CAPSULE CONSTRUCTION REMOVAL/INSTALLATION [PYUL]

CAPSULE CONSTRUCTION REMOVAL/INSTALLATION [PYUL]SM3329731

id01101a959700

D-code

• 564GX

Remove Capsule Cover

1.Remove in the order indicated in the table.

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Step	Part name
1	Capsule cover (See Capsule cover removal note)

Capsule cover removal note

1.Turn the fasteners as shown in the figure.

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Perform Precaution Before Service

Warning

• Always keep sparks and flames away from fuel. Fuel can easily ignite which could cause serious injury or death, and damage to equipment.

• Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, perform the [BEFORE SERVICE PRECAUTION] before servicing to prevent the fuel from spraying.

― Fuel may cause irritation if it comes in contact with skin and eyes.

― If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

• A person charged with static electricity could cause a fire or explosion, resulting in death or serious injury. Before servicing the fuel system, make sure to discharge static electricity by touching a vehicle.

Caution

• If foreign matter enters the fuel passage, it could cause serious damage to the fuel injection related parts. When removing/installing the fuel injection related parts, pay close attention so that foreign matter does not enter the fuel passage.

1.Disconnect the negative lead-acid battery terminal.

2.Remove the fuel-filler cap and decrease the pressure in the fuel tank.

3.Remove the fuel pump relay.

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1	Fuel pump relay

4.Disconnect the high pressure fuel pump connector.

5.Connect the negative lead-acid battery terminal.

6.Start the engine.

7.After engine stall, crank the engine 2 to 3 times repeatedly and verify that the engine idling condition is not maintained (to relieve pressure in fuel pipe).

8.Switch the main power OFF.

9.Disconnect the negative lead-acid battery terminal.

10.Install the fuel pump relay.

11.Connect the high pressure fuel pump connector.

High Voltage Part Inspection And Removal/Installation Notes

Warning

<<High voltage>>

• If the necessary measures are not taken before servicing the e-SKYACTIV PHEV, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the e-SKYACTIV PHEV, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures.

• Vehicles damaged in an accident could have electrical leakage due to internal damage of the high voltage battery. If servicing is carried out under electrical leakage conditions, it could cause electrical shock and result in serious injury or, in the worst case, death.

• Refer to [Handling high voltage battery on damaged vehicle] in [DAMAGED VEHICLE HANDLING] in the general information and determine if an internal inspection of the high voltage battery is necessary. Perform servicing only if an internal inspection of the high voltage battery is unnecessary. If it is determined that an internal inspection of the high voltage battery is necessary, contact the technical assistance for your market without performing servicing.

• Inspection/removal/installation servicing of the high-voltage parts of this vehicle is a dangerous operation defined by the Industrial Safety and Health Law. For this reason, the inspection and removal/installation work on high voltage parts can only be performed by a person who has completed special training for low voltage line work.

• Wear insulating gloves when inspecting or removing/installing the high voltage parts. Contact with a high voltage part when you are not wearing insulating gloves may result in serious injury or death caused by electric shock.

• Before inspecting or removing/installing the high voltage parts, remove the service plug and wait until 10 min have elapsed. Servicing without removing the service plug or before 10 min have elapsed after removing the service plug could cause electrical shock and result in serious injury or, in the worst case, death.

• Do not spin the tires while inspecting or removing/installing the high voltage parts. If the tires spin, power generation occurs even if the service plug is removed. If power generation occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

• Verify that the charging connector is not connected to the vehicle when inspecting or removing/installing the high voltage parts. If the charging connector is connected to the vehicle, high voltage may be supplied to the vehicle. If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

• Always observe the following thoroughly to ensure safety when inspecting or removing/installing the high voltage parts. Otherwise, the high voltage circuit may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

― Do not perform normal charging

― Access connected vehicle maintenance mode (MyMazda App connected vehicle)

― Cancel climate control timer

• When inspecting or removing/installing the high voltage parts, place a high voltage work sign on the vehicle to alert other workers.

Caution

<<High voltage>>

• Do not switch the main power ON (READY on) after removing the service plug. If the main power is switched ON (READY on) after removing the service plug, a malfunction may occur with the vehicle.

Note

• The high voltage parts can be identified as follows.

― Parts that are connected using orange wiring harnesses

― Parts with a high voltage warning label attached

1.Prepare what is shown in the figure.

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1	Insulating gloves
2	Electrical-hazard safety shoes
3	High voltage work sign
4	Electrical tape
5	Voltmeter (Capable of measuring DC 450 V or more)

2.When servicing the drive system, perform the following operation.

(1)Switch the main power ON (READY on).

Note

• Disconnect the negative lead-acid battery terminal within 20 min of operation because the selector lever position will shift to the P position on its own after 20 min have elapsed.

(2)Shift the selector lever to the N position.

(3)Release the electric parking brake. (Parking brake release is not required for rear brake system)

(4)Switch the main power OFF.

3.Verify that the READY indicator in the instrument cluster is not turned on.

4.Move the front seat forward.

Remove Cover Assembly (Passenger's Side)

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Cover assembly (See Cover assembly removal note.)

Cover assembly removal note

Note

• Release the clips according to the lock/unlock mark on the cowl grille cover.

1.Remove the cover assembly as shown in the figure.

• The figure shows the left side (same as right side).

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Symbol	Content
	Servicing procedure

Disconnect Negative Lead-Acid Battery Terminal

With e-SKYACTIV PHEV

Warning

• Before removing the SRS air bag system-related parts, always disconnect the negative lead-acid battery terminal and wait for 1 min or more to allow the back-up power supply to deplete its stored power.

• Contact with the positive lead-acid battery terminal could cause electrocution due to a short circuit and result in serious injury or death, or damage to vehicle parts. Do not contact the positive lead-acid battery terminal when performing the procedure.

Caution

• If the nut for the current sensor is loosened with the negative lead-acid battery terminal connected to the lead-acid battery, excessive torque will be applied to the negative lead-acid battery terminal and the lead-acid battery terminal will be damaged. When removing the negative lead-acid battery terminal and current sensor, be careful not to damage the lead-acid battery terminal.

• Be careful not to contact the positive lead-acid battery terminal.

1.Verify that the charge cable is not connected to the charging port.

• If the charge cable is connected to the charging port, remove the charge cable.

2.Keep the driver's door open.

3.Keep the hood open.

4.Keep the main power switched ON (READY on) for 3 s or more.

5.Switch the main power OFF and start measuring the time since the main power was switched OFF using a stopwatch.

Caution

• If the cooling fan does not stop after 5 min have elapsed since the main power was switched OFF, wait until it stops.

• If the [Battery cooling] operation notification is displayed on the center display, do not make a selection and leave it as it is.

6.Switch the main power OFF and wait for 5 min.

Warning

• Before servicing after disconnecting the negative lead-acid battery terminal, wait for 1 min or more.

Caution

• If the time since the main power was switched OFF in Step 5 to the disconnection of the negative lead-acid battery terminal exceeds 25 min, perform the procedure from Step 3 again.

Note

• In order to prevent it from falling off, the negative lead-acid battery terminal nut cannot be removed.

• After the negative lead-acid battery is disconnected, there is no restriction on opening/closing the door.

7.Disconnect the negative lead-acid battery terminal within 25 min from switching the main power OFF in Step 5 using the following procedure.

(1)Disconnect the current sensor connector.

(2)Disconnect the negative lead-acid battery terminal.

• When disconnecting a negative lead-acid battery terminal with deformed plastic, expand the gap of the negative lead-acid battery terminal using a flathead screwdriver, and remove the terminal.

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Symbol	Content
	5 N·m {51 kgf·cm, 44 in·lbf}

Without e-SKYACTIV PHEV

Warning

• Before removing the SRS air bag system-related parts, always disconnect the negative battery terminal and wait for 1 min or more to allow the back-up power supply to deplete its stored power.

• Contact with the positive battery terminal could system may electrocution due to a short circuit and result in serious injury or death, or damage to vehicle parts. Do not contact the positive battery terminal when performing the procedure.

Caution

• Do not perform servicing for a long period ( 10 min or more) with the engine switch ON (engine stop).

1.Connect the M-MDS to the DLC-2.

2.Turn ON the engine switch (engine stop).

3.Verify the[BATT_SOC] value using the M-MDS data logger function.

4.Record the [BATT_SOC] value.

[BATT_SOC] value is less than 75%

• Inspect the battery.

[BATT_SOC] value is 75% or more

• Go to the next step.

5.Turn OFF the engine switch.

Caution

• If the nut for the current sensor is loosened with the negative battery terminal connected to the battery, excessive torque will be applied to the negative battery terminal and the battery terminal will be damaged. When removing the negative battery terminal and current sensor, be careful not to damage the battery terminal.

• Be careful not to contact the positive battery terminal.

6.Disconnect the current sensor connector.

Note

• The positive battery terminal nut cannot be removed to prevent it from falling off.

7.Disconnect the negative battery terminal.

• When disconnecting the plastic deformed negative battery terminal, expand the gap of the negative battery terminal using a flathead screwdriver for removal.

