Subject:
BODY VIBRATION AT CRUISE SPEED

BULLETIN NOTE This bulletin supersedes the previous bulletin 03-001/06 issued on 7/21/2006. The APPLICABLE MODEL(S)/VINs section has been revised.

APPLICABLE MODEL(S) / VINs
2004-2007 Mazda3
2006-2007 Mazda5

Some vehicles may experience a body vibration when driving approximately 55 mph. This symptom is due to the characteristics of the No.3 & No. 4 engine mounts.

Modified No. 3 & No. 4 engine mounts have been established for service only. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

IMPORTANT NOTE: ^ This repair should only be performed if all tires and rims are confirmed to be in balance and all suspension components are in proper working condition.

^ Notify customers that use of the modified mounts will reduce vibration at cruising speed but may increase vibration at idle.

NOTE: Because idle vibration may increase, it is highly recommended to continue using mass production mounts for all other service concerns.

1. Verify concern.

2. Replace the No. 3 & 4 engine mounts with service parts according to the appropriate Workshop Manual section 01-10 ENGINE REMOVAL/INSTALLATION.

3. Center the new engine mounts as outlined in ENGINE MOUNT CENTERING PROCEDURE.

4. Verify repair.


ENGINE MOUNT CENTERING PROCEDURE

No. 1, No. 3 and No.4 Engine Mount Adjustment

1. Warm up the engine.

2. Raise and support vehicle on a hoist.

3. Remove engine under cover.

4. Lower the vehicle until the front tires lightly touch the ground.

5. Secure the engine and transaxle using an engine jack and attachment as instructed in No. 3 Engine Mount And No. 4 Engine Mount Rubber Installation Note in appropriate Workshop Manual, section 01-10 MECHANICAL.

6. Remove two bolts from No.3 engine mount bracket.

7. Lift engine using jack until No.3 engine mount is lifted slightly from vehicle body.

NOTE: Do not raise engine too much or A/C pipe damage may occur

8. Move the engine mount rubber or engine until installation hole on the vehicle body aligns with hole in the engine mount bracket.

9. Lower the jack and tighten bolts on No. 3 engine mount bracket.

Tightening torque: 55.0-77.3 ft-lbf (74.5-04.9 N.m)

NOTE: ^ Do not allow the engine mount bracket to be misaligned.


10. With engine supported as described in STEP 5, remove four (4) nuts and two (2) bolts from No. 4 engine mount top plate. Remove top plate.

NOTE: ^ To access the mount, remove battery box.


11. Lift engine again using jack until No. 4 engine mount is lifted slightly from vehicle body.

NOTE: ^ Do not raise engine too much or A/C pipe damage may occur.


12. With top plate of No. 4 engine mount removed, move engine mount bottom plate or engine until all four (4) installation studs on the vehicle align with the engine mount holes.

13. Place top plate back on and tighten No. 4 engine mount bracket nuts and bolts to torque indicated

14. Lift engine again using jack and loosen the two bolts on the No. 1 engine mount rubber until slightly loose on the No. 1 engine mount rubber.

15. Shake/rock the engine back and forth.

16. Tighten bolts in order below.

A. Crossmember-side No. 1 engine mount rubber. Tightening Torque: 68.7-86.1 ft-lbf (93.1-116.6 N.m)

B. Engine-side No. 1 engine mount rubber. Tightening Torque: 68.7-86.1 ft-lbf (93.1-116.6 N.m)



A/C Pipe Adjustment

NOTE: ^ A/C pipes and bracket are located on the right rear of the engine compartment, bolted to the frame rail.

1. Loosen the A/C pipe bracket bolt and/or nut.

2. Position the A/C pipe bracket so A/C pipes are as close to center in the bushings as possible.

NOTE: ^ On Mazda5, center both A/C pipes, on Mazda3, center only the rear pipe as the front pipe cannot be centered due to bushing thickness.

