TSB for Mazdas
 

I have at my disposal a resourse that lets me look up specs, problems, and other things for ANY car, i have NO idea how to clean this up or organize it to make it easier to find possible TSB's for your car ill do my best.

2000-2006 MULTI-MODEL - BODY VIBRATION OR STEERING WHEEL SHIMMY

Note : This bulletin supersedes the following TSB(s): 02-001/03. Please update your records accordingly.

BULLETIN NOTE This bulletin supersedes the previous bulletin 02-001/03, issued on 02/24/03.

The APPLICABLE

MODEL(S)/VINS and DESCRIPTION have been revised.

APPLICABLE MODEL(S)/VINS

2000-2003 Protege
2002-2003 Protege5
2000-2002 626
2000-2002 Millenia
2000-2006 Miata
2004-2006 RX-8
2004-2006 Mazda3
2006 Mazda5
2003-2006 Mazda6
2000-2006 MPV
2001-2006 Tribute
2000-2006 B-Series Truck

DESCRIPTION

If a vehicle has body vibration or steering wheel shimmy while driving, and the root cause is determined to be tire balance, re-balance the tires using a Hunter GSP 9700/9712 balance machine. When using the Hunter GSP 9700/9712, be sure to use the following centering cones and cone/wheel set up listed below.

Using the appropriate centering cone ensures that the wheel will be properly centered to the centering cone.

To find the location of a GSP 9700/9712 near your dealer, visit Hunter's web site at www.gsp9700.com and click on "Find a GSP9700 Near You".

09-015/05 2004-2006 MAZDA3 - SNAP OR CLUNK NOISE FROM FRONT POWER WINDOWS

APPLICABLE MODEL(S)/VINs
2004-) 2006 Mazda3 with VINs lower than JM1BK****61401679 (produced before July 6, 2005) equipped with Power Windows

DESCRIPTION

Some customers may complain of a loud snap or clunk noise when operating the front power windows. The noise is most likely to occur when the window is lowered halfway and is then raised. The noise will not occur more than once each time this operation is attempted on a window.

This noise is due to insufficient torque on the screws that hold the window carrier plate to the window regulator.

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

REPAIR PROCEDURE

1. Verify concern on the applicable power window.

2. Lower the affected window to where the top of the glass is 60 mm (2.4 in) above the top of the interior door trim.

3. Record customer's pre-set radio stations.

4. Disconnect the negative battery cable.

5. Remove the inner garnish according to Workshop Manual (section 09-17 INNER GARNISH REMOVAL/INSTALLATION).

6. Remove the front door trim according to Workshop Manual (section 09-17 FRONT DOOR TRIM REMOVAL/INSTALLATION).

7. Remove the two hole covers found in the center area of the front door unit just below the door wire harness.

CAUTION: The screws thread into plastic inserts, do not over torque them.

8. Tighten the window regulator / carrier plate screws to a torque of 4.0 Nm (35 in-lbs).

9. Reassemble the interior door trim and garnish in reverse order.

10. Reset customer's pre-set radio stations.

11. Verify repair.

2004-2006 MAZDA3

SQUEAKING NOISE FROM FRONT SUSPENSION WHEN
PASSING OVER A BUMP

APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 483440 (produced before January 27, 2006)

DESCRIPTION
Some vehicles may exhibit a squeaking noise from the front suspension when passing over a bump at a low speed. This is may be caused by one of the following.

The front lower arm making contact with the bushing, causing a squeaking noise.

The fluid in the rear bushing makes an unusual noise.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Replace front lower arm. Refer to appropriate Workshop Manual section 02-13 - FRONT LOWER ARM REMOVAL / INSTALLATION.

3. Perform toe-in inspection and adjustment. Refer to appropriate Workshop Manual section 02-11 - FRONT WHEEL ALIGNMENT

TSB: 09-012/06
2006 MAZDA3 - CLOCK INDICATION INCORRECT
APPLICABLE MODEL(S)/VINS
2006 Mazda3 with VINs lower than JM1 BK**** 61 473189 (Produced from July 1, 2005 to January 6, 2006)
DESCRIPTION
Some customers may complain that the clock runs slow or fast, and no matter how many times they have tried
to adjust the time, the clock display soon indicates the wrong time.
For the 2006 model year, the Information Display is what controls the clock, where in prior model years it was the audio unit that was the controlling component.

CLOCK RUNS FAST
It is possible that the customer has unintentionally performed the "Time Resetting Function", which will create
this symptom.
NOTE:
l The "Time Resetting Function" can create symptoms of the clock losing or
gaining time, even for vehicles that are outside of the listed VIN range. For
further details see TIME RESETTING FUNCTION.
When you encounter a customer complaint of an inaccurate clock where you suspect the "Time Resetting
Function" was performed, explain to the customer the time resetting function as described below and have
them continue to monitor the clock. (This function is also described in the owner¡Çs manual, "Interior
Equipment" section.)
CLOCK RUNS SLOW

Due to improper software, the clock may lose time when the ignition is turned to the ACC or OFF position.

NOTE:
l For vehicles that are outside of the listed VIN range that present this symptom,
refer to CLOCK RUNS FAST.
An updated Information Display has been introduced to address this concern. Customers having this concern
should have their information display replaced with an exchange unit as outlined in the repair procedure below.
NOTE:
l Do not remove the Information Display until the exchange unit is available and
in hand, because without the display, the driver cannot see the radio
information and climate control settings (on vehicles equipped with an
automatic climate control).
TIME RESETTING FUNCTION
While the clock is displayed with the ignition in the "ACC" or "ON" position, when the "SET" button ("INFO"
button for vehicles equipped with a TRIP COMPUTER) on the instrument panel is pressed for 1.5 seconds or
more then released, the time on the clock display is reset to the nearest hour and the minutes (and seconds)
are set to ZERO (00).