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Symbol	Content
	5 N·m {51 kgf·cm, 44 in·lbf}

Remove 150 W Power Supply Unit

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Cover (See Cover removal note.)	—
2	Connector	—
3	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
4	150 W power supply unit	—

Cover removal note

1.Remove the cover as shown in the figure.

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Remove Service Hole Cover (High Voltage Battery)

1.Remove in the order indicated in the table.

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Step	Part name
1	Cover (See Cover Removal Note.)	—
2	Screw	2.5 N·m {25 kgf·cm, 22 in·lbf}
3	Service hole cover (high voltage battery)	—

Cover Removal Note

1.Patially peel back the cover together with the bottom mat in the direction of the arrow as shown in the figure..

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Remove Service Plug

1.Remove in the order indicated in the table.

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Step	Part name
1	Service plug (See Service plug removal note) (See Service plug installation note)

Service plug removal note

1.Slide the lock in the direction of the arrow shown in the figure. (It will not be completely pulled out.)

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2.Raise the lever.

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3.Press the area indicated by arrow (1) shown in the figure, release the tabs, and then raise the lever until it is perpendicular.

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Symbol	Content
	Servicing procedure

4.Hold the lever and pull the service plug out straight up.

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5.After removing the service plug, leave it for 10 min.

Service plug installation note

1.Insert the service plug completely.

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2.Press the lever down completely.

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3.Slide the lock in the direction of the arrow shown in the figure.

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Remove Front Under Cover No.3

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fastener	—
3	Front undercover No.3	—

Remove Floor Under Cover (Left side)

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Cap nut	—
2	Fastener	—
3	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
4	Floor under cover	—

Remove Rear Under Cover No.1 (Lelf Side)

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Nut	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Fastener	—
3	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
4	Cap nut	—
5	Rear under cover No.1	—

Remove Terminal Cover (High Voltage Battery Side)

1.Remove in the order indicated in the table.

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Step	Part name
1	Bolt	—	11 N·m {110 kgf·cm, 95 in·lbf}
2	Terminal cover (high voltage battery side)	—	—
3	Gasket	Replacement part	—

Perform High Voltage Handling

Note

• Use a voltmeter with a measurement range of DC 450 V or more.

1.Measure the voltage at the connection points of the high voltage cables.

• Verify that the voltmeter indicates 0 V and go to the next step.

• Verify that the moisture seal is properly installed to the terminal cover.

• Install securely, being careful not to damage the interlock.

Remove Front Under Cover No.2

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fastener	—
3	Front under cover No.2	—

Remove Front Under Cover No.1

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Screw	2 N·m {20 kgf·cm, 17 in·lbf}
3	Fastener	—
4	Front under cover No.1	—

Remove Floor Under Cover (Right side)

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Fastener	—
2	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
3	Floor under cover	—

Remove Rear Under Cover No.1 (Right Side)

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Nut	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Fastener	—
3	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
4	Cap nut	—
5	Rear under cover No.1	—

Remove Cooling System Cap (Sub) (PYUL)

1.Remove in the order indicated in the table.

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Step	Part name
1	Cooling system cap (sub)

Remove Cooling System Cap

1.Remove in the order indicated in the table.

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Step	Part name
1	Cooling system cap

Drain Engine Coolant (Main)

1.Open the coolant reserve tank cap.

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1	Coolant reserve tank cap

2.Drain the engine coolant (main) from the coolant reserve tank.

3.Remove the drain plug (main) and drain the engine coolant (main).

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1	Drain plug (main)

4.Install the drain plug (main).

Recover Refrigerant

1.Correctly collect the refrigerant following the instructions for the chlorofluorocarbon (CFC) recovery device being used.

• When collecting the refrigerant, weigh the exhausted compressor oil.

Remove Cover Assembly (Driver's Side )

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Cover assembly (See Cover assembly removal note.)

Cover assembly removal note

Note

• Release the clips according to the lock/unlock mark on the cowl grille cover.

1.Remove the cover assembly as shown in the figure.

• The figure shows the left side (same as right side).

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Symbol	Content
	Servicing procedure

Remove Driver's Side Wiper Arm Cover

1.Remove using the procedure shown in the figure.

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Procedure	Part name
1	Windshield washer hose
2	Driver's side wiper arm cover

Remove Passenger's Side Wiper Arm Cover

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Windshield washer hose
2	Passenger's side wiper arm cover

Remove Driver's Side Windshield Wiper Arm And Blade

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Nut	25.5 N·m {2.6 kgf·m, 18.8 ft·lbf}
2	Driver's side windshield wiper arm and blade (See Driver's side windshield wiper arm and blade installation note)	—

Driver's side windshield wiper arm and blade installation note

1.Use a wire brush to clean the serrated connecting part.

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Symbol	Content
1	Serration engagement area

• If the serrated connecting part is damaged, replace the windshield wiper motor and link.

2.Align the driver’s side windshield wiper blade end with the hollowed mark in the ceramic coating and install.

• If the hollowed mark in the ceramic coating cannot be located, adjust the driver’s side windshield wiper blade end to the range shown in the figure and install.

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Symbol	Content
	8—12 mm {0.32—0.47 in}
1	Ceramic hollow mark
2	Driver's side windshield wiper blade
3	Cowl grille

3.Install the nut.

4.Switch the ignition ON (engine off or on).

5.Operate the windshield wipers at low speed.

6.Turn the windshield wiper switch OFF.

7.Verify that the driver's side windshield wiper is stopped at the park position by the auto-stop function.

• If the driver's side windshield wiper is not installed to the park position, change the driver's side windshield wiper arm and serrated connecting part one groove at a time and adjust it to the park position.

Remove Passenger’s Side Windshield Wiper Arm And Blade

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Nut	25.5 N·m {2.6 kgf·m, 18.8 ft·lbf}
2	Passenger's side windshield wiper arm and blade (See Passenger's side windshield wiper arm and blade installation note.)	—

Passenger's side windshield wiper arm and blade installation note

1.Use a wire brush to clean the serrated connecting part.

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Symbol	Content
1	Serration engagement area

• If the serrated connecting part is damaged, replace the windshield wiper motor and link.

2.Align the passenger's side windshield wiper blade end with the hollowed mark in the ceramic coating and install.

• If the hollowed mark in the ceramic coating cannot be located, adjust the passenger's side windshield wiper blade end to the position shown in the figure and install.

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Symbol	Content
	13—17 mm {0.52—0.66 in}
1	Ceramic hollow mark
2	Passenger's side windshield wiper blade
3	Front fender molding

3.Install the nuts.

4.Switch the ignition ON (engine off or on).

5.Operate the windshield wipers at low speed.

6.Turn the windshield wiper switch OFF.

7.Verify that the windshield wipers are stopped at the park position by the auto-stop function.

• If the passenger's side windshield wiper is not installed to the park position, change the passenger's side windshield wiper arm and serrated connecting part one groove at a time and adjust it to the park position.

Remove Driver's Side Front Fender Molding

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Front fender molding (See Front fender molding removal note.)

Front fender molding removal note

1.Remove the front fender molding as shown in the figure.

• The figure shows the left side (same as right side).

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Symbol	Content
	Servicing procedure

Remove Passenger's Side Front Fender Molding

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Front fender molding (See Front fender molding removal note.)

Front fender molding removal note

1.Remove the front fender molding as shown in the figure.

• The figure shows the left side (same as right side).

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Symbol	Content
	Servicing procedure

Remove Cowl Grille

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Washer hose
2	Fastener
3	Cowl grille (See Cowl grille removal note.)
4	Cowl grille weatherstrip (See Cowl grille weatherstrip removal note.)

Cowl grille removal note

1.Remove the cowl grille as shown in the figure.

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Cowl grille weatherstrip removal note

1.Remove the cowl grille weatherstrip as shown in the figure.

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Remove Side Cowl Grille (Passenger's Side)

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Fastener
2	Side cowl grille

Remove Side Cowl Grille (Driver's Side )

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Fastener
2	Side cowl grille

Remove Windshield Wiper Motor And Link

Caution

• Always apply protective tape to the windshield edge. If the windshield wiper motor and link contacts the windshield, it could damage the windshield.

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Symbol	Content
	Protective tape attachment positions

1.Remove using the procedure shown in the figure.

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Step	Part name
1	Connector	—
2	Bolt (See Bolt installation note.)	8.0 N·m {82 kgf·cm, 71 in·lbf}
3	Windshield wiper motor and link	—

Bolt installation note

1.Install the bolts shown in the figure.

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Symbol	Content
	Temporarily tighten
	8.0 N·m {82 kgf·cm, 71 in·lbf}

Disconnect Positive Lead-Acid Battery Terminal

1.Remove in the order indicated in the table.

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Step	Part name
1	Nut	6 N·m {61 kgf·cm, 53 in·lbf}
2	Bolt	5 N·m {51 kgf·cm, 44 in·lbf}
3	Lead-acid battery cap	—
4	Nut	9.5 N·m {95 kgf·cm, 82 in·lbf}
5	Starter wiring harness	—
6	Lead-acid battery (plus) terminal component	—

Remove Driver Side Strut Tower Bar

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Wiring harness clip (See Wiring harness clip removal note.)	—
2	Bolt	35 N·m {3.55 kgf·m, 25.8 ft·lbf}
3	Nut	35 N·m {3.55 kgf·m, 25.8 ft·lbf}
4	Strut tower bar	—

Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.

