Mazda 3 2007 Service manual

2007
Mazda3
MAZDASPEED3
Mazda5
Mazda6
MAZDASPEED6
Mazda MX-5
Mazda RX-8
Service
Highlights
FOREWORD
This manual explains components, system
operations and functions for the Mazda3,
MAZDASPEED3, Mazda5, Mazda6,
MAZDASPEED6, Mazda MX-5,
Mazda RX-8.
For proper repair and maintenance, a
thorough familiarization with this manual is
important, and it should always be kept in a
handy place for quick and easy reference.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers.
This manual should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by
any means, electronic or mechanical—
including photocopying and recording and
the use of any kind of information storage
and retrieval system—without permission in
writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN),and related materials shown
on the following page.
© 2006 Mazda Motor Corporation
PRINTED IN U.S.A., JULY 2006
Form No. 3422–1U–06G
Part No. 9999–95–MODL–07
Mazda3
MAZDASPEED3
Mazda5
Mazda6
MAZDASPEED6
Mazda MX-5
Mazda RX-8
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CONTENTS
Mazda MX-5
Mazda MX-5
TITLE
SECTION
ENGINE 01
BODY & ACCESSORIES 09
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01-00–1
01
ENGINE
SECTION
Mazda MX-5
2007 Mazda3, MAZDASPEED3, Mazda5, Mazda6, MAZDASPEED6, Mazda MX-5,
Mazda RX-8 Service Highlights (3422–1U–06G)
Toc of S CT
OUTLINE[LF] . . . . . . . . . . . . . . 01-00 ON-BOARD DIAGNOSTIC
[LF]. . . . . . . . . . . . . . . . . . . . . 01-02
CONTROL SYSTEM[LF] . . . . . 01-40
Toc of S CT
01-00 OUTLINE [LF]
ENGINE ABBREVIATIONS[LF] . . . . . . . . 01-00–1
ENGINE FEATURES[LF] . . . . . . . . . . . . . 01-00–1
On-board Diagnostic . . . . . . . . . . . . . . . 01-00–1
ENGINE SPECIFICATION[LF] . . . . . . . . 01-00–2
Specification. . . . . . . . . . . . . . . . . . . . . 01-00–2
End of Toc
NG: ENGINE COMPLETE
ENGINE ABBREVIATIONS[LF] id0100e1100100
End Of Sie
ENGINE FEATURES[LF] id0100e1100200
On-board Diagnostic
End Of Sie
ABS Antilock Brake System
AT Automatic Transmission
ATDC After Top Dead Center
BTDC Before Top Dead Center
CAN Controller Area Network
CCM Comprehensive Component Monitor
CM Control Module
DC Drive Cycle
DSC Dynamic Stability Control
EX Exhaust
HU Hydraulic Unit
IN Intake
KOEO Key On Engine Off
KOER Key On Engine Running
MT Manual Transmission
OCV Oil Control Valve
PCV Positive Crankcase Ventilation
PID Parameter Identification
RAM Random Access Memory
To meet OBD-II regulations •Mode 03 of diagnostic test modes changed
Improved serviceability •Mode 01, 06, and 08 of diagnostic test modes changed

OUTLINE [LF]
01-00–2
2007 Mazda3, MAZDASPEED3, Mazda5, Mazda6, MAZDASPEED6, Mazda MX-5,
Mazda RX-8 Service Highlights (3422–1U–06G)
Revised 12/2006 (Ref. No. R223/06)
ENGINE SPECIFICATION[LF] id0100e1100300
Specification
Item
Specification
2007MY MX-5 2006MY MX-5
LF (2.0L) LF (2.0L)
MECHANICAL
Typ e DOHC-16 valves in-line, 4-
cylinder ←
Combustion chamber Pentroof ←
Displacement (ml {cc, cu in}) 1,999
{1,999, 122.0} ←
Bore ×stroke (mm {in}) 87.5 ×83.1
{3.44 ×3.27} ←
Compression ratio 10:8 ←
Compression pressure (kPa {kgf/cm2, psi} [rpm]) 1,720
{17.54, 249.5} [300] ←
Valve
timing
IN Open BTDC (°) 0—30 ←
Close ABDC (°)32—62 ←
EX Open BBDC (°)42 ←
Close ATDC (°)5 ←
Valve clearance (mm {in})
IN 0.22—0.28 {0.0087—0.011}
[Engine cold] ←
EX 0.27—0.33 {0.0107—0.0129}
[Engine cold] ←
LUBRICATION SYSTEM
Type Force-fed type ←
Oil pressure (reference value)
[oil temperature: 100°C {212°F}] (kPa {kgf/cm2, psi} [rpm])
337—591 {3.44—6.03, 49.0—
85.8}
[3,000]
←
Oil pump
Type Trochoid gear type ←
Relief valve opening
pressure
(reference value) (kPa {kgf/cm2, psi} 420—520 {4.28—5.30, 60.9—
75.4} ←
Oil filter
Type Full-flow, paper element ←
Bypass pressure (kPa {kgf/cm2, psi}) 80—120 {0.82—1.22, 11.6—
17.4} ←
Engine oil
capacity
(approx.
