Mazda 3 Facelift 2006 Training Manual

Training Manual

Mazda3 Facelift

FL-005

No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH.

The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print.

No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

Mazda Motor Europe GmbH Training Services

Table of Contents

General Information ..........................................................................00-1

Technical Data............................................................................................................00-1

Vehicle Identification Number...................................................................................00-2

Scheduled Maintenance.............................................................................................00-3

Engine ................................................................................................01-1

1.3 MZR Engine...........................................................................................................01-1

Features ................................................................................................................01-1

Overview................................................................................................................01-1

Mechanical ............................................................................................................01-2

Camshaft........................................................................................................01-2

2.0 MZR Engine...........................................................................................................01-3

Features ................................................................................................................01-3

Engine Performance Curve...................................................................................01-4

Overview................................................................................................................01-5

1.6 MZ-CD Engine.......................................................................................................01-6

Features ................................................................................................................01-6

Overview................................................................................................................01-6

Fuel System...........................................................................................................01-7

Features .........................................................................................................01-7

Parts Location................................................................................................. 01-7

High-pressure Pump.......................................................................................01-8

Control System....................................................................................................01-10

Features .......................................................................................................01-10

Parts Location............................................................................................... 01-10

Block Diagram..............................................................................................01-12

Glow Plug Relay...........................................................................................01-14

Cruise Control System..................................................................................01-15

Suspension........................................................................................02-1

Features ................................................................................................................02-1

Front Suspension.......................................................................................................02-2

Rear Suspension........................................................................................................02-3

Driveline/Axle.....................................................................................03-1

Features ................................................................................................................03-1

Front Axle....................................................................................................................03-1

Drive Shaft...................................................................................................................03-2

Service Training Mazda3 F/L

Table of Contents

Transmission/Transaxle ...................................................................05-1

G66M-R Manual Transaxle.........................................................................................05-1

Features ................................................................................................................05-1

Specifications ........................................................................................................05-1

Overview................................................................................................................05-2

Shift Mechanism....................................................................................................05-3

Reverse Lockout Mechanism.........................................................................05-4

FN4A-EL Automatic Transaxle..................................................................................05-5

Features ................................................................................................................05-5

Overview................................................................................................................05-5

Shift Mechanism....................................................................................................05-7

Shift-lock System/Key Interlock System.........................................................05-8

Restraints...........................................................................................08-1

Airbag System ............................................................................................................08-1

Features ................................................................................................................08-1

Parts Location........................................................................................................08-2

Wiring Diagram......................................................................................................08-3

Ball-type Seat Belt Pretensioners..........................................................................08-4

Body & Accessories..........................................................................09-1

Body Panels................................................................................................................ 09-1

Features ................................................................................................................09-1

Front End...............................................................................................................09-1

Glass/Windows/Mirrors..............................................................................................09-2

Features ................................................................................................................09-2

Exterior Opening/Closing Function........................................................................09-2

Parts Location................................................................................................. 09-3

Security and Locks.....................................................................................................09-4

Features ................................................................................................................09-4

Advanced Keyless Entry and Start System...........................................................09-4

Parts Location................................................................................................. 09-5

Wiring Diagram...............................................................................................09-6

Trunk Lid Request Switch...............................................................................09-8

Keyless Control Module..................................................................................09-9

Operation......................................................................................................09-10

Warning and Guidance Function..................................................................09-10

Customization...............................................................................................09-11

Service and Repair.......................................................................................09-12

Immobilizer System......................................................................................09-14

On-board Diagnostic System........................................................................09-18

Service Training Mazda3 F/L

Table of Contents

Exterior Trim.............................................................................................................09-20

Features ..............................................................................................................09-20

Parts Location......................................................................................................09-21

Interior Trim ..............................................................................................................09-22

Features ..............................................................................................................09-22

Parts Location......................................................................................................09-22

Lighting Systems......................................................................................................09-23

Features ..............................................................................................................09-23

Headlight Auto-leveling System...........................................................................09-23

Parts Location............................................................................................... 09-23

Wiring Diagram.............................................................................................09-24

Initialization procedure for auto-leveling control module ..............................09-25

Entertainment ...........................................................................................................09-26

Features ..............................................................................................................09-26

Audio System ......................................................................................................09-26

Music Hard Disc Drive Specifications...........................................................09-26

Parts Location............................................................................................... 09-27

System Overview..........................................................................................09-28

Audio Unit.....................................................................................................09-29

Instrumentation/Driver Info .....................................................................................09-30

Features ..............................................................................................................09-30

