2004-2009 Mazda Mazda 3 Service & Repair Manual
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2007
Mazda3
MAZDASPEED3
Workshop
Manual
FOREWORD
This manual contains on-vehicle service
and/or diagnosis procedures for the
Mazda3, MAZDASPEED3.
For proper repair and maintenance,
a thorough familiarization with this manual is
important, and it should always be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical-including
photocopying and recording and the use of
any kind of information storage and retrieval
system-without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials
shown on the following page.
CONTENTS
Title
GENERAL INFORMATION
ENGINE
SUSPENSION
DRIVELINEIAXLE
BRAKES
TRANSMISSIONITRANSAXLE
STEERING
HEATER, VENTILATION &
AIR CONDITIONING HVAC
RESTRAINTS
BODY & ACCESSORIES
ALPHABETICAL INDEX
© 2006 Mazda Motor Corporation
PRINTED IN U.S.A., JULY 2006
Form No. 1886-1U-06G
Part No. 9999-95-0178-07
VEHICLE IDENTIFICATION NUMBERS (VIN)
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
JM1
..IM1
JM1
BK123*7#
BK124*7#
BK12F*7#
BK12G*7#
BK143*7#
BK144*7#
BK14L*7#
BK14M*7#
BK323*7#
BK324*7#
BK32F*7#
BK32G*7#
BK343*7#
BK344*7#
BK34L*7#
BK34M~i~7#
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
600001-
RELATED MATERIALS
I
Material Name MNAO Part No. Mazda Material No.
I
i 2004 Mazda3 Service Highlights 9999-95-064F-04 3385-1 U-031
I 200S Mazda3, Mazda MX-S Miata, Mazda MX-S, MAZDASPEED
9999-9S-MODL-OS 3400-1U-04H
MX-S, Mazda MPV, Mazda RX-8 Service Highlights
2006 Mazda3, Mazda MPV Service Highlights 9999-9S-M PV3-06 3408-1 U--0SG
2007 Mazda3, MAZDASPEED3, MazdaS, Mazda6,
9999-9S-MODL-07 3422-1 U-06G
MAZDASPEED6, Mazda MX-S, Mazda RX-8 Service Highlights
'1 99S. 1996, 1997, 1998, 1999,2000 08D-11 Service Highlights 9999-9S-08D2-00 3344-1U-99K
Engine Workshop Manual L3 WITH TC 9999-9S-0L3T-06 1833-1 U-OSH
Engine Workshop Manual LF, L3 9999-9S-LFL3-OS 1866-1U--0SH
Manual Transaxle Workshop Manual G3SM-R 9999-95-0G3S-03 17S6-1 U-021
Manual Transaxle and Transfer Workshop Manual A26M-R,
9999-9S-A26M-07 1898-1 U-06G
A26MX-R
i Automatic Transaxle Workshop Manual FN4A-EL 9999-9S-FN4A-04 1793-1 U-031
i Automatic Transaxle Workshop Manual FSSA-EL 9999-9S-FSSA-06 18S9-1U-OSF
2004 Mazda3 8odyshop Manual 9999-9S-036F-IJ4 3386-1 U-03J
2007 Mazda3 Wiring Diagram 9999-9S--019G--07 S677-1U-06G
~~G_E_NE_R_A_L_IN_F_O_R_M_AT_I_ON~~I~I~
GENERAL INFORMATION .... 00-00
00-00 GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER Dynamometer 00-00-18
(VIN) CODE 00-00-2 SST 00-00-18
VEHICLE IDENTIFICATION INSTALLATION OF
NUMBER (VIN) 00-00-2 RADIO SySTEM '" 00-00-19
HOW TO USE THIS MANUAL 00-00-3 ELECTRICAL SYSTEM 00-00-19
Range of Topics 00-00-3 Electrical Parts 00-00-19
Service Procedure 00-00-3 Wiring Harness 00-00-19
Symbols 00-00-5 Connectors 00-00-20
Advisory Messages 00-00-5 Terminals 00-00-21
Troubleshooting Procedure 00-00-6 Sensors, Switches, and Relays 00-00-21
Procedures for Use 00-00-7 Wiring Harness 00-00-22
UNITS 00-00-12 Fuse 00-00-22
Conversion to SI Units Direction of View for Connector 00-00-22