REPAIR PROCEDURE
NOTE:
l Do not remove the information display until the exchange unit is available and
in hand, because without the display, the driver cannot see the radio
information and climate control settings (on vehicles equipped with an
automatic climate control).
1. Verify customer clock concern.
2. Record radio presets.
3. Remove the center panel module. Refer to Workshop Manual section 09-20 CENTER PANEL
MODULE REMOVAL/INSTALLATION.
4. Replace the information display with a modified one. Refer to Workshop Manual section 09-20
CENTER PANEL MODULE DISASSEMBLY/ASSEMBLY.
NOTE:
l The modified part number was not changed from the original part, but all outgoing parts are to the latest modification level. Below is a
visual reference in identifying the level part equipped on a vehicle.
Modified Information Display will have a "9621" cast into the display
housing above the harness.

5. Reassemble in reverse order.
6. Reset radio presets and adjust the clock to the correct time.
7. Verify repair.
PART(S) INFORMATION

WARRANTY INFORMATION
NOTE:
l This warranty information applies only to verified customer complaints on
vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty
term information.
l Additional diagnostic time cannot be claimed for this repair.
l This part is subject to the UNITED RADIO exchange program. Claims submitted
where the Information Display was replaced without the use of an exchange
unit will be denied and/or debited.

2004-2006 MAZDA3 - UNUSUAL NOISE FROM FRONT WIPER LINK

APPLICABLE MODEL(S)/VINS
2004 - 2006 Mazda3 vehicles with VINs lower than JM1BK**** **475647 (produced before January 12, 2006)

DESCRIPTION

Some vehicles may exhibit a high frequency squeaking noise from the wipers when they are operating. There are two causes of this symptom:

1. The pivots make the noise.

2. The pivot housing makes contact with the shaft cap.

In either case, replacing the front wiper link assembly reserves both likely causes. The original wiper motor and wiper arms will be retained. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the windshield wiper motor. Refer to Workshop Manual section 09-19 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.

3. Remove the windshield wiper motor from the old front wiper link assembly and install it to the new front wiper link assembly. Refer to Workshop Manual section 09-19 WINDSHIELD WIPER MOTOR DISASSEMBLY AND ASSEMBLY.

2004-2006 MAZDA3 - PASSENGER CARPET DOES NOT FIT PROPERLY

APPLICABLE MODEL(S)/VINS^ 2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 516377 (produced before April 1, 2006)


DESCRIPTION

Some vehicles may experience poor fitting carpet in the passenger footwell area where the carpet bunches up and pulls out from under the passenger's front side trim (kick panel). There is a gap between the dash insulator pad and the carpet and when the carpet is pressed down, it moves out of position and pulls out from under the front side trim.

As a mass-production change, a felt pad has been added under the carpet attached to the dash insulator pad. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the scuff plate.

3. Remove the front side trim.

4. Pull back the carpet to expose the dash insulator pad.

5. Ensure the corner dash insulator pad is positioned properly pressed down under the carpet before installing the felt pad.

6. Apply locally sourced double-sided 3M Scotch Mounting Tape (or equivalent) to the felt pad.

7. Position the felt pad on the dash insulator pad as shown (align the corner).

8. Press the felt pad firmly onto the dash insulator pad to attach securely.

9. Place the carpet back into position and install the front side trim and scuff plate.

10. Verify repair by pressing down on area of concern and confirm carpet does not pull out from under front side trim.

2004-2006 MAZDA3 - 4-DOOR SEDAN - SQUEAKING NOISE FROM REAR OF VEHICLE WHILE DRIVING

APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 4-door Sedan vehicles
with VINs lower than JM1BK**** ** 498597 (produced before March 2, 2006)

DESCRIPTION

Some 4-door Sedan vehicles may exhibit a squeaking noise from around the rear package tray while driving. Due to the torsional movement of vehicle body while driving, the front package member makes contact with the package junction panel, resulting in a squeaking noise.

As a mass-production change, a spot weld has been added to the area of concern. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Open the trunk.

3. Using a plastic Windshield Setting Tool or equivalent, gently pry open the area where the front package member makes contact with the package junction panel to provide clearance. Repeat for both sides of the vehicle.

NOTE: ^ Plastic Windshield Setting Tool (Part Number IS742 - available from Equalizer at 800-334-1334) or similar available through a local supplier.

^ If you substitute a flat screwdriver, wrap the end of the screwdriver with tape so it will not damage the vehicle.


4. Apply spray grease to the area of concern pried open in the previous step.

MULTI-MODEL - KEY REMINDER CHIME KEEPS CHIMING OR KEYLESS ENTRY INOPERATIVE

BULLETIN NOTE: This bulletin supercedes the previous bulletin 09-32/06 issued on 7/18/06. The SUBJECT has been revised.

APPLICABLE MODEL(S)/VINS^ 2004 - 2006 Mazda3 vehicles with VINs lower than JM1 BK**** **526084 (produced before April 18, 2006)

^ 2006 Mazda5 vehicles with VINs lower than JM1 CR**** **125853 (produced before April 18, 2006)


DESCRIPTION

On some vehicles, the key reminder chime keeps chiming even though the key is pulled out of the ignition. In addition, the doors cannot be locked with the keyless entry system. This is caused by an internal failure from a contact plate that was not properly molded.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Record the customer's radio station presets.

3. Disconnect the negative battery cable.

4. Remove the column cover. Refer to Mazda3 Workshop Manual section 09-17 COLUMN COVER REMOVAL/INSTALLATION or Mazda5 Workshop Manual section 09-17 COLUMN COVER REMOVAL/INSTALLATION.

