2007-2009 Mazda Cx7 Service & Repair Manual

Title Section 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 ALPHABETICAL INDEX AI CONTENTS 2007 Mazda CX-7 Workshop Manual FOREWORD This manual contains on-vehicle service and/or diagnosis procedures for the Mazda CX-7. 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. Mazda Motor Corporation 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. Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page. © 2006 Mazda Motor Corporation PRINTED IN U.S.A., FEBRUARY 2006 Form No. 1871–1U–06B Part No. 9999–95–034B–07

VEHICLE IDENTIFICATION NUMBERS (VIN) JM3 ER29L✻7# 100001— JM3 ER293✻7# 100001— RELATED MATERIALS Material Name MNAO Part No. Mazda Material No. Mazda CX-7 2007 Service Highlights 9999–95–045F–07 3416–1U–06B Engine Workshop Manual L3 WITH TC 9999–95–0L3T–06 1833–1U–05H Automatic Transaxle and Transfer Workshop Manual AW6A-EL AW6AX-EL 9999–95–0AW6–07 1874–1U–06B Mazda CX-7 Bodyshop Manual 9999–95–093F–07 3419–1U–06C Mazda CX-7 2007 Wiring Diagram 9999–95–068G–07 5666–1U–06B

00 GENERAL INFORMATION 00-00–1 SECTION 00-00 Toc of SCT GENERAL INFORMATION . . . . 00-00 Toc of SCT 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER (VIN) CODE . . . . . . . . . . . . . . 00-00–2 VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . 00-00–2 HOW TO USE THIS MANUAL . . . . . . . . . 00-00–3 Range of Topics . . . . . . . . . . . . . . . . . . 00-00–3 Service Procedure . . . . . . . . . . . . . . . . 00-00–3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5 Advisory Messages . . . . . . . . . . . . . . . . 00-00–5 Troubleshooting Procedure . . . . . . . . . . 00-00–6 Procedures for Use . . . . . . . . . . . . . . . . 00-00–7 UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–12 Conversion to SI Units (Système International d'Unités) . . . . . 00-00–12 Rounding Off . . . . . . . . . . . . . . . . . . . . . 00-00–12 Upper and Lower Limits . . . . . . . . . . . . 00-00–12 SERVICE CAUTIONS . . . . . . . . . . . . . . . . 00-00–13 Protection of the Vehicle . . . . . . . . . . . . 00-00–13 Preparation of Tools and Measuring Equipment . . . . . . . . . . . . . 00-00–13 Special Service Tools . . . . . . . . . . . . . . 00-00–13 Malfunction Diagnosis System . . . . . . . 00-00–13 Disconnection of the Negative Battery Cable . . . . . . . . . . . . . . . . . . . 00-00–13 Oil Leakage Inspection . . . . . . . . . . . . . 00-00–14 Removal of Parts . . . . . . . . . . . . . . . . . . 00-00–14 Disassembly . . . . . . . . . . . . . . . . . . . . . 00-00–15 Inspection During Removal, Disassembly . . . . . . . . . . . . . . . . . . . . 00-00–15 Arrangement of Parts . . . . . . . . . . . . . . 00-00–15 Cleaning of Parts. . . . . . . . . . . . . . . . . . 00-00–15 Reassembly . . . . . . . . . . . . . . . . . . . . . 00-00–16 Adjustment . . . . . . . . . . . . . . . . . . . . . . 00-00–16 Rubber Parts and Tubing . . . . . . . . . . . 00-00–16 Hose Clamps. . . . . . . . . . . . . . . . . . . . . 00-00–17 Torque Formulas . . . . . . . . . . . . . . . . . . 00-00–17 Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–17 Dynamometer . . . . . . . . . . . . . . . . . . . . 00-00–17 AWD inspection/service . . . . . . . . . . . . 00-00–18 SST . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–19 INSTALLATION OF RADIO SYSTEM . . . . . . . . . . . . . . . . . . 00-00–20 ELECTRICAL SYSTEM. . . . . . . . . . . . . . 00-00–20 Electrical Parts . . . . . . . . . . . . . . . . . . . 00-00–20 Wiring Harness. . . . . . . . . . . . . . . . . . . 00-00–20 Connectors . . . . . . . . . . . . . . . . . . . . . . 00-00–21 Terminals . . . . . . . . . . . . . . . . . . . . . . . 00-00–22 Sensors, Switches, and Relays . . . . . . 00-00–23 Wiring Harness. . . . . . . . . . . . . . . . . . . 00-00–23 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–24 Viewing orientation for Connectors . . . . . . . . . . . . . . . . . . . . . 00-00–24 Electrical Troubleshooting Tools . . . . . . 00-00–25 Precautions Before Welding . . . . . . . . . 00-00–26 JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITIONS . . . . . . . . . 00-00–27 Jacking Positions . . . . . . . . . . . . . . . . . 00-00–27 Vehicle Lift Positions. . . . . . . . . . . . . . . 00-00–28 Safety Stand Positions . . . . . . . . . . . . . 00-00–28 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–29 Towing a 2WD Vehicle . . . . . . . . . . . . . 00-00–29 Towing a AWD Vehicle . . . . . . . . . . . . . 00-00–30 Towing/Tiedown Hooks . . . . . . . . . . . . 00-00–30 TIEDOWN HOOK. . . . . . . . . . . . . . . . . . . 00-00–31 IDENTIFICATION NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . 00-00–32 Vehicle Identification Number (VIN) . . . . . . . . . . . . . . . . . . . 00-00–32 Engine Identification Number . . . . . . . . 00-00–32 SAE STANDARDS . . . . . . . . . . . . . . . . . . 00-00–33 ABBREVIATIONS . . . . . . . . . . . . . . . . . . 00-00–34 PRE-DELIVERY INSPECTION . . . . . . . . 00-00–35 Pre-Delivery Inspection Table. . . . . . . . 00-00–35 SCHEDULED MAINTENANCE . . . . . . . . 00-00–37 Scheduled Maintenance Table for U.S.A., CANADA and Puerto Rico . . . . . . . . . 00-00–37 End of Toc NG: GENERAL INFORMATION