Instrument Cluster...............................................................................................09-30

Overview.......................................................................................................09-30

Odometer Write Procedure........................................................................... 09-32

Freeze Frame Data ......................................................................................09-33

Seat Belt Reminder System ................................................................................09-34

Buckle Switches ...........................................................................................09-34

Occupancy Sensor.......................................................................................09-34

Front Seat Belt Reminder Operation............................................................09-36

Rear Seat Belt Reminder Operation.............................................................09-37

Control System.........................................................................................................09-38

Features ..............................................................................................................09-38

Controller Area Network......................................................................................09-38

High-speed CAN Signal Chart......................................................................09-40

Mid-speed CAN Signal Chart .......................................................................09-42

Service Training Mazda3 F/L

Table of Contents

Service Training Mazda3 F/L

General Information

Technical Data

Item

Displacement

1.3 MZR (ZJ) ine

1,349 cm³

1.6 MZR (Z6) Engine

1,598 cm³ 1,999 cm³ Bore x stroke 74.0 x 78.4 mm 78.0 x 83.6 mm 87.5 x 83.1 mm Compression ratio 10.0 : 1 10.0 : 1 10.8 : 1

Max. power

Max. torque

62 kW (84 PS) at 6000 min

-1

122 Nm at 4000 min

-1

77 kW (105 PS)

at 6000 min

-1

145 Nm

at 4000 min

-1

Emission standard Euro 4 Euro 4 Euro 4 Transmission 5-speed manual

(F35M-R)

5-speed manual

(F35M-R) or 4-speed

automatic (FN4A-EL)

2.0 MZR (LF) Engine

110 kW (150 PS) at 6500 min

187 Nm at 4000 min

6-speed manual (G66M-R)

-1

Item

1.6 MZ-CD (Y6) Low-power Engine

1.6 MZ-CD (Y6)

High-power Engine

Displacement 1,560 cm³ 1,560 cm³ Bore x stroke 75.0 x 88.3 mm 75.0 x 88.3 mm Compression ratio 18.3 : 1 18.3 : 1

Max. power

Max. torque

66 kW (90 PS) at 4000 min

-1

215 Nm at 1750 min

-1

80 kW (109 PS)

at 4000 min

240 Nm

at 1750 min Emission standard Euro 4 Euro 4 Transmission 5-speed manual

(J65M-R)

5-speed manual

(J65M-R)

-1

M3FL_T00001

Service Training Mazda3 F/L 00-1

General Information

Vehicle Identification Number

• The VIN (Vehicle Identification Number) key is as shown below.

JMZ BK 1 4 Z 2 7 1 5 0 0 0 0 1

Serial No. 0= Hiroshima

Plant

For UK : Dummy 0 For Israel : Model year 7= 2007, 8= 2008, 9= 2009 For Others : Dummy 0 to 9 (Same as model year-Israel)

Transaxle

Engine type

Body style

1= Hofu

6= 6MTX (G66M-R) 2= 5MTX (F35M-R or J65M-R) 5= 4ATX (FN4A-EL)

Y= 1.6 MZ-CD high-power (Y6) 6= 1.6 MZ-CD low-power (Y6) J= 1.3 MZR (ZJ) Z= 1.6 MZR (Z6) F= 2.0 MZR (LF)

2= 4SD 4= 5HB

Drive axle 1= 4x2

Vehicle type BK= Mazda3

World manufacturer indication JMZ= European (LHD, UK)

M3FL_T00002

00-2 Service Training Mazda3 F/L

General Information

Scheduled Maintenance

Number of months or kilometers (miles), whichever comes first

Maintenance Item

GASOLINE ENGINE

Engine valve clearance Drive belts*1 Idle speed (ZJ, Z6)

Spark plugs*2

Air cleaner element*3 Evaporative system (if i ns talled)

DIESEL ENGINE

Drive belts*1 Engine timing belt*4 Radiator cap Fuel system (Drain water) Fuel filter Air cleaner element*3 Diesel particulate fi l t er (DPF) (if installed) Fuel additive for DPF

GASOLINE and DIESEL ENGINE

Engine oil*5 Engine oil filter*5 Cooling system

Engine coolant

Fuel lines and hoses Battery electrolyte level and specific gravity Brake lines, hoses and c onnections Brake fluid*7 Parking brake Disc brakes Steering operation and linkages

Front and rear suspension, ball joint s and wheel bearing axial play

Power steering fluid, lines, hoses and connections Manual transaxle oil (for gasoline) Manual transaxle oil (for diesel) Automatic transaxle fluid level Drive shaft dust boots Bolts and nuts on chassis and body Body condition (for rust, corrosion and perforation) Exhaust system and heat shi el ds

Tires (including spare tire) (with inflation pressure adjust ment)

Cabin air filter (If installed)

: Inspect and repair, cl ean, adjust, or replace if neces sary.

