Training Manual Mazda3 Facelift FL-005No part ofthis hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH ‘The illustrations, technical information, data and descriptive text inthis issue, to the best of our knowiedge, 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 10-1 00-1 00-2 General Information Technical Data. Vehicle Identification Numbé Scheduled Maintenance. Engine 1.3 MZR Engine. Features Overview. Mechanical Camshaft 01-2 2.0 MZR Engine. Features Engine Performance Curve 01-4 Overview. 1.6 MZ-CD Engine. Features Overview. Fuel System. Features Parts Location 01-7 High-pressure Pump. 01-8 Control System. 01-10 Features 01-10 Parts Location 01-10 Block Diagram o1-12 Glow Plug Relay o1-14 Cruise Control System 01-15 Suspension Features Front Suspension Rear Suspension Driveline/Axle. Features Front Axle. Drive Shatt.. Service Training Mazda3 F/LTable of Contents Transmission/Transaxle G66N-R Manual Transaxl Features Specitications Overview. Shift Mechanism. Reverse Lockout Mechanism 05-4 FN4A-EL Automatic Transaxle. Features Overview. Shift Mechanism. Shift-lock System/Key Interlock System 05-8 Restraints. Airbag System 08-1 Features. 08-1 Parts Location, 08-2 Wiring Diagram 08-3 Ball-type Seat Belt Pretensioners. 08-4 Body & Accessories. Body Pane! Features Front End, Glass/Windows/Mirrors. 09-2 Features 09-2 Exterior Opening/Closing Function. 09-2 Parts Location 09-3 Security and Locks. Features 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 Warming and Guidance Funetion 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.. 103-20 Features wnnnninnnnnnnnnnninnnnnnnnnnnnnnannnnnnnnnnnnnese 0920 Parts Location nnnnnmnnnnnnnnnnnnninnnnnnnnnnnmnnnnnannnnnnnnnnnn O21 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 contro! module 09-25 Entertainment... Features 09-26, Audio SYStOM so.crsnrnnnnnnn nn sssnstanninnnnnnnnnnsnnssnnn O26 Music Hard Disc Drive Specifications 09-26 Parts Location. 09.27 System Overview. 09-28 ‘Audio Unit 09-29 Instrumentation/Driver Info FeAtUtS wonnnnmnnnninnnninnninnnnnnnnnnnnnnnnannnnnnnnnnnnnse 0930 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. Features 09-38 Controller Area Network 09-38, High-speed CAN Signal Chart....on.nnnnnnninmnnnnnnnnnnnnnnnnenne O40 Mid-speed CAN Signal Chatt ..nssnssnnnnnnnmnnnnnnnnnnnnnnnnnsneO9AZ Service Training Mazda3 F/LTable of Contents Service Training Mazda3 F/LGeneral Information Technical Data [Mem f-SMZR (Za) 6 MZR (26) [2.0 mzR (LF) Engine Engine Engine Displacement 1,349 ome 1,598 ome 1.999 om® Bore x stroke 74.0 x 78.4 mm 78.0x886mm [75x 83.1 mm [Compression ratio [10.01 10.054 08:1 Max. power 62 kW (84 PS) 77 KW (105 PS) |110 KW {150 PS) fat 6000 min at 6000 min” fat 6500 min” Max. torque fi22 Nm a5 Nim 87 Nm fat 4000 min" at 4000 min" Jat 4000 min” [Emission standard Euro 4 Euro 4 yo 4 Transmission S-speed manual __|S-speed manual __|6-speed manual (F35M-R) (F35M-R) 0° 4-speed |(GB6M-A) automatic (FN4A-EL) [tem 6 MZCD (Ye) __]}.6 MZ-CD (YO) Low-power Engine_|High-power Engine Displacement 560 cm® 1.560 om? Bore x stroke 75.0 x 88.3 mm 75.0 x 88.3 mm [Compression ratio [18.31 1.321 Max. power 66 kW (0 PS) [a0 KW (109 PS) at 4000 min * at 4000 min” Max. torque 215 Nm [240 Nm fat 1750 min" at 1750 min" [Emission standard [Euro 4 Euro 4 Transmission s-speed manual _|S-speed manual (J65M-R) (J65M-R) M3FL_To0001 Service Training Mazda3 F/L 00-1General Information Vehicle Identification Number ‘+The VIN (Vehicle Identification Number) key is as shown below. JMZ BK 14 Z 27 1 500001 Plant For UK Dummy For Israel Model year For Others: ‘Transaxle Drive axle Vehicle type World manufacturer ation Serial No. 0 Hiroshima 7= 2007, 8= 2008, 9= 2008 (0 to 9 (Same as model year-Irael) .6 MZ-CD high-power (V6) {6 MZ.CD low-power (Y6) 3 MZR (2) .6 MZR (26) ONZR (LF) BK= Mazda JMZ= European (LHD, UK) MaFL_Tooo02 00-2 Service Training Mazda3 F/LGeneral Information Scheduled Maintenance Number of monihe or aon ‘ihichower comes Teal