Mazda 2: Service Cautions
Injury/damage Prevention Precautions
- Depending on the vehicle, the cooling fan may operate suddenly even when
the ignition
is switch to 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.
Protection of the Vehicle
- Always be sure to cover fenders, seats and floor areas before starting
work.

Preparation of Tools and Measuring Equipment
- Be sure that all necessary tools and measuring equipment are available
before starting
any work.

Special Service Tools
- Use special service tools or the equivalent when they are required.

Malfunction Diagnosis System
- Use the Mazda Modular Diagnostic System (M-MDS) for malfunction
diagnosis.
Connection to malfunction diagnosis system
With the ignition switched off, connect the malfunction diagnosis system to
the DLC-2
connector shown in the figure.

Negative Battery Cable Disconnection/connection
Warning
Before removing the SRS air bag system-related parts, always disconnect the
negative
battery cable and wait for 1 min. or more to allow the back-up power supply to
deplete
its stored power. (See AIR BAG SYSTEM SERVICE WARNINGS).
Negative battery cable disconnection/required procedures after
connecting

Oil Leakage Inspection
- Use either of the following procedures to identify the type of oil that
is leaking:
Using UV light (black light)
1. Remove any oil on the engine or transmission/transaxle.
NOTE:
- Referring to the fluorescent dye instruction manual, mix the specified
amount of dye into the engine oil or transmission/transaxle oil.
2. Pour the fluorescent dye into the engine oil or transmission/transaxle
oil.
3. Allow the engine to run for 30 min.
4. Inspect for dye leakage by irradiating with UV light (black light), and
identify the type of
oil that is leaking.
5. If no dye leakage is found, allow the engine to run for another 30 min. or
drive the
vehicle then reinspect.
6. Find where the oil is leaking from, then make necessary repairs.
NOTE:
- To determine whether it is necessary to replace the oil after adding the
fluorescent dye, refer to the fluorescent dye instruction manual.
Not using UV light (black light)
1. Gather sample of the leaking oil using an absorbent white tissue.
2. Then, gather some samples of engine and transaxle oil onto a white cloth or
piece of paper.
- MT vehicles: Transmission/transaxle oil
- AT vehicles: ATF
3. Compare the appearance and smell, and identify the type of oil that is
leaking.

4. Remove any oil on the engine or transmission/transaxle.
5. Allow the engine to run for 30 min.
6. Check the area where the oil is leaking, then make necessary repairs.
Removal of Parts
- While correcting a problem, also try to determine its cause. Begin work
only after first
learning which parts and sub-components must be removed and disassembled for
replacement or repair. After removing the part, plug all holes and ports to
prevent
foreign material from entering.

Disassembly
- If the disassembly procedure is complex, requiring many parts to be
disassembled, all
parts should be marked in a place that will not affect their performance or
external
appearance, and identified so that reassembly can be performed easily and
efficiently.

Inspection During Removal, Disassembly
- When removed, each part should be carefully inspected for malfunction,
deformation,
damage and other problems.

Arrangement of Parts
- All disassembled parts should be carefully arranged for reassembly.

- Be sure to separate or otherwise identify the parts to be replaced from
those that will
be reused.
Cleaning of Parts
- All parts to be reused should be carefully and thoroughly cleaned in the
appropriate
method.

WARNING:
- Using compressed air can cause dirt and other particles to fly out
causing injury to the
eyes. Wear protective eye wear whenever using compressed air.
Reassembly
- Standard values, such as torques and certain adjustments, must be
strictly observed in
the reassembly of all parts.

- If removed, these parts should be replaced with new ones:
- Oil seals
- Gaskets
- O-rings
- Lock washers
- Cotter pins
- Nylon nuts
- Depending on location:

- Sealant and gaskets, or both, should be applied to specified
locations.
- When sealant is applied, parts should be installed before sealant
hardens to prevent leakage.
- Oil should be applied to the moving components of parts.
- Specified oil or grease should be applied at the prescribed
locations
(such as oil seals) before reassembly.
Adjustment
- Use suitable gauges and testers when making adjustments.

Rubber Parts and Tubing
- Prevent gasoline or oil from getting on rubber parts or tubing.

Hose Clamps
- When reinstalling, position the hose clamp in the original location on
the hose and
squeeze the clamp lightly with large pliers to ensure a good fit.

