OJT

for SCHEDULED
MAINTENANCE

OJ02 – Maintenance
(Engine)

Mazda Motor Corporation

Technical Service Training
OJT (SCHEDULED MAINTENANCE)
OJ02 – Maintenance (Engine) TC001-08-01J
ENGINE

Engine oil

Engine Oil Replacement

Warning
• Remove and install all parts when the engine is cold, otherwise they can cause
severe burns or serious injury.
• 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.
• 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.

Caution
• In case you spill engine oil 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. Install the oil pan drain plug with a new washer.

Oil pan drain plug tightening torque

30-41 N·m {3.1-4.1 kgf·m, 23-30 ft·lbf}

Note
• The amount of residual oil in the engine can vary according to factors such as the
replacement method, oil temperature. Verify the oil level after engine oil
replacement.

6. Refill the engine with the type and amount of engine oil specified in the table.

7. Install the oil filler cap.

8. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, find the cause and repair or replace the applicable part.

9. Inspect the oil level.

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Engine Level Inspection [LF, L3]

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 and verify that the oil level is between the MAX and MIN
marks on the dipstick.
• If the oil level is below the MIN mark, add engine oil.

Engine oil filter

Oil Filter Replacement

Warning
• Remove and install all parts when the engine is cold, otherwise they can cause
severe burns or serious injury.
• 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.
• 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.

Caution
• In case you spill engine oil on the exhaust system, wipe it off completely. If you fail
to wipe the spilled engine oil, it will produce fumes or even flames because of the
heat.

1. Remove the under cover.

2. Remove the oil filter using the SST.
3. Use a clean rag to wipe off the mounting surface on the cylinder block.
4. Apply clean oil to the O-ring of a new oil filter to prevent the O-ring from twisting.
5. Install the oil filter using the SST with specified tightening torque.

Tightening torque
11.7 - 15.7 N·m {1.2 - 1.6 kgf·m, 8.7 - 11.5 ft·lbf}

6. Fill with the specified amount of engine oil.

7. Start the engine and confirm that there is no oil leakage.
• If there is oil leakage, find the cause and repair or replace the applicable part.
8. Inspect the oil level.
9. Install the under cover.

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Engine valve clearance

Valve Clearance Inspection

1. Remove the battery cover.
2. Disconnect the negative battery cable.
3. Remove the under cover and splash shield.
4. Remove the air cleaner component.
5. Remove the ignition coils.
6. Disconnect the ventilation hose.
7. Remove the cylinder head cover.
8. Measure the valve clearance.
(1) Rotate the crankshaft clockwise so that the No.1 cylinder is at TDC of the
compression stroke.
(2) Measure the valve clearance for the valves as indicated “X” in the table below.

Firing order 1 3 4 2
IN X X
EX X X

• If not within the specification, replace the tappet and adjust the valve clearance to
the median value of the standard.

Standard valve clearance [Engine cold*]

0.27—0.33 mm {0.0107—0.0129 in}

Note
• Make sure to note down the measured values for choosing the suitable replacement
tappets.

9. Rotate the crankshaft clockwise 360° so that the No.4 cylinder is at TDC of the
compression stroke.
10. Measure the valve clearance for the valves as indicated “X” in the table below
and follow Step 8.

Firing order 1 3 4 2
IN X X
EX X X

11. Install the cylinder head cover.

12. Connect the ventilation hose.
13. Install the ignition coils.
14. Install the air cleaner component.
15. Install the under cover and splash shield.

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Intake-air System Manifold Vacuum Inspection

1. Verify that the intake air hoses are installed securely.
2. Warm up the engine.
3. Disconnect the vacuum hose connecting the intake manifold and the purge
solenoid valve (purge solenoid valve side) and install the vacuum gauge.
4. Measure the intake manifold vacuum while idling (no load) by using the vacuum
gauge.
• If not within the specification, perform the following inspections.
- Accelerator cable play
- Compression pressure
- Air suction (installation areas of throttle body, fuel injector, PCV valve, intake
manifold)

Note
• If any air suction exists, the change in engine speed can be made apparent by
spraying the penetrate lubricating spray on the applicable part.

Standard
ZY: -68.0 kPa {-510 mmHg, -20.1 inHg} or more
Z6 (ATX): -71.0 kPa {-533 mmHg, -21.0 inHg} or more
Z6 (MTX): -72.0 kPa {-541 mmHg, -21.3 inHg} or more
(These are normal readings at sea level).

