engine MAZDA MODEL 3 HATCHBACK 2005 (in English) Workshop Manual

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WARNING
Keep Flames Away:
Flames and sparks near open battery cells are dangerous. Hydrogen gas, produced
during normal battery operation, could ignite and cause the battery to explode. An
exploding battery can cause serious burns and injuries. Keep all flames including
cigarettes and sparks away from open battery cells. When working near a battery, do
not allow metal tools to contact the positive (
) or negative () terminal of the
battery. Do not allow the positive (
) terminal to contact the vehicle body.
Battery-Related Explosion:
Flames and sparks near open battery cells are dangerous. Hydrogen gas, produced
during normal battery operation, could ignite and cause the battery to explode. An
exploding battery can cause serious burns and injuries. Keep all flames, including
cigarettes, and sparks away from open battery cells.
Low Fluid Level or Frozen Battery:
Jump-starting a frozen battery or one with a low fluid level is dangerous. It may
rupture or explode, causing serious injury.
Don't jump-start a frozen battery or one with a low fluid level.
Connecting to Negative Terminal:
Connecting the end of the second cable to the negative (
) terminal of the discharged
battery is dangerous.
A spark could cause the gas around the battery to explode and injure someone.
Connect the negative cable to a good ground point away from the battery.
Connecting Jumper Cable to Moving Parts:
Connecting a jumper cable near or to moving parts (cooling fans, belts) is dangerous.
The cable could get caught when the engine starts and cause serious injury. Never
connect a jumper cable to or near any part that moves.
CAUTION
Use only a 12 V booster system. You can damage a 12 V starter, ignition system, and
other electrical parts beyond repair with a 24 V power supply (two 12 V batteries in
series or a 24 V motor generator set).
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In Case of an Emergency
Emergency Starting
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Connect cables in numerical order and disconnect in reverse order.
Jumper cables Discharged
battery
Booster battery
1. For vehicle equipped with the engine
cover, remove the engine cover.2. Remove the battery cover from its front
side.
Battery cover
3. Make sure the booster battery is 12 V
and that its negative terminal is
grounded.
4. If the booster battery is in another
vehicle, don't allow the vehicles to
touch. Turn off the engine of the
vehicle with the booster battery and all
unnecessary electrical loads in both
vehicles.
In Case of an Emergency
Emergency Starting
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5. Connect the jumper cables in the exact
sequence as in the illustration.
lConnect one end of a cable to the
positive terminal on the discharged
battery (1).
lAttach the other end to the positive
terminal on the booster battery (2).
lConnect one end of the other cable
to the negative terminal of the
booster battery (3).
lConnect the other end to a solid,
stationary, exposed metallic point
(for example, the right hand side
engine mounting bolt) away from
the discharged battery (4).
6. Start the engine of the booster vehicle
and run it a few minutes. Then start the
engine of the other vehicle.
7. When finished, carefully disconnect the
cables in the reverse order described in
the illustration.
NOTE
Verify that the engine cover is securely
installed.
Push-Starting
WARNING
Towing a Vehicle to Start It:
Towing a vehicle to start it is
dangerous. The vehicle being towed
could surge forward when its engine
starts, causing the two vehicles to
collide. The occupants could be
injured. Never tow a vehicle to start it.
You can't start a vehicle with an automatic
transaxle by pushing it.
CAUTION
You shouldn't push-start a vehicle that
has a manual transaxle. It can damage
the emission control system.
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In Case of an Emergency
Emergency Starting
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8Maintenance and Care
How to keep your Mazda in top condition.
