsoft
Fig. 33: Identifying Double-Sided Adhesive Tape Applyin To Front Sash Molding
5. Affix double-sided adhesive tape B to the front sash molding as shown in the figure.
NOTE:  As for the double-sided adhesive tape, use beta tape 5078 (1
mm {0.04 in} thickness) or equivalent.
3. Peel off the backing of the double-sided adhesive tape.
Fig. 34: Identifying Double-Sided Adhesive Tape Applying To Front Sash Molding
4. Hook tab A to the body in the position where tabs B align with the sash holes.
5. Press the front sash molding in the direction of the arrow and install tabs B to the body.
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CAUTION:  Do not press the front sash molding in any place other than the
rubber areas.
6. Press the front sash molding from the vehicle rear in the direction shown in the arrow and install tab C.
NOTE:  After installing the front sash molding, verify that tabs A and B are
connected properly to the body.
Fig. 35: Identifying Double-Sided Adhesive Tape And Front Sash

Molding
DOOR SASH FILM INSTALLATION

1. Remove any grease or dirt from the affixing surface of the door.
2. Cut away the unused portion along the dotted lines.
Fig. 36: Identifying Door Sash Film Area

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3. Peel off the backing paper and attach the door sash film onto the door as shown in the figure.
Fig. 37: Attaching Door Sash Film Onto Door

Standard clearance
a: 2.0 mm or more {0.08 in or more}
b: 3.0-5.0 mm {0.12-0.19 in}
4. Peel off the transparent protective film on the door sash film.
5. Install the following parts:
1. Rear door garnish (See REAR DOOR GARNISH REMOVAL/INSTALLATION.)
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2. Rear sash molding (See REAR SASH MOLDING INSTALLATION.)

3. Front sash molding (See FRONT SASH MOLDING INSTALLATION.)
4. Rear beltline molding (See REAR BELTLINE MOLDING REMOVAL/INSTALLATION.)
5. Front beltline molding (See FRONT BELTLINE MOLDING REMOVAL/INSTALLATION.
REAR SASH MOLDING REMOVAL
when using a razor.
1. Press tab C in the direction of the arrow and remove it.

2. While cutting the double-sided adhesive tape using a flathead screwdriver or a razor, separate the rear
sash molding from the body.
3. Remove the tab D.
4. Rotate the rear sash molding in the direction of the arrow and remove tab A.
5. Rotate the rear sash molding in the direction of the arrow and remove tab B.
6. Remove the rear sash molding.
Fig. 38: Identifying Rear Sash Molding And Double-Sided Adhesive Tape Location
EXTRACTOR CHAMBER REMOVAL/INSTALLATION
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3. Remove the rear bumper. (See REAR BUMPER REMOVAL/INSTALLATION .)
4. Remove the rear over fender. (See OVER FENDER REMOVAL/INSTALLATION.)
6. Pull the extractor chamber in the direction shown by the arrow and remove it.
Fig. 39: Identifying Extractor Chamber Screw

Microsoft
2008 DRIVELINE/AXLE Front Axle - Mazda CX-9
2008 DRIVELINE/AXLE
Front Axle - Mazda CX-9
FRONT AXLE LOCATION INDEX
Fig. 1: Identifying Front Axle Components Location

WHEEL HUB, STEERING KNUCKLE INSPECTION

WHEEL BEARING EXCESSIVE PLAY INSPECTION
1. Install the magnetic base and dial gauge as shown in the figure and measure the wheel bearing axial
excessive play.
 If it exceeds the maximum specification, replace the wheel hub bearing.
Front wheel bearing maximum play
0.05 mm {0.002 in}
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Fig. 2: Measuring Wheel Bearing Axial Excessive Play

WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
wheel-speed sensor may possibly cause an open circuit in the wiring
procedures, disconnect the ABS wheel-speed sensor connector (axle
side) and fix the wiring harness to an appropriate place where it will
not be pulled by mistake while servicing the vehicle.
4. After installation, inspect the front wheel alignment and adjust it if necessary. (See FRONT WHEEL
ALIGNMENT .)
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Fig. 3: Exploded View Of Wheel Hub, Steering Knuckle & Torque Specifications

4. Install a spare nut onto the drive shaft so that the nut is flush with the end of the drive shaft.
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5. Tap the nut with a copper hammer to loosen the drive shaft from the front wheel hub.
6. Separate the drive shaft from the wheel hub.
Fig. 5: Tapping Drive Shaft

BRAKE CALIPER REMOVAL NOTE
1. Remove the brake caliper component from the steering knuckle and suspend it out of the way using a
cable.
Fig. 6: Identifying Brake Caliper

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WHEEL HUB REMOVAL NOTE
1. Remove the wheel hub using the SSTs.
Substitution SST
 49G033105
Fig. 7: Removing Wheel Hub With SSTs

2. If the bearing inner race remains on the front wheel hub component, grind a section of the bearing inner
race until approx. 0.5 mm {0.02 in} remains. Then remove it using a chisel.
Fig. 8: Grinding Wheel Hub

WHEEL BEARING REMOVAL NOTE
1. Remove the wheel bearing using the SSTs.
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Substitution SST
 49G033 106
Fig. 9: Removing Wheel Bearing With SSTs

DUST COVER REMOVAL NOTE
NOTE:  The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and steering knuckle for proper installation.
Fig. 10: Identifying Dust Cover Mark Location

2. Remove the dust cover using a chisel.
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Fig. 11: Tapping Dust Cover

WHEEL HUB BOLT REMOVAL NOTE
NOTE:  The hub bolts do not need to be removed unless they are being replaced.
1. Remove the hub bolt using a press.
Fig. 12: Pressing Hub Bolt

WHEEL HUB BOLT INSTALLATION NOTE
1. Install the new hub bolt using a press.
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Fig. 13: Pressing Hub Bolt Installation Position

DUST COVER INSTALLATION NOTE
1. Mark the new dust cover in the same way as the removed one.
2. Align the marks of the new dust cover and the knuckle.
Fig. 14: Aligning Marks Of Dust Cover And Knuckle

3. Install the new dust cover using the SSTs.
Substitution SST
 49 G033 107 A
 49 F027 009
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Fig. 15: Pressing Dust Cover

WHEEL BEARING INSTALLATION NOTE
1. Install the new wheel bearing using the SSTs.
Substitution SST
 49 F027 004
 49 F027 009
Fig. 16: Pressing Wheel Bearing Installation Position

WHEEL HUB INSTALLATION NOTE
1. Install the wheel hub using the SSTs.
Substitution SST
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 49 G033 105
 49 B025 004
Fig. 17: Pressing Wheel Hub Installation Position


FRONT WHEEL HUB BOLT REPLACEMENT

1. Remove the brake calliper component from the steering knuckle and suspend it out of the way using a
cable.
3. Tap the dust cover (the part shown in the figure) with a chisel lightly and bend the processing point back
to the steering knuckle side.
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Fig. 19: Identifying Bend Part

4. Remove the wheel hub bolt using the SST as shown in the figure.
5. Place a new wheel hub bolt in the wheel hub.
Fig. 20: Removing Wheel Hub Bolt

6. Install the wheel hub by placing a proper sized washer on the hub, and tightening the nut as shown in the
figure.
Fig. 21: Holding Wheel Hub

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2008 SUSPENSION Front Suspension - Mazda CX-9
2008 SUSPENSION
Front Suspension - Mazda CX-9
FRONT SUSPENSION LOCATION INDEX
Fig. 1: Identifying Front Suspension Components

FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION
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mistake while servicing the vehicle.
1. When working on the left side of the vehicle, remove the wiper arm (LH). (See WINDSHIELD WIPER
MOTOR REMOVAL/INSTALLATION .)
2. When working on the left side of the vehicle, partially peel back the cowl grille (LH).
3. When working on the right side of the vehicle, partially peel back the cowl grille (RH).
4. Remove the front fender molding. (See COWL GRILLE REMOVAL/INSTALLATION .)
7. Inspect for front wheel alignment, and adjust it as necessary. (See FRONT WHEEL ALIGNMENT .)
Fig. 2: Identifying ABS-Wheel-Speed Sensor, Brake Hose Clip, Cap, Nut & Torque Specifications
FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL NOTE
1. Make a mark on the body aligning the identification mark on the mounting rubber before removing the
front shock absorber and coil spring.
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Fig. 3: Identifying Identification Mark On Mounting Rubber

FRONT SHOCK ABSORBER AND COIL SPRING INSTALLATION NOTE
1. Align the identification mark on the mounting rubber with the mark on the body.
Fig. 4: Aligning Identification Mark On Mounting Rubber With Mark On Body

2. Install the front shock absorber installation bolts from the following directions.
 LH: Insert the bolts from the vehicle rear
 RH: Insert the bolts from the vehicle front
Fig. 5: Locating Front Shock Absorber Installation Bolts

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FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY
WARNING:  Removing/installing the piston rod nut is dangerous. The shock

absorber and spring could fly off under tremendous pressure and
cause serious injury or death. Secure the shock absorber in the
SSTs before removing the piston rod nut.
1. Remove the front shock absorber and coil spring. (See FRONT SHOCK ABSORBER AND COIL
SPRING REMOVAL/INSTALLATION.)
3. Assemble in the reverse order of disassemble.
Fig. 6: View Of Front Shock Absorber Components & Torque Specifications

PISTON ROD NUT DISASSEMBLY NOTE
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WARNING:  Removing the piston rod nut is dangerous. The shock absorber and
spring could fly off under tremendous pressure and cause serious
injury or death. Secure the shock absorber in the SSTs before
removing the piston rod nut.
1. Protect the coil spring using a piece of cloth, then set the SSTs.
2. Compress the coil spring using the SSTs , and remove the piston rod nut.
Fig. 7: Compressing Coil Spring

COIL SPRING ASSEMBLY NOTE
1. Compress the coil spring using the SST.

2. Install the shock absorber so that the lower end of the coil spring is seated on the step of the lower spring
seat.
Fig. 8: Installing Shock Absorber

UPPER SPRING SEAT ASSEMBLY NOTE
1. Install the upper spring seat so that the notch is facing to the out side of the vehicle.
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Fig. 9: Installing Upper Spring Seat

MOUNTING RUBBER ASSEMBLY NOTE
1. Slide the mounting rubber identification mark away from the notch of the spring seat and install.
Fig. 10: Sliding Mounting Rubber Identification Mark From Notch

FRONT SHOCK ABSORBER INSPECTION

1. Remove the front shock absorber. (See FRONT SHOCK ABSORBER AND COIL SPRING
REMOVAL/INSTALLATION.) (See FRONT SHOCK ABSORBER AND COIL SPRING
DISASSEMBLY/ASSEMBLY.)
2. Inspect for damage and oil leakage.
3. Compress and extend the shock piston at least three times. Verify that the operational force does not
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change and that there is no unusual noise.

 If not as specified, replace the front shock absorber.
FRONT SHOCK ABSORBER DISPOSAL

1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2-3 mm {0.08-0.12 in} hole at a point 20-30 mm {0.8-1.2 in} from the bottom of the tube, so that
the gas can escape.
WARNING:  Whenever drilling into a shock absorber, wear protective eye

wear. The gas in the shock absorber is pressurized, and could
spray metal chips into the eyes and face when drilling.
3. Turn the hole downwards.

4. The oil can be collected by moving the piston rod several times up and down and cutting the tube at the
end.
5. Dispose of waste oil according to the waste disposal law.
Fig. 11: Identifying Drilling Location

FRONT LOWER ARM REMOVAL/INSTALLATION

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Fig. 12: Identifying Front Lower Arm Components & Torque Specifications
FRONT LOWER ARM INSPECTION

1. Remove the lower arm from the vehicle.
2. Inspect the arm for bending or damage, and the ball joint for excessive looseness
 If there is any malfunction, replace the lower arm.
3. Rotate the ball joint stud 5 times. Install the SST and M6 x 1.0 bolt (bolt length (measured from below
the head): 20 mm {0.79 in}) to the ball joint stud, measure the rotational torque using a torque wrench.
 If not within the specification, replace the lower arm.
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Fig. 13: Rotating Ball Joint Stud

Front lower arm rotational torque
2.62 N.m {26.7 kgf.cm, 23.1 in.lbf} max.
FRONT STABILIZER REMOVAL/INSTALLATION

4. Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
6. Remove the front crossmember component. (See FRONT CROSSMEMBER
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Fig. 14: Identifying Front Stabilizer Bar Grease Applying Area & Torque Specifications
FRONT STABILIZER INSTALLATION NOTE
1. Install the stabilizer bar so that the identification mark is on the left side of the vehicle.
Fig. 15: Identifying Stabilizer Bar Identification Mark

STABILIZER BUSHING INSTALLATION NOTE

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1. Align the outer side of the positioning plate with the stabilizer bushing.
Fig. 16: Aligning Outer Side Of Positioning Plate With Stabilizer Bushing
STABILIZER BRACKET INSTALLATION NOTE
1. Install the stabilizer bracket so that the arrow is pointed to the front.
Fig. 17: Identifying Stabilizer Bracket Bolt

FRONT STABILIZER CONTROL LINK INSPECTION

1. Remove the stabilizer control link from the vehicle.
2. Inspect for bending and damage.
3. Measure the ball joint starting torque.
1. Rock the ball joint stud side to side 10 times.
2. Rotate the ball joint stud 10 times.
3. Measure the starting torque using a suitable alien socket and a torque wrench.
Front stabilizer control link ball joint starting torque
0.2-2.0 N.m {3-20 kgf.cm, 2-17 in.lbf}
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 If not as specified, replace the stabilizer control link.
Fig. 18: Measuring Ball Joint Starting Torque

FRONT CROSSMEMBER REMOVAL/INSTALLATION
4. Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)
8. Inspect the front wheel alignment, and adjust it as necessary. (See FRONT WHEEL ALIGNMENT .)
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Fig. 19: Identifying Front Cross Member Components & Torque Specifications
TIE-ROD END BALL JOINT REMOVAL NOTE
1. Remove the tie-rod end ball joint locknut.

2. Disconnect the tie-rod end ball joint using the SST.
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Fig. 20: Disconnecting Tie-Rod End Ball Joint

STEERING GEAR AND LINKAGE, FRONT STABILIZER, FRONT LOWER ARM AND FRONT
CROSSMEMBER COMPONENT REMOVAL NOTE
WARNING:  Removing the crossmember component is dangerous. The

crossmember component could fall and cause serious injury or
death. Verify that the jack securely supports the crossmember
component.
1. Support the crossmember component with a jack.
Fig. 21: Supporting Crossmember Component With Jack

2. Disconnect the following parts.

 Pressure hose eye connector
 Return hose clamp (steering gear side)
 Pressure hose bracket
 Return hose clamp (tank side)
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Fig. 22: Identifying Pressure Hose Eye Connector & Return Hose Clamp
3. Disconnect the oil cooler bracket.
Fig. 23: Identifying Oil Cooler Bracket

4. Remove the No.1 engine mounting bracket bolts.

5. Lower the steering gear and linkage, front stabilizer, front lower arm and front crossmember component
slightly.
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Fig. 24: Locating No.1 Engine Mounting Bracket Bolts

FRONT CROSSMEMBER MOUNTING RUBBER (FRONT) INSTALLATION NOTE
1. Install so that the smaller end of the outer diameter is pointing up.
Fig. 25: Identifying Front Crossmember Mounting Rubber (Front) Installation

FRONT CROSSMEMBER MOUNTING RUBBER (REAR) INSTALLATION NOTE
1. Install so that the larger end of the outer diameter is pointing up.
Fig. 26: Identifying Front Crossmember Mounting Rubber (Rear) Installation

STEERING GEAR AND LINKAGE, FRONT STABILIZER, FRONT LOWER ARM AND FRONT
CROSSMEMBER COMPONENT INSTALLATION NOTE
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1. Using a jack, install steering gear and linkage, front stabilizer, and front crossmember component.
Tightening torque
119.6-154.8 N.m {12.20-15.78 kgf.m, 88.3-114.1 ft.lbf}
Fig. 27: View Of Steering Gear & Linkage

2. Connect the following parts.

 Pressure hose eye connector
 Return hose clamp (steering gear side)
 Pressure hose bracket
 Return hose clamp (tank side)
Tightening torque
 Pressure hose eye connector: 29.4-44.1 N.m {3.00-4.49 kgf.m, 21.7-32.5 ft.lbf}
Fig. 28: Identifying Return Hose Clamp & Pressure Hose Bracket
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Tightening torque
93.1-116.6 N.m {9.50-11.8 kgf.m, 68.7-85.9 ft.lbf}
4. Teighten the No.1 engine mount bolt A at the specified torque.
Tightening torque
93.1-116.6 N.m {9.50-11.8 kgf.m, 68.7-85.9 ft.lbf}
Fig. 29: Identifying No.1 Engine Mounting Bracket Bolts

5. Install the steering gear and linkage, front stabilizer, front lower arm and front crossmember component.
6. Tighten the No.1 engine mount bolt (crossmember side).
TRANSVERSE MEMBER REMOVAL/INSTALLATION

1. Remove the transverse member.
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Fig. 30: Identifying Transverse Member & Torque Specifications

2. Install the transverse member with the identification mark facing the rear right of the vehicle.
Fig. 31: Identifying Transverse Member With Identification Mark

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2008 ENGINE Fuel System (MZI-3.7) - Mazda CX-9
2008 ENGINE
Fuel System (MZI-3.7) - Mazda CX-9
FUEL SYSTEM LOCATION INDEX [MZI-3.7]

Fig. 1: Identifying Fuel Injector, Quick Release Connector, Fuel Pump Relay & Schrader Valve
FUEL TANK SIDE
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2WD
Fig. 2: Identifying Fuel Tank, Nonreturn Valve, Fuel Pump Unit & Quick Release Connector (2WD)
AWD
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Fig. 3: Identifying Fuel Tank, Nonreturn Valve, Fuel Pump Unit & Quick Release Connector (AWD)
FUEL SYSTEM DIAGRAM [MZI-3.7]
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Fig. 4: Fuel System Diagram

BEFORE SERVICE PRECAUTION [MZI-3.7]
WARNING:  Fuel vapor is hazardous. It can easily ignite, causing serious injury
eyes. To prevent this, always complete the following "Fuel Line
Safety Procedure".
 A person charged with static electricity could cause a fire or
explosion, resulting in death or serious injury. Before performing
work on the fuel system, discharge static electricity by touching the
vehicle body.
FUEL LINE SAFETY PROCEDURE
NOTE:  Fuel in the fuel system is under high pressure also when the engine is not
running.
1. Remove the fuel-filler cap and release the pressure in the fuel tank.
3. Remove the fuel pump relay.
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6. After the engine stalls, crank the engine several times.
7. Turn the ignition switch to LOCK position.
Fig. 5: Identifying Fuel Pump Relay & Main Fuse Block

AFTER SERVICE PRECAUTION [MZI-3.7]
WARNING:  Fuel line spills and leakage are dangerous. Fuel can ignite and cause
serious injuries or death and damage. When installing the fuel hose,
observe "Fuel Leakage Inspection" described below.
FUEL LEAKAGE INSPECTION
serious injuries or death and damage. Always carry out the following
procedure with the engine stopped.
Using M-MDS

2. Using the simulation function "FP", start the fuel pump.
3. Verify that there is no fuel leakage from the pressurized parts.
 If there is leakage, replace the fuel hoses and clips.
 If there is damage on the seal on the fuel pipe side, replace the fuel pipe.
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Standard
There shall be no leakage after 5 min.
4. After reinstallation, repeat step 2 - 3 in the fuel leakage inspection.
Without using M-MDS

CAUTION:  Short the specified terminals because shorting the wrong

terminal of the main fuse block may cause malfunctions.
3. Using a jumper wire, short fuel pump relay terminals C and D in the main fuse block.
4. Connect the negative battery cable and operate the fuel pump.
Fig. 7: Identifying Main Fuse Block (Fuel Pump Relay)

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Standard
6. After repair, assemble the system and repeat Steps 4 - 5.
FUEL LINE PRESSURE INSPECTION [MZI-3.7]
serious injuries or death. Fuel can also irritate skin and eyes. To
prevent this, always complete the "BEFORE REPAIR PROCEDURE".
1. Complete the "BEFORE SERVICE PRECAUTION". (See BEFORE SERVICE PRECAUTION [MZI-
3.7].)
3. Remove the fuel line schrader valve cap.
Fig. 8: Identifying Schrader Valve Cap & Fuel Distributor

4. Turn the SST lever so that it is 90° to the hose as shown in the figure.
5. Make sure the lever of fuel pressure gauge is turned fully clockwise, then connect the SST to the schrader
valve.
6. Verify that the selector is in N position.
7. Start the fuel pump using the following procedure.
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Fig. 9: Identifying SST Lever

Using M-MDS


Without using M-MDS

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8. Measure the fuel line pressure, (during key on engine off (KOEO))
Zero or low
 FP circuit
 FP
 Fuel line (clogging)
 Fuel leakage inside pressure regulator
High
 Pressure regulator

Fuel line pressure
331-485 kPa {3.38-4.94 kgf/cm2 , 48.1-70.3 psi}
9. Stop the fuel pump using the following procedure.
Using M-MDS
1. Stop the fuel pump using the "FP" simulation function.
Using M-MDS

2. Disconnect the negative battery cable to stop the fuel pump.
10. Disconnect the fuel pressure gauge and connect the fuel pipe.
11. Complete the "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION [MZI-
3.7].)
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FUEL TANK REMOVAL/INSTALLATION [MZI-3.7]
WARNING:  Repairing a fuel tank that has not been properly steam cleaned can
be dangerous. Explosion or fire may cause death or serious injury.
Always properly steam clean a fuel tank before repairing it.
eyes. To prevent this, do not damage the sealing surface of the fuel
pump unit when removing or installing.
explosion, resulting in death or serious injury. Before draining fuel,
make sure to discharge static electricity by touching the vehicle
body.
CAUTION:  Disconnecting/connecting the quick release connector without

cleaning it may possibly cause damage to the fuel pipe and quick
release connector. Always clean the quick release connector joint
area before disconnecting/connecting using a cloth or soft brush,
and make sure that it is free of foreign material.
2WD
1. Level the vehicle.

3.7].)
6. Connect a long hose to the disconnected schrader valve cap and drain the fuel into a container used for
collecting gasoline.
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Using M-MDS

3. Using the simulation function FP, start the fuel pump.

Without using M-MDS

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CAUTION:  The fuel pump could be damaged if it is operated (fuel

pump idling) while there is no fuel in the fuel tank. Verify
the amount of fuel being discharged from the hose and
stop operation of the fuel pump when essentially no fuel is
being discharged.

8. When essentially no fuel is being discharged, stop the fuel pump.

11. To remove the fuel pump unit, remove the following parts:
1. Second-row seat (LH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)
2. Edge cover (See LONG SLIDER REMOVAL/INSTALLATION .)
3. Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION .)
4. Rear heat duct No.3 (See REAR HEAT DUCT COMPONENT
5. Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)
12. Siphon the fuel from the fuel tank.
3.7].)
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Fig. 15: Identifying Evaporative Hose Component, Fuel Tank, Fuel Tank Bracket, Fuel-Filler Pipe
Fuel-filler pipe protector removal note
1. Remove the rear tire (LH).

2. Remove the splash shield (LH).
3. Remove the fuel-filler pipe protector.
Fuel-filler pipe removal note
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1. Remove the rear tire (RH).

2. Remove the spare tire.
3. Remove the main silencer (LH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
4. Remove the main silencer insulator (LH).
5. To lower the rear crossmember, perform the following procedure:
1. Set the rear ABS wheel-speed sensor out of the way. (See REAR ABS WHEEL-SPEED
SENSOR REMOVAL/INSTALLATION [2WD] .)
2. Rear coil spring (See REAR COIL SPRING REMOVAL/INSTALLATION .)
3. Lowered the rear crossmember. (See REAR CROSSMEMBER REMOVAL/INSTALLATION
[2WD] .)
6. Remove the fuel-filler pipe.
AWD

3.7].)

Using M-MDS
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Without using M-MDS


being discharged.

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10. To remove the propeller shaft, remove the following parts:
1. Presilencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
2. Presilencer insulator
3. Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
Fig. 19: Identifying Presilencer Insulator & Torque Specifications


3.7].)
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3.7] .)
SENSOR REMOVAL/INSTALLATION [AWD] .)
[AWD] .)
FUEL TANK INSPECTION [MZI-3.7]
NOTE:  This inspection is for three rollover valves and fuel shut-off valve
integrated in the fuel tank.
1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel
from spilling from the fuel system. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)
3. To disconnect the fuel pump unit connector, remove the following parts:
5. Disconnect the fuel pump unit connector.
4. Disconnect the quick release connector and the fuel pump unit connector. (See QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
5. Disconnect the joint hose. (See FUEL TANK INSPECTION [MZI-3.7].)
6. Disconnect the evaporative hose. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)
7. Remove the fuel tank with the fuel pump unit. (See FUEL TANK REMOVAL/INSTALLATION
[MZI-3.7].)
8. Perform the following procedure to verify the fuel tank air-tightness.
1. Plug the fuel pump unit pipe and port B.
2WD
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Fig. 21: Identifying Fuel Pump Unit & Plug (2WD)

AWD
2. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.
3. Verify that there is no air leakage from the fuel tank.
 If there is airflow, replace the fuel tank.
9. Level the fuel tank.

10. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port B and wait for a while.
11. With the pressure still applied, verify that there is airflow from port A and the pressure is 0-3 kPa {0-22
mmHg, 0-0.8 inHg}.
 If malfunction, replace the fuel tank.
12. Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port B and wait for a while.

13. With the pressure still applied, verify that there is airflow from port A and the pressure is -0.5-0 kPa {-
3.8-0 mmHg, -0.2-0 inHg}.
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If there is airflow, place the fuel tank upside down.


2WD

AWD
15. With the pressure still applied, verify that there is no airflow from port A.
3.7].)

NONRETURN VALVE INSPECTION [MZI-3.7]
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3. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)
NOTE:  Nonreturn valve is integrated in the fuel tank.

 The nonreturn valve is normally closed by the spring force.
 Verify the nonreturn valve operation using a mirror.
5. Verify that the nonreturn valve is closed.

 If malfunction, replace the fuel tank. (See FUEL TANK REMOVAL/INSTALLATION [MZI-
3.7].)
6. Verify that the nonreturn valve is not stuck open and does not open even when pulled up by a finger.
3.7].)
Fig. 25: Identifying Nonreturn Valve

FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7]
Procedure".
eyes. To prevent this, before performing the fuel pump unit
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removal/installation, always complete the "Fuel Leak Inspection

After Fuel Pump Unit Installation".
body.
CAUTION:  Because the fuel tank is constructed such that the fuel level is higher
than the installation surface of the fuel pump, fuel leakage could
occur. If the fuel gauge indicates a fuel level of 3/4 or more, perform
the following Steps 3 - 8 to drain 10-15 L {2.7-3.9 US gal, 2.2-3.2 Imp
gal} of fuel.
 Disconnecting/connecting the quick release connector without

3.7].)

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Using M-MDS


Without using M-MDS


being discharged.
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8. When essentially no fuel is being discharged, stop operation of the fuel pump.
10. To remove the rear heat duct No.3, remove the following parts:
4. Remove the rear heat duct No.3. (See REAR HEAT DUCT COMPONENT
3.7].)
2WD
Fig. 29: Identifying Fuel Pump Unit, Quick Release Connector, Service Hole Cover & Torque
Specifications (2WD)
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AWD
Specifications (AWD)
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [MZI-3.7]

Fig. 31: Identifying Fuel Filter Body, Pressure Regulator, O-Ring & Fuel Pump
FUEL PUMP UNIT INSPECTION [MZI-3.7]
CAUTION:  It is normal to hear the fuel pump operating when the ignition switch
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is turned to the ON position.
NOTE:  To improve start ability, the fuel pump control operates the fuel pump unit
when the ignition switch is turned to the ON position. Due to this, fuel
pressure is rapidly increased and fuel control is stabilized.
OPERATION TEST
2. Remove the fuel-filler cap. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)
3. Start the fuel pump using the following procedure:
Using M-MDS


3. Using the simulation function FP, verify that operation sound is heard from the fuel pump when FP is
turned from OFF to ON.
 If the operation sound cannot be verified, measure the voltage at fuel pump wiring harness-side
connector terminal B.
 If as specified, inspect the following:
 Fuel pump continuity
 If not within the specification, inspect the following:
 Fuel pump relay
 Wiring harnesses and connectors between battery-fuel pump relay-fuel pump
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Fig. 33: Identifying Fuel Pump Unit Wiring Harness-Side Connector

Standard
B+ (Ignition switch at ON)
Without using M-MDS
1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-

3.7] .)

5. Verify that operation sound is heard from the fuel pump when ignition switch turn to the ON
position.

 If the operation sound cannot be verified, measure the voltage at fuel pump wiring harness-
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side connector terminal B.

 Fuel pump relay
Standard

6. Disconnect the jumper wire.

3.7].)

2. To remove the service hole cover, remove the following parts:
1. Second-row seat (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)
5. Service hole cover (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)
4. Inspect for continuity between fuel pump unit connector terminals B and D.
 If there is no continuity, replace the fuel pump unit. (See FUEL PUMP UNIT
 If as specified carry out the "Circuit Open/Short Inspection".
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Open circuit
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 Fuel pump unit terminal D and body ground

 Fuel pump unit terminal C and fuel pump relay terminal D
Short circuit

 Fuel pump unit terminal D and power supply
 Fuel pump unit terminal B and body ground
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7]
QUICK RELEASE CONNECTOR POSITION
Fig. 39: Identifying Quick Release Connector

REMOVAL
1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before
performing any work operations. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)
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Fig. 40: View Of Quick Release Connector

INSTALLATION
the fuel hose.

connector.
securely.
4. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION [MZI-3.7].)

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FUEL INJECTOR REMOVAL/INSTALLATION [MZI-3.7]
3.7].)
4. Remove the dynamic chamber (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
Fig. 42: Identifying Quick Release Connector, Wiring Harness Retainer, Fuel Injector Connectors,
Clip & Torque Specifications
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3.7].)
FUEL INJECTOR REMOVAL NOTE
CAUTION:  Use of a deformed injector retaining clip will cause the injector to not
engage correctly. Always use a new clip when reattaching the
injector, otherwise it may cause the injector to rotate.
1. Insert a screwdriver between the injector cup and the clip fingers.
Fig. 43: Identifying Injector Cup & Clip Fingers

NOTE:  When rotating the screwdriver to spread the clip fingers, deform
them sufficiently to make sure they release from the notched edge of
the injector cup.
2. Rotate the screwdriver to spread the clip fingers and remove them from the injector cup.
3. Pull the injector and clip out of the rail.
4. Remove the clip from the injector according to the following:
1. Grasp the clip with a pair of pliers.
Fig. 44: Identifying Clip Fingers & Notch

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2. Pull the clip parallel to the injector groove, and remove it from the injector.
3. Discard the clip.
Fig. 45: Pulling Clip To Injector Groove

FUEL INJECTOR INSTALLATION NOTE
1. Install the new O-ring.

2. Lightly lubricate the injector groove and O-ring.
3. Pre-attach a new clip in the injector groove.
NOTE:  When the clip is attached correctly, the central area of the injector
and the clip finger positions are aligned.
4. Hold the injector firmly, push the clip into the injector until the clip stops sliding.
5. Verify that the injector connector position is correct, and press the injector and clip into the injector cup.
Continue pressing until the clip contacts the lower surface of the injector cup.
6. Verify that the injector and clip are correctly attached with the clip locked onto the injector cup notch.
Fig. 46: Pushing Clip Into Injector

FUEL INJECTOR INSPECTION [MZI-3.7]
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NOTE:  Perform the following inspection only when directed.
OPERATION TEST
1. Carry out the "Fuel Injector Operation Inspection". (See ENGINE CONTROL SYSTEM
 If not as specified, perform the further inspection for the fuel injectors.

4. Remove the dynamic chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
5. Disconnect the fuel injector connectors.
6. Measure the resistance of the fuel injector.
 If not as specified, replace the fuel injector. (See FUEL INJECTOR
 If as specified but "Operation Test" is failed, carry out the "Circuit Open/Short Inspection". Inspect
for open or short circuit.
Fuel injector resistance
11-18 ohms
Fig. 47: Identifying Fuel Injector Connectors


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Open circuit
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 No.1 cylinder fuel injector terminal A and PCM terminal 2BJ
 No.2 cylinder fuel injector terminal A and PCM terminal 2BM
 No.3 cylinder fuel injector terminal A and PCM terminal 2BF
 No.4 cylinder fuel injector terminal A and PCM terminal 2BH
 No.5 cylinder fuel injector terminal A and PCM terminal 2BB
 No.6 cylinder fuel injector terminal A and PCM terminal 2BD
 No.1 cylinder fuel injector terminal B and fuel pump relay terminal D
Short circuit

 No.1 cylinder fuel injector terminal A and body ground
 No.1 cylinder fuel injector terminal B and power supply
ATOMIZATION
1. Inspect atomization pattern.

 If the atomization is faulty, replace the fuel injector. (See FUEL INJECTOR
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Fig. 51: Inspecting Atomization Pattern

PRESSURE REGULATOR INSPECTION [MZI-3.7]
NOTE:  Due to the adoption of the mechanical returnless fuel system, the pressure
regulator cannot be inspected separately.
1. Perform "FUEL LINE PRESSURE INSPECTION". (See FUEL LINE PRESSURE INSPECTION
[MZI-3.7].)
Microsoft
2008 ENGINE
Fuel System (MZI-3.7) - Mazda CX-9
FUEL SYSTEM LOCATION INDEX [MZI-3.7]

Fig. 1: Identifying Fuel Injector, Quick Release Connector, Fuel Pump Relay & Schrader Valve
FUEL TANK SIDE
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2WD
Fig. 2: Identifying Fuel Tank, Nonreturn Valve, Fuel Pump Unit & Quick Release Connector (2WD)
AWD
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Fig. 3: Identifying Fuel Tank, Nonreturn Valve, Fuel Pump Unit & Quick Release Connector (AWD)
FUEL SYSTEM DIAGRAM [MZI-3.7]
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Fig. 4: Fuel System Diagram

BEFORE SERVICE PRECAUTION [MZI-3.7]
WARNING:  Fuel vapor is hazardous. It can easily ignite, causing serious injury
eyes. To prevent this, always complete the following "Fuel Line
Safety Procedure".
explosion, resulting in death or serious injury. Before performing
work on the fuel system, discharge static electricity by touching the
vehicle body.
FUEL LINE SAFETY PROCEDURE
NOTE:  Fuel in the fuel system is under high pressure also when the engine is not
running.
1. Remove the fuel-filler cap and release the pressure in the fuel tank.
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6. After the engine stalls, crank the engine several times.
Fig. 5: Identifying Fuel Pump Relay & Main Fuse Block

AFTER SERVICE PRECAUTION [MZI-3.7]
serious injuries or death and damage. When installing the fuel hose,
observe "Fuel Leakage Inspection" described below.
FUEL LEAKAGE INSPECTION
serious injuries or death and damage. Always carry out the following
procedure with the engine stopped.
Using M-MDS

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Standard
4. After reinstallation, repeat step 2 - 3 in the fuel leakage inspection.
Without using M-MDS



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Standard
6. After repair, assemble the system and repeat Steps 4 - 5.
FUEL LINE PRESSURE INSPECTION [MZI-3.7]
serious injuries or death. Fuel can also irritate skin and eyes. To
prevent this, always complete the "BEFORE REPAIR PROCEDURE".
3.7].)

4. Turn the SST lever so that it is 90° to the hose as shown in the figure.
5. Make sure the lever of fuel pressure gauge is turned fully clockwise, then connect the SST to the schrader
valve.
6. Verify that the selector is in N position.
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Fig. 9: Identifying SST Lever

Using M-MDS


Without using M-MDS

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8. Measure the fuel line pressure, (during key on engine off (KOEO))
Zero or low
 FP circuit
 FP
 Fuel line (clogging)
 Fuel leakage inside pressure regulator
High
 Pressure regulator

Fuel line pressure
331-485 kPa {3.38-4.94 kgf/cm2 , 48.1-70.3 psi}
9. Stop the fuel pump using the following procedure.
Using M-MDS
1. Stop the fuel pump using the "FP" simulation function.
Using M-MDS

2. Disconnect the negative battery cable to stop the fuel pump.
10. Disconnect the fuel pressure gauge and connect the fuel pipe.
3.7].)
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FUEL TANK REMOVAL/INSTALLATION [MZI-3.7]
WARNING:  Repairing a fuel tank that has not been properly steam cleaned can
be dangerous. Explosion or fire may cause death or serious injury.
Always properly steam clean a fuel tank before repairing it.
eyes. To prevent this, do not damage the sealing surface of the fuel
pump unit when removing or installing.
body.
CAUTION:  Disconnecting/connecting the quick release connector without

2WD

3.7].)
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Using M-MDS


Without using M-MDS

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being discharged.


3.7].)
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3.7] .)
SENSOR REMOVAL/INSTALLATION [2WD] .)
[2WD] .)
AWD

3.7].)

Using M-MDS
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Without using M-MDS


being discharged.

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10. To remove the propeller shaft, remove the following parts:
1. Presilencer (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
2. Presilencer insulator
3. Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
Fig. 19: Identifying Presilencer Insulator & Torque Specifications


3.7].)
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Microsoft

3.7] .)
SENSOR REMOVAL/INSTALLATION [AWD] .)
[AWD] .)
FUEL TANK INSPECTION [MZI-3.7]
NOTE:  This inspection is for three rollover valves and fuel shut-off valve
integrated in the fuel tank.
3. To disconnect the fuel pump unit connector, remove the following parts:
4. Disconnect the quick release connector and the fuel pump unit connector. (See QUICK RELEASE
CONNECTOR REMOVAL/INSTALLATION [MZI-3.7].)
5. Disconnect the joint hose. (See FUEL TANK INSPECTION [MZI-3.7].)
6. Disconnect the evaporative hose. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)
7. Remove the fuel tank with the fuel pump unit. (See FUEL TANK REMOVAL/INSTALLATION
[MZI-3.7].)
8. Perform the following procedure to verify the fuel tank air-tightness.
1. Plug the fuel pump unit pipe and port B.
2WD
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AWD
2. Apply a pressure of 3 kPa {23 mmHg, 0.9 inHg} to port A and wait for a while.
3. Verify that there is no air leakage from the fuel tank.
9. Level the fuel tank.

11. With the pressure still applied, verify that there is airflow from port A and the pressure is 0-3 kPa {0-22
mmHg, 0-0.8 inHg}.
12. Apply a pressure of -0.5 kPa {-3.8 mmHg, -0.1 inHg} to port B and wait for a while.

13. With the pressure still applied, verify that there is airflow from port A and the pressure is -0.5-0 kPa {-
3.8-0 mmHg, -0.2-0 inHg}.
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If there is airflow, place the fuel tank upside down.


2WD

AWD
15. With the pressure still applied, verify that there is no airflow from port A.
3.7].)

NONRETURN VALVE INSPECTION [MZI-3.7]
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3. Remove the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)
NOTE:  Nonreturn valve is integrated in the fuel tank.

 The nonreturn valve is normally closed by the spring force.
 Verify the nonreturn valve operation using a mirror.
5. Verify that the nonreturn valve is closed.

3.7].)
6. Verify that the nonreturn valve is not stuck open and does not open even when pulled up by a finger.
3.7].)
Fig. 25: Identifying Nonreturn Valve

FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7]
Procedure".
eyes. To prevent this, before performing the fuel pump unit
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removal/installation, always complete the "Fuel Leak Inspection

body.
occur. If the fuel gauge indicates a fuel level of 3/4 or more, perform
the following Steps 3 - 8 to drain 10-15 L {2.7-3.9 US gal, 2.2-3.2 Imp
gal} of fuel.

3.7].)

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Using M-MDS


Without using M-MDS


being discharged.
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10. To remove the rear heat duct No.3, remove the following parts:
4. Remove the rear heat duct No.3. (See REAR HEAT DUCT COMPONENT
3.7].)
2WD
Specifications (2WD)
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AWD
Specifications (AWD)
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY [MZI-3.7]

Fig. 31: Identifying Fuel Filter Body, Pressure Regulator, O-Ring & Fuel Pump
FUEL PUMP UNIT INSPECTION [MZI-3.7]
CAUTION:  It is normal to hear the fuel pump operating when the ignition switch
Microsoft
is turned to the ON position.
NOTE:  To improve start ability, the fuel pump control operates the fuel pump unit
when the ignition switch is turned to the ON position. Due to this, fuel
pressure is rapidly increased and fuel control is stabilized.
OPERATION TEST
2. Remove the fuel-filler cap. (See FUEL TANK REMOVAL/INSTALLATION [MZI-3.7].)
3. Start the fuel pump using the following procedure:
Using M-MDS


3. Using the simulation function FP, verify that operation sound is heard from the fuel pump when FP is
turned from OFF to ON.
 If the operation sound cannot be verified, measure the voltage at fuel pump wiring harness-side
connector terminal B.
 Fuel pump relay
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Standard
Without using M-MDS
1. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZI-

3.7] .)

5. Verify that operation sound is heard from the fuel pump when ignition switch turn to the ON
position.

 If the operation sound cannot be verified, measure the voltage at fuel pump wiring harness-
Microsoft
side connector terminal B.

 Fuel pump relay
Standard

6. Disconnect the jumper wire.

3.7].)

2. To remove the service hole cover, remove the following parts:
5. Service hole cover (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-3.7].)
4. Inspect for continuity between fuel pump unit connector terminals B and D.
 If there is no continuity, replace the fuel pump unit. (See FUEL PUMP UNIT
 If as specified carry out the "Circuit Open/Short Inspection".
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Open circuit
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 Fuel pump unit terminal D and body ground

 Fuel pump unit terminal C and fuel pump relay terminal D
Short circuit

 Fuel pump unit terminal D and power supply
 Fuel pump unit terminal B and body ground
QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZI-3.7]
QUICK RELEASE CONNECTOR POSITION
Fig. 39: Identifying Quick Release Connector

REMOVAL
1. Follow "BEFORE SERVICE PRECAUTION" and remove dirt from the connecting surfaces before
performing any work operations. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)
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INSTALLATION
the fuel hose.

connector.
securely.
4. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE
PRECAUTION [MZI-3.7].)

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FUEL INJECTOR REMOVAL/INSTALLATION [MZI-3.7]
3.7].)
4. Remove the dynamic chamber (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
Fig. 42: Identifying Quick Release Connector, Wiring Harness Retainer, Fuel Injector Connectors,
Clip & Torque Specifications
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3.7].)
FUEL INJECTOR REMOVAL NOTE
CAUTION:  Use of a deformed injector retaining clip will cause the injector to not
engage correctly. Always use a new clip when reattaching the
injector, otherwise it may cause the injector to rotate.
1. Insert a screwdriver between the injector cup and the clip fingers.
Fig. 43: Identifying Injector Cup & Clip Fingers

NOTE:  When rotating the screwdriver to spread the clip fingers, deform
them sufficiently to make sure they release from the notched edge of
the injector cup.
2. Rotate the screwdriver to spread the clip fingers and remove them from the injector cup.
3. Pull the injector and clip out of the rail.
4. Remove the clip from the injector according to the following:
1. Grasp the clip with a pair of pliers.
Fig. 44: Identifying Clip Fingers & Notch

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2. Pull the clip parallel to the injector groove, and remove it from the injector.
3. Discard the clip.
Fig. 45: Pulling Clip To Injector Groove

FUEL INJECTOR INSTALLATION NOTE
1. Install the new O-ring.

2. Lightly lubricate the injector groove and O-ring.
3. Pre-attach a new clip in the injector groove.
NOTE:  When the clip is attached correctly, the central area of the injector
and the clip finger positions are aligned.
4. Hold the injector firmly, push the clip into the injector until the clip stops sliding.
5. Verify that the injector connector position is correct, and press the injector and clip into the injector cup.
Continue pressing until the clip contacts the lower surface of the injector cup.
6. Verify that the injector and clip are correctly attached with the clip locked onto the injector cup notch.
Fig. 46: Pushing Clip Into Injector

FUEL INJECTOR INSPECTION [MZI-3.7]
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OPERATION TEST
1. Carry out the "Fuel Injector Operation Inspection". (See ENGINE CONTROL SYSTEM
 If not as specified, perform the further inspection for the fuel injectors.

3.7] .)
5. Disconnect the fuel injector connectors.
6. Measure the resistance of the fuel injector.
 If not as specified, replace the fuel injector. (See FUEL INJECTOR
 If as specified but "Operation Test" is failed, carry out the "Circuit Open/Short Inspection". Inspect
for open or short circuit.
Fuel injector resistance
11-18 ohms
Fig. 47: Identifying Fuel Injector Connectors


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Open circuit
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 No.1 cylinder fuel injector terminal A and PCM terminal 2BJ
 No.2 cylinder fuel injector terminal A and PCM terminal 2BM
 No.3 cylinder fuel injector terminal A and PCM terminal 2BF
 No.4 cylinder fuel injector terminal A and PCM terminal 2BH
 No.5 cylinder fuel injector terminal A and PCM terminal 2BB
 No.6 cylinder fuel injector terminal A and PCM terminal 2BD
Short circuit

ATOMIZATION
1. Inspect atomization pattern.

 If the atomization is faulty, replace the fuel injector. (See FUEL INJECTOR
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Fig. 51: Inspecting Atomization Pattern

PRESSURE REGULATOR INSPECTION [MZI-3.7]
NOTE:  Due to the adoption of the mechanical returnless fuel system, the pressure
regulator cannot be inspected separately.
1. Perform "FUEL LINE PRESSURE INSPECTION". (See FUEL LINE PRESSURE INSPECTION
[MZI-3.7].)
Microsoft
2008 HVAC Control System (HVAC) - Mazda CX-9
2008 HVAC
Control System (HVAC) - Mazda CX-9
HVAC CONTROL SYSTEM LOCATION INDEX
Fig. 1: Identifying HVAC Control System Location Index (1 Of 2)

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Fig. 2: Identifying HVAC Control System Location Index (2 Of 2)

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AIR INTAKE ACTUATOR REMOVAL/INSTALLATION

2. Remove the dashboard under cover. (Passenger side) (See DASHBOARD UNDER COVER
4. Insert a flathead screwdriver as shown in the figure and detach the fuse block tab by prying it in the
5. Press the fuse block and remove it from the bracket.
6. Set the fuse block out of the way.
Fig. 3: Detaching Fuse Block Tab

Fig. 4: Identifying Air Intake Actuator Removal Order

AIR INTAKE ACTUATOR INSPECTION

1. Connect battery positive voltage to air intake actuator terminal G, connect terminal A (or C) to ground,
and then verify that the air intake actuator operates as shown in the table.
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 If the operation condition is not normal, replace the air intake actuator.
AIR INTAKE ACTUATOR OPERATION

Terminal
Air intake actuator operation
A C G
Ground - B+ RECIRCULATE --> FRESH
- Ground B+ FRESH --> RECIRCULATE
Fig. 5: Inspecting Air Intake Actuator

Fig. 6: Air Intake Actuator Circuit Diagram

FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION

DRIVER SIDE

1. Dashboard under cover (Driver side) (See DASHBOARD UNDER COVER
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3. Console panel (LH) (See CONSOLE PANEL REMOVAL/INSTALLATION .)

4. Hood release lever (See HOOD LATCH AND RELEASE LEVER
5. Lower panel (See LOWER PANEL REMOVAL/INSTALLATION .)
Fig. 7: Identifying Front Air Mix Actuator Removal Order - Driver Side
PASSENGER SIDE

5. Dashboard under cover (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION .)
7. Console panel (See CONSOLE PANEL REMOVAL/INSTALLATION .)
8. Console cover (See CONSOLE COVER REMOVAL/INSTALLATION .)
11. Front side trim (See FRONT SIDE TRIM REMOVAL/INSTALLATION .)
15. Lower column cover (See COLUMN COVER REMOVAL/INSTALLATION .)
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18. Combination switch (See COMBINATION SWITCH REMOVAL/INSTALLATION .)
20. Meter hood (See METER HOOD REMOVAL/INSTALLATION .)
21. Instrument cluster (See INSTRUMENT CLUSTER REMOVAL/INSTALLATION .)
22. Audio unit (See AUDIO UNIT REMOVAL/INSTALLATION .)
23. Steering shaft (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
3. Disconnect the front door wiring harness connector (Driver side). (See FRONT DOOR MODULE
4. Disconnect the dashboard harness connectors.
5. Remove the brake switch from the brake pedal with the brake switch connector connected. (See BRAKE
PEDAL REMOVAL/INSTALLATION .)
6. Remove the selector lever component. (See SELECTOR LEVER COMPONENT
10. Remove the dashboard. (See DASHBOARD REMOVAL/INSTALLATION .)
Fig. 8: Identifying Front Air Mix Actuator Remove Order - Passenger Side
FRONT AIR MIX ACTUATOR INSPECTION

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DRIVER SIDE
1. Connect battery positive voltage to front air mix actuator terminal F (or G), connect terminal G (or F) to
ground, and then verify that the front air mix actuator operates as shown in the table.
 If the operation condition is not normal, replace the front air mix actuator.
FRONT AIR MIX ACTUATOR OPERATION

Terminal
Front air mix actuator operation
F G
B+ Ground HOT --> COLD
Ground B+ COLD --> HOT
Fig. 9: Front Air Mix Actuator Circuit Diagram - Driver Side

Fig. 10: Inspecting Front Air Mix Actuator - Driver Side

2. Verify that the resistance between terminals A and E, and E and C matches the front air mix actuator
operation as shown in the graph.
 If the operation condition and resistance are not normal, replace the front air mix actuator.
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Fig. 11: Front Air Mix Actuator Operation Terminals A & E With E & C Resistance Graph -
Driver Side
PASSENGER SIDE
1. Connect battery positive voltage to front air mix actuator terminal F (or G), connect terminal G (or F) to
ground, and then verify that the front air mix actuator operates as shown in the table.
 If the operation condition is not normal, replace the front air mix actuator.
FRONT AIR MIX ACTUATOR OPERATION

Terminal
Front air mix actuator operation
F G
B+ Ground COLD --> HOT
Ground B+ HOT --> COLD
Fig. 12: Front Air Mix Actuator Circuit Diagram - Passenger Side
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Fig. 13: Inspecting Front Air Mix Actuator - Passenger Side

2. Verify that the resistance between terminals A and E, and E and C matches the front air mix actuator
 If the operation condition and resistance are not normal, replace the front air mix actuator.
Fig. 14: Front Air Mix Actuator Operation Terminals A & E With E & C Resistance Graph -
Passenger Side
REAR AIR MIX ACTUATOR REMOVAL/INSTALLATION

1. Slide the passenger-side front seat to the maximum forward end.
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Fig. 15: Identifying Rear Air Mix Actuator Removal Order

REAR AIR MIX ACTUATOR INSPECTION

1. Connect battery positive voltage to rear air mix actuator terminal F (or G), connect terminal G (or F) to
ground, and then verify that the rear air mix actuator operates as shown in the table.
 If the operation condition is not normal, replace the rear air mix actuator.
REAR AIR MIX ACTUATOR OPERATION

Terminal
Rear air mix actuator operation
F G
B+ Ground HOT --> COLD
Ground B+ COLD --> HOT
Fig. 16: Rear Air Mix Actuator Circuit Diagram

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Fig. 17: Rear Air Mix Actuator Inspection

2. Verify that the resistance between the terminals terminals C and E, and E and A matches the rear air mix
actuator operation as shown in the graph.
 If the operation condition and resistance are not normal, replace the rear air mix actuator.
Fig. 18: Rear Air Mix Actuator Operation Terminals C & E With E & A Resistance Graph
FRONT AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION

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Fig. 19: Identifying Front Airflow Mode Actuator Removal Order

FRONT AIRFLOW MODE ACTUATOR INSPECTION

1. Connect battery positive voltage to front airflow mode actuator terminal F (or G), connect terminal G (or
F) to ground, and then verify that the front airflow mode actuator operates as shown in the table.
 If the operation condition is not normal, replace the front airflow mode actuator.
FRONT AIRFLOW MODE ACTUATOR OPERATION

Terminal
Front airflow mode actuator operation
F G
B+ Ground VENT --> DEFROSTER
Ground B+ DEFROSTER --> VENT
Fig. 20: Front Airflow Mode Actuator Circuit Diagram

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Fig. 21: Inspecting Front Airflow Mode Actuator

2. Verify that the resistance between terminals C and E, and E and A matches the front airflow mode
actuator operation as shown in the graph.
 If the operation condition and resistance are not normal, replace the front airflow mode actuator.
Fig. 22: Front Airflow Mode Actuator Operation Terminals C & E With E & A Resistance
Graph
REAR AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION

1. Slide the passenger-side front seat to the maximum forward end.
5. Dashboard undercover (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION .)
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Fig. 23: Identifying Rear Airflow Mode Actuator Removal Order

REAR AIRFLOW MODE ACTUATOR INSPECTION

1. Connect battery positive voltage to rear airflow mode actuator terminal F (or G), connect terminal G (or
F) to ground, and then verify that the rear airflow mode actuator operates as shown in the table.
 If the operation condition is not normal, replace the rear airflow mode actuator.
REAR AIRFLOW MODE ACTUATOR OPERATION

Terminal
Rear airflow mode actuator operation
F G
B+ Ground VENT --> HEAT
Ground B+ HEAT --> VENT
Fig. 24: Rear Airflow Mode Actuator Circuit Diagram

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Fig. 25: Rear Airflow Mode Actuator Inspection

2. Verify that the resistance between terminals A and E, and E and C matches the rear airflow mode actuator
 If the operation condition and resistance are not normal, replace the rear airflow mode actuator.
Fig. 26: Rear Airflow Mode Actuator Operation Terminals A & E With E & C Resistance
Graph
FRONT BLOWER MOTOR REMOVAL/INSTALLATION

2. Remove the dashboard under cover, (passenger side) (See DASHBOARD UNDER COVER
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Fig. 27: Identifying Front Blower Motor Removal Order

FRONT BLOWER MOTOR INSPECTION

1. Connect battery positive voltage to front blower motor terminal B, connect terminal A to ground, and
then verify its operation.
 If there is any malfunction, replace the front blower motor.
Fig. 28: Inspecting Front Blower Motor

REAR BLOWER MOTOR REMOVAL/INSTALLATION

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10. Selector lever component (See SELECTOR LEVER COMPONENT

Fig. 29: Identifying Rear Blower Motor Removal Order

REAR BLOWER MOTOR INSPECTION

1. Connect battery positive voltage to rear blower motor terminal B, connect terminal A to ground, and then
verify its operation.
 If there is any malfunction, replace the rear blower motor.
Fig. 30: Inspecting Rear Blower Motor

FRONT POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT

TRANSISTOR (POWER MOS FET) REMOVAL/INSTALLATION
2. Remove the dashboard under cover, (passenger side) (See DASHBOARD UNDER COVER
4. Insert a flathead screwdriver as shown in the figure and detach the fuse block tab by prying it in the
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5. Press the fuse block and remove it from the bracket.

6. Set the fuse block out of the way.
Fig. 31: Detaching Fuse Block Tab


Fig. 32: Front Power Metal Oxide Semiconductor Field Effect Transistor (Power Mos Fet) Removal
Order
FRONT POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT

TRANSISTOR (POWER MOS FET) INSPECTION
1. Verify that the continuity between the front power MOS FET terminals is as indicated in the table.
 If there is any malfunction, replace the front power MOS FET.
 If the blower motor operation is not normal even though no malfunction can be verified, inspect the
front climate control unit.
FRONT POWER MOS FET TERMINALS CONTINUITY CHART

Tester lead
Resistance (kilohm)
+ -
A B 2.2
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A E Continuity detected
A F Continuity detected
B A 2.2
B E Continuity detected
B F Continuity detected
E A infinity
E B infinity
E F 11
F A infinity
F B infinity
F E 11
Fig. 33: Inspecting Front Power Metal Oxide Semiconductor Field Effect Transistor (Power Mos
Fet)
REAR POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT

TRANSISTOR (POWER MOS FET) REMOVAL/INSTALLATION
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Fig. 34: Identifying Rear Power Metal Oxide Semiconductor Field Effect Transistor (Power Mos
Fet) Removal Order
REAR POWER METAL OXIDE SEMICONDUCTOR FIELD EFFECT

TRANSISTOR (POWER MOS FET) INSPECTION
1. Verify that the continuity between the rear power MOS FET terminals is as indicated in the table.
 If there is any malfunction, replace the rear power MOS FET.
 If the blower motor operation is not normal even though no malfunction can be verified, inspect the
front climate control unit.
REAR POWER MOS FET TERMINALS CONTINUITY CHART

Tester lead
Resistance (kilohm)
+ -
A B infinity
A C 11
A D infinity
B A Continuity detected
B C Continuity detected
B D 1.5
C A 11
C B infinity
C D infinity
D A Continuity detected
D B 1.5
D C Continuity detected
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Fig. 35: Inspecting Rear Power Metal Oxide Semiconductor Field Effect Transistor (Power Mos
Fet)
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY

1. Install the SST (49 L061 001) or a commercially available filter wrench as shown in the figure and
remove the bolt.
When Using SST
Fig. 36: Removing Pressure Plate Bolt

When Using Filter Wrench
2. Insert an appropriate bolt into the pressure plate thread hole and tighten it until the pressure plate is
removed.
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Fig. 37: Removing Pressure Plate

Fig. 38: Identifying Pressure Plate Disassembly Order & Torque Specifications

5. Adjust the magnetic clutch clearance. (See MAGNETIC CLUTCH ADJUSTMENT.)
SNAP RING INSTALLATION NOTE
1. Install the snap ring so that the tapered area is on the pressure plate side.
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Fig. 39: Identifying Snap Ring & Tapered Area

MAGNETIC CLUTCH ADJUSTMENT

1. Secure the A/C compressor to the vise.
2. Secure the magnet base to the vise and install the dial gauge to the position shown in the figure.
3. Set the dial gauge to 0.
4. Connect battery voltage to stator terminal A and the A/C compressor body to ground to operate the
magnet clutch.
5. Verify that the dial gauge graduation is within the standard.
 If the clearance is not within the specification, adjust the clearance by changing the type or number
of shims.
Fig. 40: Adjusting Magnetic Clutch

Magnetic clutch clearance
0.35-0.65 mm {0.014-0.025 in}
MAGNETIC CLUTCH INSPECTION

1. Connect battery positive voltage to magnetic clutch terminal A, connect terminal B to ground.
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Fig. 41: View Of Battery Positive Voltage To Magnetic Clutch Terminal A & Terminal B
2. Verify that the magnetic clutch operates.

 If there is any malfunction, replace the magnetic clutch.
Fig. 42: Inspecting Magnetic Clutch Operation

SOLAR RADIATION SENSOR REMOVAL/INSTALLATION

2. Remove the cover from the dashboard using a fiathead screwdriver wrapped with protective tape.
3. Detach the solar radiation sensor connector tab in the position shown in the figure and disconnect the
solar radiation sensor connector.
4. Press the solar radiation sensor tab and remove the solar radiation sensor from the cover.
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Fig. 43: View Of Solar Radiation Sensor

SOLAR RADIATION SENSOR INSPECTION

1. Using a tester, connect the positive (+) lead to solar radiation sensor terminal A, the negative (-) lead to
terminal B or C, then measure the resistance.
 If the resistance is not normal, replace the solar radiation sensor.
Resistance
except infinity ohms
2. Block the light to the solar radiation sensor, connect the positive (+) lead of a tester to solar radiation
sensor terminal B or C and negative (-) lead to terminal A, then measure the resistance.
Resistance
infinity ohms (no continuity)
3. Expose the solar radiation sensor to natural sunlight.

4. Using a tester, connect the positive (+) lead to solar radiation sensor terminal B or C, the negative (-) lead
to terminal A, then measure the resistance.
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Fig. 44: Measuring Solar Radiation Sensor Terminal Resistance

Resistance
except infinity ohms
AMBIENT TEMPERATURE SENSOR REMOVAL/INSTALLATION

2. Remove the under cover.
Fig. 45: Identifying Ambient Temperature Sensor Removal Order

AMBIENT TEMPERATURE SENSOR INSPECTION

1. Measure the temperature around the ambient temperature sensor and measure the resistance between the
ambient temperature sensor terminal.
 If the characteristics of the ambient temperature sensor are not as shown in the graph, replace the
ambient temperature sensor.
Microsoft
Fig. 46: Ambient Temperature Sensor Temperature & Resistance Graph

CABIN TEMPERATURE SENSOR REMOVAL/INSTALLATION

3. Console panel (LH) (See CONSOLE PANEL REMOVAL/INSTALLATION .)
3. Remove the screw.
4. Remove the cabin temperature sensor cover in the direction of the arrow.
5. Remove the cabin temperature sensor.
Microsoft
Fig. 47: Identifying Cabin Temperature Sensor & Cover

CABIN TEMPERATURE SENSOR INSPECTION

1. Measure the temperature around the cabin temperature sensor and measure the resistance between cabin
temperature sensor terminal.
 If the characteristics of the cabin temperature sensor are not as shown in the graph, replace the
cabin temperature sensor.
Fig. 48: Cabin Temperature Sensor Temperature & Resistance Graph

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FRONT EVAPORATOR TEMPERATURE SENSOR

1. Remove the front evaporator temperature sensor from the front A/C unit. (See FRONT A/C UNIT
FRONT EVAPORATOR TEMPERATURE SENSOR INSPECTION

1. Set the fan speed MAX HI.
2. Set the temperature control at MAX COLD.
3. Set the RECIRCULATE mode.
4. Turn the A/C switch off.
5. Close all doors and windows.
6. Wait for 5 min.
7. Remove the glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION .)
8. Disconnect the front evaporator temperature sensor connector.
9. Measure the temperature at the blower inlet.
10. Measure the resistance between the front evaporator temperature sensor terminals.
 If the resistance is not as shown in the graph, replace the front evaporator temperature sensor.
Fig. 49: Front Evaporator Temperature Sensor Temperature & Resistance Graph
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REAR EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION

3. Disconnect the rear evaporator temperature sensor connector and remove it from the rear A/C unit.
4. Insert a flathead screwdriver as shown in the figure and remove the clip by prying it off.
5. Remove the rear evaporator temperature sensor.
Fig. 50: Identifying Rear Evaporator Temperature Sensor & Connector

REAR EVAPORATOR TEMPERATURE SENSOR INSPECTION
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1. Measure the temperature at the blower inlet.

2. Measure the resistance between the rear evaporator temperature sensor terminals.
 If the resistance is not as shown in the graph, replace the rear evaporator temperature sensor.
Fig. 51: Rear Evaporator Temperature Sensor Resistance & Temperature Graph
REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION

2. Discharge the refrigerant from the system. (See REFRIGERANT RECOVERY .) (See
REFRIGERANT CHARGING .)
3. Grasp the piping block using pliers and remove the pressure switch using a spanner.
4. Disconnect the refrigerant pressure switch connector.
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Fig. 52: Identifying Refrigerant Pressure Switch Components & Torque Specifications

7. Perform the refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE
TEST .)
REFRIGERANT PRESSURE SWITCH INSTALLATION NOTE
1. Apply compressor oil to O-ring and connect the joint.
REFRIGERANT PRESSURE SWITCH INSPECTION

1. Install the manifold.
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the gauge and continuity between the refrigerant pressure switch
terminals.
 If there is any malfunction, replace the refrigerant pressure switch.
Fig. 53: Refrigerant Pressure Switch Terminals Continuity Chart (1 Of 3)


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FRONT CLIMATE CONTROL UNIT REMOVAL/INSTALLATION

4. Remove the front climate control unit.
Fig. 56: Identifying Front Climate Control Unit & Screws

FRONT CLIMATE CONTROL UNIT INSPECTION

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1. Connect the front climate control unit connector.