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Remove Passenger Side Strut Tower Bar

1.Remove using the procedure shown in the figure.

• The figure shows the right side (same as left side).

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Step	Part name	Applicable condition
1	Connector	With windshield wiper de-icer	—
2	Wiring harness clip (See Wiring harness clip removal note.)	—	—
3	Bolt	—	35 N·m {3.55 kgf·m, 25.8 ft·lbf}
4	Nut	—	35 N·m {3.55 kgf·m, 25.8 ft·lbf}
5	Strut tower bar	—	—

Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.

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Remove Engine Compartment Insulator (Upper)

1.Remove in the order indicated in the table.

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Step	Part name
1	Screw (See Screw installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Fastener	—
3	Engine compartment insulator (upper)	—

Screw installation note

1.Install the screws as shown in the figure.

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Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Air Cleaner Component

1.Remove in the order indicated in the table.

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Step	Part name
1	Ventilation hose	—
2	Connector	—
3	Hose clamp	3 N·m {30 kgf·cm, 26 in·lbf}
4	Bolt	9.5 N·m {95 kgf·cm, 82 in·lbf}
5	Air cleaner component	—

Remove Front Tires(LH)

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Nut	127.5 N·m {13 kgf·m, 94.05 ft·lbf}
2	Wheel and tire (See Wheel and tire installation note.)	—

Wheel and tire installation note

1.When installing the wheel and tire, tighten the wheel nuts in a criss-cross pattern.

• The figure shows the left side (same as right side).

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Symbol	Content
	Servicing procedure

Remove Front Tires(RH)

1.Remove using the procedure shown in the figure.

• The figure shows the right side (same as left side).

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Step	Part name
1	Nut	127.5 N·m {13 kgf·m, 94.05 ft·lbf}
2	Wheel and tire (See Wheel and tire installation note.)	—

Wheel and tire installation note

1.When installing the wheel and tire, tighten the wheel nuts in a criss-cross pattern.

• The figure shows the right side (same as left side).

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Symbol	Content
	Servicing procedure

Remove Driver Side Edge Rubber

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Fastener
2	Edge rubber (See Edge rubber removal note.)

Edge rubber removal note

1.Partially peel back the cowl grille weatherstrip until the A-pillar trim can be removed.

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2.Remove the edge rubber.

Remove Passenger Side Edge Rubber

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Fastener
2	Edge rubber (See Edge rubber removal note.)

Edge rubber removal note

1.Partially peel back the cowl grille weatherstrip until the A-pillar trim can be removed.

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2.Remove the edge rubber.

Remove Driver Side Front Over Fender Lower

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Fastener
2	Front over fender lower (See Front over fender lower removal note.) (See Front over fender lower installation note.)

Front over fender lower removal note

1.Press the front over fender lower in the direction of the arrow (1) shown in the figure to create a gap of approx. 3 mm {1 in} between the front over fender lower and the front fender.

• The figure shows the left side (same as right side).

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Symbol	Content
	Approx. 3 mm {0.1 in}

2.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).

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Symbol	Content
	Protective tape attachment positions

3.Insert a remover tool into the position shown in the figure, move it in the direction of the arrow, and then detach the clip from the body.

• The figure shows the left side (same as right side).

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Symbol	Content
	50 mm {2.0 in}
	25 mm {0.98 in}

4.Detach the clips from the body using a remover tool.

• The figure shows the left side (same as right side).

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Symbol	Content
	Servicing procedure

5.Remove the front over fender lower.

Front over fender lower installation note

Warning

• If the front over fender lower is installed with the clips damaged, the front over fender lower may fall off while the vehicle is being driven, leading to a serious accident. If the clips are damaged, replace them with new one.

Remove Driver Side Front Over Fender Upper

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

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Step	Part name
1	Fastener
2	Front over fender upper (See Front over fender upper removal note.) (See Front over fender upper installation note.)

Front over fender upper removal note

1.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).

azzezw00001311

Symbol	Content
	Protective tape attachment positions

2.Pull the front over fender upper in the direction of the arrow shown in the figure and detach the clips from the front bumper.

• The figure shows the left side (same as right side).

azzezw00001312

3.Using a tape-wrapped fastener remover, move it in the direction of the arrow shown in the figure and detach the clips from the body.

• The figure shows the left side (same as right side).

azzezw00001313

Symbol	Content
	300 mm {1.18 in} or more
	Servicing procedure

4.Remove the front over fender upper.

Front over fender upper installation note

Warning

• If the front over fender upper is installed with the clips damaged, the front over fender upper may fall off while the vehicle is being driven, leading to a serious accident. If the clips are damaged, replace them with new one.

Remove Driver Side Front Mudguard

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00007557

Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fastener	—
3	Fastener	—
4	Fastener	—
5	Fastener	—
6	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
7	Fastener	—
8	Front mudguard	—

Remove Passenger Side Front Over Fender Lower

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000680

Step	Part name
1	Fastener
2	Front over fender lower (See Front over fender lower removal note.) (See Front over fender lower installation note.)

Front over fender lower removal note

1.Press the front over fender lower in the direction of the arrow (1) shown in the figure to create a gap of approx. 3 mm {1 in} between the front over fender lower and the front fender.

• The figure shows the left side (same as right side).

azzezw00001306

Symbol	Content
	Approx. 3 mm {0.1 in}

2.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).

azzezw00001308

Symbol	Content
	Protective tape attachment positions

3.Insert a remover tool into the position shown in the figure, move it in the direction of the arrow, and then detach the clip from the body.

• The figure shows the left side (same as right side).

azzezw00001309

Symbol	Content
	50 mm {2.0 in}
	25 mm {0.98 in}

4.Detach the clips from the body using a remover tool.

• The figure shows the left side (same as right side).

azzezw00001310

Symbol	Content
	Servicing procedure

5.Remove the front over fender lower.

Front over fender lower installation note

Warning

Remove Passenger Side Front Over Fender Upper

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000678

Step	Part name
1	Fastener
2	Front over fender upper (See Front over fender upper removal note.) (See Front over fender upper installation note.)

Front over fender upper removal note

1.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).

azzezw00001311

Symbol	Content
	Protective tape attachment positions

2.Pull the front over fender upper in the direction of the arrow shown in the figure and detach the clips from the front bumper.

• The figure shows the left side (same as right side).

azzezw00001312

3.Using a tape-wrapped fastener remover, move it in the direction of the arrow shown in the figure and detach the clips from the body.

• The figure shows the left side (same as right side).

azzezw00001313

Symbol	Content
	300 mm {1.18 in} or more
	Servicing procedure

4.Remove the front over fender upper.

Front over fender upper installation note

Warning

Remove Passenger Side Front Mudguard

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00007557

Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fastener	—
3	Fastener	—
4	Fastener	—
5	Fastener	—
6	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
7	Fastener	—
8	Front mudguard	—

Remove Driver Side Front Deflector

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000591

Step	Part name
1	Fastener	—
2	Fastener (See Fastener removal note.)	—
3	Screw	2 N·m {20 kgf·cm, 17 in·lbf}
4	Front deflector	—

Fastener removal note

1.Partially peel back the front over fender upper until the fasteners can be removed as shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000592

2.Remove the fasteners.

Remove Passenger Side Front Deflector

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000594

Step	Part name
1	Fastener	—
2	Fastener (See Fastener removal note.)	—
3	Screw	2 N·m {20 kgf·cm, 17 in·lbf}
4	Front deflector	—

Fastener removal note

1.Partially peel back the front over fender upper until the fasteners can be removed as shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000595

2.Remove the fasteners.

Remove Driver Side Front Splash Shield No.1

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000574

Step	Part name
1	Fastener	—
2	Screw	2 N·m {20 kgf·cm, 17 in·lbf}
3	Front splash shield No.1	—

Remove Driver Side Front Splash Shield No.2

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000575

Step	Part name
1	Fasteners
2	Front splash shield No.2

Front splash shield No.2 removal note

1.Move the front splash shield No.2 in the direction of the arrow shown in the figure, remove the front splash shield No.2 tab from the engine mount.

azzdjw00007555

Remove Passenger Side Front Splash Shield No.1

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000576

Step	Part name
1	Fastener	—
2	Screw	2 N·m {20 kgf·cm, 17 in·lbf}
3	Front splash shield No.1	—

Remove Passenger Side Front Splash Shield No.2

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000577

Step	Part name
1	Fastener
2	Front splash shield No.2

Front splash shield No.2 removal note

1.Move the front splash shield No.2 in the direction of the arrow shown in the figure, remove the front splash shield No.2 tab from the engine mount.

azzdjw00007555

Remove Front Bumper

1.Remove using the procedure shown in the figure.

azzdjw00000884

Step	Part name	Applicable condition
1	Bolt	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Fastener	—	—
3	Latch Cover	—	—
4	Fastener	—	—
5	Bolt	—	8.5 N·m {85 kgf·cm, 74 in·lbf}
6	Bolt	—	8.5 N·m {85 kgf·cm, 74 in·lbf}
7	Fastener	—	—
8	Front bumper (See Front bumper removal note.)	—	—
9	Connector	With 360° view monitor	—
10	Connector	—	—
11	Wiring harness clip (See Wiring harness clip removal note.)	—	—
12	Headlight washer hose	With headlight washer	—

Front bumper removal note

Caution

• If the front bumper and the front bumper sliders are forcibly detached, the parts may be damaged. Be careful when detaching the front bumper from the front bumper sliders.

