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Mazda 3 Facelift 2006 Training Manual

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Training Manual
Mazda3 Facelift
FL-005

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Summary of Contents for Mazda 3 Facelift 2006

  • Page 1 Training Manual Mazda3 Facelift FL-005...
  • Page 2 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.

  • Page 3: Table Of Contents

    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...
  • Page 4 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...
  • Page 5 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...
  • Page 6 Table of Contents Service Training Mazda3 F/L...
  • Page 7 General Information Technical Data 1.3 MZR (ZJ) 1.6 MZR (Z6) 2.0 MZR (LF) Item Engine Engine Engine 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...

  • Page 8: General Information

    General Information Vehicle Identification Number • The VIN (Vehicle Identification Number) key is as shown below. JMZ BK 1 4 Z 2 7 5 0 0 0 0 1 Serial No. 0= Hiroshima Plant 1= Hofu For UK Dummy For Israel Model year 7= 2007, 8= 2008, 9= 2009 For Others...

  • Page 9: Scheduled Maintenance

    General Information Scheduled Maintenance Number of months or kilometers (miles), whichever comes first Months Maintenance Item x 1000 km x 1000 miles 12.5 37.5 62.5 87.5 112.5 GASOLINE ENGINE Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust Drive belts*1 Idle speed (ZJ, Z6) Iridium type...
  • Page 10 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. –...

  • Page 11: Engine

    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...

  • Page 12: Mechanical

    Mechanical 1.3 MZR Engine Mechanical Camshaft • The exhaust-side camshaft has been modified, so that the exhaust valves open later. M3FL_01020 Variable domain 01-2 Service Training Mazda3 F/L...

  • Page 13: Features

    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) –...

  • Page 14: Engine Performance Curve

    2.0 MZR Engine Engine Engine Performance Curve M3FL_01001 Power Engine speed Torque 01-4 Service Training Mazda3 F/L...

  • Page 15: Overview

    Engine 2.0 MZR Engine Overview M3FL_01002 Service Training Mazda3 F/L 01-5...

  • Page 16: 1.6 Mz-Cd Engine

    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 –...

  • Page 17: Fuel System

    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...

  • Page 18: High-Pressure Pump

    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 Feed pump Fuel metering valve High-pressure pump element 01-8 Service Training Mazda3 F/L...
  • Page 19 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.

  • Page 20: Control System

    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 –...
  • Page 21 1.6 MZ-CD Engine Control System Low-power engine Battery High-power engine Starter relay ISV DC motor and position sensor PCM control relay Manifold absolute pressure sensor Glow plug relay IAT sensor no.2 MAF/ IAT sensor Injector Engine coolant temperature sensor Camshaft position sensor Powertrain control module (incl.

  • Page 22: Block Diagram

    Control System 1.6 MZ-CD Engine Block Diagram M3FL_01015 01-12 Service Training Mazda3 F/L...
  • Page 23 1.6 MZ-CD Engine Control System Instrument cluster Exhaust gas temperature sensor (only high-power engines) Powertrain control module (incl. DPF differential pressure sensor (only Barometric pressure sensor) high-power engines) Fuel additive control module (only high- Fuel-filler switch (only high-power power engines) engines) Cruise control switches (only high-power Fuel additive level sensor (only high-...

  • Page 24: Glow Plug Relay

    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.

  • Page 25: Cruise Control System

    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.
  • Page 26 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.

  • Page 27: Suspension

    Suspension 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 –...

  • Page 28: Front Suspension

    Suspension Front Suspension • The steering knuckle arm position has been modified to reduce wheel toe-out when driving over bumps. M3FL_02002 Coil spring Steering knuckle Stabilizer control link Lower arm Stabilizer Crossmember Shock absorber 02-2 Service Training Mazda3 F/L...

  • Page 29: Rear Suspension

    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. M3FL_02001 Shock absorber Coil spring...
  • Page 30 Suspension Notes 02-4 Service Training Mazda3 F/L...