3. Tighten the bolt and nut.

 

MAZDA3/MAZDASPEED3 - FLOOR COVERING (CARPET) CHANGED

APPLICABLE MODEL(S)/VINS
2004-2007 Mazda3/Mazdaspeed3 vehicles with
VINS lower than JM1 BK**** ** 696694 (produced before January 8, 2007)

DESCRIPTION

The floor covering (for mass production and service) has been changed since January 8, 2007, and there is no interchangeability between before and after the change.

1. When the floor covering has to be replaced on vehicles built prior to January 8, 2007, floor insulators will need to be ordered with the floor covering.

2. For vehicles originally fitted with former pads (BN8F680C1/0C2), do not fit them with these pads any more. If these vehicles need the former pads, use the new floor covering and floor insulators as mentioned above.

3. To attach the floor insulators, peel off the adhesive backing from the double-sided tape on the floor insulator and attach it to the floor covering approximately 10 mm inward from the corner of console side and the No. 2 cross member side.

NOTE: Make sure there is 10 mm if clearance between the floor insulator and the corners of the floor covering.

 

MULTI-MODEL - ENGINE VIBRATION/KNOCKING NOISE/NO. 3 ENGINE MOUNT RUBBER BROKEN

This bulletin replaces 01-021/05. Please update your records accordingly.

BULLETIN NOTE This bulletin supersedes the previous bulletin 01-021/05 issued on 07/13/05. The DESCRIPTION, APPLICABLE MODEL(S)/VINS, and PART(S) INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 with VINs lower than JM1 BK**** ** 533507
(Produced before May 8, 2006)

2006 Mazda5 with VINs lower than JM1 CR**** ** 127354
(Produced before May 8, 2006)

DESCRIPTION

Some vehicles may exhibit a knocking noise from the engine compartment when starting/shutting off the engine or may experience excessive engine vibration at idle. A likely cause of this is a broken No. 3 engine mount. This symptom could be observed under any condition such as accelerating or idling with the engine hot or cold.

The No. 3 engine mount rubber has been modified to address this concern.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify concern.

2. Replace the No. 3 engine mount rubber with a modified part. Refer to Workshop Manual section 01-10.

3. Verify repair.

 

2006-2007 MAZDA3 - ENGINE IDLE DIP WHEN A/C CYCLES ON

APPLICABLE MODEL(S)/VINS
2006-2007 Mazda3 vehicles (CA spec only)
with VINs lower than JM1BK**** ** 774383 (produced before May 31, 2007)

2006-2007 Mazda3 vehicles (2.0L and A/T except CA spec)
with VINs lower than JM1BK**** ** 791118 (produced before July 1, 2007)

DESCRIPTION

Some vehicles may experience an engine idle drop when the A/C cycles on and off (normal operation) at a stop. Body vibration may also be felt.

The PCM software has been revised to eliminate this concern. Customers having this concern should have their vehicle repaired using the following repair procedure.

When reprogramming the PCM of the 2007 Mazda3 with 2.3L (L3) engine and automatic transmission, the TCM also needs to be reprogrammed.

REPAIR PROCEDURE

1. Reboot the IDS to clear memory before reprogramming.

2. Using IDS 50.4 or later software, reprogram the PCM to the latest calibration (refer to Calibration Information table) by following the Module Reprogramming procedure.

NOTE: ^ Always update the IDS tool first, then follow on-screen instructions to download the needed calibration file for PCM reprogramming.

^ It is not necessary to remove any fuses or relays during PCM reprogramming when the IDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the IDS reprogramming procedure.

^ IDS shows the calibration part numbers after programming the PCM.

^ Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of IDS software, and additional revisions made to those calibrations for service related concerns.

^ When reprogramming a PCM, IDS will always display the latest calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.

^ When performing this procedure, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it could damage the VCM.


3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.

NOTE: ^ If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.

^ After PCM reprogramming, it is no longer necessary to road test the vehicle to relearn KAM (Keep Alive Memory).