Drive belt

Also inspect and adjust the power steering and air conditioner drive belts, if installed.

Drive Belt Inspection

Note
• Drive belt deflection/tension adjustment is not necessary because of the use of the
drive belt auto tensioner.

Verify that the drive belt auto tensioner indicator mark does not exceed the
limit.
• If it exceeds the limit, replace the drive belt.

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Idle Inspection

ENGINE TUNE-UP [ZY, Z6]

Idle Speed Inspection

Caution
• Changing the TAS while attempting to adjust the idle speed could cause an engine
malfunction. Do not change the TAS adjustment position.

1. Complete the engine tune-up preparation.

2. Verify that the ignition timing is within the specification.
3. Verify that the idle speed is within the specification using the RPM DATA
MONITOR function.
• If not within the specification, adjust the idle speed to within the specification by
turning the AAS after verifying that the ignition timing is within the specification.

Idle speed

ZY
MTX:600—700
ATX (N range):600—700
ATX (D range):525—625

Z6
MTX:600—700
ATX (N range):650—750
ATX (D range):600—700

4. Verify that the idle speed is within the specification when each load is applied. (The
speed decrease just after the load is applied is not considered.)
• If not within the specification with any of the specified loads applied, inspect the IAC
valve.
• If not within the specification when a specified load is applied, inspect the related
input parts, wiring harnesses, and connectors.

Engine Tune-up Preparation

1. Verify the following:
• ATX: Selector lever is in P position.
• MTX: Shift lever is in neutral position.
2. Warm up the engine to normal operating temperature.
(1) Increase the engine speed to 2,500—3,000 rpm until the cooling fan starts
running.
(2) When the cooling fan starts running, release the accelerator pedal and wait until
the cooling fan stops running.
3. Turn off all electrical loads.
4. Connect the WDS or equivalent to the DLC-2.
5. Turn the test mode on using a simulation function.
6. Verify that the idle speed is within the specification using the RPM DATA

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MONITOR function.
• If not within the specification, adjust the idle speed.
Idle speed

Z6
MTX: 600—700
ATX (N range): 650—750
ATX (D range): 600—700

Ignition Timing Inspection

Note
• The ignition timing cannot be adjusted.
• The WDS or equivalent is required to verify the ignition timing.
• Use a timing light that can detect the primary ignition signal.
1. Complete the engine tune-up preparation.
2. Remove the PCM connector cover.

3. By referring to the following procedure, connect the timing light to the PCM
terminal 2A wire.
Caution
• To prevent poor contact at the connector terminal, be careful not to pull the
wire on the connector side.
Note
• Pull out the wire 20—30 mm so that the pickup clip of the timing light can be
connected. After the ignition timing inspection, bundle the pulled out wire back
together with other wires using tape.
(1) Pull the PCM terminal 2A wire out of the bundle (pull the bundled side only, not
the connector side).
(2) Connect the pickup clip of the timing light to the PCM terminal 2A wire.
4. Verify that the crankshaft pulley alignment mark (white) is within the specification.
Ignition timing (Test mode on)
BTDC 9—11°
5. Turn the test mode off using a simulation test.
6. Using the timing light, verify again that the crankshaft pulley alignment mark
(white) is within the specification.
• If not within the specification, inspect the following parts:
— CMP sensor
— CKP sensor
— TP sensor
— ECT sensor
— TR switch (ATX)
— Neutral/clutch switch (MTX)

Ignition timing (Test mode off)

BTDC 6—18°

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COOLING SYSTEM

Cooling system

Cooling System Service Warning

Warning
• Remove and install all parts when the engine is cold, otherwise they can cause
severe burns or serious injury.
• 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
2.5 turns. Step back while the pressure escapes.
• When you are sure all the pressure is gone, turn the cap using the cloth, and
remove it.

Cooling System Cap Inspection

1. Clean the cooling system cap and the sealed part.

2. Inspect the crack or turn over on the sealed part of the cooling system cap.
• If there is malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the radiator cap tester.
4. Hold the cooling system cap downward and apply pressure gradually. Verify that
the pressure holds for 10 sec.
• If the pressure is not held stable within the specification, replace the cooling system
cap.