  • Page 31: Driveline/Axle

    Driveline/Axle Driveline/Axle Features • The construction and operation of the driveline/axle is essentially carried over from that of the current Mazda3 except for the following features: – Lockbolt for connection between wheel hub and drive shaft replaced by locknut (similar to that of the Mazda5) –...

  • Page 32: Drive Shaft

    Driveline/Axle Drive Shaft • On the ZJ/Z6 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 Joint shaft Right front drive shaft Bracket 03-2 Service Training Mazda3 F/L...

  • Page 33: Transmission/Transaxle

    Transmission/Transaxle G66M-R Manual Transaxle G66M-R Manual Transaxle Features • The construction and operation of the G66M-R manual transaxle is essentially carried over from that of the Mazda6 F/L and has the following features: – Triple-cone synchronizer mechanism for 1 and 2 gear –...

  • Page 34: Overview

    G66M-R Manual Transaxle Transmission /Transaxle Overview M3FL_05001 Primary shaft Secondary 5th gear Reverse idler gear shaft Secondary 4th gear Reverse idler gear Secondary 3rd gear Primary 2nd gear Secondary 2nd gear Primary 3rd gear Secondary reverse gear (integrated in clutch hub sleeve) Primary 4th gear Secondary 1st gear Primary 5th gear...

  • Page 35: Shift Mechanism

    Transmission/Transaxle G66M-R Manual Transaxle Shift Mechanism • On the G66M-R transaxle a cable-type shift mechanism with integrated reverse lockout mechanism is used. The adjustment procedure for the select cable is similar to that of the current Mazda3. M3FL_05002 Select cable Shift lever component Shift cable Base plate...

  • Page 36: Reverse Lockout Mechanism

    G66M-R Manual Transaxle Transmission /Transaxle Reverse Lockout Mechanism • The reverse lockout mechanism prevents the driver from accidentally shifting into reverse gear when shifting into 1st gear. • When shifting into 1 gear, the projection on the shift lever comes in contact with the guide plate, restricting the movement of the lever and preventing accidental shifting into reverse.
  • Page 37 Transmission/Transaxle FN4A-EL Automatic Transaxle FN4A-EL Automatic Transaxle Features • The 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 shift-lock system/key interlock system Overview M3FL_05004 Service Training Mazda3 F/L...

  • Page 38: Fn4A-El Automatic Transaxle

    FN4A-EL Automatic Transaxle Transmission/Transaxle 2-4 brake band Torque converter Reverse clutch Differential 3-4 clutch Output gear Rear planetary gear Secondary gear Front planetary gear Primary gear Forward clutch One-way clutch Oil pump Low and reverse brake 05-6 Service Training Mazda3 F/L...

  • Page 39: Shift Mechanism

    Transmission/Transaxle FN4A-EL Automatic Transaxle Shift Mechanism • On the FN4A-EL transaxle the shift mechanism features an electrically-operated shift- lock system/key interlock system to prevent inadvertent selection of the wrong gear. M3FL_05005 Brake switch Selector lever component Ignition lock Shift-lock solenoid PJB (with integrated shift-lock relay) Selector cable Key interlock solenoid...

  • Page 40: Shift-Lock System/Key Interlock System

    FN4A-EL Automatic Transaxle Transmission/Transaxle Shift-lock System/Key Interlock System • The shift-lock system prevents the selector lever from being shifted out of P position unless the brake pedal is pressed, while the key interlock system allows the key to be removed from the ignition lock only when the selector lever is in P position. •...
  • Page 41 Transmission/Transaxle FN4A-EL Automatic Transaxle P Position Switch • The P position switch is located at the selector lever component and detects, whether or not the selector lever is in P position. M3FL_05007 P position switch • When the selector lever is in P position, the switch supplies ground to the shift-lock relay. •...
  • Page 42 FN4A-EL Automatic Transaxle Transmission/Transaxle Shift-lock Solenoid • The shift-lock solenoid is located at the selector lever component and controls the position of the lock lever, which prevents the selector lever from being shifted out of P position. M3FL_05008 Lock lever Shift-lock solenoid Selector lever •...
  • Page 43 Transmission/Transaxle FN4A-EL Automatic Transaxle NOTE: In case of an 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 component. M3FL_05009 Lock lever Service Training Mazda3 F/L...
  • Page 44 FN4A-EL Automatic Transaxle Transmission/Transaxle Key Interlock Solenoid • The key interlock solenoid is located at the ignition lock and controls the position of the stopper, which prevents the key from being turned to the LOCK position. • On vehicles with standard keyless entry system the key interlock solenoid is controlled by the P position switch, and on vehicles with Advanced Keyless Entry and Start System the solenoid is controlled by the keyless control module.
  • Page 45 Restraints Airbag System Airbag System Features • The construction and operation of the airbag system is essentially carried over from that of the current Mazda3 except for the following 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).