 

Subject:
WIPER ARM HINGES CORRODED

APPLICABLE MODEL(S)/VINs
2004-2007 Mazda3 vehicles with VINs lower than JM1BK******781190
(produced before June 12, 2007)

DESCRIPTION

On some vehicles, rust may appear on the wiper arm hinge. This is caused by the paint film on the retainer coating being too thin and galvanic corrosion appearing on the wiper arm hinge. The paint on the retainer coating has now been increased and the configuration of the arm hinge has been changed from a single bush to a double bush. To prevent galvanic corrosion, the contact between the arm head and retainer has been removed. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Replace the front wiper arms with modified ones. Refer to MS3 online instructions or Workshop Manual section 09-19 WINDSHIELD WIPER ARM REMOVAL/INSTALLATION.

NOTE: Reuse the old blades.

3. Verify repair.

 

Subject:
HEAVY STEERING EFFORT/POWER STEERING FLUID LEAKAGE

APPLICABLE MODEL(S)/VINs^ 2004-2007 Mazda3 vehicles (except Mazdaspeed3) with VINs lower than JM1 BK**** ** 709745 (produced before February 1, 2007)

^ 2006-2007 Mazda5 vehicles with VINs lower than JM1 CR**** ** 150635 (produced before February 1, 2007)


DESCRIPTION

Some customers may feel the power steering effort is heavy. This can be caused by a fluid leak. One such leak can be caused by burrs found on the return port nipple of the fluid reservoir tank, making a gap between the return port and hose. All return ports are now inspected on the production line to ensure there is no burr. To avoid unnecessary parts replacement, customers having this concern should have their vehicle repaired using the following repair procedure.

1. A clean solid plug with these measurements (either from around the shop or made up) to prevent dust from entering the return port.

2. Sandpaper (# 1200, 10 mm x 100 mm)

3. Cleaning fluid (degreasing agent or parts cleaning agent))


REPAIR PROCEDURE

1. Verify concern by checking to see if the steering effort is hard and the power steering fluid level is low, indicating a leak.

NOTE: Check for the leak at the return hose directly down from the power steering fluid reserve tank. If the leak is here, continue with this Service Bulletin. If the leak is not here, refer to MS3 online instructions or Workshop Manual section 06-14 POWER STEERING FLUID INSPECTION.

2. Drain the fluid from the electric power steering pump.

3. Remove the electric power steering oil pump. Refer to MS3 online instructions or Workshop Manual section 06-14.

4. Run your finger over the parting lines on the return port to check for burrs.

NOTE: The parting lines are on the top and bottom of the port.

5. Insert the plug in the return port as shown.

6. Place the sandpaper on one of the parting lines of the return port as shown and sand off the burrs (for approximately 1 minute) until the surface is smooth.

CAUTION: Do not sand any locations other than the burrs. If you sand too much, the shape of the return port will become deformed.

7. Lightly sand the parting line on the opposite side of the return port.

8. After both sides have been sanded, wash off the particles using cleaning fluid and a clean cloth.

9. Remove the plug from the return port.

10. Install the electric power steering oil pump with a new power steering return hose. Refer to MS3 online instructions or Workshop Manual section 06-14.

11. Refill the the reservoir tank with power steering fluid. Power steering fluid specification: ATF M-III or equivalent.

12. Perform Air Bleeding of the system. Refer to MS3 online instructions or Workshop Manual section 06-14.

13. Verify repair.

 

Subject:
SQUEAK AND RATTLE FROM SEATBELT BUCKLE

APPLICABLE MODEL(S)/VINs^ 2006-2008 Mazda3 vehicles with VINs lower than JM1 BK**** ** 823850 (produced before September 11, 2007)


DESCRIPTION

Some customers may hear a squeak and rattle from the front seats (mainly from the driver's side) when passing over a bump or driving on a rough road. This issue is due to an improper fitting between the wave washer and anchor bolt of the seatbelt buckle. The diameter of the wave washer is bigger than the bolt flange, which causes the wave washer to come into contact with the anchor bolt.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify concern.

2. Remove the front seat(s) with the noise. Refer to MS3 online instructions or Workshop Manual section 09-13 FRONT SEAT REMOVAL/INSTALLATION.

CAUTION: Handle the wires with care as they are for SRS.

3. Disconnect the seat belt switch connector from the front seat connector by detaching the tab as shown. If necessary, follow the wire harness from the seatbelt buckle.