Introduction .................................................................................. 8-2
Introduction ............................................................................... 8-2
Scheduled Maintenance ................................................................ 8-3
Scheduled Maintenance (North America) ................................. 8-3
Scheduled Maintenance (Except North America) ..................... 8-7
Owner Maintenance ................................................................... 8-10
Owner Maintenance Schedule ................................................ 8-10
Owner Maintenance Precautions ............................................. 8-11
Engine Compartment Overview .............................................. 8-12
Engine Oil ............................................................................... 8-13
Engine Coolant ....................................................................... 8-16
Brake/Clutch Fluid .................................................................. 8-18
Power Steering Fluid ............................................................... 8-19
Automatic Transaxle Fluid (ATF) ........................................... 8-20
Washer Fluid ........................................................................... 8-21
Body Lubrication .................................................................... 8-22
Air Filter .................................................................................. 8-23
Wiper Blades ........................................................................... 8-24
Battery ..................................................................................... 8-28
Tires ........................................................................................ 8-30
Light Bulbs ............................................................................. 8-35
Fuses ....................................................................................... 8-45
Appearance Care ........................................................................ 8-52
How to Minimize Environmental Paint Damage .................... 8-52
Exterior Care ........................................................................... 8-54
Interior Care ............................................................................ 8-57
8-1
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qSchedule 1
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48
×1000 km 12 24 36 48 60 72 84 96
×1000 miles 7.5 15 22.5 30 37.5 45 52.5 60
ENGINE
Engine valve clearanceAudible inspect every 120,000 km (75,000 miles), if noisy,
adjust
Drive belts (tension) I
Engine oil R R R R R R R R
Engine oil filter R R R R R R R R
COOLING SYSTEM
Cooling system I I
Engine coolantReplace at first 96,000 km (60,000 miles) or 4 years ;after
that, every 2 years
FUEL SYSTEM
Air filter R
Fuel lines and hoses
*1II
Hoses and tubes for emission*1I
IGNITION SYSTEM
Spark plugs Replace every 120,000 km (75,000 miles)
CHASSIS and BODY
Brake lines, hoses and connections I I
Disc brakes I I I I
Tire (rotation) Rotate every 12,000 km (7,500 miles)
Steering operation and linkages I I
Front and rear suspension and ball joints I I
Driveshaft dust boots I I
Exhaust system and heat shields Inspect every 72,000 km (45,000 miles) or 60 months
All locks and hinges L L L L L L L L
AIR CONDITIONER SYSTEM (if installed)
Cabin air filter Replace every 40,000 km (25,000 miles) or 24 months
Chart symbols
I:Inspect and repair, clean, adjust, or replace if necessary.
R:Replace
L:Lubricate
Remarks
*1 According to state/provincial and federal regulations, failure to perform maintenance on these items will not
void your emissions warranties. However, Mazda recommends that all maintenance services be performed at
the recommended time or mileage/kilometer period to ensure long-term reliability.
8-4
Maintenance and Care
Scheduled Maintenance
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qSchedule 2
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 4 8 12 16 20 24 28 32 36 40 44 48
×1000 km 8 16 24 32 40 48 56 64 72 80 88 96
×1000 miles 5 10 15 20 25 30 35 40 45 50 55 60
ENGINE
Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
Drive belts (tension) I
Engine oilPuerto Rico Replace every 5,000 km (3,000 miles) or 3 months
Others R R R R R R RRRRRR
Engine oil filter R R R R R R RRRRRR
COOLING SYSTEM
Cooling system I I
Engine coolantReplace at first 96,000 km (60,000 miles) or 4 years ; after that,
every 2 years
Engine coolant level I I I I I I IIIIII
FUEL SYSTEM
Air filterPuerto Rico R R
Others R
Fuel lines and hoses
*1II
Hoses and tubes for emission*1I
IGNITION SYSTEM
Spark plugs Replace every 120,000 km (75,000 miles)
ELECTRICAL SYSTEM
Function of all lights I I I I I I IIIIII
CHASSIS and BODY
Brake lines, hoses and connections I I
Brake and clutch fluid level I I I I I I IIIIII
Disc brakesIIII
Tire (rotation) Rotate every 8,000 km (5,000 miles)
Tire inflation pressure and tire wear I I I I I I IIIIII
Steering operation and linkages I I
Power steering fluid level I I I I I I IIIIII
Front and rear suspension and ball joints I I
Driveshaft dust boots I I
Exhaust system and heat shields Inspect every 72,000 km (45,000 miles) or 60 months
All locks and hinges L L L L L LLLLLLL
Washer fluid level I I I I I I IIIIII
Maintenance and Care
Scheduled Maintenance
8-5
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Scheduled Maintenance (Except North America)
NOTE
lAfter the prescribed period, continue to follow the described maintenance at the
recommended intervals.
lAs the result of visual examination or functional measurement of a system's operation
(performance), correct, clean, or replace as required. (Inspect, and if necessary replace
the air filter)
Emission control and related systems
The ignition and fuel systems are highly important to the emission control system and to
efficient engine operation. Don't tamper with them.