  • Page 46: Restraints

    Airbag System Restraints Parts Location M3FL_08001 Airbag system warning light SAS control module PAD switch Seat belt pretensioner Clock spring Side airbag sensor Driver-side airbag Side airbags PAD indicator Curtain airbags Passenger-side airbag Crash zone sensor Occupancy sensor 08-2 Service Training Mazda3 F/L...

  • Page 47: Wiring Diagram

    Restraints Airbag System Wiring Diagram M3FL_08002 SAS control module Mid-speed CAN bus Instrument cluster Crash zone sensor Clock spring Twisted pair Driver-side airbag PAD indicator Passenger-side airbag PAD switch Driver-side side belt pretensioner Passenger airbag ON Driver-side curtain airbag Passenger airbag OFF Driver-side side airbag Driver-side buckle switch Passenger-side seat belt pretensioner...

  • Page 48: Ball-Type Seat Belt Pretensioners

    Airbag System Restraints Ball-type Seat Belt Pretensioners • Ball-type seat belt pretensioners are used at the 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”...

  • Page 49: Body & Accessories

    Body & Accessories Body Panels Body Panels Features • The construction of the body is essentially carried over from that of the current Mazda3 except for the following features: – Front suspension housings joined to the fender frame by brackets –...
  • Page 50 Glass/Windows/Mirrors Body & Accessories Glass/Windows/Mirrors Features • The construction and operation of the glass/windows/mirrors is essentially carried over from that of the current Mazda3 except for the following features: – Exterior open/close function for the power windows has been introduced (similar to that of the Mazda5).

  • Page 51: Parts Location

    Body & Accessories Glass/Windows/Mirrors Parts Location M3FL_09001 Driver-side request switch (with Power window sub switch (rear doors) Advanced Keyless Entry and Start System) Power window regulators Power window sub switch (passenger door) Power window main switch (driver door) Keyless control module (with Advanced Transmitter (with standard keyless entry Keyless Entry and Start System) system)

  • Page 52: Security And Locks

    Security and Locks Body & Accessories Security and Locks Features • The construction and operation of the security and lock system is essentially carried over from that of the current Mazda3 except for the following features: – Advanced Keyless Entry and Start System has been introduced (depending on the vehicle grade).

  • Page 53: Parts Location

    Body & Accessories Security and Locks Parts Location M3FL_09002 Card key Trunk lid opener Transmitter Trunk lid request switch (integrated in key cylinder push switch) Auxiliary key Keyless antenna (exterior, rear) Start knob (with ignition switch) Rear door lock actuator Steering lock unit Front door lock actuator Coil antenna...

  • Page 54: Wiring Diagram

    Security and Locks Body & Accessories Wiring Diagram M3FL_09003 09-6 Service Training Mazda3 F/L...
  • Page 55 Body & Accessories Security and Locks Keyless control module Keyless antenna (interior, rear) Keyless receiver Keyless antenna (interior, middle) Coil antenna Keyless antenna (interior, front) Steering lock unit Instrument cluster Push switch Security light Key reminder switch Keyless warning light (red) Trunk lid/Liftgate request switch Keyless indicator light (green) Request switch (LF)

  • Page 56: Trunk Lid Request Switch

    Security and Locks Body & Accessories Trunk Lid Request 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 key.