Maintenance item Monts [12 [24 [36 oo | 2 | o | 96 | 106 1000 em | ~20-| <0] 60_[ 0 | 100 | 420 | 140_| 160 | 100 E000 mies [v2.5 [25 [srs so_[e2s| 75 | ers | 00 [nas IGASOLINE ENGINE [Engine vale deararce Tin apes ovary TAO DT (75 OO Tea) TS aT [Drive bake"? ie speed (2 25) T [Cooing systems soak age" [aun Woe, pao avery 120,000 wh (75,000 me) [Sear pugs"? [except incur pe R R a 7 mn zz | ofetra|efe|rAlete,a ln cleaner element'@ zs B B a [Evaporative aytom stale) T T T [DIESEL ENGINE Drive bak" Ce [Engine ding BOE place evory 250,000 em (750,000 me) oF yoars [Rasaior cap i T T T [Fut system (Oran wate Dpope pete pe fetes Foster F f A Ine ceaneralament@ hi fl a Diesel parculte rite (OPP) (Tirtalea) pie avery 120,000 am (75,0 res) [Fost ace fr DPF lil very 60,000 am (37 500 mies) [GASOLINE and DIESEL ENGINE [Engine o's HPAP A,aAyaAyTATATATA [Engine ot ers aAteafeatealelatelala T Fars Taplace avery 200,000 em (125 050 weapon years lEnoine coolant loners pace rs a 100,000 4 (62,00 ‘ater that every 2 years les) oF yous [Foor ires and roma [Banery electrolyte eve ard spect pray T [Brave ines, roses ard coorectore T rake Huet i A i a [Parcng rake Cs bie aces Cs [Swonng operator an Taos i r T T [Front ana rear suspension al aris and wreel leaving ail play ' ' ' ‘ [Power steering Tu Ines, ROSES ana PORTERS Ct Mana rarsave ol for gasoline). i Mana rarsave ofr cesel) a [Avira ranean fui loved H i 1 Drive shat dust boas 7 7 i T [Bote andncis on chases and body r T T r [Body concton (or rust corosion afd pavraton) Toa [Exhaust system and Rea isos Tre very 80.000 kn (50,000 ea) or 5 yeare Fires (nclucng spare te) win ination pressure agusimert) [Gabi ar ier (insta) a a a = 1 Inspect and pair, clean, adjust, replace i necessary Replace Clean D: ain T: Tighten THSFL_TOODG Service Training Mazda3 F/L 00-3General Information ‘+ Refer below for a description of items marked * in the maintenance chart = 11: Also inspect and adjust the power steering and air conditioner drive belts, if stalled. = *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 \dling 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. — 17: Ifthe 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 MaFLo1018 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. MBFL_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 vaive with drive-by-wire relay and accelerator pedal position sensor (similar to that of the Mazda6 F/L) = Direct ignition coils with integrated power transist Mazdaé FIL) = Linear-type (Broadband) upstream oxygen sensor (similar to that of the Mazda6 FiL) (similar to those of the = Generator with two stator coils (similar to that of the Mazdaé FIL) — Magneto resistive-type crankshaft and camshaft position sensor (similar to that of the Mazda6 FIL) = Variable valve timing system with oil control valve and camshaft actuator (similar to that of the Mazdaé FIL) = 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 187 Nm 14000 rpm 200 ‘0 ‘0 170 10 i0@ ¥ on 2 +10 kw. 500 pm iio 400 2 2% % 5 40 0 rey 20 xan 29 3 +000 2.000 3,000 4,000 6.000 6,000 7,000 Dom M3FL_01001 1 Power 3 Engine speed 2 Torque 01-4 Service Training Mazda3 F/LEngine 2.0 MZR Engine Overview MSFL_o1002 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 Mazda 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 MSFL_o1004 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 MBFL_01008 1 Injector 6 Fuel iter 2 High-pressure line 7 Common rail 3 Fuel warmer 8 High-pressure pump 4 Quick release connector 9 Fuel metering vaive 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, (OS < itl \ INS A Ova em MBFL_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 racial-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. MGFL_o1010 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 sysiem 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 contro! module with separate power supply for all glow plugs replaced by aglow plug relay with joint power supply = Cruise control system integrated in the PCM for 1.6 MZ-CD high-power engine Parts Location MaFLo1014 01-10 Service Training Mazda3 F/L1.6 MZ-CD Engine Control System Low-power engine High-power engine ISV DC motor and position sensor Manitold absolute pressure sensor IAT sensor no.2 Injector Camshaft position sensor 8 Fuel temperature sensor 9 EGR valve DC motor and position sensor 10 Accelerator pedal position sensor 11 Engine switch 12 Brake pedal position switch 13. Clutch pedal position switch 14 Dice 15 DPF differential pressure sensor (only high-power engine) 16 7 18 19 20 at 22. 