3. Connect the negative (-) lead of the tester to body ground.
4. By inserting the positive (+) lead of the tester into each front climate control unit terminal, measure the
voltage according to the terminal voltage table.
 If the parts under "Inspection item (s)" are found to be normal, replace the front climate
control unit.
TERMINAL VOLTAGE TABLE (REFERENCE)
Fig. 57: Identifying Front Climate Control Unit Terminal

TERMINAL VOLTAGE REFERENCE

Measurement Voltage
Terminal Signal name Connected to Inspection item (s)
condition (V)
Temperature control  Wiring harness:
dial (driver side): 1.0 or continuity, short circuit
Moving towards less (Front climate control
Motor Driver-side front COLD unit-driver-side front
1A
operation air mix actuator Temperature control air mix actuator: 1A-G,
dial (driver side): 1F-F)
B+
Moving towards  Driver-side front air
HOT mix actuator
 Wiring harness:
continuity, short circuit
Under any
1B B+ BCM B+ (Front climate control
condition
unit-BCM: 1B-5H)
 BCM
Temperature control
dial (passenger  Wiring harness:
Passenger-side B+
Motor side): Moving continuity, short circuit
1C front air mix
operation towards COLD (Front climate control
actuator
unit-passenger-side
Temperature control front air mix actuator:
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dial (passenger 1C-G, 1E-F)

side): Moving 1.0 or
less  Passenger-side front
towards HOT air mix actuator
 Wiring harness:
Seat warmer switch continuity, short circuit
B+
off (Front climate control
Seat warmer unit-seat warmer (LH)
1D Seat warmer relay
(LH) on/off relay (relay block):
Seat warmer switch 1.0 or 1D-A)
on less  Seat warmer (LH)
relay
dial (passenger 1.0 or continuity, short circuit
side): Moving less (Front climate control
Passenger-side towards COLD
Motor unit-passenger-side
1E front air mix
operation Temperature control front air mix actuator:
actuator
dial (passenger 1C-G, 1E-F)
B+
side): Moving  Passenger-side front
towards HOT air mix actuator
dial (driver side): continuity, short circuit
B+
Moving towards (Front climate control
Motor Driver-side front COLD unit-driver-side front
1F
operation air mix actuator Temperature control air mix actuator: 1A-G,
dial (driver-side): 1.0 or 1F-F)
Moving towards less  Driver-side front air
HOT mix actuator
Temperature control
dial (rear side):  Wiring harness:
B+
Moving towards continuity, short circuit
Motor Rear air mix COLD (Front climate control
1G
operation actuator Temperature control unit-Rear air mix
dial (rear side): 1.0 or actuator: 1G-F, 1I-G)
Moving towards less  Rear air mix actuator
HOT
1.0 or  Wiring harness:

Defroster switch on continuity, short circuit
less
(Front climate control
Motor Front airflow unit-front airflow
1H
operation mode actuator Mode switch: mode actuator: 1H-G,
Moving towards B+ 1J-F)
VENT  Front airflow mode
actuator
Temperature control
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dial (rear side):

1.0 or  Wiring harness:
Moving towards
less continuity, short circuit
COLD
Motor Rear air mix (Front climate control
1I Temperature control
operation actuator unit-Rear air mix
dial (rear side): actuator: 1G-F, 1I-G)
B+
Moving towards
HOT  Rear air mix actuator
Defroster switch on B+  Wiring harness:

Motor Front airflow unit-front airflow
1J Mode switch:
operation mode actuator 1.0 or mode actuator: 1H-G,
Moving towards U-F)
less
VENT
 Front airflow mode
actuator
 Wiring harness:
Seat warmer switch continuity, short circuit
B+
off (Front climate control
Seat warmer unit-seat warmer (RH)
1K Seat warmer relay
(RH) on/off relay (main fuse
Seat warmer switch 1.0 or block): 1K-A)
on less  Seat warmer (RH)
relay
Temperature control
dial (rear side):  Wiring harness:
B+ continuity, short circuit
Moving towards
Motor Rear airflow mode HOT
1L unit-Rear airflow mode
operation actuator Temperature control actuator: 1L-G, 1N-F)
dial (rear side): 1.0 or
Moving towards less  Rear airflow mode
COLD actuator
REC switch:  Wiring harness:

Switched to B+ continuity, short circuit
Motor (Front climate control
1M Air intake actuator RECIRCULATE
operation unit-air intake actuator:
REC switch: 1.0 or 1M-A, 10-C)
Switched to FRESH less  Air intake actuator
Temperature control
 Wiring harness:
dial (rear side): 1.0 or
Moving towards less
Motor Rear airflow mode HOT
1N unit-Rear airflow mode
operation actuator
actuator: 1L-G, 1N-F)
Temperature control
dial (rear side): B+  Rear airflow mode
Moving towards actuator
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COLD
REC switch:  Wiring harness:
1.0 or continuity, short circuit
Switched to
Motor less (Front climate control
1O Air intake actuator RECIRCULATE
operation unit-air intake actuator:
REC switch: 1M-A, 1O-C)
B+
Switched to FRESH  Air intake actuator
Approx.
Off
7.3
1. Wiring harness:
Approx. continuity, short circuit
1st.
5.4 (Front climate control
Approx. unit-front power MOS
2nd.
4.6 FET: 1P C, 1R A)
Approx. 2. Wiring harness:
Front blower Airflow 3rd.
Front power MOS 3.7 continuity (Front
1P motor volume
FET Approx. power MOS FET-body
feedback control dial 4th.
2.9 ground: D-ground)
Approx. 3. Front power MOS FET
5th.
2.0
4. Front blower motor
Approx.
6th. 5. Front blower relay
1.1
1.0 or 6. HEATER 50 A fuse
7th,
less
 Wiring harness:
Rear window 1.0 or unit-rear window
Rear window defroster switch on less defroster relay (main
Rear window fuse block): 1Q-A)
1Q defroster
defroster relay
switch  Rear window defroster
relay
Rear window  Front climate control

B+ unit: terminal voltage
defroster switch off
(1W, 1X)
1.0 or
Off
less
Approx.
1st.
2.1
Front blower Airflow  Front climate control
Front power MOS Approx.
1R fan speed volume 2nd. unit: terminal voltage
FET 2.2
control control dial (1P)
Approx.
3rd.
2.3
4th. Approx.
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2.4
Approx.
5th.
2.5
Approx.
6th.
2.7
Approx.
7th.
10.7
Fan switch on, A/C 1.0 or  Front climate control

switch on less unit: terminal voltage
(1W, 1X)
 Wiring harness:
Refrigerant unit-refrigerant
1S A/C
pressure switch pressure switch: 1S-B)
Fan switch off B+ (Refrigerant pressure
switch-PCM: C-1B)
 Refrigerant pressure
switch
 PCM: terminal voltage
(1B)
Approx. 1. Wiring harness:
Off
8.5 continuity, short circuit
Approx. (Front climate control
1st. unit-rear power MOS
6.1
FET: 1T D, 1V C)
Approx.
Rear blower Rear airflow 2nd. 2. Wiring harness:
Rear power MOS 4.8
1T motor volume continuity (Rear power
FET MOS FET-body
feedback control dial 3rd. Approx.
3.6 ground: A-ground)
Approx. 3. Rear power MOS FET
4th.
1.9 4. Rear blower motor
1.0 or 5. Rear blower relay
5th.
less 6. R.HEATER 40 A fuse
 Wiring harness:
Check connector is 1.0 or continuity (Front
shorted. less climate control unit-
On-board check connector: 1U-
1U diagnostic Check connector A)
signal  Wiring harness: short
Other B+ circuit (Front climate
control unit-check
connector: 1U-A)
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 Front climate control

unit: terminal voltage
(1W, 1X)
1.0 or
Off
less
Approx.
1st.
2.1
Approx.
Rear blower Rear airflow 2nd. 2.2  Front climate control
Rear power MOS
1V fan speed volume unit: terminal voltage
FET Approx.
control control dial 3rd. (1T)
2.2
Approx.
4th.
2.3
Approx.
5th.
2.4
Ignition switch is at  Wiring harness:
B+ continuity, short circuit
ON position
1W IG2 A/C 7.5 A fuse
unit-fuse: 1W-A/C 7.5
Ignition switch is at 1.0 or A)
LOCK position less
 A/C 7.5 A fuse
Under any  Wiring harness:
condition: Inspect 1.0 or continuity (Front
1X Ground Body ground
for continuity to less climate control unit-
ground ground: 1X-ground)
ECT sensor communication, good/no
2A Instrument cluster -
signal good judgment by terminal
voltage is not possible.
 Wiring harness: short
circuit (Front climate
control unit-driver-side
 Driver-side front air mix actuator,
front air mix passenger-side front air
actuator mix actuator, front
 Passenger- airflow mode actuator,
Under any
2B +5V side front air 5.0 solar radiation sensor,
condition
mix actuator rear air mix actuator,
 Front rear airflow mode
airflow actuator: 2B-A, A, A,
mode C, A, A)
actuator  Driver-side front air
 Solar mix actuator
radiation  Passenger-side front
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sensor air mix actuator

 Rear air mix  Front airflow mode
actuator actuator
 Rear airflow  Solar radiation sensor
mode  Rear air mix actuator
actuator
 Rear airflow mode
actuator
Information Information communication, good/no
2C -
display signal display good judgment by terminal
voltage is not possible.
Temperature control
dial (rear side): Approx.
 Wiring harness:
Moving towards 0.5
COLD
Temperature control unit-rear airflow mode
dial (rear side): actuator: 2D-E)
Potentiometer Rear airflow mode Approx.
2D Moving towards
input actuator 2.4  Rear airflow mode
medium
temperature actuator
Temperature control  Front climate control
dial (rear side): Approx. unit: terminal voltage
Moving towards 4.3 (2B)
HOT
Mode switch:
Approx.
Moving towards
1.0
VENT  Wiring harness:
Mode switch: continuity, short circuit
Approx.
Moving towards BI- (Front climate control
1.9
LEVEL unit-front airflow
Potentiometer Front airflow Mode switch: mode actuator: 2E-E)
2E Approx.
input mode actuator Moving towards  Front airflow mode
2.5
HEAT actuator
Mode switch:  Front climate control
Approx.
Moving towards unit: terminal voltage
3.3
HEAT/DEF (2B)
Approx.
Defroster switch on
4.0

dial (driver side): continuity, short circuit
Potentiometer Driver-side front 4.0
2F Set temperature at (Front climate control
input air mix actuator MAX COLD unit-driver-side front
air mix actuator: 2F-E)
 Driver-side front air
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Temperature control mix actuator

dial (driver side):  Front climate control
1.0
Set temperature at unit: terminal voltage
MAX HOT (2B)
dial (passenger continuity, short circuit
side): Set 1.0 (Front climate control
temperature at unit-passenger-side
Passenger-side MAX COLD front air mix actuator:
Potentiometer 2G-E)
2G front air mix
input
actuator Temperature control  Passenger-side front
dial (passenger air mix actuator
side): Set 4.0  Front climate control
temperature at unit: terminal voltage
MAX HOT (2B)
 Wiring harness:
continuity (Front
climate control unit--
front evaporator
Compared with temperature sensor:
Front 2H-B, 2P-A)
temperature
evaporator Front evaporator
2H detected by front Refer to  Wiring harness: short
temperature temperature sensor
evaporator circuit (Front climate
sensor input
temperature sensor control unit-front
evaporator temperature
sensor: 2H-B)
 Front evaporator
temperature sensor
 Wiring harness:
continuity (Front
climate control unit-
ambient temperature
Compared with sensor: 21-B, 2P-A)
Ambient
Ambient temperature  Wiring harness: short
21 temperature Refer to
temperature sensor detected by ambient circuit (Front climate
sensor input
temperature sensor control unit-ambient
temperature sensor:
21-B)
 Ambient temperature
sensor
 Wiring harness:
continuity (Front
rear evaporator
Microsoft
temperature sensor: 2J-

B, 2P-A)
Compared with  Wiring harness: short
Rear
temperature circuit (Front climate
evaporator Rear evaporator
2J detected by rear Refer to control unit-rear
temperature temperature sensor
evaporator evaporator temperature
sensor input
temperature sensor sensor: 2J-B)
 Rear evaporator
temperature sensor
 Wiring harness:
continuity (Front
cabin temperature
Compared with sensor: 2K-B, 2P-A)
Cabin
Cabin temperature temperature  Wiring harness: short
2K temperature Refer to
sensor detected by cabin circuit (Front climate
sensor input
temperature sensor control unit-cabin
temperature sensor:
2K-B)
 Cabin temperature
sensor
2L - - - - -
 Wiring harness:
Natural sunlight
continuity (Front
shined directly on
4.0 climate control unit-
the solar radiation
Solar radiation solar radiation sensor:
Solar radiation sensor
2M sensor(LH) 2M-C, 2B-A)
sensor
input  Front climate control
Blocking light to unit: terminal voltage
1.0 or
solar radiation (2B)
less
sensor
 Solar radiation sensor
dial (rear side): Set continuity, short circuit
1.3 (Front climate control
temperature at
MAX COLD unit-rear air mix
Potentiometer Rear air mix actuator: 2N-E)
2N
input actuator
Temperature control  Rear air mix actuator
dial (rear side): Set Front climate control
4.0 
temperature at unit: terminal voltage
MAX HOT (2B)
Natural sunlight  Wiring harness:

4.0
shined directly on continuity (Front
the solar radiation climate control unit-
Microsoft
sensor solar radiation sensor:

20-B, 2B-A)
Solar radiation
Solar radiation Blocking light to  Front climate control
2O sensor (RH) 1.0 or
sensor solar radiation unit: terminal voltage
input less
sensor (2B)
 Solar radiation sensor
 Driver-side
front air mix
actuator
 Passenger-
side front air
mix actuator
 Front
airflow
mode
actuator
 Ambient
temperature
sensor
Under any
 Cabin condition: Inspect 1.0 or  Front climate control
2P Sensor ground temperature unit: terminal voltage
for continuity to less
sensor ground (1X)
 Front
evaporator
temperature
sensor
 Rear air mix
actuator
 Rear airflow
mode
actuator
 Rear
evaporator
temperature
sensor
3A - - - - -
3B - - - - -
 Wiring harness:
Rear control switch continuity (Front
B+ climate control unit-
on
rear climate control
unit: 3C-F)
Rear climate Rear climate  Wiring harness: short

Microsoft
control unit control unit circuit (Front climate

display control unit-rear
climate control unit:
Rear control switch 1.0 or 3C-F)
3C
off less
unit: terminal voltage
(1W, 1X)
 Wiring harness: short
circuit (Front climate
control unit-TNS relay
Turn the headlight (main fuse block): 3D-
1.0 or
switch to the off D)
less
position
 ILLUMI 10 A fuse
 TNS relay
 Headlight switch
3D TNS signal TNS relay
 Wiring harness:
Turn the headlight unit-TNS relay (main
switch to the TNS B+ fuse block): 3D-D)
position
 ILLUMI 10 A fuse
 TNS relay
 Headlight switch
1.0 or
Off unit: terminal voltage
less
(1T)
Airflow  Wiring harness:
Rear fan Rear climate Approx. continuity, short circuit
3E volume 1st.
control volume control unit 1.3 (Front climate control
control dial
unit-rear climate
control unit: 3E-A)
Max Approx.
HI 4.0  Rear climate control
unit
Turn the headlight  Wiring harness:
switch to the off
less (Front climate control
position
Rear climate unit-rear climate
3F TNS signal
control unit control unit: 3F-H)
Turn the headlight
switch to the TNS B+  TNS relay
position  Headlight switch
Temperature control
dial (rear side): 1.0 or  Wiring harness:
Microsoft
Moving towards less continuity, short circuit

COLD (Front climate control
Temperature control unit-rear airflow mode
dial (rear side): actuator: 3G-C)
Approx.
Rear Moving towards  Rear climate control
Rear climate 2.5
3G temperature medium unit
control unit
control volume temperature  Front climate control
Temperature control unit: terminal voltage
dial (rear side): Approx. (2B)
Moving towards 4.2
HOT
 Wiring harness:
Rear climate Under any continuity (Front
3H +5 V 5.0
control unit condition climate control unit-
ground: 3H-ground)
Under any  Wiring harness:

Rear climate condition: Inspect 1.0 or continuity (Front
3I Ground climate control unit-
control unit for continuity to less
ground rear climate control
unit: 31-E)
Turn the headlight  Wiring harness:
switch to the off
less (Front climate control
position
Panel light unit-instrument cluster:
3J Instrument cluster
control input 3J-1I)
Turn the headlight
switch to the TNS B+  TNS relay
position  Headlight switch
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Fig. 58: Temperature Sensors Graph Chart

REAR CLIMATE CONTROL UNIT REMOVAL/INSTALLATION

3. Remove the rear cooler duct. (See REAR COOLER DUCT REMOVAL/INSTALLATION .)
5. Remove the rear climate control unit.
Fig. 59: Identifying Rear Climate Control Unit & Screws

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REAR CLIMATE CONTROL UNIT INSPECTION

1. Connect the rear climate control unit connector.
3. Connect the negative (-) lead of the tester to body ground.
4. By inserting the positive (+) lead of the tester into each rear climate control unit terminal, measure the
voltage according to the terminal voltage table.
 If the parts under "Inspection item (s)" are found to be normal, replace the rear climate
control unit.
Fig. 60: Identifying Rear Climate Control Unit Terminals

TERMINAL VOLTAGE REFERENCE

Inspection item
Terminal Signal name Connected to Measurement condition Voltage (V) (s)
Off 1.0 or less  Front
climate
control
unit:
terminal
voltage
Airflow (1T)
Rear fan Front climate
A volume  Wiring
control volume control unit
control dial 1st. Approx. 1.3 harness:
continuity,
short
circuit
(Front
climate
control
Microsoft
unit-rear
climate
control
unit: 3E-
Max HI Approx. 4.0 A)
 Rear
climate
control
unit
B - - - - -
Temperature control dial: 1.0 or less  Wiring
Moving towards COLD harness:
continuity,
short
circuit
(Front
climate
Temperature control dial: Approx. 2.5 control
Moving towards medium unit-rear
temperature airflow
mode
Rear actuator:
Front climate
C temperature 3G-C)
control unit
control volume
 Rear
climate
control
unit
Temperature control dial: Approx. 4.2  Front
Moving towards HOT climate
control
unit:
terminal
voltage
(2B)
5.0  Front
climate
control
unit:
terminal
Front climate voltage
D +5V Under any condition
control unit (3H)
 Wiring
harness:
continuity
(Front
Microsoft
climate
control
unit-rear
climate
control
unit: 3H-
D)
 Wiring
harness:
continuity
(Front
Front climate Under any condition: Inspect climate
E Ground 1.0 or less control
control unit for continuity to ground
unit-rear
climate
control
unit: 31-
E)
 Wiring
harness:
continuity
(Front
climate
Rear control switch on B+ control
unit-rear
climate
control
unit: 3C-
F)
 Wiring
Rear climate harness:
Front climate short
F control unit
control unit circuit
display
(Front
climate
control
unit-rear
Rear control switch off 1.0 or less climate
control
unit: 3C-
F)
 Front
climate
control
unit:
terminal
Microsoft
voltage
(1W, 1X)
Turn the headlight switch to 1.0 or less  Wiring
the off position harness:
continuity,
short
circuit
(Rear
climate
Panel light Instrument control
G
control input cluster unit-
instrument
cluster: G-
Turn the headlight switch to 1I)
B+
the TNS position
 TNS relay
 Headlight
switch
Turn the headlight switch to 1.0 or less  Wiring
the off position harness:
continuity,
short
circuit
(Front
climate
Front climate control
H TNS signal unit-rear
control unit Turn the headlight switch to B+
the TNS position climate
control
unit: 3F-
H)
 TNS relay
 Headlight
switch
I - - - - -
J - - - - -
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2008 HVAC Refrigerant System - Mazda CX-9
2008 HVAC
Refrigerant System - Mazda CX-9
REFRIGERANT SYSTEM SERVICE WARNINGS

HANDLING REFRIGERANT
 Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose
and throat. Also, due to environmental concerns, the use of recovery/recycling/recharging
equipment is mandatory when draining R-134a from the air conditioning system. If accidental
system discharge occurs, ventilate work area before resuming service.
 Do not perform pressure test or leak test for R-134a service equipment and/or vehicle air
conditioning system using compressed air. Some mixtures of air and R-134a have been shown to be
combustible at elevated pressures. These mixtures, if ignited, may cause injury or property
damage. Additional health and safety information may be obtained from refrigerant
manufacturers.
 Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated
if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out
any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat
sources and maintain adequate ventilation.
 Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite.
When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes,
immediately wash them with clean water and consult a doctor.
STORING REFRIGERANT
 The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode,
scattering metal fragments and liquid refrigerant that can seriously injure you. Store the
refrigerant at temperatures below 40 °C {104 °F}.
REFRIGERANT SYSTEM SERVICE CAUTIONS

HANDLING INSUFFICIENT REFRIGERANT LEVEL
 If an insufficient refrigerant level is detected at troubleshooting, do not charge (add) the

refrigerant. Because an accurate amount of refrigerant cannot be determined from the pressure
indicated on the manifold gauge, never charge the refrigerant. If there is too much or too little
refrigerant from the refilling, there may be secondary problems such as damage to the refrigerant
cycle parts, or a decrease of cooling performance. Therefore, if it is determined that the refrigerant
level is insufficient, completely remove refrigerant from the refrigerant cycle and refill with
refrigerant to the specified amount.
HANDLING A/C RELATED PARTS
 There will be no effect on either performance or quality of A/C-related parts, including but not
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limited to the piping, etc., provided that said parts are serviced/repaired in accordance with
standard procedure.
 When serviced/repaired A/C units in locations where there is a considerable risk of contamination
from dirt or dust, plug up the openings on the parts to prevent dust/dirt from entering.
 When using adhesive material to cover openings on A/C parts, make sure that the adhesive side of
the material does not come in contact with the connectors on the parts.
 When the system is opened to atmosphere, there is no need to replace the condenser, or the receiver
dryer when it is housed within the condenser, provided that the unit is plugged accordingly.
HANDLING COMPRESSOR OIL
 Use only DENSO OIL8 compressor oil for this vehicle. Using a PAG oil other than DENSO OIL8
compressor oil can damage the A/C compressor.
 Do not spill DENSO OIL8 compressor oil on the vehicle. A drop of compressor oil on the vehicle
surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately.
 DENSO OIL8 compressor oil (PAG oil) has a higher moisture absorption efficiency than the
previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could
be damaged. Therefore, install caps immediately after using the compressor oil or removing
refrigerant system parts to prevent moisture absorption.
Fig. 1: DENSO OIL8 Compressor Oil Moisture Absorption Graph

REFRIGERANT SYSTEM GENERAL PROCEDURES

MANIFOLD GAUGE SET INSTALLATION
1. Fully close the valves of the manifold gauge.

2. Connect the charging hoses to the high and low-pressure side joints of the manifold gauge.
3. Connect the quick couplers to the ends of the charging hoses.
4. Connect the quick couplers to the charging valves.
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Fig. 2: Identifying Manifold Gauge Set Installation

REFRIGERANT CHARGING
CAUTION:  Do not exceed the specification when charging the system with
refrigerant. Doing so will decrease the efficiency of the air
conditioner or damage the refrigeration cycle parts.
CHARGING RECYCLED R-134A REFRIGERANT
1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device
manufacturer's instructions.
CHARGING PREPARATION
1. Install the manifold gauge set.

2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
3. Connect the vacuum pump hose to the center joint of the manifold gauge.
4. Connect the vacuum pump hose to the vacuum pump.
5. Connect the charging hose to the refrigerant tank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant (approx. quantity)
660-710 g {23.3-25.0 oz}
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Fig. 3: Identifying Charging Preparation

EVACUATION
1. Open all the valves of the manifold gauge.
CAUTION:  Close the manifold gauge valve immediately after stopping the
vacuum pump. If the valve is left open, the vacuum pump oil will
flow back into the refrigeration cycle and cause a decrease in
the efficiency of the air conditioner.
2. Start the vacuum pump and let it operate for 15 min.
Fig. 4: Starting Vacuum Pump

3. Verify that high-and low-pressure side readings of the manifold gauge are at - 101 kPa {-760 mmHg, -
29.9 inHg}. Close each valve of the manifold gauge.
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Fig. 5: Inspecting High And Low-Pressure Side Readings Of Manifold Gauge

AIRTIGHTNESS CHECK
1. Stop the vacuum pump and wait for 5 min.

2. Check the high-and low-pressure side readings of the manifold gauge.
 If the reading has changed, inspect for leakage and go to Evacuation. (See EVACUATION.)
 If the reading has not changed, go to Charging New R-134a Refrigerant. (See CHARGING NEW
R-134A REFRIGERANT.)
CHARGING NEW R-134A REFRIGERANT
1. Open the valve of the refrigerant tank.

2. Weigh the refrigerant tank to charge the suitable amount of refrigerant.
WARNING:  If the refrigerant system is charged with a large amount of

refrigerant when inspecting for gas leakage, and if any leakage
should occur, the refrigerant will be released into the
atmosphere. In order to prevent the accidental release of
refrigerant which can destroy the ozone layer in the
stratosphere, follow the proper procedures and charge with
only a small amount of refrigerant when inspecting for gas
leakage.
 If charging the system with refrigerant using service cans,
running the engine with the high-pressure side valve open is
dangerous. Pressure within the service cans will increase and
the cans could explode, scattering metal fragments and liquid
refrigerant that can seriously injure you. Therefore, do not open
the high-pressure side valve while the engine is running.
CAUTION:  Always being charging of refrigerant from the high-pressure

side. If changing is begun from the low-pressure side, the vanes
of the A/C compressor will not be released and abnormal noise
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may result.
3. Open the high-pressure side valve of the manifold gauge.
Fig. 6: Opening High-Pressure Side Valve Of Manifold Gauge

4. When the low-pressure side reading increases to 0.098 MPa {1.0 kgf/cm2 , 14 psi}, close the high-
pressure side valve of the manifold gauge.
5. Inspect for leakage from the cooler pipe/hose connections using a gas leak tester.
 If there is no leakage, go to Step 7.
 If leakage is found at a loose joint, tighten the joint, then go to the next step.
6. Inspect for leakage again.

 If there is no leakage after tightening the joint, go to the next step.
 If there is still a leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat
the charging procedure from evacuation.
Fig. 7: Closing High-Pressure Side Valve Of Manifold Gauge

WARNING:  If charging the system with refrigerant using service cans,

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7. Open the high-pressure side valve of the manifold gauge and charge with refrigerant until the weight of
refrigerant tank has decreased 330-355 g {11.7-12.5 oz} from the amount in Step 2.
Fig. 8: Opening High-Pressure Side Valve Of Manifold Gauge

8. Close the low-pressure side valve of the manifold gauge.
WARNING:  If charging the system with refrigerant using service cans,

Fig. 9: Closing Low-Pressure Side Valve Of Manifold Gauge

9. Start the engine and actuate the A/C compressor.

10. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of
the refrigerant tank has decreased regular amount from the amount in Step 2.
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11. Close the low-pressure side valve of the manifold gauge and the valve of the refrigerant tank.
12. Stop the engine and A/C compressor.
Fig. 10: Closing Low-Pressure Side Valve Of Manifold Gauge And Valve Of Refrigerant Tank
LEAK TEST
1. Inspect for leakage using the a gas leak tester.

 If there is no leakage, go to Step 3.
 If leakage is found at a loose joint, tighten the joint, then go to the next step.
2. Inspect for leakage again.

 If there is no leakage after tightening the joint, go to the next step.
 If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat
the charging procedure from evacuation.
3. Disconnect the manifold gauge from the charging valves.
4. Install the caps to the charging valves.
Fig. 11: Installing Caps To Charging Valves

REFRIGERANT RECOVERY
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1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device
manufacturer's instructions.
REFRIGERANT PRESSURE CHECK

1. Connect the manifold gauge. (See REFRIGERANT SYSTEM GENERAL PROCEDURES.)
2. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
3. Set the fan speed MAX HI.
4. Turn the A/C switch on.
5. Set to RECIRCULATE mode.
6. Set the temperature control to MAX COLD.
7. Set to VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and high-and low-pressure side reading of the manifold gauge.
10. Verify that the intersection of the pressure reading of the manifold gauge and ambient temperature is in
the shaded zone.
 If there is any malfunction, inspect the refrigerant system according to the troubleshooting chart.
Fig. 12: Ambient Temperature And High-And Low-Pressure Side Graph

REFRIGERANT SYSTEM PERFORMANCE TEST

1. Inspect the refrigerant pressure. (See REFRIGERANT PRESSURE CHECK.)
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2. Place a dry-bulb thermometer in the driver-side center ventilator outlet.

3. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
4. Set the fan speed to MAX HI.
5. Turn the A/C switch on.
6. Set to RECIRCULATE mode.
7. Set the temperature control to MAX COLD.
8. Set to VENT mode.
9. Close all the doors and windows.
10. Wait until the air conditioner output temperature stabilizes.
Stabilized condition
The A/C compressor repeatedly turns on and off at regular intervals.


11. After the blower air is stabilized, read the dry-bulb thermometer.
12. Verify the ambient temperature.
13. Verify that the temperature reading is in the shaded zone.
 If the there is any malfunction, inspect the refrigerant system according to the troubleshooting
chart.
Fig. 13: Ambient Temperature Graph

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2008 HVAC Technical Data (HVAC) - Mazda CX-9
2008 HVAC
Technical Data (HVAC) - Mazda CX-9
HVAC TECHNICAL DATA

HVAC TECHNICAL DATA
Item Specification
REFRIGERANT SYSTEM
Type R-134a
Refrigerant
Regular amount (approx. quantity) (g {oz}) 660-710 {23.3-25.0}
BASIC SYSTEM
Type DENSO OIL8
A/C Lubrication
compressor oil Sealed volume (approx. (ml {cc, fl
160(160,5.41}
quantity) oz})
CONTROL SYSTEM
A/C 0.35-0.65 {0.014-
Magnetic clutch clearance (mm {in})
compressor 0.025}
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2008 HVAC Symptom Troubleshooting (HVAC) - Mazda CX-9
2008 HVAC
Symptom Troubleshooting (HVAC) - Mazda CX-9
HVAC SYSTEM WIRING DIAGRAM

FRONT
Fig. 1: HVAC System Wiring Diagram - Front

REAR
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Fig. 2: HVAC System Wiring Diagram - Rear

FOREWORD
 The areas for inspection (steps) are given according to various circuit malfunctions. Use the following
chart to verify the symptoms of the trouble in order to diagnose the appropriate area.
No. TROUBLESHOOTING ITEM DESCRIPTION
 Problem with each vent and/or duct
Insufficient air (or no air) blown
1  Front airflow mode does not change when switching front
from front vents
mode switch.
 Malfunction in front blower system
Amount of air blown from front
2  Amount of air blown front vents does not change when
vents does not change
switching front climate control unit t airflow control dial.
Air intake mode from front vent  Malfunction in A/C unit and/or front climate control unit
3 air intake mode switching system
does not change
 Air intake mode does not change when switching
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REC/FRESH mode.
 Malfunction in A/C unit and/or front climate control unit
No temperature control with front air mix system
4
climate control unit  Temperature does not change when switching front
climate control unit temperature setting dial.
 Malfunction in A/C compressor control system and/or air
intake mode switching system
5 Windshield fogged  A/C compressor does not operate while airflow mode is
DEFROSTER or HEAT/DEF modes.
 Air intake mode does not change to FRESH while airflow
mode is in DEFROSTER or HEAT/DEF modes.
 Problem with each rear vent and/or duct
Insufficient air (or no air) from rear
6  Rear airflow mode does not change when front and/or
vent
rear climate control unit mode switches.
 Malfunction in rear blower motor system
Amount of air from rear vent does  Amount of air blowing rear vents does not change when
7
not change switching front and/or rear climate control unit airflow
volume control dial.
Air from front/rear vents not cold  Malfunction in A/C basic system
8
enough  Magnetic clutch operates but A/C system malfunctions.
 Malfunction in A/C compressor control system
9 No cool air from front/rear vents  Magnetic clutch does not operate when the A/C system is
turned ON.
 Problem with A/C basic system installation
10 Noise while operating A/C system  Noise from magnetic clutch, A/C compressor, hose or
refrigerant line.
 Malfunction in A/C unit and/or front climate control unit
Dual A/C control function does not dual A/C control system
11
operate  Driver or passenger-side temperature control dial does not
operate individually.
NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM FRONT VENTS

NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM FRONT VENTS DESCRIPTION AND
POSSIBLE CAUSE
1 Insufficient air (or no air) blown from front vents
 Problem with each vent and/or duct
DESCRIPTION
 Front airflow mode does not change when switching front mode switch.
 Malfunction in front airflow mode actuator

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 Malfunction in front VENT mode system

POSSIBLE CAUSE  Malfunction in front HEAT mode system
 Malfunction in front DEFROSTER mode system
NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM FRONT VENTS DIAGNOSTIC
PROCEDURE
INSPECT FRONT AIRFLOW MODE Yes Go to the next step.
ACTUATOR
1 Repair or replace malfunctioning part
No
 Is it okay?
in accordance with inspection result.
INSPECT TO SEE WHETHER MALFUNCTION
IS IN FRONT VENT MODE OR OTHER MODES Yes Go to Step 5.
2
 Does air blow out when in the front VENT
mode?
INSPECT FRONT VENT Yes Remove obstruction, then go to Step 9.
3
 Is the front vent clogged? No Go to the next step.
Inspect the duct for clogging,
VERIFY THAT DUCT IN DASHBOARD IS Yes deformation and air leakage, then go
INSTALLED to Step 9.
4
Is the duct in the dashboard properly installed? Install the duct securely in the proper
 No
position, then go to Step 9.
IS IN FRONT HEAT MODE OR FRONT
DEFROSTER MODE
5
Inspect the vent for clogging, then go
 Does air blow out when in the front HEAT
No
to Step 9.
mode?
INSPECT FRONT DEFROSTER MODE Operation is normal. Recheck
Yes
6 malfunction symptoms.
 Does air blow out when in the front
DEFROSTER mode? No Go to the next step.
INSPECT FRONT VENT Yes Remove obstruction, then go to Step 9.
7
 Is the vent clogged? No Go to the next step.
Inspect the duct for clogging,
VERIFY THAT DEFROSTER DUCT IS Yes deformation, and air leakage, then go
INSTALLED to the next step.
8
Is the defroster duct properly installed? Install the duct securely in proper
 No
position, then go to the next step.
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Troubleshooting completed. Explain

Yes
VERIFY REPAIR repairs to customer.
9 Recheck malfunction symptoms, then
 Does air blow out? No repeat from Step 1 if the malfunction
recurs.
NO.2 AMOUNT OF AIR BLOWN FROM FRONT VENTS DOES NOT CHANGE
NO.2 AMOUNT OF AIR BLOWN FROM FRONT VENTS DOES NOT CHANGE DESCRIPTION
AND POSSIBLE CAUSE
2 Amount of air blown from front vents does not change.
 Malfunction in front blower system
DESCRIPTION  Amount of air blown front vents does not change when switching front climate
control unit airflow control dial.
 Front A/C unit malfunction
POSSIBLE  Front blower motor malfunction
CAUSE  Malfunction in front power MOS FET system
 Front climate control unit malfunction
 When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors
while doing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, inspect to make sure connectors, terminals and wiring harness are
connected correctly and undamaged.
NO.2 AMOUNT OF AIR BLOWN FROM FRONT VENTS DOES NOT CHANGE DIAGNOSTIC
PROCEDURE
INSPECT HEATER BLOWER 40 A FUSE Replace the fuse, then go to
1 Step 15. If the fuse burns out
 Is it normal?
No
immediately, go to the next
step.
INSPECT TO SEE WHETHER MALFUNCTION IS IN
A/C UNIT OR ELSEWHERE Yes Go to the next step.

 Turn the fan switch to ON position.
 Recirculate air inside the vehicle. No Go to Step 4.
 Does the front blower motor operate normal speed?
Yes
Remove obstruction, then go to
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Step 15.
INSPECT FRONT A/C UNIT INTAKE VENT
3 Inspect if there are any
 Is front A/C unit intake vent clogged? No obstruction in the A/C unit
passage, then go to Step 15.
FRONT BLOWER RELAY SYSTEM OR FRONT
POWER MOS FET SYSTEM Yes Go to Step 8.
Turn the ignition switch to ON position.

4*  Turn the fan switch to OFF position.
 Measure the voltage at the following front blower motor

terminal. No Go to the next step.
 Terminal B (blower motor operation signal)
 Is voltage approx. 12 V?

WIRING HARNESS (OPEN CIRCUIT BETWEEN FUSE Yes Go to the next step.
BLOCK AND FRONT BLOWER RELAY) OR
ELSEWHERE
5* Measure the voltage at the following front blower relay


Repair the wiring harness
terminals. between the front blower relay
No
and A/C 7.5A HEATER 50 A
 Terminal B (IG2 signal)
fuse, then go to Step 15.
 Terminal E (B+ signal)

WIRING HARNESS (OPEN CIRCUIT BETWEEN Yes Go to the next step.
FRONT BLOWER RELAY AND GROUND) OR
ELSEWHERE
6* Repair the wiring harness
Measure the voltage at the following front blower relay

terminal. No between the front blower relay
and ground, then go to Step 15.
 Terminal D (GND signal)

WIRING HARNESS (OPEN OR SHORT CIRCUIT Repair the wiring harness
BETWEEN FRONT BLOWER RELAY AND FRONT between the front blower relay
BLOWER MOTOR) OR BLOWER RELAY Yes
and blower motor, then go to
7* Step 15.
 Measure the voltage at the following front blower relay
terminal.
 Terminal A (blower motor operation signal)
Replace the front blower relay,
No
then go to Step 15.

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BLOWER MOTOR OR ELSEWHERE Yes Go to the next step.
Measure the voltage at the following blower motor


8* terminal. Inspect the front blower motor,
No
then go to Step 15.

WIRING HARNESS (OPEN OR SHORT CIRCUIT
BETWEEN FRONT BLOWER MOTOR AND FRONT
POWER MOS FET) OR ELSEWHERE
Measure the voltage at the following terminal of front No
 between the front blower
power MOS FET. motor and front power MOS
FET, then go to Step 15.
 Terminal A (blower motor operation signal)

WIRING HARNESS (OPEN OR SHORT CIRCUIT
BETWEEN FRONT POWER MOS FET AND GROUND)
OR ELSEWHERE
 Measure the voltage at the following front power MOS between the front power MOS
No
FET terminal. FET and ground, then go to
Step 15.
 Terminal E (blower motor operation signal)
INSPECT FRONT A/C UNIT

Inspect the fan for following:.

 Is the fan free of interference with the A/C unit

11 case? Remove obstruction, repair or
 Is the fan free of foreign material and
No replace the fan and front A/C
obstruction? unit case, then go to Step 15.
 Is the fan normal?

FRONT POWER MOS FET OR ELSEWHERE
Replace the front power MOS
Disconnect front power MOS FET connector.

Yes
FET, then go to Step 15.
12*  Turn the fun switch to 1st position from off.
 Measure the voltage at the following front power MOS

FET terminal.
 Terminal B (blower motor control signal) No Go to the next step.
INSPECT TO SEE WHETHER MALFUNCTION IS IN Yes Go to the next step.

WIRING HARNESS (OPEN CIRCUIT BETWEEN
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FRONT POWER MOS FET AND FRONT CLIMATE

CONTROL UNIT) OR ELSEWHERE


 Disconnect front climate control unit connector. Repair the wiring harness
 Inspect for continuity at the following terminals
between the front power MOS
13* No
between the front power MOS FET and front climate FET and climate control unit,
control unit. then go to Step 15.
 Terminal F-1R (blower motor control signal)
 Terminal B-1P (blower motor feedback signal)

CLIMATE CONTROL UNIT OR WIRING HARNESS Repair the wiring harness
(SHORT TO GROUND IN WIRING HARNESS between the front power MOS
Yes
BETWEEN FRONT POWER MOS FET AND FRONT FET and ground, then go to the
CLIMATE CONTROL UNIT) next step.
14*
 Inspect for continuity at the following terminal between
the power MOS FET and ground. Replace the front climate
No control unit, then go to the next
 Terminal D (blower motor control signal)- ground
step.
Troubleshooting completed.
Yes
Explain repairs to customer.
VERIFY REPAIR
15 Recheck malfunction
 Is air discharged from vent?
symptoms, then repeat from
No
Step 1 if the malfunction
recurs.
NO.3 AIR INTAKE MODE FROM FRONT VENT DOES NOT CHANGE
NO.3 AIR INTAKE MODE FROM FRONT VENT DOES NOT CHANGE DESCRIPTION AND
POSSIBLE CAUSE
3 Air intake mode from front vent does not change.
 Malfunction in A/C unit and/or front climate control unit air intake mode
DESCRIPTION switching system
 Air intake mode does not change when switching REC/FRESH mode.
POSSIBLE  Air intake actuator malfunction
CAUSE  Air intake door malfunction
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NO.3 AIR INTAKE MODE FROM FRONT VENT DOES NOT CHANGE DIAGNOSTIC
PROCEDURE
INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
1 Replace the air intake actuator,
 Is the air intake actuator normal?
No
then go to Step 9.
(OPEN OR SHORT CIRCUIT) IS IN AIR INTAKE
ACTUATOR, WIRING HARNESS (BETWEEN
CLIMATE CONTROL UNIT AND AIR INTAKE
ACTUATOR) OR ELSEWHERE Yes Go to the next step.

 Measure the voltages at the following climate control
unit terminals.
2*
 Terminal 1O (24-pin, RECIRCULATE motor
drive signal)
 Terminal 1M (24-pin, FRESH motor drive
signal)
No Go to Step 4.
(See FRONT CLIMATE CONTROL UNIT
INSPECTION .)
Are voltages normal?



(OPEN OR SHORT CIRCUIT) IS IN AIR INTAKE Yes Go to Step 7.
ACTUATOR OR WIRING HARNESS (BETWEEN
ACTUATOR)
 Measure the voltages at the following air intake

actuator terminals.
3*  Terminal C (RECIRCULATE motor drive
signal) between the climate control unit
No
 Terminal A (FRESH motor drive signal) and air intake actuator, then go
 Are voltages as shown below? to Step 9.
 Terminal C: approx. 0.5 V during FRESH and
approx. 10 V during RECIRCULATE
 Terminal A: approx. 10 V during FRESH and
approx. 0.5 V during RECIRCULATE
AIR INTAKE ACTUATOR OR ELSEWHERE
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Disconnect the air intake actuator connector.


 Measure the voltages at the following climate control

Inspect the air intake actuator,
unit terminals. Yes
then go to Step 9.
 Terminal 10 (RECIRCULATE motor drive
4 signal)
 Terminal 1M (FRESH motor drive signal) (See
FRONT CLIMATE CONTROL UNIT
 Are voltages normal?

WIRING HARNESS (SHORT TO B+ BETWEEN Yes Go to the next step.
ACTUATOR) OR ELSEWHERE
Disconnect the climate control unit connector.


5  Measure the voltages at the following climate control
unit terminals. between the climate control unit
No
and air intake actuator, then go
 Terminal 1O (RECIRCULATE motor drive
to Step 9.
signal)
 Terminal 1M (FRESH motor drive signal)
 Are voltages approx. 0 V?

WIRING HARNESS (SHORT TO GROUND
BETWEEN CLIMATE CONTROL UNIT AND AIR
INTAKE ACTUATOR) OR ELSEWHERE Repair the wiring harness
between the climate control unit
Yes
and air intake actuator, then go
6  Inspect for continuity at the following terminals to Step 9.
between the climate control unit and ground.
 Terminal 10 (RECIRCULATE motor drive
signal)
 Terminal 1M (FRESH motor drive signal)
INSPECT AIR INTAKE LINK Yes Go to the next step.

Inspect the air intake links for followings:

 is there grease on link?

Apply grease to the links. If any
7
 Are the links securely and properly installed? the links are damaged, replace
No
 Are the links free of obstructions and
the air intake actuator, then go to
hindrances? Step 9.
 Are the above items normal?

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CLIMATE CONTROL UNIT OR AIR INTAKE DOOR Replace the climate control unit,
Yes
 Inspect the A/C unit air intake door.
Remove obstruction, or install
 Is the door free of obstructions, cracks, and
8 the doors in the proper position.
damage? No If any doors are cracked or
 Are the doors securely and properly installed? damaged, replace them, then go
 Are the above items normal? to the next step.
Yes
VERIFY REPAIR Explain repairs to customer.
9 Recheck malfunction symptoms,
 Does the air intake mode change smoothly? No then repeat from Step 1 if the
malfunction recurs.
NO.4 NO TEMPERATURE CONTROL WITH FRONT CLIMATE CONTROL

UNIT
NO.3 AIR INTAKE MODE FROM FRONT VENT DOES NOT CHANGE DESCRIPTION AND
POSSIBLE CAUSE
4 No temperature control with front climate control unit
 Malfunction in A/C unit and/or front climate control unit air mix system
DESCRIPTION  Temperature does not change when switching front climate control unit
temperature setting dial.
 A/C unit air intake link, air intake crank, air intake rod, air intake wire, wire
clamp malfunction
POSSIBLE
 Climate control unit rack-and-pinion, air intake wire malfunction
CAUSE
 A/C unit air intake door malfunction
 Heater piping malfunction
NO.3 AIR INTAKE MODE FROM FRONT VENT DOES NOT CHANGE DIAGNOSTIC
PROCEDURE
INSPECT COOLANT TEMPERATURE Yes Go to the next step.
1
 Is the engine at operating temperature? No Warm up the engine, then go to Step 9.
INSPECT A/C UNIT AIR INTAKE
SYSTEM
 Inspect the A/C unit air intake links, air

intake cranks, air intake rods, air intake
actuator, and wire clamp.
Microsoft
Is there grease on links and cranks?


Apply grease or install the links, cranks, and
 Are links, cranks, and rods securely
rods securely in their proper positions, repair
2 installed in their proper positions? No
or replace the air intake actuator or wire
 Is wire clamp free of deformation? clamp, then go to Step 9.
VERIFY THAT AIR INTAKE WIRE FROM

A/C UNIT IS POSITIONED SECURELY Yes Go to the next step.
AND CORRECTLY (IF AVAILABLE)
3
Is the air intake wire securely installed in No Adjust the air intake wire or install securely

the correct position in relation to the A/C in the correct position, then go to Step 9.
unit air intake links?
INSPECT CLIMATE CONTROL UNIT Yes Go to the next step.
4 Repair or replace the climate control unit,
 Is the climate control unit normal?
No
then go to Step 9.
INSPECT A/C UNIT
Yes Remove obstruction, then go to Step 9.
5  Is there any foreign material or
obstruction in the A/C unit air intake No Go to the next step.
doors?
INSPECT A/C UNIT AIR INTAKE DOOR Yes Inspect the air intake door for cracks or
damage, then go to the next step.
6
 Is the A/C unit air intake door securely Install the air intake door securely in the
and properly installed? No
proper position, then go to the next step.
INSPECT WIRING HANESS BETWEEN
CLIMATE CONTROL UNIT AND FRONT
AIR MIX ACTUATOR
 Disconnect the front climate control unit

connector (24-pin, 16-pin).
 Inspect following wiring harness and
connectors for open, short or poor
connection of terminals.
Repair or replace malfunctioning part, then
 Between terminals 1A (climate Yes
7 go to Step 9.
control unit) and G (driver-side
front air mix actuator)
 Between terminals 1F (climate
control unit) and F (driver-side
 Between terminals 2F (climate
control unit) and E (driver-side
 Between terminals 1C (climate
control unit) and G (passenger-side
Microsoft

 Between terminals 1E (climate
control unit) and F (passenger-side
 Between terminals 2G (climate No Go to the next step.
control unit) and E (passenger-side
 Is there any open, short or poor
connection of terminals?
INSPECT HEATER LINE
Operation is normal. Recheck malfunction
Yes
Inspect the heater lines.
 symptoms.
 Is the heater piping free of damage
and cracks?
 Are the heater piping connections
8 free of engine coolant leakage? If heater piping connections are loose,

 Are the heater piping connections tighten the connections to the specified
securely tightened? No torque.
 Are the heater piping installation
Repair or replace the heater piping, then go
points on A/C unit free of engine to the next step.
coolant leakage?
VERIFY REPAIR Troubleshooting completed.

Yes
9
 Does the unit operate in every temperature Recheck malfunction symptoms, then repeat
setting? No
from Step 1 if the malfunction recurs.
NO.5 WINDSHIELD FOGGED

NO.5 WINDSHIELD FOGGED DESCRIPTION AND POSSIBLE CAUSE
5 Windshield fogged.
 Malfunction in A/C compressor control system and/or air intake mode
switching system
DESCRIPTION  A/C compressor does not operate while airflow mode is DEFROSTER or
HEAT/DEF modes.
 Air intake mode does not change to FRESH while airflow mode is in
DEFROSTER or HEAT/DEF modes.
 Front climate control unit (B+ signal) system malfunction
 Air intake actuator malfunction
POSSIBLE
CAUSE  Front climate control unit (RECIRCULATE, FRESH signal) system
malfunction
 A/C unit air intake door malfunction
Microsoft
NO.5 WINDSHIELD FOGGED DIAGNOSTIC PROCEDURE

COOL AIR BLOW OUT INSPECTION Yes Go to the next step.
1 When both the A/C and fan switch in the front

Go to Step 1 of troubleshooting
climate control unit are on, does cool air blow out No
index No.8.
from the front vent?
INSPECT FRONT CLIMATE CONTROL UNIT Yes Go to the next step.
POWER SUPPLY FUSE FOR B+ SIGNAL Inspect for a short to ground on
2 blown fuse circuit.
 Is the front climate control unit power supply fuse
No
Repair or replace if necessary.
for B+ signal normal? Install appropriate amperage fuse.
INSPECT AIR INTAKE ACTUATOR
Inspect the air intake actuator for followings.

3  Is there grease on the link?

Apply grease or install the link
 Is the link securely and properly positioned? No properly and securely, remove
 Is the link free of obstructions? obstruction, then go to Step 14.
INSPECT WIRING HARNESS BETWEEN FUSE

BLOCK AND FRONT CLIMATE CONTROL UNIT Yes Go to the next step.
FOR CONTINUITY
Disconnect the front climate control unit connector


*4 (24-pin). Repair the wiring harness between
 Turn the ignition switch to the ON position. No the fuse block and front climate
 Measure the voltage at front climate control unit control unit, then go to Step 14.
terminal 1B (B+ signal).
INSPECT WIRING HARNESS BETWEEN FRONT Yes Go to the next step.

CLIMATE CONTROL UNIT AND GROUND FOR
VOLTAGE
*5 Repair the wiring harness between
 Measure the voltage at front climate control unit No the front climate control unit and
terminal 1X (Ground). ground, then go to Step 14.
Microsoft
VERIFY WHETHER MALFUNCTION IS IN A/C

UNIT AIR INTAKE DOOR OR ELSEWHERE

 Connect the climate control unit connector (24-

pin).
6  Remove the air intake actuator.
 Set the fan switch to 4th position. No Go to Step 12.

 Does the air intake mode (RECIRCULATE,
FRESH) change smoothly when the air intake link
is operated by hand?
INSPECT AIR INTAKE ACTUATOR Yes Go to the next step.
7 Inspect the air intake actuator. (See AIR INTAKE

ACTUATOR INSPECTION .) Replace the air intake actuator, go
No
to Step 14.
 Is it normal?
INSPECT AIR INTAKE SELECTOR SWITCH AND

DEFROSTER SWITCH IN FRONT CLIMATE Yes Go to the next step.
CONTROL UNIT
8
Measure the voltage at front climate control unit
 Replace the front climate control
No
connector (24-pin) terminals 1O and 1M. unit, then go to Step 14.
 Is it normal?
INSPECT WIRING HARNESS BETWEEN FRONT

CLIMATE CONTROL UNIT AND AIR INTAKE Yes Go to the next step.
ACTUATOR FOR CONTINUITY


*9  Is there continuity between the following front

climate control unit terminals and air intake Repair the wiring harness between
actuator terminals? No the front climate control unit and air
intake actuator, then go to Step 14.
 Terminal C - Terminal 10 (RECIRCULATE
signal)
 Terminal A - Terminal 1M (FRESH signal)

ACTUATOR FOR SHORT TO GROUND Repair the wiring harness between
Yes the front climate control unit and air
*10  Is there continuity between the following front
climate control unit terminals and ground?
 Terminal 10 (RECIRCULATE signal)
 Terminal 1M (FRESH signal)
Microsoft

Repair the wiring harness between
ACTUATOR FOR SHORT TO B+
Yes the front climate control unit and air

*11  Measure the voltage at the following front climate
control unit terminals.
 Terminal 10 (RECIRCULATE signal) Replace the front climate control
No
 Terminal 1M (FRESH signal) unit, then go to Step 14.
INSPECT A/C UNIT AIR INTAKE DOOR Remove obstruction, then go to

Yes
12 Step 14.
 Is there any foreign material or obstruction in the
A/C unit air intake door? No Go to the next step.
Inspect the air intake door for
VERIFY THAT A/C UNIT AIR INTAKE DOOR IS Yes cracks or damage, then go to the
POSITIONED SECURELY AND PROPERLY next step.
13
 Is the A/C unit air intake door securely and
Install the air intake door securely
properly positioned? No in the proper position, then go to
the next step.
Yes
VERFY REPAIR Explain repairs to customer.
 Does the malfunction disappear? No then repeat from Step 1 if the
malfunction recurs.
NO.6 INSUFFICIENT AIR (OR NO AIR) BLOWN REAR VENTS

NO.6 INSUFFICIENT AIR (OR NO AIR) BLOWN REAR VENTS DESCRIPTION AND POSSIBLE
CAUSE
6 Insufficient air (or no air) from rear vents
 Problem with each rear vent and/or duct
DESCRIPTION  Rear airflow mode does not change when front and/or rear climate control
unit mode switches.
 Rear vent mode malfunction
 Rear heat mode malfunction
POSSIBLE
CAUSE  Rear airflow mode actuator malfunction
 Open, short circuit in wiring or poor connection between front and rear
climate control unit
Microsoft
NO.6 INSUFFICIENT AIR (OR NO AIR) BLOWN REAR VENTS DIAGNOSTIC PROCEDURE
VENT MODE
1
 Does air blow out when in the rear vent mode?
VERIFY THAT REAR HEATER CONTROL USING

FRONT CLIMATE CONTROL UNIT Yes Go to Step 4.
2 Turn the rear heater to ON and OFF using the front A/C

control panel.
 Is it possible that the rear heater turns ON and OFF using
the front climate control unit?
WIRING HARNESS (OPEN, SHORT OR POOR
CONNECTION OF TERMINALS BETWEEN FRONT
AND REAR CLIMATE CONTROL UNIT) OR
ELSEWHERE Repair or replace
Yes malfunctioning part, then go
 Inspect for open, short or poor connection of terminals to Step 10.
3 between front and rear climate control unit.
 Terminal 3E (front)-terminal A (rear)
 Terminal 3G (front)-terminal C (rear)
 Terminal 3H (front)-terminal D (rear)
 Terminal 31 (front)-terminal E (rear)
 Terminal 3C (front)-terminal F (rear)

Is there any open, short or poor connection of terminals?

INSPECT VENT Remove obstruction, then go

Yes
4 to Step 10.
 Is the vent clogged? No Go to the next step.
Inspect the duct for
clogging, deformation and
Yes
VERIFY THAT REAR A/C DUCT IS INSTALLED air leakage, then go to Step
5 10.
 Is the rear A/C duct properly installed? Install the duct securely in
No the proper position, then go
to Step 10.
INSPECT TO SEE WHETHER MALFUNCTION IS IN Yes Go to the next step.
REAR HEAT MODE
6 Inspect the rear vent for
No
Does air blow out when in the rear heat mode?

clogging, then go to Step 10.
INSPECT REAR VENT Remove obstruction, then go
Yes
7 to Step 10.
 Is the rear vent clogged? No Go to the next step.
Microsoft
INSPECT REAR MODE ACTUATOR Yes Go to the next step.
8 (See REAR AIRFLOW MODE ACTUATOR

 Replace the rear airflow
INSPECTION .) No mode actuator, then go to
 Is the rear airflow mode actuator normal?
Step 10.
CONNECTION OF TERMINALS BETWEEN FRONT
AND REAR AIRFLOW MODE ACTUATOR) OR
ELSEWHERE Repair or replace
Yes malfunctioning part, then go
Inspect for open, short or poor connection of terminals

to next step.
between front and rear airflow mode actuator.
 Terminal 2P (front climate control unit)- terminal C
(rear airflow mode actuator)
9
 Terminal 2B (front climate control unit)- terminal A
 Terminal 2D (front climate control unit)- terminal E
(rear airflow mode actuator) Replace the front climate
 Terminal 1N (front climate control unit)- terminal F No control unit, go to the next
(rear airflow mode actuator) step.
 Terminal 1L (front climate control unit)- terminal G
 Is there any open, short or poor connection of terminals?
Yes
VERIFY REPAIR
10 Recheck malfunction
 Does air blow from the rear A/C vent mode?
symptoms, then repeat from
No
Step 1 if the malfunction
recurs.
NO.7 AMOUNT OF AIR FROM REAR VENTS DOES NOT CHANGE

NO.7 AMOUNT OF AIR FROM REAR VENTS DOES NOT CHANGE DESCRIPTION AND
POSSIBLE CAUSE
7 Amount of air from rear vents does not change
 Malfunction in rear blower motor system
DESCRIPTION  Amount of air blowing rear vents does not change when switching front and/or
rear climate control unit airflow volume control dial.
POSSIBLE  Rear A/C unit malfunction

CAUSE  Rear blower motor malfunction
 Rear power MOS FET malfunction
Microsoft
 Rear climate control unit malfunction
NO.7 AMOUNT OF AIR FROM REAR VENTS DOES NOT CHANGE DIAGNOSTIC PROCEDURE
IS IN REAR A/C UNIT OR ELSEWHERE Yes Go to the next step.
 Turn the rear fan switch the ON position. No Go to Step 3.
 Does the blower motor rotate smoothly?
Remove obstruction, then go to Step
Yes
INSPECT REAR A/C UNIT INTAKE VENT 13.
2 Inspect if there are any obstructions
 Is the rear A/C unit intake vent clogged? No in the rear A/C unit passage, then go
to Step 13.
IS IN REAR BLOWER RELAY SYSTEM OR
REAR POWER MOS FET
Turn the ignition switch to ON position.

3*  Turn the rear fan switch to OFF position.
 Measure the voltage at the following rear blower

motor terminal.
 Terminal B (rear blower motor operation No Go to the next step.
signal)
 Is the voltage normal (B+)?
INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.

IS IN WIRING HARNESS (OPEN OR SHORT
CIRCUIT BETWEEN FUSE BLOCK AND REAR If the terminal A voltage is not
BLOWER RELAY) OR ELSEWHERE normal, repair or replace wiring
harness between A/C 7.5 A fuse and
4* rear blower relay.
 Measure the voltage at the following rear relay
No If the terminal D voltage is not
terminals.
normal, repair or replace wiring
 Terminal A (IG2 signal) harness between R.HEATER 40 A
 Terminal D (B+ signal) fuse and rear blower relay. Then go
to Step 13.
Microsoft
INSPECT TO SEE WHETHER MALFUNCTION Yes Go to the next step.

IS IN WIRING HARNESS (OPEN CIRCIT
BETWEEN REAR BLOWER RELAY AND
GROUND) OR ELSEWHERE
5* Repair or replace for open circuit
Measure the voltage at the following rear blower No between rear blower relay and GND,

relay terminal. then go to Step 13.
 Terminal E (GND signal)

Repair or replace for open or short
CIRCUIT BETWEEN REAR BLOWER RELAY
circuit between rear blower relay and
AND REAR BLOWER MOTOR) OR Yes
rear blower motor, then go to Step
ELSEWHERE
6* 13.
 Measure the voltage at the following rear blower
relay terminal.
Replace the rear blower relay, then
 Terminal B (blower motor operation signal) No
go to Step 13.

IS IN REAR BLOWER MOTOR OR ELSEWHERE Yes Go to the next step.
7* Measure the voltage at the following rear blower


motor terminal. Replace the rear blower motor, then
No
 Terminal A (blower motor operation signal) go to Step 13.

CIRCUIT BETWEEN REAR BLOWER MOTOR
AND REAR POWER MOS FET) OR ELSEWHERE
8* Repair or replace for open or short
 Measure the voltage at the following rear power circuit between rear blower motor
No
MOS FET terminal. and rear power MOS FET, then go to
Step 13.

IS IN WIRING HARNESS (OPEN CIRCUIT Yes Go to the next step.
BETWEEN REAR POWER MOS FET AND
GROUND) OR ELSEWHERE
9* Repair or replace for open circuit
 Is there continuity at the following terminals? No between rear power MOS FET and
GND, then go to Step 13.
 Terminal (wiring harness-side connector)
A-GND
INSPECT REAR A/C UNIT
Microsoft
 Inspect the fan in rear A/C unit. Yes Go to the next step.
 Is the fan free of interference with the rear
A/C unit case? Remove obstruction, repair or
10
 Is the fan free of foreign material and No replace the fan blower unit case, then
obstructions? go to Step 13.
 Is the fan normal?
IS IN WIRING HARNESS (OPEN CIRCUIT
Replace the rear power MOS FET,
BETWEEN REAR POWER MOS FET AND Yes
CLIMATE CONTROL UNIT) OR ELSEWHERE


 Disconnect the front climate control unit

11* connector (24-pin).
 Is there continuity following terminals at harness-
Repair or replace for open circuit
side connector. between the rear power MOS FET
No
and the front climate control unit,
 Terminal D (rear power MOS FET) and
then go to Step 13.
terminal 1T (front climate control unit)
 Terminal C (rear power MOS FET) and
terminal 1V (front climate control unit)
INSPECT TO SEE WHETHER MALFUNCTION Troubleshooting completed. Explain
IS IN REAR POWER MOS FET OR ELSEWHERE Yes repairs to customer.
12
 Is the air discharged from rear vent after replace Replace the front climate control
No
the rear power MOS FET? unit, then go to the next step.
Troubleshooting completed. Explain
Yes
VERIFY REPAIR repairs to customer.
 Is the air discharged from rear vent? No then repeat from Step 1 if the
malfunction recurs.
NO.8 AIR FROM FRONT/REAR VENTS NOT COLD ENOUGH

NO.8 AIR FROM FRONT/REAR VENTS NOT COLD ENOUGH DESCRIPTION AND POSSIBLE
CAUSE
8 Air from front/rear vents not cold enough.
 Malfunction in A/C basic system
DESCRIPTION
 Magnetic clutch operates but A/C system malfunctions.
 Drive belt malfunction

 A/C unit or condenser malfunction
POSSIBLE  Receiver/drier or expansion valve malfunction (valve closes too much)
Microsoft
CAUSE  Malfunction in refrigerant lines

 A/C compressor system malfunction, insufficient compressor oil
 Over filling of compressor oil, malfunction in expansion valve or A/C unit air
mix link system
NO.8 AIR FROM FRONT/REAR VENTS NOT COLD ENOUGH DIAGNOSTIC PROCEDURE
INSPECT DRIVE BELT
 Inspect the drive belt.
1 Adjust or replace the drive belt, then go to Step 20.
(See DRIVE BELT
INSPECTION [MZI-3.7] .) No (See DRIVE BELT
Is it normal?

INSPECT REFRIGERANT SYSTEM

PERFORMANCE
Operation is normal. (Recheck malfunction
Yes
Perform refrigerant system

symptoms.)
2 performance test. (See
REFRIGERANT SYSTEM
PERFORMANCE TEST .) No Go to the next step.
 Is the operation normal?
INSPECT TO SEE WHETHER

MALFUNCTION IS IN A/C UNIT Yes Go to the next step.
INTAKE AND CONDENSER OR
3 ELSEWHERE
 Are the refrigerant high-pressure No Go to Step 6.

and low-pressure values both high?
Remove obstruction, then go to Step 20. (If air does
not reach the evaporator in the A/C unit, heat
INSPECT A/C UNIT INTAKE Yes exchange does not occur and refrigerant pressure
4 becomes high. Therefore, removal of obstruction is
 Is the A/C unit intake clogged? necessary.)
INSPECT CONDENSER Adjust refrigerant to the specified amount, then go

Yes
to Step 20. (Excessive amount of refrigerant.)
5  Inspect the condenser.
(See CONDENSER No
INSPECTION .) Replace the condenser, or repair and clean the
Microsoft
Is it normal?

condenser fins, then go to Step 20.
MALFUNCTION IS IN EXPANSION
VALVE, RECEIVER/DRIER AND
REFRIGERANT LINES OR
6
ELSEWHERE
No Go to Step 14.
Are the refrigerant high-pressure

and low-pressure values low?
VALVE AND RECEIVER/DRIER OR
ELSEWHERE
Immediately after the A/C


7
compressor operates, does the
refrigerant high-pressure value
momentarily rise to correct value,
No Go to Step 10.
then fall and stay below it? (Is there
negative pressure on low-pressure
side?)
VALVE OR RECEIVER/DRIER
Turn the A/C switch off and let the


Replace the condenser and vacuum the refrigerant
8 air conditioner stop for 10 min.
line more than 30 min by the vacuum pump, add
 Start the engine. No refrigerant to the specified level, then go to Step 20.
 Turn the both A/C switch and fan (Since water has intermixed in the receiver/drier
switch on. and it is saturated, replacement is necessary.)
 Does the malfunction occur after
the A/C compressor turns on?
VERIFY THAT EXPANSION VALVE
HEAT-SENSING TUBE WITHIN A/C Replace the expansion valve, then go to Step 20.
UNIT IS POSITIONED SECURELY Yes (Since the valve closes too much, replacement is
AND CORRECTLY necessary.)
9
 Is the expansion valve heat-sensing Install the heat-sensing tube securely in the proper
tube in the A/C unit securely No
position, then go to Step 20.
installed in the proper position?
INSPECT REFRIGERANT LINE
 Inspect the refrigerant lines. Yes Go to the next step.

 Is the piping free of damage
and cracks?
Microsoft
Are the piping connections


free of oil grime? (Visual
inspection)
 Are the piping connections
free of gas leakage?
 Are the piping installation
points on the condenser free
of gas leakage?
points on the receiver/drier If the piping or A/C component (s) are damaged or
free of gas leakage? cracked, replace them.
10 No
Then go to Step 20.
points on the A/C If there is no damage, go to Step 13.
compressor free of gas
leakage?
points on the A/C unit free of
gas leakage?
 Perform gas leakage
inspection using a gas leak
tester.
If the vane makes a noise, add 10 ml {10 cc, 0.34 fl

INSPECT EVAPORATOR PIPING oz} of compressor oil to the A/C compressor.
CONNECTION IN A/C UNIT FOR Yes Verify that the noise is no longer heard.
GAS LEAKAGE Adjust refrigerant to the specified amount, then go
11 to Step 20.
 Are piping the connections for the
evaporator in the A/C unit free of If the piping is damaged or cracked, replace it.
gas leakage? No Then go to Step 20.
If there is no damage, go to the next step.
Tighten the connections to the specified torque,
INSPECT EVAPORATOR PIPING Yes adjust both compressor oil and refrigerant to the
CONNECTION IN A/C UNIT FOR specified amount, then go to Step 20.
LOOSE If the vane makes a noise, add 10 ml {10 cc, 0.34 fl
12
oz} of compressor oil to the A/C compressor.
 Are the piping connections for the No Verify that the noise is no longer heard.
evaporator in the A/C unit loose? Replace the O-ring on piping, adjust refrigerant to
the specified amount, then go to Step 20.
Tighten the connections to the specified torque,
INSPECT PIPING CONNECTION Yes adjust both compressor oil and refrigerant to the
FOR LOOSE specified amount, then go to Step 20.
13
If the vane makes a noise, add 10 ml {10 cc, 0.34 fl
 Are the piping connections loose? No oz} of compressor oil to the A/C compressor.
Verify that the noise is no longer heard.
Microsoft
Replace O-ring on piping, adjust refrigerant to

specified amount, then go to Step 20.
Yes Go to the next step. (Pressure hardly increases.)
VALVE, AIR MIX ACTUATOR AND
COMPRESSOR OIL OR
14
ELSEWHERE
No Go to Step 17.
Does the refrigerant high-pressure

value hardly increase?
MALFUNCTION IS IN
Yes Return to Step 3.
COMPRESSOR OIL AMOUNT AND
A/C COMPRESSOR OR
15
ELSEWHERE
When the engine is racing, does the

high-pressure value increase?
MALFUNCTION IS IN Troubleshooting completed. (Explain to customer
Yes
COMPRESSOR OIL AMOUNT OR that cause was insufficient compressor oil.)
A/C COMPRESSOR
16
After compressor oil is replenished
 Replace the A/C compressor, then go to Step 20.
No
each 10 ml {10 cc, 0.34 fl oz} , (Cause is defective A/C compressor.)
does high-pressure value increase?
MALFUNCTION IS IN EXPANSION Yes Go to Step 19.
VALVE OR ELSEWHERE
17
 Is only refrigerant low-pressure No Go to the next step.
value high?
Set the fan switch to 4th position.

Turn the A/C switch on.
Set FRESH mode.
Set temperature control to MAX COLD.
Set VENT mode.
Yes 1. Start and run the engine at 1,500 rpm for 10

min.
2. Run the engine at idle for 1 min.
3. Within 12 s, idle -> 4,000 rpm -> idle.
Perform cycle 5 times.
VERIFY THAT AIR MIX IS
INSTALLED SECURELY AND 4. Run the engine at idle for 30 s.
PROPERLY 5. Drain the compressor oil completely from the
Microsoft
 Are the front (driver and passenger A/C compressor and verify the amount.
side) and rear A/C unit air mix
links, air mix cranks, and air mix
rods securely and properly  If there is approx. 90 ml {90 cc, 3.0 fl oz} of
installed? compressor oil, go to Step 20.
 If there is more than 90 ml {90 cc, 3.0 fl oz}
of compressor oil, remove surplus oil and fill
18 the A/C compressor with 90 ml {90 cc, 3.0 fl
oz} of compressor oil. Repeat Steps (1) to
(5).
(Cause is excessive amount of compressor oil.)

Repair or install the links, cranks and rods securely
No
in the proper position, then go to Step 20.
VERIFY THAT EXPANSION VALVE
HEAT-SENSING TUBE WITHIN A/C Replace the expansion valve, then go to the next
UNIT IS POSITIONED SECURELY Yes step. (Since the valve opens too much, replacement
AND CORRECTLY is necessary.)
19
Is the expansion valve heat-sensing

Install the heat-sensing tube securely in the proper
tube in the A/C unit securely No
position, then go to the next step.
installed in the proper position?
VERIFY THAT MALFUNCTION
SYMPTOM OCCURS AFTER Troubleshooting completed.
Yes
REPAIR Explain repairs to customer.
20
 Does cool air blow out? (Are Recheck malfunction symptoms, then repeat from
results of refrigerant system No
Step 1 if the malfunction recurs.
performance test normal?)
NO.9 NO COOL AIR FROM FRONT/REAR VENTS

NO.9 NO COOL AIR FROM FRONT/REAR VENTS DESCRIPTION AND POSSIBLE CAUSE
9 No cool air from front/rear vents
 Malfunction in A/C compressor control system
DESCRIPTION
 Magnetic clutch does not operate when the A/C system is turned ON.
 Malfunction in PCM A/C cut control system

 Malfunction in climate control unit
POSSIBLE CAUSE  Malfunction in refrigerant pressure switch
 Malfunction in PCM (A/C signal)
 Malfunction in PCM (IG1 signal)
 Malfunction in A/C compressor
Microsoft
 Malfunction in A/C relay

 Malfunction in evaporator temperature sensor
 Malfunction in BCM unit
while performing the inspection to discover whether poor contact points are the cause of any intermittent
malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are
NO.9 NO COOL AIR FROM FRONT/REAR VENTS DIAGNOSTIC PROCEDURE

INSPECT AIR FLOW FROM VENTS Yes Go to the next step.
1 Go to Step 1 of troubleshooting indexes
 Does air blow out?
No
No.1 and 2.
INSPECT A/C COMPRESSOR OPERATION
Go to Step 1 of troubleshooting index
Yes
 Start engine. No.7.
2
 Turn A/C switch and fan switch on.
 Does A/C compressor operate?

INSPECT FOR DTC IN PCM
Yes Go to appropriate inspection procedure.
3  Inspect for DTCs related to the PCM onboard
diagnostic system.
 Are any DTCs displayed?

MALFUNCTION IS IN CLIMATE CONTROL Replace climate control unit, then go to
UNIT OR ELSEWHERE Yes
Step 16.
4
 Does cool air blow out when terminal 1S of
climate control unit connector (24-pin, A/C No Release short, then go to the next step.
signal) is grounded?
MALFUNCTION IS IN A/C SIGNAL
CIRCUIT (BETWEEN REFRIGERANT Yes Go to Step 7.
PRESSURE SWITCH AND PCM) OR
ELSEWHERE
5*
 Test voltage at following terminal of
refrigerant pressure switch.
 Terminal B (A/C signal)
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MALFUNCTION IS IN WIRING HARNESS Repair wiring harness between PCM and
(BETWEEN REFRIGERANT PRESSURE Yes refrigerant pressure switch, then go to
Step 16.
6* SWITCH AND PCM) OR PCM
Test voltage at A/C signal terminal of PCM. No


Inspect PCM, then go to Step 16.

MALFUNCTION IS IN REFRIGERANT
PRESSURE SWITCH, REFRIGERANT
AMOUNT, OR ELSEWHERE
7
Does cool air blow out when terminals B and

No Go to Step 9.
C of refrigerant pressure switch connector are
shorted?
INSPECT TO SEE WHETHER If refrigerant amount is empty, replace
MALFUNCTION IS IN REFRIGERANT condenser, vacuum refrigerant line more
PRESSURE SWITCH OR REFRIGERANT Yes than 30 min by vacuum pump, and add
8 AMOUNT refrigerant to specified level, then go to
Step 16.
 Inspect refrigerant pressure switch. Replace refrigerant pressure switch, then
No
 Is it okay? go to Step 16.
MALFUNCTION (SHORT CIRCUIT) IS IN
A/C CONTROL SIGNAL CIRCUIT Yes Release short, then go to the next step.
(BETWEEN A/C RELAY AND PCM) OR
9 ELSEWHERE
Does cool air blow out when terminal A of No


Go to Step 11.
A/C relay connector (A/C control signal) is
grounded?
MALFUNCTION (OPEN OR SHORT Yes Inspect PCM, then go to Step 16.
CIRCUIT) IS IN PCM OR WIRING HARNESS
(BETWEEN A/C RELAY AND PCM)
10*
Test voltage at the A/C relay control signal Repair wiring harness between A/C relay
 No
terminal of PCM. and PCM, then go to Step 16.

MALFUNCTION IS IN MAGNETIC CLUTCH Inspect magnetic clutch, then go to Step
11* OR ELSEWHERE Yes
16.
 Test voltage at the following terminal of

magnetic clutch thermal protector.
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Terminal B (magnetic clutch operation


signal) No Go to the next step.

INSPECT FUSE
12 Replace fuse, then go to Step 16. If fuse
 Are A/C relay power supply fuses okay?
No burns out immediately, go to the next
step.
FUSE BLOCK AND A/C RELAY FOR LACK Yes Go to the next step.
OF CONTINUITY
13 Test voltages at following terminals of A/C


relay.
Repair wiring harness between fuse block
 Terminal E (A/C relay control signal) No
and A/C relay, then go to Step 16.
 Terminal C (A/C control signal)
 Are voltages approx. 12 V?

MALFUNCTION IS IN A/C RELAY OR Inspect wiring harness between A/C relay
WIRING HARNESS (BETWEEN A/C RELAY and magnetic clutch.
AND MAGNETIC CLUTCH) AND
EVAPORATOR TEMPERATURE SENSOR  If above wiring harness is OK, go
Yes to the next step.
14
 Test voltage at the following terminal of A/C  If above wiring harness
relay. malfunctions, repair wiring harness,
 Terminal D (magnetic clutch operation then go to Step 16.
signal)
 Is voltage approx. 12 V? No Replace A/C relay, then go to Step 16.
INSPECT EVAPORATOR TEMPERATURE Yes Go to the next step.
SENSOR
15
 Inspect evaporator temperature sensor.
Replace evaporator temperature sensor,
No
 Is it okay?
VERIFY REPAIR Troubleshooting completed. Explain

Yes
repairs to customer.
16  Does cool air blow out from front/rear vents?
(Are the results of refrigerant system Recheck malfunction symptoms, then
No
performance test okay?) repeat from Step 1 if malfunction recurs.
NO.10 NOISE WHILE OPERATING A/C SYSTEM.

NO.10 NOISE WHILE OPERATING A/C SYSTEM DESCRIPTION AND POSSIBLE CAUSE
10 Noise while operating A/C system.
 Problem with A/C basic system installation
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DESCRIPTION  Noise from magnetic clutch, A/C compressor, hose or refrigerant line.
 Magnetic clutch operation noise
 A/C compressor vane noise
POSSIBLE CAUSE
 A/C compressor slippage noise
 Hose or refrigerant line interference noise
NO.10 NOISE WHILE OPERATING A/C SYSTEM DIAGNOSTIC PROCEDURE

CHECK A/C COMPRESSOR VANE
NOISE Yes Go to Step 5.
1
Is there a jingling, popping, beeping,

or buzzing sound (A/C compressor No Go to the next step.
vane noise)?
INSPECT A/C COMPRESSOR
SLIPPAGE NOISE Yes Go to Step 14.
2
Is there a squeaking or whirling

sound (A/C compressor slippage No Go to the next step.
noise)?
INSPECT A/C COMPRESSOR
INTERFERENCE NOISE Yes Go to Step 18.
3
 Is there a rattling or vibrating sound No Go to the next step.
(interference noise)?
Adjust clearance between pressure plate of
INSPECT MAGNETIC CLUTCH magnetic clutch and A/C compressor pulley, then
OPERATION NOISE Yes go to Step 19.
4 (See MAGNETIC CLUTCH
 Is there a clicking sound (magnetic ADJUSTMENT .)
clutch operation noise)? Condition is normal. (Recheck malfunction
No
symptoms.)
INSPECT A/C COMPRESSOR NOISE
TIME
5
 Is noise heard continuously for more Condition is normal. (Noise occurs for 2-3 s
than 3 s after A/C compressor comes No immediately after A/C compressor turns on.)
on?

INSPECT IDLE SPEED
 Inspect idle speed.

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(See ENGINE TUNE-UP [MZI-

3.7] .) Follow the repair instruction described in section
6 No
01, then go to Step 19.
Is it okay?

INSPECT REFRIGERANT AMOUNT

Yes Go to Step 10.
7 Inspect refrigerant amount.

 Is it okay?
INSPECT REFRIGERANT LINES
Inspect refrigerant lines.


 Is piping free of damage and
cracks?
 Are piping connections free of
oil grime? (Visual inspection)
 Are piping connections free of
gas leakage?
 Are piping installation points
on condenser free of gas
8 leakage? If piping or A/C component(s) is damaged or
 Are piping installation points cracked, replace then go to Step 19.
on receiver/drier free of gas No If there is gas leakage, repair or replace
leakage? connection and replace condenser(1), then go to
 Are piping installation points Step 19.
on A/C compressor free of gas
leakage?
 Are piping installation points
on A/C unit free of gas leakage
 Perform gas leak inspection
using gas leak tester.
 Are above items okay?
INSPECT EVAPORATOR PIPING Adjust refrigerant amount to specified level, then

CONNECTIONS IN A/C UNIT FOR Yes
go to Step 19.
GAS LEAKAGE
9 If piping is damaged or cracked, replace then go
 Are piping connections for
to Step 19. If there is gas leakage, repair or
No
evaporator in A/C unit free of gas replace connection and replace condenser(1), then
leakage? go to Step 19.
CHECK TO SEE WHETHER
MALFUNCTION IS IN Yes Go to the next step.
COMPRESSOR OIL OR
10
ELSEWHERE
No
 Add 20 ml {20 cc, 0.8 fl oz} of Troubleshooting completed.
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compressor oil. Explain repair to customer.

 Is noise heard when racing engine?

MALFUNCTION IS IN A/C Yes Go to the next step.
COMPRESSOR OR ELSEWHERE
11
Drain compressor oil.

 Is it contaminated with metal

No Replace A/C compressor, then go to Step 19.
particles?
MALFUNCTION IS SOMEWHERE IN Yes Replace entire A/C system (excluding heater),
A/C SYSTEM OR ELSEWHERE then go to Step 19.
12
 Is compressor oil whitish and mixed
with water?
Replace A/C compressor and condenser, then go
INSPECT A/C COMPRESSOR OIL to Step 19. (Since A/C compressor may be worn
Yes
and receiver/drier may be clogged, replacement
13  Is compressor oil darker than normal
of receiver/drier is necessary.)
and contaminated with aluminum
chips? Condition is normal. Recheck malfunction
No
symptoms.
MALFUNCTION IS IN A/C Replace A/C compressor, then go to Step 19.
Yes
COMPRESSOR OR ELSEWHERE (A/C compressor discharge valve left open)
14
Is noise heard immediately after A/C

compressor is stopped?
INSPECT DRIVE BELT
 Inspect drive belt.
15
(See DRIVE BELT INSPECTION
[MZI-3.7] .)
No Adjust or replace drive belt, then go to Step 19.
Is it okay?

INSPECT DRIVE BELT CONDITION

Remove obstruction, remove oil, or replace drive
Yes
Is drive belt worn? belt, then go to Step 19.
16 
 Does it have foreign material

imbedded in it, or have oil on it? No Go to the next step.
INSPECT MAGNETIC CLUTCH
Replace A/C compressor (excluding pressure
17  Inspect magnetic clutch. Yes plate, A/C compressor pulley, and stator), then go
to Step 19.
(See MAGNETIC CLUTCH
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INSPECTION .)
No Replace magnetic clutch, then go to Step 19.
Is it okay?

CHECK TO SEE WHETHER Visually inspect A/C compressor, replace

MALFUNCTION IS IN A/C Yes appropriate parts if necessary, then go to the next
COMPRESSOR OR REFRIGERANT step.
18 LINES
If noise is due to refrigerant lines, repair detached
 Is noise emitted from A/C No or missing clips, tighten loose bolts, then go to
compressor? the next step.
VERIFY THAT MALFUNCTION Troubleshooting completed.
Yes
SYMPTOM OCCURS AFTER REPAIR Explain repairs to customer.
19
Recheck malfunction symptoms, then repeat from
 Has A/C compressor noise stopped?
No
Step 1 if malfunction recurs.
(1) If there is gas leakage, air enters into the A/C system. The desiccant within the receiver/drier absorbs
the moisture from the air and becomes saturated. If the A/C system is used in this condition, the
inside of the A/C compressor will begin to rust due to this moisture, which may cause lock up or
noise to occur. Therefore, replacement of the receiver/drier is necessary.
NO.11 DUAL A/C CONTROL DOES NOT OPERATE

NO.11 DUAL A/C CONTROL DOES NOT OPERATE DESCRIPTION AND POSSIBLE CAUSE
11 Dual A/C control function does not operate
DESCRIPTION  Driver or passenger-side temperature control does not operate individually
 Driver-side air mix door malfunction (stuck)

 Passenger-side air mix door malfunction (stuck)
 driver-side front air mix actuator malfunction
 Passenger-side front air mix actuator malfunction
 Driver-side front air mix actuator position sensor malfunction
 Passenger-side front air mix actuator position sensor malfunction
POSSIBLE  Open, short circuit in wiring or poor connection between front climate control
CAUSE unit and driver-side front air mix actuator
 Open, short circuit in wiring or poor connection between front climate control
unit and passenger-side front air mix actuator
unit and driver-side front air mix actuator position sensor
unit and passenger-side front air mix actuator position sensor
 Front climate control unit malfunction
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NO.11 DUAL A/C CONTROL DOES NOT OPERATE DIAGNOSTIC PROCEDURE

CHECK SYMPTOM
Turn on the front A/C.