5. Remove the ignition switch from the steering lock.

6. Disconnect the connector from the ignition switch by pulling down on the lever.

7. Reconnect the connector to the new ignition switch.

8. Install the new ignition switch.

9. Install the column cover.

10. Reconnect the negative battery cable.

11. Verify repair.

12. Reset the customer's radio station presets.

2004-2006 MAZDA3 - PASSENGER CARPET DOES NOT FIT PROPERLY

APPLICABLE MODEL(S)/VINS

2004-2006 Mazda3 vehicles with VINS lower than JM1 BK**** ** 516377 (produced before April 1, 2006)

Some vehicles may experience poor fitting carpet in the passenger footwell area where the carpet bunches up and pulls out from under the passenger's front side trim (kick panel). There is a gap between the dash insulator pad and the carpet and when the carpet is pressed down, it moves out of position and pulls out from under the front side trim.

As a mass-production change, a felt pad has been added under the carpet attached to the dash insulator pad.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the scuff plate.

3. Remove the front side trim.

4. Pull back the carpet to expose the dash insulator pad.

5. Ensure the corner dash insulator pad is positioned properly pressed down under the carpet before installing the felt pad.

6. Apply locally sourced double-sided 3M Scotch Mounting Tape (or equivalent) to the felt pad.

7. Position the felt pad on the dash insulator pad as shown (align the corner).

8. Press the felt pad firmly onto the dash insulator pad to attach securely.

9. Place the carpet back into position and install the front side trim and scuff plate.

10. Verify repair by pressing down on area of concern and confirm carpet does not pull out from under front side trim.

2004-2006 MAZDA3 - FRONT BRAKE SQUEAK WHEN COLD

NOTE :This bulletin replaces 04-001/05. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes the previous bulletin 04-001/05, issued 06/03/2005. The APPLICABLE MODEL(S)/VINS, REPAIR PROCEDURE, PART(S) INFORMATION, and WARRANTY INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS

2004-2006 Mazda3

^ 2.0L with VINS from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005)

^ 2.3L vehicles with VINS lower than JM1BK****41 133301 (produced before December 17, 2003)

^ 2.3L with VINS from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005)


DESCRIPTION

When applying the brakes during slow speed driving and in cold weather conditions, some vehicles may have a squeak noise coming from the front brakes. This may be caused by resonance in the pad, disc, and caliper.

A modified mounting support for the front brake calipers and modified pads have been introduced to correct this concern.

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

REPAIR PROCEDURE

Perform the appropriate repair procedure as follows:

^ 2.3L vehicles with VINS lower than JM1BK****41 133301 (produced before December 17, 2003) perform REPAIR PROCEDURE "A".

^ 2.OL with VINS from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "B".

^ 2.3L with VINS from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "C".




REPAIR PROCEDURE "A"

1. Verify customer concern.

NOTE :

If service bulletin 04-001/05 was already performed on this vehicle, the updated caliper mounting supports will already be installed. Verify that the updated supports are installed through visual inspection.

^ If updated caliper mounting supports are not installed, continue with REPAIR PROCEDURE "A".

^ If updated caliper mounting supports are installed, proceed to REPAIR PROCEDURE "B".


2. Replace front brake caliper mounting support assemblies and front pad & shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).
3. Procede to REPAIR PROCEDURE "B".


REPAIR PROCEDURE "B"

1. Verify customer concern.

2. Replace front pad and shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).

MULTI-MODEL - NON GENUINE ACCESSORIES AFFECT ON AIR BAG OPERATION

NOTE: This bulletin replaces T-023/96. Please update your records accordingly.

BULLETIN NOTE This bulletin supersedes the previous bulletin T-023/96, issued on 12/26/96. The APPLICABLE MODELS and DESCRIPTION have been revised.

APPLICABLE MODEL(S)/VINS
1995-2007 B-Series
1995-2003 Protege
1990-2005 Miata
1993-2002 626
1995-2002 Millenia
1993-2006 MPV
2001-2006 Tribute
2003-2007 Mazda6
2004-2007 Mazda3
2004-2007 RX-8
2006-2007 Mazda5
2006-2007 MX-5
2007 CX-7

DESCRIPTION

Addition of after-market accessories on Mazda vehicles equipped with Supplement Restraint Systems (SRS) units may affect air bag deployment. Installation of front-end equipment, such as frontal protection bars, winches, and snow plows, or installation of equipment to the side of the vehicle, may affect the performance of the airbag crash sensors system. This could cause the front or side air bags to inflate unexpectedly, or it could prevent the air bags from inflating during an accident. Modifying the suspension or using tires or wheels other than those specified for the vehicle could change the ride height of the vehicle and cause the system not to be able to accurately detect a collision or roll-over accident resulting in incorrect or unexpected air bag deployment. Also, installing non-approved electronic equipment around the SRS unit may affect SRS operation. The electronic energy of accessories mounted near SRS components could inadvertently induce an impact signal.

RECOMMENDATIONS

After-market accessories may not be compatible with Mazda SRS, and Mazda will not warranty any failure or repair where a non-Mazda approved accessory may have caused partial or complete failure. Service Managers and Service Advisors should inform customers that Mazda does not recommend installing after-market accessories to the front/side of the vehicle or anywhere near SRS components, or changing the suspension or wheels and tires.

MULTI-MODEL - WIND NOISE AROUND DOORS

NOTE: This bulletin replaces S-018/98. Please update your records accordingly.

BULLETIN NOTE This bulletin supersedes the previous bulletin S-018/98, issued on 07/29/98. The APPLICABLE MODELS has been revised.

APPLICABLE MODEL(S)/VINS
1995-2007 B-Series
1997-2003 Protege
1997-2002 626
1997-2002 Millenia
1997-2006 MPV
2001-2006 Tribute
2003-2007 Mazda6
2004-2007 Mazda3
2004-2007 RX-8
2006-2007 Mazda5
2007 CX-7

DESCRIPTION

Wind noise around doors may occur with some vehicles. This may be caused by the door weather-strip seal.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Examine weather-strip for the following conditions:

^ Rips, tears, cuts

^ Loose or falling off

^ Excessive deterioration


If the weather-strip has any of the above conditions, replace it and verify repair.