23, 24 25 26 a7 28 29 Battery Starter relay PCM control relay Glow plug relay MAF/ IAT sensor Engine coolant temperature sensor Powertrain control module (incl Barometric pressure sensor) Fuel pressure sensor VBC solenoid valve Crankshaft position sensor Exhaust gas temperature sensor (only high-power engine) Generator Fuel metering valve Charge-air cooler bypass valve DC motor and poston sensor ony hgh power engine) Service Training Mazda3 F/L 01-111.6 MZ-CD Engine Control System Block Diagram @ @ Ge 6 © ee) 2 (Oo 2 2) @ = (erase 1 Litttitttt — -—> [nan L—» [cause ® & 3 @ Leo @ « SOB soawera £ I eB off Hote 4 TTT Thtttit TTP aryt Kal Gh S8C8ELD af BQ % ESS © GO OD C©OOOOOO9 GD ODO OG O® 1 TT & og ® ® ® MSFL_o1015: Service Training Mazda3 F/L 01-121.6 MZ-CD Engine Control System 1 Instrument cluster 2 Powertrain control module (incl. Barometric pressure sensor) 3 Fuel additive control madule (only high power engines) Cruise control switches (only high-power engines) 5 Accelerator pedal position sensor 6 Brake pedal position switch 7 Clutch pedal position switch 8 Manifold absolute pressure sensor 9 Fuel pressure sensor 10 MAF/IAT sensor 11 Fue! temperature sensor 12 Engine coolant temperature sensor 13. Camshaft position sensor 14 Crankshaft position sensor 15 EGR vale position sensor 16 Generator (stator coil) 17 IAT sensor no. 2 18 _ISV position sensor (only low-power engines) 19. ISVposition sensor and charge-alr cooler bypass valve position sensor (only high- power engines) 20 21 22. 23 24 25 26 a7 28 29 30 31 32. 33, 34 35 36 37 Exhaust gas temperature sensor (only high-power engines) DPF diferential pressure sensor (only high-power engines) Fuel ler switch (only high-power engines) Fuel additive evel sensor (only high- power engines) Malfunction indicator light Cruise main indicator ight Cruise indicator ight Injectors VBC solenoid valve Glow plug relay Fuel metering valve Cooling fan and A'C compressor (it eauipped) POM control relay Generator (eld coi) EGR valve DC motor ISV DC motor (only low-power engines) ISV DG motor and charge-air cooler bypass valve DC motor (only high-power engines) Fuel additive pump (only high-power engines) Service Training Mazda3 F/L 01-13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. MBFL_o1016 01-14 Service Training Mazda3 F/L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. f the actual vehicle speed goes below or above the set speed, the PCM increases or decreases the injection amount. OR — + g6?Fo Oo —+ o > B10 oy — oe — +» fen |® MaFL_01017 Pom Brake pedal position switch Clutch pedal position switch Cruise control switches vss Injectors Cruise main indicator light Cruise indicator light Service Training Mazda3 F/L 01-15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. NOTE: The cruise control switches can be checked using the input/output check mode for instrument cluster. ® x @ rh, MBFL_o1018 1 Cruise contol switches 3 High-speed CAN bus 2 Instrument cluster 4 PCM 01-16 Service Training Mazda3 F/L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 = Rear twin-tube shock absorbers replaced by mono-tube shock absorbers with a larger piston diameter (similar to those of the Mazdas) Rear lateral link position has been modified Rear stabilizer mounting position has been mosified Service Training Mazda3 F/L 02-1Suspension Front Suspension ‘+ The steering knuckle arm position has been modified to reduce