All inspections and adjustments must be made by an Authorized Mazda Dealer.
Maintenance and Care
Scheduled Maintenance
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qSchedule
Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
×1000 km 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles
6.25 12.5 18.752531.25 37.5 43.755056.25 62.5 68.757581.25 87.5 93.75100
Engine valve clearance Audible inspect every 120,000 km (75,000 miles), if noisy, adjust
Drive belts
*1IIIIIIIIIIIIIIII
Engine oil*2RRRRRRRRRRRRRRRR
Engine oil filter*2RRRRRRRRRRRRRRRR
Cooling system I I I I I I I I
Engine coolant Replace every 2 years
Air filter
*3CCRCCRCC
Spark plugs
*6Iridium type Replace every 120,000 km (75,000 miles)
except
Iridium typeRRRR
Idle speed (ZJ, ZY and Z6 engine) I I I I I I I I
Fuel filterRRRR
Fuel lines and hoses I I I I I I I I
Evaporative system (if installed) I I I I I I I I
Battery electrolyte level and specific
gravityIIIIIIII
Brake lines, hoses and connections I I I I I I I I
Brake fluid
*4IIIRIIIRIIIRIIIR
Parking brake I I IIIIIIIIIIIIII
Power brake unit (Brake booster)
and hosesIIIIIIII
Disc brakes I I IIIIIIIIIIIIII
Drum brakes (if installed) I I I I I I I I
Power steering fluid, lines, hoses
and connectionsIIIIIIIIIIIIIIII
Steering operation and linkage I I I I I I I I
Manual transaxle oil R
Automatic transaxle fluid level I I I I I I I I
Front and rear suspension and ball
jointsIIII
Driveshaft dust bootsIIII
Exhaust system and heat shields Inspect every 80,000 km (50,000 miles)
Bolts and nuts on chassis and body T T T T T T T T
All electrical system
*5IIIIIIII
Body condition
(for rust, corrosion and perforation)Inspect annually
8-8
Maintenance and Care
Scheduled Maintenance
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Maintenance IntervalNumber of months or kilometers (miles), whichever comes first
Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96
×1000 km 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
×1000 miles
6.25 12.5 18.752531.25 37.5 43.755056.25 62.5 68.757581.25 87.5 93.75100
Cabin air filter (if installed) R R R R R R R R
Tires (including spare tire)
(with inflation pressure adjustment)IIIIIIII
Chart symbols
I:Inspect: Inspect and repair, clean, adjust, or replace if necessary.
R:Replace
C:Clean
T:Tighten
Remarks
*1 Also inspect and adjust the power steering and air conditioner drive belts, if installed.
*2 If the vehicle is operated under any of the following conditions, change the engine oil and oil filter more often
than recommended intervals.
a) Driving in dusty conditions
b) Extended periods of idling or low speed operation
c) Driving for long period in cold temperatures or driving regularly at short distance only.
*3 If the vehicle is operated in very dusty or sandy areas, clean and if necessary, replace the air filter more often
than the recommended intervals.
*4 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.
*5 This is a full function check of electrical systems such as lights, wiper and washer systems (including wiper
blades), and power windows.
*6 Verify the spark plug type from the spark plug itself. Refer to specifications on page 10-4.
Maintenance and Care
Scheduled Maintenance
8-9
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Owner Maintenance Schedule
The owner or a qualified service technician should make these vehicle inspections at the
indicated intervals to ensure safe and dependable operation.
Bring any problem to the attention of an Authorized Mazda Dealer or qualified service
technician as soon as possible.
qWhen Refueling
lBrake and clutch fluid level (page 8-18)
lEngine coolant level (page 8-16)
lEngine oil level (page 8-14)
lWasher fluid level (page 8-21)
qAt Least Monthly
Tire inflation pressures (page 8-31)
qAt Least Twice a Year (For Example, Every Spring and Fall)
lAutomatic transaxle fluid level (page 8-20)
lPower steering fluid level (page 8-19)
You can do the following scheduled maintenance items if you have some mechanical
ability and a few basic tools and if you closely follow the directions in this manual.
lAir filter (page 8-23)
lEngine coolant (page 8-16)
lEngine oil (page 8-14)
8-10
Maintenance and Care
Owner Maintenance
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