2013-2015 Mazda CX-5 Service & Repair Manual

BACK TO MODEL INDEX FOREWORD This wiring diagram incorporates the wiring schematics of the Mazda CX-5 and available optional equipment. Actual vehicle wiring may vary slightly depending on optional equipment or local specifications, or both. For proper repair and maintenance, a thorough familiarization with this manual is important, and it should always be kept in a handy place for quick and easy reference. All the contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Ford Motor Company reserves the right to alter the specifications and contents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical-including photocopying and recording and the use of any kind of information storage and retrieval system-without permission in writing. 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 accepted at least to 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. VIEW CONTENTS PAGE Ford Motor Company of Southern Africa © 2012 FMCSA MAZDA CX5 WORKSHOP REPAIR MANUAL

CONTENTS Title Section TO MODEL INDEX APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page. © 2012 Ford Motor Company of Southern Africa Workshop Repair Manual BACK TO FOREWORD & FRONT PAGE GENERAL INFORMATION 00 ENGINE 01 SUSPENSION 02 DRIVELINE/AXLE 03 BRAKES 04 TRANSMISSION/ TRANSAXLE 05 STEERING 06 HEATER, VENTILATION & AIR CONDITIONING (HVAC) 07 RESTRAINTS 08 BODY & ACCESSORIES 09 MULTIPLEX TEM COMMUNICATION SYSTEM 10 I-STOP 11 PERSONALIZATION FEATURES 12 MAZDA CX5 WORKSHOP REPAIR MANUAL

00 GENERAL INFORMATION SECTION 00 Toc of SCT GENERAL INFORMATION . . . 00-00 Toc of SCT TO MODEL INDEX BACK TO MAIN INDEX MAZDA CX5 WORKSHOP REPAIR MANUAL

TO MODEL INDEX BACK TO CHAPTER INDEX 00-00–1 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) CODE. . . . . . . . . . . . . . 00-00–2 European (L.H.D. U.K.) China specs. . . . . . . . . . . . . . . . . . . . 00-00–2 Australian, General (R.H.D.) specs. . . . . . . . . . . . . . . . . . . 00-00–2 General (L.H.D.) specs. . . . . . . . . . . . . 00-00–3 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . 00-00–4 European (L.H.D. U.K.) specs. . . . . . . . 00-00–4 Australian, General (R.H.D.) specs. . . . 00-00–4 General (L.H.D.) specs. . . . . . . . . . . . . 00-00–4 HOW TO USE THIS MANUAL. . . . . . . . . 00-00–5 Range of Topics . . . . . . . . . . . . . . . . . . 00-00–5 Advisory Messages . . . . . . . . . . . . . . . 00-00–5 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5 Service Procedure . . . . . . . . . . . . . . . . 00-00–6 Troubleshooting Procedure . . . . . . . . . 00-00–8 Procedures for Use . . . . . . . . . . . . . . . 00-00–9 SERVICE CAUTIONS . . . . . . . . . . . . . . . 00-00–13 Injury/damage Prevention Precautions . . . . . . . . . . . 00-00–13 Protection of the Vehicle . . . . . . . . . . . 00-00–13 Preparation of Tools and Measuring Equipment . . . . . . . . . . . . 00-00–14 Special Service Tools . . . . . . . . . . . . . . 00-00–14 Malfunction Diagnosis System . . . . . . . 00-00–14 Oil Leakage Inspection . . . . . . . . . . . . 00-00–15 Negative Battery Cable Disconnection/Connection . . . . . . . . . 00-00–16 Switch The Power Supply Using The Push Button Start And Start The Engine . . . . . . . . . . . . . . . . 00-00–17 Removal of Parts . . . . . . . . . . . . . . . . . 00-00–18 Control Unit Configuration (Initial Setting) Procedure Using M-MDS. . . . . . . . . . . . . . . . . . . 00-00–18 Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–18 Inspection During Removal, Disassembly. . . . . . . . . . . . 00-00–19 Arrangement of Parts . . . . . . . . . . . . . . 00-00–19 Cleaning of Parts . . . . . . . . . . . . . . . . . 00-00–19 Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–19 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–20 Rubber Parts and Tubing . . . . . . . . . . . 00-00–20 Hose Clamps . . . . . . . . . . . . . . . . . . . . 00-00–20 Torque Formulas . . . . . . . . . . . . . . . . . 00-00–21 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–21 Dynamometer . . . . . . . . . . . . . . . . . . . . 00-00–21 SST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–22 INSTALLATION OF RADIO SYSTEM . . . 00-00–23 ELECTRICAL SYSTEM . . . . . . . . . . . . . . 00-00–24 Electrical Parts . . . . . . . . . . . . . . . . . . . 00-00–24 Wiring Harness . . . . . . . . . . . . . . . . . . . 00-00–24 Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–24 Terminals . . . . . . . . . . . . . . . . . . . . . . . . 00-00–26 Sensors, Switches, and Relays . . . . . . . 00-00–27 Wiring Harness . . . . . . . . . . . . . . . . . . . 00-00–27 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–27 Viewing orientation for Connectors . . . . 00-00–28 Electrical Troubleshooting Tools . . . . . . 00-00–29 Precautions Before Welding . . . . . . . . . 00-00–30 JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS . . . . . . . . . . 00-00–31 Jacking Positions . . . . . . . . . . . . . . . . . . 00-00–31 Vehicle Lift Positions . . . . . . . . . . . . . . . 00-00–32 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–32 Towing Hooks . . . . . . . . . . . . . . . . . . . . 00-00–33 TIEDOWN HOOK . . . . . . . . . . . . . . . . . . . 00-00–35 IDENTIFICATION NUMBER LOCATIONS. . . . . . . . . . . . . . 00-00–36 Vehicle Identification Number (VIN) . . . 00-00–36 Engine Identification Type/Number . . . . 00-00–36 UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–37 Conversion From SI Units . . . . . . . . . . . 00-00–37 Number Of Digits For Converted Values . . . . . . . . . . . . . . . . 00-00–37 Converted Value Rounding Off And Rounding Up/down . . . . . . . . . . . 00-00–37 NEW STANDARDS . . . . . . . . . . . . . . . . . . 00-00–38 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . 00-00–40 PRE-DELIVERY INSPECTION . . . . . . . . . 00-00–41 Pre-Delivery Inspection Table . . . . . . . . 00-00–41 SCHEDULED MAINTENANCE . . . . . . . . 00-00–43 Scheduled Maintenance Table for Europe (L.H.D., U.K.) . . . . . . . . . . . 00-00–43 Scheduled Maintenance Table for Australia . . . . . . . . . . . . . . . . 00-00–45 Scheduled Maintenance Table for General . . . . . . . . . . . . . . . . . 00-00–47 Scheduled Maintenance Table for Russia/Belarus/Azerbaijan . . . . . . . . . 00-00–49 Scheduled Maintenance Service (Specific Work Required) . . . . . . . . . . 00-00–51 End of Toc NG: GENERAL INFORMATION GENERAL INFORMATION MAZDA CX5 WORKSHOP REPAIR MANUAL