wheel toe-out when driving over bumps. M3FL_o2002 1 Coil spring 5. Steering knuckle 2. Stablizer control link 6 Lower arm 3. Stabilizer 7 Crossmember 4 Shock absorber 02-2 Service Training Mazda3 F/L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. MBFL_02001 1 Shock absorber 6 Coll spring 2 Crossmember 7 Stablizer control link 3 Trailing ink 8 Stablizer 4 View from rear of the vehicle 9 Lateral link 5 Lower arm 19 Upper arm Service Training Mazda3 F/L 02-3Suspension Notes 02-4 Service Training Mazda3 F/LDriveline/Axle Driveline/Axle Features ‘+ The construction and operation of the driveline/axie is essentially carried over from that of the current Mazda3 except for the following features: = Lockbolt for connection between wheel hub and drive shatt 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) Front Axle '* Allock nut is used for the connection between wheel hub and drive shaft MaFL_oa001 1 Wheel hub 3. Wheel bearing 2 Drive shaft 4 Lock nut Service Training Mazda3 F/L 03-1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. MFL_03002 1 Joint shaft 3. Right front drive shat 2 Bracket 03-2 Service Training Mazda3 F/L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 = Double-cone synchronizer mechanism for 3" and 4" gear = Single-cone synchronizer mechanism for 5”, 6” and reverse gear = Gear ratios have been modified = Cable-type shift mechanism with integrated reverse lockout mechanism NOTE: Further information can be found in the Training Manual “Mazda6 Facelift” (FL-003). Specifications Tem Speciication rane npe Ta Manat ranean ope Sean [peraion system Cable Fransaxe contol Foorshit Fear — ware Synehomesh ica aaa ar 2058 BGR 392 ear ratio ior 7.090 GR 77 ear arr Reverse 2198 Fa gear rao 488 [eace Weenie Ga 7S Tarseaien SAE T30 jou sees [Above 10 °C (50 F) ‘SAE 80W-90_ Games eres | usa meat 2.95 12,260) MaF_To5001 Service Training Mazda3 F/L 05-1G66M-R Manual Transaxle Transmission /Transaxle Overview ‘MSFL_05001 1 Primary shaft 11 Secondary Sth gear 2 Reverse idler gear shaft 12 Secondary 4th gear 3° Reverse 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 Primary 5th gear 17 Differential @ Primary 6th gear 18 Output gear 9 Secondary shaft 19° Primary 1*/reverse gear 10. Secondary 6th gear 05-2 Service Training Mazda3 F/L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 MaFL_os002 1 Select cable 5 Shift lever component 2 Shift cable 6 Base plate 3. Shift lever knob 7 Select spring 4 Boot panel @ Select arm Service Training Mazda3 F/L 05-3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, * When shifting into reverse gear, once the shift lever is pressed down and moved towards the reverse position, the projection on the lever goes under the guide plate, releasing the reverse shift restriction and allowing for shifting into reverse. TEE MaFL_05003 1. Shifting into 1* gear 4 Projection 2 Shifting into reverse gear 5 Reverse position 3 Guide plate 05-4 Service Training Mazda3 F/L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 MSFL_05004 Service Training Mazda3 F/L 05-5FN4A-EL Automatic Transaxle Transmission/Transaxle 1 2-4 brake band @ Torque converter 2 Reverse clutch 9 Differential 3 34clutch 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 Oilpump. 14 Low and reverse brake 05-6 Service Training Mazda3 F/L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. MBFL_05005 1 Brake switch 5 Selector lever component 2. Ignition lock 6 Shiftock solenoid 3 PJB (with integrated shittlock relay) 7 Selector cable 4 Key interiock solenoid Service Training Mazda3 F/L 05-7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. ‘* The system consists of the P position switch, shif-lock relay, shift-lock solenoid, key interlock solenoid, key interlock resistor and keyless control module (the latter two are only equipped on vehicles with Advanced Keyless Entry and Start System). MaFL_o5006 05-8 Service Training Mazda3 F/LTransmission/Transaxle FN4A-EL Automatic Transaxle P Position Switch ‘+ The