  • Page 57: Keyless Control Module

    Body & Accessories Security and Locks Keyless Control Module • The Keyless Control Module is located behind the glove box. It confirms the identification of the card keys and transmits this information via the CAN bus to the PJB (for keyless entry) and to the PCM (for keyless start).

  • Page 58: Operation

    Security and Locks Body & Accessories Operation • The operation of the Keyless Entry and Start System is similar to that of the Mazda5. Warning and Guidance Function • The driver is informed of misuse or faults of the system via the exterior keyless buzzer, the keyless warning and indicator light and the interior buzzer (the latter two are integrated in the instrument cluster).

  • Page 59: Customization

    Body & Accessories Security and Locks Keyless Keyless Exterior Interior warning indicator Guidance Operating condition keyless buzzer light light buzzer (red) (green) Start knob Start knob is operable (released) when Sounds operable it is pressed. 6 times (max. 3 s) Start knob Start knob is inoperable (locked) Sounds...

  • Page 60: Service And Repair

    Security and Locks Body & Accessories Service and Repair Programming additional card keys with two or more card keys • If two or more registered card keys are available, additional card keys can be programmed without using M-MDS. A maximum of six card keys can be programmed. NOTE: Do not program card keys while M-MDS or any other computer devices are in the vehicle.
  • Page 61 Body & Accessories Security and Locks Erasing registered card keys Establish communication between M-MDS and the vehicle. Select the option Toolbox→Body→Security→PATS Functions. Select the option “Card Key Code Erase” and carry out the security access procedure (read out the M-MDS outcode, and input corresponding incode). NOTE: After erasing all registered card keys at least one card key must be programmed for the system to operate correctly.

  • Page 62: Immobilizer System

    Security and Locks Body & Accessories Immobilizer System • A D-PATS (Distributed Passive Anti-Theft System) type immobilizer system is used. The system consists of the auxiliary key (with integrated transponder), coil antenna, keyless control module and PCM. • A maximum of eight keys can be registered. •...
  • Page 63 Body & Accessories Security and Locks Operation • On vehicles with Advanced Keyless Entry and Start System the control of the immobilizer 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 Key (with integrated transponder) Security light...
  • Page 64 Security and Locks Body & Accessories The ignition switch is turned from the LOCK (ACC) to the ON (START) position (security light illuminates). 1. The keyless control 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 via the coil antenna.
  • Page 65 Body & Accessories Security and Locks Replacement of Immobilizer System Components Operation Necessary Preparation Required Action • Can be performed without M-MDS, providing "Customer spare key programming" function • Two or more programmed is enabled. Adding keys/card keys keys/card keys. •...

  • Page 66: On-Board Diagnostic System

    Security and Locks Body & Accessories On-board Diagnostic System • The on-board diagnostic system consists of the following functions: – Self test – PID monitor – Simulation test Self Test • The self-test function allows the Advanced Keyless Entry and Start System DTCs to be displayed.
  • Page 67 Body & Accessories Security and Locks Simulation Test • The simulation test function allows certain PIDs for the Advanced Keyless Entry and Start System to be activated. To do this connect M-MDS to the vehicle and select the option Toolbox→Datalogger→Modules→RKE. Unit/ Applicable Component Condition...
  • Page 68 Exterior Trim Body & Accessories Exterior Trim Features • The design of the exterior trim is essentially carried over from that of the current Mazda3 except for the following features: – New radiator grille design and front/rear bumper design – New rear combination lamp design (black bezels) and front fog lamp design (the latter one only for Sports Appearance Package) –...

  • Page 69: Exterior Trim

    Body & Accessories Exterior Trim Parts Location M3FL_09017 Front mud flap Radiator grille (Sports type) Rear spoiler Side step moulding Radiator grille (standard type) With Sports Appearance Package Rear mud flap Service Training Mazda3 F/L 09-21...

  • Page 70: Interior Trim

    Interior Trim Body & Accessories Interior Trim Features • The design of the interior trim is essentially carried over from that of the current Mazda3 except for the following features: – New seat and door trim upholstery materials – Instrument panel with new Piano Black or Titanium Grey trim (depending on vehicle grade) –...