Torque Formulas
- When using a torque wrench-SST or equivalent combination, the specified
torque must
be recalculated due to the extra length that the SST or equivalent adds to
the torque
wrench. Recalculate the torque by using the following formulas. Choose the
formula
that applies to you.



A The length of the SST past the torque wrench drive.
L The length of the torque wrench.
Vise
- When using a vise, put protective plates in the jaws of the vise to
prevent damage to
parts.

Dynamometer
- When inspecting and servicing the power train on the dynamometer or
speedometer
tester, pay attention to the following:
- Place a fan, preferably a vehicle-speed proportional type, in front
of
the vehicle.
- Make sure the vehicle is in a facility with an exhaust gas
ventilation
system.
- Keep the rear bumper cool by placing a cooling fan near the exhaust
pipe so that the rear bumper does not get deformed by the heat from
the exhaust.
- Keep the area around the vehicle uncluttered so that heat does not
build up.
- Watch the water temperature gauge and do not overheat the engine.
- Avoid added load to the engine and maintain normal driving
conditions
as much as possible.
NOTE:
- When only the front or rear wheels are rotated on a chassis dynamometer
or
equivalent, the DSC HU/CM determines that there is a malfunction in the DSC
and
illuminates the following lights:
- ABS warning light
- Brake system warning light
- DSC indicator light
- If the above lights are illuminated, dismount the vehicle from the
chassis dynamometer
and switch the ignition to off. Then, switch the ignition to ON, run the
vehicle at 10
km/h or more and verify that the warning lights go out. In this case, a DTC
will be
stored in the memory. Clear the DTC from the memory by following the memory
clearing procedure [DSC] in the on-board diagnostic system. (See ON-BOARD
DIAGNOSIS [DYNAMIC STABILITY CONTROL (DSC)] ).
SST
- Some global SST or equivalent are used as SSTs necessary for vehicle
repair. Note
that these SSTs are marked with global SST numbers.
- Note that a global SST number is written together with a corresponding
Mazda SST
number as shown below.
Example (SST List)

Example (In text)

Installation of Radio System
The control module and control unit have been designed with sufficient
attention to radio wave disturbances
from the outside. However, observe the following precautions when installing the
radio set to the vehicle to
prevent adverse effects on the control module and control unit.
- Install the radio set and its antenna as far away as possible from the
control module and
control unit.
- The antenna feeder and power cable generate radio waves, therefore, keep
them 100 mm
{3.94 in} or more from the control module, control unit, and wiring harness.
If the antenna
feeder and power cable cross over the wiring harness, place them
perpendicular to the wiring
harness.
- Do not install a high output radio set.
- Do not use the control module and control unit power source for the
radio set.
- Do not attach the antenna feeder or wiring harness of the radio set to
the wiring harness, fuel
pipe, or brake tube of the vehicle.
- Do not install any radio set-related devices in the area where the air
bag module deploys to
prevent a secondary accident if the air bag were to deploy.


- After installing the radio set, perform a test transmission with the
engine idling to verify that it
does not affect engine control.
READ NEXT:
Electrical Parts
Battery cable
Before disconnecting connectors or removing electrical parts, disconnect
the negative
battery cable.
Wiring Harness
To remove the wiring harness from the clip i
Jacking Positions
WARNING:
Improperly jacking a vehicle is dangerous. The vehicle can slip off the
jack and cause serious injury. Use only the correct front and rear
jacking points and block the
Vehicle Identification Number (VIN)
The VIN marking position is located on the floor on the front
passenger-side.
If the VIN plate is adhered to the dashboard, it is located in the
position
SEE MORE:
FRONT DOOR LATCH SWITCH INSPECTION
1. To access the glass installation bolt, position the front door glass so
that the distance from the top of the front door glass to
the upper part of the front beltline molding is approx. 110 mm {4.33 in}.
2. Disconnect the negative battery cable.
3. Remove th
DTC Reading Procedure
1. Connect the M-MDS (IDS) to the DLC-2.
2. After the vehicle is identified, select the following items from the
initialization screen of
the IDS.
Select "Self Test".
Select "Modules".
Select "PCM".
3. Then, select the "Retrieve CMDTCs" and perform procedures according t
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