: Replace

: Clean

: Drain

: Tighten

Months

x 1000 km

x 1000 miles

Iridium type except Iridium type

ZJ, Z6CCRCCRCCR LF RRR

FL22 type*6 Replace every 200,000 km (125,000 miles) or 11 years Others

12 24 36 48 60 72 84 96 108 20 40 60 80 100 120 140 160 180

12.5 25 37.5 50 62.5 75 87.5 100 112.5

Audible inspect every 120,000 k m (75,000 miles), if noisy, adjust

III

IIIII

Replace every 120,000 km (75,000 miles)

RRR

III

IIIIIIIII

Replace every 240,000 km (150,000 miles) or 10 years

IIII

DDDDDDDDD

RRR RRR

Replace every 120,000 km (75,000 miles)

Refill every 60,000 km (37,500 miles)

RRRRRRRRR RRRRRRRRR

IIII

Replace first at 100,000 k m (62,500 miles) or 4 years;

after that every 2 years

IIII IIIIIIIII IIIIIIIII

RRRR IIIIIIIII IIIIIIIII

IIII IIII

IIIIIIIII

III

IIII

TTTT

Inspect annually

Inspect every 80,000 km (50,000 miles) or 5 years

IIIIIIIII

RRRR

M3FL_T00003

Service Training Mazda3 F/L 00-3

General Information

• Refer below for a description of items marked * in the maintenance chart:

– *1: Also inspect and adjust the power steering and air conditioner drive belts, if

installed.

– *2: Verify the spark plug type from the installed spark plugs. Refer to specifications. – *3: If the vehicle is operated in very dusty or sandy areas, clean and if necessary

replace the air cleaner element more often than the recommended intervals.

– *4: Replacement of the timing belt is required every 240,000 km {150,000 miles} or

10 years. Failure to replace the timing belt may result in a major damage to the engine.

– *5: If the vehicle is operated under hard conditions (dusty road, extended periods of

idling or low speed operation, cold temperature or driving short distances), change the engine oil and oil filter every 10,000 km {6,250 miles} or less.

– *6: When replacing the coolant on vehicles with the inscription “FL22” on the radiator

cap itself or the surrounding area, use only coolant of this type.

– *7: If the brakes are used extensively (for example, continuous hard driving or

mountain driving) or if the vehicle is operated in extremely humid climates, change the brake fluid annually.

00-4 Service Training Mazda3 F/L

Engine 1.3 MZR Engine

1.3 MZR Engine

Features

• The construction and operation of the 1.3 MZR engine is essentially carried over from that of the current Mazda3 with ZJ engine except for the following features:

– Valve timing of the exhaust valves has been modified

Overview

M3FL_01019

Service Training Mazda3 F/L 01-1

Mechanical 1.3 MZR Engine

Mechanical

Camshaft

• The exhaust-side camshaft has been modified, so that the exhaust valves open later.

1 Variable domain

M3FL_01020

01-2 Service Training Mazda3 F/L

Engine 2.0 MZR Engine

2.0 MZR Engine

Features

• The construction and operation of the 2.0 MZR engine is essentially carried over from that of the current Mazda3 with LF engine except for the following features:

– Electronic throttle valve with drive-by-wire relay and accelerator pedal position

sensor (similar to that of the Mazda6 F/L)

– Direct ignition coils with integrated power transistor (similar to those of the

Mazda6 F/L)

– Linear-type (Broadband) upstream oxygen sensor (similar to that of the Mazda6 F/L) – Generator with two stator coils (similar to that of the Mazda6 F/L) – Magneto resistive-type crankshaft and camshaft position sensor (similar to that of the

Mazda6 F/L)

– Variable valve timing system with oil control valve and camshaft actuator (similar to

that of the Mazda6 F/L)

– Cruise control system integrated in the PCM, with cruise control switches and brake

pedal position switch (similar to that of the Mazda6 F/L)

NOTE: Further information can be found in the Training Manual “Basic Petrol Engine

Management” (CT-L2004)

Service Training Mazda3 F/L 01-3

2.0 MZR Engine Engine

Engine Performance Curve

1 Power 3 Engine speed 2 Torque

M3FL_01001

01-4 Service Training Mazda3 F/L

Engine 2.0 MZR Engine

Overview

M3FL_01002

Service Training Mazda3 F/L 01-5

1.6 MZ-CD Engine Engine

1.6 MZ-CD Engine

Features

• The construction and operation of the 1.6 MZ-CD engine is essentially carried over from that of the current Mazda3 with Y6 engine except for the following features:

– CP3.2 high-pressure pump has been replaced by CP1H high-pressure pump for

1.6 MZ-CD high-power engine

– Glow relay with a joint power supply for all glow plugs – Cruise control system integrated in the PCM has been introduced for 1.6 MZ-CD

high-power engine.