GENERAL INFORMATION 00-00–2 VEHICLE IDENTIFICATION NUMBER (VIN) CODE id000000100200 End Of Sie VEHICLE IDENTIFICATION NUMBER (VIN) id000000100300 JM3 ER29L*7# 100001— JM3 ER293*7# 100001— End Of Sie WM: GENERAL INFORMATION J M 3 E R 2 9 3 * 7 # 1 2 3 4 5 6 Model year Plant Serial No. 0= Hiroshima 1= Hofu 7= 2007 Engine Body, Gross vehicle weight class 9= Wagon, Gross vehicle weight class C (1814—2267 kg) Carline, Series ER= Mazda CX-7 JM3= Mazda/Multi-purpose vehicle category/U.S.A. World manufacturer identification Check digit *= 0 to 9, X L= 2.3 L (California (L3 WITH TC)) 3= 2.3 L (Federal/CANADA (L3 WITH TC)) Resraint system 2= with Curtain and Side air bags acxuuw00002316

GENERAL INFORMATION 00-00–3 00-00 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. 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. 49 H002 671 49 H032 322 49 1232 670A SHOWS PROCEDURE ORDER FOR SERVICE Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure. Tightening torque SHOWS TIGHTENING TORQUE SPECIFICATIONS Caution Connect the gauge set from under the vehicle to prevent contact with the drive belt and the cooling fan. 39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf} acxuuw00000434