Pressure
ZY, Z6: 90—110 kPa {0.92—1.12 kgf/cm2, 13.1—15.9 psi}
LF, L3: 135—155 kPa {1.38—1.58 kgf/cm2, 19.6—22.4 psi}

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Engine Coolant Leakage Inspection

1. Inspect the engine coolant level.

2. Remove the cooling system cap.
3. Clean the installation parts of the cooling system cap and the upper radiator hose.
4. Install the SST and a radiator cap tester to the coolant reserve tank filler port.
5. Apply pressure using the radiator cap tester.

Caution
• Applying more than the specified pressure can damage the hoses, fittings, and
other components, and eventually cause leakage.
ZY and Z6: 100 kPa {1.0 kgf/cm2, 14.5 psi},
LF and L3: 145 kPa {1.5 kgf/cm2, 21 psi}

Pressure
ZY, Z6: 100 kPa {1.0 kgf/cm2, 14.5 psi} [1 min]
LF, L3: 145 kPa {1.5 kgf/cm2, 21 psi} [1 min]
6. When pressurizing the coolant reserve tank, verify that the pressure is maintained.
• If the gauge needle drops, it may indicate water leakage.
- If engine coolant leaks from the upper hose installation part, replace the upper hose
and the clamp.
- If the engine coolant leaks from the main body of the radiator (caulked part), replace
the radiator.

Engine coolant

Engine Coolant Level Inspection

1. Verify that the engine coolant level in the coolant reserve tank installed in front of
the suspension tower is between the MIN and MAX marks.

2. If the engine coolant level is below MIN mark, add engine coolant.

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Engine Coolant Protection Inspection

1. Measure the coolant temperature and specific gravity with a thermometer and a
hydrometer.

Caution
• The engine has aluminum parts that can be damaged by alcohol or methanol
antifreeze. Do not use alcohol or methanol in the cooling system. Use only
ethylene-glycol-based coolant.
• Use only soft (demineralized) water in the coolant mixture. Water that contains
minerals will reduce the coolant's performance.

2. Determine the coolant protection by referring to the graph shown.

• If the coolant protection is not proper, add water or coolant.

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FUEL SYSTEM

Air cleaner element

If the vehicle is operated in very dusty or sandy areas, clean and if necessary,
replace the air cleaner element more often than the recommended intervals.

Air Cleaner Element Inspection [ZY, Z6]

1. Remove the air cleaner element.
2. Inspect the following items:
• If there is any abnormality, clean or replace the air cleaner element.
— Has the replacement interval come?
— Is the air cleaner element soiled, damaged, or bent?
— Are the air cleaner case and the air cleaner element correctly sealed?
— Is the correct air cleaner element installed?

Fuel filter/ Fuel lines and hoses

Before Service Precaution

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 from the pressurized fuel system are dangerous. Fuel
can ignite and cause serious injury or death and damage. Fuel can also irritate skin
and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”.
Caution
• If there is foreign material on the connecting area of the quick release connector, it
might damage the connector or fuel pipe. To prevent this, disconnect the connector
and clean the connecting area before connecting.

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Fuel Line Safety Procedure

1. Remove the fuel-filler cap to release the pressure inside the fuel tank.
2. Remove the fuel pump relay.
3. Start the engine.
4. After the engine stalls, crank the engine several times.
5. Turn the ignition switch to the LOCK position.
6. Install the fuel pump relay.

Fuel Filter (High-Pressure) Removal/Installation

1. Follow “BEFORE SERVICE PRECAUTION” before performing any work

operations to prevent fuel from spilling from the fuel system.
2. Disconnect the negative battery cable.
3. Remove the under cover.
4. Remove the quick release connector from the fuel filter (high-pressure).

Type B Removal (Using the SST)

1. Follow “BEFORE SERVICE PRECAUTION” and remove dirt from the

connecting surfaces before performing any work operations.
2. Insert the SST into the quick release connector.
3. Pull out the fuel hose straight from the fuel pipe and disconnect it.
4. Cover the disconnected quick release connector and fuel pipe with vinyl
sheeting or a similar material to prevent it from scratches or dirt.

5. Remove the bracket bolt.

6. Remove the fuel filter (high-pressure).
7. Install in the reverse order of removal.
8. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.

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Type B Installation (Using the SST)

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. 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. Reconnect the fuel hose straight to the fuel pipe until a click is heard.
3. Lightly pull and push the quick release connector a few times by hand, and
then verify that it is connected securely.
4. Inspect all related parts by performing “AFTER SERVICE PRECAUTION”.

After Service Precaution

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 Inspection”.

Fuel Leakage Inspection

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, complete the following inspection with the engine
stopped.