• Removing the front bumper without supporting it could cause the front bumper to fall and cause serious injury. Always perform the procedure with at least one other person to prevent the front bumper from falling.

1.Remove the front bumper as shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00000885

Symbol	Content
	Protective tape attachment positions
	Servicing procedure

Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.

azzdjw00000887

Remove Center Seal Plate

1.Remove using the procedure shown in the figure.

azzdjw00003455

Step	Part name
1	Fasteners
2	Fasteners
3	Center seal plate

Remove Bracket

Caution

• Perform the procedure with the condenser secured to the body with a string.

azzdjw00001681

1.Remove using the procedure shown in the figure.

azzdjw00003780

Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fasteners	—
3	Bracket (See Bracket installation note.)	—

Bracket installation note

1.After installing the front bumper, refer to [HOOD ADJUSTMENT] and measure the space between the hood and the front bumper.

2.If the measured value is not within the standard, move the front bumper bracket and adjust the installation position.

Remove Intake Air Guide (Upper)

1.Remove using the procedure shown in the figure.

azzdjw00003781

Step	Part name
1	Intake air guide (upper) (See Intake air guide (upper) removal note.)

Intake air guide (upper) removal note

1.Remove the intake air guide (upper) as shown in the figure.

azzdjw00001683

2.Verify that the intake air guide (upper) is inserted into the seal plate and engaged.

• The figure shows the left side (same as right side).

azzdjw00007519

Remove Driver's Side Seal Plate

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00003782

Step	Part name
1	Fasteners
2	Seal plate (See Driver's side seal plate installation note.)

Driver's side seal plate installation note

1.Verify that the driver's side seal plate is inserted into the intake air guide (lower) groove and engaged.

• The figure shows the left side (same as right side).

azzdjw00007520

Remove Passenger's Side Seal Plate

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).

azzdjw00003783

Step	Part name
1	Fasteners
2	Seal plate (See Passenger's Side seal plate installation note.)

Passenger's Side seal plate installation note

1.Verify that the passenger's side seal plate is inserted into the intake air guide (lower) groove and engaged.

• The figure shows the left side (same as right side).

azzdjw00007520

Remove Battery Cap

1.Remove in the order indicated in the table.

azzdjw00004461

Step	Part name
1	Clip
2	Battery cap

Remove Connector Cover

1.Remove in the order indicated in the table.

azzezw00000211

Step	Part name
1	Connector cover

Remove Tunnel Member

1.Remove in the order indicated in the table.

azzezw00000025

Step	Part name
1	Bolt (See Bolt installation note)	22 N·m {2.25 kgf·m, 16.25 ft·lbf}
2	Tunnel member	—

Bolt installation note

1.Install the bolt shown in the figure.

azzezw00000882

Symbol	Content
	Servicing procedure
	22 N·m {2.25 kgf·m, 16.25 ft·lbf}

Remove Middle Pipe

1.Remove in the order indicated in the table.

azzezw00000312

Step	Part name
1	Nut	Replacement part	44.5 N·m {4.55 kgf·m, 32.8 ft·lbf}
2	Rubber	—	—
3	Middle pipe	—	—
4	Gasket	Replacement part	—

Remove Insulator (Front No.1)

1.Remove in the order indicated in the table.

azzezw00000027

Step	Part name
1	Nut (See Nut and bolt installation note.)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Bolt (See Nut and bolt installation note.)	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	Insulator (front No.1) (See Insulator (front No.1) installation note.)	—

Insulator (front No.1) installation note

1.Install the insulator (front No.1) as shown in the figure.

azzezw00000028

Symbol	Content
	Servicing procedure

Nut and bolt installation note

1.Install the nuts and the bolt as shown in the figure.

azzezw00000931

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Insulator (Front No.2)

1.Remove in the order indicated in the table.

azzezw00000032

Step	Part name
1	Nut (See Insulator (front No.2) and nut installation note.)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Insulator (front No.2) (See Insulator (front No.2) and nut installation note.)	—

Insulator (front No.2) and nut installation note

1.Install the holes shown in the figure to the body side and install the nuts.

azzezw00000884

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Insulator (Front No.3)

1.Remove in the order indicated in the table.

azzezw00000035

Step	Part name
1	Fastener
2	Insulator (front No.3)

Remove Insulator (Middle No.1)

1.Remove in the order indicated in the table.

azzezw00000036

Step	Part name
1	Bolt (See Bolt installation note.)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Fastener	—
3	Insulator (middle No.1)	—

Bolt installation note

1.Install the bolts as shown in the figure.

azzezw00000951

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Insulator (Middle No.2)

1.Remove in the order indicated in the table.

azzezw00000039

Step	Part name
1	Fastener	—
2	Nut (See Nut installation note.)	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	Insulator (middle No.2) (See Insulator (middle No.2) installation note.)	—

Insulator (middle No.2) installation note

1.Install the insulator (middle No.2) as shown in the figure.

azzezw00000040

Symbol	Content
	Servicing procedure

Nut installation note

1.Install the nuts as shown in the figure.

azzezw00000933

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Insulator Bracket No.1

1.Remove in the order indicated in the table.

azzezw00000093

Step	Part name
1	Nut (See Nut installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Insulator bracket No.1	—

Nut installation note

1.Install the nuts as shown in the figure.

azzezw00000942

Symbol	Content
	Servicing procedure
	9.5 N·m {97 kgf·cm, 84 in·lbf}

Remove Insulator Bracket No.2

1.Remove in the order indicated in the table.

azzezw00000096

Step	Part name
1	Nut (See Nut installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Insulator bracket No.2	—

Nut installation note

1.Install the nuts as shown in the figure.

azzezw00000943

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Insulator Bracket No.3

1.Remove in the order indicated in the table.

azzdjw00002588

Step	Part name
1	Nut (See Nut installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Insulator bracket No.3	—

Nut installation note

1.Install the nuts as shown in the figure.

azzezw00000911

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Rear Propeller Shaft

1.Remove using the procedure shown in the figure.

Step 1

azzezw00000287

Procedure	Part name
1	Connector	—	—
2	Bolt	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	O-ring	Replacement part	—
4	Bolt	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
5	Nut	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
6	Bolt	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
7	O-ring	Replacement part	—
8	High voltage battery coolant cooling piping component	—	—

Step 2

ac6wzw00001061

Procedure	Part name
9	Heater hose (See Heater hose connection note)	—	—
10	Heater hose (See Heater hose installation note)	—	—
11	Heater hose (See Heater hose connection note)	—	—
12	Heater hose (See Heater hose connection note)	—	—
13	Bolt	—	11 N·m {110 kgf·cm, 95 in·lbf}
14	Heater pipe component (See Heater pipe component installation note)	—	—
15	Bolt	—	80 N·m {8.15 kgf·m, 59 ft·lbf}
16	Nut	—	—
17	Bolt	—	44.5 N·m {4.55 kgf·m, 32.95 ft·lbf}
18	Rear propeller shaft (See Rear propeller shaft removal note (reused).) (See Rear propeller shaft installation note (reused).) (See Rear propeller shaft installation note (newly replaced).)	—	—

Heater pipe component installation note

1.Install the heater pipe component as shown in the figure.

azzezw00000289

Heater hose connection note

1.Connect the heater hose as shown in the figure.

azzezw00000290

Symbol	Content
	2—6 mm {0.1—0.2 in}

Heater hose connection note

1.Connect the heater hoses as shown in the figure.

azzezw00000291

Symbol	Content
1	White Marking
2	Yellow marking

Heater hose installation note

1.Connect the heater hose as shown in the figure.

azzezw00000292

Symbol	Content
1	White Marking

Heater hose connection note

1.Connect the heater hoses as shown in the figure.

azzezw00000293

Symbol	Content
1	Orange marking
2	Green marking

Rear propeller shaft removal note (reused)

1.Before removing the rear propeller shaft, place an alignment mark on the boot and shaft parts as shown in the figure.

azzdjw00007701

Rear propeller shaft installation note (reused)

1.If the rear propeller shaft is reused, install it so that the alignment mark on the boot and shaft parts is aligned.

azzdjw00007701

2.Temporarily tighten the front and rear bolts and nuts.

3.Temporarily tighten the center bearing support bolts.

