Mazda 3 Facelift 2006 Training Manual Download

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Training Manual

Mazda3 Facelift

FL-005

Summary of Contents for 3 Facelift 2006

Page 1: ...Training Manual Mazda3 Facelift FL 005...

Page 2: ...mation 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 publicatio...

Page 3: ...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 Pa...

Page 4: ...gram 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 Par...

Page 5: ...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...

Page 6: ...Table of Contents Service Training Mazda3 F L...

Page 7: ...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 6 speed manual G66M R Item 1 6 MZ CD Y6 Low power Engine 1 6...

Page 8: ...odel year 7 2007 8 2008 9 2009 For Others Dummy 0 to 9 Same as model year Israel Transaxle 6 6MTX G66M R 2 5MTX F35M R or J65M R 5 4ATX FN4A EL Engine type Y 1 6 MZ CD high power Y6 6 1 6 MZ CD low po...

Page 9: ...000 km 75 000 miles Engine timing belt 4 DIESEL ENGINE Idle speed ZJ Z6 Iridium type except Iridium type Months x 1000 km x 1000 miles Drive belts 1 Maintenance Item GASOLINE ENGINE Spark plugs 2 Eva...

Page 10: ...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 o...

Page 11: ...ction 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 modif...

Page 12: ...Mechanical 1 3 MZR Engine Mechanical Camshaft The exhaust side camshaft has been modified so that the exhaust valves open later M3FL_01020 1 Variable domain 01 2 Service Training Mazda3 F L...

Page 13: ...inear 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...

Page 14: ...2 0 MZR Engine Engine Engine Performance Curve M3FL_01001 1 Power 3 Engine speed 2 Torque 01 4 Service Training Mazda3 F L...

Page 15: ...Engine 2 0 MZR Engine Overview M3FL_01002 Service Training Mazda3 F L 01 5...

Page 16: ...zda3 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...

Page 17: ...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 pre...

Page 18: ...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 M3FL_01009 1 Feed pump 3 Fuel metering valve 2...

Page 19: ...tween 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...

Page 20: ...he 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 s...

Page 21: ...tric 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...

Page 22: ...Control System 1 6 MZ CD Engine Block Diagram M3FL_01015 01 12 Service Training Mazda3 F L...

Page 23: ...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 coo...

Page 24: ...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 fail...

Page 25: ...d 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 decreas...

Page 26: ...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 NO...

Page 27: ...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 diame...

Page 28: ...uckle arm position has been modified to reduce wheel toe out when driving over bumps M3FL_02002 1 Coil spring 5 Steering knuckle 2 Stabilizer control link 6 Lower arm 3 Stabilizer 7 Crossmember 4 Shoc...

Page 29: ...formance at high temperatures In addition the lateral link position has been modified to increase wheel toe in when driving over bumps M3FL_02001 1 Shock absorber 6 Coil spring 2 Crossmember 7 Stabili...

Page 30: ...Suspension Notes 02 4 Service Training Mazda3 F L...

Page 31: ...eatures Lockbolt for connection between wheel hub and drive shaft replaced by locknut similar to that of the Mazda5 Shape of the joint shaft bracket has been modified only ZJ Z6 engine and LF engine F...

Page 32: ...engine and on the LF engine a joint shaft bracket with a modified shape is used to reduce vibration and hence booming noise at high engine speeds M3FL_03002 1 Joint shaft 3 Right front drive shaft 2 B...

Page 33: ...fied Cable type shift mechanism with integrated reverse lockout mechanism NOTE Further information can be found in the Training Manual Mazda6 Facelift FL 003 Specifications All season Above 10 C 50 F...

Page 34: ...idler gear 13 Secondary 3rd gear 4 Primary 2nd gear 14 Secondary 2nd gear 5 Primary 3rd gear 15 Secondary reverse gear integrated in clutch hub sleeve 6 Primary 4th gear 16 Secondary 1st gear 7 Prima...

Page 35: ...ism with integrated reverse lockout mechanism is used The adjustment procedure for the select cable is similar to that of the current Mazda3 M3FL_05002 1 Select cable 5 Shift lever component 2 Shift c...

