GENUINE FOG LAMP KIT Using (Installation) Instructions Applicable model : MAZDA CX-7 Part Number : ER18 V4 600 (small tank) ER19 V4 600 (large tank) Thank you very much for buying the Mazda Genuine Parts. Before removal and installation, you are expected to carefully read these instructions. To use it in its best conditions, be sure to read thoroughly these instructions for full understanding of the contents and to properly use it. <Cautions and Requests> and WARNING marks shown in these instructions indicate safety precautions, which you are requested to strictly comply with during installation and use. WARNING :Indicates a situation in which serious injury or death could result if the warning is ignored. :Indicates a situation in which bodily injury or damage to the vehicle could result in if the caution is ignored. Do not install the product in any way other than described in the following instructions. Do not modify the product. To ensure safety and reliability of the work, installation and removal work must be carried out by an Authorized Mazda Dealership. If you have any questions about the use of the accessory, ask your Mazda dealer for proper advice before using it. We may not accept the liability for any problems that might have occurred due to incompliance with these instructions. Be careful not to lose removed parts, and be sure they are kept free from scratches, grease or other dirt. To the dealer Please turn over these instructions to the customer after installation. To the customer Keep these instructions after installation. The instructions may be necessary for installing other optional parts or removal of this accessory. Should the vehicle or this accessory be resold, always leave these instructions with it for the next owner. Mazda Motor Corporation 3-1, Shinchi, Fuchu-cho, Aki-gun Hiroshima 1
1 AS-COMPLETED VIEW Light Lever (sold separately) Fog Lamp Fog Lamp 2 COMPONENTS Make sure that there is no missing component based on the following parts list and check the components for any dirt, scratches or other damage. No. Part name Q ty 1 Lamp hole cover (RH) 1 2 Lamp hole cover (LH) 1 3 Fog lamp (RH) 1 4 Fog lamp (LH) 1 5 Tapping screw 6 6 Short code 1 7 Using (Installation) instructions 1 Sold separately LH w/f-fog : GS3M 66 122A LH w/auto Light & F-Fog : EH47 66 122 2
3 PREPARATORY WORK BEFORE INSTALLATION Tools used (Have them ready at hand before starting the work) Phillips and flat blade screwdriver Protective tape (masking tape, gum tape or equivalent) Protective sheet Torque wrench Fastener remover Spanner (10mm) Socket wrench (10mm) Wheel block WARNING Make sure that operation is carried out on the level ground with the parking brake and chock block securely set. Otherwise, vehicle may start to move or injury may result. WARNING Disconnect the negative terminal of the battery and keep the terminal away from the battery. Otherwise short circuit, and accidents, electric shocks or fire may occur. Hold the connectors when disconnecting / connecting them to ensure the disconnection / connection. Otherwise, accident or fire caused by breaking or contact failure may occur. Avoid exercising excessive force when pulling a wiring harness. Otherwise, accident caused by breaking or short-circuit, electrification or fire may occur. Use right tools appropriate for the purpose and size of the work to be done to ensure proper execution of the work. Use a mat or any other protective material when removing / installing components. Place the removed parts and components on a protective sheet or equivalent to avoid any damage on such parts/components. When the negative terminal of the battery gets disconnected, the memory of clock, radio and trip counter will be erased. Record the memory contents before starting the work. When tightening a bolt, nut and screw, be sure to use torque wrench and tighten properly. Otherwise, improper connection, breakage or damage of the installed parts may occur. NOTE As for the removal or installation of vehicle parts, please refer to the vehicle workshop manual. 3
4 REMOVING THE VEHICLE COMPONENTS Negative battery terminal NOTE Since the removed components are to be reused when reassembling, keep them in a manner that will tell where to reinstall. Place the removed vehicle parts on a protective sheet to avoid any damage on the parts. Battery Headlight Protective tape Fender The illustrations show the L.H. (left) side only. Carry out the same operations at the R.H. (right) side too. Disconnecting the negative terminal 1. Disconnect the negative terminal of the battery following the instructions below. 