(Systeme International d'Unites) 00-00-12 Electrical Troubleshooting Tools 00-00-23
Rounding Oft. 00-00-12 Precautions Before Welding 00-00-24
Upper and Lower Limits 00-00-12 JACKING POSITIONS, VEHICLE LIFT
SERVICE CAUTIONS 00-00-13 (2 SUPPORTS) AND SAFETY STAND
Injury/damage Prevention (RIGID RACK) POSITIONS 00-00-25
Precautions 00-00-13 Jacking Positions 00-00-25
Protection of the Vehicle 00-00-13 Vehicle Lift Positions 00-00-26
Preparation of Tools and Measuring Safety Stand Positions 00-00-26
Equipment. 00-00-13 TOWING 00-00-27
Special Service Tools 00-00-13 Towing 00-00-27
Malfunction Diagnosis System 00-00-13 Tiedown Hooks 00-00-28
Disconnection of the Negative TIEDOWN HOOK 00-00-29
Battery Cable 00-00-14 IDENTIFICATION NUMBER
Oil Leakage Inspection 00-00-14 LOCATIONS 00-00-30
Removal of Parts 00-00-14 Vehicle Identification Number
Disassembly 00-00-15 (VIN) 00-00-30
inspection During Removal, Engine Identification Number 00-00-30
Disassembly 00-00-15 SAE STANDARDS 00-00-31
Arrangement of Parts 00-00-15 ABBREVIATIONS 00-00-32
Cleaning of Parts 00-00-15 PRE-DELIVERY INSPECTION 00-00-32
Reassembly 00-00-16 Pre-Delivery Inspection Table 00-00-32
Adjustment 00-00-16 SCHEDULED MAINTENANCE 00-00-34
Rubber Parts and Tubing 00-00-16 Scheduled Maintenance Table for U.S.A.,
Hose Clamps 00-00-17 CANADA and Puerto Rico 00-00-34
Torque Formulas 00-00-17 Scheduled Maintenance
Vise 00-00-17 Table for Mexico 00-00-36
00-00-1
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
id000000100200
JM1BK123*7#123456
'~~~~~'~l Serial No.
I
Plant
Model year
Check diqit
Engine
Body style
Restraint system
Carline and Series
World manufacturer identification
0= Hiroshima
1= Hofu
7= 2007
*= 0 to 9, X
F= 2.0 L (Federal/CANADA (LF))
3= 2.3 L (Federal/CANADA (L3))
L= 2.3 L Turbo (Federal/CANADA (L3 WITH TC))
G= 2.0 L (California (LF))
4= 2.3 L (California (L3))
M= 2.3L Turbo (California (L3 WITH TC))
4= 5HB
2= 4SD
3= with Side air bag module,
Curtain air bag module
1 = without Side air bag module,
Curtain air bag module
BK= Mazda3, Mazdaspeed3
J M1= Mazdalpassenger car
VEHICLE IDENTIFICATION NUMBER (VIN)
JM1 BK123*7# 600001-
JM1 BK124*7# 600001-
JM1 BK12F*7# 600001-
JM1 BK12G*7# 600001-
JM1 BK143*7# 600001-
JM1 BK144*7# 600001-
JM 1 BK14L*7# 600001-
JM1 BK14M*7# 600001-
JM1 BK323*7# 600001-
JM1 BK324*7# 600001-
JM1 BK32F*7# 600001-
JM1 BK32G*7# 600001-
JM1 BK343*7# 600001-
JM1 BK344*7# 600001-
JM1 BK34L*7# 600001-
JM1 BK34M*7# 600001-
am3uuw0000076
id000000100300
00-00-2
GENERAL INFORMATION
HOW TO USE THIS MANUAL
Range of Topics
id000000800100
• This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/I nstallation
Disassembly/Assembly
Replacement
•
Inspection
Adjustment
• Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
• Inspection and adjustment procedures are
SHOWS PROCEDURE ORDER
divided into steps. Important points regarding the
FOR SERVICE
location and contents of the procedures are
explained in detail and shown in the illustrations.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
~. 'Caution
Connect the gauge set from under
the vehicie to prevent contact with
the drive belt and the cooling fan.