Page 36: ...guide plate restricting the movement of the lever and preventing accidental shifting into reverse When shifting into reverse gear once the shift lever is pressed down and moved towards the reverse pos...

Page 37: ...construction and operation of the FN4A EL automatic transaxle is essentially carried over from that of the current Mazda3 except for the following features Shift mechanism with electrically operated...

Page 38: ...nd 8 Torque converter 2 Reverse clutch 9 Differential 3 3 4 clutch 10 Output gear 4 Rear planetary gear 11 Secondary gear 5 Front planetary gear 12 Primary gear 6 Forward clutch 13 One way clutch 7 Oi...

Page 39: ...an electrically operated shift lock system key interlock system to prevent inadvertent selection of the wrong gear M3FL_05005 1 Brake switch 5 Selector lever component 2 Ignition lock 6 Shift lock so...

Page 40: ...le the key interlock system allows the key to be removed from the ignition lock only when the selector lever is in P position The system consists of the P position switch shift lock relay shift lock s...

Page 41: ...3FL_05007 1 P position switch When the selector lever is in P position the switch supplies ground to the shift lock relay When the selector lever is in any other position than P the switch supplies gr...

Page 42: ...the selector lever is in P position the ignition is on and the brake pedal is pressed the shift lock relay and hence the shift lock solenoid is energized As a result the lock lever does not restrict...

Page 43: ...n open circuit the selector lever cannot be moved out of P position In order to manually release the shift lock insert a suitable object e g vehicle key screwdriver into the hole at the selector lever...

Page 44: ...he keyless control module M3FL_05010 1 Key interlock solenoid 3 Cam 2 Stopper When the selector lever is in any other position than P the key interlock solenoid is energized As a result the stopper re...

Page 45: ...features Cable type pretensioners integrated in the seat belt buckle have been replaced by ball type pretensioners integrated in the seat belt retractor similar to those of the Mazda6 F L Buckle swit...

Page 46: ...g light 8 SAS control module 2 PAD switch 9 Seat belt pretensioner 3 Clock spring 10 Side airbag sensor 4 Driver side airbag 11 Side airbags 5 PAD indicator 12 Curtain airbags 6 Passenger side airbag...

Page 47: ...AD switch 18 Driver side side belt pretensioner 7 Passenger airbag ON 19 Driver side curtain airbag 8 Passenger airbag OFF 20 Driver side side airbag 9 Driver side buckle switch 21 Passenger side seat...

Page 48: ...front seats The operation is similar to that of the Mazda6 F L NOTE Further information can be found in the Training Manual Supplemental Restraint System CT L1003 M3FL_08003 1 Ball trap 6 Cover 2 Gas...

Page 49: ...fender frame by brackets to reduce deformation of the suspension housings when cornering and hence minimize changes in wheel camber In addition the tunnel crossmember no 1 connecting the transmission...

Page 50: ...ion for the power windows has been introduced similar to that of the Mazda5 Exterior Opening Closing Function The power windows feature an exterior open close function also termed as global opening cl...

Page 51: ...witch rear doors 2 Power window regulators 7 Power window sub switch passenger door 3 PJB 8 Power window main switch driver door 4 Keyless control module with Advanced Keyless Entry and Start System 9...

Page 52: ...ally carried over from that of the Mazda5 and has the following features Card key type transmitter Three request switches trunk lid request switch integrated in the key cylinder push switch on 4SD veh...

Page 53: ...lock actuator 5 Steering lock unit 18 Front door lock actuator 6 Coil antenna 19 Keyless buzzer 7 Security light 20 Keyless receiver 8 Keyless warning light red 21 Keyless control module 9 Keyless in...

Page 54: ...Security and Locks Body Accessories Wiring Diagram M3FL_09003 09 6 Service Training Mazda3 F L...

Page 55: ...switch 22 Keyless warning light red 7 Trunk lid Liftgate request switch 23 Keyless indicator light green 8 Request switch LF 24 Keyless buzzer 9 Request switch RF 25 High speed CAN bus 10 With ATX 26...