P position switch is located at the selector lever component and detects, whether or e selector lever is in P position. MBFL_05007 1 P position switch ‘+ When the selector lever is in P position, the switch supplies ground to the shiftlock relay. ‘+ When the selector lever is in any other position than P, the switch supplies ground to the key interlock solenoid (vehicles with standard keyless entry system) or to the keyless control module (vehicles with Advanced Keyless Entry and Start System) Service Training Mazda3 F/L 05-9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. wa \ q I ie| és qi Ce SS ig * “TF 3 MaFL_05008 1 Locklever 3 Shiltiock solenoid 2 Selector lever ‘* When 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 the movement of the selector lever, allowing shifting out of P position. * Inany other condition than above the shift-lock relay and henee the shift-lock solenoid is de-energized. As a result, the lock lever restricts the movement of the selector lever, Preventing shifting out of P position 05-10 Service Training Mazda3 F/L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. MaFL_o5008 1 Lock lever Service Training Mazda3 F/L 05-11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. + Onvvehicles 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. MaFL_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 restricts the movement of the ignition lock, preventing the key from being turned to LOCK position. ‘+ When the selector lever is in P position, the key interlock solenoid is de-energized. As a result, the stopper does not restrict the movement of the ignition lock, allowing tuning the key to LOCK position. NOTE: in case of an open circuit the key can be tured to LOCK position in any position of selector lever. 05-12 Service Training Mazda3 F/L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 Mazdaé Fil). = Buckle switch and occupancy sensor on the passenger-side have been introduced for front seat belt reminder system (refer to section 09, Instrumentation/Driver Info). Service Training Mazda3 F/L 08-1Airbag System Restraints Parts Location MBFL_08001 1. Airbag system warning 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 13. Crash zone sensor 7 Occupancy sensor 08-2 Service Training Mazda3 F/LRestraints Airbag System Wiring Diagram ® @ ®@ i Phe ie i RS ®O® @| |||} © © tT SAS control module PAB Grash zone sensor ‘Twisted pair PAD indicator PAD switch Passenger airbag ON Passenger aitbag OFF Driver-side buckle switch Passenger-side buckle switch 11. Driver-side side airbag sensor 12 Passenger-side side airbag sensor See 13 14 16 16 7 18 19 20 21 22. 23, 24 MaFL_o2002 Mid-speed CAN bus Instrument cluster Clock spring Driver-side airbag Passenger-side airbag Driver-side side belt pretensioner Driver-side curtain airbag Driver-side side airbag Passenger-side seat belt pretensioner Passenger-side curtain altbag Passenger-side side alrbag ‘Occupancy sensor Service Training Mazda3 F/L 08-3Airbag System Restraints Ball-type Seat Belt Pretensioners ‘+ Ball-type seat bolt pretensioners are used at the front seats. The operation is similar to that of the Mazdaé FIL. NOTE: Further information can be found in the Training Manual “Supplemental Restraint System” (CT-L1003) MBFL_08003 1 Ball trap 6 Cover 2 Gas generator 7 Ball quide 3 Spring @ Pinion 4 Balls 9° Spindle 5 Tube 10 Housing 08-4 Service Training Mazda3 F/LBody & Accessories Body Panels Body Panels Features * The construction of the body is essentially carried over from that of the current Mazda3- except fr the following features: = Front suspension housings joined tothe fender frame by brackets = Tunnel crossmember no.1 extended tothe let and right side members Front End ‘+The front suspension housings are joined to the fender frame by brackets to reduce deformation of the suspension housings when cornering and hence minimize changes in wheel camber. ‘+ Inaddition, the tunnel cross member no.1 connecting the transmission