1  Perform the dual A/C control function for driver and

passenger-side individually.
 Is it either of cannot the temperature control on driver seat
No Go to Step 8.
side or front passenger seat side?
INSPECT TO SEE WHETHER MALFUNCTION IS IN AIR
MIX DOOR OR ELSEWHERE Yes Go to the next step.
2 Turn on the front A/C


 Change temperature control for suspect side seat at the dual

mode. No Go to Step 6.
 Does the suspect side air mix door move smoothly?
INSPECT AIR MIX DOOR Yes Go to the next step.

Inspect the suspect side air mix door.

Remove the obstruction or
3  Is the fan free of interfere with the suspect side A/C
replace the suspect side
unit case? No
A/C unit case, then go to
 Is the fan free of foreign material and obstruction? Step 9.
 Is the air mix door normal?
INSPECT FRONT AIR MIX ACTUATOR Yes Go to the next step.

4 Replace the suspect front
 Inspect the suspect side front air mix actuator. No air mix actuator, then go to
 Is the front air mix actuator normal? Step 9.
CONNECTION OF TERMINALS BETWEEN AIR MIX
ACTUATOR AND FRONT CLIMATE CONTROL UNIT) Repair or replace
OR ELSEWHERE Yes malfunction part, then go
to Step 9.
 Inspect for open, short or poor connection of terminals
between the suspect front air mix actuator and front climate
5 control unit.
 Terminal 1A (front climate control unit)- terminal G
(driver-side front air mix actuator)
 Terminal 1F (front climate control unit)- terminal F Replace the front climate
(driver-side front air mix actuator) No control unit, then go to
 Terminal 1E (front climate control unit)- terminal F Step 9.
(passenger-side front air mix actuator)
 Terminal 1C (front climate control unit)- terminal G
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(passenger-side front air mix actuator)

INSPECT FRONT AIR MIX ACTUATOR POSITION Yes Go to the next step.
SENSOR
6* Replace the suspect front
Inspect the suspect side front air mix actuator position

No air mix actuator position
sensor.
sensor, then go to Step 9.
 Is the front air mix actuator position sensor normal?

CONNECTION OF TERMINALS BETWEEN AIR MIX
ACTUATOR POSITION SENSOR AND FRONT CLIMATE Repair or replace
CONTROL UNIT) OR ELSEWHERE Yes malfunction part, then go
to Step 9.
between the suspect front air mix actuator position sensor
and front climate control unit.
7  Terminal 2F (front climate control unit)- terminal E
(driver-side front air mix actuator position sensor)
 Terminal 2G (front climate control unit)- terminal E
(passenger-side front air mix actuator position sensor)
Replace the front climate
 Terminal 2B (front climate control unit)- terminal A No control unit, then go to
(each side front air mix actuator position sensor) Step 9.
 Terminal 2P (front climate control unit)- terminal C
(each side front air mix actuator position sensor)

CONNECTION OF TERMINALS BETWEEN FRONT Repair or replace
CLIMATE CONTROL UNIT AND AIR MIX ACTUATOR Yes malfunction part, then go
POSITION SENSOR) OR ELSEWHERE to the next step.

8 between the front climate control unit and front air mix
actuator position sensor.
 Terminal 2B (front climate control unit)- terminal A
Replace the front climate
(each front air mix actuator position sensor) No control unit, then go to the
 Terminal 2P (front climate control unit)- terminal C step.
(each front air mix actuator position sensor)
Troubleshooting
Yes completed. Explain repairs
9 to customer.
CONFIRM THAT MALFUNCTION SYMPTOMS DOES
NOT RECUR AFTER REPAIR Recheck malfunction
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 Does the temperature adjust individually for driver seat and symptoms, then repeat
front passenger seat? No from Step 1 if malfunction
recurs.
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2008 HVAC Basic System - Mazda CX-9
2008 HVAC
Basic System - Mazda CX-9
HVAC BASIC SYSTEM LOCATION INDEX
Microsoft
Fig. 1: Identifying HVAC Basic System Location Index
FRONT A/C UNIT REMOVAL/INSTALLATION
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2. Discharge the refrigerant. (See REFRIGERANT CHARGING .)
5. Dashboard undercover (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION .)
8. Remove the windshield wiper arm. (See WINDSHIELD WIPER ARM AND BLADE
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12. Remove the rear heat duct fasteners and slide the rear heat duct rearward. (See REAR HEAT DUCT
COMPONENT REMOVAL/INSTALLATION.)
13. Disconnect the drain hose.
14. Remove the nuts.
15. Remove the bracket.
17. Remove the dashboard bracket.
Fig. 2: Identifying Dashboard Bracket, Nuts, Bolts & Torque Specifications
18. Remove the hose clips.

19. Remove the front heater hose No.3 and front heater hose No.4. (See HEATER PIPE AND HOSE
COMPONENT REMOVAL/INSTALLATION.)
Fig. 3: Identifying Hose Clips Of Front Heater Hose No.3 & Front Heater Hose No.4
20. Remove the front cooler pipe No.1 bracket installation nut.
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Fig. 4: Identifying Front Cooler Pipe No.1 Bracket Installation Nut & Torque Specifications
21. Remove the nut.

22. Remove the front cooler pipe No.1 and front cooler pipe No.4. (See REFRIGERANT LINE
CAUTION:  If moisture or foreign material enters the refrigeration cycle,

cooling ability will be lowered and abnormal noise or other
malfunction could occur. Always plug open fittings immediately
after removing any refrigeration cycle parts.
Fig. 5: Identifying Front Cooler Pipe No.1, Front Cooler Pipe

No.4 & Torque Specifications
23. Remove the nuts.

24. Remove the front A/C unit. Do not allow compressor oil to spill.
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Fig. 6: Identifying Front A/C Unit Nuts & Torque Specifications
FRONT A/C UNIT DISASSEMBLY/ASSEMBLY

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Fig. 7: Identifying Front A/C Unit Components & Torque Specifications
FRONT EXPANSION VALVE REMOVAL/INSTALLATION

2. Discharge the refrigerant from the system. (See REFRIGERANT RECOVERY .) (See
1. Windshield wiper blade (See WINDSHIELD WIPER ARM AND BLADE
5. Front cooler pipe No.1 bracket installation nut
Fig. 8: Identifying Front Cooler Pipe No.1 Bracket Installation Nut & Torque Specifications
6. Nut
7. Front cooler pipe No.1 and front cooler pipe No.4 (See REFRIGERANT LINE
CAUTION:  If moisture or foreign material enters the refrigeration

cycle, cooling ability will be lowered and abnormal noise
or other malfunction could occur. Always plug open
fittings immediately after removing any refrigeration cycle
parts.
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Fig. 9: Identifying Front Cooler Pipe No.1, Front Cooler

Pipe No.4 & Torque Specifications

5. Remove the front expansion valve. Do not allow compressor oil to spill.
7. Perform the refrigerant system performance test.
(See REFRIGERANT SYSTEM PERFORMANCE TEST .)
Fig. 10: Identifying Front Expansion Valve, Bolts & Torque Specifications
AIR FILTER REMOVAL/INSTALLATION

1. Remove the glove compartment service hole cover.
2. Remove the cover in the direction of the arrow.
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Fig. 11: Identifying Glove Compartment Service Hole Cover
3. Remove the air filter in the direction of the arrow.

Fig. 12: Identifying Air Filter Remove Direction
AIR FILTER INSPECTION

1. Verify that there is no damage, excessive dirt, or abnormal odor on the air filter.
 If there is any malfunction, replace the air filter.
NOTE:  The air filter cannot be reused by cleaning it with water or

compressed air.
FRONT EVAPORATOR INSPECTION

1. Inspect the front evaporator for damage, cracks, and oil leakage.
 If there is any malfunction, replace the front evaporator.
2. Visually inspect the fins for bending.

 If there is any bending, use the end of a flathead screwdriver to straighten the fins.
FRONT HEATER CORE INSPECTION

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1. Inspect the front heater core for damage, cracks, and water leakage.
 If there is any malfunction, replace the front heater core.

 If there is any bending, use the end of a flathead screwdriver to straighten the fins.
3. Visually inspect the heater hose for deformation.

 Repair with pliers if there is deformation. If there is any malfunction, replace the front heater core.
REAR HEAT DUCT COMPONENT REMOVAL/INSTALLATION

REAR HEAT DUCT NO.1

1. Front seat (See FRONT SEAT REMOVAL/INSTALLATION .)
13. Dust cover (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
3. Turn floor covering over. (See FLOOR COVERING REMOVAL/INSTALLATION .)
Fig. 13: Identifying Rear Heat Duct No.1 Remove Order
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REAR HEAT DUCT NO.2, NO.3 AND NO.4

3. Remove the two rear A/C unit retaining bolts on the rear side.
4. Turn floor covering over. (See FLOOR COVERING REMOVAL/INSTALLATION .)
5. Remove the long slider. (See LONG SLIDER REMOVAL/INSTALLATION .)
7. Lift the rear side of the rear A/C unit and remove the rear heater duct No.2.
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Fig. 14: Identifying Rear Heater Duct No.2
WHEN REMOVING THE REAR HEATER DUCT NO.3 ONLY

3. Cut away the floor covering as shown in the figure.
NOTE:  The cut part does not need to match up when installing the floor
covering.
Fig. 15: Identifying Floor Covering Cut
4. Turn floor covering over.

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Fig. 16: Identifying Rear Heat Duct No.3
WHEN REMOVING THE REAR HEATER DUCT NO.4 ONLY

1. Second-row seat (RH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)
3. Cut away the floor covering as shown in the figure.
NOTE:  The cut part does not need to match up when installing the floor
covering.
Fig. 17: Identifying Floor Covering Cutting Line
4. Turn floor covering over.

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Fig. 18: Identifying Rear Heat Duct No.4
REAR COOLER DUCT REMOVAL/INSTALLATION

4. Remove the rear cooler duct.
Fig. 19: Identifying Rear Cooler Duct
REAR A/C UNIT REMOVAL/INSTALLATION

2. Evacuate the refrigerant from the system. (See REFRIGERANT RECOVERY .) (See
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10. Selector lever component (See SELECTOR LEVER COMPONENT
5. Remove the bolt.
6. Remove the rear cooler pipe No.1. Do not allow compressor oil to spill.
CAUTION:  If moisture or foreign material enters the refrigeration cycle,

cooling ability will be lowered and abnormal noise will occur.
Always immediately plug open fittings after removing any
refrigeration cycle parts to keep moisture or foreign material out
of the cycle.
Fig. 20: Identifying Rear Cooler Pipe No.1 & Torque

Specifications
7. Jack up the vehicle.

8. Remove the hose clip.
9. Remove the rear heater hose No.1 and No.2.
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Fig. 21: Identifying Rear Heater Hose No.1 & No.2
10. Remove in the order indicated in the table

Fig. 22: Identifying Rear A/C Unit Removal Order & Torque Specifications
REAR A/C UNIT DISASSEMBLY/ASSEMBLY

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Fig. 23: Identifying Rear A/C Unit Components
REAR EVAPORATOR INSPECTION

1. Inspect for cracks, damage, and oil leakage.
 If any are found, replace the rear evaporator.
2. Inspect for bent fins.

 If any are bent, use a flathead screwdriver to straighten them.
REAR HEATER CORE INSPECTION

1. Inspect for cracks, damage, and coolant leakage.
 If any are found, replace the rear heater core.
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2. Inspect for bent fins.

 If any are bent, use a flathead screwdriver to straighten them.
3. Verify that the rear heater core inlet and "outlet are not distorted or damaged.
 If they are distorted or damaged, repair then using pliers.
A/C COMPRESSOR REMOVAL/INSTALLATION

3. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the front cooler hose (Hi). (See REFRIGERANT LINE REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table. Do not allow compressor oil to spill.
CAUTION:  If moisture or foreign material enters the refrigeration cycle, cool

ability will be lowered and abnormal noise or other malfunction c
occur. Always plug open fittings immediately after removing any
refrigeration cycle parts.
Fig. 24: Identifying A/C Compressor Components & Torque Speci

A/C COMPRESSOR INSTALLATION NOTE
CAUTION:  Due to the high moisture-absorption characteristics of the

compressor oil, it may absorb moisture if left over a long period of
time thereby negatively affecting A/C operation. Drain the
compressor oil and refill within 10 min. of each other.
1. Rotate new A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a clean
measuring device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become
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contaminated.
2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate,
clean measuring device.
3. Compare those oil amounts. The amount of the oil drained from the new A/C compressor should be
greater than the old one.
4. Pour the same amount oil of drained from the old A/C compressor back into the new A/C compressor.
A/C compressor oil type
 DENSO OIL8
A/C compressor oil sealed volume (approx. quantity)
 160 ml {160 cc, 5.41 fl oz}
Fig. 25: Comparing A/C Compressor Oil Amounts
CONDENSER REMOVAL/INSTALLATION
5. Remove the cooling fan component. (See FAN MOTOR INSPECTION [MZI-3.7] .)
7. Remove the radiator. (See RADIATOR REMOVAL/INSTALLATION [MZI-3.7] .)
8. Remove the nut and disconnect front cooler pipes No.3 and No.4. (See REFRIGERANT LINE
Microsoft
9. Remove the front cooler pipe No.3 bracket. (See REFRIGERANT LINE
10. Remove the bolts and two condenser brackets.
11. Remove in the order indicated in the table. Do not allow remaining compressor oil in the refrigerant line
to spill.

Fig. 26: Identifying Condenser Components & Torque Specificatio

3.7] .)
AW6AX-EL] .)
TEST .)
CONDENSER INSPECTION
1. Inspect the condenser for cracks, damage, and oil leakage.
 If there is any malfunction, replace the condenser.
2. Visually inspect the fins for clogging of foreign material.

 If any fins are clogged, remove the foreign material.
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 If there is any bending, use the end of a flathead screwdriver to straighten fins.
HEATER PIPE AND HOSE COMPONENT REMOVAL/INSTALLATION

1. Remove the battery. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
1. Windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE
Fig. 27: Identifying Heater Pipe, Hose Component Removal/Installation Order & Torque
Specifications

6. Under guard (LH) (See CHARCOAL CANISTER, CANISTER VENT (CV) SOLENOID VALVE,
AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-3.7] )
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Fig. 28: Identifying Front Heater Pipe, Hose Removal/Installation Order & Torque Specifications

3.7] .)
HEATER PIPE AND HOSE INSTALLATION NOTE
 Insert the heater pipe into the heater hose until the hose reaches the bracket or the protrusion on the pipe.
 When the rear heater pipe is removed, bleed the air from the rear heater pipe thoroughly after refilling the
engine coolant to prevent air from being trapped in the rear heater pipe.
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Fig. 29: Identifying Heater Pipe & Hose
REFRIGERANT LINE REMOVAL/INSTALLATION

5. Air cleaner and fresh air duct component (See INTAKE-AIR SYSTEM
6. Cooling fan component (See COOLING FAN COMPONENT REMOVAL/INSTALLATION
[MZI-3.7] .)
6. Remove the radiator (See RADIATOR REMOVAL/INSTALLATION [MZI-3.7] .)
7. Remove the condenser. (See CONDENSER REMOVAL/INSTALLATION.)
8. Remove the coolant reserve tank retaining bolts and move the coolant reserve tank.
9. Remove the power steering oil pump retaining bolt and nut and move the power steering oil pump. (See
POWER STEERING OIL PUMP REMOVAL/INSTALLATION .)
10. Do not allow remaining compressor oil in the piping and connecting parts to spill, and remove in the
order indicated in the table.

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Fig. 30: Identifying Refrigerant Line Removal/Installation Order &

Specifications
11. Remove the following parts, depending on rear cooler pipe to be removed.
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10. Front seat (passenger side) (See FRONT SEAT REMOVAL/INSTALLATION .)
11. Bolt
12. Screws
13. Rear cooler pipe No.1 bracket.
Fig. 31: Identifying Rear Cooler Pipe & Torque Specifications
13. Remove the nuts and disconnect the presilencer and middle pipe.
14. Disconnect the rubber hanger.
15. Remove the bolts and presilencer insulator.
17. Remove the nut and fastener.
18. Remove the under guard (RH).
19. Remove the transverse member retaining bolts and set the transverse member out of the way. (See
TRANSVERSE MEMBER REMOVAL/INSTALLATION .)
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Fig. 32: Identifying Presilencer, Middle Pipe & Torque Specifications
20. Remove the bolt.

21. Remove the clip.
22. Disconnect rear cooler pipe No.1 and remove rear cooler pipes No.2 and No.1.
3.7] .)
AW6AX-EL] .)
TEST .)
Fig. 33: Identifying Rear Cooler Pipes No.2, No.1 & Torque Specifications
REFRIGERANT LINE REMOVAL NOTE

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Block joint type
1. Disconnect the block joint type pipes by grasping the female side of the block with pliers or similar tool
and holding firmly, and then remove the connection bolt or nut.
Fig. 34: Disconnecting Block Joint Type Pipes By Grasping Female Side Of Block
REFRIGERANT LINE INSTALLATION NOTE
1. Temporarily tighten the joint bolt by hand.

2. Connect the block joint type pipes by grasping the female side of the block with pliers or similar tool and
holding firmly, and then tighten the connection bolt or nut with a torque wrench.
Fig. 35: Connecting Block Joint Type
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2008 ENGINE PERFORMANCE Ignition System (MZI-3.7) - Mazda CX-9
Ignition System (MZI-3.7) - Mazda CX-9
IGNITION SYSTEM LOCATION INDEX [MZI-3.7]
Fig. 1: Identifying Ignition Coil And Spark Plug

IGNITION COIL REMOVAL/INSTALLATION [MZI-3.7]

3.7] .)
CAUTION:  Apply small amount of the specified dielectric grease to the

inside of the ignition coils, then install the ignition coils to the
spark plugs.
 Specified grease: Motorcraft XG-3A

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Fig. 2: Identifying Connector, Ignition Coil & Torque Specifications

IGNITION COIL INSPECTION [MZI-3.7]

SECONDARY COIL RESISTANCE INSPECTION
1. Remove the ignition coils. (See IGNITION COIL INSPECTION [MZI-3.7].)

2. Using a tester, measure the resistance between the ignition coil terminal A and ignition coil boot socket.
 If not within the specification, replace the ignition coil.
Ignition coil secondary coil resistance 5-6 kilohms
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Fig. 3: Measuring Resistance Between Ignition Coil Terminal A And Ignition Coil Boot Socket
SPARK PLUG REMOVAL/INSTALLATION [MZI-3.7]
CAUTION:  If a spark plug that is not as specified is installed, engine

performance will be deteriorated. Install only the specified spark plug
when replacing.

2. Remove the engine cover. |j]
3.7] .)
4. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZI-3.7].)
5. Remove the spark plugs using a plug-wrench.
CAUTION:  Apply small amount of the specified dielectric grease to the

inside of the ignition coils, then install the ignition coils to the
spark plugs.
 Specified grease: Motorcraft XG-3A
Tightening torque
9-20 N.m {91-204 kgf.cm, 79-177 in.lbf}
SPARK PLUG INSPECTION [MZI-3.7]

SPECIFICATION
Spark plug type
CY01 18110
SPARK PLUG GAP INSPECTION
CAUTION:  To avoid possible damage to the tip, do not adjust the plug gap.
 To prevent damaging the tip, use a wire type plug gap gauge when
inspecting the plug gap.
1. Measure the spark plug gap using a wire type plug gap gauge.
 If not within the specification, replace the spark plug.
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Spark plug gap
1.29-1.45 mm {0.051-0.057 in}
CLEANING
CAUTION:  Carbon may adhere to the tip of the spark plug during vehicle
delivery or repeated short distance driving during the winter time. If
there is any malfunction such as rough idling or start difficulty due to
carbon adhesion causing plug fouling, burn off the carbon by
performing no-load racing of the engine.
 When performing the no-load racing, apply the side brake and foot
brake, move the selector lever to P position to prevent an accident
and serious injury.
 To avoid possible damage to the spark plug tip, do not use a wire
brush for cleaning.
NOTE:  To avoid possible damage to the tip, use gasoline to clean the spark plugs
after removing dirt.
 If the accelerator pedal is depressed continuously for a specified time, the
engine speed may decrease to the idle speed. This is does not indicate a
malfunction.
 Do not perform no-load racing at high engine speed continuously for 10 s
or more .
1. If there is carbon adhering to the spark plug, perform no-load racing at 4,000 rpm for 2 min, 2 times .
VISUAL INSPECTION

 If any of the following malfunctions are indicated, replace the spark plug.
 Insulator breakage
 Worn electrode
 Damaged gasket
 Badly burned insulator (sparking side)
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Fig. 4: Identifying Spark Plug Damage And Breakage

1. Measure the resistance of the spark plug using a tester as shown in the figure.
 If not within the specification, replace the spark plug.
Spark plug resistance
2-20 kilohms
Fig. 5: Measuring Resistance Of Spark Plug With Tester

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2008 BODY & ACCESSORIES Instrumentation/Driver Info - Mazda CX-9
Instrumentation/Driver Info - Mazda CX-9
INSTRUMENTATION/DRIVER INFO. LOCATION INDEX
Fig. 1: Identifying Instrumentation/Driver Info. Components Location

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INSTRUMENT CLUSTER REMOVAL/INSTALLATION
CAUTION:  When replacing the instrument cluster, the configuration procedure

must be performed before removing the instrument cluster.
Replacing the instrument cluster without performing the
configuration procedure will result in system malfunction.
1. Perform the instrument cluster configuration when replacing it. (See INSTRUMENT CLUSTER
CONFIGURATION.)
6. Upper column cover (See COLUMN COVER REMOVAL/INSTALLATION .)
Fig. 2: Identifying Instrument Cluster Components


6. When replacing the instrument cluster of vehicles with the immobilizer system, perform the following
procedure:
 See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND
CLEARING [KEYLESS ENTRY SYSTEM] .
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CAUTION:  The removed instrument cluster should be placed with the

display side up to prevent grease from leaking from the meters.
Fig. 3: Identifying Proper Position Of Instrument Cluster Display

INSTRUMENT CLUSTER CONFIGURATION
the INSTRUMENT CLUSTER CONFIGURATION.
 If all the following conditions are met, the odometer data (total traveled
distance) in the previous instrument cluster is automatically transferred to
a new instrument cluster during the configuration. If any of the conditions
are not met, odometer-data transfer cannot be performed.
Previous instrument cluster
 No malfunction (Configuration data can be read using the M-MDS.)
New instrument cluster
 Odometer display is less than 100 km

 Odometer has no malfunction


4. Select "IC" and perform procedures according to directions on the M-MDS screen.
 If odometer data is to be transferred to a new instrument cluster, perform the following procedure:
1. Select "Programmable Parameters" from the menu.
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2. Select "Odometer Write", and perform the procedure following the screen.

NOTE:  During the odometer data writing procedure, As-Built Data (VIN and
Vehicle Data) input is requested. Obtain the As-Built Sheet for the
vehicle, and input the necessary data.
 If a DTC (s) is detected, perform the applicable DTC inspection. (See DTC TABLE
[INSTRUMENT CLUSTER] .)
INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY
CAUTION:  Do not drop the instrument cluster or damage the printed board. This
will lead to a system malfunction.
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Fig. 5: Identifying Instrument Cluster Unit, Cover, Lens & Glass Ring
INSTRUMENT CLUSTER INSPECTION

SPEEDOMETER
Using the input/output check mode
1. Inspect the speedometer by setting it to check code 12 of the input/output check mode. (See
INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE.)
Using a speedometer tester
1. Adjust the tire pressure to the specification.

2. Using a speedometer tester, verify that the tester reading is as indicated in the table below.
SPEEDOMETER TESTER INDICATION AND ALLOWABLE RANGE REFERENCE

Speedometer tester indication (km/h) Allowable range (km/h)
20 17-23
40 38-43
60 57-63
80 77-83
100 97-103
120 116-124
140 136-144
SPEEDOMETER TESTER INDICATION AND ALLOWABLE RANGE REFERENCE

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Speedometer tester indication (mph) Allowable range (mph)

10 8-12
20 18-22
30 28-32
40 38-42
50 48-52
60 58-62
70 68-72
80 77-83
3. Verify that the speedometer reading is within the range indicated in the table.
 If the speedometer does not move or the indication is not within the allowable range, inspect the
PCM, TCM, and related wiring harnesses.
 If the PCM, TCM, and related wiring harnesses are normal, replace the instrument cluster.
TACHOMETER
Using the input/output check mode
1. Inspect the tachometer by setting it to check code 13 of the input/output check mode. (See
USING M-MDS
CAUTION:  If the engine speed exceeds the allowable range, the engine could be
damaged. Therefore, when inspecting the tachometer, do not allow
the engine speed to exceed the allowable range indication on the
tachometer.

3. Select "IC".

2. Select "IC".
3. Compare the data monitor item (IC_TACHO) with the tachometer indication.
 If the tachometer does not operate properly, inspect the PCM and related wiring harnesses.
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 If the PCM and related harnesses do not have any malfunction, replace the instrument cluster.
FUEL GAUGE
1. Inspect the fuel gauge by setting it to check code 23 of the input/output check mode. (See
WATER TEMPERATURE GAUGE
1. Inspect the water temperature gauge by setting it to check code 25 of the input/output check mode. (See
INSTRUMENT CLUSTER INPUT/OUTPUT CHECK MODE
NOTE:  In this mode, it is possible to verify the items in the following chart.
CHECK CODE TABLE
CHECK CODE TABLE

Check code Check item Related items
 Lights-on reminder warning alarm
08 TNS relay
 Each illumination light
12 Speedometer Speedometer
13 Tachometer Tachometer
14 Buzzer Buzzer
16 Fuel-level warning light Fuel-level warning light
22 Fuel gauge sender unit Fuel gauge
23 Fuel gauge Fuel gauge
25 Water temperature gauge Water temperature gauge
 Odometer/tripmeter (LCD)  Odometer/tripmeter (LCD)

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26  Warning and indicator light  Warning and indicator light

55 Panel light control switch (dimmer switch) Panel light control switch (dimmer switch)
57 Panel light control Illumination light bulb
NOTE:  Check codes which are not listed may be indicated, but they cannot be
inspected.
 The check codes are displayed in numerical order. (While performing the
inspection, if you want to inspect a check code with a number smaller than
the code number you are currently inspecting, terminate the check mode
then repeat the inspection from the beginning.)
 If a speed signal is input to the instrument cluster (the wheels are rotated),
the input/output check mode will be cancelled.
 The check codes can be fast-forwarded by pushing and holding the
odometer/tripmeter switch for 1 s or more.
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Fig. 7: Instrument Cluster Input/Output Check Mode Procedure Chart

CHECKING ORDER
NOTE:  When inspecting more than two check codes, begin with the code with the
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highest ranking.
CHECKING ORDER
Priority order of inspection Check code
1 22
2 08, 12, 13, 14, 16, 23, 25, 26, 55, 57
CHECK CODE INSPECTION
Check code 08
CHECK CODE INSPECTION CHART (CHECK CODE 08)

Check code 08 TNS relay ON/OFF signal
INSPECTION
STEP DISPLAY ACTION
CONDITION
Verify that the voltage of instrument

cluster terminal 1K is B+.
Turn the headlight switch to
1 the TNS position. (TNS relay
 If the voltage is as specified,
ON)
replace the instrument cluster.
 If the voltage is not as specified,
inspect the following parts:
 TNS relay
 Wiring harness (Battery-

TNS relay-instrument
cluster)
Verify that the voltage of the
instrument cluster terminal 1K is 1.0 V
or less.

replace the instrument cluster.
Turn the headlight switch off.
2  If the voltage is not as specified,
(TNS relay OFF)
 TNS relay
 Wiring harness (TNS

relay-instrument cluster)
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Input signal to the instrument cluster is

normal.
Check code 12

Check code 12 Speedometer display signal
INSPECTION
DISPLAY ACTION
CONDITION
The speedometer needle moves
The speedometer
full scale then returns to approx.
is normal.
60 km/h or 60 mph.
After selecting check Except above

code 12, wait for
approx. 2 s. Replace the
instrument
- cluster.
Check code 13

Check code 13 Tachometer operation signal
INSPECTION
DISPLAY ACTION
CONDITION
The tachometer needle moves
The tachometer
full scale then returns to
is normal.
approx. 3,000 rpm.
Except above
After selecting check code
13, wait for approx. 2 s.
Replace the
instrument
- cluster.
Check code 14
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Check code 14 Buzzer operation signal
INSPECTION CONDITION DISPLAY ACTION
The buzzer
The buzzer is normal.
sounds.
After selecting check code 14, wait
for approx. 2 s.
The buzzer does Replace the
not sound. instrument cluster.
Check code 16

Check code 16 Fuel-level warning light flashing signal
INSPECTION
DISPLAY ACTION
CONDITION
Fuel-level warning The fuel-level
light flashes three warning light is
After selecting check code 16, times. normal.
wait for approx. 2 s.
Replace the
Except above
instrument cluster.
Check code 22

Check code 22 Fuel level signal
STEP INSPECTION CONDITION DISPLAY ACTION
Go to the next
Select check code 22 with the fuel gauge sender step.
1
unit connector disconnected.
Except above Go to the Step 6.
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Go to the next
Connect terminals 1D and 1R of the instrument step.
2
cluster.
Using the SST (Fuel and thermometer checker) or Go to the next

3 resistor, input 20 ohms between instrument cluster step.
terminals 1D and 1R.
Using the SST (Fuel and thermometer checker) or Go to the next

4 resistor, input 60 ohms between instrument cluster step.
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Inspect the fuel

Using the SST (Fuel and thermometer checker) or gauge sender
5 resistor, input 100 ohms between instrument cluster unit.
Go to the next
Except above
step.
Inspect the wiring harness and connector between instrument cluster and fuel gauge sender unit.
6  If there is any malfunction, repair or replace the wiring harness or connector.
 If there is no malfunction, replace the instrument cluster.
Check code 23

Check code 23 Fuel gauge operation signal
INSPECTION
DISPLAY ACTION
CONDITION
The fuel gauge indicates status
in the following order approx.
every 2 s. The fuel gauge
is normal.
 F --> 1/2 --> E --> F
(fixed)
After selecting check code Replace the
23, wait for approx. 2 s. Except above instrument
cluster.
Replace the instrument cluster.
Check code 25
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Check code 25 Water temperature gauge operation signal
INSPECTION
DISPLAY ACTION
CONDITION
The water temperature gauge
indicates status in the following
The water
order approx. every 2 s.
temperature gauge
is normal.
 H --> Center --> C --> H
(fixed)
After selecting check
code 25, wait for Replace the
Except above
approx. 2 s. instrument cluster.
Replace the instrument cluster
Check code 26

Check code 26 Odometer/tripmeter display signal
INSPECTION
DISPLAY ACTION
CONDITION
 Display is normal.
 Warning and
indicator light
illuminated.
 Generator
warning light
 DSC indicator
light
 ABS warning
light
 Brake system
warning light
 Cruise set
indicator light
(1)
 Cruise main
indicator light
(1)
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 TCS OFF light

 Selector
indicator light
 Door ajar
warning light
 Seat belt
warning light
 Air bag system
warning light
 Turn indicator
light
 Oil pressure
warning light
 MIL
 The
 Keyless odometer/tripmeter is
indicator light normal.
Select check code (2)
26.  Warning and indicator
 Keyless is normal.
warning light
(2)
 Security light
 Washer fluid-
level warning
light
 ETC warning
light
 Fuel cap
warning light
 AWD warning
light
 AT warning
light
Replace the instrument
Except above
cluster.
(1) Flashing alternates
(2) Flashing alternates
Check code 55

Check code 55 Dimmer switch ON/OFF signal
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STEP INSPECTION CONDITION DISPLAY ACTION
After selecting the check code 55, press and

1 hold the dimmer switch. (Dimmer switch
ON)
cluster.

cluster.
Release the dimmer switch. (Dimmer switch

2
OFF)
Input signal to the
instrument cluster is
normal.
Check code 57

Check code 57 Panel light control signal
INSPECTION
DISPLAY ACTION
CONDITION
Illumination light
(hazard warning
The panel light control signal is
switch, center panel
normal.
unit, etc.) flashes
three times.
Turn the headlight
switch to the TNS Verify that the voltage of
position. instrument cluster terminal 1I is
After selecting B+.
check code 57, wait
for approx. 2 s. Except above  If the voltage is as
specified, replace the
instrument cluster.
 If the voltage is not as
specified, inspect the
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following parts:
 Illumination light
(hazard warning
switch, center panel
unit, etc.)
 Wiring harness
(Instrument cluster-
illumination lights-
TNS relay)
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION

FUEL GAUGE SENDER UNIT
1. Remove the fuel gauge sender unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZI-
3.7] .)
FUEL GAUGE SENDER SUB-UNIT
Procedure".
eyes. To prevent this, before performing the fuel gauge sender sub-
unit removal/installation, always complete the "Fuel Leak Inspection
body.
occur. If the fuel gauge indicates a fuel level of half or more, perform
the following Steps 1-6 to drain approx. 10-15 L {11-15 US gal, 8.8-13
lmp gal} of fuel.
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3.7] .)
Fig. 8: Identifying Fuel Line Schrader Valve Cap & Fuel Distributor
Using M-MDS

Without using M-MDS
1. Insert a flathead screwdriver into tab part of the check connector and remove the check connector
cap.
CAUTION:  Connecting to the wrong check connector terminal may

only to cause malfunction. Carefully connect the specified
terminal.
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2. Using a jumper wire, short the following check connector terminals.

 Terminal A and terminal C
 Terminal E and body ground

4. Turn the ignition switch to ON position to operate the fuel pump.

being discharged.
Fig. 10: Identifying Check Connector Terminals

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1.
Second-row seat (RH) (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)
Edge cover (See LONG SLIDER REMOVAL/INSTALLATION .)
2.
Long slider cover (See LONG SLIDER REMOVAL/INSTALLATION .)
3.
4.
Rear heat duct No.4 (See REAR HEAT DUCT COMPONENT
Fig. 11: Identifying Fuel Gauge Sender Sub-Unit Components & Torque Specifications

3.7] .)
FUEL GAUGE SENDER UNIT INSPECTION

1. Move the float to the topmost and bottommost positions, and verify that the resistance between terminals
A and C (fuel gauge sender unit) or A and B (fuel gauge sender sub-unit) of the unit and the position of
the float are as indicated in the figure.
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Fig. 12: Identifying Topmost & Bottommost Positions Of Float & Torque Specifications
 If they are not as indicated, replace the fuel gauge sender unit or fuel gauge sender sub-unit.
OIL PRESSURE SWITCH INSPECTION

1. Verify that the oil pressure warning light illuminates when the ignition switch is at the ON position.
2. Verify that the oil pressure warning light goes out when the engine is started.
 If the oil pressure warning light does not illuminate or remains illuminated, inspect the BCM and
 If the BCM and related wiring harness are normal, inspect the oil pressure. (See OIL
PRESSURE INSPECTION [MZI-3.7] .)
 If the oil pressure is normal, replace the oil pressure switch.
HORN REMOVAL/INSTALLATION
2. Slightly bend back the mudguard.
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Fig. 13: Identifying Horn Components

INFORMATION DISPLAY REMOVAL/INSTALLATION

Fig. 14: Identifying Information Display Components

INFORMATION DISPLAY INPUT/OUTPUT CHECK MODE
NOTE:  In this mode, it is possible to verify the items in the following chart.
CHECK CODE TABLE
CHECK CODE TABLE

Check
Check item Related items
code
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CAN system
01 Information display
DTC U2516: CAN system communication error

CAN system
 Audio unit DTC U0184: Communication error to audio unit
02 
 Climate control unit  DTC U0164: Communication error to climate
control unit
 TNS relay
04 TNS relay
 TNS signal wiring harness
06 Ignition switch Ignition switch

Dimmer cancel switch (Instrument  Instrument cluster
07
cluster)  Related wiring harness
- LCD LCD
NOTE:  The check codes are displayed in numerical order. (While performing the
inspection, if you want to inspect a check code with a number smaller than
the code number you are currently inspecting, terminate the check mode
then repeat the inspection from the beginning.)
Fig. 15: Information Display Input/Output Check Mode Procedure Chart

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CHECK CODE INSPECTION
Check code 01

Check code 01 CAN system
INSPECTION
DISPLAY ACTION
CONDITION
CAN system of information display is normal.
Select the check

code 01.
CAN system communication error. (DTC

U2516) (See DTC TABLE [MULTIPLEX
COMMUNICATION SYSTEM] )
Check code 02

 Communication status to audio unit
Check code 02
 Communication status to climate control unit
INSPECTION
DISPLAY ACTION
CONDITION
All communications are

normal.
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Communication to audio
unit is normal.
Select the check audio unit. (DTC U0184)
code 02. (The (See DTC TABLE
diagnostic results Audio unit
[MULTIPLEX
will be displayed
COMMUNICATION
once each in the
SYSTEM] )
order of audio unit
and heater control
unit.) Vehicle without audio unit.
Communication to climate
control unit is normal.
climate control unit. (DTC
Climate control U0164)
unit (See DTC TABLE
[MULTIPLEX
COMMUNICATION
SYSTEM] )
Vehicle without climate
control unit.
Check code 04

Check code 04 TNS relay ON/OFF signal
INSPECTION
STEP DISPLAY ACTION
CONDITION
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Turn the headlight switch to Verify that the voltage of information

1 the TNS position. (TNS relay display terminal C is B+.
ON)
replace the information display.
 TNS relay

TNS relay-information
display)
Verify that the voltage of the
information display terminal C is 1.0 V
or less.

Turn the headlight switch off.  TNS relay
2
(TNS relay OFF)  Wiring harness (TNS
relay-information display)
Input signal to the information display

is normal.
Check code 06

Check code 06 Ignition switch ON/OFF signal
INSPECTION
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STEP CONDITION DISPLAY ACTION
Turn the ignition switch Verify that the voltage of information

1 display terminal E is B+.
to the ON position.
 If the voltage is as specified, replace
the information display.
 Ignition switch

ignition switch-information
display)
Verify that the voltage of the information
display terminal E is 1.0 V or less.
 If the voltage is as specified, replace

the information display.
 Ignition switch
Turn the ignition switch  Wiring harness (Battery-
2
off. ignition switch-information
display)
Input signal to the information display is

normal.
Check code 07

Check code 07 Dimmer cancel switch ON/OFF signal
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INSPECTION
STEP DISPLAY ACTION
CONDITION
Turn the dimmer cancel Verify that the voltage of information

1
switch to the ON position. display terminal F is 0 V.

 Instrument cluster
 Wiring harness (Information

display-instrument cluster)
Verify that the voltage of the information
display terminal F is B+.

 Instrument cluster
Turn the dimmer cancel
2  Wiring harness (Information
switch off.
display-instrument cluster)
Input signal to the information display is

normal.
LCD
CHECK CODE INSPECTION CHART (LCD)

Check code - LCD
DISPLAY ACTION
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All segments and dots illuminated. LCD is normal.

Except above Replace the information display.
BLIND SPOT MONITORING (BSM) CONTROL MODULE

CAUTION:  If the BSM control modules are installed with the left and right
modules reversed, a DTC will be displayed and system will enter the
fail-safe function. Therefore, confirm that the left/right BSM control
modules are installed correctly.

4. Pull the connector in the direction shown by the arrow (2) in the+ figure and remove it while pressing the
tab in the direction shown by arrow (1).
5. Remove the nuts.
6. Remove the BSM control module.
8. Perform the blind spot monitoring radar test. (See BLIND SPOT MONITORING (BSM) RADAR
TEST.)
Fig. 16: View Of Blind Spot Monitoring Control Module & Torque Specifications
BLIND SPOT MONITORING (BSM) CONTROL MODULE INSPECTION

2. Remove the seat side box. (BSM control module (LH) only) (See SEAT SIDE BOX
3. Remove the trunk end trim. (BSM control module (LH) only) (Vehicles with Bose®) (See TRUNK END
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TRIM REMOVAL/INSTALLATION .)
4. Remove the bass-box. (BSM control module (LH) only) (Vehicles with Bose®) (See BASS-BOX
5. Remove the BSM control module with the connector connected.
6. Measure the BSM control module terminal voltage using the short wiring harness connector in the
position shown in the figure.
Fig. 17: Identifying Trunk End Trim & BSM Control Module Short Wiring Harness Connector
NOTE:  The BSM control module connector cannot be connected to a tester

due to its water-resistance processing, therefore the short wiring
harness connector is used for measuring the terminal voltage.
 If the terminal voltage is not as indicated in the table, inspect the
short wiring harness connector for continuity. (See CONTINUITY
INSPECTION OF SHORT WIRING HARNESS CONNECTOR.) If the
short wiring harness connector is normal, inspect the parts under
"Inspection items".
 If the system does not work properly even though the parts or
related wiring harnesses do not have any malfunction, replace
the BSM control module.
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Fig. 18: Identifying BSM Control Module Short Wiring Harness Connector Terminals
Connected Voltage (V)/
Terminal Signal Measurement condition Inspection item (s)
to Continuity
 Related
A BCM GND Body ground Under any condition 1.0 or less wiring
harnesses
Ignition switch is in ON  BSM
position and BSM indicator B+ indicator
BSM BSM
light is illuminated light
B indicator indicator
light signal light  Related
BSM indicator light is not wiring
1.0 or less
illuminated harnesses
C - - - - -
BSM OFF  BSM OFF
1.0 or less
switch is pressed switch
BSM OFF BSM OFF Ignition
D(1) switch signal switch switch at ON BSM OFF  Related
switch is not B+ wiring
pressed harnesses
D(2) - - - - -
E - - - - -
Because this terminal is for communication,  Related
F CAN_L - good/no good judgment by terminal voltage is wiring
not possible. harnesses
Ignition switch at ON B+  fuse
Power  Related
G fuse
supply wiring
Ignition switch off 1.0 or less
harnesses
Because this terminal is for communication,  Related
H CAN_H - good/no good judgment by terminal voltage is wiring
(1) BSM control module (RH) only
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(2) BSM control module (LH) only
NOTE:  Terminal voltage of both the left and right BSM control modules is
equivalent
CONTINUITY INSPECTION OF SHORT WIRING HARNESS CONNECTOR
1. Verify that the continuity between the short wiring harness connector terminals is as indicated in the
table.
 If the continuity is not as indicated in the table, replace the short wiring harness connector.
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Fig. 19: BSM Control Module Short Connector Terminals Continuity Chart
BLIND SPOT MONITORING (BSM) OFF SWITCH REMOVAL/INSTALLATION

2. Remove the dashboard under cover (LH). (See DASHBOARD UNDER COVER
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Fig. 20: View Of Blind Spot Monitoring OFF Switch

BSM OFF SWITCH REMOVAL NOTE
1. Access the BSM OFF switch from behind of the dashboard, and squeeze the tabs of the switch.
2. Remove the BSM OFF switch from the dashboard.
BLIND SPOT MONITORING (BSM) OFF SWITCH INSPECTION

1. Remove the BSM OFF switch. (See BLIND SPOT MONITORING (BSM) OFF SWITCH
 If not as indicated in the table, replace the BSM OFF switch.
Fig. 21: Blind Spot Monitoring OFF Switch Terminals Continuity Chart
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Fig. 22: Identifying Blind Spot Monitoring OFF Switch Terminals

BLIND SPOT MONITORING (BSM) BRACKET REMOVAL/INSTALLATION

4. Remove the BSM control module. (See BLIND SPOT MONITORING (BSM) CONTROL MODULE
5. Remove the nuts.
6. Remove the BSM bracket.
Fig. 23: Identifying Blind Spot Monitoring Bracket & Torque Specifications
CUSTOMIZED FUNCTION SETTING PROCEDURE

NOTE:  The BSM can be customized using the IDS only.
2. After vehicle identification, the following can be selected from the IDS initialization screen.
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1. Select "Programmable Parameters".
2. Select "Personality".
4. Select the item name, and than select either "Enabled/Disabled".
Items
 BSM buzzer

BLIND SPOT MONITORING (BSM) RADAR TEST

INTRODUCTION
 The BSM radar test examines the reflectivity from the SST (reflector) by forcibly emitting radar to the
SST.
 One BSM control module is installed on the left and right sides. Perform the radar test for each of them.
 Perform the radar test on level ground. The correct test results cannot be obtained if the vehicle and
reflector are set at different heights or different angles.
 A radar test cannot be performed correctly if obstructions which interfere with radar emitting adhere to
the BSM control module or the rear bumper. Perform the following procedure before performing the
radar test.
 Verify that there is no water or dirt adhering to the radar emitting surface of the BSM control
module and the rear bumper.
 Verify that there is no problem with the radar emitting surface of the BSM control module and the
rear bumper such as dirt, application of metallic stickers, or repairs using putty application.
 Perform the DTC inspection for the BSM using the M-MDS and verify that no DTCs are displayed.
 If any DTCs are displayed, perform troubleshooting according to the corresponding DTC
inspection. (See DTC TABLE [BLIND SPOT MONITORING (BSM)] .)
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RADAR TEST PROCEDURE
1. Remove any occupants and unload cargo from the cabin and trunk compartment so that the vehicle is in
an unloaded condition.
2. Adjust the air pressure of each tire to the specified value.
3. Park the vehicle on a flat, level surface.
4. Verify that there is no obstruction within a 3,500 mm {137.8 in} radius from the BSM control module as
Fig. 25: Identifying BSM Control Module Radius

CAUTION:  If an obstruction such as a drain lid or a person is within a 3,500

mm {137.8 in} radius from the BSM control module, it will
interfere with radar emitting and skew the radar test results.
Remove any obstruction which is within a 3,500 mm {137.8 in}
radius from the BSM control module.
5. Adjust the SST (plum-bob) so that it is aligned with the center of the brand emblem, determine the center
position at the front of the vehicle, and mark the center position on the floor surface.
NOTE:  The center of the brand emblem indicates the center position at the
front of the vehicle.
 A commercially-available plum-bob (weight: 150 g {5.29 oz}) can be
substituted for the SST.
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Fig. 26: Identifying Center Of Brand Emblem

6. Adjust the SST (plum-bob) so that it is aligned with the center of the brand emblem, determine the center
position at the rear of the vehicle, and mark the center position on the floor surface.
NOTE:  The center of the brand emblem indicates the center position at the
front of the vehicle.
 A commercially-available plum-bob (weight: 150 g {5.29 oz}) can be
substituted for the SST.
Fig. 27: Identifying Center Position Of Vehicle (Rear)

7. Position the leveling line over the marked positions at the front and rear of the vehicle, and then mark the
position on the floor surface 1,470 mm ± 8 mm {57.87 in ± 0.3 in} from the vehicle rear.
CAUTION:  If the center position at the vehicle rear is set first, the leveling
line could be misaligned. Determine the center position at the
vehicle front first, then set the center position at the vehicle
rear.
NOTE:  Use a commercially-available leveling line.
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Fig. 28: Identifying Leveling Line Position

8. Mark the position on the floor where a right angle is formed by the lines which cross at the point 1,470
mm ± 8 mm {57.87 in ± 0.3 in} from the vehicle rear and the point 1,790 mm ± 8 mm {70.47 in ± 0.8
in} from the vehicle side which is perpendicular to the vehicle's center line.
Fig. 29: Identifying BSM Control Module Radius

9. Set the SST (reflector) installation surface level using the bubble level built into the SST (tripod).
Fig. 30: Identifying SST (Reflector)

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10. Install the SSTs (reflector and plum-bob) to the SST (tripod) and adjust the height of the reflector at its
center to 534 mm ± 8 mm {21.0 in ± 0.3 in}.
Fig. 31: Identifying Height Of Reflector

11. Verify visually that the reflecting surface of the reflector is facing the BSM control module, and position
the SST (tripod) so that the SST (plum-bob) is positioned over the marked position.
Fig. 32: Identifying Center Plumbob Over Floor Mark

NOTE:  The BSM installation position is indicated in the figure.
12. Perform the BSM radar test according to the screen instructions using the IDS.
NOTE:  Use the IDS (laptop PC) because the PDS (Pocket PC) does not
support the blind spot monitoring (BSM) radar test.
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Fig. 33: Identifying BSM Installation Position


1. Select "Electrical".
1. Select "BSM Radar Test".
16. Perform the radar test according to the directions on the screen.
17. Verify the M-MDS display.
 "TEST PASSED" is displayed
 Radar is normal.
 "TEST FAILED" is displayed
 Perform the inspection according to the following table.

PROBLEM SYMPTOM CHART

VERIFY REFLECTOR POSITION
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Verify if the reflector is set in the correct

 Set the reflector in the correct position and
position. (See BLIND SPOT perform the BSM radar test.
1 No
MONITORING (BSM) RADAR TEST.) (See BLIND SPOT MONITORING
 Is the reflector set in the correct position?
(BSM) RADAR TEST.)
RE-PERFORM BSM RADAR TEST
 Perform the BSM radar test. Yes BSM radar test completed.
 Repeat the BSM radar test up to four times
2 until "TEST PASSED" is displayed.
(See BLIND SPOT MONITORING

(BSM) RADAR TEST.) No Go to the next step.
Is "TEST PASSED" displayed?


VERIFY EFFECT OF REAR BUMPER
 Remove the rear bumper. (See REAR

BUMPER Replace the rear bumper. (See REAR
REMOVAL/INSTALLATION .) Yes BUMPER
 Perform the BSM radar test. REMOVAL/INSTALLATION .)
3  Repeat the BSM radar test up to four times
until "TEST PASSED" is displayed.
(See BLIND SPOT MONITORING

(BSM) RADAR TEST.)
Is "TEST PASSED" displayed?

INSPECT BSM CONTROL MODULE FOR

INCORRECT INSTALLATION AND Yes Go to the next step.
DISTORTION AT VEHICLE
INSTALLATION SURFACE
4  Inspect the BSM control module for
incorrect installation and distortion at the Repair or replace the malfunctioning part,
No
vehicle installation surface. then go to the next step.
 Is the BSM control module installed
correctly without distortion?
PERFORM BSM RADAR TEST Yes BSM radar test completed.
 Perform the BSM radar test.

5
 Repeat the BSM radar test up to four times
until "TEST PASSED" is displayed. No Replace the BSM control module. (See
BLIND SPOT MONITORING (BSM)
(See BLIND SPOT MONITORING CONTROL MODULE
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(BSM) RADAR TEST.) REMOVAL/INSTALLATION.)
 Is "TEST PASSED" displayed?
Microsoft
2008 ENGINE PERFORMANCE Intake-Air System (MZI-3.7) - Mazda CX-9
Intake-Air System (MZI-3.7) - Mazda CX-9
INTAKE-AIR SYSTEM LOCATION INDEX [MZI-3.7]
Fig. 1: Identifying Intake-Air System Components Location

INTAKE-AIR SYSTEM DIAGRAM [MZI-3.7]
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Fig. 2: Intake-Air System Diagram

INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [MZI-3.7]
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Fig. 3: Intake-Air System Vacuum Hose Routing Diagram

INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7]
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.
Procedure".
3.7] .)
2. Remove the battery. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
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3.7] .)
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Fig. 4: Exploded View Of Intake-Air System & Torque Specification
Microsoft
INTAKE MANIFOLD REMOVAL NOTE

2. Disconnect the upper radiator hose.
Fig. 5: Identifying Intake Manifold Components Location

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 Intake Manifold, Thermostat Component & Torque Specification

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 Bolts Tighten 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 Bolts Tighten Sequence

AIR CLEANER ELEMENT INSPECTION [MZI-3.7]

1. Remove the air cleaner element. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-
3.7].)
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-3.7]

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
 If as specified, carry out the "Circuit Open/Short Inspection".
Throttle actuator resistance 1-900 ohms
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Fig. 9: Identifying Throttle Actuator


2. Inspect the following wiring harnesses for open or short (continuity check).
Fig. 10: Identifying Throttle Body Wiring Harness-Side Connector

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Open circuit
 Throttle body terminal A and PCM terminal 2BO
 Throttle body terminal B and PCM terminal 2BR
Short circuit
 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-3.7]

2. Remove the dashboard under cover (Driver side). (See DASHBOARD UNDER COVER
Fig. 12: Identifying Accelerator Pedal, Connector & Torque Specification

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2008 BODY & ACCESSORIES Interior Trim - Mazda CX-9
Interior Trim - Mazda CX-9
INTERIOR TRIM LOCATION INDEX
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Fig. 1: Identifying Interior Trim Location (1 Of 3)

Microsoft

Microsoft

DASHBOARD REMOVAL/INSTALLATION
1. Decoration panel (See DECORATION PANEL REMOVAL/INSTALLATION.)
2. Front console box mat (See FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION.)
3. Indicator panel (See INDICATOR PANEL REMOVAL/INSTALLATION.)
4. Front console box (See FRONT CONSOLE BOX REMOVAL/INSTALLATION.)
5. Dashboard under cover (See DASHBOARD UNDER COVER REMOVAL/INSTALLATION.)
6. Side wall (See SIDE WALL REMOVAL/INSTALLATION.)
7. Console panel (See CONSOLE PANEL REMOVAL/INSTALLATION.)
8. Console cover (See CONSOLE COVER REMOVAL/INSTALLATION.)
9. Console (See CONSOLE REMOVAL/INSTALLATION.)
10. Front scuff plate inner (See FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
11. Front side trim (See FRONT SIDE TRIM REMOVAL/INSTALLATION.)
12. Glove compartment (See GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
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14. Lower panel (See LOWER PANEL REMOVAL/INSTALLATION.)

15. Column cover (See COLUMN COVER REMOVAL/INSTALLATION.)
19. Center panel (See CENTER PANEL REMOVAL/INSTALLATION.)
20. Meter hood (See METER HOOD REMOVAL/INSTALLATION.)
24. A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION.)
25. Side panel (See SIDE PANEL REMOVAL/INSTALLATION.)
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Fig. 4: Identifying Dashboard Component Removal Sequence & Torque Specifications

BOLT D REMOVAL NOTE
CAUTION:  Bolt D cannot be removed from the body. Due to this, bolt D could be
pinched when closing the front door, resulting in damage to the front
door. When closing the front door, verify that bolt D is completely
inserted
DASHBOARD REMOVAL NOTE
WARNING:  Removing the dashboard without supporting it can be dangerous.

The dashboard may fall and injure you. Always perform the following
procedure with at least another person.
1. Raise the dashboard and detach the hooks from the body.
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Fig. 5: Identifying Dashboard & Hooks

2. Take the dashboard out through the opened front driver-side door.
DASHBOARD DISASSEMBLY/ASSEMBLY
1. Information display (See INFORMATION DISPLAY REMOVAL/INSTALLATION .)
2. GPS antenna (See GPS ANTENNA REMOVAL/INSTALLATION .)
3. Dashboard garnish (See DASHBOARD GARNISH REMOVAL/INSTALLATION.)
4. Hans-free telephone unit (See HANDS-FREE TELEPHONE (HF/TEL) UNIT
5. Passenger-side air bag module (See PASSENGER-SIDE AIR BAG MODULE
6. Front speaker (Vehicles With Bose®) (See FRONT SPEAKER
7. Tweeter (Vehicles Without Bose®) (See TWEETER REMOVAL/INSTALLATION .)
8. Center speaker (See CENTER SPEAKER REMOVAL/INSTALLATION .)
9. Keyless receiver (See KEYLESS RECEIVER REMOVAL/INSTALLATION .)
10. Keyless antenna (See KEYLESS ANTENNA REMOVAL/INSTALLATION [ADVANCED
KEYLESS SYSTEM] .)
11. keyless control module (See KEYLESS CONTROL MODULE REMOVAL/INSTALLATION
12. Auto light-off control module (Vehicles without auto light/wiper system) (See AUTO LIGHT-
OFF CONTROL MODULE REMOVAL/INSTALLATION .)
13. Auto light/wiper control module (Vehicles with auto light/wiper system) (See AUTO
LIGHT/WIPER CONTROL MODULE REMOVAL/INSTALLATION .)
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Fig. 6: Identifying Dashboard Wiring Harness, Member & Dashboard Face

COLUMN COVER REMOVAL/INSTALLATION

LOWER COLUMN COVER

2. Pull down the tilt wheel release lever.
3. Remove the lower column cover in the direction of the arrow.
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Fig. 7: Identifying Column Cover With Screw

UPPER COLUMN COVER REMOVAL
1. Pull the upper column cover upward and detach the upper column cover from the lower column cover.
Fig. 8: Identifying Upper Column Cover

2. Push the rubber in the direction of the arrow while pinching part A of the rubber.
CAUTION:  Remove the rubber by pressing it from the backside of the

upper column cover. The rubber may deform if it is pulled
forcibly or pried with a flathead screwdriver.
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Fig. 9: Identifying Rubber Pushing Direction

3. Push the rubber in the direction of the arrow while partially peeling part B of the rubber.

4. Push part C of the rubber in the direction of the arrow and remove the upper column cover.

UPPER COLUMN COVER INSTALLATION

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1. Push the rubber in the direction of the arrow in the order of A, B, and C part to install the upper column
cover to the rubber.
2. Install the upper column cover to the lower column cover.
Fig. 12: Identifying Upper Column Cover

CENTER PANEL REMOVAL/INSTALLATION

4. Detach clips A by pulling them in the direction of the arrow.
CAUTION:  When removing center panel clips A, perform the work carefully
so that the panel corners or the clips do not interfere with the
center speaker and scratch or damage it.
5. Disconnect the climate control unit connectors and hazard warning switch connector.
6. Remove the center panel.
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Fig. 13: Identifying Center Panel, Speaker & Connector

CAUTION:  The ventilator grilles will be installed to the shaded areas shown
in the figure. Therefore, if a wiring harness is in the areas, it
could get caught and damaged. When installing the center
panel, completely press in the wiring harnesses of the hazard
warning switch connector in the direction of the arrow so that
the wiring harnesses will not be caught.
Fig. 14: Identifying Air Flow

LOWER PANEL REMOVAL/INSTALLATION

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3. Console panel (LH) (See CONSOLE PANEL REMOVAL/INSTALLATION.)
4. Detach clips A and hook B by pulling them in the direction of the arrow.
5. Remove the hook B.
6. Disconnect the head light leveling switch connector and TCS OFF switch connector.
7. Disconnect the BSM OFF switch connector. (Vehicles with BSM)
8. Disconnect the PLG switch connector. (Vehicles with PLG)
9. Disconnect the cabin temperature sensor connector and air hose.
10. Remove the lower panel.
Fig. 15: Identifying Lower Panel Components

SIDE PANEL REMOVAL/INSTALLATION

1. Remove the glove compartment service hole cover. (See AIR FILTER
2. Insert fingers into the glove compartment service hole and detach the tabs A.
3. Remove the side panel in the direction of the arrow.
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Fig. 16: Identifying Side Panel & Tab

METER HOOD REMOVAL/INSTALLATION

6. Upper column cover (See COLUMN COVER REMOVAL/INSTALLATION.)
2. Detach clips A and pins B by pulling them in the direction of the arrow.
3. Remove the meter hood.
Fig. 17: Identifying Meter Hood & Clips

GLOVE COMPARTMENT REMOVAL/INSTALLATION
CAUTION:  If the glove compartment is closed without being joined to the stay
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damper, the stay damper may be damaged. Verify that the stay
damper is joined to the glove compartment before closing the glove
compartment.

2. Glove compartment service hole cover (See AIR FILTER REMOVAL/INSTALLATION .)
2. Pull the stay damper in the direction shown in the figure, and detach the connecting part between the
glove compartment and the stay damper.
Fig. 18: Identifying Glove Compartment & Stay Damper

3. Insert fingers into the glove compartment service hole and detach the stoppers while holding the
instrument panel.
Fig. 19: Identifying Glove Compartment Service Hole

4. Lower the glove compartment.

5. Detach the hook from the dashboard and remove the glove compartment.
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Fig. 20: Identifying Glove Compartment With Hook

VENTILATOR GRILLE REMOVAL/INSTALLATION

DRIVER SIDE

6. Upper column cover (See COLUMN COVER REMOVAL/INSTALLATION.)
4. Remove the hook.
5. Remove the ventilator grille in the direction of the arrow.
Fig. 21: Identifying Ventilator Grille With Hook & Screw - Driver Side
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PASSENGER SIDE

7. Dashboard garnish (See DASHBOARD GARNISH REMOVAL/INSTALLATION.)
4. Remove the hook.
Fig. 22: Identifying Ventilator Grille With Hook & Screw - Passenger Side
CENTER

3. Remove the screws
4. Remove the ventilator grille.
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Fig. 23: Identifying Ventilator Grille & Center Panel With Screw - Center
REAR

2. Remove the console cover. (See CONSOLE COVER REMOVAL/INSTALLATION.)
3. Remove the rear cooler duct. (See REAR COOLER DUCT REMOVAL/INSTALLATION .)
4. Detach the pins A while holding the console cover.
Fig. 24: Identifying Ventilator Grille & Center Panel With Screw - Rear
INNER SAIL GARNISH REMOVAL/INSTALLATION

1. Pull the sail garnish outward, then detach clips A.
2. Remove the inner sail garnish.
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Fig. 25: Identifying Inner Sail Garnish & Clip

SIDE WALL REMOVAL/INSTALLATION

2. Detach clips A and hook by pulling them in the direction of the arrow.
3. Remove the side wall.
Fig. 26: Identifying Side Wall Hook & Clips

DASHBOARD UNDER COVER REMOVAL/INSTALLATION

DRIVER SIDE

2. Detach tab A and hook by pulling them in the direction of the arrow.
3. Remove the dashboard under cover.
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Fig. 27: Identifying Dashboard Under Cover, Hook & Clips (Driver Side)
PASSENGER SIDE
1. Insert fingers into the service hole and detach clips A and pin B and hooks by pulling it in the direction of
the arrow.
2. Remove the dashboard under cover.
Fig. 28: Identifying Dashboard Under Cover, Hook & Clips (Passenger Side)
DASHBOARD GARNISH REMOVAL/INSTALLATION

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4. Detach clips A by pulling them in the direction of the arrow.
5. Remove the dashboard garnish.
Fig. 29: Identifying Dashboard Garnish Screw & Clips

INDICATOR PANEL REMOVAL/INSTALLATION

REMOVAL/INSTALLATION.
2. Detach clips A and tabs B and C by pulling them in the direction of the arrow.
3. Remove the indicator panel.
4. Install in the reverse order of removal. indicator
Fig. 30: Identifying Indicator Panel With Clips & Tab

FRONT CONSOLE BOX MAT REMOVAL/INSTALLATION

1. Insert a tape-wrapped flathead screwdriver between the indicator panel and front console box mat.
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CAUTION:  The rubber may deform if it is pried with a flathead screwdriver.

Therefore, fully insert a tape-wrapped flathead screwdriver as
shown in the figure, and do not pry the rubber.
2. Raise the front console box mat.
Fig. 31: Inserting Screwdriver Between Indicator Panel & Front Console Box Mat
3. Remove the front console box mat in the direction of the arrow.
4. Remove the front console box mat.
Fig. 32: View Of Front Console Box Mat

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FRONT CONSOLE BOX REMOVAL/INSTALLATION

4. Detach clip A and hooks by pulling them in the direction of the arrow.
6. Remove the front console box.
Fig. 33: Identifying Front Console Box & Connector

CONSOLE COVER REMOVAL/INSTALLATION

2. Detach clips A and tabs B by pulling them in the direction of the arrow.
3. Disconnect the rear climate control unit connector.
4. Remove the console cover.
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Fig. 34: Identifying Console Cover & Connector

CONSOLE REMOVAL/INSTALLATION
5. Disconnect the accessory socket connector and auxiliary jack connector, and keyless antenna connector.
6. Remove the console in the direction of the arrow.
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Fig. 35: Identifying Console With Accessory Socket Connector, Auxiliary Jack Connector &
CONSOLE DISASSEMBLY/ASSEMBLY
Fig. 36: Identifying Console Components

DECORATION PLATE REMOVAL NOTE
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1. Slide the decoration plate towards the vehicle front as shown in the figure, then pull out the pin and hooks
and remove the decoration plate.
Fig. 37: Sliding Decoration Plate

DECORATION PANEL REMOVAL/INSTALLATION

1. Detach clips A and pin B by pulling them in the direction of the arrow.
2. Remove the decoration panel.
Fig. 38: Identifying Decoration Panel With Pin & Clips

CONSOLE PANEL REMOVAL/INSTALLATION

RH
1. Remove the decoration panel (RH). (See DECORATION PANEL REMOVAL/INSTALLATION.)

3. Detach clips A and B, and hooks by pulling them in the direction of the arrow.
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4. Remove the console panel.

Fig. 39: Identifying RH Console Panel With Clips & Hooks

LH
1. Remove the decoration panel (LH). (See DECORATION PANEL REMOVAL/INSTALLATION.)

3. Remove the side wall. (See SIDE WALL REMOVAL/INSTALLATION.)
5. Detach clips A and B, and hooks by pulling them in the direction of the arrow.
6. Remove the console panel.
Fig. 40: Identifying LH Console Panel With Clips & Hooks

A-PILLAR TRIM REMOVAL/INSTALLATION

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2. Pull the A-pillar trim shown in the figure in the direction of the arrow, raise clip B from its grommet
together with the A-pillar trim, and remove clips A at the same time.
Fig. 41: Identifying A-Pillar Trim & Clips

3. Slide the A-pillar trim in the direction of the arrow shown in the figure and remove the A-pillar trim from
clip B.
Fig. 42: Sliding A-Pillar Trim

4. Rotate and pull clip B in the direction of the arrow shown in the figure until it is no longer loose, and
feels tight.
5. Pull clip B and remove it from the grommet.
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Fig. 43: Identifying Grommet & Clip

6. Insert a tape-wrapped flathead screwdriver between the body and the grommet.
7. Press the tabs and remove the grommet.
8. Install the new grommet to the body.
9. Install the new clip B to the A-pillar trim.
10. Install the A-pillar trim.
Fig. 44: Inserting Screwdriver Between Body & Grommet

FRONT SIDE TRIM REMOVAL/INSTALLATION

1. Remove the front scuff plate inner. (See FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
3. Remove the nut.
4. Pull the front side trim upward, then detach clip A, pin B.
5. Remove the front side trim.
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Fig. 45: Identifying Front Side Trim With Nut & Clips
B-PILLAR LOWER TRIM REMOVAL/INSTALLATION

1. Remove the front scuff plate inner. (See FRONT SCUFF PLATE REMOVAL/INSTALLATION.)
2. Remove the rear scuff plate inner. (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)
3. Remove the front seat belt lower anchor installation bolt (Driver side). (See FRONT SEAT BELT
5. Detach tabs A and clips B and D, and pins C, by pulling them in the direction of the arrow.
6. Remove the B-pillar lower trim.
Fig. 46: Identifying B-Pillar Lower Trim With Tab & Clips
B-PILLAR UPPER TRIM REMOVAL/INSTALLATION

2. Rear scuff plate inner (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)
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4. B-pillar lower trim (See B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.)
3. Detach clips A and C, and pin B by pulling them in the direction of the arrow.
Fig. 47: Identifying B-Pillar Upper Trim With Pin & Clips
4. Remove the B pillar upper trim in the direction of the arrow.

Fig. 48: Identifying B-Pillar Upper Trim

ROOF SIDE TRIM REMOVAL/INSTALLATION

1. Detach clip A and B, and tab C by pulling them in the direction of the arrow.
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2. Remove the roof side trim.

Fig. 49: Identifying Roof Side Trim & Clips

C-PILLAR TRIM REMOVAL/INSTALLATION

1. Trunk box (See TRUNK BOX REMOVAL/INSTALLATION.)
2. Seat side box (See SEAT SIDE BOX REMOVAL/INSTALLATION.)
3. Trunk end trim (See TRUNK END TRIM REMOVAL/INSTALLATION.)
7. Trunk side trim (See TRUNK SIDE TRIM REMOVAL/INSTALLATION.)
9. Roof side trim (See ROOF SIDE TRIM REMOVAL/INSTALLATION.)
4. Remove the cover in the direction of the arrow.
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Fig. 50: Identifying C-Pillar Trim & Cover

5. Remove the bolt.

6. Detach clip A and tab B, and pin C by pulling them in the direction of the arrow.
7. Remove the C-pillar trim.
Fig. 51: Identifying C-Pillar Trim With Bolt & Clips

D-PILLAR TRIM REMOVAL/INSTALLATION

5. Third-row seat belt lower anchor installation bolt (See REAR SCUFF PLATE
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2. Remove the PLG arm band. (Vehicles with PLG)
Fig. 52: Identifying Liftgate Side Trim & Band


5. Detach clips A and pins B by pulling them in the direction of the arrow.
6. Remove the D-pillar trim.
Fig. 53: Identifying D-Pillar Trim With Fasteners & Clips

FRONT SCUFF PLATE REMOVAL/INSTALLATION

FRONT SCUFF PLATE INNER
1. Pull the front scuff plate inner upward while detaching tab A, detach clips B, pins C, and tab D, from the
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body, and then remove the front scuff plate inner.