Page 56: ...uest Switch On 4SD vehicles the trunk lid request switch is integrated in the key cylinder push switch i e when the push switch is pressed the keyless control module sends a request signal to the card...

Page 57: ...e CAN bus to the PJB for keyless entry and to the PCM for keyless start NOTE When replacing the keyless control module the new module has to be configured To do this connect M MDS to the vehicle and s...

Page 58: ...ted inside vehicle with driver s door open and start knob in any position except LOCK Sounds 3 times Flashes 2 Card key cannot be detected inside vehicle with all doors closed and start knob in any po...

Page 59: ...he engine cannot be restarted In addition the engine cannot be restarted by turning the start knob from the ACC position to the START position even though the start knob has not been turned to the LOC...

Page 60: ...Insert auxiliary key in the ignition lock 3 Turn ignition switch to the ON position 4 Push the UNLOCK button on card key 1 once 5 Push the UNLOCK button on card key 2 once 6 Turn ignition switch to AC...

Page 61: ...using M MDS NOTE Do not program the steering lock unit while M MDS or any other computer devices are in the vehicle Make sure all card keys are operational and have good batteries NOTE To program the...

Page 62: ...ed transponder coil antenna keyless control module and PCM A maximum of eight keys can be registered The coil antenna is connected to the keyless control module which communicates via the high speed C...

Page 63: ...bilizer system is carried out by the keyless control module The keys contain a unique ID number that is programmed into the keyless control module and into the PCM M3FL_09007 1 Key with integrated tra...

Page 64: ...module sends data A to the key transponder via the coil antenna 2 The key transponder calculates data B from received data A and sends unique key ID number and data B to the keyless control module vi...

Page 65: ...programmed All card keys for the vehicle must be collected and programmed Perform the following procedure with M MDS Card Key Code Erase Replacing PCM New PCM Keys to be programmed two or more All ke...

Page 66: ...Number of continuous DTCs RPM Engine speed RPM VSS Vehicle speed KPH VPWR Supply voltage V NUMCARD Number of programmed card keys NUMKEY Number of programmed key ID numbers DRSW_D Door switch driver...

Page 67: ...icle and select the option Toolbox Datalogger Modules RKE PID Applicable Component Unit Condition BZR_OUT Exterior keyless buzzer On Off BZR_IN Interior buzzer On Off LNP_RED Keyless warning light On...

Page 68: ...ont fog lamp design the latter one only for Sports Appearance Package New aluminium alloy wheel designs for 15 16 and 17 inch wheels Seven new exterior colours True Red A4A Aurora Blue 34J Galaxy Grey...

Page 69: ...rim Parts Location M3FL_09017 1 Front mud flap 5 Radiator grille Sports type 2 Rear spoiler 6 Side step moulding 3 Radiator grille standard type 7 With Sports Appearance Package 4 Rear mud flap Servic...

Page 70: ...ey trim depending on vehicle grade New white driver meters with indirect blue lighting for better readability depending on vehicle grade New steering wheel adjustment lever design and energy absorbing...

Page 71: ...es depending on vehicle grade Headlight auto leveling control module connected to the DLC 2 similar to that of the Mazda5 Initialization procedure for the headlight auto leveling control module has be...

Page 72: ...Lighting Systems Body Accessories Wiring Diagram M3FL_09009 09 24 Service Training Mazda3 F L...

Page 73: ...d Front combination light replacement Auto leveling control module replacement Auto leveling sensor removal installation Instrument cluster replacement PJB replacement Replacement of suspension compon...

Page 74: ...ced similar to that of the Mazda5 Audio System Music Hard Disc Drive Specifications Item Specification HDD capacity 20 GB Playback signal compression method Encrypted MP3 Maximum recordable tracks 300...

Page 75: ...09014 1 Rear door speaker 6 Front door speaker 2 Front tweeter 7 Roof antenna 3 Audio control switches 8 Woofer 4 Audio unit 9 Audio amplifier 5 Capacitor for high mount brake light only 5HB vehicles...