tunnel to the underbody is now extended to the lett and right side members. This arrangement reduces the lateral deformation of the body when cornering, achieving a more linear steering response. Another benefit is decreased transmission of road vibrations from the front end to the cabin. MGFL_og001a 1 Brackets: 2 Tunnel crossmember Service Training Mazda3 F/L 09-1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 openiclose function for the power windows has been introduced (similar to that of the Mazda6), Exterior Opening/Closing Function * The power windows feature an exterior open/close function (also termed as global opening/closing function). i.e. all of the windows can either be opened or closed from outside the vehicle. The operation is similar to that of the Mazda5. NOTE: Further information can be found in the Training Manual Mazdas" (NMT-007). 09-2 Service Training Mazda3 F/LBody & Accessories Glass/Windows/Mirrors Parts Location 1 Driver-side request switch (with Advanced Keyless Entry and Start System) 2 Power window regulators 3 PAB 4 Keyless control module (with Advanced Keyless Entry and Start System) 5 Keyless receiver 10 M3FL_09001 Power window sub switch (rear doors) Power window sub switch (passenger door) Power window main switch (érver door) Transmitter (with standard keyless entry system) Transmitter (with Advanced Keyless Entry and Start System) Service Training Mazda3 F/L 09-3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). Advanced Keyless Entry and Start System +The Advanced Keyless Entry and Start System is essentially carried over trom that of the Mazda 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 vehicles) = Six keyless antennas — Keyless receiver = Keyless control module connected to the high-speed CAN bus = Steering lock unit — Exterior keyless buzzer = _D-PATS type immobilizer system with control function integrated in the keyless control module = Instrument cluster is not part of the immobilizer system NOTE: Further information can be found in the Training Manual *Mazda5" (NMT-007). 09-4 Service Training Mazda3 F/LBody & Accessories Security and Locks Parts Location 1 Card key Transmitter Auxiliary key Start knob (with ignition switch) Steering lock unit Coil antenna Security light Keyless warning light (red) Keyless indicator light (green) 10 Keyless antenna (exterior, LF) 11 Request switch 12 Key cylinder switch 13 _Lifigate latch and lock actuator 1“ 18 16 7 18 19 20 a1 22. 23, 24 25 MBFL_09002 Trunk lié opener “Trunk lid request switch (integrated in key cylinder push switch) Keyless antenna (exterior, rear) Rear door lock actuator Front door lock actuator Keyless buzzer Keyless receiver Keyless control module PUB Keyless antenna (interior, front) Koyloss antenna (interior, middle) Keyless antenna (interior, rear) Service Training Mazda3 F/L 09-5Security and Locks Body & Accessories Wiring Diagram MaFL_o9003 09-6 Service Training Mazda3 F/LBody & Accessories Security and Locks 1 Keyless control moduie 2 Keyless receiver 3° Coll antenna 4 Steering lock unit 5 Push switch 6 Key reminder switch 7 TrunklidLittgate request switch & Request switch (LF) 9 Request switch (RF) 10 With ATX 11 P position switch 12. Key interlock solenoid 13. Key interlock resistor 14 Keyless antenna (exterior, RF) 15 Keyless antenna (exterior, LF) 16 Keyless antenna (exterior, rear) 7 18 19 a1 22 23. 24 25 26 27 28 29 30 31 32 Keyless antenna (interior, rear) Keyless antenna (interior, middle) Keyless antenna (interior, front) Instrument cluster Security light Keyless warning light (red) Keyless indicator light (green) Keyless buzzer High-speed CAN bus Door lock-link switch PoM Dic.2 PUB Lock Door lock actuators Unlock Service Training Mazda3 F/L 09-7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. 