00-00–2 VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000100200 Australian, General (R.H.D.) specs. J M 0 K E 1 0 7 1 0 0 1 2 3 4 5 6 Dummy Dummy Serial No. 0 Minor change code 1 Engine Dummy 0 KE= Mazda CX-5 JM6= Mazda (General (R.H.D.) specs.) World manufacturer identification 7= 2.0 L (SKYACTIV-G 2.0) 0 Body 1= Closed body Carline and Series 2= 2.2 L (SKYACTIV-D 2.2 Hi, Diesel) JM0= Mazda (Australian specs.) ac5wzw0000464 TO MODEL INDEX BACK TO CHAPTER INDEX GENERAL INFORMATION MAZDA CX5 WORKSHOP REPAIR MANUAL

00-00–4 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300 Australian, General (R.H.D.) specs. General (L.H.D.) specs. Except for Algeria Algeria only End Of Sie JM0 KE102100 100001— JM0 KE107100 100001— JM6 KE1071*0# 100001— ac5wzw0000458 JMZ KEC978*# 100001— JMZ KEK978*# 100001— JM8 KE2W7**# 100001— JM8 KE4W7**# 100001— ac5wzw0000458 KE1071 100001 — m m : This mark is used only for Algerian model, in order to identify the manufacturer. m m ac5wzw0000458 TO MODEL INDEX BACK TO CHAPTER INDEX MAZDA CX5 WORKSHOP REPAIR MANUAL

GENERAL INFORMATION 00-00–5 00 HOW TO USE THIS MANUAL id000000800100 Range of Topics This manual contains procedures for performing all required service operations. The procedures are divided into the following five basic operations: — Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted. Advisory Messages You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this manual. Warning — A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution — A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored. Note — A Note provides added information that will help you to complete a particular procedure. Specification — The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits — The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments. Symbols There are nine symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service. Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil Apply brake fluid New appropriate brake fluid Apply automatic transmission/ transaxle fluid New appropriate automatic transmission/ transaxle fluid Apply continuously variable transaxle fluid New appropriate continuously variable transaxle fluid OIL BRAKE FLUID ATF CVT CVT FLUID FLUID Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring, gasket, etc. Use SST or equivalent Appropriate tools Symbol Meaning Kind GREASE SEALANT P R SST TO MODEL INDEX BACK TO CHAPTER INDEX MAZDA CX5 WORKSHOP REPAIR MANUAL