Page 76: ...le integrated in audio unit 11 Front door speaker right 3 Audio unit 12 Front door speaker left 4 Audio control switches 13 Front tweeter left 5 TNS signal 14 Rear door speaker right 6 VSS 15 Rear doo...

Page 77: ...milar to that of the Mazda5 NOTE Further information can be found in the Training Manual Mazda5 NMT 007 Depending on whether or not the audio unit is equipped with music HDD the base unit is different...

Page 78: ...ter write procedure for the instrument cluster has been added similar to that of the Mazda5 Freeze frame data providing information about the instrument cluster control status at the occurrence of a f...

Page 79: ...indicator light Cruise main indicator light PCM X With cruise control system 15 Fuel level warning light Fuel gauge sender unit 16 Generator warning light PCM X 17 Seat belt warning light SAS control...

Page 80: ...ituation all data other than the mileage will have been uploaded into the new instrument cluster so that the configuration is actually successful In order to upload the mileage data to a new instrumen...

Page 81: ...l messages from the PCM Warning light illumination request signal from other modules Warning light control status Warning light that was illuminated due to the malfunction Airbag system warning light...

Page 82: ...2 Passenger seat belt warning light 5 Rear right seat belt indicator light 3 Rear left seat belt indicator light Buckle Switches The buckle switches are integrated in the seat belt buckles and detect...

Page 83: ...Generator warning light 14 Buckle switch rear right 5 Instrument cluster 15 Seat belt reminder indicator 6 Passenger seat belt warning light 16 SAS control module 7 Red seat belt unfastened 17 Buckle...

Page 84: ...e SAS control module the instrument cluster activates the driver passenger seat belt warning light and the warning chime The below table shows the operation of the seat belt warning lights and the war...

Page 85: ...seat belts If the indicator light is illuminated in red the corresponding seat belt is unfastened seat belt is unbuckled If the indicator light is illuminated in green the corresponding seat belt is f...

Page 86: ...that of the current Mazda3 except for the following features Keyless control module connected to the high speed CAN bus similar to that of the Mazda5 Controller Area Network On vehicles with Advanced...

Page 87: ...D high power engine 4 EHPAS control module 15 Climate control unit 5 With 2 0 MZR 1 6 MZ CD engine 16 With full auto A C 6 ABS HU CM 17 SAS control module 7 DSC HU CM 18 Information display 8 Keyless...

Page 88: ...h power engine 2 With 2 0 MZR 1 6 MZ CD engine 3 With Advanced Keyless Entry and Start System 4 With 1 3 1 6 MZR engine 5 With standard keyless entry system 6 With 1 6 MZ CD engine IN OUT M3FL_T09006...

Page 89: ...C on request IN OUT Transaxle in reverse position IN OUT Parking brake position IN OUT Brake fluid level IN OUT Ambient temperature IN OUT Front wiper status IN OUT TNS status IN OUT PTC heater on req...

Page 90: ...tatus display request OUT IN Airbag system warning light on request OUT IN Airbag system warning chime on request OUT IN Buckle switch status OUT IN Seat belt warning light on request OUT IN Seat belt...

Page 91: ...el only vehicles with EHPAS HVAC PTC heater deleted for certain markets only vehicles with 1 6 MZ CD engine Restraints Dual stage driver passenger airbags replaced by single stage airbags Body Accesso...

Page 92: ...nit with CD player except for Base grade Bose audio system with CD changer audio amplifier and woofer added optional Navigation system without TMC replaced by navigation system with TMC Information di...

Page 93: ...Stability Control DTC Diagnostic Trouble Code EBD Electronic Brakeforce Distribution EGR Exhaust Gas Recirculation EHPAS Electro Hydraulic Power Assist Steering FACM Fuel Additive Control Module FFD F...

Page 94: ...PID Parameter ID PJB Passenger Junction Box PTC Positive Temperature Coefficient RKE Remote Keyless Entry SAS Sophisticated Airbag Sensor TCC Torque Converter Clutch TDC Top Dead Center TMC Traffic M...

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