  • Page 71: Lighting Systems

    Body & Accessories Lighting Systems Lighting Systems Features • The construction and operation of the lighting systems is essentially carried over from that of the current Mazda3 except for the following features: – LED brake light/taillight has been added for 4SD vehicles (depending on vehicle grade).

  • Page 72: Wiring Diagram

    Lighting Systems Body & Accessories Wiring Diagram M3FL_09009 09-24 Service Training Mazda3 F/L...

  • Page 73: Initialization Procedure For Auto-Leveling Control Module

    Body & Accessories Lighting Systems Initialization procedure for auto-leveling control module • An initialization procedure for the auto-leveling control module has been added. When this procedure is activated, the auto-leveling control module detects the height of the unloaded vehicle via the signal from the auto-leveling sensor and stores it as a reference value in the control module memory.

  • Page 74: Entertainment

    Entertainment Body & Accessories Entertainment Features • The construction and operation of the entertainment system is essentially carried over from that of the current Mazda3 except for the following features: – Audio unit with 20 GB music hard disc drive and remote control has been introduced (similar to that of the Mazda5).

  • Page 75: Parts Location

    Body & Accessories Entertainment Parts Location M3FL_09014 Rear door speaker Front door speaker Front tweeter Roof antenna Audio control switches Woofer Audio unit Audio amplifier Capacitor for high-mount brake light (only Remote control 5HB vehicles) Service Training Mazda3 F/L 09-27...

  • Page 76: System Overview

    Entertainment Body & Accessories System Overview M3FL_09010 Standard audio system Bose audio system Antenna Front tweeter (right) Center panel module (integrated in audio Front door speaker (right) unit) Audio unit Front door speaker (left) Audio control switches Front tweeter (left) TNS signal Rear door speaker (right) Rear door speaker (left)

  • Page 77: Audio Unit

    Body & Accessories Entertainment Audio Unit • An audio unit with 20 GB music HDD (Hard Disk Drive) is available, i.e. albums can be recorded from the CD player, stored on the hard disc in MP3 format and played back. The operation is similar to that of the Mazda5.
  • Page 78 Instrumentation/Driver Info Body & Accessories Instrumentation/Driver Info Features • The construction and operation of the instrumentation/driver information system is essentially carried over from that of the current Mazda3 except for the following features: – Odometer write procedure for the instrument cluster has been added (similar to that of the Mazda5).

  • Page 79: Instrumentation/Driver Info

    Body & Accessories Instrumentation/Driver Info Item Input signal source CAN system Note 1 EHPAS warning light EHPAS control module — — Oil pressure switch With 1.3/1.6/2.0 MZR engine 2 Oil pressure warning light With 1.6 MZ-CD engine 3 Turn indicator light —...

  • Page 80: Instrument Cluster

    Instrumentation/Driver Info Body & Accessories Odometer Write Procedure • An odometer write procedure for the instrument cluster has been added. When configuring a new instrument cluster with M-MDS, the total mileage logged in the old cluster is automatically uploaded to the new cluster. To do this, connect M-MDS to the vehicle and select the option Toolbox→Module Programming→Programmable Module Installation→IC.

  • Page 81: Freeze Frame Data

    Body & Accessories Instrumentation/Driver Info Freeze Frame Data • The FFD (Freeze Frame Data) represent the instrument cluster control status at the occurrence of a fault. The instrument cluster can store the FFDs for up to four DTCs (FFD1 to FFD4), with the most recent data being FFD1. This data will not be overwritten, except that more than four DTCs are stored.