Fig. 54: Identifying Front Scuff Plate Inner With Clips & Tab
FRONT SCUFF PLATE OUTER
1. Pull the front scuff plate outer upward, detach clips A, tabs B, and pin C, from the body, and then remove
the front scuff plate outer.
Fig. 55: Identifying Front Scuff Plate Outer With Clips & Tab
REAR SCUFF PLATE REMOVAL/INSTALLATION

REAR SCUFF PLATE INNER
1. Pull the rear scuff plate inner upward while detaching tab A, detach clips B, pins C, and tab D, from the
body, and then remove the rear scuff plate inner.
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Fig. 56: Identifying Rear Scuff Plate Inner With Tab & Clips
REAR SCUFF PLATE OUTER
1. Pull the rear scuff plate outer upward, detach clips A, tabs B, and pin C, from the body, and then remove
the rear scuff plate outer.
Fig. 57: Identifying Rear Scuff Plate Outer With Tab & Clips
INNER GARNISH REMOVAL/INSTALLATION

1. Detach clips A and hook B by pulling them in the direction of the arrow.
2. Remove the inner garnish.
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Fig. 58: Identifying Inner Garnish With Hook & Clips

REAR DOOR TRIM DISASSEMBLY/ASSEMBLY

Fig. 59: Identifying Rear Door Trim Components

TRUNK END TRIM REMOVAL/INSTALLATION

1. Remove the trunk box. (See TRUNK BOX REMOVAL/INSTALLATION.)
2. Remove the seat side box. (See SEAT SIDE BOX REMOVAL/INSTALLATION.)
3. Detach clips A and pin B by pulling them in the direction of the arrow.
4. Remove the trunk end trim.
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Fig. 60: Identifying Trunk End Trim With Pin & Clip
TRUNK SIDE TRIM REMOVAL/INSTALLATION

DRIVER SIDE

5. Rear scuff plate inner (LH) (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)
3. Pull the cup holder upward and detach clips A, pins B, and tabs C. (Vehicles without RES)
4. Pull the auxiliary terminal unit panel upward and detach clips A, pins B, and tabs C. (Vehicles with RES)
5. Disconnect the power supply socket connector and external input connector. (Vehicles with RES)
6. Remove the cup holder. (Vehicles without RES)
7. Remove the external input panel. (Vehicles with RES)
8. Remove the bolts, and remove the cargo net hook.
9. Remove the cover.
12. Pull the trunk side trim outward and detach clips D, tabs E, and pin F.
13. Remove the trunk side trim.
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Fig. 61: Identifying Trunk Side Trim Remove/Install Components (Driver Side)
PASSENGER SIDE

5. Rear scuff plate inner (RH) (See REAR SCUFF PLATE REMOVAL/INSTALLATION.)
6. Third-row seat belt lower anchor installation bolt (RH) (See THIRD-ROW SEAT BELT
3. Pull the cup holder upward and detach clips A, pins B, and tabs C.
4. Remove the cup holder.
5. Remove the bolts, and remove the cargo net hook.
9. Pull the trunk side trim outward and detach clips D, tabs E, and pin F.
10. Disconnect the accessory socket connector.
11. Remove the trunk side trim.
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Fig. 62: Identifying Trunk Side Trim Components (Passenger Side)

FRONT DOOR TRIM REMOVAL/INSTALLATION

2. Remove the inner garnish. (See INNER GARNISH REMOVAL/INSTALLATION.)
3. Open the cover using a small flathead screwdriver and remove the screw.
4. Remove the armrest garnish in the direction of the arrow.
5. Remove the bolt.
6. Detach clips A from the front door using a fastener remover.
7. Pull the front door trim upward and detach tabs B from the front door.
Fig. 63: Identifying Armrest Garnish, Clips & Bolts

8. Remove tab A, and move the front door trim in the direction of the arrow.
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Fig. 64: Identifying Inner Handle & Cover

9. Turn the inner handle cover in the direction of the arrow and remove it from the front door trim.
10. Disconnect the power window main switch connector and the power outer mirror switch connector and
door lock switch connector. (Driver side)
11. Disconnect the power window subswitch connector. (Passenger side)
12. Disconnect the courtesy light connector.
13. Remove the front door trim.
Fig. 65: Turning Inner Handle Cover

FRONT DOOR TRIM DISASSEMBLY/ASSEMBLY

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Fig. 66: Identifying Front Door Trim Components

REAR DOOR TRIM REMOVAL/INSTALLATION

2. Remove the inner sail garnish. (See INNER SAIL GARNISH REMOVAL/INSTALLATION.)
3. Open the cover A using a small flathead screwdriver and remove the screw.
4. Pull up the cover B and remove the screw.
5. Detach clips A from the front door using a fastener remover.
6. Pull the front door trim upward and detach tabs B from the front door.
Fig. 67: Identifying Rear Door Trim, Cover & Screw

7. Remove tab A, and move the rear door trim in the direction of the arrow.
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Fig. 68: Identifying Inner Handle & Cover

8. Turn the inner handle cover in the direction of the arrow and remove it from the rear door trim.
9. Disconnect the power window subswitch connector.
10. Remove the rear door trim.
Fig. 69: Turning Inner Handle Cover

TRUNK BOX REMOVAL/INSTALLATION

1. Open the trunk board.
3. Remove the trunk box in the direction of the arrow.
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Fig. 70: Identifying Trunk Box With Clips

SEAT SIDE BOX REMOVAL/INSTALLATION

WITH BOSE®

2. Detach clips A and tab B by pulling them in the direction of the arrow.
3. Remove the seat side box.
Fig. 71: Identifying Seat Side Box With Clips & Tab
WITHOUT BOSE®

2. Detach pins by pulling them in the direction of the arrow.
3. Remove the seat side box.
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Fig. 72: Identifying Seat Side Box With Clips & Tab
LIFTGATE UPPER TRIM REMOVAL/INSTALLATION

1. Detach tabs A, clips B, and pin C by pulling them in the direction of the arrow.
2. Remove the liftgate upper trim.
Fig. 73: Identifying Liftgate Upper Trim, Clips, Pin & Tab
LIFTGATE SIDE TRIM REMOVAL/INSTALLATION

1. Remove the liftgate upper trim. (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION.)
2. Remove the PLG arm band. (Vehicles with PLG)
4. Detach clips A and tab C by pulling them in the direction of the arrow.
5. Remove the liftgate side trim.
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Fig. 74: Identifying Liftgate Side Trim With Clips & Tab
LIFTGATE LOWER TRIM REMOVAL/INSTALLATION

2. Remove the liftgate upper trim. (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION.)
3. Remove the liftgate side trim. (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION.)
4. Insert a tape-wrapped flathead screwdriver into the position shown in the figure, and pull the screwdriver
in the direction of the arrow to detach clips A.
5. Detach tabs B and remove the liftgate recess.
6. Disconnect the PLG sub switch connector. (Vehicles with PLG)
Fig. 75: Removing Liftgate Recess


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8. Detach clips A, tabs B, and pins C by pulling them in the direction of the arrow.
9. Disconnect the cargo compartment light connector.
10. Remove the liftgate lower trim.
Fig. 76: Identifying Liftgate Lower Trim & Fasteners

ASSIST HANDLE REMOVAL/INSTALLATION

ASSIST HANDLE REMOVAL
1. Insert a flathead screwdriver into the service hole and remove the assist handle covers.
Fig. 77: Removing Assist Handle Covers

2. Insert a tape-wrapped flathead screwdriver into the position shown in the figure, press the flathead
screwdriver in the direction of the arrow and press the clip away from the assist handle bracket.
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CAUTION:  When inserting a flathead screwdriver, be careful not to damage

the assist handle tabs shown in the figure.
3. Remove the assist handle by shaking it up and down.
Fig. 78: Removing Assist Handle Bracket

ASSIST HANDLE INSTALLATION
1. Push the assist handle in the direction of the arrow with the assist handle cover assembled to install the
assist handle.
Fig. 79: Pushing Assist Handle

SUNVISOR REMOVAL/INSTALLATION
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4. Rotate the sunvisor in the direction of the arrow.
5. Unhook and remove the sunvisor.
6. Disconnect the vanity mirror illumination connector.
Fig. 80: Identifying Sunvisor, Cover, Hook & Screw

7. Press the center adaptor tabs as shown in the figure using two tape-wrapped flathead screwdrivers, and
remove the center adaptor.
Fig. 81: Pressing Center Adaptor Tabs

HEADLINER REMOVAL/INSTALLATION
1. A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION.)
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7. B-pillar upper trim (See B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.)
13. Trunk side trim (See TRUNK SIDE TRIM REMOVAL/INSTALLATION)
16. C-pillar trim (See C-PILLAR TRIM REMOVAL/INSTALLATION.)
18. D-pillar trim (See D-PILLAR TRIM REMOVAL/INSTALLATION.)
20. Sunvisor (See SUNVISOR REMOVAL/INSTALLATION.)
21. Assist handle (See ASSIST HANDLE REMOVAL/INSTALLATION.)
4. Disconnect the roof harness connector.
5. Disconnect the rear washer hose.
6. Remove the sunroof seaming welt. (Vehicles with sunroof)
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Fig. 82: Identifying Headliner, Roof Harness & Fasteners

8. Take the headliner out from the opened liftgate.

Fig. 83: Identifying Headliner

FLOOR COVERING REMOVAL/INSTALLATION

1. Front seat (See FRONT SEAT REMOVAL/INSTALLATION .)
4. long slider cover (See LONG SLIDER REMOVAL/INSTALLATION .)
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11. Front side trim (See FRONT SIDE TRIM REMOVAL/INSTALLATION.)
12. Dust cover (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION .)
20. Console (See CONSOLE REMOVAL/INSTALLATION.)
26. Fuel-filler lid release cover (See FUEL-FILLER LID OPENER
3. Remove the fasteners A and B.
4. Remove the nut.
5. Take the floor covering out from the opened liftgate.
Fig. 84: Identifying Floor Covering With Fasteners

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2008 BODY & ACCESSORIES Lighting Systems - Mazda CX-9
Lighting Systems - Mazda CX-9
LIGHTING SYSTEMS LOCATION INDEX
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Fig. 1: Identifying Lighting Systems Location

DISCHARGE HEADLIGHT SERVICE WARNINGS

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DISCHARGE HEADLIGHT BULB SERVICE WARNINGS
 To prevent electrical shock when replacing the discharge headlight bulb, dry hands thoroughly,
and perform the work in an area out of rain.
 When the light switch is on, approx. 25,000 V of high voltage passes through the discharge
headlight bulb socket. Because of the danger of electrical shock, do not insert fingers or a tester.
 When the headlights are on, high voltage flows around the socket and bulb. When turning on the
discharge headlights while working, always leave the headlights in the vehicle-installed condition to
prevent electrical shock.
Fig. 2: Precaution For - Discharge Headlight Bulb Service Warnings

DISCHARGE HEADLIGHT CONTROL MODULE SERVICE WARNINGS
 Because of the danger of electrical shock, when inspecting with a tester, do not inspect the
discharge headlight control module as a single unit or disassemble it.
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Fig. 3: Precaution For - Discharge Headlight Control Module Service Warnings

DISCHARGE HEADLIGHT CONTROL MODULE REUSE
 If the discharge headlight control module is dented or damaged in any way, replace the module
with a new one to prevent electrical shock and improper operation.
 Although the control module may temporarily operate normally even though it has received an
impact, it is possible that the interior may have been damaged. When reusing the control module,
inspect the following items regarding discharge headlight illumination to verify that there are no
malfunctions.
 Verify that the discharge headlights illuminate normally by testing them several times under
cold illumination (headlights off for approx. 10 min or more and then turned on) and hot
illumination (headlights on for approx. 15 min or more, turned off for approx. 1 min, and
then turned on again) conditions.
 Inspect the headlight illumination in the period from directly after cold illumination until
they are uniformly illuminated (approx. 5 min) and verify that there is no flickering or
inconsistent brightness.
 Turn on the headlights for approx. 30 min with normal condition bulbs and verify that there
is no brightness difference between the right and left, and that illumination is consistent.
FRONT COMBINATION LIGHT REMOVAL/INSTALLATION
WARNING:  Incorrect servicing of the discharge headlights could result in

electrical shock. Before servicing the discharge headlights, always
refer to the DISCHARGE HEADLIGHT SERVICE WARNINGS. (See
DISCHARGE HEADLIGHT SERVICE WARNINGS.)

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Fig. 4: Identifying Front Combination Light, Connector, Bolt & Torque Specifications

5. Adjust the headlight aiming. (See HEADLIGHT AIMING.)
HEADLIGHT AIMING
2. Position the unloaded vehicle on a flat, level surface.
3. Seat one person in the driver's seat.
4. Position the vehicle straight ahead and perpendicular to the white screen.
5. Set the headlights 3 m {9.8 ft} from the white screen.
6. Place an object in front of the headlight not being adjusted to block its light beam.
7. Start the engine so that the battery remains charged.
8. Turn on the low-beam headlight.
9. Set the headlight leveling switch to the 0 position. (Vehicles with headlight leveling switch)
Fig. 5: Adjusting Headlight Aiming

10. Adjust by turning the aiming adjustment screw so that elbow point is in the position shown in the figure.
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Fig. 6: Turning Aiming Adjustment Screw

HEADLIGHT BULB REMOVAL/INSTALLATION

LOW-BEAM
Halogen type

2. Remove the coolant reserve tank. (RH only) (See COOLANT RESERVE TANK
Fig. 7: Identifying Halogen Headlight Bulb, Connector & Cover

CAUTION:  A halogen bulb generates extremely high heat when it is

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illuminated. If the surface of the bulb is soiled, excessive heat

will build up and the life of the bulb will be shortened. When
replacing the bulb, hold the metal flange, not the glass.
Discharge type


Fig. 8: Identifying Discharge Headlight Bulb, Connector & Cover

CAUTION:  The bulb generates extremely high heat when it is illuminated. If

the surface of the bulb is soiled, excessive heat will build up
and the life of the bulb will be shortened. When replacing the
bulb, hold the metal flange, not the glass.
Discharge headlight bulb removal note
1. Press sections A to release the bulb retaining wire and remove the discharge headlight bulb.
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Fig. 9: Identifying Discharge Headlight Bulb

HIGH-BEAM

Fig. 10: Identifying Halogen Headlight Bulb, Connector & Cover


replacing the bulb, hold the metal flange, not the glass.
DISCHARGE HEADLIGHT CONTROL MODULE REMOVAL/INSTALLATION


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3. Remove the front combination light. (See FRONT COMBINATION LIGHT
Fig. 11: Identifying Discharge Headlight Control Module, Connector & Screws
DISCHARGE HEADLIGHT SYSTEM INSPECTION

DISCHARGE HEADLIGHT INOPERATIVE
WARNING:  Incorrect servicing of the discharge headlights could result in electric

shock. Before servicing the discharge headlights, always refer to the
DISCHARGE HEADLIGHT SERVICE WARNINGS. (See DISCHARGE
HEADLIGHT SERVICE WARNINGS.)
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Fig. 12: Identifying Relay & Main Fuse Block

Inspection procedure
INSPECTION PROCEDURE
INSPECT POWER SUPPLY CIRCUIT OF
DISCHARGE HEADLIGHT CONTROL
MODULE
Yes Go to Step 6.
 Disconnect the discharge headlight control
module connector.
1  Turn the headlight switch to the
HEADLIGHT (LO) position.
 Measure the voltage at discharge headlight
control module terminal A (wiring harness- No Go to the next step.
side).
INSPECT FUSE
2  Turn the headlight switch to the OFF
position.
 Remove the H/L LOW R 15 A fuse or H/L
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LOW L 15 A fuse.
 Inspect the fuses. No Replace the fuse.
 Are the fuses normal?
INSPECT H/L LOW RELAY Yes Go to the next step.

3 Inspect the H/L LOW relay. (See RELAY

INSPECTION .) Replace the H/L LOW relay. (See RELAY
No
INSPECTION .)
 Is the H/L LOW relay normal?
INSPECT LIGHT SWITCH Yes Go to the next step.
4 Inspect the light switch. (See LIGHT

 Replace the light switch. (See LIGHT
SWITCH INSPECTION.) No SWITCH
 Is the light switch normal?
BATTERY AND DISCHARGE HEADLIGHT
CONTROL MODULE
 Disconnect the negative battery cable.

5  Battery (positive terminal) and H/L
LOW relay terminal E.
 H/L LOW R 15 A fuse and discharge
headlight control module terminal A No Replace the related wiring harness.
 H/L LOW L 15 A fuse and discharge
headlight control module terminal A

MODULE AND GROUND Yes Go to the next step.
 Inspect the wiring harness between

6 discharge headlight control module terminal
B and ground for the following:
No Replace the related wiring harness.
 Open circuit

DISCHARGE HEADLIGHT BULB OR Yes System inspection completed.
MODULE
 Install the discharge headlight low bulb

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(previously verified as illuminating

normally). (See HEADLIGHT BULB
REMOVAL/INSTALLATION.) Replace the discharge headlight control
 Connect the discharge headlight control module. (See DISCHARGE
7 module connector. No
HEADLIGHT CONTROL MODULE
 Turn the headlight switch to the REMOVAL/INSTALLATION.)
HEADLIGHT (LO) position.
 Does the headlight (low-beam) illuminate?
PARKING/FRONT SIDE MARKER LIGHT BULB REMOVAL/INSTALLATION

Fig. 13: Identifying Parking/Front Side Marker Light Bulb, Connector & Socket
FRONT TURN LIGHT BULB REMOVAL/INSTALLATION

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Fig. 14: Identifying Front Turn Light Bulb & Socket

FRONT FOG LIGHT REMOVAL/INSTALLATION

Fig. 15: Identifying Front Fog Light, Bolt & Torque Specifications

5. Adjust the front fog light aiming. (See FRONT FOG LIGHT AIMING.)
FRONT FOG LIGHT AIMING

1. Make a front fog light adjustment screen as shown in the figure using double-weight, white paper.
3. Position the unloaded vehicle on a flat, level surface.
4. Seat one person in the driver's seat.
Fig. 16: Identifying Front Fog Light Adjustment Screen

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5. Line up the front fog lights with the white screen at a distance of 3 m {9.8 ft} apart.
6. Place an object in front of the fog light not being adjusted to block its light beam.
7. Start the engine so that the battery remains charged.
8. Turn the front fog lights on.
Fig. 17: Adjusting Front Fog Light Aiming

9. Remove the adjusting bolt and cut the front fog light hole cover at the position shown in the figure.
10. Loosen the screw, move the front fog light in the direction of the arrows, and adjust the center of the front
fog light to the position shown in the figure.
11. Install the adjusting bolt and tighten the screw.
Fig. 18: Identifying Adjusting Bolt & Torque Specifications

FRONT FOG LIGHT BULB REMOVAL/INSTALLATION

2. Remove the front undercover B. (See FRONT UNDER COVER REMOVAL/INSTALLATION .)
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Fig. 19: Identifying Front Fog Light Bulb & Connector

FRONT FOG LIGHT BULB REMOVAL NOTE
1. Remove the front fog light bulb by turning it in the direction shown by the arrow.

handling the bulb, hold the flange, not the glass.
Fig. 20: Identifying Front Fog Light Bulb

FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION
NOTE:  Front side turn lights are integrated with the power outer mirror.

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REAR COMBINATION LIGHT REMOVAL/INSTALLATION

Fig. 21: Identifying Rear Combination Light Components

INBOARD LIGHT REMOVAL/INSTALLATION

2. Remove the service hole cover.
Fig. 22: Identifying Service Hole Cover

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Fig. 23: Identifying Inboard Light, Connector, Bracket, Nut & Torque Specifications
INBOARD LIGHT INSTALLATION NOTE
1. Insert the inboard light into the liftgate as shown in the figure, pivot it inward and then fix in place.
Fig. 24: Inserting Inboard Light Into Liftgate

2. Push the bracket onto the liftgate as shown in the figure and install.
Fig. 25: Pushing Bracket Onto Liftgate

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HIGH-MOUNT BRAKE LIGHT REMOVAL/INSTALLATION

3. Remove the rear spoiler. (See REAR SPOILER REMOVAL/INSTALLATION .)
Fig. 26: Identifying High-Mount Brake Light & Screw

INBOARD LIGHT BULB REMOVAL/INSTALLATION

Fig. 27: Identifying Service Hole Cover

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Fig. 28: Identifying Inboard Light Bulb, Taillight Bulb, Connector & Socket
LICENSE PLATE LIGHT REMOVAL/INSTALLATION

LICENSE PLATE LIGHT

2. Remove the liftgate upper trim.(See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION .)
3. Remove the liftgate side trim.(See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION .)
4. Remove the liftgate lower trim.(See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
Fig. 29: Identifying License Plate Light, Connector & Lens

LICENSE PLATE LIGHT BULB

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Fig. 30: Identifying License Plate Light Bulb & Lens

LENS REMOVAL NOTE
1. Insert a tape-wrapped flathead screwdriver into the service hole and pry with the screwdriver in the
direction shown by the arrow to remove the lens.
Fig. 31: Inserting Screwdriver Into Service Hole

COMBINATION SWITCH REMOVAL/INSTALLATION
WARNING:  If the negative battery cable or the steering angle sensor connector
is disconnected, the stored initial position of the steering angle
sensor will be cleared and the DSC will not operate properly, making
the vehicle unsafe to drive. Perform the steering angle sensor
initialization procedure after connecting the negative battery cable.

2. Disconnect the negative battery cable and wait for 1 min or more.
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4. Put aside the upper column cover.
Fig. 32: Identifying Combination Switch, Connector & Screw

6. Disconnect the steering angle sensor connector.

COMBINATION SWITCH DISASSEMBLY/ASSEMBLY
CAUTION:  If the disc on the combination switch is deformed or has foreign

material adhering to it, performance of the steering angle sensor may
be reduced, causing abnormal operation. When handling the
combination switch, be careful not to deform the disc and make sure
there is no foreign material on it.
Fig. 33: Identifying Combination Switch Components

LIGHT SWITCH REMOVAL/INSTALLATION

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2. Remove the lower column cover. (See COLUMN COVER REMOVAL/INSTALLATION .)
Fig. 34: Identifying Light Switch, Connector & Screw

LIGHT SWITCH INSPECTION

1. Verify that the continuity between the light switch terminals is as indicated in the table.
 If not as indicated in the table, replace the light switch.
HEADLIGHT SWITCH (VEHICLE WITHOUT AUTO LIGHT)
Fig. 35: Terminals Continuity Chart

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Fig. 36: Checking Continuity Between Headlight Switch Terminals (Vehicle Without Auto Light)
HEADLIGHT SWITCH (VEHICLE WITH AUTO LIGHT)
Fig. 37: Checking Continuity Between Headlight Switch Terminals (Vehicle With Auto Light)
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TURN SWITCH

Fig. 40: Checking Continuity Between Turn Switch Terminals

FRONT FOG LIGHT SWITCH INSPECTION

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1. Verify that continuity between the front fog light switch terminals is as indicated in the table.

Fig. 42: Checking Continuity Between Front Fog Light Switch Terminals
HAZARD WARNING SWITCH REMOVAL/INSTALLATION

3. Remove in hazard warning switch.
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Fig. 43: Identifying Hazard Warning Switch

HAZARD WARNING SWITCH INSPECTION

1. Verify that the continuity between the hazard switch terminals is as indicated in the table.
 If not as indicated in the table, replace the hazard warning switch.

Fig. 45: Checking Continuity Between Hazard Switch Terminals

HEADLIGHT LEVELING SWITCH REMOVAL/INSTALLATION

2. Remove the dashboard under cover. (Driver side) (See DASHBOARD UNDER COVER
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Fig. 46: Identifying Headlight Leveling Switch & Connector

HEADLIGHT LEVELING SWITCH INSPECTION

1. Verify that continuity between the headlight leveling switch terminals is as indicated in the table.
 If not as indicated in the table, replace the headlight leveling switch.

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Fig. 48: Checking Continuity Between Headlight Leveling Switch Terminals

DRL & AUTO LIGHT-OFF SYSTEM WIRING DIAGRAM

AUTO LIGHT/WIPER CONTROL MODULE VEHICLES WITH DRL
Fig. 49: DRL & Auto Light-Off System (Vehicles With DRL) - Wiring Diagram
Vehicles without DRL

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Fig. 50: DRL & Auto Light-Off System (Vehicles Without DRL) - Wiring Diagram
AUTO LIGHT-OFF CONTROL MODULE
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Fig. 51: DRL & Auto Light-Off System (Auto Light-Off Control Module) - Wiring Diagram
AUTO LIGHT-OFF CONTROL MODULE REMOVAL/INSTALLATION

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Fig. 52: Identifying Auto Light-Off Control Module, Connector, Bolt & Torque Specifications
AUTO LIGHT-OFF CONTROL MODULE INSPECTION

1. Measure the voltage at the auto light-off control module terminals as indicated below.
Fig. 53: Identifying Auto Light-Off Control Module Connector Terminals

CONNECTOR TERMINALS REFERENCE

Terminal Signal Connection Test condition Voltage Action
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(V)
Ignition switch at ON B+
METER 10 A  METER 10 A fuse
2C IG 1 Ignition switch at LOCK 1.0 or
fuse  Related wiring harnesses
or ACC less
 BCM (See BODY
 BCM CONTROL MODULE
Power  ROOM Constant (BCM) INSPECTION .)
2D B+
supply 15 A  Inspect ROOM 15 A fuse
fuse
 Related wiring harnesses
Light switch at low-  TAIL 10 A fuse
Below
TNS relay beam or high-beam  TNS relay (See RELAY
2G TNS relay 1.5
operation position INSPECTION .)
Light switch at OFF B+  Related wiring harnesses
Light switch at high- Below  H/L LOW relay (See
H/L LOW beam position 1.5
H/L LOW RELAY
2K relay
relay Light switch at OFF or INSPECTION .)
operation B+
low-beam position  Related wiring harnesses
Light switch
at low-beam 1.0 or
 Light switch (See
Ignition or high-beam less
TNS switch LIGHT SWITCH
2M Light switch switch at position
on/off INSPECTION.)
ON Light switch
at OFF B+  Related wiring harnesses
position
Light switch
at low-beam 1.0 or
 Light switch (See
Light Ignition or high-beam less
position LIGHT SWITCH
2N switch Light switch switch at
INSPECTION.)
on/off ON Light switch
at OFF B+  Related wiring harnesses
position
1.0 or
2O GND GND Under any condition  Related wiring harnesses
less
AUTO LIGHT/WIPER CONTROL MODULE REMOVAL/INSTALLATION
NOTE:  Auto light-off system are integrated with the auto light/wiper control
module.

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Fig. 54: Identifying Auto Light-Off Control Module, Connector, Bolt & Torque Specifications
AUTO LIGHT/WIPER CONTROL MODULE INSPECTION

1. Measure the voltage at the auto light/wiper control module terminals as indicated below.
Fig. 55: Identifying Auto Light/Wiper Control Module Connector Terminals


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Voltage
Terminal Signal Connection Test condition Action
(V)
Dimmer
switch at the
B+
Light high-beam
RH switch at position
 RH headlight
headlight RH headlight HEAD Dimmer
1A(1) operation (high-beam) position switch at the 1.0 or  Related wiring
(high-beam) low-beam less harnesses
position
Approx
DRL mode
6.0
Dimmer
switch at the
B+
Light high-beam
LH switch at position
HEAD Dimmer  LH headlight
headlight LH headlight
1B(1) operation (high-beam) position switch at the 1.0 or  Related wiring
(high-beam) low-beam less harnesses
position
Approx
DRL mode
6.0
Windshield  Autostop switch
wiper switch B+ (Windshield wiper
at LO position motor) (See
Ignition
Autostop Autostop WINDSHIELD
1C switch at Windshield
switch signal switch WIPER MOTOR
ON wiper switch 1.0 or INSPECTION .)
at OFF less  Related wiring
position harnesses
Windshield  Windshield wiper and
wiper switch B+ washer switch (See
at LO position WINDSHIELD
Windshield Windshield Ignition
WIPER AND
1D wiper switch wiper and switch at Windshield
WASHER SWITCH
signal (OFF) washer switch ON wiper switch 1.0 or INSPECTION .)
position harnesses
Ignition switch at ON B+  WIPER 30 A fuse
WIPER 30 A
1E IG2 Ignition switch at 1.0 or  Related wiring
fuse
LOCK or ACC less harnesses
wiper switch B+ washer switch (See
at HI position WINDSHIELD
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WIPER AND
Windshield WASHER SWITCH
Windshield Windshield Ignition
wiper switch 1.0 or INSPECTION .)
1F wiper switch wiper and switch at
at OFF less
signal (HI) washer switch ON  Related wiring
position
harnesses
1.0 or  Related wiring
1G(1) GND GND Under any condition
less harnesses
wiper switch washer switch (See
B+
Windshield at AUTO WINDSHIELD
Windshield Ignition position
wiper switch WIPER AND
1H wiper and switch at
signal Windshield WASHER SWITCH
washer switch ON
(AUTO) wiper switch 1.0 or INSPECTION .)
position harnesses
 HEAD LIGHT 20 A
Power HEAD LIGHT fuse
1I(1) supply 20 A fuse
Constant B+
 Related wiring
harnesses
Washer switch  Windshield wiper and

B+ washer switch (See
at ON position
WINDSHIELD
Windshield Ignition
Washer WIPER AND
1J wiper and switch at
switch signal Washer switch WASHER SWITCH
washer switch ON 1.0 or
at OFF INSPECTION .)
less
position  Related wiring
harnesses
Ignition
switch at ON B+
LH Light position  LH headlight
headlight LH headlight switch at
1K(1) operation (high-beam) the OFF Ignition  Related wiring
(high-beam) position switch LOCK 1.0 or harnesses
or ACC less
position
Dimmer
1.0 or  Light switch (See
switch at high-
Ignition less LIGHT SWITCH
High-beam beam position
1L(1) on/off
Light switch switch at INSPECTION.)
ON Dimmer
switch at low- B+  Related wiring
beam position harnesses
 Instrument cluster (See

Because this terminal is INSTRUMENT
Vehicle Instrument for communication, CLUSTER
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speed signal cluster good/no good judgment INPUT/OUTPUT

input by terminal voltage is CHECK MODE .)
2A not possible. -
 Related wiring
harnesses
 Windshield wiper and
Sensitivity washer switch (See
adjustment 0 --> 0.8 WINDSHIELD
Sensitivity Windshield Ignition
volume turned --> 1.5 -- WIPER AND
2B adjustment wiper and switch at
from + > 1.9 --> WASHER SWITCH
volume washer switch ON
position to - 2.2 INSPECTION .)
position  Related wiring
harnesses
Ignition switch at ON B+  METER 10 A fuse
METER 10 A
2C IG 1 Ignition switch at 1.0 or  Related wiring
fuse
LOCK or ACC less harnesses
 BCM (See BODY
CONTROL
 BCM MODULE (BCM)
Power  ROOM Constant INSPECTION .)
2D B+
supply 15 A  ROOM 15 A fuse
fuse
 Related wiring
harnesses
Because this terminal is
Wiper or
for communication,  Rain sensor
headlight
2E Rain sensor good/no good judgment -  Related wiring
operation
by terminal voltage is harnesses
request
not possible.
DLC-2
2F power DLC-2 Under any condition B+  Related wiring
supply harnesses
Light switch at low-  TNS relay (See

Below RELAY
TNS relay beam or high-beam
2G TNS relay 1.5 INSPECTION .)
operation position
 Related wiring
Light switch at OFF B+ harnesses
Because this terminal is
Rain sensor for communication,  Rain sensor
2H operation Rain sensor good/no good judgment -  Related wiring
request by terminal voltage is harnesses
not possible.
Light switch at high- Below  H/L LOW relay (See
2K H/L LOW beam position 1.5 RELAY
relay H/L LOW INSPECTION .)
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operation relay Light switch at OFF or  Related wiring

B+
low-beam position harnesses
Light switch  Light switch (See
Ignition at AUTO 1.0 or LIGHT SWITCH
Light switch less
2L Light switch switch at position INSPECTION.)
signal
ON  Related wiring
Other B+ harnesses
Light switch
at low-beam 1.0 or  Light switch (See
Ignition or high-beam less LIGHT SWITCH
TNS switch
2M Light switch switch at position INSPECTION.)
on/off
ON Light switch  Related wiring
at OFF B+ harnesses
position
Light switch
at low-beam 1.0 or  Light switch (See
Ignition or high-beam less LIGHT SWITCH
Light switch
2N Light switch switch at position INSPECTION.)
on/off
ON Light switch  Related wiring
at OFF B+ harnesses
position
1.0 or  Related wiring
2O GND GND Under any condition
less harnesses
 BCM (See BODY
Parking brake 1.0 or CONTROL
 BCM switch on less MODULE (BCM)
Parking Ignition
2P(1) brake switch  Parking switch at INSPECTION .)
on/off brake ON  Parking brake switch
switch Parking brake
B+ Related wiring
switch OFF 
harnesses
(1) For vehicles with DRL only.
AUTO LIGHT/WIPER CONTROL MODULE CONFIGURATION
the AUTO LIGHT/WIPER CONTROL MODULE CONFIGURATION.

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2. Select "LCM".
 If a DTC (s) is detected, perform the applicable DTC inspection. (See DTC TABLE [AUTO
LIGHT/WIPER CONTROL MODULE] .)

AUTO LIGHT ILLUMINATION LEVEL SETTING

WITHOUT USING M-MDS
CAUTION:  If any of the following occurs, the sensitivity cannot be set properly.
Therefore, resume from Step 1.
 Each procedure and operation interval exceeds 5 s.
 Procedures are performed incorrectly.
NOTE:  Perform the procedure in a condition that allows verification of the

headlight illumination because it is necessary to verify the setting
condition according to the number of times headlights turn on.
1. Turn the ignition switch to the ON position with the light switch in the OFF position and pulled back
(Flash-to-pass ON).
2. Switch the light switch from the OFF to TNS position five times and return it to the OFF position.
3. Pull the light switch back once. (Flash-to-pass ON)
4. Turn the light switch to the TNS position.
5. Switch the light switch from the TNS to ON position five times and return it to the TNS position.
6. Turn the light switch to the ON position.
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7. Switch the light switch from the ON to AUTO position five times and return it to the ON position.
8. Turn the light switch to the TNS position.
NOTE:  Switches to the sensitivity setting mode when the above operations
are performed.
 The headlights turn on for the number of times according to the
current setting conditions.
 Illumination (Two times): Standard sensitivity
 Illumination (Three times): Low sensitivity
9. Switch the sensitivity by pulling the light switch back (Flash-to pass ON).
10. Verify the number of times the headlights turn on and that the sensitivity is set properly.
 Illumination (Two times): Standard sensitivity
 Illumination (Three times): Low sensitivity
USING M-MDS


1. Select "Programming".
2. Select "Exterior Lighting".
3. Select "Autolamp On Setting- (GEM)".
4. Select "Standard (Other)" or "Low (Other)" on the M-MDS to set the illumination level.

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NOTE:  When the M-MDS is set to Low (Other), the auto-light sensor
sensitivity decreases, and the TNS and headlight illumination timing
is slower.
5. Perform the procedure as indicated on the screen.
FRONT MAP LIGHT REMOVAL/INSTALLATION

Fig. 58: Identifying Removal Sequence Of Front Map Light Components

LENS REMOVAL NOTE
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FRONT MAP LIGHT INSPECTION

1. Verify that the continuity between the front map light terminals is as indicated in the table.
 If not as indicated in the table, replace the front map light.

Fig. 61: Checking Continuity Between Front Map Light Terminals

INTERIOR LIGHT REMOVAL/INSTALLATION

INTERIOR LIGHT

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1.
A-pillar trim (See A-PILLAR TRIM REMOVAL/INSTALLATION .)
Front scuff plate inner (See FRONT SCUFF PLATE REMOVAL/INSTALLATION .)
2.
Rear scuff plate inner (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
3.
4.
Front seat belt lower anchor installation bolt (Driver side) (See FRONT SEAT BELT
19. Front map light (See FRONT MAP LIGHT REMOVAL/INSTALLATION.)
4. Detach the tab and remove the bulb housing.
NOTE:  The valve housing and the wiring harness have been integrated and
attached to the headliner. When replacing the valve housing, remove
the wiring harness which passes under the urethane by cutting the
urethane.
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Fig. 62: Identifying Interior Light & Bulb Housing

5. Pull in the direction of the arrows and detach the tabs.

6. Remove the interior light.
NOTE:  After installing the wiring harness, reinforce the urethane that was
cut when removing the valve housing with vinyl tape.
Fig. 63: Identifying Interior Light With Tab

INTERIOR LIGHT BULB

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3. Remove the rear interior light bulb.

Fig. 65: Identifying Interior Light & Bulb

CARGO COMPARTMENT LIGHT REMOVAL/INSTALLATION

CARGO COMPARTMENT LIGHT

Fig. 66: Identifying Cargo Compartment Light & Connector

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CARGO COMPARTMENT LIGHT BULB


3. Remove the cargo compartment light bulb.

Fig. 68: Identifying Cargo Compartment Light & Bulb

CARGO COMPARTMENT LIGHT INSPECTION

1. Verify that the continuity between the cargo compartment light terminals is as indicated in the table.
 If not as indicated in the table, replace the cargo compartment light.
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Fig. 70: Checking Continuity Between Cargo Compartment Light Terminals

COURTESY LIGHT BULB REMOVAL/INSTALLATION

Fig. 71: Identifying Courtesy Light Bulb & Lens

LENS REMOVAL NOTE
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IGNITION KEY ILLUMINATION BULB REMOVAL/INSTALLATION

VEHICLES WITHOUT ADVANCED KEYLESS SYSTEM

2. Pull the upper column cover upward and detach the upper column cover from the lower column cover.
(See COLUMN COVER REMOVAL/INSTALLATION .)
3. Put aside the upper columm cover.
4. Remove the ignition key illumination bulb.
Fig. 73: Identifying Ignition Key Illumination Bulb

VEHICLES WITH ADVANCED KEYLESS SYSTEM

3. Remove the coil antenna. (See COIL ANTENNA REMOVAL/INSTALLATION [ADVANCED
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KEYLESS SYSTEM] .)
Fig. 74: Identifying Ignition Key Illumination Bulb, Socket, Lens & Screw
SOCKET REMOVAL NOTE
1. Remove the socket by turning it in the direction shown by the arrow.
Fig. 75: Socket Removal

GLOVE COMPARTMENT LIGHT BULB REMOVAL/INSTALLATION

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Fig. 76: Identifying Glove Compartment Light Bulb & Socket

VANITY MIRROR ILLUMINATION BULB REMOVAL/INSTALLATION

Fig. 77: Identifying Vanity Mirror Illumination Bulb & Lens

LENS REMOVAL NOTE
1. Insert a tape-wrapped flathead screwdriver into the service hole, and pry it in the direction indicated by
the arrow to remove the lens.
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VANITY MIRROR ILLUMINATION INSPECTION

1. Remove the sunvisor. (See SUNVISOR REMOVAL/INSTALLATION .)
2. Verify that the continuity between the vanity mirror illumination terminals is as indicated in the table.
 If not as indicated in the table, inspect the bulb. If there is no malfunction, replace the sunvisor.

Fig. 80: Checking Continuity Between Vanity Mirror Illumination Terminals

INDIRECT ILLUMINATION REMOVAL/INSTALLATION

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CONSOLE

2. Remove the front map light. (See FRONT MAP LIGHT REMOVAL/INSTALLATION.)
Fig. 81: Identifying Console Indirect Illumination & Connector

FRONT DOOR POCKET

3. Remove the handle pull. (See FRONT DOOR TRIM DISASSEMBLY/ASSEMBLY .)
Fig. 82: Identifying Front Door Pocket Indirect Illumination, Cover & Connector
FRONT DOOR POCKET INDIRECT ILLUMINATION REMOVAL NOTE
1. Open the cover in the direction of the arrow and remove the front door pocket indirect illumination.
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Fig. 83: Identifying Front Door Pocket Indirect Illumination Tabs

REAR DOOR POCKET

2. Remove the rear door trim. (See REAR DOOR TRIM REMOVAL/INSTALLATION )
Fig. 84: Identifying Rear Door Pocket Indirect Illumination, Cover & Connector
REAR DOOR POCKET INDIRECT ILLUMINATION REMOVAL NOTE
1. Open the cover in the direction of the arrow and remove the rear door pocket indirect illumination.
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Fig. 85: Identifying Rear Door Pocket Indirect Illumination Tabs

DOOR SWITCH REMOVAL/INSTALLATION

Fig. 86: Identifying Door Switch, Connector & Screw

DOOR SWITCH INSPECTION

1. Verify that the continuity between door switch terminal and the body ground is as indicated in the table.
 If not as indicated in the table, replace the door switch.

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Fig. 88: Checking Continuity Between Door Switch Terminal & Body Ground
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2008 BODY & ACCESSORIES Security and Locks - Mazda CX-9
Security and Locks - Mazda CX-9
SECURITY & LOCKS LOCATION INDEX

KEYLESS ENTRY SYSTEM
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Fig. 1: Identifying Keyless Entry System Locks Location

ADVANCED KEYLESS SYSTEM

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Fig. 2: Identifying Advanced Keyless System Locks Location (1 Of 2)

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Fig. 3: Identifying Advanced Keyless System Locks Location (2 Of 2)

FRONT OUTER HANDLE REMOVAL/INSTALLATION

4. Front door glass (See FRONT DOOR GLASS REMOVAL/INSTALLATION .)
5. Front door module (See FRONT DOOR MODULE REMOVAL/INSTALLATION .)
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3. Disconnect the rod.
Fig. 4: Identifying Rod

4. Remove the bolt.

5. Remove the front door key cylinder. (Driver side) (See FRONT DOOR KEY CYLINDER
Fig. 5: Identifying Front Door Key Cylinder Bolt & Torque Specifications
6. Secure the rear part of the front outer handle and, with the front outer handle lever pulled outward (1),
remove the rear part of the front outer handle from the front door.
7. Pull out the front side of the front outer handle from the front door.
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Fig. 6: Pulling Out Front Side Of Front Outer Handle

REAR OUTER HANDLE REMOVAL/INSTALLATION

5. Rear door module (See REAR DOOR MODULE REMOVAL/INSTALLATION .)
5. Remove the shock-absorbing pad.
6. Disconnect the rod.
7. Remove the nuts.
8. Remove the handle base.
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Fig. 7: Identifying Shock-Absorbing Pad, Handle Base, Rod & Torque Specifications
10. Secure the rear part of the rear outer handle and, with the rear outer handle lever pulled outward (1),
remove the rear part of the rear outer handle from the rear door.
Fig. 8: Removing Rear Part Of Rear Outer Handle

INNER HANDLE REMOVAL/INSTALLATION

FRONT

4. Disconnect the door lock switch connector.
5. Detach the cables from the inner handle and door lock knob.
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Fig. 9: Identifying Inner Handle & Door Lock Knob

REAR

4. Detach the cables from the inner handle and door lock knob.
Fig. 10: Identifying Inner Handle & Door Lock Knob

HOOD LATCH & RELEASE LEVER REMOVAL/INSTALLATION

1. Air cleaner (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
2. Splash shield (LH) (See SPLASH SHIELD REMOVAL/INSTALLATION .)
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5. Adjust the hood. (See HOOD ADJUSTMENT .)
Fig. 11: Identifying Hood Latch, Release Lever Components & Torque Specifications
HOOD RELEASE LEVER REMOVAL NOTE
1. Pull the lever.

2. Insert a tape-wrapped flathead screwdriver into the position shown in the figure.
CAUTION:  Be careful not to damage the hood release cable when removing
the hood release lever with the flathead screwdriver.
3. Pull the hood release lever outward and remove it.
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Fig. 12: Identifying Hood Release Lever

HOOD LATCH SWITCH INSPECTION

1. When inspecting the latch, press the latch lever using a flathead screwdriver or a similar tool.
Fig. 13: Identifying Hood Latch Switch, Latch Lever

2. Inspect for continuity between the hood latch switch terminals.

 If not as specified, replace the hood latch.

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Fig. 15: Checking Continuity Between Hood Latch Switch Terminals

FRONT DOOR KEY CYLINDER REMOVAL/INSTALLATION

Fig. 16: Identifying Front Door Key Cylinder Bolt, Rod & Torque Specifications
FRONT DOOR KEY CYLINDER REMOVAL NOTE
1. Remove the front door key cylinder by turning it in the direction shown by the arrow.
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Fig. 17: Identifying Front Door Key Cylinder

FRONT DOOR KEY CYLINDER SWITCH INSPECTION

1. Inspect for continuity between the front door key cylinder switch terminals.
 If not as specified, replace the front door latch and lock actuator.

Fig. 19: Checking Continuity Between Front Door Key Cylinder Switch Terminals
FRONT DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION

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Fig. 20: Identifying Front Door Latch & Lock Actuator, Connector, Screws & Torque
Specifications
FRONT DOOR LATCH AND LOCK ACTUATOR INSPECTION

1. The following actuators and switches are integrated with the front door latch and lock actuator. Inspect
the front door latch and lock actuator according to each inspection procedure for the following items.
 Front door lock actuator (See FRONT DOOR LOCK ACTUATOR INSPECTION.)
 Front door key cylinder switch (Driver side) (See FRONT DOOR KEY CYLINDER SWITCH
INSPECTION.)
 Door lock-link switch (See DOOR LOCK-LINK SWITCH INSPECTION.)
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Fig. 21: Checking Front Door Latch & Lock Actuator

DOOR LOCK SWITCH REMOVAL/INSTALLATION

4. Remove the screws, then remove the door lock switch.
Fig. 22: Identifying Door Lock Switch & Screws

DOOR LOCK SWITCH INSPECTION

1. Inspect for continuity between the door lock switch terminals using an ohmmeter.
 If not as specified, replace the door lock switch.
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Fig. 24: Checking Continuity Between Door Lock Switch Terminals

FRONT DOOR LOCK ACTUATOR INSPECTION

1. Apply battery positive voltage and connect ground to the corresponding front door lock actuator
terminals, and inspect the front door lock actuator operation.
FRONT DOOR LOCK ACTUATOR REFERENCE

Connection
Lock actuator operation
B+ GND
Lock 1A 1B
Unlock 1B 1A
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Fig. 25: Identifying Front Door Lock Actuator Connector Terminals

DOOR LOCK STRIKER REMOVAL/INSTALLATION

1. Remove the screws, then remove the door lock striker.
3. Adjust the door. (See DOOR ADJUSTMENT .)
Fig. 26: Identifying Door Lock Striker With Screw & Torque Specifications
DOOR LOCK-LINK SWITCH INSPECTION

FRONT/REAR
1. Inspect for continuity between the door lock-link switch terminals.

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Fig. 28: Checking Continuity Between Door Lock-Link Switch Terminals

REAR DOOR LATCH & LOCK ACTUATOR REMOVAL/INSTALLATION

1. Inner sail garnish. (See INNER SAIL GARNISH REMOVAL/INSTALLATION .)
5. Rear door module (See REAR DOOR MODULE REMOVAL/INSTALLATION .)
Fig. 29: Identifying Rear Door Latch & Lock Actuator, Connector, Screws & Torque Specifications
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REAR DOOR LATCH AND LOCK ACTUATOR INSPECTION

1. The following actuator and switch are integrated with the rear door latch and lock actuator. Inspect the
rear door latch and lock actuator according to each inspection procedure for the following items.
 Rear door lock actuator (See REAR DOOR LOCK ACTUATOR INSPECTION.)
 Rear door latch switch (See DOOR LOCK-LINK SWITCH INSPECTION.)
Fig. 30: Checking Rear Door Latch & Lock Actuator

REAR DOOR LOCK ACTUATOR INSPECTION

1. Apply battery positive voltage and connect ground to the corresponding front door lock actuator
terminals, and inspect the front door lock actuator operation.
REAR DOOR LOCK ACTUATOR REFERENCE

Connection
Lock actuator operation
B+ GND
Lock 1A 1B
Unlock 1B 1A
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Fig. 31: Identifying Rear Door Lock Actuator Connector Terminals

LIFTGATE LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION

Fig. 32: Identifying Liftgate Latch & Lock Actuator, Connector, Bolt & Torque Specifications
Fig. 33: Identifying Liftgate Latch & Lock Actuator, Connector, Bolt & Torque Specifications

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LIFTGATE LOCK STRIKER REMOVAL/INSTALLATION

3. Remove the trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)
4. Remove the bolts, then remove the liftgate lock striker.
6. Adjust the liftgate. (See LIFTGATE ADJUSTMENT .)
Fig. 34: Identifying Liftgate Lock Striker, Bolt & Torque Specifications
LIFTGATE LATCH & LOCK ACTUATOR INSPECTION

VEHICLES WITH PLG
Liftgate latch switch
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Fig. 35: Pressing Latch Lever


 If not as indicated in the table, replace the liftgate latch and lock actuator.

Fig. 37: Checking Continuity Between Liftgate Latch & Lock Actuator Terminals
Full latch switch, Half latch switch, Return switch
1. Press the latch in using a flathead screwdriver to inspect the latch condition.
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Fig. 38: Identifying Full Latch Switch, Half Latch Switch, Return Switch
Fig. 39: Checking Continuity Between Full Latch Switch, Half Latch Switch, Return Switch
Terminals
Fig. 40: Identifying Blinking Pattern

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Closer motor
1. Apply battery positive voltage and connect ground to the corresponding closer motor terminals, and
inspect the closer motor operation.
Fig. 41: Applying Battery Positive Voltage & Connect Ground To Corresponding Closer Motor
Terminals
LIFTGATE LATCH AND LOCK ACTUATOR REFERENCE

Terminal
Operation
A B
Normal rotation GND B+
Reverse rotation B+ GND
Fig. 42: Identifying Closer Motor Reverse & Normal Rotation

VEHICLES WITHOUT PLG
Liftgate latch switch
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Fig. 43: Pressing Latch Lever



Fig. 45: Checking Continuity Between Liftgate Latch Switch Terminals

Liftgate lock actuator
1. Apply battery positive voltage and connect ground to the corresponding liftgate lock actuator terminals,
and inspect the liftgate lock actuator operation.
 If not as specified, replace the liftgate latch and lock actuator.
LIFTGATE LATCH AND LOCK ACTUATOR REFERENCE

Terminal
Operation
A B
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Lock B+ GND
Unlock GND B+
Fig. 46: Identifying Liftgate Lock Actuator Terminals

LIFTGATE OUTER HANDLE REMOVAL/INSTALLATION

5. Remove the rear finisher. (See REAR FINISHER REMOVAL/INSTALLATION .)
6. Disconnect the liftgate outer handle switch connector. (Vehicles with power liftgate system)
7. Disconnect the cable. (Vehicles without power liftgate system)
Fig. 47: Identifying Liftgate Outer Handle With Nut & Torque Specifications
LIFTGATE OUTER HANDLE SWITCH INSPECTION

1. Verify that the continuity between the liftgate outer handle switch terminals is as indicated in the table.
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 If not as indicated in the table, replace the liftgate outer handle. (See LIFTGATE OUTER
HANDLE REMOVAL/INSTALLATION.)

Fig. 49: Checking Continuity Between Liftgate Outer Handle Switch Terminals
FUEL-FILLER LID OPENER REMOVAL/INSTALLATION

1. When removing the fuel-filler lid opener, perform the following procedure:
1. Trunk box. (See TRUNK BOX REMOVAL/INSTALLATION .)
2. Seat side box. (See SEAT SIDE BOX REMOVAL/INSTALLATION .)
3. Trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)
4. Third-row seat. (See THIRD-ROW SEAT REMOVAL/INSTALLATION .)
5. Rear scuff plate inner. (LH) (See REAR SCUFF PLATE REMOVAL/INSTALLATION .)
6. Third-row seat belt lower anchor installation bolt. (Driver side) (See THIRD-ROW SEAT BELT
7. Trunk side trim. (Driver side) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
2. When removing the fuel-filler lid opener cable, perform the following procedure:
1. Front scuff plate inner (LH) (See FRONT SCUFF PLATE REMOVAL/INSTALLATION .)
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4.B-pillar lower trim (LH) (See B-PILLAR LOWER TRIM REMOVAL/INSTALLATION .)

5.Trunk box. (See TRUNK BOX REMOVAL/INSTALLATION .)
6.Seat side box. (See SEAT SIDE BOX REMOVAL/INSTALLATION .)
7.Trunk end trim. (See TRUNK END TRIM REMOVAL/INSTALLATION .)
8.Third-row seat. (See THIRD-ROW SEAT REMOVAL/INSTALLATION .)
9.Third-row seat belt lower anchor installation bolt. (Driver side) (See THIRD-ROW SEAT BELT
10. Trunk side trim. (Driver side) (See TRUNK SIDE TRIM REMOVAL/INSTALLATION .)
3. Remove the fuel-filler lid release cover in the direction of the arrow.
4. Slightly bend back the floor covering.
Fig. 50: Identifying Fuel-Filler Lid Release Cover With Tab

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Fig. 51: View Of Fuel-Filler Lid Opener Components Installation Sequence & Torque
Specifications
KEYLESS CONTROL MODULE REMOVAL/INSTALLATION [ADVANCED

KEYLESS SYSTEM]
NOTE:  If the keyless control module is replaced, always perform the following
procedure.
Without immobilizer system
 Card key programming (See CLEARING CARD KEY [ADVANCED

KEYLESS SYSTEM].)
 Steering lock unit programming (See STEERING LOCK UNIT ID CODE
REGISTRATION [ADVANCED KEYLESS SYSTEM].)
With immobilizer system
 Card key programming (See CLEARING CARD KEY [ADVANCED

KEYLESS SYSTEM].)
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 Steering lock unit programming (See STEERING LOCK UNIT ID CODE

 Immobilizer system resetting (with immobilizer system) (See
IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION
AND CLEARING [ADVANCED KEYLESS SYSTEM].) (See
IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION
AND CLEARING [KEYLESS ENTRY SYSTEM].)

3. Remove the auto light/wiper control module. (Vehicles with auto light/wiper system) (See AUTO
LIGHT/WIPER CONTROL MODULE REMOVAL/INSTALLATION .)
4. Remove the auto light-off control module. (Vehicles without auto light/wiper system) (See AUTO
LIGHT-OFF CONTROL MODULE REMOVAL/INSTALLATION .)
Fig. 52: Identifying Keyless Control Module, Connector & Screw

KEYLESS CONTROL MODULE INSPECTION [ADVANCED KEYLESS

SYSTEM]
1. Measure the voltage or inspect for continuity according to the Terminal Voltage Table (Reference).
"Inspection item(s)" and related wiring harnesses.
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Fig. 53: Identifying Keyless Control Module Connector Terminals


Measured Voltage Inspection item
Terminal Signal name Connected to
condition (V)/Continuity (s)
Under any
Keyless antenna Keyless antenna condition: Inspect Continuity Keyless antenna
1A
(Exterior, LF)(+) (Exterior, LF) for continuity to detected (Exterior, LF)
keyless antenna.
Under any
1B
(Exterior, LF)(-) (Exterior, LF) for continuity to detected (Exterior, LF)
Keyless antenna.
Under any
1C
(Exterior, RF)(+) (Exterior, RF) for continuity to detected (Exterior, RF)
keyless antenna.
Under any
1D
(Exterior, RF)(-) (Exterior, RF) for continuity to detected (Exterior, RF)
keyless antenna.
Under any
1E
(Exterior, rear)(+) (Exterior, rear) for continuity to detected (Exterior, rear)
keyless antenna.
Under any
1F
(Exterior, rear)(-) (Exterior, rear) for continuity to detected (Exterior, rear)
keyless antenna.
Related wiring
1G GND Body ground Under any condition 1.0 or less
harnesses
Related wiring
1H GND Body ground Under any condition 1.0 or less
harnesses
Under any
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condition: Inspect
keyless antenna Keyless antenna Continuity Keyless antenna
11 for continuity to
(Interior, rear)(+) (Interior, rear) detected (Interior, rear)
keyless antenna.
Under any
1J
(Interior, rear)(-) (Interior, rear) for continuity to detected (Interior, rear)
keyless antenna.
Under any
Keyless antenna
Keyless antenna condition: Inspect Continuity Keyless antenna
1K (Interior, middle)
(Interior, middle) for continuity to detected (Interior, middle)
(+)
keyless antenna.
Under any
1L
(Interior, middle)(-) (Interior, middle) for continuity to detected (Interior, middle)
keyless antenna.
Under any
Keyless antenna Keyless antenna Keyless antenna
condition: Inspect Continuity
1M (Interior, front (Interior, front (Interior, front
for continuity to detected
center)(+) center) center)
keyless antenna.
Under any
1N (Interior, front (Interior, front (Interior, front
center)(-) center) center)
keyless antenna.
Under any
1O (Interior, front RH) (Interior, front (Interior, front
(+) RH) RH)
keyless antenna.
Under any
1P (Interior, front RH) (Interior, front (Interior, front
(-) RH) RH)
keyless antenna.
ROOM 15 A ROOM 15 A
2A Power supply Under any condition B+
fuse FUSE
Related wiring
2B GND Body ground Under any condition 1.0 or less
harnesses
Ignition switch is at
B+
ON position
ENG.IGA7.5 A ENG.IGA7.5 A
2C IG1 Ignition switch is at
fuse fuse
LOCK or ACC 1.0 or less
position
B+
ACC position
MIRROR 7.5 A MIRROR 7.5 A
2E ACC Ignition switch is at
fuse fuse
LOCK or ON 1.0 or less
position
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Beeper operated 1.0 or less

2K Beeper Keyless beeper Keyless beeper
Other 5.0
Power supply
3A Keyless receiver Under any condition B+ Keyless receiver
(keyless receiver)
Under any
Communication condition: Inspect Continuity
3C Keyless receiver Keyless receiver
(Keyless receiver) for continuity to detected
keyless receiver.
Start knob (Push Steering lock Start knob is pushed B+ Steering lock
3E
switch) unit Other 1.0 or less unit
Key reminder
Key reminder Steering lock B+ Steering lock
3F switch is ON
switch unit unit
Other 1.0 or less
Under any
Communication Steering lock condition: Inspect Continuity Steering lock
3H
(Steering lock unit) unit for continuity to detected unit
steering lock unit.
Passenger-side
request switch is
Continuity
ON: Inspect for
detected
continuity to
Request switch Request switch ground. Request switch
3I input (Passenger input (Passenger input (Passenger
side) side) Passenger-side side)
request switch is
OFF: Inspect for No continuity
continuity to
ground.
Driver-side request
switch is ON:
Continuity
Inspect for
detected
continuity to
Request switch ground. Request switch
Request switch
3K input (Driver input (Driver
input (Driver side) Driver-side request
side) side)
switch is OFF:
Inspect for No continuity
continuity to
ground.
Liftgate request
switch is ON:
Continuity
Inspect for
detected
Request switch Request switch continuity to Request switch
3M
input (Liftgate) input (Liftgate) ground. input (Liftgate)
Liftgate request
switch is OFF: No continuity
Inspect for
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continuity to
ground.
Driver-side door is
locked: Inspect for
No continuity
continuity to
Door lock-link ground. Door lock-link
3N Lock signal input
switch Driver-side door is switch
unlocked: Inspect Continuity
ground.
Under any
Communication condition: Inspect Continuity
3Q BCM BCM
(BCM) for continuity to detected
BCM.
B+
ON position
3U Tx-SKE Coil antenna Ignition switch is at Coil antenna
position
B+
ON position
3V Rx-SKE Coil antenna Ignition switch is at Coil antenna
position
Under any
3W HS-CAN- PCM -
PCM.
Under any
3X HS-CAN+ PCM -
PCM.
KEYLESS CONTROL MODULE CONFIGURATION [ADVANCED KEYLESS

SYSTEM]
the KEYLESS CONTROL MODULE CONFIGURATION.

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2. Select "RKE".


 If a DTC (s) is detected, perform the applicable DTC inspection. (See DTC TABLE
[ADVANCED KEYLESS AND START SYSTEM] .)
TRANSMITTER BATTERY REPLACEMENT [KEYLESS ENTRY SYSTEM]

1. Insert a small flathead screwdriver into the transmitter notch and remove the key from the transmitter by
pressing the tab.
Fig. 55: Removing Key From Transmitter

2. Insert a small flathead screwdriver into the transmitter notch and the transmitter.
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Fig. 56: Inserting Screwdriver Into Transmitter Notch & Transmitter

3. Remove the battery.
Fig. 57: Removing Battery

4. Install the new battery (CR1620) with the positive pole facing down.
5. Align the upper and lower cover and close the transmitter.
Used battery
Lithium battery CR1620
Battery life
Approx. 2 years (when used 10 times/day)
6. Install the key to the transmitter.
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Fig. 58: Installing Battery

TRANSMITTER ID CODE REGISTRATION [KEYLESS ENTRY SYSTEM]
NOTE:  When registering the ID code into a keyless control module, verify that
other transmitters are not being operated in the vicinity.
 After ID code registering, remove the key from the steering lock and verify
that all doors lock/unlock normally using the transmitter.
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Fig. 59: Transmitter ID Code Registration Flow Chart

CARD KEY ID CODE REGISTRATION [ADVANCED KEYLESS SYSTEM]
CAUTION:  Do not place the following devices in the vehicle while programming,
otherwise programming cannot be performed.
 M-MDS
 Personal computer
 Device that can send/receive radio waves
 Verify that the other transmitter is not being operated around the
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servicing area during card key programming.
NOTE:  Use the M-MDS and start programming if the condition corresponds to the
following:
 One or No Programmed Card Keys
 Keyless control module is replaced
 If six card keys are already programmed, the programming mode does not
activate. If programming is needed, use the M-MDS to erase the
unnecessary card key programming.
WITH TWO PROGRAMMED CARD KEYS
1. Bring the programmed card keys (2) and a unprogrammed card key into the vehicle.
2. Close all doors.
3. Insert the supplementary key into the ignition key cylinder.
NOTE:  Complete the procedures up to Step 7 within 30 s after the

supplementary key is inserted.

5. Press the UNLOCK button on card key 1.
6. Press the UNLOCK button on card key 2.
7. From the ignition switch in the ON position, switch the ignition switch in the order indicated below.
 ACC --> ON --> ACC --> ON --> ACC --> ON
8. Open the driver-side front door, press the door switch twice , and then close the door.
NOTE:  After Step 3 is completed and the card key programming mode is
activated, the door lock actuator operates to lock, and then operates
to unlock.
 If the door lock actuator does not operate, repeat the procedure from
Step 2.
9. Press the UNLOCK button on the unprogrammed card key twice.
NOTE:  After Step 8 is completed and the card key is programmed, the door
lock actuator operates to lock, and then operates to unlock.
10. If programming more card keys, remove the supplementary key once, and then repeat the procedure from
Step 2.
USING M-MDS
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1. Fully lower the driver-side door glass.

3. Pull out the M-MDS cable from the door glass opening and set the M-MDS outside the vehicle.
CAUTION:  Protect the cable and body contact area with a clean rag,
otherwise they could be damaged.
1. Select "Body".
2. Select "Security".

1. Select "PATS Functions".
2. Select "Program Additional card key".
6. Security access begins and the M-MDS displays the "OUT-CODE".
NOTE:  When "OUT-CODE" is first displayed, turning the ignition switch from
the LOCK to the ON position 5 times will change the "OUT-CODE".
7. Input the "IN-CODE" that corresponds to the "OUT-CODE" displayed on the M-MDS screen.
NOTE:  After Step 7 is completed and the card key programming is activated,
the door lock actuator operates to lock, and then operates to unlock.
8. Press the unprogrammed card key UNLOCK button twice.
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NOTE:  After Step 8 is completed and the card key is programmed, the door
lock actuator operates to lock, and then operates to unlock.
9. If programming more card keys, remove the supplementary key once, and then repeat the procedure by
following the instructions on the M-MDS screen.
CLEARING CARD KEY [ADVANCED KEYLESS SYSTEM]


1. Select "Body".
2. Select "Card Key Code Erase and Program".
6. Security access begins and the M-MDS displays the "OUT-CODE".
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7. Input the "IN-CODE" that corresponds to the "OUT-CODE" displayed in the M-MDS screen.
8. Select "CARD KEY CLEARING" from the M-MDS screen menu.
STEERING LOCK UNIT ID CODE REGISTRATION [ADVANCED KEYLESS

SYSTEM]
otherwise programming cannot be performed.
 M-MDS
 Device that can send/receive radio waves
NOTE:  The steering lock unit and steering lock component are a single unit.
Therefore, replace the steering lock component when replacing steering
lock unit. (See STEERING WHEEL AND COLUMN
 For this procedure, a programmed card key is necessary. If there is no
programmed card key, perform the steering lock unit programming after
the card key programming.
1. Bring the programmed card key into the vehicle.


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When using the IDS (laptop PC)


1. Select "Body".
2. Select "Steering Lock Unit Programming".
7. The security access begins and the M-MDS displays "OUT-CODE".
8. Input the "IN-CODE" that corresponds to the "OUT-CODE" displayed on the M-MDS screen.
9. Perform procedures according to the directions on the M-MDS screen.
CUSTOMIZED FUNCTION SETTING PROCEDURE [ADVANCED KEYLESS

SYSTEM]
1. Select "Module programming".

2. Select "Module programming".
2. Select "RKE".
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4. Select the item name, and than select either "OFF/ON".
Items
 Automatic Locks
 Answer Back Buzzer
 Card Key Battery Low Warning
KEYLESS RECEIVER REMOVAL/INSTALLATION

6. Upper column cover (See COLUMN COVER REMOVAL/INSTALLATION .)
Fig. 64: Identifying Keyless Receiver, Connector & Screw

KEYLESS RECEIVER INSPECTION [ADVANCED KEYLESS SYSTEM]

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Fig. 65: Identifying Keyless Receiver Connector Terminals


Connected Voltage Inspection item
Terminal Signal name Measured condition
to (V) (s)
 Keyless
control
Keyless
module
A Power supply control Under any condition B+
module  Related
wiring
harnesses
Keyless
Because this terminal is for control
Keyless
Serial communication, good/no good module
C control -
communication judgment by terminal voltage is  Related
module
not possible. wiring
harnesses
1.0 or Related wiring
E GND Body ground Under any condition.
less harnesses
KEYLESS RECEIVER INSPECTION [KEYLESS ENTRY SYSTEM]

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Fig. 66: Identifying Keyless Receiver Connector Terminals


Voltage
Terminal Signal name Connected to Measured condition Inspection item(s)
(V)
 BCM
A Power supply BCM Under any condition B+  Related wiring
harnesses
Ignition switch is at ON  ENG.IGA7.5
B+
ENG.IGA7.5 position A fuse
B IG1
A fuse Ignition switch is at LOCK or 1.0 or  Related wiring
ACC position less harnesses
 BCM
Serial communication, good/no good
D BCM -  Related wiring
communication judgment by terminal voltage
is not possible. harnesses
E GND Body ground Under any condition.
less harnesses
KEYLESS ANTENNA REMOVAL/INSTALLATION [ADVANCED KEYLESS

SYSTEM]
EXTERIOR, LF/RF

5. Disconnect the connector, then remove the keyless antenna.
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Fig. 67: Identifying Keyless Antenna & Connector With Screw (Exterior, LF/RF)
EXTERIOR, REAR

Fig. 68: Identifying Keyless Antenna, Connector With Screw & Torque Specifications (Exterior,
Rear)
INTERIOR, FRONT
Center

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6. Disconnect the connector, then remove the screws.

7. Remove the keyless antenna.
Fig. 69: Identifying Keyless Antenna & Connector With Screw (Interior, Front)
RH

4. Disconnect the connector, then remove the screws.
5. Remove the keyless antenna.
Fig. 70: Identifying Keyless Antenna & Connector With Screw - RH

INTERIOR, MIDDLE
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3. Remove the clips.
Fig. 71: Identifying Keyless Antenna & Connector With Screw (Interior, Middle)
INTERIOR, REAR

4. Partially peel back the floor covering.
5. Remove the nuts.
Fig. 72: Identifying Keyless Antenna, Connector With Screw & Torque Specifications (Interior,
Rear)
KEYLESS BEEPER REMOVAL/INSTALLATION [ADVANCED KEYLESS

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SYSTEM]
2. Partially peel back the splash shield (LH).
3. Remove the bolt and screw.
4. Disconnect the connector, then remove the keyless beeper.
Fig. 73: Identifying Keyless Beeper, Connector, Bolt & Torque Specifications
REQUEST SWITCH REMOVAL/INSTALLATION [ADVANCED KEYLESS

SYSTEM]
DRIVER SIDE/PASSENGER SIDE

3. Remove the screw A, then remove the handle seat.
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4. Remove screw B, then remove the request switch.
Fig. 74: Identifying Request Switch & Handle Seat With Screws
LIFTGATE

5. Remove the rear finisher. (See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
6. Press the tabs and remove the request switch.
Fig. 75: Identifying Request Switch & Rear Finisher

REQUEST SWITCH INSPECTION [ADVANCED KEYLESS SYSTEM]

1. Inspect for continuity between request switch terminals A and B.
 If not as specified, replace the request switch.
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Fig. 77: Checking Continuity Between Request Switch Terminals A & B

CARD KEY BATTERY REPLACEMENT [ADVANCED KEYLESS SYSTEM]

1. Pull out the auxiliary key.
Fig. 78: Identifying Auxiliary Key

2. Replace the cap using a flathead screwdriver, then rotate and remove the cap.
CAUTION:  Do not turn the cap excessively. The cap may be damaged.
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Fig. 79: Removing Cap

3. Insert a flathead screwdriver into the crack and press the battery out.
Fig. 80: Removing Battery

4. Insert the new battery (CR2025) with the positive pole (+) facing the (+) mark on the cap.
Battery specification
Lithium CR2025 x 1
NOTE:  The batteries will last about 1 years when used 10 times a day.
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Fig. 81: Inserting Battery

5. Rotate and close the cap.

6. Reinsert the auxiliary key.
Fig. 82: Installing Auxiliary Key

COIL ANTENNA REMOVAL/INSTALLATION [ADVANCED KEYLESS

SYSTEM]
NOTE:  Do not remove the coil antenna unless you are replacing it.

3. Disconnect the coil antenna connector.
4. Detach the steering lock tabs from the holes on the coil antenna.
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Fig. 83: Identifying Coil Antenna & Connector

SECURITY ACCESS PROCEDURE

1. Select "Body"
2. Select "Security"

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1. Select "PATS Function"
4. Select the items to be performed from the following:
 Program Additional card key
 Card Key Code Erase and Program
 Steering Lock Unit Programming
 Program additional ignition key
 Ignition Key Code Erase and Program
 Customer Spare Key Programming Enable
 Customer Spare Key Programming Disable
 Parameter Reset
5. The security access begins and the M-MDS displays the "OUT-CODE".
6. Input "IN-CODE" corresponding to "OUT-CODE" displayed on the M-MDS screen.

7. If the security access is successful, selected item can be performed.
IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION &

CLEARING [ADVANCED KEYLESS SYSTEM]
M-MDS EXECUTION MENU/SEQUENCE FOR THE IMMOBILIZER SYSTEM COMPONENT
PARTS REPLACEMENT
NOTE:  When the component parts of the immobilizer system are replaced, the
menu and execution sequence of the M-MDS vary depending on the type
of the replaced unit and parts. Perform the procedures referring to the
following table.
 When performing the procedure, follow each procedure. If the procedure is
not followed, the procedure may not be completed correctly.
 NO.1 ADDITIONAL KEY PROGRAMMING PROCEDURE (USING TWO
VALID KEYS)
 NO.2 KEY ADDITIONAL PROGRAMMING PROCEDURE (USING THE
M-MDS)
 NO.3 KEY REPLACEMENT PROCEDURE (CLEARING PREVIOUSLY
PROGRAMMED KEY ID NUMBERS, KEY RE-PROGRAM)
 NO.4 PCM REPLACEMENT PROCEDURE
 NO.5 KEY ADDITIONAL PROGRAMMING PROCEDURE CHANGING
 NO.6 STEERING LOCK UNIT REPLACEMENT PROCEDURE
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 NO.7 KEYLESS CONTROL MODULE REPLACEMENT PROCEDURE

 NO.8 THE PROCEDURE FOR WHEN SEVERAL PARTS (PCM,
KEYLESS CONTROL MODULE, AND STEERING LOCK UNIT) ARE
REPLACED AT THE SAME TIME
M-MDS MENU
1. "Program Additional card key"

2. "Card Key Code Erase"
3. "Steering Lock Unit Programming"
4. "Program additional ignition key"
5. "Ignition Key Code Erase"
6. "Customer Spare Key Programming Enable"
7. "Customer Spare Key Programming Disable"
8. "Parameter Reset"
M-MDS EXECUTION MENU/SEQUENCE CHART

Replacement Part M-MDS Execution Menu/Sequence
Keyless control module 8 --> 5 --> 1 --> 3
PCM 8
Steering lock unit 5 --> 3
Keyless control module and PCM 8 --> 5 --> 1 --> 3
Keyless control module and steering lock unit 8 --> 5 --> 1 --> 3
PCM and steering lock unit 8 --> 5 --> 3
Keyless control module, PCM and steering lock unit 8 --> 5 --> 1 --> 3
BEFORE SERVICE PREPARATION & PRECAUTIONS
 When performing the following procedures, the immobilizer resetting procedure using the M-MDS must
also always be performed: "Keyless control module replacement", "PCM replacement", "Steering lock
unit replacement", and "Key ID number clearing". The engine will not start unless all work is performed
using the M-MDS.
 A card key that can start the engine is necessary for the key programming. If there is no card key that can
start the engine, perform the key programming after the card key programming. (See CARD KEY ID
CODE REGISTRATION [ADVANCED KEYLESS SYSTEM].)
 There are two ways to add supplemental key: Using the M-MDS or using two keys that can start the
engine to program.
 When replacing any of the immobilizer system component parts, adding/clearing keys, or performing
other functions, refer to the following table and perform the applicable procedure (No.1 to 8).
 Verify that the room fuse is equipped.
BEFORE SERVICE PREPARATION AND PRECAUTIONS CHART

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Items necessary for

Ref. procedure (Prepare
Condition Cautionary notes
No. before starting
procedure)
 The M-MDS is necessary for
Since two or more keys that can start the additional key
the engine are necessary, make a spare programming if "Customer
key. Or program an additional key. (See  Programming spare key programming
1
NO.1 ADDITIONAL KEY key disable" is performed before
PROGRAMMING PROCEDURE the procedure using the M-
(USING TWO VALID KEYS).) MDS. In this case, perform
No. 2.
 Programmed
Make a spare key when the customer card key or
has one key or card key that can start programmed key
the engine. If there is no key, program
2 an additional key.  Programming -
(See NO. 2 KEY ADDITIONAL key or
PROGRAMMING PROCEDURE programmed card
(USING THE M-MDS).) key
 M-MDS
Make a spare key when the customer
has no key or card key that can start the  Unless keys are
engine. Or program an additional key. reprogrammed after the
(See NO.3 KEY REPLACEMENT procedure, the engine cannot
3
PROCEDURE (CLEARING be started. Before beginning
PREVIOUSLY PROGRAMMED  Programming the procedure, verify that the
KEY ID NUMBERS, KEY RE- keys (Two or customer has turned in all of
PROGRAM).) more) the card keys and keys for
Clearing the programmed key ID  M-MDS the vehicle.
number. (See NO.3 KEY  The engine cannot be started
REPLACEMENT PROCEDURE unless a card key and two or
3
(CLEARING PREVIOUSLY more keys are programmed
PROGRAMMED KEY ID after the procedure.
NUMBERS, KEY RE-PROGRAM).)  The card key and keys (two
Replacing all the keys. (Steering lock  Programmed or more) prepared before the
unit is not replaced) card key procedure do not have to be
(See NO.3 KEY REPLACEMENT new ones and there is no
3 PROCEDURE (CLEARING  Programming
keys (Two or problem with using the keys
PREVIOUSLY PROGRAMMED that were used to start the
KEY ID NUMBERS, KEY RE- more)
engine before the procedure.
PROGRAM).)  M-MDS
Replacing the PCM only.  New PCM

4 (See NO.4 PCM REPLACEMENT  Programmed -
PROCEDURE.) card key or
programmed key
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 M-MDS
Changing the additional key  The additional key
programming procedure. (Method for programming using No. 1
programming other keys using two keys cannot be performed after
5 that can start the engine is disabled.)  M-MDS the procedure. It is possible
(See NO. 5 KEY ADDITIONAL to restore the setting. For
PROGRAMMING PROCEDURE restoring the setting, the M-
CHANGING.) MDS is necessary.
Changing the additional key
programming procedure. Allows
programming using two keys that can  New vehicles have this
5  M-MDS
start the engine. (See NO. 5 KEY setting.
ADDITIONAL PROGRAMMING
PROCEDURE CHANGING.)
 Have two or more keys
ready for programming
before beginning the
 New steering procedure, since the
lock unit previous keys will be
invalid.
Replacing the steering lock unit. (See  Programmed
6 NO.6 STEERING LOCK UNIT card key  The steering lock unit
REPLACEMENT PROCEDURE.) programming is necessary
 New keys (Two for the keyless control
or more) module before the key
 M-MDS programming.
 Two or more keys need to be
programmed after the
procedure to start the engine.
 Unless keys are

reprogrammed after the
procedure, the engine cannot
be started. Before beginning
 New keyless the procedure, verify that the
control module customer has turned in all of
Replacing the keyless control module.  Programming the card keys and keys for
(See NO.7 KEYLESS CONTROL card key the vehicle.
7
MODULE REPLACEMENT  Programming  Programming the card key.
PROCEDURE.) keys (Two or  Programming the steering
more) lock unit.
 M-MDS  The engine cannot be started
unless a card key and two or
more keys are programmed
after the procedure.
 The card key and keys (two
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or more) prepared before the

procedure do not have to be
new ones and there is no
problem with using the keys
that were used to start the
engine before the procedure.
Replacing several parts (PCM, keyless  Parts to be
control module, and steering lock unit) replaced
at the same time.  Programming  Refer to No. 4, No. 6, and
(See NO.8 THE PROCEDURE FOR card key No. 7 above and prepare the
8
WHEN SEVERAL PARTS (PCM,  Programming required items according to
KEYLESS CONTROL MODULE, keys (Two or the parts to be replaced.
AND STEERING LOCK UNIT) are more)
Replaced at The Same Time.)
 M-MDS
- Replacing the coil antenna.  Immobilizer system resetting

 New coil antenna
is not necessary.
CAUTION:  The following conditions may cause poor signal communication

between the key and vehicle, resulting in the engine not starting or a
key registration error. Do not perform any work under the following
conditions:
 Placing the following items close to the key grip or contacting it.
 Spare keys
 Keys for other vehicles equipped with an immobilizer

system
 Any metallic object
 Any electronic device, or any credit or other card with

magnetic strips
 Do not place the following devices in the vehicle while programming,
otherwise programming cannot be performed:
 Card key
 M-MDS
 Devices that can send/receive the radio waves
NOTE:  The "valid key" used in this manual indicates the key that can start the
engine.
 If the key adding, programming, clearing, and immobilizer system
construction parts replacement are performed, verify that the all keys can
start the engine within 5 s after the procedure.
 When verifying that the engine starts, wait at least 5 s or more before
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starting the engine using the next key.