Overview

M3FL_01004

01-6 Service Training Mazda3 F/L

1.6 MZ-CD Engine Fuel System

Fuel System

Features

• The fuel system of the 1.6 MZ-CD engine is essentially carried over from that of the current Mazda3 with 1.6 MZ-CD engine (Euro 4) except for the following features:

– CP3.2 high-pressure pump replaced by the CP1H pump for the 1.6 MZ-CD high-

power engine

Parts Location

M3FL_01008

1 Injector 6 Fuel filter 2 High-pressure line 7 Common rail 3 Fuel warmer 8 High-pressure pump 4 Quick release connector 9 Fuel metering valve 5 Fuel warmer relay

Service Training Mazda3 F/L 01-7

Fuel System 1.6 MZ-CD Engine

High-pressure Pump

• The 1.6 MZ-CD high-power engine is equipped with the CP1H high-pressure pump, which is also manufactured by Bosch. The operation is similar to that of the CP3.2 pump.

1 Feed pump 3 Fuel metering valve 2 High-pressure pump element

M3FL_01009

01-8 Service Training Mazda3 F/L

1.6 MZ-CD Engine Fuel System

Fuel Metering Valve

• On the CP1H high-pressure pump the fuel metering valve closes the passage between feed pump and radial-piston pump when de-energized.

NOTE: In case of an open circuit the fuel metering valve adopts in the closed position. As a

result, the engine stalls and does not start anymore.

1 From PCM control relay 3 PCM 2 Fuel metering valve 4 Current detection circuit

M3FL_01010

Service Training Mazda3 F/L 01-9

Control System 1.6 MZ-CD Engine

Control System

Features

• The control system of the 1.6 MZ-CD engine is essentially carried over from that of the current Mazda3 with 1.6 MZ-CD engine (Euro 4) except for the following features:

– Glow plug control module with separate power supply for all glow plugs replaced by

a glow plug relay with joint power supply

– Cruise control system integrated in the PCM for 1.6 MZ-CD high-power engine

Parts Location

M3FL_01014

01-10 Service Training Mazda3 F/L

1.6 MZ-CD Engine Control System

1 Low-power engine 16 Battery 2 High-power engine 17 Starter relay 3 ISV DC motor and position sensor 18 PCM control relay 4 Manifold absolute pressure sensor 19 Glow plug relay 5 IAT sensor no.2 20 MAF/ IAT sensor 6 Injector 21 Engine coolant temperature sensor 7 Camshaft position sensor 22 Powertrain control module (incl.

Barometric pressure sensor) 8 Fuel temperature sensor 23 Fuel pressure sensor 9 EGR valve DC motor and position sensor 24 VBC solenoid valve

10 Accelerator pedal position sensor 25 Crankshaft position sensor 11 Engine switch 26 Exhaust gas temperature sensor (only

high-power engine)

12 Brake pedal position switch 27 Generator 13 Clutch pedal position switch 28 Fuel metering valve 14 DLC-2 29 Charge-air cooler bypass valve DC motor

and position sensor (only high-power

engine)

15 DPF differential pressure sensor (only

high-power engine)

Service Training Mazda3 F/L 01-11

Control System 1.6 MZ-CD Engine

Block Diagram

M3FL_01015

01-12 Service Training Mazda3 F/L

1.6 MZ-CD Engine Control System

1 Instrument cluster 20 Exhaust gas temperature sensor (only

high-power engines) 2 Powertrain control module (incl.