9 aa a” a WIT ADVANCED HERES SYSTEM, Ts a - ‘Lem ab _! i {fmt FR eA ee — MaFL_o9008 09-8 Service Training Mazda3 F/L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) NOTE: When replacing the keyless control module, the new module has to be configured. To do this connect M-MDS to the vehicle and select the option Toolbox—>Module Programming-»Programmable Module Installation-»RKE. MBFL_o9005 1. View from rear of the glove box 3 Keyless control module 2 Nut 4 Connectors Service Training Mazda3 F/L 09-9Security and Locks Body & Accessories Operation ‘+ The operation of the Keyless Entry and Start System is similar to that of the Mazdas. 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) aes] Rees inerr | warns | nto Muiog | Onmtgcenton | fons | ior [wai nda ted) | gran BEST lovers azar apo win 3085 | aes tin LOCK. rthrabin ACC poston. times Guay enol danced sso nner sor sounds | Rashes enantio Stim | 2 Peston cent caci Ge ny cur bo SORT ace ence nator seunds pastes ers tov out ced an saterb ay Simos sf poston et 0K ca ay aot be dwcsinao ferice win oat ttn any raves] penton cpt LOS an unr 4 feconstonar tar above Sacra on PRO ORR ROR oo eatayiot [Pepercacioy ate vchce ara” Sout : ferwecwd tay acs Peoteek [isfemevardecseroponcrsan | sa inoperable [knob not in LOCK position. mes exter tomer fey” cautery stan (spp 0° IGON) War, Toon 09-10 Service Training Mazda3 F/LBody & Accessories Security and Locks Keyens | Kevless Exiir Interior | warning | indator Guidance Operating condton sapere | ter Mam | Maen (ves)_| green) [Sarina [Stan kno i operablo oleasod) when Sounds on everatie [tis presse times (rae 38) [Bart inob Sar knob operable Toke sound Tags linoperable [when itis pressed. Btimes | Flashes Toaied \ Sours tocnsec Poreaelitadnecas wt une : anewer back [Termelaavarcsakevess erty | aoc nen ‘Souncs aca “1: Ifthe stat knob is tumed to the LOCK positon with the card key out of the vehicle, the Sart knob is inoperable the engine cannot be restated). In accion, the engine cannot be restarted by turning the start knob from the AGC postion to the START position even though the stan knob has not been tured tothe LOCK positon before, "2 : Stops flashing and goes out the card ky is detacie inside the vehicle “3 : Stops flashing and goes out the card key is dtected inside the vehicle and door is. opened MaFL_Tosoota Customization ‘+ The following functions can be activated or deactivated using M-MDS: = Out of range auto-lock function (set to OFF from factory) = Lock/unlock answer-back buzzer (set to OFF from factory). = Card key battery voltage low warning (set to ON from factory). * Todo this connect M-MDS to the vehicle and select the option Toolbox->Module Programming-»Programmable Parameters>RKE. Service Training Mazda3 F/L 09-11Security and Locks Body & Accessories Service and Repair Programming additional card keys with two or more card keys © Iftwo 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. Make sure all card keys are operational and have good batteries. NOTE: Steps 3 to 6 below must be completed within 30 seconds after inserting the auxiliary key in the ignition lock. 1. Bring the two registered card keys (key 1 and key 2), and the card key to be programmed into the vehicle and close all doors. Insert auxiliary key in the ignition lock. Tum ignition switch to the ON position Push the UNLOCK button on card key 1 once. Push the UNLOCK button on card key 2 once. Turn ignition switch to ACC then back to ON three times, Open and close the driver's door three times. The door lock actuators will lock once, then unlock to confirm that programming mode is active. 8. Push the UNLOCK button on the card key to be programmed twice. The door lock actuators will lock once, then unlock to confirm that programming was successful Programming additional card keys with M-MDS 1, Establish communication between M-MDS and the vehicle. 2. Select the option Toolbox-»Body-»Security-»PATS Functions. 8. Select the option “Program Additional Card Key” and carry out the security access procedure (read out M-MDS outcode, and input corresponding incode). 