GENERAL INFORMATION 00-00–4 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. GREASE GREASE GREASE GREASE INDICATES RELEVANT REFERENCES THAT NEED TO BE FOLLOWED DURING INSTALLATION SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION SHOWS SPECIAL SERVICE TOOL (SST) NO. SHOWS TIGHTENING TORQUE SPECIFICATIONS SHOWS PROCEDURE ORDER FOR SERVICE SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS EXPENDABLE PARTS SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS KNUCKLE UPPER TRAILING LINK LOWER TRAILING LINK SST SST SST SST R R R R 9 2 1 4 5 3 6 1 2 8 7 12 10 11 N·m {kgf·m, ft·lbf} 118—156 {12.0—16.0, 87—115} 94—116 {9.5—11.9, 69—86} 44—60 {4.4—6.2, 32—44} 43—56 {4.3—5.8, 32—41} 49 T028 304 49 T028 305 49 T028 303 Procedure "Removal/Installation" Portion "Inspection After Installation" Portion INSTALL THE PARTS BY PERFORMING STEPS 1 3 IN REVERSE ORDER SHOWS REFERRAL NOTES FOR SERVICE SHOWS REFERRAL NOTES FOR SERVICE 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. SHOWS SERVICE ITEM (S) 1 Split pin 2 Nut 3 Lower trailing link ball joint 4 (See 02-14-5 Lower Trailing Link Ball Joint Removal Note) Bolt 5 Lower trailing link 6 Dust boot (lower trailing link) 7 Split pin 8 Nut 9 Upper trailing link ball joint (See 02-14-5 Upper Trailing Link Ball Joint Removal Note) 10 Nut 11 Upper trailing link 12 Dust boot (upper trailing link) Lower Trailing Link Ball Joint, Upper Trailing Link Ball Joint Removal Note Remove the ball joint using the SSTs. — acxuuw00000435

GENERAL INFORMATION 00-00–5 00-00 Symbols • There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. use. These symbols show application points or use of these materials during service. 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. Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil Apply brake fluid New appropriate brake fluid Apply automatic transaxle/ transmission fluid New appropriate automatic transaxle/ transmission fluid Apply grease Appropriate grease Apply sealant Appropriate sealant Apply petroleum jelly Appropriate petroleum jelly Replace part O-ring, gasket, etc. Use SST or equivalent Appropriate tools OIL BRAKE FLUID A ATF TF GREASE GREASE SEALANT P R SST

GENERAL INFORMATION 00-00–6 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 NO WARNING LIGHT* WITH SYMPTOM CHECK DTC IGNITION ON TEST, IDLING TEST WITHOUT DTC DIAGNOSE BY SYMPTOM (SYMPTOM TROUBLESHOOTING) 1. DIAGNOSTIC INDEX 2. QUICK DIAGNOSIS CHART (IF MENTIONED) 3. SYMPTOM TROUBLESHOOTING *: INDICATOR LIGHTS AND WARNING LIGHTS THAT INDICATE MALFUNCTIONS DTC TROUBLESHOOTING FLOW DIAGNOSE BY DTC (ON-BOARD DIAGNOSTIC) WARNING LIGHT* ON/FLASHING CHECK FOR PRIORITIZED DTC acxuuw00000444

GENERAL INFORMATION 00-00–7 00-00 Procedures for Use Using the basic inspection (section 05) • Perform the basic inspection procedure before symptom troubleshooting. • Perform each step in the order shown. • The reference column lists the location of the detailed procedure for each basic inspection. • Although inspections and adjustments are performed according to the reference column procedures, if the cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the action column. BASIC INSPECTION STEP INSPECTION ACTION 1 2 3 4 5 Perform the stall test. (See 05-13-4 Stall Speed Test.) Is the stall speed normal? Yes Yes Yes Yes Yes No No No No No Go to the next step. Go to next step. Go to the next step. Go to the next step. Go to the next step. REFERENCE COLUMN SHOWS INSPECTION ORDER SHOWS ITEM NAMES FOR DETAILED PROCEDURES SHOW POINTS REQUIRING ATTENTION BASED ON INSPECTION RESULTS Repair or replace any malfunctioning parts according to the inspection result. Repair or replace any malfunctioning parts according to the inspection result. Flush ATX and cooler line as necessary. Repair or replace any malfunctioning parts according to the inspection result. Repair or replace any malfunctioning parts according to the inspection result. Perform the mechanical system test. (See 05-13-3 MECHANICAL SYSTEM TEST.) Is mechanical system normal? Inspect the ATF color condition. (See 05-13-8 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION.) Are ATF color and odor normal? Perform the line pressure test. (See 05-13-3 Line Pressure Test.) Is the line pressure normal? Turn the ignition switch to the ON position. When the selector lever is moved, does the selector illumination indicate synchronized position to the lever location? Also, when other ranges are selected from N or P during idling, does the vehicle move within 1—2 s? Inspect the selector lever and TR switch. Repair or replace malfunctioning parts. (See 05-14-5 SELECTOR LEVER INSPECTION.) (See 05-13-10 TRANSMISSION RANGE (TR) SWITCH INSPECTION.) If the selector lever and TR switch are normal, go to the next step. Inspect the voltage at the following TCM terminals. (See 05-13-29 TCM INSPECTION.) Terminal 2J (TFT sensor) Terminals 1D, 2B, 2C, 2E (TR switch) Terminal 2G (turbine sensor) Terminal 2D (down switch) Terminal 2I (up switch) Terminal 1E (M range switch) Terminal 1W (steering shift switch) Is the voltage normal? Yes No Go to the next step. Repair or replace any malfunctioning parts according to the inspection result. acxuuw00000445