NOTE: Disconnect the front seat connector from the seat frame if needed.

4. Remove the seat belt switch wire harness from the clip and cut the zip ties holding the wire harness to the seat frame.

5. Remove the front seat belt buckle bolt, then remove the buckle from the seat.

6. Install the new seat belt buckle and bolt.

Tightening torque: 40-50 Nm (4.1-5.0 kgfm, 30-36 ft-lbf)

7. Route the wire harness for the seat belt switch like it was before.

8. Install the wire harness in the clip and zip tie the wire harness in the two places where it was previously attached.

9. Connect the seat belt switch connector to the front seat connector.

NOTE: Connect the front seat connector to the seat frame if it was removed.

10. Install the front seat(s). Refer to MS3 online instructions or Workshop Manual section 09-13 FRONT SEAT REMOVAL/INSTALLATION.

NOTE: If the passenger's seat was removed, perform the Seat Weight Sensor Calibration.

11. Verify repair.

^ Driver's side: With the driver's seatbelt buckle unbuckled, turn the ignition switch ON and verify seatbelt warning light is on. Then buckle the driver's seatbelt and verify warning light turns off.

^ Passenger's side: With the front passenger's seatbelt buckle unbuckled, turn the ignition switch ON and verify passenger's air bag off indicator turns on, then off. Next, buckle the passenger's seatbelt and verify passenger's air bag off indicator turns on and stays on.

 

Subject:
MODE 6 THERMOSTAT MONITOR BELOW LOWER TEST LIMIT

APPLICABLE MODEL(S)/VINs
2006 Mazda3 with VINs lower than JM1BK******600001
2006 Mazda5 with VINs lower than JM1CR******129846
2006 MAZDASPEED6 with VINs lower than JM1GG******108052
2006 MX-5 with VINs lower than JM1NC******121032
2006 RX-8 with VINs lower than JM1FE******207002
2006-2007 Mazda6 3.0L built before November 10, 2006

DESCRIPTION

In rare cases, the Mode 6 On-Board test results may show the thermostat monitor below the lower test limit even though diagnostic procedures indicate the thermostat is operating normally. As a mass-production change, the PCM calibration has been changed.

For detailed Mode 6 On-Board test results, refer to the appropriate Workshop Manual section 01-02 - DIAGNOSTIC MONITORING TEST RESULTS ACCESS PROCEDURE.

If this condition is present, the vehicle's on-board diagnostic functions will continue to operate properly and there is no impact on exhaust emission or driveability. As a result, no repair is planned for this concern.

 

Subject:
MIL COMES ON WITH DTC P2006 / VARIABLE TUMBLE SHUTTER VALVE CANNOT COMPLETELY CLOSE

APPLICABLE MODEL(S)/VINs
2004-2008 Mazda3 vehicles (2.3L) with VINs lower than JM1 BK**** ** 872056 (produced before December 14, 2007)

2006-2008 Mazda5 vehicles with VINs lower than JM1 CR**** ** 308293 (produced before December 14, 2007)

On some vehicles, the MIL may come on with DTC P2006 stored in memory because the variable tumble shutter valve (VTSV) gets stuck causing the valve not to close enough. This is due to product variation of the actuator and lever where the clearance between them is not enough for smooth movement. The production process of the actuator has now been improved.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify concern.

2. Record customer's radio presets.

3. Disconnect the negative battery cable.

4. Remove the air cleaner cover and case along with the air hose disconnected from the throttle body. Refer to MS3 online instructions or Workshop Manual section 01-13 INTAKE AIR SYSTEM REMOVAL/INSTALLATION.

5. Remove the bottom screw from the VTSV actuator.

6. Remove the four bolts from the throttle body and carefully move it out of the way to gain access to the top bolt for the VTSV actuator.

7. Remove the top screw from the VTSV actuator, then slowly remove the VTSV actuator with lever and seal assembled.

CAUTION: DO NOT pry the lever out of the intake manifold. If the lever does not want to come out of the intake manifold, separate the lever from the VTSV actuator at the ball socket with a screwdriver. Then remove the lever from the intake manifold by moving it up and down and pulling out on it.