1 Make sure that headlight, air conditioner and other devices are switched off. 2 Disconnect the negative terminal of the battery. WARNING After disconnect the negative terminal of the battery, keep the terminal from the battery. Otherwise, electrification or injury caused by short-circuit accident may occur. Protecting the vehicle 1. Apply masking tape around the headlights and the fenders to protect the components and vehicle. (Shaded area in the left diagram) Fastener Bolt A Vehicle front Bolt B Fastener Fastener Removing the front bumper 1. Remove the bolt C and the screw at the bottom of the bumper. Bolt C : One for each of the right and left : Three for each of the right and left 2. Remove the bolt B, then remove the fasteners on the both ends of the bumper with using a fastener remover wrapped in protective tape. Bolt B : One for each of the right and left Fastener : One for each of the right and left 3. Remove the fastener and the bolt A at the top of the bumper. Fastener : Five places Bolt A : One for each of the right and left 4. Disconnect the front bumper from the bumper retainer. Bolt C NOTE Avoid pulling the front bumper hard. A harness is connected. Washer tank 5. Disconnect the connector of vehicle harness. 6. Pull the front bumper forward in order to remove it. Connector of the vehicle harness 4
Removing the vehicle harness 1. Disconnect the connectors of the vehicle harness from the combination lamps, and then remove the vehicle harness from the front bumper as shown in the diagram below (ten places). Disconnect from rib Disconnect from rib Disconnect from fasteners Disconnect from rib Disconnect from rib Same as Same as Rib Same as View A Disconnect the connector Vehicle harness Disconnect the connector Disconnect from rib Tab Tab Front combination lamp The removed harness is not necessary for this product. Removing the front combination lamp cover Fasten the tapping screw by inserting a screw driver from here Tapping screw Fasten the tapping screw by inserting a screw driver from here (RH/LH) 1. Remove the tapping screws (two places). 2. Disconnect the tabs (two places), then remove the front combination lamp in the direction of the arrow. Tab Combination lamp cover 3. Disconnect the tapping screws (two places) and the tab (one place), then remove the combination lamp cover in the direction of the arrow. The removed combination lamp cover is not necessary for this product. Front combination lamp (back surface) Tapping screw NOTE The removed front combination lamp and the tapping screws are to be reused. Be careful not to lose them. 5
Column cover (lower) Switch Push Removing the column cover (lower) 1. Push the buttons on the both sides of the switch in order to remove it. (Vehicle equipped with advanced keyless system only) 2. Lower the tilt lever. 3. Remove the screws (three places) and then remove the column cover (lower). Tilt lever Remove 5 INSTALLING THE FOG LAMPS NOTE The procedures shown here is for the right-hand side only. Use the same procedure for the left-hand side parts. Fog lamp Lamp hole cover Tapping screw :Locator pin Installing the fog lamp (RH/LH) 1. Align the 3 fog lamp with the locator pins (two places) of the 1 lamp hole cover. Then attach it with the 5 tapping screws (three places). Tightening torque 5Tapping screw:1.0~1.5n m If you fasten with those torques other than specified, the fog lamp might be broken or fallen off. Be careful to fasten accurately. Lamp hole cover Tab Installing the front combination lamp (RH/LH) 1. Connect the tab (one place) of the 1 lamp hole cover to the front combination lamp, then fix it with tapping screws (two places : reused). Tightening torque Tapping screw : 1.0~1.5N m Front combination lamp (back surface) Tapping screw (reused) If you fasten with those torques other than specified, the front combination lamp might be broken or fallen off. Be careful to fasten accurately. 6
Tab Fasten the tapping screw by inserting a screw driver from here Tab Front combination lamp Tapping screw (reused) Fasten the tapping screw by inserting a screw driver from here 2. Connect the tabs (two places) of the front combination lamp and fix it with the tapping screws (two places : reused). Tightening torque Tapping screw:1.0~1.5n m If you fasten with those torques other than specified, the front combination lamp might be broken or fallen off. Be careful to fasten accurately. Installing the short code 1. Connect the connector of the 6 short code to the fog lamp and the combination lamp. Then wire and secure it to the front bumper as shown in the figure below (ten places). Connect to rib Fit the harness in the hook Fix with fastener Pass behind Connect to rib Same as Same as Connect to rib Same as View A Connect the connector (Fog lamp) Connect the connector (Combination lamp) Connect the connector (Combination lamp) Connect the connector (fog lamp) Rib Connect to rib 7