  • Page 82: Seat Belt Reminder System

    Instrumentation/Driver Info Body & Accessories Seat Belt Reminder System • The seat belt reminder system warns the driver, when the driver/passenger seat belt and/or the rear seat belts are unfastened. It consists of driver-side/passenger-side buckle switch, passenger-side occupancy sensor, rear buckle switches, seat belt reminder indicator, driver seat belt warning light and warning chime (the latter two are integrated in the instrument cluster).
  • Page 83 Body & Accessories Instrumentation/Driver Info M3FL_09013 Microcomputer Rear right seat belt indicator light Buzzer Buckle switch (rear left) Driver seat belt warning light Buckle switch (rear center) Generator warning light Buckle switch (rear right) Instrument cluster Seat belt reminder indicator Passenger seat belt warning light SAS control module Red (seat belt unfastened)

  • Page 84: Front Seat Belt Reminder Operation

    Instrumentation/Driver Info Body & Accessories Front Seat Belt Reminder Operation • When the driver and/or the passenger seat belt is unfastened (driver side: seat belt is unbuckled; passenger side: seat belt is unbuckled and a weight of 15 kg or more is on the passenger seat) and the vehicle speed is less than 20 km/h, the SAS control module sends a “seat belt warning light on request”...

  • Page 85: Rear Seat Belt Reminder Operation

    Body & Accessories Instrumentation/Driver Info NOTE: The passenger seat belt warning light can be checked using the input/output check mode for the instrument cluster. Rear Seat Belt Reminder Operation • The seat belt reminder indicator activates all rear seat belt indicator lights after the ignition is switched on, or when the rear seat belts are unfastened or fastened while the engine is running.

  • Page 86: Control System

    Control System Body & Accessories Control System Features • The construction and operation of the control system is essentially carried over from 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 •...
  • Page 87 Body & Accessories Control System High-speed CAN bus Mid-speed CAN bus PCM (ZJ/Z6 engine) DLC-2 PCM (LF engine) Fuel additive control module PCM (1.6 MZ-CD engine) With 1.6 MZ-CD high-power engine EHPAS control module Climate control unit With 2.0 MZR/1.6 MZ-CD engine With full-auto A/C ABS HU/CM SAS control module...

  • Page 88: High-Speed Can Signal Chart

    Control System Body & Accessories High-speed CAN Signal Chart • The following signals are transmitted via the high-speed CAN bus. Multiplex module EHPAS Keyless ABS HU/CM Signal Instrument FACM (*1) control control cluster DSC HU/CM module (*2) module (*3) Engine speed Vehicle speed —...
  • Page 89 Body & Accessories Control System Multiplex module EHPAS Keyless ABS HU/CM Signal Instrument FACM (*1) control control cluster DSC HU/CM module (*2) module (*3) EHPAS warning light on request — — — — (*2) Brake system status (EBD/ — — —...

  • Page 90: Mid-Speed Can Signal Chart

    Control System Body & Accessories Mid-speed CAN Signal Chart • The following signals are transmitted via the mid-speed-CAN bus. Multiplex module Climate Signal SAS control Audio unit Information Instrument control unit module (base unit) display cluster (*1) Ambient temperature — —...
  • Page 91 Appendix Mazda3 Product Changes History • This section describes the product changes introduced during the cost reduction F/L of the Mazda3 in March 2005 (from VIN JMZBK1*****261573 on, except for vehicles with 1.6 MZ-CD high-power engine and DPF that were face-lifted from VIN JMZBK1*Y2**270808 on).
  • Page 92 Appendix • Audio unit (base unit) with separate upper module replaced by audio unit (base unit) with integrated upper module. • Audio unit without CD player replaced by audio unit with CD player (except for Base grade). • Bose audio system with CD changer, audio amplifier and woofer added (optional). •...
  • Page 93 List of Abbreviations Anti-lock Brake System EHPAS Electro-Hydraulic Power Assist Steering Air Conditioning FACM Fuel Additive Control Module Automatic Transmission Freeze Frame Data Automatic Transaxle Face Lift Bottom Dead Center Gear Ratio Controller Area Network Hard Disk Drive Compact Disc HU/CM Hydraulic Unit/Control Module...
  • Page 94 List of Abbreviations M-MDS Mazda-Modular Diagnostic Variable Boost Control System Vehicle Identification Number Music Picture Experts Group Layer-3 Vehicle Speed Sensor Passenger Airbag Deactivation 4-door Sedan PATS Passive Anti-Theft System 5-door Hatchback Powertrain Control Module Parameter ID Passenger Junction Box...

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