 If the engine cannot be started using a programmed key, repeat the
procedure from the beginning.
 Do not start the engine unless indicated in the procedure. If the engine is
started during the programming procedure, programming is stopped at
that point. Repeat the procedure starting from the beginning if the engine
is started before completion.
 Do not place the card key in the vehicle or bring it within approx. 1 m of
the vehicle unless indicated in the procedure.
 Two or more key ID numbers must be programmed for the engine to start.
 A maximum of eight key ID numbers can be programmed for one vehicle.
The M-MDS can be used to verify the number of key ID numbers
programmed to a single vehicle.
 Do not select a M-MDS screen menu other than one indicated in the
procedure.
M-MDS CONNECTING PROCEDURE
CAUTION:  Do not place the M-MDS in the vehicle while programming, otherwise
programming cannot be performed.
1. Fully lower the door glass.


NO.1 ADDITIONAL KEY PROGRAMMING PROCEDURE (USING TWO VALID KEYS)
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Condition
 Have two or more valid keys.
NOTE:  A maximum of eight keys can be programmed for one vehicle. If key
programming is not successful and DTC 15 appears even though the
procedure was performed properly, use the PID/data monitor function
of the M-MDS and verify the number of keys that have been
programmed.
 If eight keys have already been programmed, and it is necessary to
program other keys, the previously programmed key ID numbers
must first be cleared. To clear the key, refer to " CLEARING CARD
KEY [ADVANCED KEYLESS SYSTEM]".
Procedure
Fig. 86: Additional Key Programming Procedure

1. Prepare key 3 for programming.

2. Start the engine using key 1.
3. Verify that the security light illuminates for approx. 3 s , and then goes out.
5. Using key 1, turn the ignition switch to the ON position.
7. Using key 1, turn the ignition switch to the LOCK position within approx. 4 s after the security light
goes out.
8. Remove key 1.
9. Repeat Steps 5-8 using key 2 instead of key 1.
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10. Repeat Steps 5-8 using key 3 instead of key 1.

11. If an additional key is to be programmed, repeat Steps 2-10 with the additional key as key 4.
12. Verify that the all keys can start the engine for 5 s or more after the procedure.
NO. 2 KEY ADDITIONAL PROGRAMMING PROCEDURE (USING THE M-MDS)
Condition
 There is only one valid key. Or, there is no valid key but there is a card key that can start the engine.
NOTE:  A maximum of eight keys can be programmed for one vehicle. If key
registration is not successful and DTC 15 appears even though the
programmed.
 If eight keys have already been programmed, and it is necessary to
program other keys, the previously programmed key ID numbers
must first be cleared. To clear the key ID number, refer to "
CLEARING CARD KEY [ADVANCED KEYLESS SYSTEM]".
Procedure (If one key is to be programmed)
Fig. 87: Key Additional Programming Procedure (If One Key Is To Be Programmed)

2. Start the engine using a valid key 1 or card key 1.
CAUTION:  Do not place the card key in the vehicle when starting the
engine with the valid key, otherwise programming cannot be
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performed. If the engine is started with the card key, remove the
card key from the vehicle after the engine is started.
5. Connect the M-MDS to the DLC-2. (See M-MDS MENU.)
NOTE:  Although the security light starts flashing and DTC 15 is displayed
after approx. 1 min, this does not indicate an improper procedure.
Continue to perform the procedure as indicated.
 Select "Body".
 Select "Security".
 Select "Programming".
 Select "PATS Functions".
9. Select "Program additional ignition key" from the M-MDS screen menu and perform the procedure
according to the M-MDS screen
10. Perform the security access according to the directions on the M-MDS screen. (See SECURITY
ACCESS PROCEDURE.)
NOTE:  After selecting the above menu, "This operation has been
successful" is displayed. At this point, the key that turned the
ignition switch to the ON position is completely programmed.
11. After verifying that the PATS function menu is displayed again on the M-MDS screen, select the "Exit
(From This Menu)" to finish the M-MDS procedure.
12. After Step 11, wait 5 s or more , and then turn the ignition switch to the LOCK position.
Procedure (If two or more keys are to be programmed)
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Fig. 88: Key Additional Programming Procedure (If Two Or More Keys Are To Be Programmed)

2. Start the engine using a valid key 1 or card key 1.
CAUTION:  Do not place the card key in the vehicle when starting the
engine with the valid key, otherwise programming cannot be
performed. If the engine is started with the card key, remove the
card key from the vehicle after the engine is started.
 Select "Body".
according to the M-MDS screen
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ACCESS PROCEDURE.)
11. Turn the ignition switch to the LOCK position and remove key 2.
12. If additional keys need to be programmed, repeat Steps 6-10, and replace key 3 in Step 10 with the key to
be programmed.
NO.3 KEY REPLACEMENT PROCEDURE (CLEARING PREVIOUSLY PROGRAMMED KEY ID

NUMBERS, KEY RE-PROGRAM)
Condition
 Prepare two or more keys to be programmed after the key ID number is cleared.
Procedure
Fig. 89: Key Replacement Procedure

1. Prepare two or more keys to be programmed after the key ID number is cleared.
NOTE:  Although the security light starts flashing and DTC 15 or DTC 23 is
displayed after approx. 1 min, this does not indicate an improper
procedure. Continue to perform the procedure as indicated.
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 Select "Body".
6. Select "Ignition Key Code Erase" from the M-MDS screen menu and perform the procedure according to
the M-MDS screen
ACCESS PROCEDURE.)
CAUTION:  The M-MDS displays "You must now program a minimum of two
keys.", however, do not perform the key programming and
proceed to Step 7. If the procedure is not followed, the engine
may not be started. The key programming procedure is
performed at Steps 12 to 17.
8. After verifying that the PATS function menu is displayed again on the M-MDS screen, select "Exit (From
This Menu)" to finish the M-MDS procedure.
9. After Step 8, wait 5 s or more and then turn the ignition switch to the ON position.
10. Ignition switch to the LOCK position.
11. Disconnect the M-MDS from the DLC-2.
13. After verifying that the security light and keyless warning light illuminate for 3 s or more , turn the
ignition switch to the LOCK position and remove key 1.
NOTE:  Although the security light remains illuminated and DTC 21 is


15. Verify that the security light and keyless warning light illuminate for approx. 3 s , and then goes out.
16. After verifying that the security light goes out, turn the ignition switch to the LOCK position using key 2,
and then remove key 2.
17. If programming one more keys, repeat Steps 14 to 16 with a key to be programmed as key 3. If the
vehicle is left with the ignition switch in the ON position for 1 min or more, additional key programming
according to Steps 14 to 16 is disabled. If this occurs, refer to the "NO.1 ADDITIONAL KEY
PROGRAMMING PROCEDURE (USING TWO VALID KEYS)" to program any additional keys.
(See NO.1 ADDITIONAL KEY PROGRAMMING PROCEDURE (USING TWO VALID KEYS).)
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18. Start the engine with key 1.

19. Verify that the security light and keyless warning light operate as follows:
 From the point when the ignition switch is turned to the ON position, the security light illuminates
for approx. 3 s , and goes out.
 The keyless warning light illuminates when the ignition switch is turned to the ON position, and the
light goes out after approx. 1 s , and then displays the number of the programmed keys.
Fig. 90: Identifying Blinking Pattern - Keyless Warning Light

20. After verifying that the keyless warning light goes out, turn the ignition switch to the LOCK position
using key 1, and then remove the key.
21. Repeat Steps 18 to 20 using key 2 instead of key 1.
NOTE:  If three or more keys have already been programmed, perform Steps
18 to 20.
22. Start the engine using the card key 1.
CAUTION:  Remove any key from the key cylinder.

 Close all doors.
 Bring the card key into the vehicle.
 From the point that ignition switch is turned to the ON position, the security light illuminates for
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approx. 3 s , and goes out.

 The keyless warning light illuminate when the ignition switch is turned to the ON position for
approx. 1 min , and goes out.
24. After verifying that the keyless warning light goes out, turn the ignition switch to the LOCK position.
NO.4 PCM REPLACEMENT PROCEDURE
Condition
 Prepare a valid key or a card key that can start the engine.
CAUTION:  Before starting Step 1, complete the procedure for PCM

replacement. (See PCM REMOVAL/INSTALLATION [MZI-3.7] .)
Procedure
Fig. 91: PCM Replacement Procedure


3. Using a valid key or card key, turn the ignition switch to the ON position.

4. Verify that the keyless warning light illuminates for approx. 3 s , and then goes out.
 Select "Body".
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7. Select "Parameter Reset" from the M-MDS screen menu and perform the procedure according to the M-
MDS screen
ACCESS PROCEDURE.)
9. Select the replaced parts according to the directions on the M-MDS.
 If the PCM is replaced: Select "PCM".
NOTE:  At this time, do not select the other parts from the M-MDS menu.
12. Using key, turn the ignition switch to the ON position.
13. After verifying that the security light and keyless warning light illuminates for 3 s or more turn the
NO. 5 KEY ADDITIONAL PROGRAMMING PROCEDURE CHANGING
NOTE:  This procedure is performed for enabling/disabling the "No.1 Additional

Key Programming Procedure (Using Two Valid Keys)" setting.
 This procedure is possible when the vehicle is new, and when replacing
the keyless unit with a new one.
 If "No.1 Additional Key Programming Procedure (Using Two Valid Keys)"
is set to disable, the additional key programming can be only performed
using the M-MDS preventing the forging of a spare key by using two keys
that can start the engine. This function is for use by rental car agencies or
other companies with vehicle fleets.
Procedure
1. Using the key, turn the ignition switch to the ON position. (The key can be either the valid key or an
unprogrammed key)

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 Select "Body".
5. Select "Customer Spare Key Programming Enable" or "Customer Spare Key Programming Disable" from
the M-MDS screen menu. The key additional programming procedure is as follows according to the
selected menu:
ADDITIONAL KEY PROGRAMMING PROCEDURE

Additional key programming procedure
Setting
Method using two valid keys Method using the M-MDS
Customer spare key programming enable - -
Customer spare key programming disable X -
- : Available
x : Unavailable
ACCESS PROCEDURE.)
8. After Step 7, wait 5 s or more and then turn the ignition switch to the LOCK position.
NO.6 STEERING LOCK UNIT REPLACEMENT PROCEDURE
Condition
 Have two or more keys to be programmed after the replacement.
Procedure
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Fig. 92: Steering Lock Unit Replacement Procedure


 Select "Body".
the M-MDS screen
ACCESS PROCEDURE.)
8. Perform the steering lock unit programming. (See STEERING LOCK UNIT ID CODE
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according to Steps 15 to 17 is disabled. If this occurs, refer to the "M-MDS CONNECTING
PROCEDURE" to program any additional keys. (See M-MDS MENU.)

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19 to 21.
23. Start the engine using the card key.

NO.7 KEYLESS CONTROL MODULE REPLACEMENT PROCEDURE
 Card key
 M-MDS
Condition
 Have two or more keys to be programmed after the replacement.

 Have one or more card keys to be programmed after the replacement.
Procedure
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Fig. 94: Keyless Control Module Replacement Procedure

 Select "Body".
MDS screen
ACCESS PROCEDURE.)
 If the keyless control module is replaced: Select "SKE".
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the M-MDS screen.
10. Perform the card key programming. (See CARD KEY ID CODE REGISTRATION [ADVANCED
KEYLESS SYSTEM].)


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22 to 24.

NO.8 THE PROCEDURE FOR WHEN SEVERAL PARTS (PCM, KEYLESS CONTROL MODULE,
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AND STEERING LOCK UNIT) ARE REPLACED AT THE SAME TIME
 Card key
 M-MDS
Condition
 The menu executed on the M-MDS varies depending on the replaced parts. Verify the M-MDS menu to
be executed referring to the M-MDS EXECUTION MENU/SEQUENCE FOR THE IMMOBILIZER
SYSTEM COMPONENT PARTS REPLACEMENT.
Procedure
Fig. 96: Procedure For - PCM, Keyless Control Module & Steering Lock Unit
 Select "Body".
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MDS screen
ACCESS PROCEDURE.)
 If the keyless control module is replaced: Select "SKE".
9. Select "Ignition Key Code Erase," from the M-MDS screen menu and perform the procedure according to
the M-MDS screen.
10. Perform the card key programming. (See CARD KEY ID CODE REGISTRATION [ADVANCED
KEYLESS SYSTEM].)


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22 to 24.

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IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY ADDITION AND

CLEARING [KEYLESS ENTRY SYSTEM]
FOREWORD
 The immobilizer resetting procedure using the M-MDS must also always be performed when performing
the following procedure: "instrument cluster replacement", "PCM replacement", "instrument cluster and
PCM joint replacement", and "key ID number clearing". The engine will not start unless all work is
performed using the M-MDS.
 For adding a key, there are two ways, either using the M-MDS or using two keys with which the engine
can be started.
 When replacing any of the immobilizer system component parts, adding/clearing keys, or performing
other functions, refer to the following table and perform the applicable procedure (No.1 to 7).
IMMOBILIZER SYSTEM COMPONENT REPLACEMENT REFERENCE

Reference
Situation Required items Cautionary notes
number
Have two or more keys with which  The M-MDS is necessary

the engine can be started, and for the additional key
making a spare key, or programming programming if "Customer
1 an additional key. (See NO.1  Registration Spare Key Programming
ADDITIONAL KEY key Disable" is set before the
REGISTRATION PROCEDURE procedure using the M-
(USING TWO VALID KEYS).) MDS. In this case, perform
No. 2.
If there is only one key that can start
the engine, make a spare key. If there
 Registration
is no key, program an additional key.
2 key -
(See NO.2 ADDITIONAL KEY
REGISTRATION PROCEDURE  M-MDS
(USING THE M-MDS).)
 All the key ID numbers

programmed to the vehicle
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will be cleared.
 Unless keys are
procedure, the engine
cannot be started. Before
beginning the procedure,
Clearing the programmed key ID verify that the customer has
number. turned in all of the keys for
 Registration the vehicle.
(See NO.3 KEY REPLACEMENT
keys (Two or
3 PROCEDURE (CLEARING  Two or more keys need to
more)
PREVIOUSLY PROGRAMMED be programmed after the
KEY ID NUMBERS, KEY RE-  M-MDS procedure to start the
PROGRAM).) engine.
 The keys (two or more) to
prepare for the procedure do
not have to be new ones;
there is no problem with
using the keys with which
the engine can be started.
 The previous keys will be
invalid since the steering
Replace all the keys. (Steering lock
lock is replaced. Have two
replacement or similar procedure)
or more new keys ready for
(See NO.3 KEY REPLACEMENT  New keys
programming before
3 PROCEDURE (CLEARING (two or more)
beginning the procedure.
PREVIOUSLY PROGRAMMED  M-MDS
KEY ID NUMBERS, KEY RE-  Unless keys are
PROGRAM).) reprogrammed after the
cannot be started.
Changing the additional key  The additional key
programming procedure. (Method programming using No. 1
for programming other keys using cannot be performed after
two keys that can start the engine is the procedure. It is possible
4  M-MDS
disabled.) to restore the setting. For
(See NO.4 ADDITIONAL KEY restoring the setting, the M-
PROGRAMMING PROCEDURE MDS or equivalent is
CHANGING.) necessary.
Changing the additional key
programming procedure. (Allows
programming using two keys that
4 can start the engine.) (See NO.4  New vehicles have this
 M-MDS
ADDITIONAL KEY setting.
PROGRAMMING PROCEDURE
CHANGING.)
 Unless keys are
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verify that the customer has
Replacing the instrument cluster  New turned in all of the keys for
only. instrument the vehicle.
(See NO.5 RESETTING cluster  Two or more keys need to
PROCEDURE FOR THE
5  Registration be programmed after the
IMMOBILIZER SYSTEM
keys (two or procedure to start the
WHEN REPLACING THE
more) engine.
INSTRUMENT CLUSTER
REPLACEMENT.)  M-MDS  The keys (two or more) to
Replacing the PCM only. (See NO.6
 Replacement
RESETTING PROCEDURE FOR
6 PCM -
THE IMMOBILIZER SYSTEM
WHEN REPLACING THE PCM.)  M-MDS
 Unless keys are
 New PCM verify that the customer has
 New turned in all of the keys for
instrument the vehicle.
Replacing the PCM and instrument
cluster  Two or more keys need to
7 cluster at the same time.
(See PROCEDURE.)  Registration be programmed after the
keys (two or procedure to start the
more) engine.
 M-MDS  The keys (two or more) to
- Replacing the coil antenna.  New coil  Immobilizer system

antenna resetting is not necessary.
CAUTION:  If any of the following items are touching or near the key head, signal
communication between the key and vehicle is negatively affected,
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resulting in the engine not starting or the key registration failure. Do

not perform the procedure if any of the following items are touching
or near the key head.
 Any metallic object
 Spare keys or keys for other vehicles equipped with an

immobilizer system
 Any electronic device, or any credit or other cards with
magnetic strips
NOTE:  Within the following procedures, the term a "valid key" means a "key that
can start the engine".
 After adding/registering keys, clearing ID numbers or replacing any
component part of the immobilizer system, verify that all keys can start the
engine within 5 s.
 When verifying that the keys can start the engine, wait at least 5 s or more
between inserting them.
 If the engine cannot be started using a registered key, repeat the
Fig. 98: Precaution For - Immobilizer System Key

 Do not start the engine until the key registration procedure for all the
necessary keys is completed. If the engine is started during the
registration procedure, registration is stopped at that point. Repeat the
procedure starting from the beginning if the engine is started before
completion.
 Two or more key ID numbers must be registered for the engine to start.
 A maximum of eight key ID numbers can be registered for one vehicle. The
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M-MDS can be used to verify the number of key ID numbers registered to a

single vehicle.
 Do not select screen menus of the M-MDS that are not indicated within the
procedures.
M-MDS CONNECTING PROCEDURE
CAUTION:  Do not place the M-MDS in the vehicle while programming, otherwise
programming cannot be performed.
1. Fully lower the door glass.


NO.1 ADDITIONAL KEY REGISTRATION PROCEDURE (USING TWO VALID KEYS)
Conditions
 Have two or more valid keys.
NOTE:  A maximum of eight keys can be registered for any one vehicle. If key
registered.
 If eight keys have already been registered, and it is necessary to
register other keys, the previously registered key ID numbers must
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first be cleared. To clear the key ID numbers, refer to " NO.3 KEY
REPLACEMENT PROCEDURE (CLEARING PREVIOUSLY
PROGRAMMED KEY ID NUMBERS, KEY RE-PROGRAM)".
Procedure
Fig. 100: Additional Key Registration Procedure

1. Have one key (key 3) ready for registration.

3. Verify that the security light illuminates for approx. 3 s and then goes out.
4. Using key 1, turn the ignition switch to the LOCK position within approx. 4 s after the security light
goes out.
5. Remove key 1
6. Repeat Steps 2-5 using key 2.
7. Repeat Steps 2-5 using key 3.
8. If additional keys need to be registered, repeat Steps 2-5 in the same manner as key 4.
NO.2 ADDITIONAL KEY REGISTRATION PROCEDURE (USING THE M-MDS)
Conditions
 Customer has only one valid key. Or customer has no valid keys. (Can also be performed even if there are
two or more valid keys)
NOTE:  A maximum of eight keys can be registered for any one vehicle. If key
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procedure was performed properly, use the PID/data monitor function of

the M-MDS and verify the number of keys that have been registered.
 If eight keys have already been registered, and it is necessary to register
other keys, the previously registered key ID numbers must first be cleared.
To clear the key ID numbers, refer to " NO.3 KEY REPLACEMENT
PROCEDURE (CLEARING PREVIOUSLY PROGRAMMED KEY ID
NUMBERS, KEY RE-PROGRAM)".
Procedure
1. Have one key (key 1) ready for registration.

2. Connect the M-MDS to the DLC-2. (See M-MDS CONNECTING PROCEDURE.)
 Select "Body".
according to the M-MDS screen.
ACCESS PROCEDURE.)
 In this procedure, the necessary number of the keys are completely
programmed. To finish the additional key programming, go to 11.
 If additional keys need to be programmed, go to the next step.
8. After verifying that the PATS function menu is displayed again on the M-MDS screen, turn the ignition
switch to the LOCK position and remove key 1.
9. Using the additional key to be programmed, turn the ignition switch to the ON position.
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10. Return to the Step 3.

NO.3 KEY REPLACEMENT PROCEDURE (CLEARING PREVIOUSLY PROGRAMMED KEY ID

NUMBERS, KEY RE-PROGRAM)
Conditions
 Have two or more keys to be programmed after the key ID number clearing.
Procedure
Fig. 101: Key Replacement Procedure

 Select "Body".
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the M-MDS screen
ACCESS PROCEDURE.)
8. After verifying that the PATS function menu is displayed again on the M-MDS or equivalent screen,
select "Exit (From This Menu)" to finish the M-MDS procedure.
9. After Step 8, wait 5 s or more and then turn the ignition switch to the LOCK position using key 1.
11. After verifying that the security light illuminates for 3 s or more, turn the ignition switch to the LOCK
position and remove key 1.


13. Verify that the security light illuminates for approx. 3 s and then turns off.
14. After verifying that the security light turns off, turn the ignition switch to the LOCK position and remove
key 2.
15. If programming one more keys, repeat Steps 12 to 14 with a key to be programmed as key 3. Steps 12 to
14 must be performed within 1 min for each key. If the vehicle is left with the ignition switch in the ON
position for 1 min or more, additional key programming according to Steps 12 to 14 is disabled. If this
occurs, refer to "NO.1 ADDITIONAL KEY REGISTRATION PROCEDURE (USING TWO
VALID KEYS)" to register any additional keys.
NO.4 ADDITIONAL KEY PROGRAMMING PROCEDURE CHANGING
NOTE:  This procedure is performed for enabling/disabling the "No.1 Additional

Key Programming Procedure (Using Two Valid Keys)" setting.
 The setting is "Enable" when the vehicle is new or the instrument cluster
is replaced with a new one.
 If "No. 1 Additional Key Programming Procedure (Using Two Valid Keys)"
is set to disable, the additional key programming can be only performed
using the M-MDS preventing the forging of a spare key by using two valid
keys. This function is for use by rental car agencies or other companies
with vehicle fleets.
Procedure
1. Using the key, turn the ignition switch to the ON position. (The key can be either the valid key or an
unprogrammed key)
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 Select "Body".
5. Select "Customer Spare Key Programming Enable" or "Customer Spare Key Programming Disable" from
the M-MDS screen menu. Additional key programming procedure is as follows according to the selected
menu:
ADDITIONAL KEY REGISTRATION METHOD

Additional key registration method
Setting Procedure using two valid Procedure using the M-
keys MDS
Customer spare key programming enable X X
Customer spare key programming
- X
disable
x. Procedure is possible
-. Procedure is not possible
ACCESS PROCEDURE.)
7. After verifying that the PATS function menu is displayed again on the M-MDS or equivalent screen,
select "Exit (From This Menu)" to finish the M-MDS procedure.
NO.5 RESETTING PROCEDURE FOR THE IMMOBILIZER SYSTEM WHEN REPLACING THE
INSTRUMENT CLUSTER REPLACEMENT
Conditions
CAUTION:  Before starting Step 1, complete the procedure for the

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instrument cluster replacement. (See INSTRUMENT CLUSTER

Procedure
Fig. 102: Resetting Procedure For - Immobilizer System When Replacing Instrument Cluster
Replacement
3. Using the key 1, turn the ignition switch to the ON position.
 Select "Body".
the M-MDS screen
ACCESS PROCEDURE.)
8. Select "Parameter Reset" from the M-MDS screen menu.
 If the instrument cluster is replaced: Select "IC".
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position, remove key 1, and go to the next step.
key 2.
PCM
CAUTION:  Before starting Step 1, complete the procedure for the PCM
replacement. (See PCM REMOVAL/INSTALLATION [MZI-3.7] .)
Procedure
Fig. 103: Resetting Procedure For - Immobilizer System When Replacing PCM
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 Select "Body".
MDS screen
ACCESS PROCEDURE.)
13. After verifying that the security light turns off, turn the ignition switch to the LOCK position.
PCM AND INSTRUMENT CLUSTER AT THE SAME TIME
Conditions
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CAUTION:  Before starting Step 1, complete the procedure for the PCM and
instrument cluster replacement. (See PCM
REMOVAL/INSTALLATION [MZI-3.7] .) (See INSTRUMENT
CLUSTER REMOVAL/INSTALLATION .)
Procedure
Fig. 104: Resetting Procedure For - Immobilizer System When Replacing PCM & Instrument Cluster
NOTE:  Although the security light flashes and DTC 15 is displayed after
approx. 1 min, this does not indicate an improper procedure.
 Select "Body".
the M-MDS screen
ACCESS PROCEDURE.)
8. Select "Parameter Reset" from the M-MDS screen menu.
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 If the instrument cluster is replaced: Select "IC".

position, remove key 1, and go to the next step.
key 2.
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2008 ENGINE Lubrication (MZI-3.7) - Mazda CX-9
2008 ENGINE
Lubrication (MZI-3.7) - Mazda CX-9
LUBRICATION SYSTEM LOCATION INDEX [MZI-3.7]
Fig. 1: Identifying Lubrication Components

ENGINE OIL LEVEL INSPECTION [MZI-3.7]

1. Position the vehicle on level ground.
2. Warm up the engine.
3. Stop the engine and allow approx. 5 min before continuing.
4. Remove the dipstick, wipe it clean, and reinstall it fully.
5. Remove the dipstick and verify that the oil level is between the L and F marks on the dipstick.
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 If the oil level is below the L mark, add engine oil.
Fig. 2: Identifying Engine Oil Level In Dipstick

ENGINE OIL REPLACEMENT [MZI-3.7]
WARNING:  Hot engines and engine oil can cause severe burns. Turn off the
engine and wait until it and the engine oil have cooled.
 A vehicle that is lifted but not securely supported on safety stands is
dangerous. It can slip or fall, causing death or serious injury. Never
work around or under a lifted vehicle if it is not securely supported
on safety stands.
CAUTION:  If engine oil is spilled on the exhaust system, wipe it off completely. If
you fail to wipe the spilled engine oil, it will produce fumes because
of the heat.
1. Position the vehicle on level ground.

2. Remove the oil filler cap.
3. Remove the oil pan drain plug.
4. Drain the engine oil into a container.
5. Inspect the rubber seal of the oil pan drain plug and make sure there are no cracks, deterioration, or
damage.
 If necessary, replace the oil pan drain plug.
6. Clean the flange surface (seal rubber) on the oil pan drain plug, then install the oil pan drain plug.
Oil pan drain plug tightening torque
27 N.m {2.8 kgf.m, 20 ft.lbf}
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NOTE:  The amount of residual oil in the engine can vary according to factors
such as the replacement method and oil temperature. Verify the oil
level after engine oil replacement.
7. Refill with the following type and amount of the engine oil.
Engine oil capacity (approx. quantity)
Oil replacement: 4.7 L {5.0 US qt, 4.2 Imp qt}
Oil and oil filter replacement: 5.2 L {5.5 US qt, 4.6 Imp qt}
Total (dry engine): 5.9 L {6.2 US qt, 5.2 Imp qt}
Engine oil specification
ENGINE OIL SPECIFICATION

Item U.S.A. and CANADA Except U.S.A. and CANADA
Engine oil grade
Engine oil viscosity 5W-20
8. Install the oil filler cap.

9. Start the engine and confirm that there is no oil leakage.
 If there is oil leakage, repair or replace the applicable part.
10. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [MZI-3.7].)
OIL FILTER REPLACEMENT [MZI-3.7]
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on safety stands.
CAUTION:  If engine oil is spilled on the exhaust system, wipe it off completely. If
you fail to wipe the spilled engine oil, it will produce fumes because
of the heat.
1. Remove the oil filter using a oil filter wrench.

2. Use a clean rag to wipe off the mounting surface on the oil filter adapter and the oil filter.
3. Apply clean engine oil to the O-ring of a new oil filter.
4. Install the oil filter until the O-ring contacts the sealing surface.
5. Tighten the oil filter 3/4 turns by hand.
Fig. 3: Removing Oil Filter

OIL PRESSURE INSPECTION [MZI-3.7]
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on safety stands.

3. Remove the fan control module No.2 with the connectors still connected. (Dual fan control module) (See
COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the oil pressure switch.
5. Screw the SSTs into the oil pressure switch installation hole.
8. Run the engine at the specified speed, and note the gauge readings.
 If not within the specification, inspect for the cause and repair or replace if necessary.
Fig. 4: Identifying Oil Pressure With SST

NOTE:  The oil pressure can vary with oil viscosity and temperature.
Oil pressure (reference value) [oil temperature: 93.3°C {200°F}]
310-621 kPa {3.17-6.33 kgf/cm2 , 45.0-90.0 psi} [2,000 rpm]
9. Stop the engine and wait until it is cool.

11. Remove the SSTs.
CAUTION:  Be sure there is no sealant adhering to the first two threads

from the end of the oil pressure switch to prevent a possible
operation malfunction.
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12. Apply silicone sealant to the oil pressure switch threads as shown in the figure.
13. Install the oil pressure switch.
Tightening torque
10.7-24.5 N.m {1.1-2.4 kgf.m, 7.9-18.0 ft.lbf}
14. Install the fan control module No.2. (Dual fan control module) (See COOLING FAN COMPONENT
Fig. 5: Applying Silicone Sealant To Oil Pressure Switch Threads

17. Install the engine cover.
OIL COOLER REMOVAL/INSTALLATION [MZI-3.7]
on safety stands.

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5. Remove the exhaust manifold insulator (LH). (See EXHAUST SYSTEM
7. Use a clean rag to wipe off the mounting surface on the oil filter adapter and the oil cooler.
8. Install in the reverse order of the removal.
3.7] .)
Fig. 6: Identifying Water Hose, Oil Cooler, O-Ring & Torque Specifications
OIL COOLER INSTALLATION NOTE
1. Tighten the oil cooler bolts in the order shown in the figure.
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Fig. 7: Identifying Oil Cooler Bolts Tighten Sequence

OIL PAN REMOVAL/INSTALLATION [MZI-3.7]
serious injures or death and damage. Fuel can also intake skin and
laboratory nice. Protect your skin by washing with soap and water
NOTE:  The following procedure "OIL PAN REMOVAL/INSTALLATION" is

vehicle.
1. Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZI-3.7].)

3.7] .)
3. Using a hoist, lower the engine and transaxle component on a level surface.
WARNING:  Protect and stabilize the lowered engine and transaxle

component with crossties to prevent injury or damage due to
roll over.

EL] .)
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[MZI-3.7] .)
11. Remove the exhaust manifold (RH). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-
3.7] .)
12. Remove the transfer bracket. (AWD) (See TRANSFER REMOVAL/INSTALLATION .)
13. Install the engine to the SST (engine stand). (See ENGINE MOUNTING/DISMOUNTING.)
14. Remove the engine front cover. (See TIMING CHAIN REMOVAL/INSTALLATION [MZI-3.7] .)
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Fig. 8: Identifying Oil Pan, Oil Stainer, Bolts & Torque Specifications
ENGINE MOUNTING/DISMOUNTING
Mounting
1. Remove the WU-TWC (RH) bracket. (AWD)
Fig. 9: Identifying WU-TWC (RH) Bracket & Torque Specifications

2. Install the SSTs (arms) to the cylinder block four holes are shown in time figure, and hand-tighten the
bolts (M10 X 1.5T length 90 mm {3.55 in}).
Fig. 10: Identifying Cylinder Block Four Holes With SST

3. Assemble the SSTs (bolts, nuts, and plate) to the specified positions as shown in the figure.
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Fig. 11: Identifying Bolts, Nuts, And Plate With SST

4. Assemble the SST (bolts, nuts, and plate) set in Step 3 to the SST (arms) set in Step 2.
5. Adjust the SSTs (bolts) so that approx. 20 mm {0.79 in} of thread is exposed from the side of the SST
(plate).
6. Make the SSTs (arms and plate) parallel by adjusting the SSTs (bolts and nuts).
7. Tighten the SSTs (bolts and nuts) to affix the SSTs firmly.
Fig. 12: Identifying Engine With SST

8. Mount the engine on the SST (engine stand).
WARNING:  Self-locking brake system of the engine stand may not be

effective when the engine is held in an unbalanced position.
This could lead to sudden, rapid movement of the engine and
mounting stand handle and cause serious injury. Never keep
the engine in an unbalanced position, and always hold the
rotating handle firmly when turning the engine.
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Fig. 13: Identifying Engine Mount With SST

Dismounting
1. Dismount in the reverse order of mounting.
OIL PAN REMOVAL NOTE
1. Install two of the oil pan bolts temporarily into the two threaded holes in the oil pan.
2. Alternately tighten the two bolts one turn at a time until the oil pan-to-cylinder block seal is released.
3. Remove the oil pan.
Fig. 14: Locating Oil Pan Bolts

OIL PAN INSTALLATION NOTE
CAUTION:  Apply silicon sealant in a single, unbroken line around the whole
perimeter.
 The oil pan and bolts must be installed and the oil pan aligned to the
cylinder block within 5 min of sealant application. Final tightening of
the oil pan bolts must be carried out within 60 min of sealant
application.
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 Using bolts with the old seal adhering could cause cracks in the
cylinder block.
1. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the
cylinder block and oil pan.
2. When reusing the oil pan installation bolts, clean any old sealant from the bolts.
Fig. 15: Removing Old Sealant

3. Apply silicone sealant (Loctite 5900) to the oil pan along the inside of the bolt holes as shown in the
figure.
Thickness
A: Approx. 3.0 mm {0.12 in}
B: 5.0-6.0 mm {0.20-0.23 in}
C: 10.0 mm {0.39 in}
4. Install the oil pan and the bolts to the cylinder block.
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Fig. 16: Identifying Oil Pan Sealant Area

Tightening torque
3.0 N.m {31 kgf.cm, 27 in.lbf}
2. Loosen the bolts 180°.
Fig. 17: Identifying Oil Pan Tighten Sequence

5. Using a straightedge, align the oil pan flush with the rear of the cylinder block at the two areas as shown.
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Fig. 18: Aligning Oil Pan Flush With Rear Of Cylinder Block
Tightening torque
Bolt A: 20-28 N.m {2.1-2.8 kgf.m, 15-20 ft.lbf}
Bolt B: 8.5-11.5 N.m {87-117 kgf.cm, 76-101 in.lbf}
Fig. 19: Identifying Oil Pan Bolts Tighten Sequence

OIL PUMP REMOVAL/INSTALLATION [MZI-3.7]
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NOTE:  The following procedure "OIL PUMP REMOVAL/INSTALLATION" is

vehicle.
1. Drain the engine oil. (See ENGINE OIL REPLACEMENT [MZI-3.7].)

3.7] .)
[MZI-3.7] .)
9. Remove the timing chain component. (See TIMING CHAIN REMOVAL/INSTALLATION [MZI-
3.7] .)
Fig. 20: Lifting Engine With Engine Jack


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13. Inspect the oil pressure. (See OIL PRESSURE INSPECTION [MZI-3.7].)
Fig. 21: Identifying Oil Pump, O-Ring & Torque Specifications

Microsoft
2008 BODY & ACCESSORIES Symptom Troubleshooting (Car Navigation System) - Mazda CX-9
Symptom Troubleshooting (Car Navigation System) - Mazda CX-9
CAR-NAVIGATION SYSTEM [CAR-NAVIGATION SYSTEM]

 Use the chart below and verify the trouble in order to diagnose the appropriate area.
No. Malfunction symptom
1 Display screen changes to black.
2 Display screen changes to white.
3 System does not load map disc.
4 Vehicle position deviates from the route map.
5 No voice navigation
Display screen does not change to the night mode. (Front and rear combination lights operate
6
normally.)
7 Display does not change to the back camera image.
8 Speech recognition does not start.
QUICK DIAGNOSTIC CHART
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Fig. 1: Quick Diagnostic Chart - Car Navigation System

NO.1 DISPLAY SCREEN CHANGES TO BLACK. [CAR-NAVIGATION

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SYSTEM]
1 Display screen changes to black.
 Open or short circuit in car-navigation unit (power supply (B+)) wiring
harness
 Open or short circuit in car-navigation unit (power supply (ACC)) wiring
harness
 Open or short circuit in car-navigation unit (GND) wiring harness
 Open or short circuit in wiring harness between audio unit and car-navigation
unit
 Poor connection of rear mount camera control module connector, terminal
damage
POSSIBLE  Open or short circuit in audio unit (power supply (B+)) wiring harness
CAUSE
 Open or short circuit in audio unit (power supply (ACC)) wiring harness
 Open or short circuit in audio unit (power supply (IG1)) wiring harness
 Open or short circuit in audio unit (GND) wiring harness
 Open or short circuit in wiring harness between audio unit and rear view
monitor
 Poor connection of car-navigation unit connector, terminal damage
 Poor connection of audio unit connector, terminal damage
 Car-navigation unit malfunction
 Audio unit malfunction
The system is normal.
NOTE:
 If the "VOICE" button is pressed for approx.
ACC position. 2 s or more , the "DISP OFF" menu appears
1  Does the display screen change Yes on the bottom-left side of screen. If "DISP
from blank to NAVI mode when OFF" mode is selected, the audio unit will
pressing the joystick of the car- not display anything. "DISP OFF" mode is
navigation control switch? cancelled when the ignition switch is turned
to the LOCK position or the joystick of the
car-navigation control switch is pressed.
 Shift the selector lever in R Yes Go to the next step.

position.
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2  Does it change to rear view No Go to Step 11.

screen?
LOCK position. Yes Go to the next step.
 Remove the car-navigation unit.
3  Inspect the car-navigation unit
connector (24-pin).
No Securely connect the car-navigation unit connector.
 Is the car-navigation unit
connector connected securely?
 Disconnect the car-navigation Yes Go to the next step.
unit connector. If the car-navigation unit connector is wrong:
 Inspect both car-navigation unit
connector and wiring harness-  Replace the car-navigation unit.
4 side connector for poor
No
connection (such as
damaged/pulled-out pins, If the wiring harness-side connector is wrong:
corrosion).
 Are all the pins normal?  Repair or replace the pins and/or the connector.
 Inspect the voltage between the Yes Go to the next step.

car-navigation unit wiring
5 harness-side connector (16-pin)
Inspect the suspect wiring harness and repair or
terminals B (B+) and A (GND). No
replace the wiring harness as necessary.
ACC position. Yes Go to the next step.
 Inspect the voltage between the
6 car-navigation unit wiring
harness-side connector (16-pin) Inspect the suspect wiring harness and repair or
terminals D (ACC) and A No
replace the wiring harness as necessary.
(GND).
 Remove the audio unit.
7  Inspect the audio unit connector
(24-pin).
No Securely connect the audio unit connector.
 Is the audio unit connector
connected securely?
 Disconnect the audio unit
connector (24-pin).
 Inspect both audio unit connector If the audio unit connector is wrong:
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and wiring harness-side  Replace the audio unit.

connector for poor connection
(such as damaged/pulled-out
8 pins, corrosion). No
If the wiring harness-side connector is wrong:
 Are all the pins normal?
 Repair or replace the pins and/or the connector.
 Inspect the continuity between
the following wiring harness: Inspect for short circuit in wiring harness. If there is a
 Audio unit terminal I (24- short circuit, repair or replace the suspect wiring
pin)-car-navigation unit Yes harness.
9 terminal N (24-pin) If the wiring harness is okay, replace the audio unit,
 Audio unit terminal E (24- then go to the next step.
pin)-car-navigation unit
terminal P (24-pin)
 Is there continuity? No Repair or replace the suspect wiring harness.
Yes Troubleshooting is completed.
10  Does system work properly? No Replace the car-navigation unit.
 Remove the rear view monitor.
11  Inspect the connection of the rear
mount camera connector (4-pin).
No Securely connect the rear view monitor.
 Is the rear mount camera
connector connected securely?
 Disconnect the rear mount Yes Go to the next step.
camera connector (4-pin). If the rear mount camera connector is wrong:
 Inspect both rear mount camera
connector and wiring harness-  Replace the rear view monitor.
12 side connector for poor
No
connection (such as
damaged/pulled-out pins, If the wiring harness-side connector is wrong:
corrosion).
 Are all the pins normal?  Repair or replace the pins and/or the connector.

13  Inspect the audio unit connector
(4-pin).
No Securely connect the audio unit connector.
 Is the audio unit connector
connected securely?
 Disconnect the audio unit
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connector (4-pin). If the audio unit connector is wrong:

 Inspect both audio unit connector
and wiring harness-side  Replace the audio unit.
14 connector for poor connection No
(such as damaged/pulled-out
pins, corrosion). If the wiring harness-side connector is wrong:
 Repair or replace the pins and/or the connector.
 Verify continuity between rear
mount camera and audio unit at
harness-side connector.
 Rear mount camera Yes Go to the next step.
terminal A (4-pin,
POWER) and audio unit
terminal A (4-pin,
POWER)
 Rear mount camera
terminal B (4-pin, P-GND)
and audio unit terminal B
15 (4-pin, P-GND)
terminal C (4-pin, V-
GND) and audio unit
terminal D (4-pin, V- Inspect the suspect wiring harness and repair or
No
GND) replace the wiring harness as necessary.
terminal D (4-pin,
CONPOSITE) and audio
unit terminal C (4-pin,
CONPOSITE)
 Is there any continuity?
NO.2 DISPLAY SCREEN CHANGES TO WHITE. [CAR-NAVIGATION

SYSTEM]
2 Display screen changes to white.
POSSIBLE CAUSE  Audio unit malfunction
 Improper adjustment of the screen contrast
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 Turn the ignition switch to the ACC position. Replace the car-navigation
Yes
1  Shift the selector lever in R position. unit.
 Is the rear view screen normal? No Go to the next step.
 Does the display screen change to "display quality Yes Go to the next step.
2 adjustment" mode when pressing the MODE button for
approx. 2 s or more? No Replace the audio unit.
 Select "default display" or "display quality adjustment" Troubleshooting is
Yes
mode in the NAVI mode. completed.
3
 Press "ENTER" button. Replace the audio unit, then
No
 Does system work properly? go to the next step.
NO.3 SYSTEM DOES NOT LOAD THE MAP DISC. [CAR-NAVIGATION

SYSTEM]
3 System does not load the map disc.
 Map disc malfunction
 Moisture inside of car-navigation unit
 Non-designated disc is inserted
NOTE:
 If dewdrops are formed inside of the car-navigation unit, the display
POSSIBLE screen shows the "The disc installed is not a map DVD" message. Remove
CAUSE the map disc, ventilate or remove moisture from the passenger
compartment, and then leave it for approx. 1 h . The dewdrops will be
removed and the car-navigation unit will operate normally.
 In case of a dirty/damaged map disc or car-navigation unit malfunction, the
display screen will show the "Please insert a map DVD" message for few
seconds to 1 min, then change to "The disc installed is not a map DVD"
message after the ignition switch is turned to the ACC position.
 If a non-designated disc is inserted, the display screen shows the "The
disc installed is not a map DVD" message.
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 Eject the map disc. Yes Go to the next step.

1
 Is the map okay? No Insert a designated disc, then go to the next step.
 Eject the map disc then
insert the map disc Yes Trouble shooting is completed.
2 again.
 Does the system load No Go to the next step.
the map disc?
 Eject the map disc and Yes Trouble shooting is completed.
clean the surface of
map disc with a soft
cloth.
3 Replace car-navigation unit and map disc at the same time,
 Insert map disc again.
No (consult distributor) (See CAR-NAVIGATION UNIT
 Does the "Cannot Read REMOVAL/INSTALLATION .)
Disc" error message
show up on the screen?
NO.4 VEHICLE POSITION DEVIATES FROM THE ROUTE MAP. [CAR-

NAVIGATION SYSTEM]
4 Vehicle position deviates from the route map.
 Jammed radio signals from after market equipment (radar, remote engine
starter, anti-theft device etc.)
 Open or short circuit in the wiring harness (vehicle speed signal related).
POSSIBLE  Car-navigation unit malfunction.
CAUSE  Poor connection of the GPS antenna connector, terminal damage
 GPS antenna malfunction.
 Open or short circuit in feeder line between GPS antenna feeder and car-
navigation unit.
 Is any of the following after-market Yes Go to the next step.

equipment installed? (Inspect especially
1 near the GPS antenna.)
 Radar
 Remote engine starter No Go to Step 3.

 Anti-theft device.
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 Other
 Remove the after-market equipment.
NOTE: System is normal. The after-market electrical

Yes device might be interrupting to the GPS
 The procedure requires an reception.
2 assistant.
 Drive the vehicle without any obstacles.

 Does the vehicle indicator follow the No Go to the next step.
steering wheel direction?
 Position the vehicle without any obstacles Yes Go to the next step.
and receive GPS for 5 min at idle.
3
 Does "GPS" show up on the left lower No Go to Step 8.
side of the display screen?
CAUTION:
 This procedure requires an assistant.
 Start the diagnostic function. Yes Go to the next step.

 Drive the vehicle.
 Check the "Speed" on the diagnosis
screen.
4
 Does the "Speed" change according to the
vehicle speed?
NOTE:
No Go to Step 6.
 If the engine is started after
diagnostic functions activated,
the diagnostic function mode is
reset.
CAUTION: NOTE:
 This procedure requires an assistant.  The vehicle indicator might be out of
Yes
position in the following areas:
5  Drive the vehicle and turn the steering  Parallel road, high-level road,
wheel to the left and/or right. loop road, tower type parking,
high-rise buildings lot
 Does the vehicle indicator follow the
steering direction? Replace the car-navigation unit. (See CAR-
No NAVIGATION UNIT
 Turn the ignition switch to the LOCK Yes Go to the next step.
position.
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 Remove the car-navigation unit. (See

CAR-NAVIGATION UNIT
REMOVAL/INSTALLATION .) Securely connect the car-navigation unit
6 No
 Inspect the connection of the car- connector.
navigation unit connector (16-pin).
 Is the connector securely connected?
Inspect for vehicle speed signal input circuit.
Yes
If the car-navigation unit connector is
wrong:
 Disconnect the car-navigation unit
connector (16-pin).  Replace the car-navigation unit. (See
 Inspect both car-navigation unit connector CAR-NAVIGATION UNIT
7 and wiring harness-side connector REMOVAL/INSTALLATION .)
terminal H for poor connection (such as No
 Are all the pins normal? If the wiring harness-side connector is
wrong:
 Repair or replace the pins and/or the

connector.
NOTE:
 If the engine is started after diagnostic
functions activated, the diagnostic Yes Go to the next step.
function mode is reset.
8  Turn the ignition switch to ON position.

 Start the diagnostic function.
 Inspect the "GPS antenna" on diagnosis No Go to Step 6.
screen.
 Is the "OK" indicated?
 Turn the ignition switch to the LOCK
position.
 Remove the car-navigation unit. (See
CAR-NAVIGATION UNIT
 Inspect the connection of the car-
navigation unit connector and GPS No Securely connect the GPS antenna connector.
antenna connector.
Replace the car-navigation unit. (See CAR-
Yes NAVIGATION UNIT
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If the wiring harness-side connector is

wrong:
 Repair or replace the suspect wiring

 Disconnect the GPS antenna connector.
harness.
 Inspect both GPS antenna connector and
10 car-navigation unit connector for poor No
connection (such as damaged/pulled-out If the car-navigation unit side connector is
pins, corrosion). wrong:
 Replace the car-navigation unit. (See
CAR-NAVIGATION UNIT
NO.5 NO VOICE NAVIGATION [CAR-NAVIGATION SYSTEM]

5 No voice navigation
 Improper adjustment of the NAVI voice volume
 Poor connection of the driver-side front door speaker connector, terminal
POSSIBLE damage
CAUSE  Driver-side front door speaker malfunction
 Poor connection of the car-navigation unit connector, terminal damage
 Open or short circuit in driver-side front door speaker wiring harness
 Poor connection of the audio amplifier connector, terminal damage
1  Is the voice navigation volume mute? No Turn on the voice navigation.
 Turn the audio power switch (CD, MD, Yes Go to step 7.
radio) to ON.
2
 Does the driver-side front door speaker No Go to the next step.
work?
position.
3
 Remove the driver-side front door
speaker. (See FRONT DOOR
SPEAKER
Microsoft
 Inspect the connection of the driver-side Securely connect the driver-side front door
No
front door speaker connector (2-pin). speaker connector.
If the driver-side front door speaker side
connector is wrong:
 Disconnect the driver-side front door  Replace the driver-side front door
speaker connector (2-pin). speaker. (See FRONT DOOR
 Inspect both the driver-side front door SPEAKER
4 speaker and wiring harness-side REMOVAL/INSTALLATION .)
No
connector for poor connection (such as
 Are all the pins normal? If the wiring harness-side connector is
wrong:

connector.
 Inspect for continuity between audio Yes Go to the next step.
amplifier and the driver-side front door
5
speaker.
No Repair or replace the wiring harness.
 Inspect the driver-side front door speaker. Yes Go to the next step.
(See FRONT DOOR SPEAKER Replace the driver-side front door speaker.
6
INSPECTION .) No (See FRONT DOOR SPEAKER
 Is it normal? REMOVAL/INSTALLATION .)
 Remove the car-navigation unit. (See Yes Go to the next step.
CAR-NAVIGATION UNIT
7
 Inspect the connection of the car- Securely connect the car-navigation unit
navigation unit connector (16-pin). No
connector.
 Disconnect the car-navigation unit If the car-navigation unit side connector is

connector (16-pin). wrong:
 Inspect both the car-navigation unit and
8 wiring harness-side connector terminal F, No  Replace the car-navigation unit. (See
I and K for poor connection (such as CAR-NAVIGATION UNIT

damaged/pulled-out pins, corrosion). REMOVAL/INSTALLATION .)
If the wiring harness-side connector is
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wrong:

connector.
 Remove the audio amplifier. Yes Go to the next step.
9  Inspect connection of the audio amplifier
connector (40-pin).
No Securely connect the audio amplifier.
 Disconnect the audio amplifier connector
(40-pin).
 Inspect the audio amplifier and wiring
10 harness connector terminal 3B, 3G and
3H for poor connection (such as Repair or replace the pins and/or the
No
damaged/pulled-out pins, corrosion). connector.
 Inspect the continuity between following
car-navigation unit and audio amplifier at
harness-side connector.
 Car-navigation unit terminal F (16-
pin, MUTE) and audio amplifier Inspect for short circuit in wiring harness.
terminal 3B (40-pin, NAVI INT) If there is a short circuit, repair or replace the
Yes suspect wiring harness.
 Car-navigation unit terminal I (16-
If the wiring harness is okay, go to the next
11 pin, PRE SP OUT+) and audio step.
amplifier terminal 3G (40-pin,
NAVI-)
 Car-navigation unit terminal K (16-
pin, PRE SP OUT-) and audio
amplifier terminal 3H (40-pin,
NAVI+) No Repair or replace the wiring harness.
 Replace the audio amplifier. (See
Troubleshooting completed. (The audio
AUDIO AMPLIFIER Yes
amplifier malfunction)
 Does the voice navigation operate
properly. No Replace the car-navigation unit.
NO.6 DISPLAY SCREEN DOES NOT CHANGE TO THE NIGHT MODE.

(FRONT AND REAR COMBINATION LIGHTS OPERATE NORMALLY.) [CAR-
NAVIGATION SYSTEM]
Display screen does not change to the night mode. (Front and rear combination
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6 lights operate normally.)

 Improper setting of NAVI map indication
 Open or short circuit in TNS signal wiring harness (TNS signal related)
 audio unit malfunction
 Poor connection of the audio unit connector, terminal damage
POSSIBLE NOTE:
CAUSE  The car-navigation control switch is inoperative if the following circuit
has malfunction
 Audio unit connector (24-pin) terminal I (UART-2)-car-navigation
unit connector (24-pin) terminal N (UART-2)
 Audio unit connector (24-pin) terminal E (UART-1)-car-navigation
unit connector (24-pin) terminal P(UART-1)
 When the ignition switch is turned to LOCK position, then ACC
position, display screen changes to black.
position. Yes The system is normal.
1  Does the display screen change to the
night mode when the light switch is turned
to the TNS position, and the dimmer No Go to the next step.
cancel switch is turned to OFF?
 Press the "MENU" button. Yes Go to the next step.
 Select "Navigation Set Up".
2  Select "User Setting".
System is normal. Set the "MAP Mode" to
 Inspect "MAP Mode". No
"Auto".
 Is the "MAP Mode" set to "Auto"?.
 Start diagnostic function is started. Replace the car-navigation unit. (See CAR-
 Turn the light switch to TNS position. Yes NAVIGATION UNIT
3  Inspect the "TNS" on the diagnosis check REMOVAL/INSTALLATION .)
screen.
 Does the "TNS" indicate "ON"? No Go to the next step.
position.
 Remove the audio unit. (See AUDIO
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UNIT REMOVAL/INSTALLATION .)
 Inspect the connection of the audio unit
4 No Securely connect the audio unit connector.
connector (24-pin).
If the audio unit side connector is wrong:
 Disconnect the audio unit connector (24-  Replace the audio unit. (See AUDIO
pin). UNIT
 Inspect both the audio unit and wiring REMOVAL/INSTALLATION .)
5 harness-side connector terminal E for poor No
connection (such as damaged/pulled-out
pins, corrosion). If the wiring harness-side connector is
 Are all the pins normal? wrong:

connector.
 Inspect the voltage of the audio unit Replace the audio unit, then go to the next
wiring harness-side connector (24-pin) Yes step. (See AUDIO UNIT
6 terminal E (TNS signal) REMOVAL/INSTALLATION .)
 Is voltage B+ when the light switch is Inspect for TNS signal circuit. Repair or
No
turned to the TNS position? replace if necessary.
NO.7 DISPLAY DOES NOT CHANGE TO THE BACK CAMERA IMAGE. [CAR-
NAVIGATION SYSTEM]
7 Display does not change to the back camera image
 Back camera malfunction
 Poor connection of the back camera connector, terminal damage
 Audio unit malfunction
POSSIBLE
CAUSE  Poor connection of the audio unit connector, terminal damage
 Open or short circuit in wiring harness between audio unit and rear view
monitor
 Open or short circuit in reverse signal wiring harness
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Clean the lens of the back camera or

 Is the lens of the back camera dirty or view is Yes
1 remove the obstruction.
obstructed? No Go to the next step.
2  Does the lens of the back camera have a crack and Yes Replace the back camera.
damage? No Go to the next step.
If poor connection of back camera
connector:
 Turn the ignition switch to the LOCK position.  Securely connect the back
camera connector.
 Remove the back camera.
 Inspect the connection of the back camera
connector (4-pin). If the back camera connector is
3  Disconnect the back camera connector (4-pin). wrong:
No
 Inspect both the back camera and wiring harness-
 Replace the back camera.
side connector for poor connection (such as
 Are all the pins normal? If the wiring harness-side
connector is wrong:
 Repair or replace the pins

and/or the connector.
If poor connection of audio unit
connector:
 Turn the ignition switch to the LOCK position.  Securely connect the audio
unit connector.
 Inspect the connection of the audio unit connector
(4-pin). If the audio unit connector is
4  Disconnect the audio unit connector (4-pin). wrong:
No
 Inspect both the audio unit connector terminal for
 Replace the audio unit.
poor connection (such as damaged/pulled-out pins,
corrosion).
 Are all the pins normal? If the wiring harness-side
connector is wrong:
 Repair or replace the pins

and/or the connector.
 Inspect the following wiring harnesses between Yes Go to the next step.
the audio unit and rear mount camera.
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 Terminal A (4-pin, POWER)-terminal A (4-

pin, POWER)
 Terminal B (4-pin, P-GND)-terminal B (4-
pin, P-GND)
Inspect the suspect wiring harness.
5  Terminal C (4-pin, V-GND)-terminal D (4- No
pin, V-GND)
 Terminal D (4-pin, COMPOSITE)-terminal
C (4-pin, COMPOSITE)
 Is there open or short circuit?
Replace the back camera, then
inspect generating of malfunction
 Turn the ignition switch to the LOCK position. symptom.
 Remove the audio unit. Even if it exchanges back camera,
 Disconnect the audio unit connector (24-pin). when a fault phenomenon occurs:
Yes
 Turn the ignition switch to ON.
6  Replace the audio unit.
 Shift the selector lever in R range.
 Reinspect the malfunction
 Inspect the voltage between the rear view monitor symptom, then repeat from
control module terminals M (24-pin, REV) and W Step 1 if malfunction recurs.
(24-pin, GND).
Inspect the suspect wiring harness
 Is the voltage B+? No (reverse signal). Repair or replace if
necessary.
NO.8 SPEECH RECOGNITION DOES NOT START [CAR-NAVIGATION

SYSTEM]
8 Speech recognition does not start
 Microphone malfunction
 Audio control switch malfunction
POSSIBLE
CAUSE  Poor connection of audio unit connector, terminal damage
 Poor connection of car-navigation unit connector, terminal damage
 Open or short circuit in wiring harness between audio unit and car-navigation
unit

 Turn the ignition switch to the ACC position.
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 Start the car-navigation.

 Display the map screen.
1  Press the VOICE button (audio control switch). No Go to Step 4.
 Is the speech recognition icon displayed on the
screen upper left?
 Start the diagnostic function.
 Press the Menu button inside of diagnostic CAUTION:
screen.
 Sound may not be recognized
 Select "Navigation check". by the influence of the
Yes following.
2  Select "Microphone check".
 Speaker's utterance
 After pressing the VOICE button, it utters method
somewhat greatly toward a microphone.
 Road noise
 Inspect the display of "Microphone input level
 Other noises
judging".
Replace the microphone, then go to
 Is a judgment "OK" (blue display)? No
the next step.
3  Does the fault phenomenon improve? No Replace the car-navigation unit.
 Start the diagnostic function. Yes Go to the next step.
4  Inspect the display of "Microphone" in
diagnostic screen.
No Go to Step 6.
 Is it display "OK"?
 The power supply of the audio unit is turned on. Yes Replace the car-navigation unit.
5 Audio control switch system
 Press the VOICE button (audio control switch). No malfunction. Go to the audio symptom
 Does it muffle? troubleshooting.
 Turn the ignition switch to the LOCK position. Yes Go to the next step.
 Remove the microphone.
6  Inspect the connection of the microphone Securely connect the microphone
connector (6-pin). No
connector.
 Is the connection securely connected?
 Disconnect the microphone connector (6-pin). If the microphone connector is

wrong:
 Inspect both microphone connector and wiring
7 harness-side connector for poor connection No  Replace the microphone.
(such as damaged/pulled-out pins, corrosion).
If the wiring harness-side connector
is wrong:
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 Repair or replace the pins and/or

the connector.
 Remove the car-navigation unit. Yes Go to the next step.
8  Inspect the connection of the car-navigation unit
connector (6-pin). Securely connect the car-navigation
No
unit connector.
 Is the connection securely connected?
If the car-navigation unit connector
 Disconnect the car-navigation unit connector (6- is wrong:
pin).
 Replace the car-navigation unit.
 Inspect both car-navigation unit connector and
9 wiring harness-side connector for poor No
connection (such as damaged/pulled-out pins,
If the wiring harness-side connector
corrosion).
is wrong:
 Repair or replace the pins and/or
the connector.
 Inspect the following wiring harnesses between
the microphone and HF/TEL unit.
 Terminal A (6-pin, MIC+)-terminal B
(24-pin, MIC IN+) Repair or replace suspect wiring
Yes
 Terminal B (6-pin, MIC-)-terminal D (24- harness.
pin, MIC IN-)
10  Terminal C (6-pin, MIC +B)-terminal U
(24-pin, MIC+B)
 Terminal D (6-pin, GND)-terminal F (24-
pin, MIC IN SHIELD)
 Terminal E (6-pin, MIC SENSE)-terminal No Go to the next step.
J (24-pin, MIC SENSE)
 Inspect the following wiring harnesses between
the hands-free unit and car-navigation unit.
 Terminal A (24-pin, MIC OUT+)-
Repair or replace suspect wiring
Yes
terminal A (6-pin, MIC+) harness.
 Terminal C (24-pin, MIC OUT-)-terminal
11 B (6-pin, MIC-)
 Terminal E (24-pin, MIC OUT SHIELD)-
terminal D (6-pin, GND) Replace the microphone, then go to
 Terminal J (24-pin, MIC SENSE)-
No
the next step.
terminal E (6-pin, MIC SENSE)
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12  Does the fault phenomenon improve? No Replace the car-navigation unit.
REFERENCE INFORMATION [CAR-NAVIGATION SYSTEM]

STARTING PROCEDURE FOR DIAGNOSTIC FUNCTION

2. Press the MENU button.
3. Select "Navigation Set Up".
4. Select "Calibration".
5. Select "Map Version".
6. Press the upper left part of the screen 2 times, then press the lower left part 2 times.
7. Perform the following procedures according to the purpose of the item checked.
Vehicle status signal inspection:
Fig. 2: Diagnosis Check Screen Display - Vehicle Status Signal

VEHICLE STATUS SIGNAL INSPECTION CHART

No. Display item Description
NOTE:
1 PKB
 Displayed but not used in the inspection.
Indicates reverse signal status.
2 REV  ON: Reverse
 OFF: Others
Indicates the connection status of the microphone.

3 Microphone  OK: Connected
 NCON: Disconnected
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4 SPEED(1) Indicates the present vehicle speed in kph/mph (maximum of 3 digits).

Indicates TNS signal status.
5 TNS(1)  ON: Turn TNS ON
 OFF: Turn TNS OFF
Indicates the connection status of the GPS antenna.

6 GPS Antenna(1)  OK: Connected
 NCON: Disconnected
Indicates RDS-TMC system availability on the vehicle.

7 Traffic System TMC: Equipped
 NONE: Not equipped
(1) Used for symptom troubleshooting. (Troubleshooting index No. 5 and No. 8)
Microphone related signal inspection:
1. Press the "Menu" button on the "Diagnosis Check" screen.

2. Select "Navigation Check Menu".
3. Select "Microphone Check".
Fig. 3: Diagnosis Check Screen Display - Microphone Check

MICROPHONE CHECK INSPECTION CHART

No. Display item Description
Indicates the status of the VOICE button.
1 PTT switch status  < OK >: Press the button (Keep the state until the screen is
changed.)
 < Please Push Switch >: Other than above condition.
Indicates the test results.

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Microphone input level  Blue indicator: Sound is input from the microphone correctly.
2
judging  Gray indicator: Sound is input from the microphone incorrectly.
3 Microphone level Indicates the input level of the microphone using a bar graph.
FINISHING PROCEDURE FOR DIAGNOSTIC FUNCTION

2. Turn the ignition switch to the ACC or ON position.
3. Return to the normal screen.
Microsoft
2008 BRAKES Parking Brake System - Mazda CX-9
2008 BRAKES
Parking Brake System - Mazda CX-9
PARKING BRAKE SYSTEM LOCATION INDEX
Fig. 1: Identifying Parking Brake System Components Location

PARKING BRAKE INSPECTION

1. Depress the parking brake pedal a few times.
2. Depress the brake pedal a few times.
3. Inspect the parking brake stroke by depressing the parking brake pedal with a force of 180 N {18.4 kgf,
40.5 lbf}.
Parking brake pedal stroke when depressed at 180 N {18.4 kgf, 40.5 lbf}
1-3 notches
PARKING BRAKE ADJUSTMENT

1. Turn the adjusting nut at the front of the parking cable.
2. After adjustment, inspect the following points:
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1. Turn the ignition switch on, depress the parking brake pedal one notch, and verify that the brake
system warning light illuminates.
2. Verify that the rear brakes do not drag.
Fig. 2: Identifying Adjusting Nut

PARKING BRAKE REMOVAL/INSTALLATION [2WD]
1. Perform the following procedure and remove the parking brake pedal.
2. Perform the following procedure and remove the front parking brake cable.
1. Remove the front seat (Driver side). (See FRONT SEAT REMOVAL/INSTALLATION .)
3. Remove the front console box mat, (See FRONT CONSOLE BOX MAT
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11. Remove the dust cover.
12. Remove the front side trim (LH). (See FRONT SIDE TRIM REMOVAL/INSTALLATION .)
13. Remove the front scuff plate (LH). (See FRONT SCUFF PLATE
14. Remove the fuel-filler lid release lever cover.
15. Turn the floor covering over until the front parking brake cable cover appears.
16. Remove the rear heat duct (LH). (See REAR HEAT DUCT COMPONENT
17. Remove the under guard (LH). (See CHARCOAL CANISTER, CANISTER VENT (CV)
SOLENOID VALVE, AIR FILTER COMPONENT REMOVAL/INSTALLATION [MZI-
3.7] .)
3. Perform the following procedure and remove the rear parking brake cable.
3.7] .)
4. Perform the following procedure and remove the parking brake plate, back plate and wheel hub.
1. Remove the rear ABS wheel-speed sensor from the rear wheel hub. (See REAR ABS WHEEL-
SPEED SENSOR REMOVAL/INSTALLATION [2WD] .)
7. Adjust the parking brake stroke. (See PARKING BRAKE ADJUSTMENT.)
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Fig. 3: Exploded View Of Parking Brake With Torque Specification

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BRAKE CALIPER COMPONENT REMOVAL NOTE
1. Remove the brake caliper assembly from the trailing link and suspend it with a cable so it does not
interfere.
Fig. 4: Identifying Brake Caliper Component

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Fig. 5: Removing Disc Plate

PARKING BRAKE SHOE REMOVAL NOTE
1. Pull the parking brake shoe downward and disengage it from the shoe stopper.
2. Press the adjuster bolt and tappet by hand, and slowly remove the parking brake shoe.
NOTE:  When removing the parking brake shoe, firmly press the adjuster bolt
and tappet by hand and slowly remove the parking brake shoe to
prevent the adjuster bolt, tappet, operation lever and other parts from
flying off.
Fig. 6: Pulling Parking Brake Shoe

OPERATION LEVER, PIN, ADJUSTER BOLT AND NUT, TAPPET INSTALLATION NOTE
1. Install the operation lever, pin, adjuster bolt and nut, and tappet so that the adjuster nut is facing toward
the vehicle front.
2. Completely tighten the adjuster bolt and nut.
3. Move the operation lever by hand and verify that it operates properly.
 If proper operation cannot be verified, reinstall.
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Fig. 7: Identifying Operation Lever, Pin, Adjuster Bolt And Nut, Tappet
PARKING BRAKE SHOE INSTALLATION NOTE
1. Measure the parking brake lining thickness with a vernier caliper or measuring scale.
 If it is less than the minimum thickness, install a new parking brake shoe.
2. Apply grease to the contact surface of the parking brake shoe and shoe stopper.
Fig. 8: Measuring Parking Brake Lining Thickness

3. After installing the opening of the parking brake shoe to the adjuster bolt and tappet, push the brake shoe
upward and attach it to the shoe stopper.
Fig. 9: Pushing Brake Shoe To Shoe Stopper

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1. Measure the inner diameter of the disc plate with a vernier caliper.
 If it exceeds the maximum diameter, install the new disc plate.
2. Install the disc plate and screw.

Fig. 10: Measuring Inner Diameter Of Disc Plate

Fig. 11: Adjusting Disc Plate Adjuster

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Fig. 12: Rotating Disc Plate

FRONT PARKING BRAKE CABLE INSTALLATION NOTE
1. Install the front parking brake cable and equalizer so that the installation area of the equalizer spring is on
the underside of the vehicle as shown in the vehicle.
Fig. 13: Installing Parking Brake Cable

ADJUSTING NUT INSTALLATION NOTE
1. Verify that the front parking brake cable is installed below the cable deviation prevention tab of the brake
cable.
2. Install the adjusting nut.
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Fig. 14: Identifying Front Parking Brake Cable And Tab

PARKING BRAKE REMOVAL/INSTALLATION [AWD]
1. Perform the following procedure and remove the parking brake pedal.
2. Perform the following procedure and remove the front parking brake cable.
1. Remove the front seat (Driver side). (See FRONT SEAT REMOVAL/INSTALLATION .)
11. Remove the dust cover.
12. Remove the front side trim (LH). (See FRONT SIDE TRIM REMOVAL/INSTALLATION .)
13. Remove the front scuff plate (LH). (See FRONT SCUFF PLATE
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14. Remove the fuel-filler lid release lever cover.

15. Turn the floor covering over until the front parking brake cable cover appears.
16. Remove the rear heat duct (LH). (See REAR HEAT DUCT COMPONENT
3.7] .)
3. Perform the following procedure and remove the rear parking brake cable.
1. Remove the under guard. (See CHARCOAL CANISTER, CANISTER VENT (CV)
3.7] .)
4. Perform the following procedure and remove the parking brake plate, back plate and wheel hub.
1. Remove the rear ABS wheel-speed sensor from the trailing link. (See REAR ABS WHEEL-
SPEED SENSOR REMOVAL/INSTALLATION [AWD] .)
4. Remove the trailing link component. (See REAR TRAILING LINK
7. Adjust the parking brake stroke. (See PARKING BRAKE ADJUSTMENT.)
8. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT [AWD] .)
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Fig. 15: Exploded View Of Parking Brake With Torque Specification

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1. Remove the brake caliper assembly from the trailing link and suspend it with a cable so it does not
interfere.
Fig. 16: Identifying Brake Caliper Component


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PARKING BRAKE SHOE REMOVAL NOTE
1. Pull the parking brake shoe downward and disengage it from the shoe stopper.
2. Press the adjuster bolt and tappet by hand, and slowly remove the parking brake shoe.
NOTE:  When removing the parking brake shoe, firmly press the adjuster bolt
and tappet by hand and slowly remove the parking brake shoe to
prevent the adjuster bolt, tappet, operation lever and other parts from
flying off.
Fig. 18: Pulling Parking Brake Shoe

OPERATION LEVER, PIN, ADJUSTER BOLT AND NUT, TAPPET INSTALLATION NOTE
1. Install the operation lever, pin, adjuster bolt and nut, and tappet so that the adjuster nut is facing toward
the vehicle front.
2. Completely tighten the adjuster bolt and nut.
3. Move the operation lever by hand and verify that it operates properly.
 If proper operation cannot be verified, reinstall.
Fig. 19: Identifying Operation Lever, Pin, Adjuster Bolt, Nut & Tappet
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PARKING BRAKE SHOE INSTALLATION NOTE
1. Measure the parking brake lining thickness with a vernier caliper or measuring scale.
 If it is less than the minimum thickness, install a new parking brake shoe.
2. Apply grease to the contact surface of the parking brake shoe and shoe stopper.
Fig. 20: Measuring Parking Brake Lining Thickness

3. After installing the opening of the parking brake shoe to the adjuster bolt and tappet, push the brake shoe
upward and attach it to the shoe stopper.
Fig. 21: Pushing Brake Shoe To Shoe Stopper

1. Measure the inner diameter of the disc plate with a vernier caliper.
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 If it exceeds the maximum diameter, install the new disc plate.
2. Install the disc plate and screw.

Fig. 22: Measuring Inner Diameter Of Disc Plate



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Fig. 24: Rotating Disc Plate Adjuster

FRONT PARKING BRAKE CABLE INSTALLATION NOTE
1. Install the front parking brake cable and equalizer so that the installation area of the equalizer spring is on
the underside of the vehicle as shown in the vehicle.
Fig. 25: Installing Parking Brake Cable

ADJUSTING NUT INSTALLATION NOTE
1. Verify that the front parking brake cable is installed below the cable deviation prevention tab of the brake
cable.
2. Install the adjusting nut.
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Fig. 26: Identifying Front Parking Brake Cable And Tab

PARKING BRAKE SWITCH INSPECTION

1. Disconnect the parking brake switch connector.
 If not as indicated in the table, replace the parking brake switch. (See PARKING BRAKE
REMOVAL/INSTALLATION [2WD].) (See PARKING BRAKE
REMOVAL/INSTALLATION [AWD].)

