2004 Mazda RX-8 Service and Repair Manual

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Factory-Grade Data

2004 Mazda RX-8 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Coupe 4-Door

Engines covered

  • 1.3L 1308CC R2 GAS Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Mazda RX-8 Recalls & Complaints

NHTSA #19V78100031/10/2019Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Mazda North American Operations (Mazda) is recalling certain 2003-2008 Mazda6, 2004-2005 MPV, 2004 RX-8, and 2006-2007 Mazdaspeed6 vehicles. These vehicles had their passenger frontal air bag inflato

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants res

Remedy

Owners are advised not to drive their vehicles until the remedy is performed. Mazda will notify own

NHTSA #16V79300031/10/2016Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Mazda North America Operations (Mazda) is recalling certain model year 2004-2008 RX-8 vehicles manufactured April 10, 2003, to February 18, 2008. The affected vehicles have fuel pump sealing rings th

Consequence

The deteriorated seals may leak fuel, which, in the presence of an ignition source, can increase the

Remedy

Mazda will notify owners, and dealers will replace the fuel pump sealing ring set and add a thermal

NHTSA #17V47400026/07/2017Component: AIR BAGS:FRONTAL:DRIVER SIDE:INFLATOR MODULE

Mazda North American Operations (Mazda) is recalling certain model year 2003-2008 Mazda6, 2004-2008 RX-8, and 2006-2007 Mazdaspeed6 vehicles. The affected vehicles are equipped with a dual-stage driv

Consequence

In the event of a crash necessitating deployment of the driver's frontal air bag, the inflator could

Remedy

Owners are advised not to drive their vehicles until the remedy is performed. Mazda will notify own

NHTSA #05V32500020/07/2005Component: SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT

ON CERTAIN PASSENGER VEHICLES, DUE TO IMPROPER FORGING OF THE LOWER CONTROL ARM, CRACKS MAY OCCUR IN THE BALL JOINT SOCKET.

Consequence

IN SEVERE DRIVING CONDITIONS, THE BALL MAY SEPARATE FROM THE BALL JOINT SOCKET AND A LOSS OF STEERIN

Remedy

DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE CONTROL ARMS. THE RECALL BEGAN ON AUGUST 30, 2

NHTSA #04V07400017/02/2004Component: AIR BAGS:FRONTAL

AS A RESULT OF AN NCAP TEST, CERTAIN PASSENGER VEHICLES ARE BEING RECALLED FOR IMPROPERLY WIRED FRONT PASSENGER SEAT AIR BAGS.

Consequence

THE AIR BAG WILL NOT PROVIDE ADEQUATE PROTECTION WHEN THE VEHICLE IS INVOLVED IN A FRONTAL CRASH.

Remedy

DEALERS WILL INSTALL A NEW WIRING HARNESS IN THE FRONT PASSENGER SEAT AIR BAG SYSTEM. THE RECALL BE

NHTSA #04V07500017/02/2004Component: POWER TRAIN:MANUAL TRANSMISSION

ON CERTAIN PASSENGER VEHICLES WITH MANUAL TRANSMISSIONS, THE HEAT INSULATOR MAY BE CRACKED CAUSING ABNORMAL NOISE.

Consequence

CONTINUED OPERATION OF THE VEHICLE CAN CAUSE THE INSULATOR TO COME OFF AND COULD POSE A HAZARD TO FO

Remedy

DEALERS WILL REPLACE THE HEAT INSULATOR. THE RECALL BEGAN MARCH 5, 2004. OWNERS SHOULD CONTACT MA

NHTSA #05V31700007/07/2005Component: ENGINE AND ENGINE COOLING

IF CERTAIN PASSENGER VEHICLES ARE PARKED AND THE ENGINE IS OPERATED AT HIGH RPM'S FOR AN EXCESSIVE LENGTH OF TIME, SOME OF THE PARTS AROUND THE EXHAUST SYSTEM CAN MELT AND PRODUCE A VARIETY OF MALFUNC

Consequence

FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy

DEALERS WILL INSPECT AND REPLACE PARTS. THE RECALL BEGAN ON AUGUST 30, 2005. OWNERS MAY CONTACT MA

NHTSA #17V35500001/06/2017Component: SUSPENSION:FRONT:CONTROL ARM:LOWER ARM

Mazda North American Operations (Mazda) is recalling certain 2004 Mazda RX-8 vehicles. The ball joint socket on the front suspension lower control arm may crack and the ball joint may separate from t

Consequence

If the ball joint separates, steering control may be lost, increasing the risk of a crash.