If weather-strip does not have any of the above conditions, but wind noise still exists, proceed to the "Card Test."

3. Open the door and insert a business card (0.2 mm thickness) between the door and the weatherstrip at the base of the A-pillar. Close the door.

4. Slide the business card up along the A-pillar.

^ If the card slides easily at any location along the A-pillar, the sealing contact between the door is insufficient and requires adjustment. Proceed to Door Adjustment.

^ If there is consistent resistance, proceed to the "White Grease Test".

NOTE: The Card Test only be used to evaluate the A-pillar sealing contact. Use the following "White Grease Test" to evaluate the rest of the weather-strip.

White Grease Test

5. Roll down windows and adequately cover all interior surfaces to prevent contact with grease.

6. Thoroughly and evenly spray the sheet metal surface of the body that seals against the weatherstrip on the door. Do not spray the weather-strip.

NOTE: It is recommended that you use Permatex Product # 81981 "Multi-purpose white lithium grease (aerosol spray)" or equivalent.

7. Using only the door handle, very gently close the door. This will prevent over-slam which could result in an inaccurate reading.

8. Open the door and measure the width of the grease pattern that is left along the length of the weather-strip (check for any unevenness in width).

^ If 4 mm or more, sealing contact is adequate if door closing effort is acceptable. Clean grease from vehicle.

^ If 3 mm or less, sealing contact is insufficient. Clean grease from vehicle and proceed to "Door Adjustment".

The door should be adjusted to obtain the proper seal compression while maintaining proper door alignment. The hinges control the in/out location of the door at the front as well as overall tip or tilt of the door when viewed from the front or rear. The door striker controls the in/out location of the door at the rear latch.

CAUTION: Do not pry or force the door into alignment.

In addition to Workshop Manual procedures for door alignment, the following information tips are provided:

^ As a guideline, if the weather-strip contact is insufficient, the door hinge(s) should be adjusted 2-4 mm inward. Determine the amount of movement by outlining the hinge mount area before door adjustment and after.

^ Adjusting one hinge at a time will prevent any extreme door movement. This is done by loosening the hinge bolts and moving the door with a padded pry bar just enough to permit movement of the door.

^ Hinges should be adjusted first, followed by the striker.

^ Adjustment to the rear door(s), if applicable, may require adjustments to the front door and possibly to the front fender to maintain alignment.

^ Door closing effort should be checked to ensure that it remains acceptable after adjustments are completed. If any doors are too difficult to close, the seal compression may be excessive and adjustment will need to be repeated.

^ After completing adjustments, verify seal compression by using the "Card Test" and "White Grease Test".

MULTI-MODEL - SULFUR SMELL FROM EXHAUST SYSTEM

NOTE :This bulletin replaces 01-029/02. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes the previous bulletin 01-029/02, issued on 11/22/02. The APPLICABLE MODELS has been revised.

APPLICABLE MODEL(S)/VINS

2000-2007 B-Series

2000-2003 Protege

2000-2005 Miata

2000-2002 626

2000-2002 Millenia

2000-2006 MPV

2001-2006 Tribute

2003-2007 Mazda6

2004-2007 Mazda3

2004-2007 RX-8

2006-2007 Mazda5

2006-2007 MX-5

2007 CX-7

DESCRIPTION

On some vehicles, a sulfur smell or "rotten egg" odor may be noticed coming from the exhaust system. The odor is usually noticed after a cold start, fast idle, extended periods of idling and full throttle acceleration. Sulfur smell is not an indication of an engine concern and will not cause reduced driveability or durability of the engine or any of its emission components.

The sulfur smell or "rotten egg" odor is caused by high amounts of sulfur in the gasoline being used in the vehicle. Sulfur is normally eliminated during the refining process, but the EPA regulation of sulfur in gasoline differs from state to state. Vehicles using fuel containing high amounts of sulfur will most likely emit sulfur smell from the exhaust system.
When high sulfur fuel is burned, there is a chemical reaction in the catalytic converter causing the sulfur to oxidize. As the vehicle is driven, the oxidizing reaction odor in the converter will decrease with mileage and age.

RECOMMENDATIONS

CAUTION :Replacing the catalytic converter will not eliminate sulfur smell and replacement will just extend the period of time needed for the converter to "age" allowing it to reduce sulfur smell to an acceptable level.

1. Switch to a different brand of fuel and drive the vehicle for at least 100 miles. Monitor the decrease or increase in sulfur smell.

2. Do not add any type of "fuel additive" as this could add sulfur to the fuel and cause/increase the odor.

3. Try to avoid extended periods of short trip driving or aggressive acceleration.

4. Request information from your local fuel dealers on the amounts of sulfur in their gasoline. Try to use fuel containing the lowest amounts of sulfur.

5. Visit the EPA and gasoline company websites to stay informed on any changes in fuel or environmental regulations. A website to check is: www.epa.gov

MULTI-MODEL - MIL ON WITH DTC P0106

APPLICABLE MODEL(S)/VINS

2004-2006 Mazda3 vehicles with VINS lower than JM1BK******545535 (produced before June 1, 2006)

2006 Mazda5 vehicles with VINS lower than JM1CR******129154 (produced before June 1, 2006)

2006 Mazda MX-5 vehicles with VINs lower than JM1NC******119712 (produced before June 1, 2006)

2003-2006 Mazda6 vehicles with 2.3L produced before August 9, 2006

DESCRIPTION

On some vehicles, the MIL may come on with DTC P0106 (MAP sensor malfunction) stored in memory due to corrosion of the MAP sensor chip. This produces a short circuit which causes the output characteristics of the MAP sensor to fall out of specification.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Replace the MAP sensor with a modified one.

3. Verify repair.

2004-2006 MAZDA3, MAZDA6 - MIL ILLUMINATION, P0171 / P0172 / P0441 / P0442 / P0455 / P0456 / P2177 / P2178 / P2187 / P2188

NOTE :This bulletin replaces 01-025/05. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes the previous bulletin 01-025/05, issued on 09/21/05. The PART(S) and WARRANTY INFORMATION has been revised.

