2004 Mazda RX-8 Service Highlights

Mazda RX-8 Service Manual

AIM OF DEVELOPMENT

New Model Concept
"New four-door, four-passenger sports car"

• The Mazda RX-8 is an entirely new concept in a state-of-the-art sports car, combining unique sports-car styling and excellent driving performance, together with the comfort and practicality of a four-door, fourpassenger layout.

Mazda RX-8 External view

Outline
Mazda RX-8 Exterior design

• The dynamic styling, from front to back and along the body sides, creates a sense of "motion".
• A compact cabin supported by pronounced overfenders, lowers the visual center of gravity, emphasizing a sense of "stability".
• A pared-down body shape and a boldly contoured form gives the Mazda RX-8 an aggressive appearance.

Mazda RX-8 Interior design

• Modern, high-quality design
  • Vibrant styling from the dashboard to the rear.
  • Tight and compact dashboard emphasizes lightness and sophistication by adopting new textures, coloring, and metallic-look materials that add to its unique style.
  • Rotor-motif shift-lever knob and sunvisors employing mesh texturing demonstrate the value and attention to detail.
• Comfortable interior
  • Front and rear console boxes with cup holders.
  • Door pockets are provided for road maps or a small bag.
  • Sunvisors are equipped with illuminated vanity mirrors.
  • Premium audio system with nine BOSE speakers is available, offering an acoustic space of high quality.
• Center pillarless freestyle doors providing unhindered access to the cabin have been adopted
• Trunk compartment with a practical capacity
  • A storage capacity of approx. 290 L {306 US qt, 255 lmp qt}, sufficient for two golf bags or two size-67 Samsonite suitcases, has been realized by lowering the floor thanks to the emergency puncture repair kit which requires no spare tire.

MAzda RX-3 Engine - the "RENESIS" - a new-generation rotary engine

• Engine
  • 13B-multi side port (MSP) (High power and Standard power), new-generation rotary engine has been adopted.
  • Side exhaust system has been adopted by transferring the exhaust ports from the rotor housing to the side housing.
  • The intake port area has been in increased by 30% over previous rotary engines. This results in reduced intake resistance and increased air flow which makes more power.
  • Cut-off seals have been provided between the oil seals and the side seals of the rotors, preventing combustion gas from flowing into the intake air process.
  • Keystone-shaped (wedge-shaped) side seals have been adopted for increased sealing performance.
  • Ribs in the side housing and rotors have been decreased in thickness and weight while maintaining high rigidity.
  • Spark plugs with iridium tips have been adopted for improved heat resistance and durability.
  • Flank cuts on the corners of the rotors provide improved exhaust efficiency by delaying the exhaust-port closing timing.
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• Intake and control
  • Sequential dynamic air intake system (S-DAIS) has been adopted, realizing powerful output at high engine speed provides a wide-range of torque in the low and medium-speed ranges through full use of air intake pulsating unique to the rotary engine.
  • Large, low-resistance air cleaner and variable fresh air duct (VFAD) (High power only) have been adopted.
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  • Three injectors per rotor have been provided on the High power model (2 per rotor for Standard power). Together with the electronically controlled (drive-by-wire) throttle valves and the 32-bit powertrain control module (PCM), the injector arrangement has realized fine control of the air-fuel ratio and reduced response time.
  • New jet air fuel mixing system that promotes atomization, vaporization, and mixing of fuel has been adopted on the intake port unique to the rotary engine, realizing improved combustion and reduced fuel consumption.
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Mazda RX-8 Advanced front-midship layout

• Combination of state-of-the-art technologies such as a compact rotary engine, a thin engine oil pan, a forwardlocated air intake system, a compact air-conditioning unit, has produced a small and light powerplant package.
• Adoption of an advanced front-midship layout, saddle-shaped plastic fuel tank, and an emergency puncture repair kit requiring no spare tire has realized a 50-50 front/rear weight distribution, minimal yaw-inertia moment, and high roll-rigidity.

Mazda RX-8 Suspension and steering

• Tire pressure monitoring system
  • The tire pressure monitoring system (TPMS) has been adopted to assist the driver in understanding the tire status to improve the safety.
• Front suspension
  • Newly developed, in-wheel type double-wishbone suspension has been adopted.
  • Relatively long arms promote linear alignment changes during bounce and rebound, realizing excellent controllability at the vehicle handling limits in diverse road and driving conditions. 
• Rear suspension
  • Multi-link suspension employing five links per wheel has been adopted.
  • Excellent handling stability, ride comfort, and road noise performance have been realized by optimizing each link arrangement in consideration of geometry and compliance in order to maintain the optimum tire contact area at any time in the optimal condition against external forces during driving. 

Mazda RX-8 Brake

1. Large-diameter, 17-inch type front brakes have been adopted on sport-suspension vehicles for consistent stopping power.
2. 16-inch type front brakes have been adopted on standard-suspension vehicles.
3. 16-inch type rear brakes have been adopted on both for sport and standard-suspension vehicles.

Mazda RX-8 Repair Manual And Parts Catalog

1. 2004 Mazda RX-8 U.S.A and Canada Parts Catalog
2. Mazda RX-8 Collision Manual
3. Mazda RX-8 13B-MSP Engine Workshop Manual (RENESIS Rotary Engine Workshop Manual)
4. 2004-2008 Mazda RX-8 Manual Transmission Workshop Manual
5. Mazda RX-8 Weber DCOE Book
6. BOSCH L-Jetronic Injection Manual

Mazda RX-8 Transmission

• • Manual transmission
  • Cross-ratio six-speed manual transmission has been adopted on the 13B-MSP (High power).
• • Automatic transmission (13B-MSP (Standard power))
  • Four-speed sport automatic transmission has been adopted that can be shifted up/down by operating the one-touch steering-wheel-mounted switches.
  • Shift patterns have been adopted that optimize the frequently used operating positions of N-D and manual modes by reducing the shift-lever stroke.

Mazda RX-8 Safety

• Lightweight and highly rigid safe body structure developed uniquely for the Mazda RX-8 has achieved high international standards of crash safety.
• Reinforcement with high strength has been installed on the area equivalent to the center pillar on the rear doors, realizing strength nearly equal to that of a center pillar of a standard sedan.
• Dual-inflator type air bags that control deployment of the air bags in two stages by detecting the scale of an impact have been adopted for front-seat passengers.
• Curtain air bags have been adopted that deploy and cover the front and rear windows and protect the heads of front and rear passengers.
• Side air bags effective in protecting the upper abdomen of passengers have been adopted and installed in the outboard sides of the front seat backs.
• Pre-tensioner and load limiter mechanisms have been adopted for the front seat belts.
• Intrusion minimizing mechanism has been adopted for the brake pedal.
• ISO-FIX anchors and tether straps have been adopted for installing child restraint systems on the rear seats.
• Aluminum hood with a shock-absorbing cone structure has been adopted in consideration of pedestrian protection.