Mazda RX-8 Instruction manual

BODY (w)

LOCATION INDEX

1 Hood

2 Front bumper reinforcement

3 Front bumper

4 Front fender panel

5 Fuel-filler lid

6 Trunk lid

7 Rear bumper reinforcement

8 Rear bumper

(w) RX-8 Body

Page 1

HOOD

HOOD REMOVAL/INSTALLATION

WARNING:

•Removing the hood without proper support can be dangerous. The hood may fall and injure you. Always

perform the following procedure with at least another person.

1. Disconnect the negative battery cable.

2. To remove the hood hinge, remove the following parts:

a. Front side marker lights

b. Front bumper

c. Front combination lights

d. Front fender panel

3. Remove in the order indicated in the table.

1 Hood insulator

2 Shroud seal weatherstrip

3 Hood

4 Hood hinge

5 Hood stay

4. Install in the reverse order of removal.

5. Adjust the hood.

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Page 2

HOOD ADJUSTMENT

Gap Adjustment

1. Disconnect the negative battery cable.

2. Remove the following parts:

a. Front side marker lights

b. Front bumper

c. Front combination lights

d. Front fender panel

3. Loosen the hood hinge installation bolts and adjust the hood.

4. Tighten the bolts.

5. Verify that the gap between the hood and the body is within the specification.

Standard clearance

oa: 3.56.5 mm {0.140.25 in}

ob: 3.06.0 mm {0.120.23 in}

oc: 2.54.5 mm {0.100.17 in}

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Page 3

Height Difference Adjustment

1. Turn the stop rubber to adjust the height of the hood.

2. Verify that the height difference between the hood and the body is within the specification.

Standard clearance

oa: −1.81.2 mm {−0.070.04 in}

ob: −1.01.0 mm {−0.030.03 in}

(w) RX-8 Body

Page 4

TRUNK LID

TRUNK LID REMOVAL/INSTALLATION

WARNING:

•Removing the stay damper without supporting the trunk lid can be dangerous. The trunk lid may fall and

injure you. Be sure to open the trunk lid completely and support it securely before removing the stay

damper.

1. Disconnect the negative battery cable.

2. Disconnect the trunk lid wiring harness connector, then take the trunk lid harness out from the vehicle.

3. Remove the clips that secure the trunk lid wiring harness.

4. Pry off the stay damper band using a flathead screwdriver.

(w) RX-8 Body

Page 5

5. Pry out the connecting part of the stay damper and the hinge with a flathead screwdriver to disconnect

them, then remove the stay damper.

6. Remove nuts A, then remove the trunk lid.

7. Remove nuts B, then remove the trunk lid hinge.

8. Install in the reverse order of removal.

9. Adjust the trunk lid.

TRUNK LID ADJUSTMENT

1. Measure the gap and height difference between the trunk lid and the body.

2. Loosen the trunk lid hinge installation nuts or the trunk lid lock striker installation screws, and adjust the

trunk lid.

Standard clearance

oa: 2.54.5 mm {0.100.17 in}

ob: −1.01.0 mm {−0.030.03 in}

oc: 4.08.0 mm {0.160.31 in}

3. Tighten the bolts or screws.

(w) RX-8 Body

Page 6

STAY DAMPER DISPOSAL

NOTE:

•The gas in the stay damper is colorless, odorless, and non-toxic.

1. Wear protective eye wear.

2. Lay the stay damper flat.

3. Saw 2



3 mm {0.08



0.11 in} into the stay damper using a hacksaw, and allow the gas to escape from

the stay damper.

4. Verify that the gas has escaped from the stay damper.

5. Discard the stay damper.

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Page 7

Notes:

FUEL-FILLER LID

FUEL-FILLER LID REMOVAL/INSTALLATION

1. Remove the bolts.

2. Remove the fuel-filler lid.

3. Install in the reverse order of removal.

4. Adjust the fuel-filler lid.

FUEL-FILLER LID ADJUSTMENT

1. Measure the gap and height difference between the fuel-filler lid and the body.

2. Loosen the fuel-filler lid installation bolts, and adjust the fuel-filler lid.

Standard clearance

oa: 1.73.7 mm {0.070.14 in}

ob: −0.51.5 mm {−0.010.05 in}

oc: −1.01.0 mm {−0.030.03 in}

od: 1.83.8 mm {0.080.14 in}

oe: 1.73.7 mm {0.070.14 in}

of: −0.81.2 mm {−0.030.04 in}

3. Tighten the bolts.

(w) RX-8 Body

Page 8

BUMPER

FRONT BUMPER REMOVAL/INSTALLATION

1. Disconnect the negative battery cable.

2. Disconnect the front fog light connectors for vehicles with front fog lights.

3. Remove the front side marker lights.

4. Remove in the order indicated in the table.

1 Fastener A

2 Seal plate

3 Screw A

4 Screw B

5 Fastener B

6 Bolt

7 Front bumper

5. Disconnect the headlight cleaner hose for vehicles with the headlight cleaner.

6. Install in the reverse order of removal.

7. Adjust the front fog light aiming for vehicles with the front fog lights.

Front Bumper Removal Note

1. Pull the front bumper ends (wheel arch) outward to detach from the bumper slider.

CAUTION:

•When detaching the front bumper from the bumper slider, the front bumper could fall and be

damaged. Secure the front bumper so that it does not fall.

(w) RX-8 Body

Page 9

2. Remove the front bumper from the body.

Front Bumper Installation Note

1. Spread the front bumper ends apart.

2. Attach the front bumper to the body.

3. Press the front bumper connecting area into the body to engage with the bumper slider.

FRONT BUMPER DISASSEMBLY/ASSEMBLY

1. To disassemble the front bumper, remove the following parts:

a. Front fog lights (Vehicles with the front fog lights)

b. Headlight cleaner hose (Vehicles with the headlight cleaner)

c. Headlight cleaner nozzles (Vehicles with the headlight cleaner)

d. Headlight cleaner actuator (Vehicles with the headlight cleaner)

2. Disassemble in the order indicated in the table.

(w) RX-8 Body

Page 10

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