Mazda 3 Facelift 2006 Installation guide

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.
©2006
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 1.3 MZR (ZJ)
En
g
ine 1.6 MZR (Z6) En
g
ine 2.0 MZR (LF) En
g
ine
Displacement 1,349 cm³ 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 62 kW (84 PS)
at 6000 min-1 77 kW (105 PS)
at 6000 min-1 110 kW (150 PS) at 6500 min-1
Max. torque 122 Nm
at 4000 min-1 145 Nm
at 4000 min-1 187 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)
6-speed manual
(G66M-R)
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 66 kW (90 PS)
at 4000 min-1 80 kW (109 PS)
at 4000 min-1
Max. torque 215 Nm
at 1750 min-1 240 Nm
at 1750 min-1
Emission standard Euro 4 Euro 4
Transmission 5-speed manual
(J65M-R) 5-speed manual (J65M-R)
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.
Plant 0= Hiroshima
1= Hofu
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
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-power (Y6)
J= 1.3 MZR (ZJ)
Z= 1.6 MZR (Z6)
F= 2.0 MZR (LF)
Body style 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
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
III
IIIII
RRR
ZJ,Z6CCRCCRCCR
LF RRR
III
IIIIIIIII
IIII
DDDDDDDDD
RRR
RRR
RRRRRRRRR
RRRRRRRRR
IIII
IIII
IIIIIIIII
IIIIIIIII
RRRR
IIIIIIIII
IIIIIIIII
IIII
IIII
IIIIIIIII
R
IIIIIIIII
III
IIII
TTTT
IIIIIIIII
RRRR
I : Inspect and repair, clean, adjust, or replace if necessary.
R : Replace
C : Clean
D : Drain
T : Tighten
M3FL_T00003
Engine coolant FL22 type*6 Replace every 200,000 km (125,000 miles) or 11 years
Others Replace first at 100,000 km (62,500 miles) or 4 years;
after that every 2 years
Inspect annually
Inspect every 80,000 km (50,000 miles) or 5 years
Fuel lines and hoses
Battery electrolyte level and specific gravity
Replace every 240,000 km (150,000 miles) or 10 years
Air cleaner element*3
Engine valve clearance
Drive belts*1
Replace every 120,000 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
Evaporative system (if installed)
Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
Number of months or kilometers (miles), whichever comes first
Radiator cap
Fuel system (Drain water)
Fuel filter
Air cleaner element*3 Replace every 120,000 km (75,000 miles)
Refill every 60,000 km (37,500 miles)
GASOLINE and DIESEL ENGINE
Fuel additive for DPF
Engine oil*5
Diesel particulate filter (DPF) (if installed)
Cooling system
Engine oil filter*5
Brake lines, hoses and connections
Bolts and nuts on chassis and body
Brake fluid*7
Parking brake
Disc brakes
Steering operation and linkages
Front and rear suspension, ball joints 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
Cabin air filter (If installed)
Drive shaft dust boots
Body condition (for rust, corrosion and perforation)
Exhaust system and heat shields
Tires (including spare tire)
(with inflation pressure adjustment)
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.
M3FL_01020
1 Variable domain
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
M3FL_01001
1 Power 3 Engine speed
2 Torque
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.
M3FL_01009
1 Feed pump 3 Fuel metering valve
2 High-pressure pump element
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.
M3FL_01010
1 From PCM control relay 3 PCM
2 Fuel metering valve 4 Current detection circuit
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