APPLICABLE MODEL(S)/VINS

2004 - 2006 MAZDA3

2004 - 2006 MAZDA6 2.3L

DESCRIPTION

Some vehicles may experience MIL illumination with DTC P0171 / P0172 / P0441 / P0442 / P0455 / P0456 /P2177 / P2178 / P2187 / P2188 stored in PCM memory.

P0171: Fuel trim system too lean. (Federal Spec.)

P0172: Fuel trim system too rich. (Federal Spec.)

P0441: Evaporative emission control system incorrect purge flow.

P0442: Evaporative emission control system leak detected (small leak)

P0455: Evaporative emission control system leak detected (gross leak)

P0456: Evaporative emission control system leak detected (very small leak) (Calif. Spec.)

P2177: Fuel system too lean at off idle. (Calif. Spec.)

P2178: Fuel system too rich at off idle. (Calif. Spec.)

P2187: Fuel system too lean at idle. (Calif. Spec.)

P2188: Fuel system too rich at idle. (Calif. Spec.)

This may be due to a stuck opened purge solenoid valve.

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

REPAIR PROCEDURE

1. Verify concern.

2. Capture freeze frame data then clear all DTCs.

3. Inspect the airflow sealing of the purge solenoid valve by using the Purge Solenoid Test Cap (MT04-F2-001) and vacuum pump below. Apply vacuum to at least 20". The vacuum reading should hold indefinitely.

^ If the vacuum reading does not hold, replace the purge solenoid valve.

^ If the vacuum reading holds, go to next step.


NOTE :Make sure the Purge Solenoid Test Cap (MTO4-F2-001) does not leak at the fitting before testing purge solenoid valve.

4. Cycle purge solenoid valve a few times to check for intermittent sealing issues. Refer to page 01-16-14 Airflow Inspection of 2004 Mazda3 Workshop Manual and page 01-16-15 Airflow Inspection of 2004 Mazda3 Workshop Manual.

2006 MAZDA3 WITH 2.0L/2.3L (CA SPEC ONLY) - ENGINE HAS ROUGH IDLE AFTER COLD START

APPLICABLE MODEL(S)/VINS

2006 Mazda3 vehicles with 2.0L/2.3L (CA Spec)

DESCRIPTION

Some vehicles may exhibit a rough idle for 5-10 seconds after a cold start. It may happen after filling up with 87 octane gasoline and then parking overnight. There is no DTC stored in PCM memory and fuel holding pressure is 36.2 psi or more. This is due to a sensitive PCM calibration to specific local gasoline quality.

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

REPAIR PROCEDURE

1. Reboot the PDS/IDS to clear memory before reprogramming.

2. Using PDS/IDS 44.2 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 PDS/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 PDS/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 PDS/IDS reprogramming procedure.

^ PDS/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 PDS/IDS software, and additional revisions made to those calibrations for service related concerns.

^ When reprogramming a PCM, PDS/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).

2004-2006 MAZDA3 - WATER DRIPS FROM CEILING

APPLICABLE MODEL(S)/VINS
2004 - 2006 Mazda3

DESCRIPTION

The ceiling becomes damp and water starts dripping from the front sides of the headliner. This is likely to happen during the winter in an area where the weather gets extremely cold, followed by a rise in the ambient temperature to 32 degrees Fahrenheit or higher.

This is caused by either snow entering the vehicle cabin through the cowl grille or the climate control system is constantly set to use recirculated air which results in a buildup of moisture. To prevent snow from entering the vehicle cabin, the shape of cowl grille has been modified since December 1, 2005. For now, a special insulator will be added to the front of the roof under the headliner. You can also inform the customer to not use recirculated air all the time; try to use fresh air whenever possible.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. For vehicles built prior to December 1, 2005 with VINs lower than JM1 BK**** ** 461950, perform Procedures A and B. For vehicles built after December 1, 2005, perform Procedure B only.

A. COWL GRILLE REPLACEMENT PROCEDURE

1. Remove the windshield wiper arm and blade.

2. Remove the weatherstrip.

3. Move the cowl grille in the direction indicated by the arrow and disengage tabs A from the windshield.

4. Remove the cowl grille.

5. Install the modified right cowl grille.

6. Install the weatherstrip.

7. Install the windshield wiper arm and blade.

8. Verify repair.

B. INSULATOR INSTALLATION PROCEDURE

1. Remove the headliner. Refer to Workshop Manual section 09-17 HEADLINER REMOVAL/INSTALLATION. If the vehicle is equipped with an overhead console and no sunroof, remove the console bracket as well.

2. Prepare the pieces of roof insulator(s) listed in the PARTS INFORMATION and cut as shown. You will cut two pieces of insulator for vehicles without a sunroof and one piece for vehicles with a sunroof.

3. Peel the adhesive backing from the roof insulator and install the pieces to the roof as shown.

4. Peel the adhesive backing from the windshield insulator and install the windshield insulator as shown. It should be placed 15 mm back from the black band (frit) where it is solid without dots.

5. Install in the reverse order of removal.

6. Verify repair.

2006-2007 MAZDA3 (EXCEPT CA SPEC & MAZDASPEED3) - ENGINE STALL AND HESITATION AFTER START-UP UNDER HIGH AMBIENT TEMPERATURE

APPLICABLE MODEL(S)/VINS
2006-2007 Mazda3 (except CA spec and Mazdaspeed3) vehicles with VINs lower than JM1BK**** ** 696694 (produced before January 1, 2007)

DESCRIPTION

Some vehicles may experience the following symptoms due to improper PCM software:

1. The engine stalls when depressing the accelerator pedal slightly, then releasing it with the A/C on.

2. The engine hesitates when doing a quick take-off after start-up with a high ambient temperature.


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

REPAIR PROCEDURE

1. Reboot the IDS to clear memory before reprogramming.

2. Using IDS 46.6 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 PDS/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).