quantity)
(AT, 5MT)*1
Total (dry engine) (L {US qt, lmp qt}) 4.6 {4.9, 4.0} ←
Oil replacement (L {US qt, lmp qt}) 3.9 {4.1, 3.4} ←
Oil and oil filter
replacement (L {US qt, lmp qt}) 4.3 {4.5, 3.8} ←
Engine oil
capacity
(approx.
quantity)
(AT, 5MT)*2
Total (dry engine) (L {US qt, lmp qt}) 4.75 {5.02, 4.18} 4.6 {4.9, 4.0}
Oil replacement (L {US qt, lmp qt}) 4.05 {4.28, 3.56} 3.9 {4.1, 3.4}
Oil and oil filter
replacement (L {US qt, lmp qt}) 4.45 {4.70, 3.92} 4.3 {4.5, 3.8}
Engine oil
capacity
(approx.
quantity)
(6MT)
Total (dry engine) (L {US qt, lmp qt}) 4.85 {5.12, 4.27} ←
Oil replacement (L {US qt, lmp qt}) 4.05 {4.28, 3.56} ←
Oil and oil filter
replacement (L {US qt, lmp qt}) 4.55 {4.81, 4.00} ←
COOLING SYSTEM
Type Water-cooled, Electromotive ←
Coolant capacity (approx. quantity) (L {US qt, lmp qt}) 7.5 {7.9, 6.6} ←
Water pump Type Centrifugal, V-ribbed belt-
driven ←

OUTLINE [LF]
01-00–3
Mazda MX-5
2007 Mazda3, MAZDASPEED3, Mazda5, Mazda6, MAZDASPEED6, Mazda MX-5,
Mazda RX-8 Service Highlights (3422–1U–06G)
Thermostat
Type Wax, bottom-bypass ←
Opening
temperature
(°C {°F}) 80—84 {176—183} ←
Full-open temperature (°C {°F}) 97 {207} ←
Full-open lift (mm {in}) 8.0 {0.31} or more ←
Radiator Type Corrugated fin ←
Cooling system cap
Cap valve
opening
pressure
(kPa {kgf/cm2, psi}) 93.2—122.6 {0.95—1.25,
13.5—17.8} ←
Cooling fan
Type Electric ←
Number of blades 5 ←
Outer
diameter (mm {in}) 360 {14.2} ←
Fan motor
output (W) 120 ←
FUEL SYSTEM
Injector
Type Hi-ohmic ←
Type of fuel delivery Top-feed ←
Type of drive Voltage ←
Pressure regulator control pressure (kPa {kgf/cm2, psi}) Approx. 390 {3.98, 56.6} ←
Fuel pump type Electric ←
Fuel tank capacity (L {US gal, lmp gal}) 48 {12, 10} ←
Fuel type (Anti-knock index)
Premium unleaded fuel
91 [(R+M)/2 method] or adove
(96 RON or more)
←
EMISSION SYSTEM
EGR type Stepping motor ←
Catalyst form WU-TWC (monolith), TWC
(monolith) ←
Evaporative emission (EVAP) control system Charcoal canister type ←
Positive crankcase ventilation (PCV) system Closed type ←
CHARGING SYSTEM
Battery
Voltage (V) 12 ←
Type and capacity
(5-hour rate) (A·h) 46B24L (36) ←
Generator
Output (V-A) 12-100 ←
Regulated voltage Controlled by PCM ←
Self diagnosis function ←
IGNITION SYSTEM
Ignition system
Type SEI (Single Electronic Ignition) ←
Spark advance Electronic ←
Firing order
1—3—4—2 (all cylinders
independent firing) ←
←
Spark plug Type L3G2 18 110, L3Y1 18 110 ←
Item
Specification
2007MY MX-5 2006MY MX-5
LF (2.0L) LF (2.0L)
1
2
3
4
ENGINE
CYLINDER No.