1. Connect the WDS or equivalent to the DLC-2.

2. Turn the ignition switch to the ON position.
3. Using the simulation function “FP”, start the fuel pump.
4. 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.

Standard: There shall be no leakage after 5 min.

5. After reinstallation, repeat step 2—3 in the fuel leakage inspection.

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IGNITION SYSTEM

Spark plugs

Spark Plug Removal/Installation

Caution
• If a spark plug that is not as specified is installed, sealing performance will be
deteriorated. Install only the specified spark plug when replacing.

1. Remove the battery cover.

2. Disconnect the negative battery cable.
3. Remove the air cleaner.
4. Remove the ignition coil.
5. Remove the spark plugs using a plug-wrench.
6. Install in the reverse order of removal.
Tightening torque
14-22 N·m {1.5-2.3 kgf·m, 11-16 ft·lbf}

Spark Plug Inspection

Plug Gap Inspection

Caution
• To avoid possible damage to the tip, do not adjust the plug gap.
• To prevent damaging the tip, use wire type plug gap gauge when inspecting the
plug gap.

1. Measure the spark plug gap using the wire type plug gap gauge.
• If it exceeds the specification, replace the spark plug.

Standard plug gap

ZY, Z6: 1.0—1.1 mm {0.039—0.043 in}
LF, L3: 1.25—1.35 mm {0.049—0.053 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 no-load racing the engine.
• When performing the no-load racing, apply the side brake and foot brake, move the
shift lever to neutral (MTX), or the selector lever to P position (ATX) to prevent
serious injury.
• To avoid possible damage to the spark plug tip, do not use a wire brush for
cleaning.

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Note
• To avoid possible damage to the tip, use gasoline to clean the spark plugs after
removing dirt.

1. If there is carbon adhering to the spark plug, perform no-load racing at 3,000 rpm
for 3 min.

Visual inspection

1. Inspect the following items:

• If there is any malfunction, replace the spark plug.
— Insulator breakage
— Worn electrode
— Damaged gasket
— Badly burned insulator (sparking side)

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EMISSION CONTROL SYSTEM

Evaporative system (if installed)

Positive Crankcase Ventilation (PCV) Valve Inspection

1. Remove the intake manifold.

2. Remove the PCV valve.
3. Verify that there is no airflow when pressure is applied to port A.
• If there is airflow, replace the PCV valve.
4. Verify that there is airflow when vacuum is applied to port A.
• If there is no airflow, replace the PCV valve.

Purge Solenoid Valve Inspection

Evaporative Purge Control Inspection

Without using WDS or equivalent
1. Warm up the engine and idle it.
2. Disconnect the vacuum hose which is connected to the charcoal canister from
purge solenoid valve.
3. Place your finger onto the purge solenoid valve as shown in the figure and verify
that vacuum is applied.

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Power Brake Unit Inspection

Note
• If there is any malfunction in the power brake unit, replace the power brake unit as a
single unit.

Operation inspection
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

1. Start the engine.
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

1. Start the engine.
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

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ELECTRICAL SYSTEM

Battery electrolyte level and specific gravity

Battery Inspection
Warning
• Wear safety glasses to protect your eyes.
• 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 gravity
1. Measure the electrolyte gravity using a hydrometer.
• If it is less than the specification, recharge the battery.

Standard electrolyte gravity

1.22—1.29 [20 °C {68 °F}]

Back-up current
1. Verify that the ignition switch is off and that the key has been removed.
2. Disconnect the negative battery cable.
3. Measure the back-up current between the negative battery terminal and the
negative battery cable.
• 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.
Caution
• Operating electrical loads while the back-up current is being measured can damage
the tester.

Maximum back-up current

20 mA

4. Inspect and repair wiring harnesses and connectors of the fuse where the current
decreased.

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All electrical system

This is a full function check of electrical systems such as lights, wiper and washer
systems (including wiper blades), and power windows.

1. Ignition key illumination

2. Discharge headlight control module
3. Front fog light
4. Front combination light
5. Front side turn light
6. Back-up light switch (MTX)

7. High-mount brake light

8. Inboard light
9. License plate light
10. Rear fog light
11. Rear combination light
12. Cargo compartment light

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13. Hazard warning switch

14. Ashtray illumination
15. Panel light control switch
16. Headlight leveling switch
17. Combination switch
18. Light switch
19. Glove compartment light
20. Map light
21. Interior light

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