Remedy

Mazda will notify owners, and dealers will replace the front lower control arms, free of charge. The

NHTSA #17V35400001/06/2017Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Mazda North America Operations (Mazda) is recalling certain model year 2004-2008 RX-8 vehicles. Heat from the engine and the exhaust may cause the main fuel pump pipe to crack.

Consequence

If the fuel pump pipe cracks, fuel may leak, increasing the risk of a fire.

Remedy

Mazda will notify owners, and dealers will replace the fuel pump filter kit, free of charge. The re

TSB #11032103

This Service Alert supersedes the previously issued SA listed below: The changes are noted in Red. SA-011/24 02/12/24, 06/06/24, 07/29/24 DESCRIPTION Mazda has developed factory recommended scheduled maintenance services that support all ma

TSB #11022742

Some vehicles may experience exterior trim heat damage such (melted, separating, etc.) when parked near a glass building or Low-E windows. This may be caused by the sun's reflection. If a structure's windows create enough of a curve, the co

TSB #11020039

Some customers may complain about a noisy HVAC blower motor or odor after a cabin air filter replacement. Foreign debris on the blower motor after servicing the cabin air filter may be the cause. During the removal of the cabin air filter,

TSB #11007022

Some vehicles may experience exterior trim heat damage such (melted, separating, etc.) when parked near a glass building or Low-E windows. This may be caused by the sun's reflection.

TSB #11006987

In accordance with Federal regulations, follow the procedure listed below when replacing a speedometer. NOTE: Tampering with a motor vehicle odometer is strictly prohibited by Federal, and State laws. It is the dealers responsibility to com

TSB #11005671

Mazda has developed factory recommended scheduled maintenance services that support all major vehicle systems. Mazda recommends dealers follow the scheduled maintenance tables as cited in the vehicle-specific workshop manual or owner's manu

TSB #11003398

Mazda has developed factory recommended scheduled maintenance services that support all major vehicle systems. Mazda recommends dealers follow the scheduled maintenance tables as cited in the vehicle-specific workshop manual or owner's manu

TSB #10251387

Mazda has developed factory recommended scheduled maintenance services that support all major vehicle systems. Mazda recommends dealers follow the scheduled maintenance tables as cited in the vehicle-specific workshop manual or owner's manu

Showing the 8 most recent of 200 technical service bulletins on file with NHTSA.

20040322Component: ENGINE AND ENGINE COOLINGCrash reportedFire reported

THERE IS CONTAMINATION IN THE OIL. SO MUCH SO THAT IT IS IMPOSSIBLE TO CHECK THE OIL. I'VE GONE 3000 MILES AND NEVER BEEN ABLE TO CHECK THE OIL. EVEN AFTER WIPING THE DIPSTICK, SIMPLY PUTTING IT B

20191021Component: AIR BAGSCrash reported1 injured

ON 10/19/19 THE VEHICLE WAS INVOLVED IN A CRASH WHEN SWERVING TO AVOID A DEER ON THE ROAD. TWO TREES WERE HIT AND THE VEHICLE WAS FLIPPED ON ITS SIDE. NO AIRBAGS DEPLOYED DURING THIS ACCIDENT AS I WAS

20190207Component: POWER TRAINCrash reported1 injured

AS I PRESSED MY CARS CLUTCH TO CHANGE GEARS (6 SPEED MANUAL ) WHILE DRIVING ON MY REGULAR SUNDAY DRIVE IN A CITY STREET, I HEARD AND FELT A VERY LOUD EXPLOSION AND NOISES OF METAL PIECES EJECTING FROM

20190207Component: UNKNOWN OR OTHERCrash reported1 injured

AS I PRESSED MY CARS CLUTCH TO CHANGE GEARS (6 SPEED MANUAL ) WHILE DRIVING ON MY REGULAR SUNDAY DRIVE IN A CITY STREET, I HEARD AND FELT A VERY LOUD EXPLOSION AND NOISES OF METAL PIECES EJECTING FROM

20180204Component: STEERINGCrash reported1 injured

ON SEPTEMBER 15TH, 2016 I HAD STOPPED TO VACUUM OUT MY CAR AT A CAR WASH ON HIGHWAY 11 IN ATTALLA, AL. UPON LEAVING THE CAR WASH I TURNED LEFT ONTO PLEASANT VALLEY RD AT A SLOW SPEED IN FIRST GEAR. AS

Showing the 5 most serious of 625 complaints filed with NHTSA.

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