acxuuw00000434
00-00-3
GENERAL INFORMATION
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only removal/installation procedures that need to be
performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S)
... / INDICATES RELEVANT
I LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAUINSTALLATION I REFERENCES THAT NEED
"R III t II t'" 1.JaCkup therearotthevehlclea.ndsu
pp
ort. it with safely stands. __--- TO BE FOLLOWED DURING
emova ns a a Ion 2. Remove the undercover (See 01-10-4 Undercover Removal
Portion 3. Remove in the order indicated ,n the table INSTALLATION
U
4. Install in the reverse order of removal.
---- _.- ---------------- -~-.- ~ 5. Inspect the rear wheel alignment and adjust it if necessary.
SHOWS TIGHTENING
TORQUE UNITS
SHOWS DETAILS
94--116 {9.5-11.9, 69--a6}
SHOWS REFERRAL
NOTES FOR SERVICE
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
"Inspection After
Installation" Portion
INSTALL THE PARTS BY
PERFORMING STEPS
1-3 IN REVERSE ORDER
SHOWS PROCEDURE ORDER
FOR SERVICE
"'-.",. ,
Split pm
2 Nul
ower Iral In
'"
a jOint
(See O?-14-5 Lower Trailing Link Sal! Joint Removal Nole)
3
4 Bolt
Lower traihno link
Dust boot (lower trailing link)
5
6
7 50lit Din
8 Nul
9 Upper trailing link ball jOint
(See 02-14-5 Upper Trailing link Ball Joint Removal Note)
10 NUl
11 Upper trailing hnk
12 Dust boot (upper trailing link)
LowerTrailing Link Ball Joint, Upper Trailing Link
Ball Joint Removal Note
• Remove the ball jOint using the SSTs.
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
KNUCKLE
'€i"f1:'ft§1
SHOWS REFERRAL
NOTES FOR
SERVICE
acxuuw00000435
00-00-4
GENERAL INFORMATION
Symbols
• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
..
Symbol Meaning Kind
-~
I
Apply oil
New appropriate
engine oil or gear
oil
•
" .
Apply brake fluid
New appropriate
brake fluid
I
I
•
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
I
I
,
i
-A
I
Apply grease
Appropriate
grease
I
! ~I
Apply sealant
Appropriate
sealant
e
Apply petroleum
jelly
Appropriate
petroleum jelly
iii
Replace part
O-ring, gasket,
etc.
lID
Use SST or
equivalent
Appropriate tools
Advisory Messages
• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this
manual.
Warning
• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Caution
• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.
Note
• A Note provides added information that will help you to complete a particular procedure.
Specification
• The values indicate the allowable range when performing inspections or adjustments.
Upper and lower limits
• The values indicate the upper and lower limits that must not be exceeded when performing inspections or
adjustments.
00-00-5
GENERAL INFORMATION
Troubleshooting Procedure
Basic flow of troubleshooting
WARNING L1GHT*
ON/FLASHING
CHECK FOR
PRIORITIZED DTC
DIAGNOSE BY DTC
•
(ON-BOARD DIAGNOSTIC)
.. DTCTABLE
.. DTC
TROUBLESHOOTING
FLOW
CUSTOMER ARRIVES
I
DTC
*: INDICATOR LIGHTS AND WARNING
LIGHTS THAT INDICATE MALFUNCTIONS
!
DTC troubleshooting flow (on-board diagnostic)
NO WARNING L1GHT*
WITH SYMPTOM
•
~
.. CHECK DTC
.. IGNITION ON TEST, IDLING
TEST
I
~ WITHOUT DTC
DIAGNOSE BY SYMPTOM
(SYMPTOM TROUBLESHOOTING)
1. DIAGNOSTIC INDEX
2. QUICK DIAGNOSIS CHART
(IF MENTIONED)
3. SYMPTOM
TROUBLESHOOTING
acxuuw00000444
.. Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate.