Caution

• If the center bearing support bracket is installed upside down, an abnormal noise may occur. Install the bracket as shown in the figure.

azzezw00000803

Symbol	Content
1	Vehicle lower side
2	Bracket

4.Shake the position at the arrow shown in the figure up and down 2 or 3 times so that the center bearing support bolts and rubber bushings are adjusted correctly according to the good example.

azzdjw00007702

5.Tighten in the order of the front side, rear side, and then the center bearing support.

Rear propeller shaft installation note (newly replaced)

Note

• A new rear propeller shaft is delivered with a protector equipped.

1.Install the rear propeller shaft to the vehicle with the protector attached.

azzdjw00007703

Symbol	Content
1	Protector

2.Temporarily tighten the front and rear bolts and nuts.

3.Temporarily tighten the center bearing support bolts.

Caution

• If the center bearing support bracket is installed upside down, an abnormal noise may occur. Install the bracket as shown in the figure.

azzezw00000803

Symbol	Content
1	Vehicle lower side
2	Bracket

4.Remove the protector from the rear propeller shaft.

5.Shake the position at the arrow shown in the figure up and down 2 or 3 times so that the center bearing support bolts and rubber bushings are adjusted correctly according to the good example.

azzdjw00007702

6.Tighten in the order of the front side, rear side, and then the center bearing support.

Remove Member Bracket (LH)

1.Remove using the procedure shown in the figure.

azzdjw00003111

Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fastener	—
3	Front mudguard (LH) (See Partially peeling back front mudguard (LH) note)	—
4	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
5	Bolt	82 N·m {8.35 kgf·m, 60.35 ft·lbf}
6	Member bracket	—

Partially peeling back front mudguard (LH) note

1.Remove the bolt and fasteners and partially peel back the front mudguard.

Remove Member Bracket (RH)

1.Remove using the procedure shown in the figure.

azzdjw00003112

Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Fastener	—
3	Front mudguard (RH) (See Partially peeling back front mudguard (RH) note.)	—
4	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
5	Bolt	82 N·m {8.35 kgf·m, 60.35 ft·lbf}
6	Member bracket (RH)	—

Partially peeling back front mudguard (RH) note

1.Remove the bolt and fasteners and partially peel back the front mudguard.

Remove Radiator Mount (LH)

1.Remove in the order indicated in the table.

azzdjw00005754

Step	Part name
1	Bolt	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Radiator mount (LH)	—

Remove Radiator Mount (RH)

1.Remove in the order indicated in the table.

azzdjw00006812

Step	Part name
1	Bolt	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Radiator mount (RH)	—

Remove Inverter Bracket

1.Remove in the order indicated in the table.

azzezw00000212

Step	Part name
1	Bolt (See Bolt installation note)	26 N·m {2.65 kgf·m, 19.2 ft·lbf}
2	Inverter bracket	—

Bolt installation note

1.Install the bolts as shown in the figure.

azzezw00000934

Symbol	Content
	Servicing procedure
	Temporarily tighten
	26 N·m {2.65 kgf·m, 19.2 ft·lbf}

Disconnect Motor Cable (Inverter Side)

1.Remove in the order indicated in the table.

azzezw00000240

Step	Part name
1	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
2	Bolt	11 N·m {110 kgf·cm, 95 in·lbf}
3	Motor cable (inverter side)	—

Disconnect Quick Release Connector (Fuel System) No.3

Warning

• Fuel can easily ignite, therefore always keep sparks and flames away from fuel. If fuel ignites, it could cause serious injury or death and damage to facilities.

• Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the [Fuel Line Safety Procedure] to prevent the fuel from spraying.

― Fuel may cause irritation if it comes in contact with skin and eyes.

― If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

Caution

• If there is foreign matter on the connecting area of the quick release connector it might damage the connector opposite side. To prevent this, disconnect the quick release connector and clean the connecting area before connecting it again.

1.Disconnect in the order indicated in the table.

azzezw00000115

Step	Part name
1	Quick release connector (fuel system) No.3 (See Quick release connector (fuel system) No.3 disconnection note) (See Quick release connector (fuel system) No.3 connection note)	Engine oil

Quick release connector (fuel system) No.3 disconnection note

1.Move the retainer upward using a small flathead screwdriver or equivalent.

azzezw00000116

2.Pull out the quick release connector at a level angle from the opposite side and disconnect it.

3.Protect the disconnected quick release connector and fuel pipe by wrapping them in plastic to prevent damage or soiling.

Quick release connector (fuel system) No.3 connection note

Note

• If the quick release connector O-ring is damaged or it has slipped, replace the fuel hose.

1.Inspect the fuel hose and the sealing surface on the opposite side for damage or deformation.

• If there is any malfunction, perform replacement.

2.Install the quick release connector in the order shown in the figure.

azzezw00000117

Symbol	Content
	Servicing procedure
	Engine oil application area

Replacing fuel hose

1. Press the fuel hose into the opposite pipe parallel until a click sound is heard and connect.

2. Press the retainer down with your fingers.

― If the retainer cannot be pressed down or the checker tab cannot be removed, press the quick release connector further into the opposite pipe.

3. Pull out the checker tab by hand.

― Do not use pliers.

Reassembling the fuel hose (when not replacing fuel hose)

1. Press the fuel hose into the opposite pipe parallel until a click sound is heard and connect.

2. Press the retainer down with your fingers.

― If the retainer cannot be pressed down, press the quick release connector further into the opposite pipe.

3. Press and pull the quick release connector forward/back several times and verify that it is connected securely.

Disconnect Quick Release Connector (Emission System) No.1

Caution

1.Disconnect in the order indicated in the table.

azzezw00000831

Step	Part name
1	Quick release connector (emission system) No.1 (See Quick release connector (emission system) No.1 disconnection note) (See Quick release connector (emission system) No.1 connection note)	Engine oil

Quick release connector (emission system) No.1 disconnection note

1.Move the retainer upward using a small flathead screwdriver or equivalent.

azzezw00000132

2.Pull out the quick release connector at a level angle from the opposite side and disconnect it.

3.Protect the disconnected quick release connector and evaporative pipe by wrapping them in plastic to prevent damage or soiling.

Quick release connector (emission system) No.1 connection note

Note

• If the quick release connector O-ring is damaged or it has slipped, replace the evaporative hose.

1.Inspect the evaporative hose and the sealing surface on the opposite side for damage or deformation.

• If there is any malfunction, perform replacement.

2.Install the quick release connector in the order shown in the figure.

azzezw00000133

Symbol	Content
	Servicing procedure
	Engine oil application area

Replacing evaporative hose

1. Press the evaporative hose into the opposite pipe parallel until a click sound is heard and connect.

2. Press the retainer down with your fingers.

― If the retainer cannot be pressed down or the checker tab cannot be removed, press the quick release connector further into the opposite pipe.

3. Pull out the checker tab by hand.

― Do not use pliers.

Reassembling evaporative hose (not replacing evaporative hose)

1. Press the evaporative hose into the opposite pipe parallel until a click sound is heard and connect.

2. Press the retainer down with your fingers.

― If the retainer cannot be pressed down, press the quick release connector further into the opposite pipe.

3. Press and pull the quick release connector forward/back several times and verify that it is connected securely.

Remove Muffler Hanger Bracket

1.Remove in the order indicated in the table.

azzezw00000945

Step	Part name
1	Bolt	22 N·m {2.25 kgf·m, 16.25 ft·lbf}
2	Weight	—
3	Muffler hanger bracket	—

Remove Transmission Mount Member

1.Remove in the order indicated in the table.

Step 1

azzezw00000294

Step	Part name
1	Coolant hose	—	—
2	Coolant hose	—	—
3	Coolant hose	—	—
4	Radiator hose	—	—
5	Coolant hose	—	—
6	Bolt	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
7	Condenser refrigerant cooling piping	—	—
8	O-ring	Replacement part	—
9	Connector	—	—
10	Wiring harness clip	—	—
11	Bolt	—	11 N·m {110 kgf·cm, 95 in·lbf}
12	Connector	—	—
13	Connector	—	—
14	Wiring harness clip	—	—
15	Connector	—	—
16	Wiring harness clip	—	—
17	Connector	—	—
18	Nut	—	8.5 N·m {85 kgf·cm, 73 in·lbf}
19	Bolt	—	9.5 N·m {95 kgf·cm, 82 in·lbf}
20	Refrigerant cooling piping	—	—
21	O-ring	Replacement part	—

Step 2

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Step	Part name
21	Clip	—
22	Bolt	164 N·m {16.7 kgf·m, 120.8 ft·lbf}
23	Front brake caliper component (See Front brake caliper component removal note)	—
24	Bolt	9.5 N·m {95 kgf·cm, 82 in·lbf}
25	Front ABS wheel-speed sensor	—
26	Bolt	—
27	Nut	42.5 N·m {4.3 kgf·m, 31.15 ft·lbf}
28	Knuckle	—
29	Nut	158 N·m {16.15 kgf·m, 116.7 ft·lbf}
30	Bolt	—
31	Strut damper component	—

Step 3

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Step	Part name
32	Dust boot (See Dust boot removal note)	—	—
33	Bolt	Replacement part	29 N·m {2.95 kgf·m, 21.4 ft·lbf}
34	Intermediate shaft	—	—
35	Bolt (See Bolt removal note)	—	11 N·m {110 kgf·cm, 95 in·lbf}
36	Wiring harness clip	—	—
37	Nut	—	19 N·m {1.95 kgf·m, 14.1 ft·lbf}
38	Bolt	—	56.5 N·m {5.75 kgf·m, 41.55 ft·lbf}
39	Transmission mount member	—	—

Front brake caliper component removal note

1.Set it aside with the brake hose connected so that it does not interfere with the servicing.