Barometric pressure sensor)

3 Fuel additive control module (only high-

power engines)

4 Cruise control switches (only high-power

engines) 5 Accelerator pedal position sensor 24 Malfunction indicator light 6 Brake pedal position switch 25 Cruise main indicator light 7 Clutch pedal position switch 26 Cruise indicator light 8 Manifold absolute pressure sensor 27 Injectors 9 Fuel pressure sensor 28 VBC solenoid valve

10 MAF/ IAT sensor 29 Glow plug relay 11 Fuel temperature sensor 30 Fuel metering valve 12 Engine coolant temperature sensor 31 Cooling fan and A/C compressor (if

13 Camshaft position sensor 32 PCM control relay 14 Crankshaft position sensor 33 Generator (field coil) 15 EGR valve position sensor 34 EGR valve DC motor 16 Generator (stator coil) 35 ISV DC motor (only low-power engines) 17 IAT sensor no. 2 36 ISV DC motor and charge-air cooler

18 ISV position sensor (only low-power

engines)

19 ISV position sensor and charge-air cooler

bypass valve position sensor (only high-

power engines)

21 DPF differential pressure sensor (only

high-power engines)

22 Fuel-filler switch (only high-power

engines)

23 Fuel additive level sensor (only high-

power engines)

equipped)

bypass valve DC motor (only high-power engines)

37 Fuel additive pump (only high-power

engines)

Service Training Mazda3 F/L 01-13

Control System 1.6 MZ-CD Engine

Glow Plug Relay

• The glow plug relay is located in the main fuse block and features a joint power supply terminal for all glow plugs. Depending on the operating conditions the PCM energizes the glow plug relay, which in turn switches the power supply to the glow plugs. To facilitate failure detection the PCM monitors the voltage outputted to the glow plugs.

M3FL_01016

01-14 Service Training Mazda3 F/L

1.6 MZ-CD Engine Control System

Cruise Control System

• The 1.6 MZ-CD high-power engine features a cruise control system integrated in the PCM, i.e. the vehicle speed is controlled by variation of the fuel injection amount. When the desired vehicle speed has been set, the PCM determines the target injection amount based on the vehicle speed signal. If the actual vehicle speed goes below or above the set speed, the PCM increases or decreases the injection amount.

1 PCM 5 VSS 2 Brake pedal position switch 6 Injectors 3 Clutch pedal position switch 7 Cruise main indicator light 4 Cruise control switches 8 Cruise indicator light

M3FL_01017

Service Training Mazda3 F/L 01-15

Control System 1.6 MZ-CD Engine

Cruise Control Switches

• The cruise control switches are connected to the instrument cluster. Depending on the switch position the resistance and hence the voltage drop at the switches changes. The instrument cluster determines the driver’s cruise control settings according to the voltage signal from the switches, and transmits a corresponding information via the high-speed CAN bus to the PCM.

NOTE: The cruise control switches can be checked using the input/output check mode for

the instrument cluster.

1 Cruise control switches 3 High-speed CAN bus 2 Instrument cluster 4 PCM

M3FL_01018

01-16 Service Training Mazda3 F/L

Suspension

Features

• The construction and operation of the suspension is essentially carried over from that of the current Mazda3 except for the following features:

– Front shock absorbers have been modified – Front steering knuckle arm position has been modified – Rear twin-tube shock absorbers replaced by mono-tube shock absorbers with a

larger piston diameter (similar to those of the Mazda5)

– Rear lateral link position has been modified – Rear stabilizer mounting position has been modified

Service Training Mazda3 F/L 02-1

Suspension

Front Suspension

• The steering knuckle arm position has been modified to reduce wheel toe-out when driving over bumps.

1 Coil spring 5 Steering knuckle 2 Stabilizer control link 6 Lower arm 3 Stabilizer 7 Crossmember 4 Shock absorber

M3FL_02002

02-2 Service Training Mazda3 F/L

Suspension

Rear Suspension

• Mono-tube shock absorbers are used at the rear axle to reduce oil foaming and hence deterioration of the shock absorber performance at high temperatures. In addition, the lateral link position has been modified to increase wheel toe-in when driving over bumps.

1 Shock absorber 6 Coil spring 2 Crossmember 7 Stabilizer control link 3 Trailing link 8 Stabilizer 4 View from rear of the vehicle 9 Lateral link 5 Lower arm 10 Upper arm

M3FL_02001

Service Training Mazda3 F/L 02-3

+ 65 hidden pages

Mazda 3 Facelift 2006 Training Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Training Manual

Mazda3 Facelift

FL-005

Technical Data

Vehicle Identification Number

Scheduled Maintenance

1.3 MZR Engine

Features

Overview

Mechanical

Camshaft

2.0 MZR Engine

Features

Engine Performance Curve

Overview

1.6 MZ-CD Engine

Features

Overview

Fuel System

Features

Parts Location

High-pressure Pump

Fuel Metering Valve

Control System

Features

Parts Location

Block Diagram

Glow Plug Relay

Cruise Control System

Cruise Control Switches

Suspension

Features

Front Suspension

Rear Suspension