CAUTION: If the old seal on the lever is left in the intake manifold, remove it using a pick or pin, being careful not to scratch the interior wall.

8. Disconnect the vacuum hose and electrical connector from the VTSV actuator.

NOTE: Carefully disconnect the vacuum hose from the top of the intake manifold to make it easier to disconnect the vacuum hose from the VTSV actuator.

9. Before installing the new VSTV actuator, install the lever from the old actuator without the seal to confirm that it can move all the way between the stops.

NOTE: ^ If the lever does not move all the way between the stops, remove it reinstall it at a different angle. The lever must move all the way between the stops.

^ When the lever moves between the stops, move it to the top of the range and remove it.

10. Apply mild soap around the seal at the actuator lever, then install a new VTSV actuator on the intake manifold with the lever at the top of the range.

11. Install the two bolts and tighten them to mount the VTSV actuator. Tightening torque: 2.8 - 3.8 Nm (2.1 - 2.8 ft-lbf)

12. Connect the vacuum hose and electrical connector to the VTSV actuator.

NOTE: Connect the vacuum hose to the top of the intake manifold if disconnected.

13. Verify the mounting surface is clean, then install the throttle body with the four bolts and tighten them to mount the throttle body. Tightening torque: 8.0 - 11.5 Nm (6 - 8 ft-lbf)

14. Connect the air hose to the throttle body and install the air cleaner case and cover. Refer to MS3 online instructions or Workshop Manual section 01-13 INTAKE AIR SYSTEM REMOVAL/INSTALLATION.

15. Connect the negative battery cable.

16. Enter customer's radio presets.

17. Verify repair.

 

Subject:
STARTER MOTOR WILL NOT CRANK AND ENGINE DOES NOT START (INTERMITTENTLY)

APPLICABLE MODEL(S)/VINS
2004 - 2008 Mazda3 vehicles (NOT including Mazdaspeed3)

On some vehicles, the starter motor will not crank and the engine does not start. The problem is intermittent. This is caused by poor contact of the connector for the magnet switch terminal "S" in the starter motor.

Customers having this concern should have their vehicle repaired using the following repair procedure where the connector for the magnet switch terminal "S" is replaced with a short cord set.

REPAIR PROCEDURE

1. Verify customer concern.

NOTE: If the following symptoms are present, address them before proceeding.

^ After turning the ignition on, the Security Indicator Light does not turn off after 3 seconds, and remains on, flashing repeatedly. This could be a sign of a frozen main relay (in extreme cold conditions) or a possible immobilizer issue. For immobilizer concerns, reference section 09-02A in the the Workshop Manual for diagnosing the system.

^ On automatic transaxle vehicles with the vehicle in Park (when the condition occurs), the Shift Position Indicator Light will not be illuminated around P, and if the vehicle is shifted to N the engine can be started. This could be caused by an issue with mechanical movement of the shifter cable at the inhibitor switch, or an issue with the switch circuit.


2. Record the customer's radio station presets.

3. Disconnect the negative battery.

4. Lift the vehicle up.

5. Remove the engine under cover.

6. Disconnect the connector from the magnet switch terminal "S" of the starter motor.

7. Clean the magnet switch terminal "S" of the starter motor, then polish it using fine sandpaper.

8. Cut the harness near the connector.

9. Cut the black wire cover off by 35 mm as shown.

10. Remove the wire covering from the harness and short cord by 10 mm as shown.

11. Twist the wires of the harness and the short cord together and solder them.

12. Cover the soldered wires with a heat shrink tube (length: 30 - 35 mm) as shown.

13. Place the solder iron close to the heat shrink tube to allow it to shrink from the heat of the solder iron.

14. Connect the short cord (with modified connector) on the magnet switch terminal "S."

15. Tie the short cord to the main harness with the band.
NOTE: Cut off the excess portion of the band.

16. Re-install the parts in the order of removal.

17. Connect the negative battery cable.

18. Verify repair.

19. Enter the customer's radio station presets and set the clock.