Dust boot removal note

1.Partially peel back so that the intermediate shaft bolt can be removed.

Bolt removal note

1.Place the engine lifter under the engine/transmission/front crossmember.

2.Remove the bolt.

Lower Engine Component

1.Remove in the order indicated in the table.

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Step	Part name
1	Bolt	210.5 N·m {21.45 kgf·m, 155.1 ft·lbf}
2	Bolt	83 N·m {8.45 kgf·m, 61.05 ft·lbf}
3	Engine component	—

Remove Engine Compartment Insulator (Lower)

1.Remove in the order indicated in the table.

azzdjw00002475

Step	Part name
1	Bolt (See Fastener, nut, and bolt installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Nut (See Fastener, nut, and bolt installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	Fastener (See Fastener, nut, and bolt installation note)	—
4	Engine compartment insulator (lower)	—

Fastener, nut, and bolt installation note

1.Install fastener as shown in the figure.

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2.Install the nuts as shown in the figure.

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Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

3.Install fasteners as shown in the figure.

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4.Install the bolts shown in the figure.

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Symbol	Content
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Engine Wall

1.Remove in the order indicated in the table.

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Step	Part name
1	Hose	—
2	Bolt	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	Engine wall	—

Remove Engine Compartment Insulator (RH)

1.Remove in the order indicated in the table.

azzdjw00002485

Step	Part name
1	Screw (See Nut and screw installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
2	Nut	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	Engine compartment insulator (RH)	—

Nut and screw installation note

1.Install the nuts and screws as shown in the figure.

azzdjw00006718

Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Remove Engine Compartment Insulator (LH)

1.Remove in the order indicated in the table.

azzdjw00002481

Step	Part name
1	Fastener	—
2	Bolt (See Nut and bolt installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
3	Nut (See Nut and bolt installation note)	9.5 N·m {95 kgf·cm, 82 in·lbf}
4	Engine compartment insulator (LH)	—

Nut and bolt installation note

1.Install the nuts and bolts as shown in the figure.

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Symbol	Content
	Servicing procedure
	9.5 N·m {95 kgf·cm, 82 in·lbf}

Install in Reverse Order of Removal

1.Install in the reverse order of removal.

Add Engine Coolant (Main)

1.Add engine coolant (main) to the top surface of the radiator filler port.

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Bottle

2.Add engine coolant (main) to the coolant reserve tank up to the FULL line.

azzdjw00007652

Bottle

Total coolant amount (reference)

Specification	Capacity
With e-SKYACTIV PHEV	8.6 L {9.1 US qt, 7.6 Imp qt}
Without e-SKYACTIV PHEV	7.0 L {7.4 US qt, 6.2 Imp qt}

3.After the engine coolant (main) is added up to the FULL line of the coolant reserve tank, add an additional 0.26 L {0.27 US qt, 0.23 Imp qt.}.

Add Coolant (Sub) [PYUL] (With e-SKYACTIV PHEV)

1.Add coolant (sub) to the coolant reserve tank up to the F line.

azzdjw00007654

Bottle

Total coolant amount (reference)

6.5 L {6.9 US qt, 5.7 Imp qt}

Install cooling system cap

1.Install in the order indicated in the table.

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Step	Part name
1	Cooling system cap

Install cooling system cap (sub)

1.Remove in the order indicated in the table.

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Step	Part name
1	Cooling system cap (sub)

Perform Engine Coolant (Main) Air Bleeding (With e-SKYACTIV PHEV)

1.Perform the following procedure switch to compulsory engine start mode.

(1)Switch the ignition ON (Ready off) under the following conditions.

• Shift position: P position

• Brake pedal: Not depressed

(2)Depress and release the accelerator pedal 5 times with the brake pedal depressed.

(3)Release the brake pedal and depress the accelerator pedal again the same number of times.

(4)Depress the accelerator pedal the same number of times again while depressing the brake pedal again.

(5)Release the brake pedal.

(6)When the output limit warning light flashes 5 times, the preparation to switch to maintenance mode is competed.

• If the output limit warning light does not flash because the transition to maintenance mode has failed, switch the ignition OFF and verify if the implementation permit conditions are met. If there is no problem, repeat the procedure from Step 1.(See MAINTENANCE MODE.)

Note

• When the preparation for switching to maintenance mode is completed, maintenance mode is not completed even if the ignition is switched OFF.

• The mode returns to the transition preparation completion status by switching the ignition ON again after switching the ignition OFF.

(7)Depress the brake pedal again and switch the main power ON to switch to the desired mode.

2.Perform the engine coolant (main) air bleeding using the following procedure.

(1)Maintain the engine speed at approx. 2,000 rpm for 5 min.

(2)Maintain the engine speed at approx. 2,000 rpm for 10 s.

(3)Maintain idling for 30 s.

(4)Repeat Steps (2) and (3) 5 times.

(5)Maintain the engine speed at approx. 3,000 rpm for 10 s.

(6)Maintain idling for 30 s.

(7)Repeat Steps (5) and (6) 5 times.

(8)Increase the engine speed to approx. 4,000 rpm, and then idle.

(9)Maintain the engine speed at approx. 2,000 rpm for 10 s.

(10)Maintain idling for 30 s.

(11)Repeat Steps (2) to (10) until the air is bled out.

3.Stop the engine and wait until the engine coolant (main) temperature decreases.

4.If the engine coolant (main) level is low, add engine coolant (main) and inspect the coolant amount.

Bleed Coolant (Sub) Air (With e-SKYACTIV PHEV)

1.Verify that the coolant system cap (sub) is securely closed.

2.Perform the following procedure within 60 s and switch to air bleeding mode.

(1)Switch the main power ON (READY off).

(2)Release and depress the accelerator pedal 5 times.

(3)Release and depress the brake pedal 10 times.

(4)Switch the main power ON (READY on).

(5)Verify that [Air Bleeding Mode] is displayed in the instrument cluster or on the center display.

• If the liquid level in the coolant reserve tank decreases during air bleeding mode and air becomes mixed in, switch the ignition OFF, and then repeat Steps (1) to (5).

3.After completing air bleeding mode, verify the height of liquid surface in the coolant reserve tank.

Coolant (sub) liquid surface is F line or less

• Remove the coolant system cap (sub), replenish the coolant (sub) up to the F line, and switch to air bleeding mode again.

Coolant (sub) liquid surface is F line

• If there is neither no change in the liquid surface nor bubbles in the coolant reserve tank, the air bleeding is completed.

Note

Air bleeding mode cancellation conditions

• Air bleeding mode elapses for 900 s.

• Changes to a position other than the P position.

• Switch the main power OFF.

4.Inspect the coolant (sub).

5.If the coolant (sub) level is low, add coolant (sub) and perform air bleeding again.

Remove Cooling System Cap

1.Remove in the order indicated in the table.

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Step	Part name
1	Cooling system cap

Remove Cooling System Cap (Sub) (PYUL)

1.Remove in the order indicated in the table.

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Step	Part name
1	Cooling system cap (sub)

Inspect For Engine Coolant Leakage

Warning

• A hot engine can cause severe burns. Turn off the engine and wait until it is cool before performing the servicing.

• If the engine cooling system cap is removed when the engine is hot, steam and boiling water may be ejected, causing severe burns or severe injury. Perform the removal of the engine cooling system cap when the engine is cool.

• When removing the engine cooling system cap, cover the engine cooling system cap with a clean cloth and remove it slowly.

Note

• Perform the procedure with the engine cooling system cap removed.

1.Install the radiator cap tester to the filling port.

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2.Apply pressure using the radiator cap tester.

Coolant leakage inspection pressure

122.6 kPa {1.250 kgf/cm2, 17.78 psi} [1 min]

3.When pressurizing the radiator, verify that the pressure is maintained.

• If the pressure decreases, repair or replace the location where water is leaking because water leakage can be considered.

Inspect For PHEV Coolant Leakage

Warning

<<High voltage>>

•Always observe the following thoroughly to ensure safety when inspecting or removing/installing parts in the motor compartment. Otherwise, the high voltage circuit may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause electrical shock and result in serious injury or, in the worst case, death.

―Do not perform normal charging or quick charging

―Access connected vehicle maintenance mode (MyMazda App connected vehicle)

―Cancel climate control timer

Warning

•Always observe the following thoroughly to ensure safety when inspecting or removing/installing parts in the motor compartment. Otherwise, the cooling fan may operate on the vehicle regardless of whether or not the main power is switched OFF or ON (READY off or on). If this occurs, it could cause injuries such as lacerations and from getting caught in the cooling fan.