2006-2007 MAZDA3, MAZDA6, MAZDASPEED6, RX-8, MAZDA5 AND 2007 CX-7, CX-9, MAZDASPEED3 - NAVIGATION SYSTEM DISPLAYS NO MAP OR INCORRECT MAP

NOTE: This bulletin replaces 09-008/06. Please update your records accordingly.

BULLETIN NOTE This bulletin supersedes the previous bulletin 09-008/06, issued on 03/17/06. The APPLICABLE MODEL(S)/VINS have been revised.

APPLICABLE MODEL(S)/VINS
2006-2007 Mazda3 with Navigation
2007 Mazdaspeed3 with Navigation
2006-2007 Mazda6 with Navigation
2006-2007 Mazdaspeed6 with Navigation
2006-2007 RX-8 with Navigation
2006-2007 Mazda5 with Navigation
2007 CX-7 with Navigation
2007 CX-9 with Navigation

DESCRIPTION

Some vehicles equipped with the factory navigation system that have been activated in one location, then transported long distances with the battery disconnected or room fuse removed, may not display a map or may display an incorrect map.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Turn ignition switch to "ON" position and press "OPEN" to open navigation system display

3. Select "Agree" and press "ENTER".

NOTE: Normally the current position screen appears, but the navigation system may exhibit one of the following failures depending on symptom(s).

^ Displays NO MAP in screen (white or blue). Proceed to "A" NAVIGATION SYSTEM DISPLAYS NO MAP".

^ Displays map, but does not display "the vehicle's current position". Proceed to "B". NAVIGATION SYSTEM DISPLAYS MAP, BUT DOES NOT DISPLAY VEHICLES CURRENT POSITION".



A. NAVIGATION SYSTEM DISPLAYS NO MAP

1. Move vehicle outside to open area away from buildings or high walls where GPS is receivable.

2. Stop vehicle in a safe location, set parking brake, and ensure all doors are closed.

NOTE: Closing all doors prevents RF interference between navigation system and advanced keyless entry system.

3. With engine running, operate navigation for "vehicle current position" following steps a - m:

a. Press "Menu Key".

b. Select "Destination Entry".

c. Press "Change".

d. Select AREA (vehicle current position), press "OK". .

e. Select "Address".

f. Input address of vehicles current location.

g. Display current location.

h. Press "Menu" and select "Navigation Set Up".

i. Select "Calibration".

j. Select "Position/Direction".

k. Press "Enter".

l. Press "OK".

m Display MAP.

4. Wait for a maximum of 20 minutes with engine running and all doors closed.

2004-2006 MAZDA3 - NO START DUE TO FROZEN MAIN RELAY

NOTE: This bulletin replaces 01-007/06. Please update your records accordingly.

BULLETIN NOTE This bulletin supersedes the previous bulletin 01-007/06 issued on 03/15/06. The APPLICABLE MODEL(S)/VINS has been revised.

APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 vehicles with VINs lower than JM1 BK**** ** 485606 (produced before February 1, 2006)

DESCRIPTION

In extremely cold weather below -22°F (-30°C), some vehicles may experience a no-start condition. The contact point of the main relay may have frozen after short distance driving in extremely cold weather. Due to the design, moisture can enter the inside of the relay, allowing the contact point to freeze. As a countermeasure for Mazda3 vehicles, a mass production change has occurred with the following

^ For all Mazda3 vehicles (FED/CA/CAN) a breathing hole has been added to the main relay, and the capacity of relay coil has been increased.

^ For FED and CAN spec Mazda3 vehicles, the PCM logic of the main relay electric current control has been changed. After the ignition is turned off, a small, regulated amount of electric current will continue to run through the relay for 10-20 minutes.


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

REPAIR PROCEDURE

1. Verify customer concern.

2. For all vehicles (FED, CA, and CAN), replace the main relay with a modified one.

3. For FED and CAN spec vehicles, reprogram the PCM.


PCM REPROGRAMMING

1. Reboot the IDS to clear memory before reprogramming.

2. Using IDS 47.5 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:
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.

I can guarantee you all that this is at best a temporary fix for the problem which is actually caused by the plastic screws used that will not stay tight.
I have had this done twice while my car was still under warranty and it is back again.
This is Mazdas answer to save them money to the question, "Will this work long enough for the customer to be out of warranty when it happens again?"

icspots once came up with the solution (not covered by Mazdas warranty of course) to replace all current hardware with the late '06 hardware. But that requires that you BUY the hardware from a dealer and DIY
.

Subject:
A/C STOPS COOLING/REDUCED AIRFLOW DURING A LONG DRIVE IN HUMID TEMPERATURES

APPLICABLE MODEL(S)/VINS
2006 - 2008 Mazda3 vehicles (including Mazdaspeed3)

DESCRIPTION

Some customers may report that with the A/C on during an extended drive, the vent air volume decreases and/or the vents start to blow warm air. This could be result of the evaporator freezing, and it is most likely to occur while driving for an extended time at steady highway speeds with the A/C on MAX in high humidity conditions. When the freeze-up occurs, the following symptoms may be present:

^ During freeze-up, the low pressure side pipe will have frost on it, giving the appearance it is frozen.

^ Allowing the evaporator to unfreeze will temporarily address the concern.
NOTE: There are other conditions that can create similar symptoms, which include:

^ A/C cutoff control operation, where the PCM stops energizing the A/C relay when certain conditions are met. This can include the following situations:

- During acceleration (throttle valve opening angle 50% or more). The duration is 5 seconds.

- When ECT (engine coolant temperature) is 113°C (235°F). The system repeatedly turns on and off every 20 seconds until the ECT is less than approximately 110°C (230°F).