00-00–6 GENERAL INFORMATION Service Procedure Inspection, adjustment Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations. Attach the cooling system cap to the SST and a radiator cap tester. 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 {0.951—1.250 kgf/cm 2 , 13.6—17.7 psi} COOLING SYSTEM CAP INSPECTION [MZR-CD 2.2] COOLING SYSTEM CAP 49 9200 147 SHOWS PROCEDURE ORDER FOR SERVICE SHOWS SPECIFICATION am5ezw0000364 TO MODEL INDEX BACK TO CHAPTER INDEX MAZDA CX5 WORKSHOP REPAIR MANUAL

GENERAL INFORMATION 00-00–7 00 Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also shown. 3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part. SST SST SST SST R R R R 9 1 2 8 7 12 10 11 GREASE GREASE 4 5 3 6 GREASE GREASE LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION 1. Jack up the rear of the vehicle and support it with safety stands. 2. Remove the undercover. (See 01-10-4 Undercover Removal) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the rear wheel alignment and adjust it if necessary. 10 11 N·m {kgf·m, ft·lbf} 118—156 {12.0—16.0, 87—115} 94—116 {9.5—11.9, 69—86} 43—56 {4.3—5.8, 32—41} 44—60 {4.4—6.2, 32—44} KNUCKLE UPPER TRAILING LINK LOWER TRAILING LINK Split pin Nut Lower trailing link ball joint (See 02-14-5 Lower Trailing Link Ball Joint Removal Note) Bolt Lower trailing link Dust boot (lower trailing link) Split pin Nut Upper trailing link ball joint (See 02-14-5 Upper Trailing Link Ball Joint Removal Note) Nut Upper trailing link Dust boot (upper trailing link) Remove the ball joint using the SSTs. 1 2 3 4 5 6 7 8 9 10 11 12 Lower Trailing Link Ball Joint, Upper Trailing Link Ball Joint Removal Note 49 T028 304 49 T028 305 49 T028 303 Procedure SHOWS TIGHTENING TORQUE UNITS SHOWS DETAILS SHOWS EXPENDABLE PARTS SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION SHOWS SERVICE ITEM (S) INDICATES RELEVANT REFERENCES THAT NEED TO BE FOLLOWED DURING INSTALLATION 2 1 "Removal/Installation" Portion "Inspection After Installation" Portion INSTALL THE PARTS BY PERFORMING STEPS 1—3 IN REVERSE ORDER SHOWS TIGHTENING TORQUE SPECIFICATIONS SHOWS PROCEDURE ORDER FOR SERVICE SHOWS REFERRAL NOTES FOR SERVICE SHOWS REFERRAL NOTES FOR SERVICE SHOWS SPECIAL SERVICE TOOL (SST) NO. am5ezw0000364 TO MODEL INDEX BACK TO CHAPTER INDEX MAZDA CX5 WORKSHOP REPAIR MANUAL

00-00–8 GENERAL INFORMATION Troubleshooting Procedure Basic flow of troubleshooting DTC troubleshooting flow (on-board diagnostic) Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction. The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic function. Diagnostic index The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely relating to the malfunction. Quick diagnosis chart (If mentioned) The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction. Symptom troubleshooting Symptom troubleshooting quickly determines the location of the malfunction according to symptom type. CUSTOMER ARRIVES DTC TABLE DTC CHECK DTC WITHOUT DTC 1. DIAGNOSTIC INDEX 2. QUICK DIAGNOSIS CHART (IF MENTIONED) 3. SYMPTOM TROUBLESHOOTING *: INDICATOR LIGHTS AND WARNING LIGHTS THAT INDICATE MALFUNCTIONS DTC TROUBLESHOOTING FLOW WARNING LIGHT* ON/FLASHING CHECK FOR PRIORITIZED DTC NO WARNING LIGHT* WITH SYMPTOM IGNITION ON TEST, IDLING TEST DIAGNOSE BY DTC DIAGNOSE BY SYMPTOM (SYMPTOM TROUBLESHOOTING) (ON-BOARD DIAGNOSTIC) am5ezw0000364 TO MODEL INDEX BACK TO CHAPTER INDEX MAZDA CX5 WORKSHOP REPAIR MANUAL

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2013-2015 Mazda CX-5 Service & Repair Manual

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