CRANKSHAFT
PULLEY

OUTLINE [LF]
01-00–4
2007 Mazda3, MAZDASPEED3, Mazda5, Mazda6, MAZDASPEED6, Mazda MX-5,
Mazda RX-8 Service Highlights (3422–1U–06G)
Revised 12/2006 (Ref. No. R223/06)
*1 : Applied VIN (Assumed)
JM1 NC15F*7# 100001—130613
JM1 NC16F*7# 100001—130613
JM1 NC25F*7# 100001—130613
JM1 NC26F*7# 100001—130613
*2 : Applied VIN (Assumed)
JM1 NC15F*7# 130614—
JM1 NC16F*7# 130614—
JM1 NC25F*7# 130614—
JM1 NC26F*7# 130614—
Engine oil specification
End Of Sie
STARTING SYSTEM
Starter Type Coaxial reduction ←
Output (kW) 1.4 ←
Item
Specification
2007MY MX-5 2006MY MX-5
LF (2.0L) LF (2.0L)
Item U.S.A. and CANADA Except U.S.A. and CANADA
Engine oil grade
API SM or ILSAC
Engine oil viscosity 5W–20
(ILSAC) (ILSAC)
SM
SM

ON-BOARD DIAGNOSTIC [LF]
01-02–1
Mazda MX-5
01-02 ON-BOARD DIAGNOSTIC [LF]
DIAGNOSTIC TEST MODE[LF] . . . . . . . 01-02–1
Sending Diagnostic Data . . . . . . . . . . . 01-02–2
Sending Freeze Frame Data . . . . . . . . 01-02–3
Sending Emission-related
Malfunction Code . . . . . . . . . . . . . . . . 01-02–4
Sending Intermittent Monitoring
System Test Results . . . . . . . . . . . . . 01-02–7
Sending Continuous Monitoring
System Test Results . . . . . . . . . . . . . 01-02–7
DLC-2 Outline . . . . . . . . . . . . . . . . . . . 01-02–8
DTC DETECTION LOGIC AND
CONDITIONS[LF]. . . . . . . . . . . . . . . . . . 01-02–8
KOEO/KOER SELF-TEST[LF] . . . . . . . . . 01-02–17
KOEO (Key ON, Engine Off)
Self-test . . . . . . . . . . . . . . . . . . . . . . . . 01-02–17
KOER (Key ON, Engine Running)
Self-test . . . . . . . . . . . . . . . . . . . . . . . . 01-02–17
PID/DATA MONITOR AND
RECORD[LF] . . . . . . . . . . . . . . . . . . . . . 01-02–20
SIMULATION TEST[LF] . . . . . . . . . . . . . . 01-02–23
End of Toc
NG: ON-BOARD DIAGNOSTIC (ENGINE CONTROL SYSTEM)
DIAGNOSTIC TEST MODE[LF] id010245100200
•To meet OBD-II regulations, the following diagnostic test modes have been adopted.