- When ECT is 117°C (242°F) or more. The system will remain off until the ECT decreases to less than 114°C (237°F). These conditions signify the engine is running hot and could be on the verge of overheating.


^ Electrical or mechanical concerns that could restrict vent air flow, causing irregular operation of the blower motor, and/or engagement of the A/C compressor.


The cause of the evaporator freeze-up is product variation of the evaporator temperature sensor and uneven airflow across the evaporator. To correct the sensor, a short harness with a built-in resistor will need to be installed in series with evaporator temperature sensor circuit. This cord will correct it by reducing the measured value 1°C (1.8°F). To correct the airflow, a cabin filter with a built-in diffuser will need to be installed in place of the current filter.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Record the customer's radio station presets.

3. Disconnect the negative battery for at least one minute.

4. Remove the side wall on the passenger side foot well.

5. Remove the Passenger Juction Box. Refer to MS3 online instructions or Workshop Manual section 09-40 PASSENGER JUNCTION BOX (PJB) REMOVAL/INSTALLATION.

NOTE: PJB module configuration does not need to be performed since the same module will be used.

6. Remove the metal bracket.

7. Disconnect the connector from the evaporator temperature sensor connector.

8. Disconnect the power MOSFET (if equipped with automatic climate control).

9. Remove the evaporator access cover from the A/C unit.

10. Remove the upper and lower air filters from the A/C unit.

11. Install the air filter with diffuser plate.

12. Install the air filter.

NOTE: Make sure the arrows marked on the air filter are facing towards the rear of the vehicle.

13. Install the evaporator access cover to the A/C unit.

14. Install the short harness with resistor to the connector, then connect the evaporator temperature sensor connector to it.

15. Reassemble in the reverse order of removal.

16. Reconnect the negative battery cable.

17. Verify repair.

18. Enter the customer's radio presets and set the clock.

Subject:
AMBIENT TEMPERATURE DISPLAY

BULLETIN NOTE This bulletin supersedes the previous bulletin 09-018/05 issued 09/23/05. The APPLICABLE MODEL(S)/VINS has been revised.

APPLICABLE MODEL(S)/VINS
2006-2009 Mazda3 equipped with Ambient Temperature Display

DESCRIPTION

In some cases, a vehicle may have the ambient temperature display switched from "Fahrenheit (°F)" to "Centigrade (°C)" or vice versa after removing/installing the battery or room fuse.

On vehicles equipped with Automatic Air Conditioning, the ambient temperature and temperature set for the air conditioner share the same location on the display. Therefore, if the ambient temperature is displayed in Fahrenheit, then the temperature set for the air conditioner is also displayed in Fahrenheit.

NOTE: If this concern occurs, DO NOT REPLACE ANY COMPONENTS! Customers having this concern should have their temperature display changed to the alternate units by performing the procedure below.

NOTE: The procedure below is also in the 2007 - 2009 Mazda3 Owner's Manuals under Ambient Temperature Display.

Technicians are also encouraged, after removing/installing the battery or room fuse, to identify if the temperature display has changed units, and to perform the following procedure when necessary.

PROCEDURE

1. Turn the ignition switch to "ON".

2. Allow the ambient temperature to be displayed. (Make sure that "AMB" is displayed next to the Temperature on the display.)

3. Make sure that the audio system is on. (If it is not, turn it on.)

4. While pressing and holding the "Power/Volume" dial, press and hold the "MEDIA" button on the audio system for 5 seconds or more.

5. Release your fingers off the MEDIA button followed by the Power/Volume dial, at which point the display is switched.

6. Turn the ignition switch "OFF".

7. Turn the ignition switch "ON", and verify the display is correct.

Subject:
FRONT WIPERS DO NOT WIPE WELL

BULLETIN NOTE This bulletin supersedes the previous bulletins 09-029/08 issued 9/16/2008, 09-023/05 issued 12/16/2005, and 09-030/04 issued 07/28/2004. The WARRANTY INFORMATION has been revised.

APPLICABLE MODEL(S)/VINS
2004-2006 Mazda3 with VINs less than JM1 BK**** 61423974
(Built Prior to August 29, 2005)

DESCRIPTION

Some customers may complain that the front wipers do not effectively clean the windshield in cold ambient temperatures. New wiper blades have been introduced to correct this concern.

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

REPAIR PROCEDURE

1. Verify concern.

2. Replace the front wiper blades with new parts.

3. Verify repair.

Subject:
ENGINE COOLANT LEAKAGE FROM WATER OUTLET

APPLICABLE MODEL(S)/VINS
2006 - 2008 Mazda3 vehicles (except Mazdaspeed3) with VINs lower than JM1BK3*****187397 (produced before July 1, 2008)

2008 Mazda5 vehicles with VINs lower than JM1CR******327438 (produced before July 1, 2008)

DESCRIPTION

On some vehicles, the engine coolant may leak from the water outlet. This is caused by the gasket making contact with the corner of the water outlet groove. The shape of the water outlet gasket groove and gasket has now been changed.

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

REPAIR PROCEDURE

1. Verify customer concern.

NOTE: Let the engine cool down before proceding with the repair.

2. Remove the battery and battery tray with PCM. Refer to MS3 online instructions or Workshop Manual section 01-17.

3. Remove the air cleaner case and cover, and move any hoses or wiring harnesses with brackets to the side. Refer to MS3 online instructions or Workshop Manual section 01-13.

4. Drain the engine coolant. Refer to MS3 online instructions or Workshop Manual section 01-12.

5. Remove the hoses attached to the water outlet and move any other hoses or wiring harnesses to the side to remove the four water outlet bolts.

6. Remove the water outlet and replace the gasket with a modified one.

NOTE: ^ Do not allow mineral oil (engine oil, ATF, or fuel) to get on the gasket.

^ Degrease and clean the cylinder head surface and water outlet.