Fig. 28: Identifying Parking Brake Switch Connector Terminal

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2008 BODY & ACCESSORIES On-Board Diagnostic (Power Liftgate (PLG) System) - Mazda CX-9
On-Board Diagnostic (Power Liftgate (PLG) System) - Mazda CX-9
FOREWORD [POWER LIFTGATE (PLG) SYSTEM]

OUTLINE
 The OBD (on-board diagnostic) system has the following functions:

 Malfunction detection function: Detects malfunctions in the power liftgate (PLG) system and
outputs DTCs.
 Data monitor function: Reads out specific input/output signals and the system status.
 Diagnostic DTCs can be read/cleared using the M-MDS.
SYSTEM WIRING DIAGRAM [POWER LIFTGATE (PLG) SYSTEM]
Fig. 1: Power Liftgate (PLG) System Wiring Diagram

DTC INSPECTION [POWER LIFTGATE (PLG) SYSTEM]

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CAUTION:  Some of the PLG system DTCs cannot be stored unless the PLG
system is operated. Therefore, always operate the PLG system before
performing the DTC inspection.


3. Select "LTM".

2. Select "LTM".
inspection.

4. After completion of repairs, clear all DTCs stored in the PLG control module. (See CLEARING DTC
[POWER LIFTGATE (PLG) SYSTEM].)
DTC TABLE [POWER LIFTGATE (PLG) SYSTEM]

DTC CHART
DTC Description Page
Door lock-link switch
B1311 (See DTC B1311 [POWER LIFTGATE (PLG) SYSTEM].)
circuit (unlock) failure
Power supply voltage
decreases
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PLG control module

internal malfunction
PLG touch sensor circuit
B241A (See DTC B241A [POWER LIFTGATE (PLG) SYSTEM].)
malfunction
Rotation sensor circuit
malfunction
Rotation sensor A circuit
B266B (See DTC B266B [POWER LIFTGATE (PLG) SYSTEM].)
malfunction
Rotation sensor B circuit
B266C (See DTC B266C [POWER LIFTGATE (PLG) SYSTEM].)
malfunction
Rotation sensor
B266E (See DTC B266E [POWER LIFTGATE (PLG) SYSTEM].)
malfunction
Half latch switch circuit
malfunction
Full latch switch circuit
B267B (See DTC B267B [POWER LIFTGATE (PLG) SYSTEM].)
malfunction
Return switch circuit
B267C (See DTC B267C [POWER LIFTGATE (PLG) SYSTEM].)
malfunction
PLG touch sensor (LH)
circuit malfunction
PLG touch sensor (RH)
circuit malfunction
PLG touch sensor (LH)
circuit malfunction
PLG touch sensor (RH)
circuit malfunction
Closure motor circuit
malfunction
PLG motor circuit
malfunction
PLG motor circuit
malfunction
B2939 Clutch circuit malfunction (See DTC B2939 [POWER LIFTGATE (PLG) SYSTEM].)
U0073 Unit communication error
U0100
PCM
U0101
TCM (See PROCEDURES FOR DETERMINING THE LOCATION
Communication error to OF A MALFUNCTION [MULTIPLEX COMMUNICATION
U0140 SYSTEM] .)
BCM
U0155
instrument cluster
U0214
keyless control module
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CLEARING DTC [POWER LIFTGATE (PLG) SYSTEM]


3. Select "LTM".

2. Select "LTM".

PID/DATA MONITOR INSPECTION [POWER LIFTGATE (PLG) SYSTEM]

3. Select "LTM".

2. Select "LTM".
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PID/DATA MONITOR TABLE [POWER LIFTGATE (PLG) SYSTEM]

PID name
Unit/Condition Operation Condition (Reference) Terminal
(definition)
DTC_CNT
(Number of - Indicates number of DTC -
continuous DTCs)
LAT_FULL
(Liftgate latch and  Full latch switch on: on
Off / On 3G
lock actuator (full  Other: off
latch switch))
LAT_HALF
(Liftgate latch and  Half latch switch on: on
Off / On 3H
lock actuator (half  Other: off
latch switch))
LAT_RTN
(Liftgate latch and  Return switch on: on
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lock actuator (return  Other: off

Off / On 3E
switch))
MTR_CLS_CL
 Closure motor (CLOSE) operation: on
(Closure motor Off / On 1A
(CLOSE))  Other: off
MTR_CLS_OP
 Closure motor (OPEN) operation: on
(Closure motor Off / On 1B
(OPEN))  Other: off
 Voltage: Refer to
NOTE:
MTR_PLG_C
A  The values in the graph are a reference 1E, 1F
(PLG motor current) showing the relation between the elapsed
period and voltage. The values change
according to vehicle conditions/status,
temperature, and battery voltage.
MTR_PLG_CL
 PLG motor (CLOSE) operation: on
(PLG motor Off/On 1F
(CLOSE))  Other: off
MTR_PLG_OP
 PLG motor (OPEN) operation: on
(PLG motor Off/On 1E
(OPEN))  Other: off
PWR_IG1
 Ignition switch is at ON: on
(Ignition 1 (IG1) Off/On 2A
electric source)  Other: off
SW_CCL
 Unlatch (liftgate is open): on
(Liftgate latch Off/On 3F
switch)  Latch (liftgate is closed): off
SW_MAIN  PLG front switch on position: on
Off / On 3Q
(PLG front switch)  Other: off
SW_SUB  PLG rear switch on position: on
Off/On 2B
(PLG rear switch)  Other: off
TCH_L_FLT
 PLG touch sensor (LH) normal: O.K.
(PLG touch sensor O.K. / Fault 3B
(LH) failure)  PLG touch sensor (LH) malfunction: Fault
TCH_L_ST
 PLG touch sensor (LH) on: on
(PLG touch sensor Off/On 3B
(LH) condition)  Other: off
TCH_L_V
(PLG touch sensor V Normal with no obstruction: 2.5 V 3B
(LH) voltage)
TCH_R_FLT
 PLG touch sensor (RH) normal: O.K.
(PLG touch sensor O.K. / Fault 3A
(RH) failure)  PLG touch sensor (RH) malfunction: Fault
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TCH_R_ST (PLG
 PLG touch sensor (RH) on: on
touch sensor (RH) Off/On 3A
condition)  Other: off
TCH_R_V
(PLG touch sensor V Normal with no obstruction: 2.5 V 3A
(RH) voltage)
VPWR
(Module supply V Under any condition: VB 2A, 20
voltage)
Fig. 5: Current Flow Graph

DTC B1311 [POWER LIFTGATE (PLG) SYSTEM]

DTC B1311 - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B1311 Door lock-link switch circuit (unlock) failure
DETECTION Open circuit in wiring harness between PLG control module and passenger-side door
CONDITION lock-link switch
 Open circuit in wiring harness between PLG control module terminal 3N and front
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door latch and lock actuator (passenger-side) terminal 2A

 Open circuit in wiring harness between PLG control module terminal 3C and front
door latch and lock actuator (passenger-side) terminal 2B
 Open circuit in wiring harness between front door latch and lock actuator
POSSIBLE CAUSE
(passenger-side) terminal 2B and body GND
 Door lock-link switch front door latch and lock actuator (passenger-side)
malfunction
 PLG control module malfunction
DTC B1311 - DIAGNOSTIC PROCEDURE

INSPECT DOOR LOCK-LINK SWITCH
1  Disconnect the door lock-link switch
(Passenger side) connector. No
Replace the front door latch and lock actuator.
 Inspect the door lock-link switch (See FRONT DOOR LATCH AND LOCK
(Passenger side). ACTUATOR
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(See FRONT DOOR LATCH AND REMOVAL/INSTALLATION .)

LOCK ACTUATOR INSPECTION .) Go to Step 3.
Is the door lock-link switch normal?


INSPECT THE FOLLOWING WIRING

HARNESSES
Disconnect the PLG control module

connector.
 Disconnect the door lock-link switch
(Passenger side) connector.
 Inspect the wiring harness between PLG
control module terminal 3N and front
2 door latch and lock actuator terminal 2A
for an open circuit.
control module terminal 3C and front Repair or replace the wiring harness.
No
door latch and lock actuator terminal 2B Go to the next step.
 Inspect the wiring harness between front
door latch and lock actuator terminal 2E
and body ground for an open circuit.
VERIFY CORRECTION COMPLETED

Replace the PLG control module.
(See POWER LIFTGATE (PLG)
 Reconnect the disconnected connector. Yes
3 CONTROL MODULE
 Clear the DTC. REMOVAL/INSTALLATION .)
 Is DTC B1311 displayed after 10 s or
more have elapsed. No DTC troubleshooting completed.

DTC B1318 Power supply voltage decreases
DETECTION
Input voltage from the battery is excessively low (below 10.5 V)
CONDITION
 PLG 20 A fuse malfunction
 Open or short circuit in wiring harness between PLG control module terminal
1C and battery
POSSIBLE CAUSE
 Battery malfunction
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INSPECT BATTERY VOLTAGE
 Inspect the battery voltage.
1
(See BATTERY INSPECTION [MZI- Recharge or replace the battery.
3.7] .) No
Go to Step 4.
Is the battery voltage normal?

INSPECT FOR PCM DTCs Perform troubleshooting according to the

Yes corresponding DTC inspection.
2  Connect the M-MDS to the DLC-2. Go to Step 4.
 Are any DTCs for the PCM displayed? No Go to the next step.
INSPECT THE FOLLOWING WIRING
HARNESSES
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 Disconnect the negative battery cable.

 Disconnect the positive battery cable.
Repair or replace the wiring harness.
 Disconnect the PLG control module Yes
connector.
3  Inspect the wiring harness between PLG
control module terminal 1C (wiring
harness-side) and positive battery terminal
(wiring harness-side) for an open
circuit/short circuit to ground system. No Go to the next step.
Reconnect the disconnected connector. (See POWER LIFTGATE (PLG)
 Yes
4 CONTROL MODULE
 Operate the PLG system.
 Is DTC B1318 stored? No DTC troubleshooting completed.

DTC B1342 PLG control module internal malfunction
DETECTION CONDITION Malfunction in the PLG control module internal circuit
POSSIBLE CAUSE  Malfunction in the PLG control module internal circuit

VERIFY DTC
 Clear the DTC. Yes (See POWER LIFTGATE (PLG) CONTROL MODULE
1  Operate the PLG REMOVAL/INSTALLATION .)
system.
 Is DTC B1342
stored?
DTC B241A [POWER LIFTGATE (PLG) SYSTEM]

DTC B241A - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B241A Touch sensor circuit malfunction
DETECTION A short circuit to ground in the PLG touch sensor (RH/LH) continues for 5 min or
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CONDITION more.
 Short to GND in wiring harness between PLG control module terminal 3A and
PLG touch sensor (RH) terminal B
 Short to GND in wiring harness between PLG control module terminal 3B and
POSSIBLE CAUSE
PLG touch sensor (LH) terminal B
 PLG touch sensor malfunction
DTC B241A - DIAGNOSTIC PROCEDURE

INSPECT PLG TOUCH SENSOR Yes Go to the next step.
 Inspect the PLG touch sensor.
Replace the PLG touch sensor.
1 (See POWER LIFTGATE (PLG)
(See POWER LIFTGATE (PLG) TOUCH
TOUCH SENSOR No
SENSOR REMOVAL/INSTALLATION .)
INSPECTION .)
Go to Step 3.
 Is the touch sensor normal?
Microsoft
INSPECT THE FOLLOWING

WIRING HARNESSES

connector.
 Disconnect the PLG touch sensor
connector.
 Inspect for a short circuit to ground
2 system between the following

wiring harnesses:
 PLG control module terminal Repair or replace the wiring harness.
3A and PLG touch sensor No
(RH) terminal B
 PLG control module terminal
3B and PLG touch sensor
(LH) terminal B
VERIFY CORRECTION
COMPLETED
 Reconnect the disconnected
Yes (See POWER LIFTGATE (PLG) CONTROL
3 connector. MODULE REMOVAL/INSTALLATION .)
 Clear the DTC.
 Is DTC B241A stored after 5 min No DTC troubleshooting completed.
or more have elapsed?

DTC B266A Rotation sensor circuit malfunction
DETECTION A short circuit to ground in the PLG drive unit (rotation sensor) continues for 5 min
CONDITION or more.
 Short to GND in wiring harness between PLG control module terminal 2K and
PLG drive unit terminal E
POSSIBLE CAUSE
 Rotation sensor malfunction
Microsoft

INSPECT WIRING HARNESS
BETWEEN PLG CONTROL UNIT AND
PLG DRIVE UNIT Replace the PLG drive unit.
Microsoft


(See POWER LIFTGATE (PLG) DRIVE
connector. UNIT REMOVAL/INSTALLATION .)
 Disconnect the PLG drive unit
1 connector.
 Inspect the wiring harness between
PLG control module terminal 2K and Repair or replace the wiring harness.
No
PLG drive unit terminal E for a short Go to the next step.
circuit to ground system.
2 CONTROL MODULE
 Is DTC B266A stored after 5 min or
more have elapsed? No DTC troubleshooting completed.
DTC B266B [POWER LIFTGATE (PLG) SYSTEM]

DTC B266B - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B266B Rotation sensor A circuit malfunction
DETECTION
Rotation sensor A signal does not change
CONDITION
 Open circuit in wiring harness between PLG control module terminal 2J and PLG
drive unit terminal F Short to power supply in wiring harness between PLG control
module terminal 2J and PLG drive unit terminal F
POSSIBLE
 Short to GND in wiring harness between PLG control module terminal 2J and PLG
CAUSE
drive unit terminal F
Microsoft
DTC B266B - DIAGNOSTIC PROCEDURE

PLG CONTROL UNIT AND PLG DRIVE
UNIT Replace the PLG drive unit.
Microsoft


 Disconnect the PLG drive unit connector.
1 control module terminal 2J and PLG drive
unit terminal F for an open circuit/short
circuit to power supply system/short Repair or replace the wiring harness.
No
circuit to ground system. Go to the next step.

 Reconnect the disconnected connector.
Yes
2 CONTROL MODULE
 Clear the DTC.
 Is DTC B266B stored? No DTC troubleshooting completed.
DTC B266C [POWER LIFTGATE (PLG) SYSTEM]

DTC B266C - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B266C Rotation sensor B circuit malfunction
DETECTION
Rotation sensor B signal does not change
CONDITION
 Open circuit in wiring harness between PLG control module terminal 2L and PLG
drive unit terminal J Short to power supply in wiring harness between PLG control
module terminal 2L and PLG drive unit terminal J
POSSIBLE
 Short to GND in wiring harness between PLG control module terminal 2L and PLG
CAUSE
drive unit terminal J
Microsoft
DTC B266C - DIAGNOSTIC PROCEDURE

PLG CONTROL UNIT AND PLG DRIVE
UNIT Replace the PLG drive unit.
Microsoft


connector. DRIVE UNIT
 Disconnect the PLG drive unit connector. Yes
1 control module terminal 2L and PLG drive
unit terminal J for an open circuit/short
circuit to the power supply system/short Repair or replace the wiring harness.
circuit to the ground system. No

 Reconnect the disconnected connector.
Yes
2 DRIVE UNIT
 Clear the DTC.
 Is DTC B266C stored? No DTC troubleshooting completed.
DTC B266E [POWER LIFTGATE (PLG) SYSTEM]

DTC B266E - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B266E Rotation sensor malfunction
DETECTION The PLG operation direction (open/close) and the PLG motor rotation direction from
CONDITION the rotation sensor do not correspond.
 PLG arm malfunction
 PLG slider malfunction
 Torque cable malfunction
POSSIBLE CAUSE
 Reverse connection of the PLG motor
 PLG drive unit (rotation sensor) malfunction
Microsoft
DTC B266E - DIAGNOSTIC PROCEDURE

BETWEEN PLG CONTROL UNIT
AND PLG DRIVE UNIT
Microsoft


connector.
connector.
following wiring harnesses:
1E and PLG drive unit terminal
A
1  PLG control module terminal
1F and PLG drive unit terminal
B Repair or replace the wiring harness.
No
Go to Step 5.
2J and PLG drive unit terminal
F
2L and PLG touch sensor (LH)
J
INSPECT PLG ARM

Inspect the PLG arm for the

2 following: Replace the PLG arm.

 Is the ball joint dislocated or is No (See POWER LIFTGATE (PLG) ARM
there excessive play? REMOVAL/INSTALLATION .)
 Is the PLG arm normal?
INSPECT PLG SLIDER Yes Go to the next step.

Inspect the PLG slider for the

3 following: Replace the PLG slider.
No (See POWER LIFTGATE (PLG) DRIVE
 Is the PLG slider spinning?
 Is the PLG slider normal?
INSPECT TORQUE cable

Inspect the torque cable for the

4 following: Replace the PLG slider.

 Is the torque cable No (See POWER LIFTGATE (PLG) DRIVE
disconnected? UNIT REMOVAL/INSTALLATION .)
 Is the torque cable normal?

Yes
 Reconnect the disconnected Replace the PLG control module.
connector. (See POWER LIFTGATE (PLG) CONTROL
Microsoft
 Clear the DTC. MODULE REMOVAL/INSTALLATION .)

5  Operate the PLG system.
 Is DTC B266E stored?

DTC B267A Half latch switch circuit malfunction
DETECTION The voltage input to the half latch switch does not change while the PLG system is
CONDITION operating.
 Open circuit in wiring harness between PLG control module terminal 3H and
liftgate latch and lock actuator terminal B
 Short to GND in wiring harness between PLG control module terminal 3H and
liftgate latch and lock actuator terminal B
POSSIBLE CAUSE
 Open circuit in wiring harness between liftgate latch and lock actuator terminal
C and body GND
 Half latch switch malfunction
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PLG CONTROL UNIT AND LIFTGATE
LATCH AND LOCK ACTUATOR Yes Go to the next step.
 Disconnect the PLG control module

connector.
1  Disconnect the liftgate latch and lock
actuator connector.
 Inspect the wiring harness between PLG No Repair or replace the wiring harness.
control module terminal 3H and liftgate Go to Step 3.
latch and lock actuator terminal B for an
open circuit/short circuit to ground
system.
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Is the wiring harness normal?



LIFTGATE LATCH AND LOCK Replace the liftgate latch and lock actuator.
ACTUATOR AND BODY GROUND (See LIFTGATE LATCH AND LOCK
Yes
ACTUATOR
2  Inspect the wiring harness between
liftgate latch and lock actuator terminal C
and body ground for an open circuit. Repair or replace the wiring harness.
No
 Reconnect the disconnected connector. (See POWER LIFTGATE (PLG)
Yes
3  Clear the DTC. CONTROL MODULE
 Operate the PLG system. (Open
operation)
 Is DTC B267A stored? No DTC troubleshooting completed.
DTC B267B [POWER LIFTGATE (PLG) SYSTEM]

DTC B267B - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B267B Full latch switch circuit malfunction
DETECTION A short circuit to the ground system in the wiring harness between the liftgate latch
CONDITION and lock actuator and PLG control module.
 Short to GND in wiring harness between PLG control module terminal 3G and
liftgate latch and lock actuator terminal D
POSSIBLE CAUSE
 Full latch switch malfunction
Microsoft
DTC B267B - DIAGNOSTIC PROCEDURE

LIFTGATE LATCH AND LOCK
ACTUATOR Replace the liftgate latch and lock actuator.
(See LIFTGATE LATCH AND LOCK
Yes ACTUATOR
1 connector.
 Disconnect the liftgate latch and lock
actuator connector.
control module terminal 3G and liftgate
latch and lock actuator terminal D for a No
short circuit to ground system. Repair or replace the wiring harness.
Microsoft


Yes
 Operate the PLG system. (Close
operation)
 Is DTC B267B stored? No DTC troubleshooting completed.
DTC B267C [POWER LIFTGATE (PLG) SYSTEM]

DTC B267C - DETECTION CONDITION POSSIBLE CAUSE CHART
DTC B267C Return switch circuit malfunction
DETECTION The voltage input to the return switch does not change while the PLG system is
CONDITION operating.
 Open circuit in wiring harness between PLG control module terminal 3E and
liftgate latch and lock actuator terminal E
 Short to power supply in wiring harness between PLG control module terminal
3E and liftgate latch and lock actuator terminal E
 Short to GND in wiring harness between PLG control module terminal 3E and
POSSIBLE CAUSE
liftgate latch and lock actuator terminal E
 Open circuit in wiring harness between liftgate latch and lock actuator terminal C
and body GND
 Return switch malfunction
Microsoft
DTC B267C - DIAGNOSTIC PROCEDURE

LIFTGATE LATCH AND LOCK Yes Go to the next step.
ACTUATOR

1 connector.
 Disconnect the liftgate latch and lock
actuator connector. Repair or replace the wiring harness.
No
 Inspect the wiring harness between Go to Step 3.
PLG control module terminal 3E and
liftgate latch and lock actuator terminal
E for an open circuit.
Microsoft



BETWEEN LIFTGATE LATCH AND Replace the liftgate latch and lock actuator.
LOCK ACTUATOR AND BODY (See LIFTGATE LATCH AND LOCK
GROUND Yes ACTUATOR
Inspect the wiring harness between

liftgate latch and lock actuator terminal
C and body ground. Repair or replace the wiring harness.
No
Yes
 Operate the PLG system. (Open
operation)
 Is DTC B267C stored? No DTC troubleshooting completed.

DTC B2699 PLG touch sensor (LH) circuit malfunction
DETECTION
Open circuit is detected in the PLG touch sensor (LH)
CONDITION
 Short to power supply circuit in wiring harness between PLG control module
terminal 3B and PLG touch sensor (LH) terminal B
 Open circuit in wiring harness between PLG control module terminal 3B and
POSSIBLE CAUSE
terminal 2D and PLG touch sensor (LH) terminal A
 Open circuit in wiring harness between PLG control module terminal 2D and
PLG touch sensor (LH) terminal A
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INSPECT PLG TOUCH SENSOR (LH) Yes Go to the next step.
 Inspect the PLG touch sensor (LH). Replace the PLG touch sensor (LH).
1 (See POWER LIFTGATE (PLG)
(See POWER LIFTGATE (PLG) No TOUCH SENSOR
TOUCH SENSOR INSPECTION .) REMOVAL/INSTALLATION .)
Go to Step 4.
Is the touch sensor normal?


PLG CONTROL MODULE AND PLG Yes Go to the next step.
TOUCH SENSOR (LH)

2 control module terminal 3B and PLG
touch sensor (LH) terminal B for an open No Repair or replace the wiring harness.
circuit/short circuit to power supply Go to Step 4.
system.
3 TOUCH SENSOR (LH)

control module terminal 2D and PLG
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touch sensor (LH) terminal A for an open

circuit/short circuit to power supply Repair or replace the wiring harness.
system. No

 Reconnect the disconnected connector. Yes (See POWER LIFTGATE (PLG) DRIVE
4 UNIT REMOVAL/INSTALLATION .)
 Clear the DTC.
 Is DTC B2669 stored after 1 min or more
have elapsed? No DTC troubleshooting completed.

DTC B2700 PLG touch sensor (RH) circuit malfunction
DETECTION
Open circuit is detected in the PLG touch sensor (RH)
CONDITION
terminal 3A and PLG touch sensor (RH) terminal B
 Open circuit in wiring harness between PLG control module terminal 3A and
POSSIBLE CAUSE
terminal 2D and PLG touch sensor (RH) terminal A
 Open circuit in wiring harness between PLG control module terminal 2D and
PLG touch sensor (RH)terminal A
Microsoft

INSPECT PLG TOUCH SENSOR (RH) Yes Go to the next step.
 Inspect the PLG touch sensor (RH). Replace the PLG touch sensor (RH).
1 (See POWER LIFTGATE (PLG) TOUCH
(See POWER LIFTGATE (PLG) No SENSOR
TOUCH SENSOR INSPECTION .) REMOVAL/INSTALLATION .)
Go to Step 4.


TOUCH SENSOR (RH)
Inspect the wiring harness between PLG


2 control module terminal 3A and PLG
touch sensor (RH) terminal B for an open Repair or replace the wiring harness.
No
circuit/short circuit to power supply Go to Step 4.
system.

TOUCH SENSOR (RH)
Inspect the wiring harness between PLG


3 control module terminal 2D and PLG
touch sensor (RH) terminal A for an open No Repair or replace the wiring harness.
circuit/short circuit to power supply Go to the next step.
system.

4 CONTROL MODULE
 Is DTC B2700 stored after 1 min or more
have elapsed? No DTC troubleshooting completed.

DTC B2701 PLG touch sensor (LH) circuit malfunction
DETECTION A short circuit to ground in the PLG touch sensor (LH) continues for 5 min or more
Microsoft
CONDITION
 Short to GND in wiring harness between PLG control module terminal 3B and
POSSIBLE CAUSE  PLG touch sensor (LH) malfunction
 Obstructions in the detection part

INSPECT PLG TOUCH SENSOR (LH) Yes Go to the next step.
 Inspect the PLG touch sensor (LH).
Replace the PLG touch sensor (LH).
1 (See POWER LIFTGATE (PLG) TOUCH
(See POWER LIFTGATE (PLG) No
TOUCH SENSOR INSPECTION .) SENSOR REMOVAL/INSTALLATION .)
Go to Step 3.


TOUCH SENSOR (LH)
2
control module terminal 3B and PLG Repair or replace the wiring harness.
No
touch sensor (LH) terminal B for a short Go to the next step.
Microsoft



3 CONTROL MODULE
 Is DTC B2701 stored after 5 min or

DTC B2702 PLG touch sensor (RH) circuit malfunction
DETECTION
A short circuit to ground in the PLG touch sensor (RH) continues for 5 min or more.
CONDITION
 Short to GND in wiring harness between PLG control module terminal 3A and
POSSIBLE CAUSE  PLG touch sensor (RH) malfunction
 Obstructions in the detection part

INSPECT PLG TOUCH SENSOR (RH) Yes Go to the next step.
Microsoft
 Inspect the PLG touch sensor (RH).

Replace the PLG touch sensor (RH).
(See POWER LIFTGATE (PLG) (See POWER LIFTGATE (PLG) TOUCH
1 No
TOUCH SENSOR INSPECTION .) SENSOR REMOVAL/INSTALLATION .)
Go to Step 3.
Is touch sensor normal?


PLG COTROL MODULE AND PLG Yes Go to the next step.
TOUCH SENSOR (RH)
2 Inspect the wiring harness between PLG


control module terminal 3A and PLG Repair or replace the wiring harness.
touch sensor (RH) terminal B for a short No Go to the next step.

3 CONTROL MODULE
 Is DTC B2702 stored after 5 min or

DTC B2821 Closure motor circuit malfunction
DETECTION
Liftgate latch switch signal does not change (ON) when closure motor is operating
CONDITION
 Open circuit in wiring harness between PLG control module terminal 1A and
closure motor terminal A (liftgate latch and lock actuator)
 Open circuit in wiring harness between PLG control module terminal 1B and
closure motor terminal B (liftgate latch and lock actuator)
POSSIBLE CAUSE  A short circuit to ground in the wiring harness between the liftgate latch switch
and PLG control module
 Closure motor malfunction
 Liftgate latch switch malfunction
Microsoft

INSPECT LIFTGATE LOCK ACTUATOR Yes Go to the next step.
 Inspect the liftgate lock actuator. Replace the liftgate latch and lock actuator.
1 (See LIFTGATE LATCH AND LOCK
(See LIFTGATE LATCH AND No ACTUATOR
LOCK ACTUATOR INSPECTION .) REMOVAL/INSTALLATION .)
Go to Step 5.
 Is the liftgate lock actuator normal?
Microsoft

PLG CONTROL MODULE AND
LIFTGATE LOCK ACTUATOR


connector.
2  Disconnect the liftgate latch switch
connector.
Repair or replace the wiring harness.
 Inspect the wiring harness between PLG No
Go to Step 5.
control module terminals 1A and 1B, and
liftgate lock actuator terminals A and B
INSPECT LIFTGATE LATCH SWITCH Yes Go to the next step.
 Inspect the liftgate latch switch. Replace the liftgate latch and lock actuator.
3 (See LIFTGATE LATCH AND LOCK
(See LIFTGATE LATCH AND No ACTUATOR
LOCK ACTUATOR INSPECTION .) REMOVAL/INSTALLATION .)
Go to Step 5.
Is the liftgate latch switch normal?


PLG CONTROL MODULE AND Yes Go to the next step.
LIFTGATE LATCH SWITCH
4 Inspect the wiring harness between PLG


control module terminal 3F and liftgate Repair or replace the wiring harness.
latch switch terminal B for a short circuit No Go to the next step.
to ground system.

Yes
 Operate the PLG system. (Close
operation)

DTC B2936 PLG motor circuit malfunction
DETECTION The current flowing to the PLG motor is significantly low (1 A or less) and the output
CONDITION signal of rotation sensor A continues to not change while the PLG is operating.
Microsoft
 Open circuit in wiring harness between PLG control module terminal 1E and PLG
motor terminal A (PLG drive unit)
 Open circuit in wiring harness between PLG control module terminal 1F and PLG
POSSIBLE CAUSE motor terminal B (PLG drive unit)
 PLG drive unit (clutch) malfunction
 PLG motor malfunction
Microsoft

BETWEEN PLG CONTROL MODULE
AND PLG DRIVE UNIT
Replace the PLG drive unit.
 Disconnect the PLG control module Yes
connector.
1  Disconnect the PLG drive unit
connector.
 Inspect PLG control module
terminals 1E and 1F, and PLG drive
unit terminals A and B for an open Repair or replace the wiring harness.
No
circuit. Go to the next step.
VERIFY CORRECTION
COMPLETED
 Reconnect the disconnected
Yes (See POWER LIFTGATE (PLG) CONTROL
2 connector. MODULE REMOVAL/INSTALLATION .)
 Clear the DTC.

 Is DTC B2936 stored?

DTC B2937 PLG motor circuit malfunction
DETECTION
PLG motor current is excessively low. (less than 1A)
CONDITION
 Open circuit in wiring harness between PLG control module terminal 1E and
PLG motor terminal A (PLG drive unit)
 Open circuit in wiring harness between PLG control module terminal 1F and
POSSIBLE CAUSE
PLG motor terminal B (PLG drive unit)
 PLG motor malfunction
Microsoft

AND PLG DRIVE UNIT Replace the PLG drive unit.
Microsoft


connector.
PLG control module terminals 1E and
1F, and PLG drive unit terminals A and Repair or replace the wiring harness.
No
B for an open circuit. Go to the next step.

2 CONTROL MODULE
 Clear the DTC.

DTC B2939 Clutch circuit malfunction
DETECTION The current flowing to the PLG motor is normal (1 A or more), however, the output
CONDITION signal of rotation sensor A continues to not change while the PLG is operating.
 Open circuit in wiring harness between PLG control module terminal 21 and PLG
drive unit terminal M
 Open circuit in wiring harness between PLG control module terminal 2G and PLG
POSSIBLE CAUSE
drive unit terminal N
 Clutch malfunction
Microsoft

AND PLG DRIVE UNIT
Microsoft


Replace the PLG drive unit.
connector. (See POWER LIFTGATE (PLG) DRIVE
Yes
connector. Go to the next step.
PLG control module terminals 21 and
2G, and PLG drive unit terminals M Repair or replace the wiring harness.
and N for an open circuit. No

2 CONTROL MODULE
 Clear the DTC.
Microsoft
2008 STEERING Power Steering - Mazda CX-9
2008 STEERING
Power Steering - Mazda CX-9
STEERING LOCATION INDEX
Fig. 1: Identifying Steering Location Index

AIR BLEEDING
CAUTION:  Do not turn the steering wheel during the fluid level inspection,
otherwise the fluid level changes and cannot be inspected correctly.
1. Inspect the fluid level. (See POWER STEERING FLUID INSPECTION.)

2. Jack up the front of the vehicle and support it on safety stands.
3. Turn the steering wheel fully to the left and right several times with the engine not running.
4. Reinspect the fluid level.
 If it has dropped, add fluid.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.

6. Lower the vehicle.
7. Start the engine and let it idle.
8. Turn the steering wheel fully to the left and right several times.
9. Verify that the fluid is not foamy and that the fluid level has not dropped.
 If the fluid level has dropped, add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTION
Microsoft
FLUID LEVEL INSPECTION
1. Inspect the power steering fluid level.

 Add fluid to the specified level as necessary.
Power steering fluid type
ATF-MIII, M-V or Dexron®II
Power steering fluid capacity (approximate quantity) 1.27 L {1.34 US qt, 1.11 lmp qt}
FLUID LEAKAGE INSPECTION
1. Start the engine and let it idle.

2. Turn the steering wheel fully to the left and right to apply fluid pressure.
CAUTION:  If the steering wheel is kept in the fully turned position for more
than 5 seconds, the fluid temperature will rise excessively and
adversely affect the oil pump.
3. Inspect for fluid leakage.

 If fluid leakage is found, replace related pipe or hose.
NOTE:  The points where fluid leakage may occur are indicated in the figure.
Fig. 2: Inspecting For Fluid Leakage

FLUID PRESSURE INSPECTION
1. Assemble the SSTs as shown in the figure.

Microsoft
2. Disconnect the pressure pipe from the steering gear and linkage, and connect the SSTs.
Fig. 3: Identifying SSTs

3. Bleed the air from the system. (See AIR BLEEDING.)

4. Open the gauge valve fully.
5. Start the engine and turn the steering wheel fully left and right to raise the fluid temperature to 50-60 °C
{122-140 °F}.
6. Close the gauge valve completely.
7. Increase the engine speed to 1,000-1,500 rpm and measure the fluid pressure generated by the oil pump.
 If the pressure is not within the specification, repair or replace the oil pump component.
CAUTION:  If the valve is left closed for more than 5 seconds, the fluid
temperature will rise excessively and adversely affect the oil
pump.
Fig. 4: Measuring Fluid Pressure Generated By Oil Pump

Oil pump fluid pressure 11.3-11.8 MPa {116-120 kgf/cm2 , 1639-1711 psi}
Microsoft
8. Open the gauge valve fully and increase the engine speed to 1,000-1,500 rpm.
9. Turn the steering wheel fully to the left and right, then measure the fluid pressure generated at the gear
housing.
 If the pressure is not within the specification, repair or replace the steering gear component.
Fig. 5: Measuring Fluid Pressure Generated At Gear Housing

CAUTION:  If the steering wheel is kept in the fully turned position for more
than 5 seconds, the fluid temperature will rise excessively and
adversely affect the oil pump.
Gear housing fluid pressure 11.3-11.8 MPa {116-120 kgf/cm2 , 1639-1711 psi}
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque.
11. Bleed the air from the system.
STEERING WHEEL AND COLUMN INSPECTION

STEERING WHEEL PLAY INSPECTION
1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and
verify that the play is within the specification.
 If the play exceeds the specification, either the steering joints are worn or the backlash of the
steering gear is excessive. Correct as necessary.
Steering wheel play 0-30 mm {0-1.18 in}
STEERING WHEEL LOOSENESS INSPECTION
1. Move the steering wheel as shown in the figure to inspect for column bearing wear, steering shaft joint
Microsoft
play, steering wheel looseness, and column looseness.

 Repair or replace as necessary.
Fig. 6: Inspecting For Column Bearing Wear, Steering Shaft Joint Play, Steering Wheel
Looseness, And Column Looseness
STEERING WHEEL EFFORT INSPECTION
1. Inspect the following points:

 Tire size and tire pressure
 Fluid level
 Drive belt deflection
2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position.
3. Remove the air bag module.
WARNING:  Handling the air bag module improperly can accidentally

deploy the air bag module, which may seriously injure you.
Read AIR BAG SYSTEM WARNINGS before handling the air bag
module. (See AIR BAG SYSTEM SERVICE WARNINGS .) (See
AIR BAG SYSTEM SERVICE CAUTIONS .)
4. Start the engine and warm the power steering fluid to 50-60 °C {122-140 °F}.
5. Measure the steering wheel effort using a torque wrench.
 If not within the specification, verify the following:
 No air in steering system
 No fluid leakage at hose or connectors
 Function of oil pump and steering gear
Microsoft
Fig. 7: Measuring Steering Wheel Effort Using Torque Wrench

Steering wheel effort 7.8 N.m {80 kgf.cm, 58 in.lbf} max.
NOTE:  To determine whether the steering effort is satisfactory or not,

perform the inspection on another vehicle of the same model and
under the same conditions, and compare the results.
 The steering wheel effort varies with conditions as shown below.
 Road conditions, such as dry or wet, and asphalt or concrete.
 Tire conditions, such as brand, wear, and tire pressure.
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION
air bag module, which may seriously injure you. Read AIR BAG
SYSTEM WARNINGS before handling the air bag module. (See AIR
BAG SYSTEM SERVICE WARNINGS .) (See AIR BAG SYSTEM
SERVICE CAUTIONS .)
1. Remove the dashboard under cover (driver side). (See DASHBOARD UNDER COVER
2. Remove the column cover. (See COLUMN COVER REMOVAL/INSTALLATION .)
3. Remove the coil antenna (with advanced keyless system). (See COIL ANTENNA
REMOVAL/INSTALLATION [ADVANCED KEYLESS SYSTEM] .)
6. If the steering lock component of a vehicle equipped with the advanced keyless system is replaced,
perform the following procedure after installation.
 Without immobilizer system
 Steering lock unit programming (See STEERING LOCK UNIT ID CODE

REGISTRATION [ADVANCED KEYLESS SYSTEM] .)
Microsoft
 With immobilizer system

 Immobilizer system resetting (See IMMOBILIZER SYSTEM COMPONENT
REPLACEMENT/KEY ADDITION AND CLEARING [ADVANCED KEYLESS
SYSTEM] .) (See IMMOBILIZER SYSTEM COMPONENT REPLACEMENT/KEY
ADDITION AND CLEARING [KEYLESS ENTRY SYSTEM] .)
Fig. 8: Identifying Steering Wheel, Column Components & Torque Specifications

STEERING WHEEL REMOVAL NOTE
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CAUTION:  Do not try to remove the steering wheel by hitting the shaft with a
hammer. The column will collapse.
1. Set the vehicle in the straight-ahead position.

2. Remove the steering wheel using a suitable puller.
STEERING SHAFT REMOVAL NOTE
CAUTION:  When removing/installing the steering shaft, protect the lower panel
with a clean rag to prevent it from being scratched by interference.
1. Protect the lower panel with a clean rag.

2. Remove the steering wheel using any commercially available puller.
STEERING LOCK MOUNTING BOLTS REMOVAL NOTE
1. Make a groove in the heads of the steering lock mounting bolts using a chisel and a hammer.
2. Remove the bolts using a screwdriver.
3. Disassemble the steering lock component.
Fig. 9: Making Groove In Heads Of Steering Lock Mounting Bolts Using Chisel And Hammer
KEY CYLINDER (WITHOUT ADVANCED KEYLESS SYSTEM) REMOVAL NOTE
1. Turn the key to the ACC position.

2. Push the pin and remove the outer cylinder.
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Fig. 10: Locating Pin

STEERING LOCK MOUNTING BOLTS INSTALLATION NOTE
1. Assemble the steering lock component to the steering shaft.

2. Verify that the lock operates correctly.
3. Install new steering lock mounting bolts.
4. Tighten the bolts until the heads break off.
Fig. 11: Installing Steering Lock Mounting Bolts

STEERING SHAFT INSTALLATION NOTE
CAUTION:  Do not apply a shock in the axial direction of the shaft.
1. Lock the tilt lever.

2. Tighten nut A.
3. Tighten nut B.
4. Tighten bolt C.
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Fig. 12: Identifying Steering Shaft Nuts And Bolt

STEERING WHEEL INSTALLATION NOTE
1. Make sure the wheels in the straight-ahead position, and install the steering wheel.
STEERING SHAFT INSPECTION

1. Inspect the following.
1. Column bearing for damage
2. Steering shaft length
 Replace the steering shaft component as necessary.
Steering shaft length 211.6 mm {8.331 in}
Fig. 13: Identifying Steering Shaft Length

2. Inspect the tilt operation.

1. Verify that the adjusting lever moves smoothly from unlock position to lock position.
2. Verify that the steering shaft is fixed firmly when the adjusting lever is locked.
 Replace the steering shaft component as necessary.
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Fig. 14: Inspecting Tilt Operation

STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
1. Drain the power steering fluid. (See POWER STEERING FLUID INSPECTION.)
4. Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)
5. Remove the front crossmember, steering gear and linkage component. (See FRONT CROSSMEMBER
8. After installation, adjust the total toe-in. (See FRONT WHEEL ALIGNMENT .)
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Fig. 15: Identifying Steering Gear, Linkage Components & Torque Specifications
STEERING GEAR AND LINKAGE INSTALLATION NOTE
1. Tighten the mounting bracket bolts to the specified torque in the order shown.
Fig. 16: Identifying Mounting Bracket Bolts Tightening Order

BOLT (INTERMEDIATE SHAFT) INSTALLATION NOTE
1. Align the marks and install the intermediate shaft and bolt.
STEERING GEAR AND LINKAGE DISASSEMBLY

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CAUTION:  Place copper plates, rag, or similar material in a vise, when securing
the mounting bracket portion of the steering gear.
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Fig. 17: Identifying Steering Gear And Linkage Disassembly Order

TIE-ROD END DISASSEMBLY NOTE

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1. Place alignment marks as shown in the figure for proper installation.
Fig. 18: Identifying Tie-rod End Alignment Marks

LOCK WASHER, TIE ROD DISASSEMBLY NOTE
1. Unclamp the washer.

2. Lock the steering rack end against rotation with a wrench and remove the tie rod.
3. Remove the lock washer.
Fig. 19: Removing Tie Rod

HOLDER, OIL SEAL (HOLDER SIDE) DISASSEMBLY NOTE
1. Remove the holder from the gear housing using the SST.
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Fig. 20: Removing Holder From Gear Housing Using SST

2. Remove the oil seal from the holder using the SST and a press.
Fig. 21: Removing Oil Seal From Holder Using SST & Press
ADJUSTING COVER DISASSEMBLY NOTE
1. Install two nuts to the bolt across a flat 24 mm {0.94 in} and tighten them using a wrench.
2. Disassemble the adjusting cover with the bolt and nuts created in Step 1.
Fig. 22: Installing Nuts To Bolt Across Flat
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OIL SEAL (GEAR HOUSING SIDE), INNER GUIDE DISASSEMBLY NOTE
1. Set the SSTs as shown.

2. Insert the SSTs from the valve housing side.
3. Remove the oil seal (gear housing side) and inner guide using a press.
Fig. 23: Removing Oil Seal (Gear Housing Side) And Inner Guide Using Press
MOUNTING RUBBER DISASSEMBLY NOTE
1. Press the mounting rubber out from the gear housing using the SSTs and a press.
Substitution SST
 49B032 317
 49T028 301
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Fig. 24: Pressing Mounting Rubber Out From Gear Housing Using SSTs And Press
STEERING GEAR AND LINKAGE INSPECTION

RACK INSPECTION
1. Inspect the rack for cracking, damage, and tooth wear. Replace it if necessary.
2. Measure the runout of the rack.
Steering rack runout
Near point A: 0.15 mm {0.006 in} max.
Near point B: 0.20 mm {0.008 in} max.
3. If not within the specification, replace the rack.
Fig. 25: Measuring Runout Of Rack

TIE-ROD END INSPECTION
1. Inspect the tie-rod end for damage and boot cracks. Replace it if necessary.
2. Inspect the ball joint for looseness. Replace the tie-rod end if necessary.
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3. Rotate the ball joint five times.

4. Measure the rotation torque of the ball joint using the SST and a pull scale.
Tie-rod end rotational torque 0.4-2.7 N.m {4.1-27.5 kgf.cm, 3.6-23.8 in.lbf}
[Pull scale reading: 3.4-25.5 N {0.35-2.60 kgf, 0.8-5.7 lbf}]
5. If not within the specification, replace the tie-rod end.
Fig. 26: Measuring Rotation Torque Of Ball Joint Using And Pull Scale
TIE ROD INSPECTION
1. Inspect the tie rod for bending and damage. Replace it if necessary.
2. Inspect the ball joint for looseness. Replace the tie rod if necessary.
3. Swing the tie rod five times.
4. Measure the swinging torque using a pull scale.
Tie-rod swing torque 0.1-4.0 N.m {1.1-40 kgf.cm, 0.89-35 in.lbf}
5. If not within the specification, replace the tie rod.
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Fig. 27: Measuring Swinging Torque Using Pull Scale

STEERING GEAR AND LINKAGE ASSEMBLY
CAUTION:  Place copper plates, rag, or similar material in a vise, when securing
the mounting bracket portion of the steering gear.
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Fig. 28: Identifying Steering Gear, Linkage Assembly Order & Torque Specifications
MOUNTING RUBBER ASSEMBLY NOTE

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1. Apply soapy water to the rubber part of the mounting rubber.

2. Temporarily install the mounting rubber to the steering gear so that the mounting rubber are in the
positions shown in the figure.
CAUTION:  If the mounting rubber is placed in the wrong position or

assembled in the wrong direction, an installation malfunction
will result when the vehicle is loaded. When assembling the
mounting rubber, verify the position and directions.
Fig. 29: Identifying Mounting Rubber Install Positions

3. Press the mounting rubber until the mounting rubber end comes out completely from the gear housing
using the SSTs and a press.
Substitution SST
 49B032 317
 49T028 301
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Fig. 30: Pressing Mounting Rubber Until Mounting Rubber End Comes Out Completely
From Gear Housing
4. Reverse the gear housing, then press the mounting rubber until the mounting rubber end comes out
completely from the other side. At this time, the mounting rubber end and steel pipe are aligned.
Fig. 31: Pressing Mounting Rubber Until Mounting Rubber End Comes Out Completely From
Other Side
STEERING RACK, OIL SEAL (GEAR HOUSING SIDE), INNER GUIDE ASSEMBLY NOTE
1. Apply multi-purpose grease to the oil seal (gear housing side) and Inner guide.
2. Install the plastic bag to the steering rack teeth so as not to damage the oil seal (gear housing side) and the
inner guide, and install the oil seal (gear housing side) and the inner guide to the seal. Move the oil seal
(gear housing side) and the inner guide together with the plastic bag so that they pass the steering rack
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teeth, then remove the plastic bag.

3. Put the steering rack into the gear housing.
4. Using a press, press-in the oil seal (gear housing side) and inner guide until the press-in force increases
rapidly.
Fig. 32: Installing Plastic Bag To Steering Rack Teeth

OIL SEAL (HOLDER SIDE) ASSEMBLY NOTE
1. Assemble the oil seal (holder side) to the holder using a press and the SST.
Fig. 33: Assembling Oil Seal (Holder Side) To Holder Using Press And SST
HOLDER ASSEMBLY NOTE
1. Assemble the holder to the gear housing using the SST.

2. Connect the SSTs to the power cylinder section of the gear housing.
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Fig. 34: Assembling Holder To Gear Housing Using SST

3. Apply 53.3 kPa {400 mmHg, 15.7 inHg} vacuum with a vacuum pump and verify that it is held for at
least 30 seconds.
4. If the vacuum is not held, replace the oil seal.
Fig. 35: Applying 53.3 kPa {400 mmHg, 15.7 inHg} Vacuum With Vacuum Pump
ADJUSTING COVER ASSEMBLY NOTE
1. Set the rack to the center position.

2. Install two nuts to the bolt across a flat 24 mm {0.94 in} and tighten them using a wrench.
3. Assemble the adjusting cover with the bolt and nuts created in Step 1.
4. Tighten the adjusting cover to 19.6 N.m {2.0 kgf.m, 15 ft.lbf}.
5. Slide the rack back and forth 60 mm {2.4 in} three times.
6. Retighten the adjusting cover to 19.6 N.m {2.0 kgf.m, 15 ft.lbf}.
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Fig. 36: Installing Nuts To Bolt Across Flat

7. Loosen the adjusting cover 63° using the SST.
Fig. 37: Loosening Adjusting Cover 63° Using SST

8. Hold the adjusting cover so as not to rotate and tighten the locknut.
Fig. 38: Measuring Pinion Torque Using SST And Pull Scale
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9. Measure the pinion torque using the SST and pull scale. (Measurement speed: 0.5-2.0 rpm)
Pinion shaft rotation torque
Center of rack ± 90°: 1.0-1.6 N.m {1-16 kgf.cm, 8.9-14 in.lbf}
[Pull scale reading: 9-13 N {1.0-1.3 kgf, 2.1-2.9 lbf}]
Except center of rack ± 90°: Less than 1.68 N.m {17.1 kgf.cm, 14.8 in.lbf}
[Pull scale reading: Less than 13.8 N {1.4 kgf, 3.1 lbf}]
10. If not within the specification, repeat Step 4 to 9.
LOCK WASHER, TIE ROD ASSEMBLY NOTE
1. Temporary assemble the lock washer and the tie rod to the steering rack.
2. Lock the steering rack end against rotation with a wrench and assemble the tie rod.
3. Clamp the lock washer.
Fig. 39: Installing Tie Rod

POWER STEERING OIL PUMP REMOVAL/INSTALLATION

2. Remove the cowl grill. (See COWL GRILLE REMOVAL/INSTALLATION .)
3. Remove the windshield wiper motor (See WINDSHIELD WIPER MOTOR
5. Remove the right side splashing shield.
6. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7] .)
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8. Install in the reserve order of removal.
Fig. 40: Identifying Power Steering Oil Pump Components & Torque Specifications
POWER STEERING FLUID TANK REMOVAL NOTE
1. Remove the coolant reserve tank with the hose still connected, and position the coolant reserve tank out
of the way.
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Fig. 41: Identifying Power Steering Fluid Tank

POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY
NOTE:  The following procedure is for replacement of the O-ring and oil seal only.
Replace the pump component if other repairs are necessary.

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Fig. 42: Identifying Power Steering Oil Pump Disassembly/Assembly Order & Torque
Specifications
POWER STEERING OIL PUMP COMPONENT DISASSEMBLY NOTE

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1. Secure the power steering oil pump using the SST.
CAUTION:  Use the SST to prevent damage to the pump when securing it in
a vise.
Fig. 43: Securing Power Steering Oil Pump Using SST

SHAFT COMPONENT DISASSEMBLY NOTE
1. Tap out the shaft component from the front pump body using a plastic hammer.
Fig. 44: Tapping Out Shaft Component From Front Pump Body Using Plastic Hammer
1. Install the oil seal in the front pump body using the SST and plastic hammer.
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Fig. 45: Installing Oil Seal In Front Pump Body Using And Plastic Hammer
SIDE PLATE ASSEMBLY NOTE
1. Install the side plate in the position shown in the figure.
Fig. 46: Locating Side Plate Install Position

ROTOR ASSEMBLY NOTE
1. Install to the front pump body so that area B of the groove is on the rear pump body side as shown in the
figure.
Fig. 47: Identifying Rotor Assembly Note

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CAM RING ASSEMBLY NOTE
1. Install the cam ring in the front pump body with the mark facing upward.
Fig. 48: Installing Cam Ring In Front Pump Body With Mark Facing Upward
REAR PUMP BODY ASSEMBLY NOTE
1. After installing the rear body, manually turn the shaft to verify that it rotates smoothly.
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2008 ACCESSORIES & BODY, CAB Power Systems - Mazda CX-9
Power Systems - Mazda CX-9
POWER SYSTEM LOCATION INDEX
Fig. 1: Identifying Power System Components Location

FUSE SERVICE CAUTIONS
CAUTION:  Determine and correct the cause of the burnt fuse before replacing it
with the specified type, if the fuse is replaced before doing this, it
may burn again.
MAIN FUSE REMOVAL/INSTALLATION

2. Remove the main fuse block cover.
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Fig. 2: Identifying Main Fuse Screw

IGNITION SWITCH REMOVAL/INSTALLATION

Fig. 3: Identifying Ignition Switch Remove/Install Components

IGNITION SWITCH INSPECTION

1. Verify that the continuity between the ignition switch terminals is as indicated in the table.
 If not as indicated in the table, replace the ignition switch.
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Fig. 4: Ignition Switch Terminals Continuity Chart

Fig. 5: Identifying Ignition Switch Terminals

KEY REMINDER SWITCH REMOVAL/INSTALLATION

3. Disconnect the key reminder switch connector.
4. Remove the key reminder switch.
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Fig. 6: Identifying Key Reminder Switch And Steering Lock

KEY REMINDER SWITCH INSPECTION

3. Disconnect the key reminder switch connector.
4. Inspect for continuity between the key reminder switch terminals using a tester.
 If there is any malfunction, replace the key reminder switch.
Fig. 7: Key Reminder Switch Terminals Continuity Chart

Fig. 8: Identifying Key Reminder Switch Terminals

STEERING LOCK UNIT INSPECTION

1. Measure the voltage at each terminal is as indicated in the Terminal Voltage Tables.
have any malfunction, replace the steering look unit.
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Fig. 9: Identifying Steering Lock Unit Terminals

Measured Voltage
Terminal Signal name Connected to Inspection item(s)
condition (V)
 Ignition key illumination
bulb
 BCM
Interior light Under any  BCM (See BODY
C  Ignition key condition B+
power supply CONTROL MODULE
illumination (BCM) INSPECTION )
Ignition switch  Ignition key illumination
off and driver 1.0 or bulb
Ignition key  BCM side door less
 BCM (See BODY
D illumination  Ignition key opened. CONTROL MODULE
control illumination 15 s or more
after all doors B+ (BCM) INSPECTION )
closed.  Related wiring harnesses
 Keyless control module
Start knob (See KEYLESS
B+
pressed CONTROL MODULE
Push switch Keyless control
E INSPECTION
signal module
Start knob 1.0 or [ADVANCED
released less KEYLESS SYSTEM] )
 BCM (See BODY
Under any CONTROL MODULE
F Power supply BCM B+
condition (BCM) INSPECTION )
Key inserted B+  Keyless control module

Key reminder Keyless control
G (See KEYLESS
switch signal module
CONTROL MODULE
1.0 or INSPECTION
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less [ADVANCED
Key removed KEYLESS SYSTEM] )
 BCM (See BODY
Under any CONTROL MODULE
I Power supply BCM B+
condition (BCM) INSPECTION )
Because this terminal is (See KEYLESS
for communication, CONTROL MODULE
Serial Keyless control
K good/no good judgment INSPECTION
communication module
by terminal voltage is not [ADVANCED
possible. KEYLESS SYSTEM] )
Under any 1.0 or
L GND Body ground Related wiring harnesses
condition less
RELAY LOCATION
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Fig. 10: Identifying Relay Location

RELAY INSPECTION
RELAY TYPE
RELAY TYPE REFERENCE

Terminal type Part name
 Main relay No. 1

 Fuel pump relay
 Rear window defroster relay
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 Starter relay
 Back-up light relay
 A/C relay
 TNS relay
 Horn relay
Type A  Seat warmer relay RH
 H/L HI relay
 Main relay No.2
4 terminals
 H/L LOW relay
 Seat warmer relay LH
 Front fog light relay
 Front blower relay
 Rear blower relay
Type B  Fan relay
 Cooling fan relay No.1
 Cooling fan relay No.2
TYPE A
1. Verify the continuity between the relay terminals.

 If not as indicated in the table, replace the relay.
Fig. 11: Relay Terminals Continuity Chart (Type A)

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Fig. 12: Identifying Relay Terminals (Type A)

TYPE B
1. Verify the continuity between the relay terminals.

 If not as indicated in the table, replace the relay.
Fig. 13: Relay Terminals Continuity Chart (Type B)

Fig. 14: Identifying Relay Terminals (Type B)

Microsoft
2008 DRIVELINE/AXLE Propeller Shaft - Mazda CX-9
2008 DRIVELINE/AXLE
Propeller Shaft - Mazda CX-9
PROPELLER SHAFT LOCATION INDEX
Fig. 1: Identifying Propeller Shaft

PROPELLER SHAFT ON-VEHICLE INSPECTION

JOINT AREA EXCESSIVE PLAY INSPECTION
1. Shake the universal joint by hand and verify that there is no excessive play.
2. If there is any excessive play, replace the propeller shaft. (See PROPELLER SHAFT
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Fig. 2: Shaking Universal Joint

PROPELLER SHAFT RUNOUT INSPECTION
CAUTION:  Do not rotate the propeller shaft using engine force when inspecting.
1. Shift to neutral position and release the parking brake.

2. Rotate the rear wheel by hand and inspect the propeller shaft runout at the three locations shown in the
figure.
 If it exceeds the standard specification, replace the propeller shaft.
Standard propeller shaft runout (on-vehicle) 0.8 mm {0.031 in}
Fig. 3: Checking Propeller Shaft Runout

PROPELLER SHAFT REMOVAL/INSTALLATION
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1. Remove the presilencer installation nuts. (Middle pipe side) (See EXHAUST SYSTEM
2. Disconnect the hanger rubber as shown in the figure.
3. Suspend the presilencer using a cable.
Fig. 4: Identifying Presilencer Insulator And Presilencer

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Fig. 5: Identifying Propeller Shaft Components & Torque Specifications

BOLT AND NUT REMOVAL NOTE
CAUTION:  Do not mark with a punch to prevent imbalance.
1. Before removing the nut, place alignment marks on the companion flange (front) and constant velocity
joint, and on the companion flange (rear) and yoke.
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Fig. 6: Locating Alignment Marks On Companion Flange (Front) And Constant Velocity Joint
PROPELLER SHAFT INSTALLATION NOTE
1. Align the alignment marks and install the propeller shaft.
Fig. 7: Aligning Alignment Marks

2. When installing a new propeller shaft, align the rear differential companion flange mark with the tag on
the propeller shaft so that they are at the nearest position, and assemble.
3. Perform a road test and verify that there is no abnormal vibration or noise.
Fig. 8: Aligning Rear Differential Companion Flange Mark

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PROPELLER SHAFT INSPECTION

1. Measure the propeller shaft center runout using the dial gauge.
 If it exceeds the maximum specification, replace the propeller shaft as a single component.
Propeller shaft maximum runout 0.8 mm {0.031 in}
Fig. 9: Measuring Propeller Shaft Center Runout

2. Inspect the play and rotation of the joint by turning the universal joint in the directions shown by the
arrows.
 If it is not within the specification, replace the propeller shaft.
Propeller shaft starting torque 0.29-1.47 N.m {3.0-14.9 kgf.cm, 2.6-13.0 in.lbf}
Fig. 10: Inspecting Play And Rotation Of Joint

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2008 DRIVELINE/AXLE Rear Axle - Mazda CX-9
2008 DRIVELINE/AXLE
Rear Axle - Mazda CX-9
REAR AXLE LOCATION INDEX
Fig. 1: Identifying Rear Axle Components Location

WHEEL HUB COMPONENT INSPECTION

WHEEL BEARING EXCESSIVE PLAY INSPECTION
1. Install the magnetic base and dial gauge as shown in the figure and measure the wheel bearing axial
excessive play.
 If it exceeds the maximum specification, replace the wheel hub component.
Rear wheel bearing maximum play 0.05 mm {0.002 in}
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Fig. 2: Measuring Wheel Bearing Axial Excessive Play

WHEEL HUB COMPONENT REMOVAL/INSTALLATION [2WD]
procedures, disconnect the ABS wheel-speed sensor connector
(body side) and fix the wiring harness to an appropriate place where
it will not be pulled by mistake while servicing the vehicle.
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Fig. 3: Exploded View Of Wheel Hub (2WD) & Torque Specifications

1. Remove the brake caliper component from the trailing link and suspend it out of the way using a cable.
Fig. 4: Identifying Brake Caliper

WHEEL HUB BOLT REMOVAL NOTE
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NOTE:  The wheel hub bolts do not need to be removed unless they are being
replaced.
1. Remove the wheel hub bolt using a press.
Fig. 5: Removing Wheel Hub Bolts

WHEEL HUB BOLT INSTALLATION NOTE
1. Install the new wheel hub bolt using a press.
Fig. 6: Installing Wheel Hub Bolts

WHEEL HUB COMPONENT REMOVAL/INSTALLATION [AWD]
procedures, disconnect the ABS wheel-speed sensor connector
(body side) and fix the wiring harness to an appropriate place where
it will not be pulled by mistake while servicing the vehicle.
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7. Inspect for rear wheel alignment, and adjust it as necessary. (See REAR WHEEL ALIGNMENT
[AWD] .)
Fig. 7: Exploded View Of Wheel Hub (AWD) & Torque Specifications


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REAR TRAILING LINK AND REAR WHEEL HUB COMPONENT REMOVAL NOTE
1. Support the rear trailing link and rear wheel hub component using a jack.
CAUTION:  Removing the rear trailing link and rear wheel hub component is
dangerous. The rear trailing link and rear wheel hub component
could fall and cause serious injury or death. Verify that the jack
securely supports the trailing link.
Fig. 9: Supporting Rear Trailing Link And Rear Wheel Hub

2. Separate the rear drive shaft (rear axle side) from the wheel hub.
3. Remove the trailing link and rear wheel hub component.
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Fig. 10: Locating Locknut

REAR WHEEL HUB BOLT REPLACEMENT

1. Remove the brake calliper component and suspend it out of the way using a cable.
3. Remove the parking brake shoe.
4. Remove the wheel hub bolt using the SST as shown in the figure.
5. Place a new wheel hub bolt in the wheel hub.
Fig. 11: Removing Wheel Hub Bolt

6. Install the wheel hub by placing a proper sized washer on the hub, and tightening the nut as shown in the
figure.
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Fig. 12: Tightening Nut

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2008 SUSPENSION Rear Suspension - Mazda CX-9
2008 SUSPENSION
Rear Suspension - Mazda CX-9
REAR SUSPENSION LOCATION INDEX [2WD]
Fig. 1: Identifying Rear Suspension Components Location - 2WD

REAR SUSPENSION LOCATION INDEX [AWD]
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Fig. 2: Identifying Rear Suspension Components Location - AWD

REAR SHOCK ABSORBER REMOVAL/INSTALLATION

2. Support the rear lower arm using a garage jack.
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Fig. 3: Supporting Rear Lower Arm

Fig. 4: Identifying Rear Shock Absorber Components & Torque Specifications

REAR SHOCK ABSORBER INSPECTION

1. Remove the rear shock absorber. (See REAR SHOCK ABSORBER REMOVAL/INSTALLATION.)
2. Inspect for damage and oil leakage.
3. Compress and extend the shock piston at least three times. Verify that the operational force does not
change and that there is no unusual noise.
 If not as specified, replace the rear shock absorber.
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REAR SHOCK ABSORBER DISPOSAL

1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2-3 mm {0.08-0.11 in} hole at a point 20-30 mm {0.8-1.1 in} from the bottom of the tube, so that
the gas can escape.
WARNING:  Whenever drilling into a shock absorber, wear protective eye

wear. The gas in the shock absorber is pressurized, and could
spray metal chips into the eyes and face when drilling.
Fig. 5: Identifying Rear Shock Absorber Length

3. Turn the hole downwards.

4. The oil can be collected by moving the piston rod several times up and down and cutting the tube at the
end.
5. Dispose of waste oil according to the waste disposal law.
REAR COIL SPRING REMOVAL/INSTALLATION
CAUTION:  Perform the work using the garage jack.

 When removing/installing the coil spring, it is necessary to jack up
the rear suspension with unload condition. At that time, to prevent
bending the front of the vehicle, support the jack up point for the
front crossmember using a jack.
REMOVAL/INSTALLATION [2WD] .) (See REAR ABS WHEEL-SPEED SENSOR
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Fig. 6: Supporting Front Crossmember

4. Inspect the rear wheel alignment. (See REAR WHEEL ALIGNMENT [2WD] .) (See REAR WHEEL
ALIGNMENT [AWD] .)
Fig. 7: Identifying Suspension Assembly Components & Torque Specifications

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REAR SHOCK ABSORBER LOWER SIDE BOLT REMOVAL NOTE
1. Raise the rear trailing link to the unloaded condition with a jack.
2. Remove the rear shock absorber lower side bolt.
Fig. 8: Identifying Rear Trailing Link

REAR COIL SPRING REMOVAL NOTE
WARNING:  Removing the coil spring is dangerous. The coil spring could fly off,
and cause serious injury or death.
1. Support the rear lower arm inner side using a garage jack.
2. Loosen the rear lower arm outer side bolt.
3. Lower the rear lower arm inner side slowly.
4. Remove the rear coil spring.
Fig. 9: Supporting Rear Lower Arm Inner Side

REAR COIL SPRING INSTALLATION NOTE
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WARNING:  Installing the coil spring is dangerous. The coil spring could fly off,
and cause serious injury or death.
1. Install the rear coil spring so that the lower end of the rear coil spring is seated on the step of the rear
lower spring seat.
2. Position the jack under the lower arm inner side and compress the rear coil spring slowly.
Fig. 10: Positioning Jack Under Lower Arm Inner Side

3. Support the rear lower arm outer side and raise the rear suspension to the unloaded condition with a
separate garage jack.
4. Install the lower arm inner side bolt.
Tightening torque
 120-163 N.m {12.3-16.6 kgf.m, 89-120 ft.lbf}
Fig. 11: Supporting Rear Lower Arm Outer Side

5. Tighten the rear lower arm outer side bolt.
Tightening torque
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 120-163 N.m {12.3-16.6 kgf.m, 89-120 ft.lbf}
REAR LOWER ARM REMOVAL/INSTALLATION

[2WD] .) (See REAR WHEEL ALIGNMENT [AWD] .)
Fig. 12: Identifying Rear Lower Arm Components & Torque Specifications
REAR UPPER ARM REMOVAL/INSTALLATION [2WD]
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NOTE:  The rear upper arm inner bolt cannot be tightened completely with the rear
upper arm installed to the vehicle due to the narrow operation space.
Therefore, mark the position before removing the rear upper arm, align the
rear crossmember and rear upper arm markings when installing the rear
upper arm, and tighten the rear upper arm inner bolt completely before
installing the rear crossmember component to the vehicle.

3. Support the jack up point for the front crossmember using a garage jack.
CAUTION:  Perform the work using a garage jack. When jacking up the rear
suspension with unloaded condition, to prevent bending the
front of the vehicle, support the jack up point for the front
crossmember using a garage jack.
Fig. 13: Supporting Jack Up Point For Front Crossmember

4. Jack up the rear suspension with unloaded condition.
NOTE:  Jacking up the rear suspension with unloaded condition will lighten
the force on the bushing and make it easier to perform the procedure.
5. Mark the rear upper arm and rear crossmember shown in the figure.
6. Remove the rear coil spring. (See REAR COIL SPRING REMOVAL/INSTALLATION.)
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[2WD] .)
Fig. 14: Marking Rear Upper Arm And Rear Crossmember

Fig. 15: Identifying Coil Spring Components & Torque Specifications

REAR UPPER ARM REMOVAL NOTE
1. Remove the rear lateral link installation bolts.
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2. Loosen the rear upper arm installation bolts.

3. Support the rear crossmember component using a mission jack.
Fig. 16: Supporting Rear Crossmember

4. Remove the crossmember bracket.

5. Loosen the rear crossmember installation nut, and lower the crossmember approx. 50 mm {2.0 in}.
6. Remove the rear upper arm inner side bolt.
Fig. 17: Identifying Crossmember Bracket Bolt

REAR UPPER ARM INSTALLATION NOTE
1. Place the new rear upper arm together with the removed rear upper arm and place an alignment mark on
the new rear upper arm.
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Fig. 18: Identifying Alignment Mark On Rear Upper Arm

2. Point the 'IN' mark towards the inside of the vehicle, align the rear upper arm and rear crossmember
alignment marks, and install the rear upper arm.
3. Tighten the rear upper arm inner side bolt.
Tightening torque
120-163 N.m {12.3-16.6 kgf.m, 89-120 ft-lbf}
Fig. 19: Pointing Of 'IN' Mark

4. Install the rear crossmember component.
Tightening torque
Rear crossmember installation nut: 93-131
N.m {9.5-13.3 kgf.m, 68.6-96.6 ft.lbf}
Crossmember bracket installation bolt: 18.6-25.5 N.m {1.90-26.0 kgf.m, 13.8-18.8 ft.lbf}
Crossmember bracket installation nut: 18.6-25.5 N.m {1.90-26.0 kgf.m, 13.8-18.8 ft.lbf}
REAR UPPER ARM REMOVAL/INSTALLATION [AWD]

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INSPECTION [AWD] .)
Fig. 20: Identifying Presilencer Insulator, Bolts & Torque Specifications

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[AWD] .)
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Fig. 23: Identifying Differential Oil Temperature Sensor Connector, Rear Upper Arm & Torque
Specifications
REAR UPPER ARM REMOVAL NOTE
1. Remove the rear lateral link installation bolts.

2. Loosen the rear upper arm installation bolts.
3. Support the rear crossmember and differential component using a mission jack.
Fig. 24: Supporting Rear Crossmember And Differential

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4. Remove the crossmember bracket.

5. Loosen the rear crossmember installation nut, and lower the crossmember approx. 50 mm {2.0 in}.
6. Remove the rear upper arm.
Fig. 25: Identifying Crossmember Bracket Nut

REAR UPPER ARM INSTALLATION NOTE
1. Place the new rear upper arm together with the removed rear upper arm and place an alignment mark on
the new rear upper arm.
Fig. 26: Identifying Alignment Mark On Rear Upper Arm

2. Point the 'IN' mark towards the inside of the vehicle, align the rear upper arm and rear crossmember
alignment marks, and install the rear upper arm.
3. Tighten the rear upper arm inner side bolt.
Tightening torque
120-163 N.m {12.3-16.6 kgf.m, 89-120 ft.lbf}
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Fig. 27: Pointing Of 'IN' Mark

4. Install the rear crossmember component.
Tightening torque
Rear crossmember installation nut: 93-131
N.m {9.5-13.3 kgf m, 68.6-96.6 ft.lbf}
Crossmember bracket installation bolt: 18.6-25.5 N.m {1.90-26.0 kgf.m, 13.8-18.8 ft.lbf}
Crossmember bracket installation nut: 18.6-25.5 N.m {1.90-26.0 kgf.m, 13.8-18.8 ft.lbf}
REAR LATERAL LINK REMOVAL/INSTALLATION

1. Mark the adjusting cam bolt and cam plate of the rear lateral link.
3. Remove the rear lateral link.
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Fig. 28: Identifying Rear Lateral Link Components & Torque Specifications
4. Install the rear lateral link by aligning it with the mark placed during removal.
[2WD] .) (See REAR WHEEL ALIGNMENT [AWD] .)
REAR STABILIZER REMOVAL/INSTALLATION [2WD]

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Fig. 29: Identifying Rear Stabilizer Components & Torque Specifications - 2WD
REAR STABILIZER INSTALLATION NOTE
1. Install the rear stabilizer so that the identification mark faces the right side of the vehicle.
Fig. 30: Identifying Rear Stabilizer Identification Mark

REAR STABILIZER REMOVAL/INSTALLATION [AWD]
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Fig. 31: Identifying Presilencer Insulator, Presilencer & Torque Specifications

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Fig. 32: Identifying Rear Stabilizer Components & Torque Specifications - AWD
REAR STABILIZER COMPONENT REMOVAL NOTE

2. Remove the rear differential mounting bracket (front) installation bolts.

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3. Tilt the rear differential towards the front.

4. Remove the rear stabilizer from through the gap between the rear differential and rear crossmember.
Fig. 34: Identifying Rear Differential Mounting Bracket Bolts

REAR STABILIZER INSTALLATION NOTE
1. Install the rear stabilizer so that the identification mark faces the right side of the vehicle.
Fig. 35: Identifying Rear Stabilizer Identification Mark

REAR STABILIZER CONTROL LINK INSPECTION

1. Remove the stabilizer control link from the vehicle. (See REAR STABILIZER
REMOVAL/INSTALLATION [2WD].) (See REAR STABILIZER REMOVAL/INSTALLATION
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[AWD].)
2. Inspect for bending and damage.
3. Measure the ball joint starting torque.
1. Rock the ball joint stud side to side 10 times.
2. Rotate the ball joint stud 10 times.
3. Measure the starting torque using a suitable Allen socket and a torque wrench.
Rear stabilizer control link ball joint starting torque 0.2-2.0 N.m {3-20 kgf.cm, 2-17 in.lbf}
 If not as specified, replace the rear stabilizer control link.
Fig. 36: Measuring Ball Joint Starting Torque

REAR TRAILING LINK REMOVAL/INSTALLATION [2WD]
2. Remove the rear lateral link. (See REAR LATERAL LINK REMOVAL/INSTALLATION.)
4. Remove the rear lower arm. (See REAR LOWER ARM REMOVAL/INSTALLATION.)
[2WD] .)
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Fig. 37: Identifying Rear Trailing Link Components & Torque Specifications - 2WD
CALIPER COMPONENT REMOVAL NOTE
1. Remove the caliper component and suspend it with a cable in a location out of the way.
REAR TRAILING LINK COMPONENT REMOVAL NOTE
1. Support the rear trailing link using a jack.