Diagnostic test mode Item
Mode 01 Sending diagnostic data (PID data monitor/On-board system readiness test)
Mode 02 Sending freeze frame data
Mode 03 Sending emission-related malfunction code (DTC)
Mode 04 Clearing/resetting emission-related malfunction information
Mode 06 Sending intermittent monitoring system test results (DMTR)
Mode 07 Sending continuous monitoring system test results (pending code)
Mode 08 On-board device control (simulation test, active command mode)
Mode 09 Request vehicle information
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ON-BOARD DIAGNOSTIC [LF]
01-02–2
Sending Diagnostic Data
PID data monitor
•The PID data monitor items are shown below.
PID data monitor table
Meaning of fuel system loop status
•The following information is displayed on the tester.
—Feedback stops: ECT is lower than the determined feedback zone.
—Feedback operating: HO2S being used for feedback is normal.
—Feedback stops: Open loop due to driving condition
—Feedback stops: Open loop due to detected system fault
—Feedback operating: Malfunction occurred in HO2S (rear) system
Full names Unit
Fuel system loop status Refer to list below.
LOAD %
ECT °C°F
Short term fuel trim %
Long term fuel trim %
MAP kPa
Engine speed rpm
Vehicle speed km/h mph
Spark advance °
IAT °C°F
MAF g/s
Absolute TP %
O2S location No unit
Input voltage from rear HO2S V
Short term fuel trim associated with rear HO2S %
OBD requirement according to vehicle design No unit
Time since engine start s
Distance travelled while MIL is activated km miles
EGR valve control signal %
Purge solenoid valve control signal %
Fuel level %
Number of warm-ups since DTCs cleared No unit
Distance travelled since DTCs cleared km miles
Barometric pressure kPa
Lambda —
Front HO2S output current mA
Estimated catalyst converter temperature °C°F
PCM voltage V
Absolute load value %
Theoretical air/fuel ratio coefficient to calculate target air/fuel ratio No unit
Relative TP %
Ambient air temperature °C°F
TP from TP sensor No.2 %
APP from APP sensor No.1 %
APP from APP sensor No.2 %
Throttle actuator control signal %
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ON-BOARD DIAGNOSTIC [LF]
01-02–3
Mazda MX-5
On-board system readiness test
•The items supported by the on-board system readiness test are shown below.
Continuous monitoring system
—HO2S heater
—HO2S
—Fuel system
—Misfire
—CCM
Intermittent monitoring system
—HO2S heater
—HO2S
—Catalyst
—EGR system
—Evaporative system
—Engine cooling system
—Cold start emission reduction strategy monitoring
Sending Freeze Frame Data
•The Freeze Frame Data monitor items are shown below.
Freeze frame data monitor table
Meaning of fuel system loop status
•The following information is displayed on the tester.
—Feedback stops: ECT is lower than the determined feedback zone.
—Feedback operating: HO2S being used for feedback is normal.
—Feedback stops: Open loop due to driving condition
—Feedback stops: Open loop due to detected system fault
—Feedback operating: Malfunction occurred in HO2S (rear) system
Full names Unit
DTC that caused required Freeze Frame Data storage No unit
Fuel system loop status Refer to list below.
LOAD %
ECT °C°F
Short term fuel trim %
Long term fuel trim %
MAP kPa
Engine speed rpm
Vehicle speed km/h mph
Spark advance °
IAT °C°F
MAF g/s
Absolute TP %
Time since engine start s
EGR valve control signal %
Purge solenoid valve control signal %
Fuel level %
Number of warm-ups since DTCs cleared No unit
Distance travelled since DTCs cleared km miles
Barometric pressure kPa
Estimated catalyst converter temperature °C°F
PCM voltage V
Absolute load value %
Theoretical air/fuel ratio coefficient to calculate target air/fuel ratio No unit
Relative TP %
Ambient air temperature °C°F
TP from TP sensor No.2 %
APP from APP sensor No.1 %
APP from APP sensor No.2 %
Throttle actuator control signal %
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