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Mazda3 Offered in both a sedan and wagon, this sporty model offers a great car for the family, as well a fun track car.

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  #11  
Old 08-20-2009, 05:44 PM
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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.
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Old 08-20-2009, 05:47 PM
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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".
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  #13  
Old 08-20-2009, 05:48 PM
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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
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  #14  
Old 08-20-2009, 05:50 PM
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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.
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Old 08-20-2009, 05:50 PM
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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.
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  #16  
Old 08-20-2009, 05:51 PM
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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).
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  #17  
Old 08-20-2009, 05:52 PM
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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.
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Old 08-20-2009, 05:53 PM
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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).
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Old 08-20-2009, 05:58 PM
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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.
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Old 08-20-2009, 05:59 PM
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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 -22F (-30C), 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).
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