―Do not perform normal charging or quick charging

―Access connected vehicle maintenance mode (MyMazda App connected vehicle)

―Cancel climate control timer

•The EV system is hot immediately after driving and charging, and can cause severe burns. Turn off the EV system and wait until it is cool before performing the servicing.

•If the PHEV cooling system cap is removed while the PHEV cooling system is hot, hot coolant may be ejected, causing severe burns or injury. Perform the removal of the PHEV cooling system cap when the PHEV cooling system is cool.

•When removing the PHEV cooling system cap, cover the PHEV cooling system cap with a clean cloth and remove it slowly.

Note

•Perform the procedure with the PHEV cooling system cap removed.

1.Install the radiator cap tester to the filling port.

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2.Apply pressure using the radiator cap tester.

Coolant leakage inspection pressure

122.6 kPa{1.148 kgf/cm2, 16.33 psi} [1 min]

3.When pressurizing the radiator, verify that the pressure is maintained.

•If the pressure decreases, repair or replace the location where water is leaking because water leakage can be considered.

Install cooling system cap (sub)

1.Remove in the order indicated in the table.

azzdjw00005277

Step	Part name
1	Cooling system cap (sub)

Install cooling system cap

1.Install in the order indicated in the table.

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Step	Part name
1	Cooling system cap

Perform Battery Condition Initial Setting (i-Stop Setting)

Caution

• If the engine is started with the hood open, i-stop will not operate until the hood is closed and the engine is restarted. (Not system malfunction) If the engine was started with the hood open, switch the ignition OFF, close the hood, and then restart the engine.

Without M Hybrid Boost (With i-stop)

• (i-stop non operation) If the vehicle is brought in with i-stop not operating, the malfunction cannot be resolved by only performing the battery condition initial setting (i-stop setting). Verify the PID BATT_SOC value and if the value is less than 75%, perform a battery inspection. (See BATTERY INSPECTION.)

• If the [BATT_SOC] has not been verified before disconnecting the negative battery terminal, perform the battery condition initial setting (i-stop setting) after performing the battery inspection.

• Directly after connecting the negative battery terminal, a BATT_SOC value of [ 0%] is displayed because the battery charge status is unstable. (It is necessary to leave vehicle for 6 to 48 hours until battery charge status stabilizes)

Note

• If the diesel particulate filter regeneration control is not performed at a traveled distance of 10 km or less, the PCM performs the diesel particulate filter regeneration control while the setting procedure for the battery condition initial setting (i-stop setting) is performed to stabilize the exhaust gas purification. (Regular regeneration control)

• While the regular regeneration control is performed, a condition in which high engine speed is continued for a specified period of time. (Up to 22 min (depends on engine coolant temperature))

Circle: Applicable—: Not applicable

Purpose	Operation	Without M Hybrid Boost (With i-stop)
Purpose	Operation	T3	PYUL
1. Verify that the BATT_SOC value measured when the vehicle is in the shop is 75% or more.	1. Using the M-MDS, verify that the PID [BATT_SOC] value is 75% or more.	O	O
	2. In the following cases, perform a battery inspection. (See BATTERY INSPECTION.) • [BATT_SOC] value is less than 75% • [BATT_SOC] value cannot be verified	O	O
2. Have the [BATT_SOC] value determined by the PCM.	1. Disconnect the negative battery terminal and wait for 5 min or more. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) Note • It is necessary to leave the lead-acid battery undisturbed for or more because the voltage may not be stabilized depending on the battery usage condition and it could cause the PCM to determine the BATT_SOC value incorrectly.	O	O
3. Have the PCM learn the battery condition.	1. Connect the negative battery terminal and wait for 10 s or more. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)	O	O
	2. Switch the ignition ON (engine off) and wait between 15 s to 60 s.	O	O
	3. Press and hold the i-stop OFF switch for approx.10 s.	O	O
	4. Verify that the i-stop warning light (amber) illumination changes to the i-stop indicator light (green) flashing. • If the i-stop warning light (amber) does not turn off, it is possible that the procedure was performed incorrectly, therefore, perform the procedure again from the beginning. • If the i-stop warning light (amber) flashes, perform a battery inspection. (See BATTERY INSPECTION.)	O	O
	5. Switch ignition OFF.	O	O
	6. Close the hood.	O	O
4. Perform idle air control learning.	1. Switch the ignition ON (engine on).	—	O
	2. Turn off the following systems to which electrical load is applied. • Lighting systems such as headlights. • Climate control system • Rear window defogger	—	O
	3. Warm up the engine completely.	—	O
	4. Switch the ignition OFF.	—	O
5. Verify the i-stop control settings.	Perform the following procedure from Step 1 to 5 within 25 s.	O	O
	1. Switch the ignition ON (engine off) and within 5 s, press and hold the i-stop OFF switch for 3 s or more.	O	O
	2. Verify that the i-stop warning light (amber) is on.	O	O
	3. Switch the ignition ON (engine on).	O	O
	4. Verify that the i-stop warning light (amber) illumination changes to the i-stop indicator light (green) flashing. • If the i-stop warning light (amber) illuminates or flashes, perform a battery inspection. (See BATTERY INSPECTION.)	O	O
	5. Press and hold the i-stop OFF switch for approx. 3 s.	O	O
	6. Wait for 30 s while idling (with no electrical load).	O	O
	7. Perform engine racing for a minimum 10 times and a maximum 20 times. Then, wait for 30 s while idling (with no electrical load). • After the flashing i-stop indicator light (green) turns off, switch the ignition OFF. • If the i-stop indicator light (green) does not turn off, it is possible that there is a problem with the M Hybrid system, therefore, perform an inspection of the M Hybrid system. Note • The flashing i-stop indicator light (green) may turn off early and the i-stop control setting verification may be completed early depending on the battery condition.	—	—
	8. Maintain the idling condition (with no electrical load) until the i-stop indicator light (green) flashing turns off.	O	O
	9. After the flashing i-stop indicator light (green) turns off, switch the ignition OFF.	O	O
6. Perform an i-stop control operation verification.	1. Switch the ignition ON (engine on).	O	O
	2. Accelerate to a vehicle speed of 15 km/h in approx. 5 s without operating the steering wheel.	O	O
	3. Stop the vehicle.	O	O
	4. Verify that the engine stops and restarts by the i-stop control.	O	O
	5. Switch the ignition OFF.	O	O

Perform Precaution After Service

Warning

• Fuel is highly flammable and dangerous. Fuel line spills and leakage can cause serious injury or death, and damage to equipment. In addition, fuel can also irritate skin and eyes. To prevent this, perform the following inspections with the engine stopped.

1.Disconnect the negative lead-acid battery terminal.

2.Remove the fuel pump relay.

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1	Fuel pump relay

Caution

• Shorting the wrong terminal in the relay and fuse block may cause malfunctions. Always short only the specified terminal.

3.Short fuel pump relay terminal C and terminal D in the relay and fuse block using a jumper wire.

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4.Connect the negative lead-acid battery terminal and operate the fuel pump.

5.Verify that there is no fuel leakage at the serviced location.

Standard

No leakage after 5 min have elapsed

6.If there is fuel leakage, replace the following parts and perform the [AFTER SERVICE PRECAUTION] again.

• If there is fuel leakage, replace the fuel hoses and clips.

• If the sealing surface on the fuel pipe side is scratched, replace the fuel pipe.

Charge Refrigerant

Caution

• If a different type of refrigerant is charged or a refrigerant exceeding the specified amount is charged, the cooling ability will be lowered and the refrigerant system parts could be damaged. Do not use a different type of refrigerant or charge beyond the specified level.

e-SKYACTIV PHEV

Refrigerant type	Specified refrigerant amount (reference value) (g{OZ.EN_UK})
HFO-1234yf (R-1234yf)	935—985 {33.0—34.7}

H3T

Refrigerant type	Specified refrigerant amount (reference value) (g{OZ.EN_UK})
HFO-1234yf (R-1234yf)	775—825 {27.4—29.1}

Note

• When recovering/charging the refrigerant, verify the type of refrigerant and the specified amount of refrigerant on the caution label.

azzdjw00000125

Symbol	Content
1	Caution label

1.Open all the valves on the manifold gauge.

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Symbol	Content
1	Manifold gauge
2	Valve
3	Vacuum pump
4	Vacuum flow

2.Start the vacuum pump and evacuate the refrigeration cycle for 15 min.

3.Verify that the high pressure side and low pressure side indications on the manifold gauge indicate -0.1 MPa {-1 kgf/cm2, -15 psi}.

4.Stop the vacuum pump.

Caution

• If the manifold gauge valves are left open, vacuum pump oil will backflow into the refrigeration cycle and cause the cooling performance to lower. After stopping the vacuum pump, close the manifold gauge valves immediately.

5.Close all the valves of the manifold gauge.

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Symbol	Content
1	Manifold gauge
2	Valve

6.Wait for 5 min after stopping the vacuum pump, and perform an airtightness check for the refrigerant cycle.

7.Verify that the manifold gauge reading has not changed.

azzdjw00000128

Symbol	Content
1	Manifold gauge

• If the manifold gauge reading has changed, inspect the refrigerant system following the symptom troubleshooting procedure.