GENERAL INFORMATION 00-00–8 Using the DTC troubleshooting flow • DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each DTC. B E D 36 88 4 4 4 7 5 6 6 POSSIBLE CAUSE 1 2 4 3 A B C D E 1P DTC P0103 DTC PO103 DETECTION CONDITION MAF sensor malfunction Connector or terminal malfunction Open circuit in wiring between MAF sensor terminal D and PCM terminal 36 Open circuit in MAF sensor ground circuit PCM MAF SENSOR MAF SENSOR HARNESS SIDE CONNECTOR PCM HARNESS SIDE CONNECTOR Diagnostic procedure STEP INSPECTION Has FREEZE FRAME DATA been recorded? VERIFY RELATED REPAIR INFORMATION AVAILABILITY Connect diagnostic tool to DLC-2. Start engine. Access MAF V PID using diagnostic tool. Is MAF V PID within 0.2 - 8.3 V? Turn ignition key to OFF. Disconnect MAF sensor connector. Are there any malfunctions? ACTION Go to next step. Yes No Yes No Yes No Yes If vehicle is not repaired, then go to next step. Go to next step. Go to next step. Repair or replace terminals, then go to Step 8. POSSIBLE CAUSE describes possible point(s) of malfunction Indicates the inspection step No. to be performed (01 and 05 section) STEP shows the order of troubleshooting INSPECTION describes the method to quickly determine the malfunctioning part(s). Reference item(s) to perform ACTION. ACTION describes the appropriate action to be taken according to the result (Yes/No) of the INSPECTION. Indicates the connector related to the inspection Indicates the circuit to be inspected (01 and 05 section) DETECTION CONDITION describes the condition under which the DTC is detected. Check for poor connection (damaged, pulled- out terminals, corrosion etc.). INSPECT POOR CONNECTION OF MAF SENSOR CONNECTOR VERIFY CURRENT INPUT SIGNAL STATUS IS CONCERN INTERMITTENT OR CONSTANT Are related Service Bulletins and/or on-line repair information available? VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record FREEZE FRAME DATA on repair order, then go to next step. Perform repair or diagnosis according to available repair information. Intermittent concern is existing. Go to INTERMITTENT CONCERNS TROUBLESHOOTING procedure. (See 01-03-33 INTERMITTENT CONCERN TROUBLESHOOTING) FROM MAIN RELAY TERMINAL D MIL illuminates if PCM detects the above malfunction during first drive cycle. Therefore, PENDING CODE is not available. FREEZE FRAME DATE is available. DTC is stored in the PCM memory. This is a continuous monitor (CCM). Diagnostic support note PCM monitors input voltage from TP sensor after ignition key is turned on. If input voltage at PCM terminal 68 is above 8.25 V, PCM determines that TP circuit has malfunction. MAF circuit high input TROUBLE CONDITION acxuuw00000446

2007-2009 Mazda Cx7 Service & Repair Manual

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