Periorm the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
.. The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a
malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic
function.
Diagnostic index
.. The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely
relating to the malfunction.
Quick diagnosis chart (If mentioned)
.. The quick diagnosis chart lists diagnosis and inspection procedures to be periormed specifically relating to the
cause of the malfunction.
Symptom troubleshooting
.. Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
00-00-6
GENERAL INFORMATION
Procedures for Use
Using the basic inspection (section 05)
• Perform the basic inspection procedure before symptom troubleshooting.
• Perform each step in the order shown.
.. The reference column lists the location of the detailed procedure for each basic inspection.
• Although inspections and adjustments are performed according to the reference column procedures, if the
cause of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
action column.
SHOWS INSPECTION
S EP INSPECTION
Perform the mecnanical system test. Yes
(See 05-13-3 MECHANICAL SYSTEM TEST.)
No Repair or replace any malfunctioning parts according to
Is mechanical system normal?
the inspection result.
2 Turn the Ignition switch to the ON position. Yes Go to next step.
When the selector lever is moved, does the selector
No Inspect the selector lever and TR sWitch. Repair or
illumination indicate synchronized position to the
replace malfunctioning parts.
lever location? Also, when other ranges are selected
(See 05-14-5 SELECTOR LEVER INSPECTION.)
from N or P during idling. does the vehicle move
(See 05-13-10TRANSMISSION RANGE (TR) SWITCH
within 1-2 s? INSPECTION.)
If the selector iever and TR switch are normal, go to the
next step.
3
Inspect the ATF color condition Yes Go to the next steD.
(See 05-13-8 AUTOMATIC TRANSMISSION
No Repair or replace any malfunctioning parts according to
FLUID (ATF) INSPECTION.)
The inspection resulT
Are ATF color and odor normal?
Flush ATX and cooler line as necessary.
4 Perform the line pressure test. Yes Go to the next step.
(See 05-13-3 Line Pressure Test.) No
Repair or replace any malfunctioning pans according to
Is the line pressure normal?
the inspection result
5 Perform the stall test. Yes Go to the next steD.
REFERENCE
(See 05-13-4 Stall Speed Test.)
No Repair or replace any malfunctioning parts according to
COLUMN
Is the stall speed normal?
the inspection result.
Inspect the voltage at the following TCM terminals.
Yes Go to the next step.
(See 05-13-29TCM INSPECTION.)
No
SHOW POINTS REQUIRING
SHOWS ITEM NAMES FOR
ORDER
ATTENTION BASED ON
DETAILED PROCEDURES
INSPECTION RESULTS
BA~ C INSPECTION
/
ACTION
/
,
Go to the next step. 1
Repair or replace any malfunctioning pans according to
the inspection result.
·
·
·
·
·
Terminal 2J (TFT sensor)
Terminals 1D, 26, 2C, 2E (TR switch)
Terminal 2G (turbine sensor)
Terminal 2D (down switch)
Terminal 21 (up sWitch)
Terminal 1E (M range switch)
Terminal 1W (steering shih switch)
Is the voltage normal?
[
..
acxuuw00000445
00-00-7
GENERAL INFORMATION
Using the DTC troubleshooting flow
• DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each
DTC.
I
I
I
POSSIBLE
CAUSE
describes
possible
point(s) of
malfunction
I
Iindicates the
inspection step
No. to be
performed
(01 and 05
section)
STEP shows
the order of
troubleshooting
---..:..
INSPECTION
describe sthe
method t 0
/
quickly
Idetermin ethe
'malfunct ioning
part(s).
[
I
TROUBLE CONDITION
DTC P0103
DTC P0103 MAF circuit high input
DETECTION
CONDITION
Diagnostic support note
This is a continuous monitor (GeM).
MIL illuminates if PCM detects the above malfunction during first drive cycle. Therefore,
PENDING CODE is nor available
FREEZE FRAME DATE is available.
DTC is stored in the PCM memory.
