Index Mazda Mazda engine MZR–CD - service manual 2002 year

Mazda engine MZR–CD. Manual - part 1

CONTENTS

Engine
Workshop
Manual
MZR–CD
(RF Turbo)

FOREWORD

This manual explains the disassembly,

inspection, repair, and reassembly
procedures for the above-indicated engine.
In order to do these procedures safely,
quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.

The information in this manual is current

up to April, 2002. Any changes that
occur after that time will not be reflected in
this particular manual. Therefore,
the contents of this manual may not exactly
match the mechanism that you are
currently servicing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

PRINTED IN THE NETHERLANDS, APRIL 2002
1744–1E–02D

Title

Section

General Information

Engine

Technical Data

Special Tools

WARNING

Servicing a vehicle can be dangerous. If you have not received
service-related training, the risks of injury, property damage, and
failure of servicing increase. The recommended servicing procedures
for the vehicle in this workshop manual were developed with
Mazda-trained technicians in mind. This manual may be useful to
non-Mazda trained technicians, but a technician with our
service-related training and experience will be at less risk when
performing service operations. However, all users of this manual are
expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks
not normally encountered in a general technician's experience.
They should be followed to reduce the risk of injury and the risk that
improper service or repair may damage the vehicle or render it unsafe.
It is also important to understand that the "Warnings" and "Cautions"
are not exhaustive. It is impossible to warn of all the hazardous
consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are
effective methods of performing service and repair. Some require tools
specifically designed for a specific purpose. Persons using procedures
and tools which are not recommended by Mazda Motor Corporation
must satisfy themselves thoroughly that neither personal safety nor
safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are
the latest available at the time of printing, and Mazda Motor Corporation
reserves the right to change the vehicle designs and alter the contents
of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or
with parts which match the quality of genuine Mazda replacement
parts. Persons using replacement parts of lesser quality than that of
genuine Mazda replacement parts must satisfy themselves thoroughly
that neither personal safety nor safety of the vehicle will be
jeopardized.

Mazda Motor Corporation is not responsible for any problems which
may arise from the use of this manual. The cause of such problems
includes but is not limited to insufficient service-related training, use of
improper tools, use of replacement parts of lesser quality than that of
genuine Mazda replacement parts, or not being aware of any revision
of this manual.

GI–1

GENERAL INFORMATION

HOW TO USE THIS MANUAL ............................. GI-2

RANGE OF TOPICS .......................................... GI-2
SERVICE PROCEDURE ................................... GI-2
SYMBOLS.......................................................... GI-3
ADVISORY MESSAGES ................................... GI-4

UNITS ................................................................... GI-5

UNITS ................................................................ GI-5

FUNDAMENTAL PROCEDURES ........................ GI-6

PREPARATION OF TOOLS AND MEASURING

EQUIPMENT................................................... GI-6

SPECIAL SERVICE TOOLS .............................. GI-6
DISASSEMBLY.................................................. GI-6
INSPECTION DURING REMOVAL,

DISASSEMBLY............................................... GI-7

ELECTRICAL SYSTEM...................................... GI-10

ELECTRICAL PARTS ...................................... GI-10
CONNECTORS................................................ GI-10

NEW STANDARDS ............................................ GI-13

NEW STANDARDS.......................................... GI-13

ABBREVIATIONS .............................................. GI-15

ABBREVIATIONS ............................................ GI-15

GI–2

HOW TO USE THIS MANUAL

RANGE OF TOPICS

AME201000001101

•

This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
— Removal/Installation
— Disassembly/Assembly
— Replacement
— Inspection
— Adjustment

•

Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts and visual inspection) have been omitted.

End Of Sie

SERVICE PROCEDURE

AME201000001102

Inspection, adjustment

•

Inspection and adjustment procedures are divided into steps. Important points regarding the location and
contents of the procedures are explained in detail and shown in the illustrations.

Repair procedure

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit

together and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.

2. Expendable parts, tightening torques and symbols for oil, grease, and sealant are shown in the overview

illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.

HOW TO USE THIS MANUAL

XME2010001

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