7. Install the water outlet with the four bolts.

Tightening torque: 8.0-11.5 Nm {82-117 kgf cm, 71-101 in lbf}

8. Attach the hoses to the water outlet and place the other hoses and wiring harnesses back into place.

9. Install the air cleaner case and cover, and place the hoses and wiring harnesses with brackets back into place. Refer to MS3 online instructions or Workshop Manual section 01-13.

10. Refill the engine coolant.

11. Install the battery tray with PCM and the battery. Refer to MS3 online instructions or Workshop Manual section 01-17.

12. Verify repair.

Subject:
ENGINE WILL NOT START IN P-RANGE INTERMITTENTLY

APPLICABLE MODEL(S)/VINS
2004-2008 Mazda3 vehicles with VINs lower than JM1BK**** ** 848579 (produced before November 1, 2007)

DESCRIPTION

On some vehicles, the shift position lamp in the instrument cluster does not come on in the "P" position, and the engine does not start. However, the engine can be started in the "N" position. This is due to rust on the connecting point of the shift cable and lock cable lever causing the select lever not to move to the location where it is recognized as "P" range. There is no issue about the transmission reaching Park. This is only an issue about the confirming "P" indicator in the instrument cluster. A slit on the mud guard has been removed to prevent salt water from getting to the location where rust would occur.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. First verify that rust appears on the connecting point of the shift cable (A) and lock cable lever (B), then replace the lock cable lever with modified one by removing the nut (C) and washer (D). Also, replace the nut and washer.

NOTE: ^ When removing or installing the lock nut, always be sure to hold the lock cable lever with an adjustable wrench. Failure to use an adjustable wrench may cause TR switch breakage.

^ If corrosion is present, apply penetrating oil to the shaft and nut threads before loosening.

^ When loosening, if there is binding because of corrosion on the threads, work the nut back and forth until it comes off.


Tightening Torque: 31.4 Nm (3.2 - 4.7 kgf-m, 23.2 - 33.9 ft. lbf.)

3. Verify repair.

Subject:
UNSTABLE IDLING/ENGINE STALLS JUST AFTER STOPPING

APPLICABLE MODEL(S)/VINS
2003-2009 Mazda6 with 2.3L/2.5L (including Mazdaspeed6)
2004-2009 Mazda3 (including Mazdaspeed3)
2006-2009 Mazda5
2006-2009 Mazda MX-5
2007-2009 Mazda CX-7

DESCRIPTION

Some vehicles may exhibit a concern of unstable idling or, in some rare cases, stalling, just after the vehicle stops with no DTCs detected. The problem is due to the accumulation of carbon deposits inside the throttle body causing air flow to decrease.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the throttle body.

a. Write down the customer's radio station presets.

b. Disconnect the battery terminals.

c. Remove the air hose from the throttle body.

d. Disconnect the throttle body connector.

e. Remove the throttle body from the intake manifold with the water hose connected.

3. Clean the throttle body.

a. Clean the inside throttle body on the air hose side using a clean and soft shop cloth sprayed with engine cleaner (part number 000-77-A86) along the cross hatch areas, and especially around the circled areas as shown.

CAUTION:
DO NOT spray the cleaner directly inside the throttle body and DO NOT wipe around the throttle valve shaft shown with an X.

b. Turn the throttle body to clean it at the intake manifold side.

c. Clean the throttle with the throttle valve opened using the same shop cloth and cleaner.

WARNING:
Be careful not to pinch your fingers in the throttle valve when it is opened because the valve will close automatically from spring tension.

CAUTION:
DO NOT spray the cleaner directly inside the throttle body and DO NOT wipe around the throttle valve shaft shown with an X.

d. Make sure there is no foreign material inside the throttle body.

4. Re-install the throttle body using a new gasket.

5. Connect the battery cables.

6. Perform the throttle valve position learning and idling engine rpm inspection.

a. Connect the M-MDS.

b. Turn the ignition to ON without starting the engine for one minute, then turn it to OFF.

c. After one minute has passed, start the engine.

d. Warm up the engine at idling until the cooling fan starts operating or until the coolant temperature reaches 194°F (90°C) or higher.

e. Turn off any electrical load, including the A/C, with the shifter in Neutral or Park position.

f. Let the engine run for five minutes.

g. Measure the engine rpm at idle using the M-MDS to confirm it is within specification according to the Workshop Manual.

7. Verify repair.

8. Enter the customer's radio station presets.

9. Perform "Power Window Initialization Procedure" on vehicles with AUTO UP/AUTO DOWN windows.

10. Inform customers with vehicles with memory seats that the memory positions will need to be set again to their desired positions because the battery was disconnected.

Subject:
CHATTERING NOISE FROM COWL GRILL WHEN PASSING OVER A BUMP OR DRIVING ON A ROUGH ROAD

APPLICABLE MODEL(S)/VINS
2004-2009 Mazda3 (including Mazdaspeed3) vehicles with VINs lower than JM1BK**** ** 209750 (produced before August 7, 2008)

Some vehicles may experience a chattering noise being heard form the cowl grill when passing over a bump or driving on a rough road. The cause of this is a stick-slip occuring between the cowl grill and the windshield.

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

REPAIR PROCEDURE

1. Verify customer concern.

2. Remove the cowl panel. Refer to MS3 online instructions or Workshop Manual section 09-10 COWL PANEL REMOVAL/INSTALLATION.

3. Install or replace the pads on the hooks on the back of the cowl grill (in 8 locations) with the service pads, folding in and attaching to the hook any excess material as shown.

4. Install the cowl panel. Refer to MS3 online instructions or Workshop Manual section 09-10 COWL PANEL REMOVAL/INSTALLATION.

5. Verify repair.

Here's another good one folks. The factory fix is to add a spot weld on each side of the vehicle. The dealer/customer fix is to pry open the offending panels/supports and add grease so it doesn't squeak... for a while.
Can you say, "Band-Aid?" Sure! Thought ya' could.

Good job, Mazda.