• If the manifold gauge indication does not change, charge with refrigerant.

Warning

• If the valve on the high pressure side is opened while the A/C compressor is operating, highly pressurized refrigerant could backflow into the refrigerant tank and cause damage. Never open the valve on the high pressure side.

8.Open the refrigerant tank valve.

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9.Open the manifold gauge valve on the low pressure side.

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Symbol	Content
1	Manifold gauge
2	Valve on low pressure side
3	Refrigerant flow

10.Verify that the manifold gauge indication on the low pressure side indicates 0.1 MPa {1 kgf/cm2, 15 psi}.

11.Close all the valves on the low pressure side of the manifold gauge.

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Symbol	Content
1	Manifold gauge
2	Valve on low pressure side

12.Inspect for gas leakage from the piping connection using a gas leak detector or a fluorescent agent-detecting UV black light.

• If there is no gas leakage, go to Step 14.

• If there is gas leakage, tighten the piping connection to the specified torque, then go to the next step.

13.Inspect for gas leakage from the piping connection again using a gas leak detector or a fluorescent agent-detecting UV black light.

• If there is no gas leakage, go to the next step.

• If there is gas leakage, inspect the refrigeration system following the symptom troubleshooting procedure.

14.Open the manifold gauge valve on the low pressure side.

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Symbol	Content
1	Manifold gauge
2	Valve on low pressure side
3	Refrigerant flow

Caution

• If the refrigerant system is charged with the refrigerant tank upside down, liquid refrigerant will be charged into the system, and the A/C compressor could become highly pressurized and damaged. Do not turn the refrigerant tank upside down to charge the refrigerant.

15.Weigh the refrigerant tank and charge approx. 380 g {13.4 oz}. of refrigerant.

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16.Close all the valves on the low pressure side of the manifold gauge.

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Symbol	Content
1	Manifold gauge
2	Valve on low pressure side

17.Operate the A/C compressor.

Warning

18.Open the manifold gauge valve on the low pressure side.

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Symbol	Content
1	Manifold gauge
2	Valve on low pressure side
3	Refrigerant flow

Caution

19.Weigh the refrigerant tank and charge with the specified amount of refrigerant.

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20.Close all the valves on the low pressure side of the manifold gauge.

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Symbol	Content
1	Manifold gauge
2	Valve on low pressure side

21.Switch the main power OFF.

22.Perform the leak test.

Leak test

Caution

• Looking directly at a fluorescent agent-detecting UV black light may cause injury to the eyes. Do not look directly into the light of a fluorescent agent-detecting UV black light.

Note

• Because fluorescent agents are in the refrigeration cycle, the leak test can be performed with a fluorescent agent-detecting UV black light.

1.Inspect for gas leakage from the piping connection using a gas leak detector or a fluorescent agent-detecting UV black light.

• If there is no gas leakage, go to Step 3.

• If there is gas leakage, tighten the piping connection to the specified torque, then go to the next step.

2.Inspect for gas leakage from the piping connection again using a gas leak detector or a fluorescent agent-detecting UV black light.

• If there is no gas leakage, perform the procedure from the vacuum pump operation again.

• If there is gas leakage, inspect the refrigeration system following the symptom troubleshooting procedure.

3.Remove the quick couplers from the charging valves (high/low pressure).

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Symbol	Content
1	Quick coupler
2	Charging valve
3	Cap

4.Install caps to the charging valves (high/low pressure).

Connect Manifold Gauge

Connect manifold gauge to system piping

1.Close all the valves of the manifold gauge.

2.Connect a manifold gauge to the system piping.

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1	Manifold gauge
2	Quick coupler
3	High-pressure line charging valve
4	Low-pressure line charging valve
5	Charging hose

Connect manifold gauge to the vacuum pump/refrigerant tank

1.Connect a manifold gauge to the vacuum pump/refrigerant tank.

azzdjw00000124

1	Manifold gauge
2	Vacuum pumps hose
3	Vacuum pump
4	Charging hose
5	Valve
6	Refrigerant tank
7	Measuring instrument

Inspect Refrigerant System Performance

Note

• Perform the procedure after the refrigerant pressure inspection. (See REFRIGERANT PRESSURE CHECK)

• Perform the procedure while the vehicle is not exposed to direct sunlight.

1.Install a dry-bulb thermometer at the center of the driver-side air vent.

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1	Dry-bulb thermometer

2.Switch the main power ON (READY on).

3.Prepare the vehicle as follows.

― Engine speed is 1,500 rpm

― A/C switch: ON

― Air intake mode: REC

― Airflow mode: Vent

― Airflow temperature setting: MAX COLD

― Airflow volume setting: Maximum

― Hood: Open

― All doors and liftgate: Closed

― All door glass: Fully closed

― Active air shutter (with active air shutter): Open

4.Wait for 8 min after the engine is started.

5.Record the airflow temperature and ambient air temperature for 2 min.

6.Verify that the airflow temperature is within the range of the shaded area shown in the figure.

e-SKYACTIV PHEV

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1	Center vent
2	Rear vent
3	Airflow temperature (°C{°F})
4	Ambient temperature (°C{°F})

H3T

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1	Center vent
2	Rear vent
3	Airflow temperature (°C{°F})
4	Ambient temperature (°C{°F})

• If it cannot be verified, inspect the refrigerant system according to the symptom troubleshooting procedure. (Refer to [SYMPTOM TROUBLESHOOTING CHART [FULL-AUTO AIR CONDITIONER]] in the troubleshooting manual)

Inspect Refrigerant Pressure

Note

• Perform the procedure with the manifold gauge connected. (See MANIFOLD GAUGE SET CONNECTION)

• Start the engine and operate at an engine speed of 1,500 rpm.

• Perform the procedure while the vehicle is not exposed to direct sunlight.

1.Prepare the vehicle as follows.

― A/C switch: ON

― Air intake mode: REC

― Airflow mode: Vent

― Airflow temperature setting: MAX COLD

― Airflow volume setting: Maximum

― Hood: Open

― All doors and liftgate: Closed

― All door glass: Fully closed

― Active air shutter (with active air shutter): Open

2.Wait for 8 min after the engine is started.

3.Record the pressure indicated on the manifold gauge and ambient temperature for 2 min.

4.Verify that the refrigerant pressure on the high pressure side and low pressure side is within the range of the shaded area shown in the figure.

e-SKYACTIV PHEV

azzezw00001450

1	High pressure side
2	Low pressure side
3	Refrigerant pressure (MPa{kgf/cm2, psi})
4	Ambient temperature (°C{°F})

H3T

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1	High pressure side
2	Low pressure side
3	Refrigerant pressure (MPa{kgf/cm2, psi})
4	Ambient temperature (°C{°F})

Perform Power Liftgate Initialization

Note

• If the negative battery terminal is disconnected with the power liftgate fully opened or half-open, the auto open/close operation of the power liftgate is disabled.

1.Close the power liftgate manually.

Initialize Power Outer Mirror Retract/Return Function

Note

• After reconnecting the negative battery terminal, the power outer mirror retract/return position recognized by the door-electrical supply unit may differ from the power outer mirror retract/return position of the vehicle. For this reason, it may be necessary to initialize the power outer mirror retract/return function.

Power outer mirrors are in returned position

1.Switch the ignition ON (engine off)/switch the main power ON (READY off).

2.Press the power outer mirror retract/return switch to retract the power outer mirrors.

3.Press the power outer mirror retract/return switch again to return the power outer mirrors.

4.Switch the ignition OFF/switch the main power OFF.

Power outer mirrors are in retracted position

1.Switch the ignition ON (engine off)/switch the main power ON (READY off).

2.Press the power outer mirror retract/return switch 2 times to return the power outer mirrors.

3.Switch the ignition OFF/switch the main power OFF.

Perform Windshield Wiper Arm And Blade Initial Setting

• Refer to the troubleshooting manual for the procedure for using the M-MDS.

Perform 360° View Monitor System Aiming

• Refer to the troubleshooting manual for the procedure for using the M-MDS. (Refer to [360° VIEW MONITOR SYSTEM AIMING] in the troubleshooting manual.)

Perform Radar Sensor (Front) Aiming (Without Radar Sensor (Front Side))

• Refer to the troubleshooting manual for the procedure for using the M-MDS. (Refer to [RADAR SENSOR (FRONT) AIMING] in the troubleshooting manual.)

Simultaneously Aim Radar Sensor (Front) And (Front Side) (With Radar Sensor (Front Side))

Caution

• When repainting the front bumper face, do not repaint the radar emitting area shown in the figure (same as right side) because the radar sensor (front side) aiming may not be performed correctly.

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Symbol	Content
	Radar emitting area
	118 mm {4.65 in}
	220 mm {8.66 in}
	55 mm {2.2 in}
	35 mm {1.4 in}
	157 mm {6.18 in}
	100 mm {3.94 in}

Note

• Refer to the troubleshooting manual for the procedure for using the M-MDS. (Refer to [RADAR SENSOR (FRONT) AND (FRONT SIDE) SIMULTANEOUS AIMING] in the troubleshooting manual.)