Headlight (RH) Restoring the front bumper 1. Connect the connector of the 6 short code to the vehicle connector which was disconnected in the item 6 of REMOVING THE FRONT BUMPER (page 4). WARNING When connecting the harness, insert the connectors firmly until they lock securely into place. Otherwise, accident or fire caused by breaking or contact failure may occur. Connector Vehicle front Fastener Bolt A Vehicle front Bolt B Fastener Fastener 2. Reinstall the front bumper in the reverse order of removing it. (See the item Removing the front bumper in the page 4.) Tightening torque Bolt A:4.0~9.8N m Bolt B:1.0~1.5N m Bolt C:6.9~9.8N m :1.0~2.0N m 3. Remove the masking tapes. Bolt C 8
6 INSTALLING THE LIGHT LEVER ( Light levers are sold separately) Light lever Light lever (back side) Harness Clip Removing the existing light lever 1. Disconnect the connector of the light lever. 2. Remove the harness from the clips (two places) on the back surface of the light lever. 3. Remove the screws (two places : to be reused later), then remove the light lever in the direction of the arrow. Connector Light lever (sold separately) Light lever (back side) Harness Clip Installing the light lever (sold separately) 1. Insert the light lever, then place the harness back into the clips (two places) on the back surface of the light lever. 2. Fix it with using the screws (two places) that had been removed when the pre-installed light lever was removed. 3. Connect the connector. 4. Carry out an operation check. (Refer to "7. CHECKING OPERATION".) Connector Reinstalling the column cover 1. Reinstall the column cover (lower) in the reverse order of Removing the column cover (lower) (page 6). 9
8 FOG LAMP AIMING ADJUSTMENT Forward 60mm Rearward Identical at left and right Insert a spanner into this gap Aiming adjustment screw Fog lamp center point Light/dark boundary line 9 FOG LAMP BULB REPLACEMENT Fog lamp 1. Inflate the tires to the standard pressure. 2. Set the vehicle to the unladen condition, and park it on a level surface. 3. Have one person sit in the driver's seat. 4. Place a screen perpendicularly in front of the vehicle so that there is a distance of 3 meters between the screen and the fog lamps. 5. Cover the fog lamp that is not being adjusted. 6. Start the engine and charge the battery. 7. Turn on the fog lamps. 8. This completes the adjustment if operation is normal. (Proceed to the item 9 if operation is not normal) 9. With using a spanner (10mm), loosen the aiming adjustment screw, and then adjust the position of the fog lamp so that it is within the light/dark boundary line as shown in the diagram. Tightening torque Aiming adjustment screw:2.2~2.8n m Because any looseness in the adjustment bolt can result in the aiming becoming misaligned, be sure to turn the screw in the direction of tightening when adjusting. If you fasten with those torques other than specified, the fog lamps might be broken or fallen off. Be careful to fasten accurately. WARNING Always be sure to use the properly-specified bulb. If an incorrect bulb is used, it may result in fire. Fog lamp bulb Connector Fog lamp bulb Replacement of the bulbs should be carried out by a properly-qualified technician. Use the following bulbs as replacement fog lamp bulbs. Part No.: 90703 7550[H11 12V 55W] When replacing a light bulb, avoid touching the glass part of the light bulb. Otherwise, bulb life may be decreased. 1. Disconnect the negative terminal of the battery. 2. Remove the fastener on the bumper side and the screw at the bottom of the bumper. (Refer to the illustration of the item -2. (page 8)) 3. Pull up the mud guard. 4. Disconnect the connector from the fog lamp. 5. Turn the fog lamp bulb in the direction of the arrow in the left figure in order to remove it. 6. Install a new bulb in the reverse order of removing the old one. 7. Connect the connector to the fog lamp. 11
Installation inspection sheet To be used by installation workshop A. Reinstalling the vehicle parts MAZDA CX-7 FOG LAMP KIT ER18 V4 600 (small tank) ER19 V4 600 (large tank) Install in the reverse order of 4. REMOVING THE VEHICLE COMPONENTS. After installing the vehicle parts, check for dirt. Clean any dirty parts. Check if the connectors have been securely connected. B. Inspection items after installation Inspect the installed parts and removed and re-installed parts following the items below. Section to be inspected Inspection item (circle) Scratch, stain, Gap / fit Tightening & Aiming Operation harness Function & finish engagement interference adjustment check Fog lamp (RH/LH) Fog lamp indicator Light lever Front bumper Column cover Front combination lamp Lamp hole cover Battery Power window DSC C. Important check points No. Item Check 1 Check if the fog lamps work properly 2 Check if the bolt / screw used to tighten the following part are tightened correctly. Battery terminal Important point Procedure Part name Specified torque Torque value at the time of check Inspector (name) -1 (page 6) 5Tapping screw 1.0~1.5 N m N m CHECK Fog lamp kit installation inspection Date (year/month/day): VIN No. Retention period of the sheet : 3 years Approved Checked Prepared