2. Remove the rear trailing link.
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Fig. 38: Supporting Rear Trailing Link

BRACKET INSTALLATION NOTE
1. Install the bracket so that its angle as opposed to the rear trailing link is as shown in the figure.
Fig. 39: Identifying Bracket Angle

REAR TRAILING LINK REMOVAL/INSTALLATION [AWD]
2. Remove the rear lateral link. (See REAR LATERAL LINK REMOVAL/INSTALLATION.)
4. Remove the rear lower arm. (See REAR LOWER ARM REMOVAL/INSTALLATION.)
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[AWD] .)
Fig. 40: Identifying Rear Trailing Link Components & Torque Specifications - AWD
1. Remove the caliper component and suspend it with a cable in a location out of the way.
REAR TRAILING LINK COMPONENT REMOVAL NOTE

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1. Support the rear trailing link using a jack.
CAUTION:  Removing the trailing link is dangerous. The trailing link could
fall and cause serious injury or death. Verify that the jack
securely supports the trailing link.
2. Separate the rear drive shaft (rear axle side) from the wheel hub.
3. Remove the rear trailing link.
Fig. 41: Supporting Rear Trailing Link

BRACKET INSTALLATION NOTE
1. Install the bracket so that its angle as opposed to the rear trailing link is as shown in the figure.
Fig. 42: Identifying Bracket Angle

REAR CROSSMEMBER REMOVAL/INSTALLATION [2WD]
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upper arm, and tighten the rear upper arm inner bolt completety before

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[2WD] .)

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Fig. 45: Identifying Rear Wheel Alignment Components & Torque Specifications - 2WD
1. Remove the rear brake caliper component, and suspend it with a cable in a location out of the way.
REAR CROSSMEMBER COMPONENT REMOVAL NOTE

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WARNING:  Removing the crossmember is dangerous. The crossmember

component could fall and cause serious injury or death. Verify that
the mission jack securely supports the crossmember component.
1. Support the crossmember component using a mission jack and remove the installation nuts.
2. Remove the rear crossmember component.
Fig. 46: Supporting Crossmember

REAR CROSSMEMBER REMOVAL/INSTALLATION [AWD]
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Fig. 49: Identifying Presilencer Insulator And Presilencer

[AWD] .)
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Fig. 50: Identifying Rear Wheel Alignment Components & Torque Specifications - AWD
1. Remove the rear brake caliper component, and suspend it with a cable in a location out of the way.
REAR DIFFERENTIAL AND REAR CROSSMEMBER COMPONENT REMOVAL NOTE

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WARNING:  Removing the crossmember is dangerous. The crossmember

component could fall and cause serious injury or death. Verify that
the mission jack securely supports the crossmember component.
1. Support the crossmember component using a mission jack and remove the installation nuts.
2. Remove the rear crossmember component.
Fig. 51: Supporting Crossmember Component

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2008 RESTRAINTS Seat Belt - Mazda CX-9
2008 RESTRAINTS
Seat Belt - Mazda CX-9
SEAT BELT LOCATION INDEX
Fig. 1: Identifying Seat Belt Location

FRONT SEAT BELT REMOVAL/INSTALLATION
WARNING:  Handling the front seat belt (pre-tensioner seat belt) improperly can
accidentally deploy the pre-tensioner seat belt, which may seriously
injure you. Read the service warnings and cautions before handling
the front seat belt (pre-tensioner seat belt). (See AIR BAG SYSTEM
SERVICE WARNINGS .) (See AIR BAG SYSTEM SERVICE
CAUTIONS .)
 Side air bag sensor No.1 is attached to the lower part of the B-pillar.
When working around the B-pillar, disconnect the negative battery
cable or work carefully, avoiding excessive impact to the lower part
of the B-pillar.
CAUTION:
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 The ELR (emergency locking retractor) has a spring that will unwind
if the retractor cover is removed. The spring cannot be rewound by
hand. If this occurs, the ELR will not work properly. Therefore, do not
disassemble the retractor.

3. Remove the front scuff plate inner. (See FRONT SCUFF PLATE REMOVAL/INSTALLATION .)
5. Remove the cover by pulling it in the direction of the arrow.
Fig. 2: Identifying Front Seat Belt, Bolts & Torque Specifications

6. Remove the bolt A.

7. Remove the B-pillar lower trim. (See B-PILLAR LOWER TRIM REMOVAL/INSTALLATION .)
8. Remove the adjuster anchor cover.
9. Remove the bolt B and bolt C, then remove the front seat belt.
10. Using a screwdriver, pry out the pre-tensioner seat belt connector's stopper plate.
11. Disconnect the pre-tensioner seat belt connector.
 If the air bag system warning light does not operate, refer to the on-board diagnostic system (air
bag system) and perform inspection of the system. (See FLOWCHART .)
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Fig. 3: Prying Out Pre-Tensioner Seat Belt Connector's Stopper Plate Using Screwdriver
ADJUSTER ANCHOR REMOVAL/INSTALLATION
WARNING:  Side air bag sensor No.1 is attached to the lower part of the B-pillar.
When working around the B-pillar, disconnect the negative battery
cable or work carefully, avoiding excessive impact to the lower part
of the B-pillar.

3. Front seat belt lower anchor installation bolt (See FRONT SEAT BELT
4. Remove the bolt.
5. Rotate the adjuster anchor in the direction of the arrow.
6. Remove the adjuster anchor by pulling it outward.
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Fig. 4: Rotating Adjuster Anchor & Torque Specifications

SECOND-ROW SEAT BELT REMOVAL/INSTALLATION
CAUTION:  The ELR (emergency locking retractor) has a spring that will unwind

5. Remove the bolt.
6. Remove the second-row seat belt.
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Fig. 5: Identifying Second-Row Seat Belt, Bolt & Torque Specifications

SECOND-ROW CENTER SEAT BELT REMOVAL/INSTALLATION

4. Front seat belt lower anchor installation bolt (See FRONT SEAT BELT
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4. Remove the bolt.
5. Remove the second-row center seat belt.
Fig. 6: Identifying Second-Row Center Seat Belt, Bolt & Torque Specifications
THIRD-ROW SEAT BELT REMOVAL/INSTALLATION
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6. Remove the bolt B.
7. Remove the third-row seat belt.
Fig. 7: Identifying Third-Row Seat Belt, Bolt & Torque Specifications

SEAT BELT INSPECTION

BELT
1. Verify that the belt is installed properly with no twists or kinks.

2. Verify that there is no damage to the seat belt and no deformation of the metal fittings.
 If there is any malfunction, replace the seat belt.
ELR
1. Verify that the belt can be pulled out smoothly, and that it retracts smoothly.
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If there is any malfunction, replace the seat belt.


2. Verify that the retractor locks when the belt is pulled quickly.
3. Remove the retractor.
Fig. 8: Checking Retractor

4. While pulling the seat belt out, make sure that the seat belt does not lock when the retractor is tilted
slowly up to 15° from the mounted position and locks when the retractor is tilted 40° or more .
Fig. 9: Identifying Retractor Angle

ALR
1. Pull the belt out fully to change the lock mode from ELR to ALR.
2. Verify that retractor makes a clicking sound as the belt slowly retracts. If no sound is heard, the lock
mode has not changed to ALR. If necessary, repeat Step 1.
3. Verify that the retractor locks when pulled.

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4. Verify that the lock mode changes to ELR when the belt is fully pulled out.
LOAD LIMITER RETRACTOR
WARNING:  When the load limiter operates, the belt and anchor rub against each
other strongly leaving wear tracks. If the seat belt is used in this
state, the seat belt will not function at its full capability and there is
the possibility of serious injury to passengers. Be sure to replace
the seat belt once the load limiter operates.
1. If the vehicle has been subjected to a shock in an accident, pull the belt from the retractor and confirm
that there are no wear tracks (the load limiter has not operated) by visually inspecting and feeling the belt.
Fig. 10: Pulling Belt From Retractor

FRONT BUCKLE REMOVAL/INSTALLATION

1. Remove the front seat. (See FRONT SEAT REMOVAL/INSTALLATION .)
2. Remove the side cover No.1. (See FRONT SEAT DISASSEMBLY/ASSEMBLY .)
3. Remove the bolt.
4. Remove the front buckle.
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Fig. 11: Identifying Front Buckle, Bolt & Torque Specifications

SECOND-ROW BUCKLE REMOVAL/INSTALLATION

LH
1. Remove the second-row seat (LH). (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)

3. Remove the second-row center buckle.
4. Remove the second-row seat (LH) seat cushion pad. (See SECOND-ROW SEAT
5. Remove the bolt B.
6. Remove the second-row buckle (LH).
Fig. 12: Identifying Second-Row Center Buckle, Bolt & Torque Specifications
RH
1. Remove the second-row seat (RH). (See SECOND-ROW SEAT REMOVAL/INSTALLATION .)

2. Remove in bolt.
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3. Remove the second-row buckle (RH).

Fig. 13: Identifying Second-Row Buckle (RH), Bolt & Torque Specifications
THIRD-ROW BUCKLE REMOVAL/INSTALLATION

REMOVAL
1. Fold the third-row seat backs forward.

3. Remove the bolt.
4. Remove the third-row buckle.
Fig. 14: Identifying Third-Row Buckle & Bolt

INSTALLATION
1. Bind the third-row seat belt buckles in a band as shown in the figure.
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Fig. 15: Binding Third-Row Seat Belt Buckles In Band

2. Install the bolt.

Fig. 16: Identifying Third-Row Buckle, Bolt & Torque Specifications

BUCKLE SWITCH INSPECTION

1. Inspect for continuity between the buckle switch terminals using a tester.
 If not as indicated in the table, replace the front buckle.

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Fig. 18: Buckle Switch Circuit

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2008 BODY & ACCESSORIES Seats - Mazda CX-9
Seats - Mazda CX-9
SEAT LOCATION INDEX
Fig. 1: Identifying Seat Components Location

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FRONT SEAT REMOVAL/INSTALLATION
WARNING:  Handling the front seat (with a side air bag) improperly can
accidentally deploy the air bag, which may seriously injure you.
Read the service warnings and cautions before handling the front
seat (with a side air bag). (See AIR BAG SYSTEM SERVICE
WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .)

2. Disconnect the negative battery cable and wait 1 min or more.
3. Press connector tab A in the direction of the arrow.
Fig. 2: Pressing Connector Tab

4. Pull out the connector lock in the direction of the arrow and disconnect the connector.
Fig. 3: Pulling Out Connector Lock


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Fig. 4: Identifying Front Seat Connector & Torque Specifications

FRONT SEAT DISASSEMBLY/ASSEMBLY
WARNING:  Handling the front seat (with a side air bag) improperly can
accidentally deploy the air bag, which may seriously injure you.
Read the service warnings and cautions before handling the front
seat (with a side air bag). (See AIR BAG SYSTEM SERVICE
WARNINGS .) (See AIR BAG SYSTEM SERVICE CAUTIONS .)
CAUTION:  If any of the following work is performed, perform the seat weight
sensor calibration using the M-MDS. (See SEAT WEIGHT SENSOR
CALIBRATION .)
 Replacement with new passenger-side seat parts
 Disassembly of the passenger-side seat
 If any of the following work is performed, perform the seat weight

sensor inspection using the M-MDS. (See SEAT WEIGHT SENSOR
INSPECTION .)
 Removal of the passenger-side seat
 Loosening and retightening of passenger's seat fixing bolts
1. Disconnect the negative battery cable and wait for more than 1 minute.
2. Remove the side air bag module. (See SIDE AIR BAG MODULE REMOVAL/INSTALLATION .)
DRIVER SEAT (MANUAL SEAT)
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Fig. 5: Exploded View Of Front Seat - Driver Seat (Manual Seat) & Torque Specifications
DRIVER SEAT (POWER SEAT)
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Fig. 6: Exploded View Of Front Seat - Driver Seat (Power Seat) & Torque Specifications
PASSENGER SEAT (MANUAL SEAT)
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Fig. 7: Exploded View Of Front Seat - Passenger Seat (Manual Seat) & Torque Specifications
PASSENGER SEAT (POWER SEAT)
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Fig. 8: Exploded View Of Front Seat - Passenger Seat (Power Seat) & Torque Specifications
SIDE COVER DISASSEMBLY NOTE
1. Pull the side cover outward and remove clip A.

2. Pull the side cover rearward and up at an angle, and remove tabs B and C.
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Fig. 9: Pulling Side Cover

SEAT BACK PAD DISASSEMBLY NOTE
1. Remove the headrest.

2. Slide hook A upward and remove it from hook B.
3. Open the fastener.
Fig. 10: Identifying Fastener And Hook

4. Insert a flathead screwdriver between hook C and the frame.

5. Pull the flathead screwdriver in the direction of the arrow as shown in the figure.
6. Remove the hook C.
7. Remove the hook D.
8. Remove the hook E.
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Fig. 11: Inserting Flathead Screwdriver Between Hook And Frame

9. Remove the hook F.

10. Remove the pole guide.
11. Remove the C ring
12. Remove the seat back trim.
13. Remove the seat back pad.
Fig. 12: Removing Hook

LUMBER SUPPORT LEVER DISASSEMBLY NOTE
1. Remove the pin from the lumber support lever installation part with rag.
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Fig. 13: Identifying Lumber Support Lever & Pin

SEAT WEIGHT SENSOR INSTALLATION NOTE
1. Install the seat weight sensor to the slide adjusters and temporarily tighten the four nuts.
2. Tighten nuts A (both right and left) at the same time to the specified tightening torque.
3. Tighten nuts B (both right and left) at the same time to the specified tightening torque.
4. Install the seat under bracket to the seat weight sensor and temporarily tighten the four nuts.
5. Tighten nuts C (both right and left) at the same time to the specified tightening torque.
6. Tighten nuts D (both right and left) at the same time to the specified tightening torque.
Fig. 14: Identifying Seat Under Bracket, Seat Weight Sensor & Torque Specifications
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FRONT TILT MOTOR INSPECTION

1. Disconnect the front tilt motor connector.
2. Apply battery positive voltage to the front tilt motor terminals and inspect the front tilt motor operation
 If not as specified, replace the slide adjuster.
MOTOR OPERATION
Connection
Motor operation
B+ GND
Up E D
Down D E
3. Connect the front tilt motor connector.

4. Measure the front tilt motor terminal A waveform during motor operation using the oscilloscope.
Condition Voltage (V)
High output 4.8 or more
Low output 1.0 or less
Fig. 15: Front Tilt Motor - Circuit Diagram

REAR TILT MOTOR INSPECTION

1. Disconnect the rear tilt motor connector.
2. Apply battery positive voltage to the rear tilt motor terminals and inspect the rear tilt motor operation
MOTOR OPERATION
Connection
Motor operation
B+ GND
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Up E D
Down D E
3. Connect the rear tilt motor connector.

4. Measure the rear tilt motor terminal A waveform during motor operation using the oscilloscope.
Fig. 16: Rear Tilt Motor - Circuit Diagram

SLIDE MOTOR INSPECTION

1. Disconnect the slid motor connector.
2. Apply battery positive voltage to the slide motor terminals and inspect the slide motor operation
MOTOR OPERATION
Connection
Motor operation
B+ GND
Forward 2B 2A
Backward 2A 2B
3. Connect the slide motor connector.

4. Measure the slide motor terminal 1C waveform during motor operation using the oscilloscope.
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Fig. 17: Slide Motor - Circuit Diagram

RECLINER MOTOR INSPECTION

1. Disconnect the recliner motor connector.
2. Apply battery positive voltage to the recliner motor terminals and inspect the recliner motor operation
MOTOR OPERATION
Connection
Motor operation
B+ GND
Forward E A
Backward A E
3. Connect the recliner motor connector.

4. Measure the recliner motor terminal C waveform during motor operation using the oscilloscope.
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Fig. 18: Recliner Motor - Circuit Diagram

LUMBAR SUPPORT SWITCH INSPECTION

1. Disconnect the lumbar support switch connector.
2. Inspect for continuity between the lumbar support switch connector terminals.
 If not as specified, replace the lumbar support switch.
Fig. 19: Lumbar Support Switch Continuity Chart

Fig. 20: Lumbar Support Switch - Circuit Diagram

LUMBAR SUPPORT MOTOR INSPECTION
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1. Disconnect the lumbar support motor connector.

2. Connect battery positive voltage to lumbar support motor terminal A or B, then verify that the lumbar
support motor operate as shown in the table.
 If the lumbar support motor does not operate as indicated in the table, replace the Seat back frame.
MOTOR OPERATION
Connection
Motor operation
B+ GND
Forward B A
Backward A B
Fig. 21: Lumbar Support Motor - Circuit Diagram

POWER SEAT SWITCH INSPECTION

1. Disconnect the power seat switch connector.
2. Inspect for continuity between the power seat switch connector terminals.
 If not as specified, replace the power seat switch.
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Fig. 22: Power Seat Switch (Driver Seat) - Circuit Diagram (Vehicles With Position Memory
Seat)
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Fig. 23: Power Seat Switch (Driver Seat) - Circuit Diagram (Vehicles Without Position
Memory Seat)
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Fig. 24: Power Seat Switch (Passenger Seat) - Circuit Diagram

POSITION MEMORY CONTROL MODULE REMOVAL/INSTALLATION

1. Operate the power seat switch and move the seat cushion forward and upward.
3. Disconnect the negative battery cable and wait 1 min or more.
4. Remove the driver-side front seat. (See FRONT SEAT REMOVAL/INSTALLATION.)
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Fig. 25: Identifying Position Memory Control Module And Connector

POSITION MEMORY CONTROL MODULE INSPECTION

1. Measure the voltage at each terminal is as indicated in the Terminal Voltage Tables.
have any malfunction, replace the position memory control module.
Fig. 26: Identifying Position Memory Control Module Connector Terminal

Voltage
Terminal Signal name Connected to Measured condition Inspection item(s)
(V)
 BCM
Keyless entry communication, good/no good
1A BCM  Related wiring
signal judgment by terminal voltage is not
possible. harness
High
output: B+  Instrument
Measure the waveform
Vehicle speed Instrument cluster
1D while driving using the Low
input cluster  Related wiring
oscilloscope. output: 1.0
or less harness
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Driver-side door open: Inspect for  Door switch

Door Door switch continuity to ground. B+ (Driver side)
1F
open/closed (Driver side) Driver-side door closed: Inspect for  Related wiring
continuity to ground. 1.0 or less harness
Ignition switch is at ON Instrument

Instrument B+ cluster 10 A
position
1G IG1 cluster 10 A fuse
fuse Ignition switch is at LOCK  Related wiring
1.0 or less
or ACC position harness
Related wiring
1H Signal GND Body ground Under any condition 1.0 or less
harness
Related wiring
1J Power GND Body ground Under any condition 1.0 or less
harness
 ROOM 15 A
ROOM 15 A fuse
1M Power supply Under any condition B+
fuse  Related wiring
harness
 P/SEAT 40 A
P/SEAT 40 A fuse
1O Power supply Under any condition B+
fuse  Related wiring
harness
Press the slide switch to  Power seat
Slide switch Power seat 1.0 or less switch
2A forward
input (forward) switch  Related wiring
Other 5.0 harness
Press the slide switch to  Power seat
Slide switch 1.0 or less
Power seat backward switch
2B input
switch  Related wiring
(backward)
Other 5.0 harness
Press the front tilt switch to  Power seat
Front tilt switch Power seat 1.0 or less switch
2C up
input (up) switch  Related wiring
Other 5.0 harness
Press the front tilt switch to  Power seat
Front tilt switch Power seat 1.0 or less switch
2D down
input (down) switch  Related wiring
Other 5.0 harness
Press the rear tilt switch to  Power seat
Rear tilt switch Power seat 1.0 or less switch
2E up
input (up) switch  Related wiring
Other 5.0 harness
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Press the rear tilt switch to  Power seat

Rear tilt switch Power seat 1.0 or less switch
2F down
input (down) switch  Related wiring
Other 5.0 harness
Press the recliner switch to  Power seat
Recliner switch Power seat 1.0 or less switch
2G forward
input (forward) switch  Related wiring
Other 5.0 harness
Press the recliner switch to  Power seat
Recliner switch 1.0 or less
Power seat backward switch
2H input
(backward)
Other 5.0 harness
 Power seat
Signal GND Power seat switch
2I Under any condition 1.0 or less
input switch  Related wiring
harness
 Position
Position memory
Signal GND
2J memory Under any condition 1.0 or less switch
input
harness
 Position
Position Press the set switch 1.0 or less memory
2K Set switch input memory switch
switch Other 5.0  Related wiring
harness
 Position
Position Press the memory switch 1 1.0 or less memory
Memory switch
2L memory switch
1 input
harness
 Position
Memory switch
2M memory switch
2 input
harness
 Position
Memory switch
2N memory switch
3 input
harness
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While slide motor is  Slide motor

Slide motor B+
3A Slide motor moving to forward
output (forward)  Related wiring
Other 1.0 or less harness
Slide motor While slide motor is  Slide motor
B+
3B output Slide motor moving to backward  Related wiring
(backward) Other 1.0 or less harness
While front tilt motor is  Front tilt
Front tilt motor Front tilt B+ motor
3C moving to up
output (up) motor  Related wiring
While front tilt motor is  Front tilt
Front tilt motor Front tilt B+ motor
3D moving to down
output (down) motor  Related wiring
While rear tilt motor is  Rear tilt motor
Rear tilt motor B+
3E Rear tilt motor moving to up  Related wiring
output (up)
While rear tilt motor is  Rear tilt motor
Rear tilt motor B+
3F Rear tilt motor moving to down  Related wiring
output (down)
While recliner motor is  Recliner
Recliner motor B+ motor
3G Recliner motor moving to forward
output (forward)  Related wiring
While recliner motor is  Recliner
Recliner motor B+ motor
3H output Recliner motor moving to backward
(backward)  Related wiring
Slide motor moving B+  Slide motor
Slide motor
3I Slide motor  Related wiring
power supply Slide motor stopped 1.0 or less harnesses
High
Measure the waveform output: 4.8
while driving motor or more
operation using the  Slide motor
Slide motor Low
3J Slide motor oscilloscope.  Related wiring
pulse output: 1.0
or less harnesses
1.0 or less
Slide motor stopped
or 5.0
Front tilt motor moving B+  Front tilt
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motor
Front tilt motor Front tilt
3K Front tilt motor stopped 1.0 or less  Related wiring
power supply motor
harnesses
High
while driving motor or more  Front tilt
Front tilt motor Front tilt operation using the Low motor
3L oscilloscope.
pulse motor output: 1.0  Related wiring
or less harnesses
1.0 or less
Front tilt motor stopped
or 5.0
Rear tilt motor moving B+  Rear tilt motor
Rear tilt motor
3M Rear tilt motor  Related wiring
power supply Rear tilt motor stopped 1.0 or less harnesses
High
while driving motor or more
operation using the  Rear tilt motor
Rear tilt motor Low
3N Rear tilt motor oscilloscope.  Related wiring
pulse output: 1.0
or less harnesses
1.0 or less
Rear tilt motor stopped
or 5.0
Recliner motor moving B+  Recliner
Recliner motor motor
3O Recliner motor
power supply  Related wiring
Recliner motor stopped 1.0 or less
harnesses
High
while driving motor or more  Recliner
Recliner motor operation using the Low motor
3P Recliner motor oscilloscope.
pulse output: 1.0  Related wiring
or less harnesses
1.0 or less
Recliner motor stopped
or 5.0
POSITION MEMORY SWITCH INSPECTION

1. Disconnect the position memory switch connector.
2. Inspect for continuity between the power seat switch connector terminals.
 If not as specified, replace the position memory switch.
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Fig. 27: Position Memory Switch Continuity Chart

Fig. 28: Position Memory Switch - Circuit Diagram

SEAT WARMER UNIT INSPECTION

SEAT CUSHION
1. Remove the front seat. (See FRONT SEAT REMOVAL/INSTALLATION.)

2. Remove the seat cushion trim. (See FRONT SEAT DISASSEMBLY/ASSEMBLY.)
3. While inspecting for continuity between the connector terminals A and B, use a dryer to warm the
thermostat of the seat warmer unit on seat cushion.
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Fig. 29: Checking Thermostat With Air Gun

4. When the ohmmeter indicates that there is no continuity, turn off the dryer, then use a thermometer to
measure the temperature of the thermostat.
5. Verify that the temperature is approx. 43°C {109°F}.
Fig. 30: Identifying Thermostat Connector

6. Using an ohmmeter, verify that there is continuity between the seat warmer unit connector terminals
when temperature drops to approx. 34°C {93°F}.
 If not as indicated in the table, replace the seat warmer unit.
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Fig. 31: Thermostat Continuity Chart

Fig. 32: Thermostat - Circuit Diagram

SEAT BACK
1. Remove the front seat. (See FRONT SEAT REMOVAL/INSTALLATION.)

2. Remove the seat back trim. (See FRONT SEAT DISASSEMBLY/ASSEMBLY.)
3. Verify that the continuity between terminals A and B is as indicated in the table.
 If not as indicated in the table, replace the seat warmer unit.

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Fig. 34: Seat Back - Circuit Diagram

SECOND-ROW SEAT REMOVAL/INSTALLATION

1. Remove the covers.
Fig. 35: Identifying Second-Row Seat, Bolt With Cover & Torque Specifications
2. Remove the bolts, then remove the second-row seat.

Fig. 36: Identifying Second-Row Seat, Bolt With Cover & Torque Specifications
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SECOND-ROW SEAT DISASSEMBLY/ASSEMBLY

LH

Fig. 37: Exploded View Of Second-Row Seat (LH) & Torque Specifications
RH
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Fig. 38: Exploded View Of Second-Row Seat (RH) & Torque Specifications
LONG SLIDER REMOVAL/INSTALLATION

2. Remove the second-row seat. (See SECOND-ROW SEAT REMOVAL/INSTALLATION.)
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Fig. 39: Identifying Edge Cover And Long Slider Cover


4. Third-row seat (See THIRD-ROW SEAT REMOVAL/INSTALLATION.)
5. Set the floor covering out of the way.
Fig. 40: Identifying Long Slider, Bolt & Torque Specifications

THIRD-ROW SEAT REMOVAL/INSTALLATION

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Fig. 41: Identifying Third-Row Seat, Bolt & Torque Specifications

THIRD-ROW SEAT DISASSEMBLY/ASSEMBLY

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Fig. 42: Exploded View Of Third-Row Seat & Torque Specifications

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2008 ENGINE Starting System (MZI-3.7) - Mazda CX-9
2008 ENGINE
Starting System (MZI-3.7) - Mazda CX-9
STARTING SYSTEM LOCATION INDEX [MZI-3.7]
Fig. 1: Identifying Starter

STARTER REMOVAL/INSTALLATION [MZI-3.7]
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 starter 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.
2. Position the selector cable out of the way.
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Fig. 2: Identifying Wiring Harness Bracket, Starter, Connector & Torque Specifications
STARTER INSPECTION [MZI-3.7]


2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
 If the starter does not operate, inspect the following:
 Remove the starter, and inspect the starter unit.
 Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch.
NO-LOAD TEST

2. Connect the starter, battery, and a tester as shown in the figure.
3. Operate the starter and verify that it rotates smoothly.
 If the starter does not rotate smoothly, inspect the starter unit.
4. Measure the voltage and current while the starter is operating.
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 If not within the specification, replace the starter.
Starter no-load test voltage 11 V
Starter no-load test current 90 A or less
Fig. 3: Connecting Starter, Battery, And A Tester

MAGNETIC SWITCH OPERATION INSPECTION
Pull-out test
NOTE:  Depending on the battery charge condition, the starter motor pinion may
rotate while in an extended state. This is due to current flowing to the
starter motor through the pull-in coil to turn the starter motor, and does
not indicate an abnormality.
1. Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S
and the starter body is grounded.
 If the starter motor pinion is not extended, repair or replace the starter.
Fig. 4: Checking Battery Positive Voltage Terminal S And Starter Body

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Return test
1. Disconnect the motor wire from terminal M.

2. Connect battery positive voltage to terminal M and ground the starter body.
3. Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released.
 If it does not return, repair or replace the starter.
Fig. 5: Connecting Battery Positive Voltage To Terminal M And Ground Starter Body
PINION GAP INSPECTION
1. Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body
grounded.
Fig. 6: Pulling Drive Pinion With Battery Positive Voltage Connected To Terminal S And Starter
Body Grounded
CAUTION:  Applying power for more than 10 s can damage the starter. Do
not apply power for more than 10 s.
2. Measure the pinion gap while the drive pinion is extended.

 If not as specified, adjust with an adjustment washer (between drive housing front cover and
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magnetic switch).
Starter pinion gap 0 mm {0 in}
Fig. 7: Measuring Pinion Gap

STARTER INNER PARTS INSPECTION
Armature
1. Verify that there is no continuity between the commutator and the core at each segment using a tester.
 If there is continuity, replace the armature.
Fig. 8: Checking Continuity Between Commutator And Core

2. Verify that there is no continuity between the commutator and the shaft using a tester.
 If there is continuity, replace the armature.
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Fig. 9: Checking Continuity Between Commutator And Shaft

3. Place the armature on V-blocks, and measure the runout using a dial indicator.
Starter armature runout
0.1 mm {0.004 in} max.
Fig. 10: Measuring Runout With Dial Indicator

4. Measure the commutator diameter.

 If not within the minimum specification, replace the armature.
Starter commutator diameter
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Fig. 11: Measuring Commutator Diameter

5. Measure the segment groove depth of the commutator.

 If not within the minimum specification, undercut the grooves to the standard depth.
Segment groove depth of starter commutator
Fig. 12: Measuring Segment Groove Depth Of Commutator

Magnetic switch
1. Inspect for continuity between terminals S and M using a tester.

 If there is no continuity, replace the magnetic switch.
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Fig. 13: Checking Continuity Between Terminals S And M

2. Inspect for continuity between terminal S and the body using a tester.
 If there is no continuity, replace the magnetic switch.
Fig. 14: Checking Continuity Between Terminal S And Body With Tester
3. Verify that there is no continuity between terminals M and B using a tester.

 If there is continuity, replace the magnetic switch.
Fig. 15: Checking Continuity Between Terminals M And B With Tester

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Brush and brush holder
1. Verify that there is no continuity between each insulated brush and plate using a tester.
 If there is continuity, replace the brush holder.
Fig. 16: Checking Continuity Between Brush And Plate With Tester
2. Measure the brush length.

 If any brush is worn almost to or beyond the minimum specification, replace all of the brushes.
Starter brush length
Fig. 17: Identifying Brush Length

3. Measure the brush spring force using a spring balance.

 If not within the minimum specification, replace the brush and brush holder component.
Starter brush spring force

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Minimum: 2.75 N {0.28 kgf, 0.62 lbf}
Fig. 18: Measuring Brush Spring Force With Spring Balance

STARTER DISASSEMBLY/ASSEMBLY [MZI-3.7]

Fig. 19: Identifying Starter Components & Torque Specifications

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2008 STEERING Technical Data (Steering) - Mazda CX-9
2008 STEERING
Technical Data (Steering) - Mazda CX-9
STEERING TECHNICAL DATA

STEERING TECHNICAL DATA
Item Specification
Power steering fluid type ATF-MIII, M-V or Dexron®II
Power steering fluid capacity (approximate
1.27 L {1.34 US qt, 1.11 Imp qt}
quantity)
Oil pump fluid pressure 11.3-11.8 MPa {116-120 kgf/cm2 , 1639-1711 psi}
Gear housing fluid pressure 11.3-11.8 MPa {116-120 kgf/cm2 , 1639-1711 psi}
Steering wheel play 0-30 mm {0-1.18 in}
Steering wheel effort 7.8 N.m {80 kgf.cm, 58 in.lbf} max.
Steering shaft length 211.6 mm {8.331 in}
Near point A: 0.15 mm {0.006 in} max.
Steering rack runout
Near point B: 0.20 mm {0.008 in} max.
0.4-2.7 N.m {4.1-27.5 kgf.cm, 3.6-23.8 in.lbf}
Tie-rod end rotational torque
0.1-4.0 N.m {1.1-40 kgf.cm, 0.89-35 in.lbf}
Tie-rod swing torque
Center of rack ± 90°: 1.0-1.6 N.m {1-16 kgf.cm, 8.9-14
in.lbf}
[Pull scale reading: 9-13 N {1.0-1.3 kgf, 2.1-2.9 lbf}]
Pinion shaft rotation torque
Except center of rack ± 90°: Less than 1.68 N.m {17.1
kgf.cm, 14.8 in.lbf}
[Pull scale reading: Less than 13.8 N {1.4 kgf, 3.1 lbf}]
Microsoft
2008 BODY & ACCESSORIES Sunroof - Mazda CX-9
Sunroof - Mazda CX-9
SUNROOF LOCATION INDEX
Fig. 1: Identifying Sunroof Components Location
DEFLECTOR REMOVAL/INSTALLATION
1. Fully open the glass panel.
2. Press the spring in the direction shown by the arrow and remove it from the hook.
3. Remove the deflector.
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Fig. 2: Identifying Deflector Hook & Spring
GLASS PANEL REMOVAL/INSTALLATION

1. Fully close the glass panel.
2. Fully open the sunshade.
3. Remove the screws, and then remove the glass panel.
Fig. 3: Identifying Glass Panel With Screws
4. Peel the weatherstrip off the glass panel.

6. Adjust the glass panel. (See GLASS PANEL ADJUSTMENT.)
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Fig. 4: Identifying Weatherstrip & Glass Panel
GLASS PANEL ADJUSTMENT

1. Fully close the glass panel.
2. Measure the gap and height between the glass panel and body.
3. If not as specified, loosen the glass panel installation screws and reposition the glass panel.
Clearance
a:0-2.7 mm {0-0.106 in}
b: 0 mm {0 in}
4. Tighten the installation screws.
Fig. 5: Measuring Gap And Height Between Glass Panel & Body
5. Insert a plastic card between the weatherstrip and the body of the vehicle. Verify that the sunroof is shut
tightly (there is resistance when the credit card is moved).
 If the sunroof is not shut tightly, readjust by performing Steps 3 and 4.
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Fig. 6: Inserting Plastic Card Between Weatherstrip & Body Of Vehicle
SUNROOF UNIT REMOVAL/INSTALLATION
CAUTION:  If the sunshade is forced close while the sunroof is open, the
sunshade could be damaged.

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3. Remove the sunroof seaming welt.
4. Remove the headliner. (See HEADLINER REMOVAL/INSTALLATION .)
5. Remove the glass panel (See GLASS PANEL REMOVAL/INSTALLATION.)
6. Disconnect the front and rear drain hose from the sunroof frame.
8. Remove the nuts, and then remove the sunroof unit.
10. Adjust the glass panel. (See GLASS PANEL ADJUSTMENT.)
Fig. 7: Identifying Sunroof Unit Nuts, Bolts & Torque Specifications
SUNROOF UNIT DISASSEMBLY/ASSEMBLY
NOTE:  If the guide or sunroof motor is removed, the glass panel will not be
positioned properly after the re-installation. To ensure proper positioning
of the glass panel, place alignment marks on the guide pin and frame
before removing the guide or sunroof motor.

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Fig. 8: Identifying Sunroof Unit Components
SUNROOF MOTOR ASSEMBLY NOTE
NOTE:  If the guide or sunroof motor is removed, the sunroof motor initial position
setting has to be performed. After installing the sunroof unit, perform the
initial position setting using the following procedure.
1. The initialization mode starts after approx. 13 s from when the tilt up switch has been pressed and held.
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The glass stops after it has moved approx. 30 mm {1.2 in} towards the closed position.
NOTE:  Only the tilt up switch is available during the initialization mode.
 The initialization may finish at the first inching operation depending
on the glass position when the motor is installed.
 If the glass position is between the closed and semi-tilt positions
when the motor is removed, the glass moves in the tilt up direction
(to the full tilt position stored in the motor). However, if the tilt up
switch is pressed and held, the initialization mode starts.
2. When the tilt up switch is pressed again, the glass continues to move approx. 30 mm {1.2 in} and stops.
3. Repeat this procedure several times so that the glass moves to the fully closed, full tilt (normal operation
position), and full tilt (mechanical stopper position) positions.
4. After the glass is moved to the full tilt position (mechanical stopper position), it returns to the tilt down
direction slightly and the initialization is completed.
REAR DRIP ASSEMBLY NOTE
NOTE:  If the rear drip is removed, butyl seal must be applied when re-installing.
1. Apply a 6.0-8.0 mm {0.24-0.31 in} wide line of butyl seal to the area shown in the figure.
Fig. 9: Identifying Applying Area Of Wide Line To Butyl Seal
GUIDE DISASSEMBLY NOTE
1. Place an alignment mark on the guide pin and flame.
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Fig. 10: Identifying Alignment Mark On Guide Pin & Flame
2. Slide the guide to the rear of the sunroof frame, and remove the guide and decoration link as a single unit.
Fig. 11: Identifying Guide
GUIDE ASSEMBLY NOTE
1. Move the pin to the position shown in the figure.
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Fig. 12: Identifying Guide Assembly Mark
DECORATION LINK ASSEMBLY NOTE
1. Set the guide pin to the decoration link.
Fig. 13: Setting Guide Pin To Decoration Link
FRONT DRAIN HOSE REMOVAL

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4. Disconnect the front drain hose from the sunroof frame.
5. Remove the front drain hose from the clips.
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6. Pull the front drain hose into the room side.

7. Remove the front drain hose.
Fig. 14: Identifying Front Drain Hose Clips
FRONT DRAIN HOSE INSTALLATION
CAUTION:  If the front drain hose is pinched or bent anywhere, the water in the
hose may not discharge and enter the inside of the vehicle. During
and after installation of the trims and the headliner, always make sure
there is no interference with the front drain hose. Fix any problem if
found.
1. Apply soapy water to the front drain hose inserting area.

2. Insert one end (the wider end) of the front drain hose into the sunroof frame.
3. Install the front drain hose to the clips, parallel to the pillar and free of slack.
4. Insert the front drain hose joint into the hinge pillar inner hole.
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6. Install the seaming welt.
REAR DRAIN HOSE REMOVAL

4. Disconnect the rear drain hose from the sunroof frame.
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5. Remove the rear drain hose from the clips.
Fig. 15: Identifying Rear Drain Hose Clips
6. Pull the rear drain hose into the room side.

7. Remove the rear drain hose.
REAR DRAIN HOSE INSTALLATION
CAUTION:  If the rear drain hose is pinched or bent anywhere, the water in the
hose may not discharge and enter the inside of the vehicle. During
and after installation of the trims and the headliner, always make sure
there is no interference with the rear drain hose. Fix any problem if
found.
1. Apply soapy water to the rear drain hose inserting area.

2. Insert one end (the wider side) of the rear drain hose into the sunroof frame.
3. Install the rear drain hose to the clips parallel to the pillar and free of slack.
4. Insert the rear drain hose joint into the rear pillar inner hole.
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18. Front seat belt upper anchor installation bolt (Driver side) (See FRONT SEAT BELT
20. Front seat belt lower anchor installation bolt. (See FRONT SEAT BELT
6. Install the seaming welt.
SUNROOF MOTOR REMOVAL/INSTALLATION

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3. Remove the sunroof seaming welt.
5. Disconnect the sunroof motor connector.
6. Remove the screws, and then remove the sunroof motor.
NOTE:  If the glass panel or the sunroof motor is moved with the sunroof
motor removed, initial position setting of the sunroof motor will be
required. Perform initial position setting referring to the SUNROOF
MOTOR ASSEMBLY NOTE. (See SUNROOF UNIT
DISASSEMBLY/ASSEMBLY.)
Fig. 16: Identifying Sunroof Motor & Connector
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SUNROOF MOTOR INSPECTION

1. Measure the voltage at each terminal (other than terminal G).
 If not as specified, inspect the parts listed under "Inspection item" and the related wiring harnesses.

3. If the parts and wiring harnesses are normal but the system still does not work properly, replace the
sunroof motor.
Fig. 17: Identifying Sunroof Motor Connector Terminals

Connected Voltage
Terminal Signal Test condition Inspection item
to (V)
Sunroof is fully opening. B+  Sunroof
switch
Sunroof
A Slide open  Related
switch 1.0 or
Other wiring
less
harnesses
Sunroof is closing/tilting down. B+  Sunroof
switch
Slide close/tilt Sunroof
B  Related
down switch 1.0 or
Other wiring
less
harnesses
Sunroof is tilting up. B+  Sunroof
switch
Sunroof
C Tilt up  Related
switch 1.0 or
Other wiring
less
harnesses
E IG1 B+
ON position.  METER 10A
METER 10A fuse
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fuse  Related
1.0 or
Other wiring
less
harnesses
Instrument
cluster
Instrument
F Vehicle speed Pulse signal -  Related
cluster
wiring
harnesses
G GND GND Under any condition
less harnesses
Because this terminal is for  BCM
communication, good/no good  Related
H Communication BCM -
judgment by terminal voltage is wiring
 SUNROOF
15A fuse
SUNROOF
J Power supply Under any condition B+  Related
15A fuse
wiring
harnesses
SUNROOF SWITCH REMOVAL/INSTALLATION
NOTE:  The sunroof switch is together with the front map light.

2. Remove the map light from the headliner. (See FRONT MAP LIGHT
SUNROOF SWITCH INSPECTION

1. Verify that the continuity between the sunroof switch terminals is as indicated in the table.
 If not as specified, replace the sunroof switch.
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Fig. 19: Checking Continuity Between Sunroof Switch Terminals
Microsoft
2008 SUSPENSION Technical Data (Suspension) - Mazda CX-9
2008 SUSPENSION
Technical Data (Suspension) - Mazda CX-9
SUSPENSION TECHNICAL DATA
Front wheel alignment [2WD] (Unloaded)*1
FRONT WHEEL ALIGNMENT SPECIFICATION - (2WD) (UNLOADED)

Fuel gauge indication
Item
Empty 1/4 1/2 3/4 Full
Inner 38°
Maximum steering angle [Tolerance ± 3°]
Outer 32°
[Tolerance ± 4 {± 0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°18' ± 0°32'
Caster angle(1)[Tolerance ± 1 °] 3°01' 3°02' 3°03' 3°04'
Camber angle(1)[Tolerance ± 1 °] -0°19' -0°20' -0°21'
Steering axis inclination (Reference value) 11°31' 11°32' 11°33' 11°34' 11°35'
*1 : Engine coolant and engine oil are at specified level. Jack and tools are in designated position.
(1) Difference between left and right must not exceed 1°30'.
Front wheel alignment [AWD] (Unloaded)*1
FRONT WHEEL ALIGNMENT SPECIFICATION - (AWD) (UNLOADED)

Item
Inner 38°
Maximum steering angle [Tolerance ± 3°]
Outer 32°
[Tolerance ± 4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°18' ± 0°32'
Caster angle(1) [Tolerance ± 1 °] 3°02' 3°03' 3°04' 3°05'
Camber angle(1) [Tolerance ± 1 °] -0°19' -0°20' -0°21'
Steering axis inclination (Reference value) 11°31' 11°32' 11°33' 11°34' 11°35'
Rear wheel alignment [2WD] (Unloaded)*1
REAR WHEEL ALIGNMENT SPECIFICATION - (2WD) (UNLOADED)

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Item Empty 1/4 1/2 3/4 Full

[Tolerance ± 4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°09' ± 0°18'
Camber angle(1) (Reference value) [Tolerance ± 1°] -0°26' -0°27' -0°29' -0°30' -0°32'
Thrust angle (Reference value) [Tolerance ± 0°48'] 0°
Rear wheel alignment [AWD] (Unloaded)*1
REAR WHEEL ALIGNMENT SPECIFICATION - (AWD) (UNLOADED)

Item
[Tolerance ± 4 {±0.16}] (mm {in}) 2 {0.08}
Total toe-in
(degree) 0°09' ± 0°18'
(1)
Camber angle (Reference value) [Tolerance ± 1°] -0°27' -0°28' -0°30' -0°31' -0°33'
Thrust angle (Reference value) [Tolerance ± 0°48'] 0°
Suspension
SUSPENSION SPECIFICATION
Item Specification
Front lower arm rotational torque 2.62 N.m {26.7 kgf.cm, 23.1 in.lbf} max.
Front stabilizer control link ball joint starting torque 0.2-2.0 N.m {3-20 kgf.cm, 2-17 in.lbf}
Rear stabilizer control link ball joint starting torque 0.2-2.0 N.m {3-20 kgf.cm, 2-17 in.lbf}
Standard tire
TIRE SPECIFICATION
Item Specification
Size P245/60R18 104H P245/50R20 102V
Air pressure Front
250 {36} 230 {34}
Tire (kPa {psi}) Rear
Remaining
(mm {in}) 1.6 {0.07}
treed
Size 18x7 1/2J 20x7 1/2J
Wheel Material Aluminum alloy
Wheel offset (mm {in}) 45 {1.8}
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Wheel pitch
circle (mm {in}) 114.3 {4.5}
diameter
Wheel and tire Lateral
2.0 {0.08}
runout direction
Radial
(mm {in}) 1.5 {0.06}
direction
Adhesive-type*1 : 10 {0.35} Adhesive-type*1 : 6 {0.21}
Standard max. max.
tire *2 *2
Knock-type : 6 {0.21} max. Knock-type : 4 {0.14} max.
Wheel and tire *1 : Total weight exceeds 160 g {5.65 oz} .
(g {oz})
imbalance *2 : One balance weight: 60 g {2.12 oz} max . If the total
weight exceeds 100 g {3.53 oz} on one side, rebalance after
moving the tire around on the rim. Do not use three or more
balance weights.
(N.m
Wheel nut tightening
{kgf.m, 107.8-147.0 {11.0-14.9, 79.6-108.4}
torque
ft.bf})
Temporary spare tire
TIRE SPECIFICATION
Item Specification
Size T155/90D 18 195/80R17 99M
Tire Air pressure (kPa {psi}) 420 {60} 250 {36}
Remaining treed (mm {in}) 1.6 {0.07}
Size 18x4T 17x5 1/2J
Material Steel
Temporary spare Wheel Wheel offset (mm {in}) 40 {1.57} 45 {1.8}
tire Wheel pitch circle
(mm {in}) 114.3 {4.5}
diameter
Wheel and tire runout Lateral direction 2.0 {0.08}
(mm {in}) Radial direction 1.5 {0.06}
(N.m {kgf.m, 107.8-147.0 {11.0-14.9, 79.6-
Wheel nut tightening torque
ft.bf}) 108.4}
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2008 SUSPENSION On-Board Diagnostic (Suspension) - Mazda CX-9
2008 SUSPENSION
On-Board Diagnostic (Suspension) - Mazda CX-9
TIRE PRESSURE MONITORING SYSTEM (TPMS) WIRING DIAGRAM

WITH ADVANCED KEYLESS SYSTEM
Fig. 1: Tire Pressure Monitoring System (TPMS) - Wiring Diagram (With Advanced Keyless System)
WITH KEYLESS ENTRY SYSTEM
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Fig. 2: Tire Pressure Monitoring System (TPMS) - Wiring Diagram (With Keyless Entry System)
TIRE PRESSURE MONITORING SYSTEM (TPMS) ON-BOARD DIAGNOSIS

ON-BOARD DIAGNOSTIC (OBD) TEST DESCRIPTION
 The OBD test inspects the integrity and function of the TPMS and outputs the results when requested by
the specific tests.
 On-board diagnostic test also:
 Provides a quick inspection of the TPMS usually performed at the start of each diagnostic
procedure.
 Provides verification after repairs to ensure that no other faults occurred during service.
 The OBD test is divided into 3 tests:

 Read/clear diagnostic results, PID monitor and active command mode.
Read/clear diagnostic results
 This function allows you to read or clear DTCs in the instrument cluster memory.
PID/Data monitor and record
 This function allows you to access certain data values, input signals, calculated values, and system status
information.
Active command modes
 This function allows you to control devices through the M-MDS.

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READING DTCS PROCEDURE


3. Select "IC".

2. Select "IC".


inspection.
4. After completion of repairs, clear all DTCs stored in the instrument cluster. (See DTC TABLE
[INSTRUMENT CLUSTER] .)
CLEARING DTCS PROCEDURES


3. Select "IC".

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2. Select "IC".


3. Select "IC".

2. Select "IC".
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ACTIVE COMMAND MODES PROCEDURE

3. Select "IC".

2. Select "IC".
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3. Select the active command modes from the PID table.

4. Perform the active command modes, inspect the operations for each parts.
 If the operation of output parts cannot be verified after the active command mode inspection is
performed, this could indicate the possibility of an open or short circuit, sticking, or operation
malfunction in the output parts.
FREEZE FRAME PID DATA ACCESS PROCEDURE

 This function is available for only the IDS (laptop PC)
1. Select the "Body" tab.

2. Select "TPMS Functions".

3. Select "Freeze Frame Data".
DTC TABLE
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DTC CHART
DTC
M- Description Page
MDS
(See DTC B1342 [INSTRUMENT
B1342 Instrument cluster internal malfunction
CLUSTER] .)
B2143 ID registration failure (See DTC B2143.)
(See DTC B2477 [INSTRUMENT
B2477 Instrument cluster configuration not performed
CLUSTER] .)
(See DTC B2868, B2869, B2870,
B2868 Wheel unit No.1 internal malfunction
B2871.)
(See DTC B2868, B2869, B2870,
B2871.)
(See DTC B2868, B2869, B2870,
B2871.)
(See DTC B2868, B2869, B2870,
B2871.)
Communication failure between instrument cluster and
U0127 (See DTC U0127.)
keyless receiver
(See DTC U2616, U2617, U2618,
U2616 Wheel unit No.1 (No response)
U2619.)
(See DTC U2616, U2617, U2618,
U2619.)
(See DTC U2616, U2617, U2618,
U2619.)
(See DTC U2616, U2617, U2618,
U2619.)

PID Name (Definition) Unit/Condition Condition/Specification Action
AI_WU1_ID
AI_WU2_ID  Replace the wheel
Indicates the wheel unit ID code.
AI_WU3_ID unit.
- (During wheel unit ID
AI_WU4_ID  Perform the wheel
registration.)
(Wheel unit ID code unit ID registration.
(during ID registration))
AI_WU1_P  Adjust tire pressure.
AI_WU2_P
AI_WU3_P Indicates the tire pressure. (During  Replace the wheel
Pa, psi unit.
AI_WU4_P ID registration.)
(Tire pressure value  Perform the wheel
(during ID registration)) unit ID registration.
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FFD1_WU1_P
FFD1_WU2_P
FFD1_WU3_P
Indicates the tire pressure. (Freeze
FFD1_WU4_P Pa, psi Adjust tire pressure.
frame PID data 1)
(Tire pressure value
(freeze frame PID data
1))
FFD2_WU1_P
FFD2_WU2_P
FFD2_WU3_P
Indicates the tire pressure. (Freeze
FFD2_WU4_P Pa, psi Adjust tire pressure.
frame PID data 2)
(Tire pressure value
2))
FFD1_WU1_T
FFD1_WU2_T
FFD1_WU3_T
Indicates the internal tire air
FFD1_WU4_T
°C, °F temperature. (Freeze frame PID Adjust tire pressure.
(Internal tire air
data 1)
temperature value
1))
FFD2_WU1_T
FFD2_WU2_T
FFD2_WU3_T
FFD2_WU4_T
°C, °F temperature. (Freeze frame PID Adjust tire pressure.
(Internal tire air
data 2)
temperature value
2))
FFD1_MLG
(Wheel unit mileage Indicates the mileage. (Freeze
m, mi (ft) Adjust tire pressure.
value (freeze frame PID frame PID data 1)
data 1))
FFD2_MLG
(Wheel unit mileage Indicates the mileage. (Freeze
m, mi (ft) Adjust tire pressure.
value (freeze frame PID frame PID data 2)
data 2))
FFD1_SPD
(Wheel unit speed value Indicates the speed. (Freeze frame
KPH, MPH Adjust tire pressure.
(freeze frame PID data PID data 1)
1))
FFD2_SPD
(Wheel unit speed value Indicates the speed. (Freeze frame
KPH, MPH Adjust tire pressure.
(freeze frame PID data PID data 2)
2))
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IC_DTC_CNT
Perform the DTC
(Number of continuous - Indicates number of DTC
inspection.
DTCs)
ID_LAST(1)  Replace the wheel
(Last received tire Indicates the last ID that is unit.
-
transmitter ID code transmitted from the wheel unit.  Perform the
value) configuration.
ID_WU1(1)
ID_WU2(1)  Replace the wheel
ID_WU3(1) -
Indicates the registered ID that is unit.
ID_WU4(1) transmitted from the wheel unit.  Perform the wheel
(Registered wheel unit unit ID registration.
ID code)
WU1_P(1)
WU2_P(1) Indicates the tire pressure. (See  Adjust tire pressure.
WU3_P(1) Pa, psi SUSPENSION TECHNICAL  Replace the wheel
WU4_P(1) DATA .) unit.
(Tire pressure value)
WU1_T(1)
WU2_T(1)
WU3_T(1) °C, °F
Replace the wheel unit.
WU4_T(1) temperature.
(Internal tire air
temperature value)
(1) Data transmission from the wheel unit occurs when the vehicle speed is 25 km/h {15.5 mph} or
more . Due to this, the current air pressure and temperature data can only be displayed after the
vehicle is driven at 25 km/h {15.5 mph} or more . Also, the ID_LAST, and tire pressure and internal
tire air temperature data are erased when the instrument cluster connector and the battery terminal are
disconnected. If the instrument cluster is replaced or the battery terminals are disconnected, drive the
vehicle at 25 km/h {15.5 mph} or more and display the tire pressure PID after the data transmission.
ACTIVE COMMAND MODES TABLE
ACTIVE COMMAND MODES CHART

Command Name Definition Operation Note
IDR_MODE Wheel unit ID registration mode OFF/ON Ignition switch at ON
MALFUNCTIONING WHEEL UNIT IDENTIFICATION
NOTE:  The tire pressure monitoring system (TPMS) does not identify the location
of the malfunctioning wheel unit on the vehicle (RF, LF, LR, RR). The TPMS
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identifies each wheel unit as No.1, No.2, No.3 and No.4. In order to identify
the location of the wheel unit, perform the following procedure.
1. Adjust the air pressure as follows:

 RF: 220 kPa {2.2 kgf/cm2 , 32 psi}
 LF: 240 kPa {2.4 kgf/cm2 , 35 psi}
 LR: 260 kPa {2.6 kgf/cm2 , 38 psi}
RR: 280 kPa {2.8 kgf/cm2 , 40 psi}


5. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 2 min or more
6. Select the following PIDs using the M-MDS, and monitor them.
 WU1_P
 WU2_P
 WU3_P
 WU4_P
7. Determine which wheel unit identification code matches which wheel and tire by comparing the PID
monitor values with the air pressure values set in Step 1.
8. Select the ID_LAST PID using the M-MDS, and take a note of four displayed identification codes.
9. Inspect the DTCs using the M-MDS.
Fig. 8: Wheel Unit Identification Code Chart

DTC B2143
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DTC B2143  ID registration failure
DETECTION CONDITION  Two or more codes are overlapping.

POSSIBLE CAUSE  ID registration procedure has not been performed properly.

VERIFY THE PROGRAMMED ID



Register the wheel unit ID, then go to the next
Yes step. (See WHEEL UNIT ID
M-MDS:
REGISTRATION .)
1  ID_WU1
 ID_WU2
 ID_WU3
 ID_WU4

position. No Go to the next step.
 Is the same code in the output ID?
COMPLETED  Repeat the inspection from Step 1.
Clear the DTC from the memory.


(See TIRE PRESSURE If the malfunction recurs, replace the instrument
MONITORING SYSTEM Yes cluster and/or wheel unit.
2
(TPMS) ONBOARD DIAGNOSIS.) (See INSTRUMENT CLUSTER
 Drive the vehicle at a speed of 25
(See WHEEL UNIT
km/h {15.5 mph} or more for 10
min or more.
VERIFY AFTER REPAIR Go to the applicable DTC inspection. (See TIRE
PROCEDURE Yes PRESSURE MONITORING SYSTEM
3 (TPMS) ON-BOARD DIAGNOSIS.)
 Are there any other DTCs present? No DTC troubleshooting completed.
DTC B2868, B2869, B2870, B2871

DTC B2868, B2869, B2870, B2871 DETECTION CONDITION AND POSSIBLE CAUSE
DTC B2868 Wheel unit No.1 (internal malfunction)
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DETECTION CONDITION  The instrument cluster receives error signals from the wheel unit.
POSSIBLE CAUSE  Internal malfunction of wheel unit
DTC B2868, B2869, B2870, B2871 DIAGNOSTIC PROCEDURE

IDENTIFY MALFUNCTIONING WHEEL  Identify the malfunctioning wheel unit.
UNIT  Replace and register the wheel unit. (See
1 WHEEL UNIT ID
 (See MALFUNCTIONING WHEEL REGISTRATION .)
UNIT IDENTIFICATION.)  Go to the next step.
COMPLETED
Yes Go to Step 1.
Clear the DTC from the memory. (See

TIRE PRESSURE MONITORING
2 SYSTEM (TPMS) ONBOARD
DIAGNOSIS.)
 Drive the vehicle at a speed of 25 km/h
{15.5 mph} or more for 10 min or No Go to the next step.
more.

VERIFY AFTER REPAIR PROCEDURE Yes TIRE PRESSURE MONITORING
3 SYSTEM (TPMS) ON-BOARD
 Are there any other DTCs present? DIAGNOSIS.)
DTC U0127
DTC U0127 DETECTION CONDITION AND POSSIBLE CAUSE
DTC U0127  Communication failure between instrument cluster and keyless

receiver
DETECTION  The instrument cluster cannot receive signal from the keyless CM or
CONDITION keyless receiver.
With advanced keyless system
 Open or short circuit in the wiring harness between the keyless CM

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terminal 3Q and the instrument cluster terminal 1N.

 Keyless control module malfunction.
 Instrument cluster malfunction.
POSSIBLE CAUSE With keyless entry system
 Open or short circuit in the wiring harness between the keyless receiver
terminal D and the instrument cluster terminal 1N.
 Keyless receiver malfunction.
 Instrument cluster malfunction.
WITH ADVANCED KEYLESS SYSTEM
Diagnostic procedure
DTC U0127 DIAGNOSTIC PROCEDURE

INSPECT WHEEL UNIT SIGNAL


 Disconnect keyless CM and

instrument cluster connectors.
1
 Inspect for continuity between Repair or replace the wiring harness for an open circuit
keyless CM terminal 3Q No between keyless CM terminal 3Q and instrument
(harness-side) and instrument cluster terminal 1N, then go to Step 5.
cluster terminal 1N (harness-
side).

FOR SHORT TO POWER
Repair or replace the wiring harness for a short to
 Turn the ignition switch off. Yes power between keyless CM terminal 3Q and
 Disconnect keyless CM and instrument cluster terminal 1N, then go to Step 5.
2 instrument cluster connectors.
keyless CM terminal 3Q
(harness-side) and ground. No Go to the next step.
 Is there B+?
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FOR SHORT TO GROUND


ground between keyless CM terminal 3Q and
 Disconnect keyless CM and
Yes
instrument cluster terminal 1N, then go to the next
3 instrument cluster connectors. step.
keyless CM terminal 3Q
INSPECT FOR KEYLESS CM

MALFUNCTION

Yes TABLE [IMMOBILIZER SYSTEM (KEYLESS
4 ENTRY SYSTEM)] .)
DTC inspection for the keyless
CM.
 Is any DTCs present?
COMPLETED  If the malfunction recurs, replace the instrument
cluster. (See INSTRUMENT CLUSTER

ON position and drive the
vehicle at a speed of 25 km/h  Configure the instrument cluster. (See
{15.5 mph} or more. Yes INSTRUMENT CLUSTER
5 CONFIGURATION .)
memory. (See TIRE  Register the wheel unit ID. (See WHEEL
PRESSURE MONITORING UNIT ID REGISTRATION .)
SYSTEM (TPMS) ONBOARD  Go to the next step.
DIAGNOSIS.)
VERIFY AFTER REPAIR
PROCEDURE
Go to the applicable DTC inspection. (See TIRE
Yes PRESSURE MONITORING SYSTEM (TPMS)
 Drive the vehicle at a speed of
6 ON-BOARD DIAGNOSIS.)
25 km/h {15.5 mph} or more
for 10 min or more.
 Are there any other DTCs No DTC troubleshooting completed.
present?
WITH KEYLESS ENTRY SYSTEM
Diagnostic procedure
DTC U0127 DIAGNOSTIC PROCEDURE
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
 Disconnect keyless receiver and

instrument cluster connectors.
1
 Inspect for continuity between Repair or replace the wiring harness for an open circuit
keyless receiver terminal D No between keyless receiver terminal D and instrument
(harness-side) and instrument cluster terminal 1N, then go to Step 4.
cluster terminal 1N (harness-
side).

FOR SHORT TO POWER

Yes power between keyless receiver terminal D and
 Disconnect keyless receiver and instrument cluster terminal 1N, then go to Step 4.
keyless receiver terminal D
 Is there B+?

FOR SHORT TO GROUND Repair or replace the wiring harness for a short to
ground between keyless receiver terminal D and
Yes
 Turn the ignition switch off. instrument cluster terminal 1N, then go to the next
 Disconnect keyless receiver and
step.
Replace keyless receiver, then go to the next step. (See
keyless receiver terminal D
No KEYLESS RECEIVER
(harness-side) and ground.
 If the malfunction recurs, replace the instrument

VERIFY TROUBLESHOOTING cluster. (See INSTRUMENT CLUSTER
COMPLETED REMOVAL/INSTALLATION .)
 Configure the instrument cluster. (See
Yes INSTRUMENT CLUSTER
4 memory. (See TIRE
CONFIGURATION .)
PRESSURE MONITORING
SYSTEM (TPMS) ONBOARD  Register the wheel unit ID. (See WHEEL UNIT
DIAGNOSIS.) ID REGISTRATION .)
 Turn the ignition switch to the  Go to the next step.
ON position and wait for 30 s.
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VERIFY AFTER REPAIR
PROCEDURE
Go to the applicable DTC inspection. (See TIRE
Yes PRESSURE MONITORING SYSTEM (TPMS)
 Drive the vehicle at a speed of
25 km/h {15.5 mph} or more
for 10 min or more.
 Are there any other DTCs No DTC troubleshooting completed.
present?
DTC U2616, U2617, U2618, U2619

DTC U2616, U2617, U2618, U2619 DETECTION CONDITION AND POSSIBLE CAUSE
DTC U2616 Wheel unit No.1 (No response)
DETECTION  The keyless receiver has continuously not received a signal from the
CONDITION wheel unit for a certain period.
 Wheel unit identification code is not registered in the instrument cluster.
 No signal is received from the wheel unit.
POSSIBLE CAUSE
 Wheel unit is not installed.
 Poor connection at connectors (female terminal).
DTC U2616, U2617, U2618, U2619 DIAGNOSTIC PROCEDURE

VERIFY WHEEL UNIT IS
 Install the wheel unit. (See WHEEL UNIT
INSTALLED TO EACH WHEEL
1
 Are all four wheels equipped with
No  Register the wheel unit ID. (See WHEEL
a wheel unit? UNIT ID REGISTRATION .)

INSPECT FOR DTCs

 Drive the vehicle at a speed of 25
2 km/h {15.5 mph} or more for 10 With advanced keyless system: go to the Step 4.
min or more. No
With keyless entry system: go to the Step 5.
IDENTIFY MALFUNCTIONING  Identify the malfunctioning wheel unit.

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WHEEL UNIT  Replace the wheel unit. (See WHEEL UNIT

3  (See MALFUNCTIONING
 Register the wheel unit ID. (See WHEEL
WHEEL UNIT
UNIT ID REGISTRATION .)
IDENTIFICATION.)
 Go to the Step 5.
INSPECT FOR KEYLESS CM
MALFUNCTION

Yes TABLE [IMMOBILIZER SYSTEM (KEYLESS
4 ENTRY SYSTEM)] .)
DTC inspection for the keyless
CM.
 Is any DTCs present?
COMPLETED  If the malfunction recurs, replace the
instrument cluster. (See INSTRUMENT
Clear the DTC from the memory.
 CLUSTER REMOVAL/INSTALLATION .)
(See TIRE PRESSURE  Configure the instrument cluster. (See
MONITORING SYSTEM Yes INSTRUMENT CLUSTER
5 (TPMS) ONBOARD CONFIGURATION .)
DIAGNOSIS.)  Register the wheel unit ID. (See WHEEL
 Drive the vehicle at a speed of 25 UNIT ID REGISTRATION .)
km/h {15.5 mph} or more for 10  Go to the next step.
min or more.
VERIFY AFTER REPAIR Go to the applicable DTC inspection. (See TIRE
PROCEDURE Yes PRESSURE MONITORING SYSTEM (TPMS)
 Are there any other DTCs
present? No DTC troubleshooting completed.
NOTE:  If the installed wheel unit ID number is known, verification of whether the
instrument cluster is receiving data from the wheel unit can be easily
confirmed using the following procedure:
1. Drive the vehicle at 25 km/h {15.5 mph} or more , and send data from
the wheel unit.
2. Select [ID_LAST] from the PID items, and monitor the data.
3. Verification that the instrument cluster is receiving data is possible if
the monitored ID number matches the installed wheel unit ID number.
 If the wheel unit has been newly replaced, the TPMS warning light may
flashes before the ID registration is complete, and DTC U2616, U2617,
U2618 and U2619 may be stored in the memory. In this case, re-implement
the wheel unit ID registration, and after confirming that the TPMS warning
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light is no longer flashing, erase the DTC. If the TPMS warning light does
not go out, a malfunction on any one of the wheel units may have occurred
and the ID registration will not have been correctly performed. Repeat the
diagnostic procedure from Step 1 and perform and inspection.
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2008 DRIVELINE/AXLE Transfer - Mazda CX-9
2008 DRIVELINE/AXLE
Transfer - Mazda CX-9
TRANSFER LOCATION INDEX
Fig. 1: Identifying Transfer Oil Seal And Transfer

TRANSFER SERVICE CAUTIONS

 Do not perform overhauling and other servicing such as transfer oil inspection, adjustment, and
replacement. Adjusting the oil amount leads to over-fill or under-fill, which could cause oil leakage or
seizure of the transfer while driving. In addition, internal parts for overhauling are not available.
 A maintenance-free type transfer has been adopted. If there is a malfunction with the transfer unit, replace
the transfer as a single component.
TRANSFER OIL SEAL REPLACEMENT

RIGHT SIDE

2. Remove the front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
3. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [AWD] .)
4. Using the SST , remove the deflector.
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5. Using the SST , remove the oil seal.

6. Mark the SST at position 18 mm {0.71 in} from the end.
Fig. 4: Marking SST At Position

7. Using the SST and a hammer, tap new oil seal.
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Substitution SST
 49 B032 334
8. Warm up the new deflector using a hot air blower.

9. Within 10 s after warming up the deflector, install the new deflector using the SST. Substitution SST
 49 B032 334
10. Install the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [AWD] .)
11. Install the front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
12. Install the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
13. Inspect for leakage of transfer oil.
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Fig. 6: Installing Deflector

LEFT SIDE
1. Remove the transfer. (See TRANSFER REMOVAL/INSTALLATION.)

2. Remove the oil seal using a screwdriver.

3. Install the new oil seal.

4. Install the transfer. (See TRANSFER REMOVAL/INSTALLATION.)
5. Inspect for leakage of transfer oil.
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TRANSFER REMOVAL/INSTALLATION
1. Middle pipe (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
2. Front pipe (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
3. Stabilizer control link (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
4. Tie-rod end ball joint (right side) (See FRONT CROSSMEMBER
5. Front lower arm ball joint (right side) (See FRONT CROSSMEMBER
6. Front drive shaft (right side) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
7. Joint shaft (See JOINT SHAFT REMOVAL/INSTALLATION [AWD] .)
3. Disconnect the propeller shaft from the transfer side. (See PROPELLER SHAFT
6. Warm up the engine and transaxle, inspect for oil leakage, and inspect the transfer operation.
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Fig. 9: Identifying Transfer Removing/Installing Components & Torque Specifications

TRANSFER REMOVAL NOTE
1. Disconnect the front stabilizer control link, and rotate the stabilizer to the front to secure a space from the
side.
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Fig. 10: Rotating Stabilizer To Front

2. Remove the No.1 engine mount bolt and nut.

3. Remove the transfer installation bolts.
Fig. 11: Identifying No.1 Engine Mount Bolt And Nut

4. Push the engine forward so that the front side of the transfer faces downward, then remove the transfer.
Fig. 12: Identifying Front Side Of Transfer Faces

TRANSFER INSTALLATION NOTE
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1. Push the engine forward so that the front side of the transfer faces downward, then install the transfer.
2. Install the transfer installation bolts.
Tightening torque
90-100 N.m {9.2-10.1 kgf.m, 66.4-73.7 ft.lbf}
Fig. 13: Identifying Front Side Of Transfer Faces

3. Install the No.1 engine mount bolt and nut.
Tightening torque
85.3-116.6 N.m {8.70-11.88 kgf.m, 63.0-85.9 ft.lbf}
Fig. 14: Identifying No.1 Engine Mount Bolt And Nut

4. Rotate the front stabilizer to the rear to set it in its original position.
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Fig. 15: Rotating Front Stabilizer To Rear

TRANSFER BRACKET INSTALLATION NOTE
1. Install the transfer bracket to the transfer, then temporarily tighten bolt C.
2. Temporarily tighten bolt A and B.
3. Tighten bolt A, B and G in the order of C-->A-->B.
Tightening torque
Bolt A, B, C: 42-62 N.m {4.3-6.3 kgf.m, 31-45 ft.lbf}
4. Tighten bolt D.
Tightening torque
Bolt D: 42-62 N.m {4.3-6.3 kgf.m, 31-45 ft.lbf}
Fig. 16: Identifying Transfer Bracket Bolts

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2008 SUSPENSION Wheels and Tires - Mazda CX-9
2008 SUSPENSION
Wheels and Tires - Mazda CX-9
WHEEL AND TIRE SPECIFICATION

Item Specification
Size P245/60R18 104H P245/50R20 102V
Air pressure Front
250 {36} 230 {34}
Tire (kPa {psi}) Rear
Remaining
(mm {in}) 1.6 {0.07}
treed
Size 18x7 1/2J 20x7 1/2J
Material Aluminum alloy
Wheel Wheel offset (mm {in}) 45 {1.8}
Wheel pitch
circle (mm {in}) 114.3 {4.5}
diameter
Wheel and tire Lateral
2.0 {0.08}
Standard runout direction
tire Radial
(mm {in}) 1.5 {0.06}
direction
Adhesive-type*1 : 10 {0.35} Adhesive-type*1 : 6 {0.21}
max. max.
*2 *2
Knock-type : 6 {0.21} max. Knock-type : 4 {0.14} max.
Wheel and tire *1 : Total weight exceeds 160 g {5.65 oz} .
(g {oz})
imbalance *2 : One balance weight: 60 g {2.12 oz} max . If the total
weight exceeds 100 g {3.53 oz} on one side, rebalance after
moving the tire around on the rim. Do not use three or more
balance weights.
(N.m
Wheel nut tightening
{kgf.m, 107.8-147.0 {11.0-14.9, 79.6-108.4}
torque
ft.bf})
Temporary spare tire

Item Specification
Size T155/90D 18 195/80R17 99M
Tire Air pressure (kPa {psi}) 420 {60} 250 {36}
Remaining treed (mm {in}) 1.6 {0.07}
Size 18x4T 17x5 1/2J
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Material Steel
Wheel offset (mm {in}) 40 {1.57} 45 {1.8}
Wheel
Wheel pitch circle
(mm {in}) 114.3 {4.5}
Temporary spare diameter
tire Wheel and tire runout Lateral direction 2.0 {0.08}
(mm {in}) Radial direction 1.5 {0.06}
(N.m {kgf.m, 107.8-147.0 {11.0-14.9, 79.6-
Wheel nut tightening torque
ft.bf}) 108.4}
WHEEL BALANCE ADJUSTMENT (ALUMINUM ALLOY WHEEL)
CAUTION:  Adjust the outer wheel balance first, then the inner wheel balance.
 Be careful not to scratch the wheels.
ADHESIVE-TYPE BALANCE WEIGHT (OUTER)
1. Remove the old balance weight from the wheel.

2. Remove the double-sided adhesive tape remaining on the wheel, then clean and degrease the bonding
area.
3. Set the wheel on a wheel balancer, measure the amount of unbalance and the position with the mode set
for knock-type balance weight.
4. Multiply the amount of unbalance by 1.6 to get the balance weight value.
5. Select a balance weight closest to the weight value and attach the balance weight on the position (outer)
indicated by the wheel balancer.
Example calculation of balance weight value Indicated amount of unbalance: 23 g {0.81 oz}
23 g {0.81 oz}x1.6 = 36.8 g {1.30 oz}
Selected balance weight value: 35 g {1.24 oz}
Fig. 1: Identifying Adhesive-Type Balance Weight (Outer)

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NOTE:  When selecting a balance weight, select one closest to the calculated
value.
Example: 32.4 g {1.14 oz}= 30 g {1.06 oz}, 32.5 g {1.15 oz}= 35 g {1.24
oz}
CAUTION:  Use a genuine balance weight or equivalent (steel).

 When attaching the weight balance, press the balance weight
with a force of 25 N {2.5 kgf, 5.5 lbf} per 5 g {0.17 oz} for 2
seconds or more.
6. If attaching 2 balance weights, position them so that each is on either side of the position indicated by the
wheel balancer.
CAUTION:  Do not attach weight balances in a row.

 Do not overlap the balance weights.
 Total weight must not exceed 160g {5.65 oz}.
Fig. 2: Locating Wheel Balancer Position

KNOCK-TYPE BALANCE WEIGHT (INNER)
1. Measure the amount of unbalance with a wheel balancer.

2. Attach a balance weight corresponding to the measured weight value on the position (inner) indicated by
Microsoft
the wheel balancer.
CAUTION:  Do not attach 3 or more balance weights.