PCM monitors input voltage from TP sensor after ignition key is turned on. If Input voltage at PCM terminal 68 !
above 8.25 V. PCM determines thai TP Circuit nas malfunccion
POSSIBL
CAUSE
MAF sensor malfunction
Connector or terminal malfunction
Open circuit in wiring between MAF sensor terminal 0 and PCM terminal 36
o en circuit in MAF sensor round circuit
lP
PCM
HARNESS SIDE COM~ECTOR
FROM
MAIN RELAY PCM
TERMINAL D
MAF SENSOR
HARNESS SIDE CONNECTOR
Diagnostic procedure describes the
STEP INSPECTION ACTION
appropriate
1
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
Yes
No
Go to next step.
Record FREEZE FRAME DATA on repair order, then go
~
/
action to be taken
Has FREEZE FRAME DATA been recorded? to next step, according to
2 VERIFY RELATED REPAIR INFORMATION Yes Perform repair or diagnosis according to available repair
the result
AVAILABILITY
Are related Service Bullelins and/or on-line
information.
If vehicle is not repaired. then go to next step. (Yes/No) of the
repair information available? No Go to next steD. INSPECTION.
3 VERIFY CURRENT INPUT SIGNAL STATUS IS
Yes Intermittent concern is existing. Go to INTERMITTENT
CONCERN INTERMITIENT OR CONSTANT
/
Connect diagnostic tool to DLC-2.
Start engine.
Access MAF V PID using diagnostic tool. No
CONCERNS TROUBLESHOOTING procedure.
(See 01-03-33INTERMITIENT CONCERN _
TROUBLESHOOTING)
Go to next step.
Reference
item(s) to
perform
Is MAF V PID within 02 - 8.3 V?
4 INSPECT POOR CONNECTION OF MAF Yes Repair or replace terminals, then go to Step 8.
ACTION.
SENSOR CONNECTOR
Turn ignition key to OFF.
Disconnect MAF sensor connector
Check for poor connection (damaged, pulled-
out terminals, corrosion etc.).
Are there any malfunctions?
DETECTION CONDITION
describes the condition
under which the DTC is
detected.
Indicates the
circuit to be
inspected
(01 and 05
section)
Indicates the
connector
related to the
inspection
ACTION
acxuuw00000446
00-00-8
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For individuals with basic mechanical skills and independent auto service professionals, this manual provides access to the same specifications and procedures available to an authorized dealer service department. It is a valuable resource for car owners who may not intend to perform repairs themselves but wish to be better informed and able to discuss repairs knowledgeably with automotive technicians.
These files are in PDF format, allowing for viewing on PC, Mac, and various devices including many phones and e-readers like the Amazon Kindle. The option to print individual pages as needed helps prevent the original from becoming obscured and unreadable due to oil stains.
Upon completion of payment through our secure platform, you can instantly access the product without incurring shipping costs or waiting for a CD.
Language: English
Format: PDF file
Engine: 1.3, 1.6, and 2.0
Every aspect of the car is covered, including but not limited to:
- General Info
- Engine Service and Overhauling
- Transmission
- Chassis
- Body
- Wiring
- Fuel System
- Emission Control
- Induction
- Mechanical
- Control System
- Transmission and Differentials
- Troubleshooting and Diagnostics
- Steering and Suspension
- Brakes
- ABS
- Full Specifications and Torque Settings
- Service Work
This product is beneficial for various reasons, including:
- Diagnosing engine fault symptoms of any vehicles with any models, cars, or trucks
- Researching and evaluating the best approach to fixing vehicle problems
- Testing suspected parts using techniques employed by top mechanics in your brand of car
- Tracing and verifying wiring diagrams by providing specific terminal pins connections and expected readings
- Understanding and analyzing different engine management systems
- Providing common fixes to effectively communicate with mechanics, potentially reducing service costs
- Checking the quality of mechanic or garage work and knowing what to ask them
- Testing the vehicle after repair and knowing what to communicate if issues persist
- Offering practical quick solutions to problems with easy-to-analyze drawings
- Providing common tips about vehicles to prevent small problems from escalating
If you require a different service manual for another model, make, or year, visit: www.infoautomotriz.cl