 One balance weight must not exceed 60g {2.12 oz}, and a total
of 2 balance weights must not exceed 100g {3.53 oz}.
Fig. 3: Locating Wheel Balance Position

REMAINING AMOUNT OF UNBALANCE CONFIRMATION
1. After installing the outer and inner balance weights, operate the wheel balancer again.
2. Confirm that the remaining unbalance does not exceed following on either side.
Standard
WHEEL SPECIFICATIONS
Outer Inner
18 inch wheel 10 g {0.35 oz} 6 g {0.21 oz}
20 inch wheel 6 g {0.21 oz} 4g {0.14 oz}
TIRE PRESSURE ADJUSTMENT (WITH TPMS)

1. Use of a digital gauge is recommended for accurate measurement of the air pressure.
2. Tire pressure lowers gradually as time passes. Due to this, monthly air pressure inspection is
recommended.
3. Perform tire pressure adjustment before driving. (When tires are cold.)
 Tire pressure will increase after driving because the internal temperature of the tire is high. If tire
pressure is adjusted to specifications when the internal temperature of the tire is high, tire pressure
will decrease when the internal temperature of the tire decreases to the same level as ambient
temperature. If the tire pressure is lower than the lower-limit pressure, the TPMS warning light may
illuminate.
 Even though the air pressure is adjusted to specifications, the indicated air pressure may be higher
than the specified value when the internal temperature of the tire is higher than ambient
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temperature. (Example: Air pressure changes approx. 10 kPa {0.1 kgf/cm2 , 1.5 psi} when the
temperature changes 10 °C {18 °F})
CAUTION:  In an area or a season with varying temperatures, tire

pressure will change due to ambient temperature change.
If the tire pressure is lower than the lower-limit pressure
due to low ambient temperature, the TPMS warning light
may illuminate. Adjust the pressure when the TPMS
warning light illuminates.
 Do not tilt or use excessive side force when checking air
pressure or inflating the tire with air. Which can provide
enough leverage to easily bend or break the wheel unit.
 To prevent damage to the valve area of the wheel unit or
pressure loss during air pressure adjustment, use a type B
tool with a round end as shown in the figure, not a type A
tool.
Fig. 4: Identifying Air Pressure Adjustment Tool Types

WHEEL UNIT ID REGISTRATION
NOTE:  After the wheel unit replacement, registration of the wheel unit
identification codes must be performed.
 ID registration can be done using the M-MDS, or not using the M-MDS.
USING M-MDS
 This function is available for only the IDS (notebook PC).
Microsoft
1. Select the "Toolbox" tab.

2. Select the "Body" tab.
3. Select the "TPMS Functions".
4. Select the "Wheel Unit ID Registration".
2. Leave the vehicle with the engine off for 15 min or more .
3. Verify that the TPMS warning light turns on and off in 0.5 s cycles repeatedly.
4. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 10 min to implement the wheel unit ID
registration.
NOTE:  If the ID registration is not completed even after driving the vehicle
for 10 min or more at a speed of 25 km/h {15.5 mph} or more , the
TPMS warning light flashes.
5. Verify that the TPMS warning light turns off.
NOTE:  If the wheel unit ID registration cannot be performed after driving 10

min or more, refer to the symptom troubleshooting procedure.
WITHOUT USING M-MDS
1. Turn the ignition switch to the ON position, then turn it off.

2. Leave the vehicle with the engine off for 15 min or more .
3. Drive the vehicle at a speed of 25 km/h {15.5 mph} or more for 10 min or more .
4. After driving for 10 min, verify that the TPMS warning light does not flash and is not illuminated.
WHEEL UNIT REMOVAL/INSTALLATION

3. When replacing wheel unit (s), register the new wheel unit ID (s). (See WHEEL UNIT ID
REGISTRATION.)
NOTE:  If the wheel unit is replaced with a new one, the ID registration must be
performed. When the ID registration is finished, the data for the new
wheel unit is displayed on the M-MDS.
Microsoft
Fig. 5: Identifying Wheel Unit Seal Washer, Valve Cap & Torque
Specifications
VALVE CORE REMOVAL NOTE
1. Remove the valve core of the wheel unit, and bleed the air from the tire.
WHEEL UNIT REMOVAL NOTE
1. Push the tire valve completely into the tire.
CAUTION:  Breaking the tire bead with the wheel unit installed normally
could damage the unit. Be sure to always push the wheel unit
so that it is completely inside the tire to prevent any damage.
2. Position the shoe (bead breaker) of the tire changer 10-20 mm {0.40-0.78 in} from the outer edge of the
wheel, and break both tire beads.
3. Remove the bead from one side of the wheel.
4. Remove the wheel unit.
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WHEEL UNIT INSTALLATION NOTE
1. Insert the wheel unit valve into the valve hole so that the polyurethane foam side faces the rim.
NOTE:  Maintain the wheel unit in contact with the rim, then start manually to
screw the valve nut for a few turns.
2. Install the nut from the outer side of the wheel.

3. Tighten the valve nut slowly (15 rpm max.) to 8.0 N.m {82 kgf.cm, 71 in.lbf} in one rotation.
Fig. 6: Inserting Wheel Unit Valve Into Valve Hole

CAUTION:  Do not retighten the valve nut after the initial operation.
4. Set the tire changer so that it is 45° away (point A) from the valve hole.
CAUTION:  Do not position the tire changer near the tire valve to avoid any
damage to the wheel unit.
Microsoft
Fig. 7: Setting Tire Changer

5. Fill the tire with air and verify the valve nut tightening torque.
CAUTION:  To prevent damage to the valve area of the wheel unit or

charging loss during air pressure adjustment, use a type B tool
with a round end as shown in the figure, not a type A tool.
Fig. 8: Identifying Air Pressure Adjustment Tool Type

Microsoft
2008 BODY & ACCESSORIES Symptom Troubleshooting [Power Window System (Exterior Open/Close Function)] -
Mazda CX-9
Symptom Troubleshooting [Power Window System (Exterior Open/Close Function)] - Mazda

CX-9
SYMPTOM TROUBLESHOOTING CHART [POWER WINDOW SYSTEMS

(EXTERIOR OPEN/CLOSE FUNCTION)]
SYMPTOM TROUBLESHOOTING CHART
NO. TROUBLESHOOTING ITEM PAGE
(See NO.1 UNABLE TO COMMUNICATE WITH
Door glass does not operate even
GENERIC ELECTRONIC MODULE (GEM) [POWER
1 through various operation are
WINDOW SYSTEMS (EXTERIOR OPEN/CLOSE
performed
FUNCTION)].)
(See NO.2 DOOR GLASS DOES NOT OPERATE USING
Door glass does not operate using
2 THE KEYLESS TRANSMITTER [POWER WINDOW
the keyless transmitter
SYSTEMS (EXTERIOR OPEN/CLOSE FUNCTION)].)
(See NO.3 DOOR GLASS DOES NOT OPERATE USING
Door glass does not operate using
3 THE REQUEST SWITCH [POWER WINDOW
the request switch
(See NO.4 PASSENGER DOOR GLASS DOES NOT
4 Passenger door glass do not operate OPERATE [POWER WINDOW SYSTEMS (EXTERIOR
OPEN/CLOSE FUNCTION)].)
(See NO.5 DOOR GLASS STOPS BEFORE FULLY
Door glass stops before fully
5 OPENING/CLOSING [POWER WINDOW SYSTEMS
opening/closing
(EXTERIOR OPEN/CLOSE FUNCTION)].)
(See NO.6 DOOR GLASS REVERSES BEFORE IT
Door glass reverse before it fully
6 FULLY OPENS [POWER WINDOW SYSTEMS
opens
(See NO.7 DRIVER AND PASSENGER DOOR GLASSES
Driver and passenger door glasses
7 OPERATE ACCIDENTALLY [POWER WINDOW
operate accidentally
(See NO.8 PASSENGER DOOR GLASS OPERATES
Passenger door glass operates
8 ACCIDENTALLY [POWER WINDOW SYSTEMS
accidentally
QUICK DIAGNOSTIC CHART [POWER WINDOW SYSTEMS (EXTERIOR

OPEN/CLOSE FUNCTION)]
Microsoft
Mazda CX-9
Fig. 1: Troubleshooting Chart

NOTE:  The exterior open/close function does not operate when the following
conditions are met.
 Any door or liftgate is open.
 The key is inserted in the steering lock.
 The start knob is not in the LOCK position.
 The auto-open/close function (the exterior open/close function) does not

operate if the power window initialization procedure has been reset.
Microsoft
Mazda CX-9
 Depending on the temperature and battery conditions, the window may

reverse on rare occasions.
NO.1 UNABLE TO COMMUNICATE WITH GENERIC ELECTRONIC MODULE

(GEM) [POWER WINDOW SYSTEMS (EXTERIOR OPEN/CLOSE FUNCTION)]
POSSIBLE CAUSE CHART
1 Door glass does not operate even though various operations are performed
 Power window main switch malfunction
 Power window motor malfunction
 Battery malfunction (low voltage)
POSSIBLE CAUSE  power window initialization procedure error
 Open circuit in wiring harness between power window main switch and
BCM
 BCM malfunction
Inspect the following parts, and repair or replace.
 Power window main switch
 Inspect the operation of the door (See POWER WINDOW MAIN SWITCH
glass by operating the power window INSPECTION .)
1
main switch. No
 Is the manual operation normal?  Power window motor
(See POWER WINDOW MOTOR

INSPECTION .)
Battery (low voltage)

 Inspect the operation of the door
glass by operating the power window Perform the power window initialization
2 procedure.
main switch. No
(See POWER WINDOW INITIALIZATION
 Does the door glass operate in auto? PROCEDURE .)
Inspect the wiring harness between the power
window main switch and the BCM.
3 Yes
If there is any malfunction, repair or replace the
applicable part.
Microsoft
Mazda CX-9
Replace the BCM.

 Does the door lock/unlock normally? No (See BODY CONTROL MODULE (BCM)
NO.2 DOOR GLASS DOES NOT OPERATE USING THE KEYLESS

TRANSMITTER [POWER WINDOW SYSTEMS (EXTERIOR OPEN/CLOSE
FUNCTION)]
DOOR GLASS DOES NOT OPERATE USING THE KEYLESS
2
TRANSMITTER
 Keyless control module malfunction
 BCM malfunction
POSSIBLE
CAUSE  Open circuit in wiring harness between keyless control module and BCM
 Any door or liftgate is open
 Key is inserted in steering lock
 BCM
(See BODY CONTROL MODULE

(BCM) INSPECTION .)
 Inspect the door lock/unlock operation Yes
1 using the transmitter.
 Keyless control module (Vehicles with
 Does it operate normally? advanced keyless system)
(See KEYLESS CONTROL MODULE

INSPECTION [ADVANCED KEYLESS
SYSTEM] .)
 Inspect the open/close condition of the
System is normal (Does not operate when a door
doors and the liftgate. Yes
or the liftgate is open).
2  Is the reason why they do not
lock/unlock because a door or the
liftgate is open? No Go to the next step.
System is normal (Does not operate when the key

 Verify whether the key is in the Yes
is inserted in the steering wheel lock)
steering lock.
Microsoft
Mazda CX-9
 Is the reason why they do not

3 lock/unlock because the key is No Go to the next step.
inserted in the steering lock?

Yes
 When the lock/unlock operation does INSPECTION [ADVANCED KEYLESS
4 not operate for reasons other than the SYSTEM] )
above Steps 2 and 3.
Wiring harness between keyless control

module and BCM.
Reinspect for malfunction recurrence. If the
No malfunction is not corrected, repeat the procedure
from Step 1.
NO.3 DOOR GLASS DOES NOT OPERATE USING THE REQUEST SWITCH
[POWER WINDOW SYSTEMS (EXTERIOR OPEN/CLOSE FUNCTION)]
3 Door glass does not operate using the request switch
 BCM malfunction
 Open circuit in wiring harness between request switch and keyless control
POSSIBLE
module.
CAUSE
 Any door or liftgate is open.
 Key is inserted in steering lock.
 Start knob is in a position other than LOCK position.

 Verify the door lock/unlock operation
1 by operating the request switch. Yes (See KEYLESS CONTROL MODULE
 Does it operate normally? INSPECTION [ADVANCED KEYLESS
SYSTEM] .)
 BCM
Microsoft
Mazda CX-9

(BCM) INSPECTION .)
 Verify the open/close condition of the
The system is normal (When any door or the
doors and the liftgate. Yes
liftgate is open, the system does not operate).
2  Is the reason why they do not
lock/unlock because a door or the
liftgate is open? No Go to the next step.
 Verify the start knob position, or if the

key is in the steering lock. The system is normal (When the start knob is in a
Yes position other than LOCK, or the key is inserted in
3  Is the reason why the door the steering lock, the system does not operate).
lock/unlock does not operate because
the start knob is in a position other
than LOCK, or the key is inserted? No Go to the next step.

Yes
 The door lock/unlock does not operate INSPECTION [ADVANCED KEYLESS
4 for reasons other than Steps 2 and 3 SYSTEM] .)
above.
Wiring harness between the request switch

and the keyless control module.
No malfunction is not corrected, repeat the procedure
from Step 1.
NO.4 PASSENGER DOOR GLASS DOES NOT OPERATE [POWER WINDOW

SYSTEMS (EXTERIOR OPEN/CLOSE FUNCTION)]
4 Passenger door glass does not operate
 Power window subswitch (passenger side) malfunction
POSSIBLE  Battery malfunction (low voltage)
CAUSE  Open circuit in wiring harness between power window main switch and power
window subswitch (passenger side)
 power window initialization procedure error
Microsoft
Mazda CX-9
 Power window subswitch (passenger side)
 Inspect the door glass operation by (See POWER WINDOW SUBSWITCH

operating the power window INSPECTION .)
1
subswitch (passenger side). No
 Does it operate normally?  Power window motor

INSPECTION .)

Inspect the wiring harness between the power
window main switch and the power window
 Inspect the door glass operation by Yes subswitch (passenger side).
operating the power window If there is any malfunction, repair or replace the
2 applicable part.
subswitch (passenger side).
 Does it operate in auto? Perform the power window initialization procedure.
No (See POWER WINDOW INITIALIZATION
PROCEDURE .)
NO.5 DOOR GLASS STOPS BEFORE FULLY OPENING/CLOSING [POWER

WINDOW SYSTEMS (EXTERIOR OPEN/CLOSE FUNCTION)]
5 DOOR GLASS STOPS BEFORE FULLY OPENING/CLOSING
 Power window main switch malfunction
 Battery malfunction (low voltage)
POSSIBLE  Door glass improper installation
CAUSE  Power window initialization procedure error
 BCM malfunction
 Keyless entry system signal reception error (outside operation area, radio
signal interference)
Microsoft
Mazda CX-9
Inspect the following parts, and repair or
replace.
 Power window main switch
(See POWER WINDOW MAIN

SWITCH INSPECTION .)
 Operate the door glass in auto/manual by  Power window subswitch (passenger

operating the power window main side)
switch/power window subswitch Yes
1 (See POWER WINDOW
(passenger side).
SUBSWITCH INSPECTION .)
 Does the door glass stop before fully
opening/closing using either operation?
 Power window motor)

INSPECTION .)

 Door glass (Installation condition)

 Inspect the operation of the door glass by Perform the power window initialization
repeating Step 1 above. Yes procedure. (See POWER WINDOW
2 INITIALIZATION PROCEDURE .)
opening/closing while in auto operation? No Go to the next step.
replace.
 Keyless control module (Vehicles with

advanced keyless system)
 Open the door glass by operating the (See KEYLESS CONTROL

transmitter. Yes MODULE INSPECTION
3 [ADVANCED KEYLESS
opening? SYSTEM] .)
 BCM

(BCM) INSPECTION .)
Microsoft
Mazda CX-9
replace.
 Keyless control module (Vehicle with

advanced keyless system)
(See KEYLESS CONTROL

MODULE INSPECTION
 Close the door glass by operating the Yes [ADVANCED KEYLESS
transmitter. SYSTEM] .)
4
closing?  BCM (See BODY CONTROL
MODULE (BCM) INSPECTION .)
 Keyless entry system signal reception
error (outside operation area, radio
signal interference)
No malfunction is not corrected, repeat the
procedure from Step 1.
NO.6 DOOR GLASS REVERSES BEFORE IT FULLY OPENS [POWER

6 Door glass reverses before it fully opens
 Malfunction in power window motor
POSSIBLE CAUSE  Malfunction in battery
 Improper installation of door glass
Step INSPECTION ACTION
Inspect the power window motor and repair or
Yes replace it. (See POWER WINDOW MOTOR
INSPECTION .)
Inspect the following parts and repair or replace
 By operating a power window main them.
switch / power window subswitch
1 (passenger side), operate the door
 Power window motor (See POWER
glass.
No WINDOW MOTOR INSPECTION .)
 Does the door glass mis-reverse?
 Battery (brownout)
 Door glass (improper installation)
Microsoft
Mazda CX-9
NOTE:
 Depending on the temperature,
battery, and voltage condition, the
door glass may mis-reverse.
NO.7 DRIVER AND PASSENGER DOOR GLASSES OPERATE

ACCIDENTALLY [POWER WINDOW SYSTEMS (EXTERIOR OPEN/CLOSE
FUNCTION)]
7 Driver and passenger door glasses operate accidentally
 Transmitter malfunction
 Request switch malfunction
 Open or short circuit in wiring harness between request switch (each door) and
keyless control module.
POSSIBLE
CAUSE  Power window main switch malfunction
 Open or short circuit in wiring harness between power window main switch and
power window subswitch (passenger side)
 BCM malfunction
Yes Inspect the transmitter.
With keyless entry system
 Go to Step 3.
1  Inspect if malfunction is in
operating by transmitter No
With advanced keyless system
Inspect the following parts and repair or replace.
 Request switch
2  Inspect if malfunction is in Yes
operating by request switch (See REQUEST SWITCH INSPECTION
 Wiring harness between request switch and

Microsoft
Mazda CX-9
keyless control module

Inspect power window main switch
 Inspect if malfunction is in Yes (See POWER WINDOW MAIN SWITCH
3 operating power window main INSPECTION .)
switch No Go to the next step.
Inspect the following parts and repair or replace
 Power window subswitch (passenger side)
(See POWER WINDOW SUBSWITCH

INSPECTION .)
Yes
4  Inspect if malfunction is in BCM (See BODY CONTROL MODULE
without operating Step 1 to 3 (BCM) INSPECTION .)
 Wiring harness between power window
subswitch (passenger side) and power window
main switch
No malfunction is not corrected, repeat the procedure from
Step 1.
NO.8 PASSENGER DOOR GLASS OPERATES ACCIDENTALLY [POWER

8 Passenger door glass operates accidentally
POSSIBLE CAUSE  Power window subswitch (passenger side) malfunction
ACTION
Inspect the power window subswitch of the passenger door glass and repair or replace
(See POWER WINDOW SUBSWITCH INSPECTION .)
Microsoft
2008 BODY & ACCESSORIES Glass/Windows/Mirrors - Mazda CX-9
Glass/Windows/Mirrors - Mazda CX-9
GLASS/WINDOWS/MIRRORS LOCATION INDEX
Microsoft
Fig. 1: Identifying Glass/Windows/Mirrors Components Location

FRONT DOOR GLASS REMOVAL/INSTALLATION

Microsoft
1. Adjust the door glass position as shown in the figure.

5. Remove the front door speaker. (See FRONT DOOR SPEAKER REMOVAL/INSTALLATION .)
Fig. 2: Identifying Front Door Glass Position

6. Remove the hole cover.

Fig. 3: View Of Hole Cover & Torque Specifications

8. Lift the front door glass up and remove it in the direction of the arrow.
NOTE:  When installing the front door glass, align the glass edge with the
Microsoft
glass run channel by hand through the speaker installation hole.
Fig. 4: Lifting Front Door Glass Remove Position

REAR DOOR GLASS REMOVAL/INSTALLATION

1. Adjust the door glass position as shown in the figure.
4. Remove the rear door garnish. (See REAR DOOR GARNISH REMOVAL/INSTALLATION .)
6. Remove the rear door speaker. (See REAR DOOR SPEAKER REMOVAL/INSTALLATION .)
Fig. 5: Identifying Rear Door Glass Position

Microsoft
Fig. 6: View Of Bolt & Torque Specifications

8. Remove the rear door glass guide and glass run channel as a single unit.
Fig. 7: Locating Rear Door Glass Guide & Glass Run Channel
9. Remove the hole cover.

10. Remove the bolt.
11. Lift the rear door glass up and remove it in the direction of the arrow.
NOTE:  When installing the rear door glass, align the glass edge with the
glass run channel by hand through the speaker installation hole.
Microsoft
Fig. 8: View Of Door Glass In Removal Position & Torque

Specifications
FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION

4. Front door glass (See FRONT DOOR GLASS REMOVAL/INSTALLATION.)
5. Power window motor (See POWER WINDOW MOTOR REMOVAL/INSTALLATION.)
3. Remove the nuts.
Microsoft
Fig. 9: Identifying Front Power Window Regulator Nuts & Torque Specifications
4. Insert a hand through the speaker installation hole, rotate the drum housing in the direction shown in the
figure to detach the tabs from the front door module.
Fig. 10: Rotating Drum Housing

5. Move the front power window regulator in the direction of the arrow and remove it.
CAUTION:  Make sure the cable does not unspool from the drum housing
when installing.
Fig. 11: Identifying Front Power Window Regulator

REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION
Microsoft

4. Rear door glass (See REAR DOOR GLASS REMOVAL/INSTALLATION.)
5. Power window motor (See POWER WINDOW MOTOR REMOVAL/INSTALLATION.)
3. Remove the nuts.
Fig. 12: Identifying Rear Power Window Regulator Nuts & Torque Specifications
4. Insert a hand through the speaker installation hole, rotate the drum housing in the direction shown in the
figure to detach the tabs from the rear door unit.
Fig. 13: Rotating Drum Housing

5. Move the rear power window regulator in the direction of the arrow and remove it.
Microsoft
CAUTION:  Make sure the cable does not unspool from the drum housing
when installing.
Fig. 14: View Of Rear Power Window Regulator

POWER WINDOW MOTOR REMOVAL/INSTALLATION

1. Fully lower the rear door glass.
Front door
 Inner garnish (See INNER GARNISH REMOVAL/INSTALLATION )

 Front door trim (See FRONT DOOR TRIM REMOVAL/INSTALLATION )
 Front door speaker (See FRONT DOOR SPEAKER REMOVAL/INSTALLATION )
Rear door
Inner sail garnish (See INNER SAIL GARNISH REMOVAL/INSTALLATION )

 Rear door trim (See REAR DOOR TRIM REMOVAL/INSTALLATION )
 Rear door speaker (See REAR DOOR SPEAKER REMOVAL/INSTALLATION )

5. Remove the power window motor from the power window regulator.
6. Disconnect the power window motor connector.
NOTE:  When installing the power window motor to the power window
regulator drum, the drum housing tabs may detach from the door
Microsoft
module. If this happens, insert a hand through the speaker

installation hole to engage the drum housing tabs, and install the
power window motor to the drum while supporting the drum housing.
Fig. 15: Identifying Power Window Motor Components & Torque

Specifications
POWER WINDOW MOTOR INSPECTION

FRONT SIDE
1. Apply battery positive voltage and connect the ground to power window motor terminals E and F, and
then inspect the power window motor operation.
 If the power window motor does not operate as indicated in the table, replace it.
CAUTION:  If the power window motor temperature is high, the motor may
not rotate due to the motor internal bimetal function. Leave it
untouched for about 3 min to cool it down, then reinspect.
Microsoft
Fig. 16: Power Window Motor (Front Side) - Circuit Diagram


Terminal
Operation
F E
Open B+ Ground
Close Ground B+
2. Connect the battery positive voltage to power window motor terminal D and connect terminal C to
ground.
3. Operate the power window motor and measure the voltage at terminals A and B.
 If there is any malfunction, replace the power window motor.
Voltage
 Pulse: max. 12 V/min. 0 V
REAR SIDE
1. Apply battery positive voltage and connect the ground to the power window motor terminals, and then
inspect the power window motor operation.
 If the power window motor does not operate as indicated in the table, replace it.
CAUTION:  If the power window motor temperature is high, the motor may
not rotate due to the motor internal bimetal function. Leave it
untouched for about 3 min to cool it down, then reinspect.
Microsoft
Fig. 17: Power Window Motor (Rear Side) - Circuit Diagram


Terminal
Operation
F E
Open B+ Ground
Close Ground B+
POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION

3. Remove the front door trim. (See FRONT DOOR TRIM REMOVAL/INSTALLATION )
4. Remove the screw, and remove the power window main switch from inside the front door trim.
Fig. 18: Identifying Power Window Main Switch & Screw

POWER WINDOW MAIN SWITCH INSPECTION
NOTE:  Before proceeding with diagnosis of malfunctioning power windows,
Microsoft
ensure the POWER WINDOW INITIALIZATION PROCEDURE has been

performed.
FRONT SIDE
1. Measure the voltage at each terminal (other than terminals 1M and 2A).
 If the voltage is not as specified in the Terminal Voltage Table, inspect the parts under "inspection
have any malfunction, replace the power window main switch.
Fig. 19: Identifying Power Window Main Switch Connector Terminal

Connected Measured Voltage (V)/
Terminal Signal name Inspection item (s)
to condition Continuity
Ignition switch is
B+
at ON position  Inspect METER 10 A
METER 10
1E IG 1 Ignition switch is fuse
A fuse
at LOCK 1.0 or less  Related wiring harnesses
position
 Power window
Ignition switch at subswitch (See POWER
Power
Power-cut ON and power- WINDOW
1F window B+
signal cut switch at SUBSWITCH
subswitch
UNLOCK INSPECTION)
Because this terminal is for  Power window

Power
communication, good/no good subswitch (See POWER
1G Communication window
judgment by terminal voltage is WINDOW
subswitch
not possible. SUBSWITCH
INSPECTION)
Microsoft

Because this terminal is for  BCM (See BODY
communication, good/no good CONTROL MODULE
1H Communication BCM
judgment by terminal voltage is (BCM) INSPECTION )
not possible.  Related wiring harnesses
While door glass  Power window motor
Power 1.0 or less (See POWER
is opening
1I Close output window WINDOW MOTOR
motor While door glass INSPECTION.)
B+
is closing  Related wiring harnesses
While door glass  Power window motor
Power B+ (See POWER
is opening
1K Open output window WINDOW MOTOR
motor While door glass INSPECTION.)
1.0 or less
is closing  Related wiring harnesses
Under any
1M GND Body ground 1.0 or less  Related wiring harnesses
condition
P/W 30 A Under any  P/W 30 A fuse
1N Power supply B+
fuse condition  Related wiring harnesses
 Power window motor
Power (See POWER
Under any
2A Sensor ground window 1.0 or less WINDOW MOTOR
condition
motor INSPECTION.)
Power While IG ON or (See POWER
2B Power supply window IG OFF timer B+ WINDOW MOTOR
motor works INSPECTION.)
Door glass is not  Power window motor
0 or 5.0
Power in motion (See POWER
2C Pulse 1 window Alternates WINDOW MOTOR
motor Door glass is in INSPECTION.)
between 0
motion
and 5.0  Related wiring harnesses
Alternates  Power window motor
Door glass is in
Power between 0 (See POWER
motion
2D Pulse 2 window and 5.0 WINDOW MOTOR
motor Door glass is not INSPECTION.)
0 or 5.0
in motion  Related wiring harnesses
REAR SIDE
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1. Remove the power window main switch. (See POWER WINDOW MAIN SWITCH
2. When inspecting the rear, turn the power-cut switch UNLOCK.
3. Inspect for continuity between the power window main switch terminals.
 If not as specified, replace the power window main switch.
Fig. 20: Power Window Main Switch (Rear Side) - Circuit Diagram
POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION
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PASSENGER SIDE

3. Remove the front door trim. (See FRONT DOOR TRIM REMOVAL/INSTALLATION )
4. Remove the screw, and remove the power window subswitch from inside the front door trim.
Fig. 21: Identifying Power Window Subswitch & Screw (Passenger Side)
REAR SIDE

3. Remove the rear door trim. (See REAR DOOR TRIM REMOVAL/INSTALLATION )
4. Remove the screw, and remove the power window subswitch from inside the front door trim.
Fig. 22: Identifying Power Window Subswitch & Screw (Rear Side)
POWER WINDOW SUBSWITCH INSPECTION

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PASSENGER SIDE
1. Measure the voltage at each terminal (other than terminals I).

 If the voltage is not as specified in the Terminal Voltage Table, inspect the parts under "Inspection
have any malfunction, replace the power window subswitch.
Fig. 23: Power Window Subswitch (Passenger Side) - Circuit Diagram

Connected Measured Voltage (V)/
Terminal Signal name Inspection item (s)
to condition Continuity
Because this terminal is for (See POWER
Power
communication, good/no good WINDOW MAIN
A Communication window
judgment by terminal voltage is SWITCH
main switch
not possible. INSPECTION.)
Power Ignition switch (See POWER
B Power supply window at ON or during B+ WINDOW MOTOR
motor IG-OFF timer INSPECTION.)
Power While door  Power window motor

1.0 or less
C Close output window glass is opening (See POWER
motor WINDOW MOTOR
While door INSPECTION.)
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glass is closing B+  Related wiring harnesses

Power (See POWER
Under any
D Sensor ground window 1.0 or less WINDOW MOTOR
condition
motor INSPECTION.)
Under any
E GND Body ground 1.0 or less  Related wiring harnesses
condition
Door glass
Power between 1.0 or (See POWER
moving
G Pulse 2 window less and 5.0 WINDOW MOTOR
motor Door glass 1.0 or less or INSPECTION.)
stopped 5.0  Related wiring harnesses
P/W 30 A Under any  P/W 30 A fuse
I Power supply B+
fuse condition  Related wiring harnesses
Door glass
Power between 1.0 (See POWER
moving
J Pulse 1 window and 5.0 WINDOW MOTOR
motor Door glass 1.0 or less or INSPECTION.)
stopped 5.0  Related wiring harnesses
While door  Power window motor
Power B+ (See POWER
glass is opening
K Open output window WINDOW MOTOR
motor While door INSPECTION.)
1.0 or less
glass is closing  Related wiring harnesses
 Power window main
Ignition switch
switch(See POWER
Power at ON and
Power-cut WINDOW MAIN
L window power-cut B+
signal SWITCH
main switch switch at
INSPECTION)
UNLOCK
REAR SIDE
1. Inspect for continuity between the power window subswitch terminals.

 If not as specified, replace the power window subswitch.
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Fig. 24: Rear Side Power Window Subswitch Continuity Chart

Fig. 25: Power Window Subswitch - Circuit Diagram

POWER WINDOW INITIALIZATION PROCEDURE
NOTE:  If the following operations have been performed, initial setting is reset,
and auto up/down and two-step down operation are disabled. Therefore,
performing initial setting is necessary.
 Negative battery cable disconnected or power window system power
supply fuse removed, (perform initial setting for the switches of all
seats.)
 Power window switch connector disconnected. (Perform initial
setting for the switch connected with the connector.)
 Prolonged open/close operation of the power window main or sub
switches causes the circuit breaker to activate and automatic
operation is disabled.
 The driver-side power window initialization procedure can be performed
only using the power window main switch.
 The passenger-side power window initialization procedure can be
performed using the power window main switch and subswitch
(Passenger side).
 If the power window initialization procedure is not completed, the power
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window (Driver and passenger sides) does not operate automatically. Each
power window can be operated only in manual operation.

2. Press the switch of each window and fully open the door glass.
3. Pull the switch of each window to the manual-up position to fully close the door glass, and keep holding
the switch up at the position for approx. 2 s.
TWO-STEP DOWN FUNCTION OPERATIVE/NON-OPERATIVE SWITCHING

PROCEDURE
NOTE:  By following the procedure below, the two-step down function is switched
to non-operative when it is operative, and to operative when it is non-
operative.
Fig. 26: View Of Flow Chart

DOOR GLASS POSITION CHANGE PROCEDURE
NOTE:  After performing the following procedure, verify that the two-step down
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function operates normally and the door glass position has changed. If the
two-step down function does not operate or the door glass position has
not changed, the procedure was not performed properly. Repeat the
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Fig. 27: Door Glass Position Change Procedure Flow Chart

WINDSHIELD REMOVAL
3. Rain sensor (Vehicles with auto light/wiper system)(See RAIN SENSOR
4. Rearview mirror (See REARVIEW MIRROR REMOVAL [VEHICLES WITH AUTO
LIGHT/WIPER SYSTEM]) (See REARVIEW MIRROR REMOVAL [VEHICLES
WITHOUT AUTO LIGHT/WIPER SYSTEM])
3. Set the headliner out of the way.
4. Apply protective tape along the edge of the body.
NOTE:  Overlap and adhere the protective tape to the corners to prevent
damage.
5. Remove the windshield molding by pulling it outward.
NOTE:  If the windshield molding is difficult to remove, warm the windshield

molding using a hot air blower.
 The windshield molding is a replacement part.
Fig. 28: Applying Protective Tape Of Body

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NOT REUSING WINDSHIELD
NOTE:  For the areas of the sealant that are difficult to cut, use the piano wire and
follow the procedure under "Reusing Windshield".
1. Cut out the sealant all around the glass using a sealant remover.
2. Remove the windshield.
Fig. 29: Cutting Sealant Around Glass

REUSING WINDSHIELD
WARNING:  Using the piano wire with bare hands can cause injury. Always wear
gloves when using the piano wire.
NOTE:  Before removing the windshield from the body, mark the position of the
windshield by affixing tape to the windshield and body panel.
1. Avoiding the pin on the inside of the vehicle, insert the piano wire which has been cut to sufficient length.
2. Wind each end of the piano wire around a bar.
NOTE:  Use a long sawing action to spread the work over the whole length of
the piano wire to prevent it from breaking due to localized heating.
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Fig. 30: Identifying Pin

Fig. 31: Identifying Sealant Applying Area

3. Secure one end of the piano wire, and while pulling the other end, cut the sealant around the windshield.
4. Pinch the pin from the inside of the vehicle and detach it.
5. Remove the windshield.
6. If the pin is damaged, remove the pin.
NOTE:  Before removing the pin from the windshield glass, place an
alignment mark on the windshield.
Fig. 32: Pulling Piano Wire

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WINDSHIELD INSTALLATION
when using a razor.
CAUTION:  If a door is opened or closed when all the window glass is closed, the
resulting change in air pressure could cause the sealant to crack
preventing the proper installation of the glass. Keep the door glass
opened until the windshield installation is completed.
 On vehicles with the auto wiper system, when the ignition switch is
turned to the ON position after replacing the rain sensor with a new
one, the windshield condition is verified and the initial setting is
stored. Before installing a rain sensor, always remove water or dirt
from the windshield. Perform the initial setting again in the following
cases: (See RAIN SENSOR REINITIALIZATION SETTING )
 The windshield is replaced and the rain sensor is reused.
 The auto wiper system operates incorrectly.
1. Remove the sealant along the perimeter of the glass using a cutting a razor. (When reusing the glass)
2. Clean and degrease an approx. 50 mm {1.97 in} wide strip along the perimeter of the windshield.
3. If the existing windshield is to be reinstalled, attach the dam along the ceramic voids.
4. Inspect the glass for cracks. If it is cracked, chamfer it using sandpaper.
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Fig. 33: Identifying Dam Cut Point

5. Align the marks made before removal and install the pin to the windshield referring to the figure, (when
reusing the glass, and the pin was removed)
6. Install the windshield molding.
Fig. 34: Identifying Hollowed Mark In Ceramic Coating

7. Use glass primer on the glass, then allow it to dry for approx. 30 min.
CAUTION:  To prevent weakening of the primer adhesion, keep the bonding

surface free of dirt, moisture, and grease. Do not touch the
surface with your hand.
NOTE:  Make sure to apply primer to the hollowed marks in the ceramic coating.
Fig. 35: Identifying Primer Applying Area

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8. Cut away the old sealant using a razor or scraper so that 1-2 mm {0.04-0.07 in} thickness of sealant
remains along the perimeter of the frame.
9. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approx. 30 min to dry. Then apply 2 mm {0.08 in} thickness of new sealant.

10. Clean and degrease along the perimeter of the bonding area on the body.
Fig. 36: Cutting Old Sealant With Razor

11. Apply body primer on the body as shown in the figure, then allow it to dry for approx. 30 min.

NOTE:  Apply primer to the hollowed marks in the ceramic coating.
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Fig. 37: Identifying Primer Applying Area

12. Apply sealant to the area of the glass surface as shown in the figure.
13. Insert the windshield locator pins to the body and install the windshield.
Fig. 38: Applying Sealant To Area Of Glass Surface

14. Verify that the clearance of the A-pillar is within the range shown in the figure, and press along the
perimeter of the glass.
15. Install the headliner.
3. Map light (See FRONT MAP LIGHT REMOVAL/INSTALLATION .)
5. Rearview mirror (See REARVIEW MIRROR INSTALLATION [VEHICLES WITH AUTO
LIGHT/WIPER SYSTEM].) (See REARVIEW MIRROR INSTALLATION [VEHICLES
WITHOUT AUTO LIGHT/WIPER SYSTEM])
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Fig. 39: Identifying Sealant Applying Area & Torque Specifications

6. Rain sensor (Vehicles with auto light/wiper system)(See RAIN SENSOR

17. Allow the sealant to harden completely.
Sealant hardening time: 24 h
REAR WINDOW GLASS REMOVAL

2. Remove the rear wiper arm and blade. (See REAR WIPER ARM AND BLADE
4. Remove the liftgate side trim. (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION )
6. Remove the rear wiper motor. (See REAR WIPER MOTOR REMOVAL/INSTALLATION .)
8. Remove the high-mount brake light. (See HIGH-MOUNT BRAKE LIGHT
9. Disconnect the filament connector.
10. Apply protective tape along the edge of the body.
NOTE:  Overlap and adhere the protective tape to the corners to prevent
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damage.

11. Insert the piano wire, which has been cut to sufficient length from inside the vehicle.
WARNING:  Using the piano wire with bare hands can cause injury. Always
wear gloves when using the piano wire.
NOTE:  Before removing the rear window glass from the body, mark the
position of the glass by affixing tape to the glass and body panel.
Fig. 41: Identifying Protective Tape, Piano Wire & Sealant

13. Secure one end of the piano wire, and while pulling the other end, cut the sealant around the rear window
glass.
14. Remove the rear window glass.
15. Remove the fasteners from the rear window glass.
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NOTE:  Place alignment marks on the rear window glass before removing the
fasteners from the rear window glass.

REAR WINDOW GLASS INSTALLATION
when using a razor.
open until the rear window glass installation is completed.
 Leave the power liftgate (PLG) unoperated for two days after the rear
window glass installation. If the power liftgate (PLG) is operated
automatically with the sealant not hardened after the rear window
glass installation, the liftgate may deform. It is recommended that
you refrain from operating the power liftgate (PLG) for seven days
after the rear window glass installation. Manual opening/closing will
not cause liftgate deformation.
1. Remove the sealant along the perimeter of the glass using a razor or scraper, (when reusing the glass)
2. Clean and degrease an approx. 50 mm {1.97 in} wide strip along the perimeter of the glass.
4. Install the spacers and pin to the glass as shown in the figure. When reusing the glass, align with the
alignment mark marked before removing.
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Fig. 43: Identifying Spacer And Pin

5. Apply glass primer on the glass as shown in the figure then allow it to dry for approx. 30 min.

Fig. 44: Applying Glass Primer On Glass

7. Clean and degrease the bonding area along the perimeter of the body.
8. When reusing the liftgate, apply primer to the area where the sealant has come off completely and allow it
to dry for approx. 30 min.
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9. Apply body primer on the body as shown in the figure, then allow it to dry for 30 min.

Fig. 45: Applying Body Primer On Body

10. Apply sealant to the area of the glass surface as shown in the figure.
11. Install the rear window glass.
Fig. 46: Applying Sealant To Area Of Glass Surface

12. Verify that the gap at the upper and lower parts of the glass is within the standard value shown in the
figure, then press along the perimeter of the glass.
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13. Connect the filament connector.

14. Install the high-mount brake light. (See HIGH-MOUNT BRAKE LIGHT
15. Install the rear spoiler. (See REAR SPOILER REMOVAL/INSTALLATION .)
16. Install the rear wiper motor. (See REAR WIPER MOTOR REMOVAL/INSTALLATION .)
17. Install the liftgate lower trim. (See LIFTGATE LOWER TRIM REMOVAL/INSTALLATION .)
18. Install the liftgate side trim. (See LIFTGATE SIDE TRIM REMOVAL/INSTALLATION )
19. Install the liftgate upper trim. (See LIFTGATE UPPER TRIM REMOVAL/INSTALLATION .)
20. Install the rear wiper arm and blade. (See REAR WIPER ARM AND BLADE

QUARTER WINDOW GLASS REMOVAL

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10. C-pillar trim (See D-PILLAR TRIM REMOVAL/INSTALLATION .)
11. Third-row seat belt upper anchor installation bolt (See REAR SCUFF PLATE
2. Set the headliner out of the way.
3. Apply protective tape along the edge of the body and the quarter window glass.

NOT REUSING WINDSHIELD
NOTE:  For the areas of the sealant that are difficult to cut, use the piano wire and
follow the procedure under "Reusing Windshield".
1. Cut out the sealant all around the glass from inside the vehicle using a sealant remover.
WARNING:  Using a razor with bare hands can cause injury. Always wear
gloves when using a razor.
2. Remove the quarter window glass.
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Fig. 49: Cutting Sealant Around Glass

REUSING WINDSHIELD
WARNING:  Using the piano wire with bare hands can cause injury. Always wear
gloves when using the piano wire.
1. Avoiding the pin on the inside of the vehicle, insert the piano wire which has been cut to sufficient length.
Fig. 50: Identifying Pin And Fastener

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Fig. 51: Identifying Quarter Glass, Piano Wire, Sealant And Protective
Tape
3. Secure one end of the piano wire, and while pulling the other end, cut the sealant around the quarter
window glass.

4. Pull the quarter window glass outward and detach the pins from the body.
5. If a pin or spacer is damaged, remove it.
NOTE:  Before removing the pins or spacers from the quarter window glass,
place alignment marks on the quarter window glass.
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Fig. 53: Identifying Quarter Window Glass And Pin

QUARTER WINDOW GLASS INSTALLATION
when using a razor.
open until the quarter window glass installation is completed.
1. Remove sealant along the perimeter of the glass using a razor or scraper, (when reusing the glass)
2. Clean and degrease the ceramic part along the perimeter of the glass.
4. If the glass is reused, attach the pins and fastener to the glass as shown in the figure. Align with the
alignment marks marked before removing the glass.
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Fig. 54: Identifying Pin & Fastener

5. Apply glass primer along the hollowed marks in the ceramic coating on the new glass, along the sealant
tracks on the reused glass, then allow it to dry for approx. 30 min.

Fig. 55: Applying Primer To Hollowed Marks In Ceramic Coating

7. If the sealant has come off completely in any one place, apply some primer after degreasing, and allow it
approx. 30 min to dry. Then apply 2 mm {0.079 in} thickness of new sealant.
8. Clean and degrease the bonding surface along the perimeter of the body.
9. Apply body primer on the body as shown in the figure, then allow it to dry for approx. 30 min.
CAUTION:  To prevent weakening of the primer adhesion, keep the bonding s

free of dirt, moisture, and grease. Do not touch the surface with y
hand.
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Fig. 56: Applying Body Primer On Body

10. After the primer has dried, apply 11 mm {0.43 in} in thickness, 5 mm {0.20 in} in width of sealant using
a sealant gun. Where it is not applied properly, correctly apply it using a spatula.
Fig. 57: Applying In Thickness In Width Of Sealant

11. Align the window side fastener with the bead on the body and adhere.
12. Press the quarter window glass until the quarter window glass fastener and stud pin are locked, and then
install the quarter window glass.
2. Third-row seat belt upper anchor installation bolt (See REAR SCUFF PLATE
3. C-pillar trim (See D-PILLAR TRIM REMOVAL/INSTALLATION .)
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Fig. 58: Identifying Bead And Fastener

FILAMENT INSPECTION
2. Turn the rear window defroster switch on.
CAUTION:  Directly touching the rear window defroster filament with the
lead of the tester could damage it. Wrap aluminum foil around
the end of the lead and inspect the filament by touching it with
the foil.
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Fig. 59: Checking Rear Window Defroster Filament

3. Connect the positive lead of the tester to the positive side of each filament and the negative lead to
ground.
4. Gradually slide the positive lead from the positive side to the negative side and verify that the voltage
decreases accordingly.
 If the voltage changes rapidly, the filament has a malfunction. Repair the filament.
Measured part Voltage (Reference)
(1) to (2) Approx. 11 V to 0 V
Fig. 60: Connecting Positive Lead Of Tester To Positive Side Of Filament & Negative Lead To
Ground
FILAMENT REPAIR
1. Clean the filament using isopropyl alcohol.
2. Attach tape to both sides of the filament.
3. Using a small brush or marking pen, apply silver paint.
4. After 2-3 min , carefully remove the tape without damaging the applied area.
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CAUTION:  Do not operate the rear window defroster until the paint is
completely dry. It may cause other malfunctions if it is used
before the paint is dry.
5. Dry the repaired part according to the following procedure.

 When the room temperature is 25°C {77°F} , leave it as it is for 24 h.
 When a hot air blower is used, dry with the 150°C {302°F} air for 30 min.
Fig. 61: Attaching Tape To Both Sides Of Filament

POWER OUTER MIRROR REMOVAL/INSTALLATION

4. Disconnect the power outer mirror connector.
6. Push the power outer mirror against the vehicle and detach the tab while lifting the mirror up to remove.
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Fig. 62: Identifying Power Outer Mirror Components & Torque Specifications
OUTER MIRROR GLASS REMOVAL

1. Press area A of the mirror glass so that area B moves outward.
Fig. 63: Pressing Area Of Mirror Glass

2. Detach pin A while lifting up the inside of the mirror glass holder.
3. Pull the mirror glass holder and remove pins B.
4. Disconnect the heated outer mirror connectors, (vehicles with heated outer mirrors)
5. Disconnect the BSM indicator light connector, (vehicles with BSM)
6. Remove the mirror glass holder and the outer mirror glass as a single unit.
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Fig. 64: Identifying Mirror Glass Holder & Outer Mirror Glass
OUTER MIRROR GLASS INSTALLATION

1. Connect the heated outer mirror connectors, (vehicles with heated outer mirrors)
2. Connect the BSM indicator light connector, (vehicles with BSM)
3. Press part A on the outer mirror glass and install pin A.
4. Press part B on the outer mirror glass and install pins B.
Fig. 65: Identifying BSM Indicator Light Connector, Outer Mirror Glass & Mirror Glass Holder
OUTER MIRROR GARNISH REMOVAL

1. Remove the outer mirror glass from the outer mirror. (See OUTER MIRROR GLASS REMOVAL.)
2. Pinch the ends of the visible clips (4 locations) shown in the figure, and detach them by pressing them
towards the vehicle front.
3. Grasp the upper side of the outer mirror garnish and remove it by pulling it in the direction of the arrow.
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Fig. 66: View Of Outer Mirror Garnish

OUTER MIRROR GARNISH INSTALLATION

1. Position the outer mirror garnish against the mirror body in the direction of the arrow shown in the figure,
and insert the outer mirror garnish clips (6 locations) into the mirror body.
2. Install the outer mirror garnish so that there are no gaps around the component.
Fig. 67: View Of Outer Mirror Garnish

POWER OUTER MIRROR INSPECTION

1. Apply battery positive voltage to the power outer mirror terminals and inspect the operation of the power
outer mirror.
 If not as specified, replace the power outer mirror.
MIRROR OPERATION CHART

terminal
Mirror operation
B+ GND
Up A B
Down B A
Left C B
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Right B C
Fig. 68: Power Outer Mirror - Circuit Diagram

2. Inspect for continuity between the power outer mirror heater terminals.
 If not as specified, replace the power outer mirror.
Fig. 69: Power Outer Mirror Heater Continuity Chart

Fig. 70: Power Outer Mirror Heater - Circuit Diagram


 If not as indicated, replace the power outer mirror.
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Fig. 71: BSM Indicator Light Connector Continuity Chart

Fig. 72: BSM Indicator Light Connector - Circuit Diagram

BLIND SPOT MONITORING (BSM) INDICATOR LIGHT INSPECTION

1. Apply battery voltage to BSM indicator light terminal A, and connect terminal B to ground.
2. Verify that the BSM indicator light illuminates.
 If there is any malfunction, replace the outer mirror glass.
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Fig. 73: Blind Spot Monitoring Indicator Light - Circuit Diagram

POWER OUTER MIRROR SWITCH REMOVAL/INSTALLATION
NOTE:  The power outer mirror switch is integrated with the power window main
switch.(See POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION)
POWER OUTER MIRROR SWITCH INSPECTION

1. Inspect for continuity between the power outer mirror switch terminals using an ohmmeter.
 If not as indicated in the table, replace the power outer mirror switch.
Fig. 74: Power Outer Mirror Switch Continuity Chart

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Fig. 75: Power Outer Mirror Switch - Circuit Diagram

BASE REMOVAL
1. Remove the rearview mirror. (See REARVIEW MIRROR REMOVAL [VEHICLES WITH AUTO
LIGHT/WIPER SYSTEM].) (See REARVIEW MIRROR REMOVAL [VEHICLES WITHOUT
AUTO LIGHT/WIPER SYSTEM].)
2. Wind each end of a wire around a bar.
WARNING:  Using the piano wire with bare hands can cause injury. Always
wear gloves when using the piano wire.
the piano wire to prevent it from breaking.
3. Fix one end of the piano wire, and while pulling the other end, cut the sealant to remove the base.
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BASE INSTALLATION
1. Cut away all of the original sealant using a razor.
WARNING:  Using a razor with bare hands can cause injury. Always wear
gloves when using a razor.
2. Clean and degrees the ceramic coating on the glass and the base.
CAUTION:  Keep the area free of dirt and grease, and do not touch the
surface. Otherwise, the primer may not properly bond to the
surface of the glass.
3. Apply primer to the bonding area of the glass and the base.
4. Use only glass primer on the glass, and body primer on the base. Allow the primer to dry for approx. 30
min.
5. Apply 3.0 mm {0.12 in} layer of sealant to the base.

6. Center the base in the ceramic coating and press it onto the glass.
7. Use is propyl alcohol to remove any excess repair sealant.
Hardening time of sealant
TEMPERATURE SPECIFICATION
Temperature Surface hardening time Time required until car can be put into service
5°C {41°F} Approx. 1.5 h Approx. 12h
20°C {68°F} Approx. 1 h Approx. 4 h
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35°C {95°F} Approx. 10 min Approx. 2 h
8. Install the rearview mirror.
Fig. 78: Identifying Ceramic Coating On Glass

REARVIEW MIRROR REMOVAL [VEHICLES WITH AUTO LIGHT/WIPER

SYSTEM]
1. Insert a tape-wrapped flathead screwdriver into the notch and pry with the screwdriver in the direction
shown by the arrow to remove the covers.
Fig. 79: View Of Mirror Cover Notch


3. Remove the rain sensor.(See RAIN SENSOR REMOVAL/INSTALLATION .)
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Fig. 80: Identifying Rearview Mirror And Rearview Mirror Cover

4. Make a tool as shown in the figure using wire.
CAUTION:  Using the tool with bare hands can cause injury. Always wear
gloves when using the tool.
 To prevent damage to the lens sensor, do not use a screwdriver.
Fig. 81: Identifying Rearview Mirror Removal Tool

5. Insert the tool to the position shown in the figure and push the center part of the spring.
CAUTION:  Perform the procedure while being careful not to damage the
lens sensor.
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Fig. 82: Inserting Tool To Position

6. Remove the rearview mirror in the direction of the arrow.
CAUTION:  When removing the rearview mirror, the mirror may hit the top
sealing, possibly damaging it. Therefore, hold the mirror body
securely by hand when removing the rear view mirror so that
the mirror does not contact it.
Fig. 83: Removing Rearview Mirror

REARVIEW MIRROR REMOVAL [VEHICLES WITHOUT AUTO LIGHT/WIPER

SYSTEM]
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1. Insert a flathead screwdriver between the mirror and the base.

2. Insert the flathead screwdriver to the position shown in the figure and press the center part of the spring.
3. Remove the rearview mirror in the direction of the arrow.
CAUTION:  When removing the rearview mirror, the mirror may hit the top
sealing, possibly damaging it. Therefore, hold the mirror body
securely by hand when removing the rear view mirror so that
the mirror does not contact it.
Fig. 84: Inserting Flathead Screwdriver Between Mirror & Base

REARVIEW MIRROR INSTALLATION [VEHICLES WITH AUTO LIGHT/WIPER

SYSTEM]
1. Install the rearview mirror onto the base.
2. Install the rain sensor.(See RAIN SENSOR REMOVAL/INSTALLATION .)
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Fig. 85: View Of Rearview Mirror & Base (Vehicles With Auto Light/Wiper System)
3. Install the covers.
Fig. 86: Identifying Rearview Mirror & Rearview Mirror Cover

REARVIEW MIRROR INSTALLATION [VEHICLES WITHOUT AUTO

LIGHT/WIPER SYSTEM]
1. Install the rearview mirror onto the base.
Fig. 87: View Of Rearview Mirror & Base (Vehicles Without Auto Light/Wiper System)
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2008 ACCESSORIES & BODY, CAB Wiper/Washer System - Mazda CX-9
Wiper/Washer System - Mazda CX-9
WIPER/WASHER SYSTEM LOCATION INDEX
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Fig. 1: Identifying Wiper/Washer System Components Location

WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION

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Fig. 2: Identifying Windshield Wiper Arm, Blade Components & Torque Specifications

3. Adjust the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE
ADJUSTMENT.)
WINDSHIELD WIPER ARM INSTALLATION NOTE
1. Clean the windshield wiper arm connector shafts using a wire brush before installing the windshield
wiper arms.
Fig. 3: Cleaning Windshield Wiper Arm Connector Shafts Using Wire Brush
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WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT

1. Operate the windshield wipers, and then turn off the windshield wiper motor to set the wipers in the park
position.
2. Slide the serrated connecting part and adjust the windshield wiper arm and blade so that its end is aligned
with the hollowed mark in the ceramic coating.
NOTE:  If the hollowed mark in the ceramic coating cannot be located, measure
the distance from the cowl grille end line, and adjust the windshield wiper
arm and blade.
Fig. 4: Identifying Windshield Wiper Arm And Blade Adjusting

Dimensions
WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION

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Fig. 5: Identifying Windshield Wiper Motor Components & Torque Specifications

WINDSHIELD WIPER MOTOR DISASSEMBLY/ASSEMBLY

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Fig. 6: View Of Windshield Wiper Motor & Torque Specifications

BALL JOINT ASSEMBLY NOTE
1. Use a clean rag to protect the link, and squeeze using pliers.
Fig. 7: Identifying Ball Joint Assembly

WINDSHIELD WIPER MOTOR ASSEMBLY NOTE
1. Connect the windshield wiper motor to the vehicle wiring harness connector, operate the windshield
wipers, and then stop them at the auto-stop position.
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2. Adjust the motor crank and wiper link No.1 so that they are parallel as shown in the figure.
3. Assemble the windshield wiper motor.
Fig. 8: Identifying Proper Position Of Motor Crank And Wiper Link

WINDSHIELD WIPER MOTOR INSPECTION

1. Disconnect the windshield wiper motor connector.
2. Connect battery positive voltage to windshield wiper motor terminal A or B, and ground to terminal D,
then verify that the windshield wipers operate as shown in the table.
 If the windshield wipers do not operate as indicated in the table, replace the windshield wiper
motor.
TERMINALS AND OPERATION CONDITION REFERENCE

Terminal connected to battery positive voltage Operation condition
A LO
B HI
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Fig. 9: Identifying Windshield Wiper Motor Terminals

3. Disconnect battery positive voltage from the motor terminal A while the wipers are operating.
4. Verify that the wipers do not stop in the park position.
5. Short between the motor terminals A and C, and connect battery positive voltage to the motor terminal E.
6. Verify that the wipers operate at low speed again, then stop in the park position.
 If there is any malfunction, replace the windshield wiper motor.
WASHER TANK REMOVAL/INSTALLATION

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Fig. 10: Identifying Washer Tank Components & Torque Specifications

WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION

2. Partially peel back the splash shield (RH).
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Fig. 11: Identifying Windshield Washer Motor Remove/Install Components

WINDSHIELD WASHER MOTOR INSPECTION

1. Connect battery positive voltage to windshield washer motor terminal A and terminal B to ground.
2. Verify that the windshield washer motor operates normally.
 If there is any malfunction, replace the windshield washer motor.
Fig. 12: Identifying Windshield Washer Motor Terminals

WINDSHIELD WASHER NOZZLE REMOVAL/INSTALLATION

3. Remove the windshield washer hose from the windshield washer nozzle.
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4. Squeeze the tabs of the windshield washer nozzle.

5. Pull the windshield washer nozzle out to remove it.
Fig. 13: Removing Windshield Washer Nozzle

WINDSHIELD WASHER HOSE REMOVAL/INSTALLATION

1. Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION .)
2. Disconnect windshield washer hose A from the windshield washer motor.
3. Remove windshield washer hose A from clip A.
4. Disconnect joint pipe A and remove windshield washer hose A.
5. Detach clips B.
6. Disconnect joint pipe A and B and remove windshield washer hose B.
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Fig. 14: Identifying Windshield Washer Hoses, Joint Pipe And Clips
9. Remove windshield washer hose C from hook A.

10. Disconnect joint pipe B and C, than remove windshield washer hose C.
11. Disconnect joint pipe C and remove windshield washer hose D.
12. Disconnect windshield washer hose E from the windshield washer nozzle.
13. Disconnect joint pipe D and remove windshield washer hose E.
14. Remove the windshield washer hose F from the hooks B.
15. Disconnect windshield washer hose F from the windshield washer nozzle.
16. Disconnect joint pipe D and remove windshield washer hose F.
Fig. 15: Identifying Windshield Washer Hoses, Hooks And Joint Pipes
WASHER FLUID-LEVEL SENSOR REMOVAL/INSTALLATION

3. Remove the washer tank. (See WASHER TANK REMOVAL/INSTALLATION.)
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Fig. 16: Identifying Washer Fluid-Level Sensor Remove/Install Components

WASHER FLUID-LEVEL SENSOR INSPECTION

2. Verify that continuity between the washer fluid-level sensor terminals is as indicated in the table.
 If not as specified, replace the washer fluid-level sensor.
Fig. 17: Washer Fluid-Level Sensor Terminals Continuity Chart

Fig. 18: Identifying Washer Fluid-Level Sensor Terminals

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WIPER AND WASHER SWITCH REMOVAL/INSTALLATION

Fig. 19: Identifying Wiper And Washer Switch Remove/Install Components

WINDSHIELD WIPER AND WASHER SWITCH INSPECTION

VEHICLES WITHOUT AUTO WIPER SYSTEM
1. Verify that the continuity between the windshield wiper and washer switch is as indicated in the table.
 Verify that the continuity between the windshield wiper and washer switch is as indicated in the
table.
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Fig. 20: Identifying Wiper And Washer Switch Terminals Continuity Chart
Fig. 21: Wiper And Washer Switch Circuit Diagram

VEHICLES WITH AUTO WIPER SYSTEM
1. Verify that the continuity between the windshield wiper and washer switch is as indicated in the table.
 Verify that the continuity between the windshield wiper and washer switch is as indicated in the
table.
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Fig. 22: Wiper And Washer Switch Terminals Continuity Chart (Vehicles With Auto Wiper
System)
Fig. 23: Wiper And Washer Switch Circuit Diagram (Vehicles With Auto Wiper System)
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Fig. 24: Wiper And Washer Switch Terminals Continuity Chart (Vehicles With Auto Wiper
System)
REAR WIPER AND WASHER SWITCH INSPECTION

1. Verify that the continuity between the rear wiper and washer switch terminals is as indicated in the table.
 If not as indicated in the table, replace the wiper and washer switch.
Fig. 25: Rear Wiper And Washer Switch Terminals Continuity Chart
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Fig. 26: Rear Wiper And Washer Switch Circuit Diagram

REAR WIPER ARM AND BLADE REMOVAL/INSTALLATION

Fig. 27: Identifying Rear Wiper Arm, Blade Components & Torque Specifications

3. Adjust the rear wiper arm and blade. (See REAR WIPER ARM AND BLADE ADJUSTMENT.)
REAR WIPER ARM INSTALLATION NOTE

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1. Clean the rear wiper arm connector shaft using a wire brush before installing the rear wiper arm.
Fig. 28: Cleaning Rear Wiper Arm Connector Shaft Using Wire Brush
REAR WIPER ARM AND BLADE ADJUSTMENT

1. Turn off the rear wiper switch while operating the rear wiper motor, and then stop the rear wiper at the
auto-stop position.
2. Set the rear wiper arm onto the ceramic end line.
Fig. 29: Identifying Rear Wiper Arm And Blade Adjusting Dimension
REAR WIPER MOTOR REMOVAL/INSTALLATION

1. Rear wiper arm and blade (See REAR WIPER ARM AND BLADE
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Fig. 30: Identifying Rear Wiper Motor Components & Torque Specifications
REAR WIPER MOTOR INSPECTION

1. Connect battery positive voltage to the rear wiper motor terminal A, and ground the rear wiper motor
terminal B.
2. Verify that the rear wiper motor operates.
 If there is any malfunction, replace the rear wiper motor.
Fig. 31: Rear Wiper Motor Circuit Diagram

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REAR WASHER MOTOR REMOVAL/INSTALLATION

2. Partially peel back the splash shield (RH).
Fig. 32: Identifying Rear Washer Motor Remove/Install Components

REAR WASHER MOTOR INSPECTION

1. Connect battery positive voltage to rear washer motor terminal A and terminal B to ground.
2. Verify that the rear washer motor operates normally.
 If there is any malfunction, replace the rear washer motor.
Fig. 33: Rear Washer Motor Circuit Diagram

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REAR WASHER NOZZLE REMOVAL/INSTALLATION

4. Press the tabs and remove the rear washer nozzle.
6. Adjust the rear washer nozzle. (See REAR WASHER NOZZLE ADJUSTMENT.)
Fig. 34: Removing Rear Washer Nozzle

REAR WASHER NOZZLE ADJUSTMENT

1. Insert a needle or an equivalent tool into the spray hole of the rear washer nozzle and adjust the nozzle
direction as shown.
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Fig. 35: Identifying Rear Washer Nozzle Adjusting Dimensions

REAR WASHER HOSE REMOVAL/INSTALLATION

2. Remove the splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION .)
3. Disconnect rear washer hose A from the washer tank.
4. Remove rear washer hose A from clip A, B.
5. Disconnect joint pipe A and remove rear washer hose A.
6. Disconnect joint pipe B and remove rear washer hose B.
7. Remove the grommet.
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Fig. 36: Identifying Rear Washer Hoses, Joint Pipes And Clips
6. Glove compartment service hole cover (See AIR FILTER REMOVAL/INSTALLATION .)

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9. Disconnect joint pipe C and remove rear washer hose B.

10. Remove rear washer hose C from clips C.
11. Disconnect joint pipe D and remove rear washer hose C.
13. Disconnect joint pipe E and remove rear washer hose D.
NOTE:  Rear washer hose C is integrated with the headliner. If rear washer
hose C is to be replaced, replace it with the headliner as a single unit.
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Fig. 37: Identifying Rear Washer Hose And Joint Pipe

15. Remove rear washer hose E from the rear washer nozzle.
Fig. 38: Identifying Rear Washer Hose, Joint Pipe And Rear Washer Nozzle
AUTO LIGHT/WIPER CONTROL MODULE REMOVAL/INSTALLATION
NOTE:  Auto wiper system are integrated with the auto light/wiper control module.

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3. Remove the auto light/wiper control module. (See AUTO LIGHT/WIPER CONTROL MODULE
AUTO LIGHT/WIPER CONTROL MODULE INSPECTION
NOTE:  Auto wiper system are integrated with the auto light/wiper control module.
1. Auto light/wiper control module inspection. (See AUTO LIGHT/WIPER CONTROL MODULE
INSPECTION .)
RAIN SENSOR REMOVAL/INSTALLATION
CAUTION:  When the ignition switch is turned to the ON position after replacing
the rain sensor with a new one, the windshield condition is verified
and the initial setting is stored. Before installing a rain sensor,
always remove water and dirt from the windshield.
NOTE:  Perform the initial setting again in the following cases: (See RAIN SENSOR
REINITIALIZATION SETTING.)
 The rain sensor is integrated with the auto light sensor as a single unit.

2. Remove the rearview mirror cover, (See REARVIEW MIRROR REMOVAL [VEHICLES WITH
AUTO LIGHT/WIPER SYSTEM] .)
3. Disconnect the rain sensor connector.
4. Slide both tabs located on each side of the rain sensor in the direction of the arrow and remove the rain
sensor.
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Fig. 39: Removing Rain Sensor

RAIN SENSOR REINITIALIZATION SETTING
CAUTION:  If the initialization is performed again with water or dirt on the

windshield, the rain sensor may not operate normally. Before
performing the rain sensor initialization again, remove water and dirt
from the windshield
NOTE:  When the ignition switch is turned to the ON position after replacing the
rain sensor with a new one, the windshield condition is verified and the
initial setting is stored.
 Perform the initial setting again in the following cases:
WITHOUT USING M-MDS
1. Remove water and dirt from the windshield surface.

3. Turn the windshield wiper switch to the AUTO position.
4. Within 10 s after turning the ignition switch to the ON position, turn the windshield wiper switch from
the AUTO to the OFF position for five times and return it to the AUTO position.
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CAUTION:  If the operation is too fast, the windshield wiper switch position
cannot be detected and the initial setting may not be performed.
Operate the windshield wiper switch for one cycle (AUTO--
>OFF-->AUTO) per 1 s.
NOTE:  When the initial setting is performed correctly, the windshield wiper
operates once at low speed.
USING M-MDS

1. Select "Electrical".

1. Select "Rain Sensor Reset".
4. Perform the procedure as indicated on the screen.
Fig. 40: Identifying Data Link Connector

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2007 SYSTEM WIRING DIAGRAMS Mazda - CX-9
2007 SYSTEM WIRING DIAGRAMS
Mazda - CX-9
USING MITCHELL1'S WIRING DIAGRAMS

For information on using these wiring diagrams, see USING MITCHELL1'S SYSTEM WIRING
DIAGRAMS article.
AIR CONDITIONING
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Fig. 1: Automatic A/C Circuit, Dual Fans (1 of 3)
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Fig. 4: Automatic A/C Circuit, Single Fan (1 of 3)
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ANTI-LOCK BRAKES
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Fig. 7: Anti-lock Brakes Circuit
ANTI-THEFT
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Fig. 8: Forced Entry Circuit
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Fig. 9: Immobilizer Circuit
BODY CONTROL MODULES
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Fig. 10: Body Control Modules Circuit
COMPUTER DATA LINES
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Fig. 11: Computer Data Lines Circuit
COOLING FAN
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Fig. 12: Cooling Fan Circuit, Dual Fans
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Fig. 13: Cooling Fan Circuit, Single Fan
CRUISE CONTROL
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Fig. 14: Cruise Control Circuit
DEFOGGERS
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Fig. 15: Defoggers Circuit
ENGINE PERFORMANCE
3.5L
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Fig. 16: 3.5L, Engine Performance Circuit (1 of 4)
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EXTERIOR LIGHTS
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Fig. 20: Backup Lamps Circuit
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Fig. 21: Exterior Lamps Circuit
GROUND DISTRIBUTION
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Fig. 22: Ground Distribution Circuit
HEADLIGHTS
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Fig. 23: Headlights Circuit, W/ Auto Lights Off
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Fig. 24: Headlights Circuit, W/O Auto Lights Off
HORN
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Fig. 25: Horn Circuit
INSTRUMENT CLUSTER
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Fig. 26: Instrument Cluster Circuit (1 of 2)
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Fig. 27: Instrument Cluster Circuit (2 of 2)
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Fig. 28: Multi-Information System Circuit
INTERIOR LIGHTS
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Fig. 29: Courtesy Lamps Circuit
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Fig. 30: Instrument Illumination Circuit
MEMORY SYSTEMS
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Fig. 31: Driver"s Memory Seat Circuit (1 of 2)
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Fig. 32: Driver"s Memory Seat Circuit (2 of 2)
NAVIGATION
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Fig. 33: Navigation Circuit
POWER DISTRIBUTION
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Fig. 34: Power Distribution Circuit (1 of 2)
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Fig. 35: Power Distribution Circuit (2 of 2)
POWER DOOR LOCKS
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Fig. 36: Door Lock Circuit
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Fig. 37: Keyless Entry Circuit (1 of 2)
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Fig. 38: Keyless Entry Circuit (2 of 2)
POWER MIRRORS
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Fig. 39: Power Mirrors Circuit
POWER SEATS
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Fig. 40: Driver Power Seat Circuit
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Fig. 41: Heated Seats Circuit
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Fig. 42: Lumbar Circuit
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Fig. 43: Passenger Power Seat Circuit
POWER TOP/SUNROOF
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Fig. 44: Power Top/Sunroof Circuit
POWER WINDOWS
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Fig. 45: Power Windows Circuit (1 of 2)
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Fig. 46: Power Windows Circuit (2 of 2)
RADIO
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Fig. 47: Radio Circuit, W/ Base Radio
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Fig. 48: Radio Circuit, W/ Bose (1 of 2)
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Fig. 49: Radio Circuit, W/ Bose (2 of 2)
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Fig. 50: Rear Seat Entertainment Circuit
SHIFT INTERLOCK
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Fig. 51: Shift Interlock Circuit
STARTING/CHARGING
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Fig. 52: Charging Circuit
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Fig. 53: Starting Circuit
SUPPLEMENTAL RESTRAINTS
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Fig. 54: Supplemental Restraints Circuit (1 of 2)
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Fig. 55: Supplemental Restraints Circuit (2 of 2)
TRANSMISSION
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Fig. 56: 4WD Circuit
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Fig. 57: A/T Circuit
TRUNK, TAILGATE, FUEL DOOR
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Fig. 58: Power Liftgate Circuit
WARNING SYSTEMS
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Fig. 59: Warning Systems Circuit
WIPER/WASHER
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Fig. 60: Front Wiper/Washer Circuit, W/ Automatic Wiper
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Fig. 61: Front Wiper/Washer Circuit, W/O Automatic Wiper
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Fig. 62: Rear Wiper/Washer Circuit
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2008 Mazda CX-9 Grand Touring

2008 RESTRAINTS On-Board Diagnostic (Restraints) - Mazda CX-9

On-Board Diagnostic (Restraints) - Mazda CX-9

 The OBD (on-board diagnostic) system has the following functions:

 Diagnostic DTCs can be read/cleared using the M-MDS.

Fig. 1: Flow Chart

AIR BAG SYSTEM WIRING DIAGRAM (ON-BOARD DIAGNOSTIC)

Fig. 2: Air Bag System Wiring Diagram

1. Select "Self Test".

1. Select "Module Tests".

Fig. 3: Identifying DLC-2 Connector

3. Verify the DTC according to the directions on the screen.

1. Select "Self Test".

1. Select "Module Tests".

Fig. 4: Identifying DLC-2 Connector

module and other air bag (See DTC B1046, B2773,

(inflator No.1) and other air B1932, B1934, B1936.)

SAS control module power

Driver-side air bag module (See DTC B1057, B1916,

(inflator No.1) circuit short B1932, B1934, B1936.)

Passenger-side side air bag

Passenger-side curtain air

PID/DATA MONITOR DISPLAY

Fig. 5: Identifying DLC-2 Connector

When using the PDS (Pocket PC)

1. Select "Module Tests".

PID/DATA MONITOR TABLE

PID name Unit/Condition Operation Condition Terminal

 Seat weight sensor

(Passenger sensing  Seat weight sensor

curtain air bag 1.0-9.7 ohms 2AL

 Calibration set value not within valid range.

CAUSE  Seat weight sensor deformed or malfunction

DTC B1013 DIAGNOSTIC PROCEDURE

 Turn the ignition switch to

INSPECT SEAT WEIGHT

DTC B1046, B2773, B2774, B2775, B2776

 SAS control module malfunction

DTC B1046, B2773, B2774, B2775, B2776 DIAGNOSTIC PROCEDURE

 Is the resistance of the driver-side curtain air

INSPECT DRIVER-SIDE CURTAIN AIR BAG

 Handling the air bag system components

(See AIR BAG SYSTEM SERVICE

(See AIR BAG SYSTEM SERVICE

Turn the ignition switch to the LOCK position.

 Connect the leads of the SST (Fuel and

 Turn the ignition switch to the LOCK position.

 Disconnect the clock spring connector. (See

 Short to power supply

 Is the wiring harness normal?

DTC B1047, B1992, B1993, B1994, B1995

B1994 Driver-side side air bag module circuit resistance high

 SAS control module malfunction

DTC B1047, B1992, B1993, B1994, B1995 DIAGNOSTIC PROCEDURE

INSPECT DRIVER-SIDE SIDE AIR BAG

(See PID/DATA MONITOR TABLE.)

 Is the resistance of the driver-side side air bag

INSPECT DRIVER-SIDE SIDE AIR BAG

(See AIR BAG SYSTEM SERVICE

Turn the ignition switch to the LOCK position.

 Disconnect the negative battery cable and wait

 Connect the leads of the SST (Fuel and

INSPECT WIRING HARNESS BETWEEN

 Turn the ignition switch to the LOCK position.