09-12 Service Training Mazda3 F/LBody & Accessories Security and Locks Erasing registered card keys 1. Establish communication between M-MDS and the vehicle. 2. Select the option Toolbox->Body-»Security-»PATS Functions. 3. 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 systom to operate correctly Steering lock unit programming ‘+ Ifthe steering lock unit is replaced, the new unit must be programmed using M-MDS. NOTE: Do not program the steering lock unit while M-MDS or any other computer devicos are in the vehicle. Make sure all card keys are operational and have good batteries. NOTE: To program the steering lock unit a registered card key is necessary. If there is no registered card key, perform the card key programming first and then the steering lock unit programming. Bring a registered card key into the vehicle and close all the doors. Establish communication between M-MDS and the vehicle. Select the option Toolbox-»Body-»Security-»PATS Functions. Select the option “Steering Lock Unit Programming’ and carry out the security access. procedure (read out the M-MDS outcode, and input corresponding incode) Service Training Mazda3 F/L 09-13Security and Locks Body & Accessories Immobilizer System + AD-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. * Amaximum of eight keys can be registered. ‘+ The coil antenna is connected to the keyless control module, which communicates via the high-speed CAN bus to the PCM. ol 7° MaFL_09008 1 Coll antenna 5 Security light 2 Keyless control module 6 High-speed CAN bus 3 PCM 7 Rxline 4 Instrument cluster 8 Txline 09-14 Service Training Mazda3 F/LBody & Accessories Security and Locks Operation ‘+ Onvehicles 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, ® a wm = MaFL_o9007 1 Key (with integrated transponder) 4° Security light 2 Coilantenna 5 Keyless control module 3. Instrument cluster 6 PCM Service Training Mazda3 F/L 09-15Security and Locks Body & Accessories [Fhe ignition awitch & turned from Te LOOK (ACO) fo he ON START) position (security ight iluminates) Tha Kayiess convol module sends Gata Aw the Key transponder) via the col antenna. + [2 The key (ransponder) calculates data B from received data JA. and sends unique key ID number and data B to the keyless [contol module via the col antenna, Y [5 The keyless convrol module verlfes consistency between The roceived key ID number and the previously repistored key ID numbers. ‘SATISFACTORY RESULT [& The keyless control module makes a calouation using UNSATISFACTOR' received dala B and compares it with sont dala A. RESULT ‘SATISFACTORY RESULT y [The keyless coniral module requests data for vercalion Krom the Pon [BThe POM sends data ©” fo te hayiess contol module. ¥ 7. The kayless control module calculates data D from received ldata C and sends ito the PCM, [&. The POM makes a calculation using recewed data D a ‘and compares it with sent data ©. RESULT ‘SATISFACTORY RESULT y Engine staring i porniiog Engine staring fs not permed {securty ignt goes out alter approx. 3s), Arter detecting a faut (such as, *:Data A and C are ciferent random values each time. hon-verication or malfunction), tne security ight illuminates or hashes continuously for approx. min, and then repeatedly displays Ja DTC 10 mes. MaFL_To9008 09-16 Service Training Mazda3 F/LBody & Accessories Security and Locks Replacement of Immobilizer System Components [Operation [Necessary Preparation [Required Action |. Two or more programmed keysicard keys. |- One ore more keysioard keys to be programmed. JAdcing keysicard keys {two or more programmed keysicard keys available) Can be performed without M-MDS, providing “Customer spare key programming” function is enabled, i “customer spare key programming” function is cisabled, perform the fllowing procedure with M-MDS: Program Adkitional Ignition Key! Program Additional Cara Key lading keysicard keys fone oF no programmed keyieard key avaliable) |- One or more keysleard keys o be programmed. Perform the following procedure with M-MDS: Program Adtional Ignition Key! Program Adkitional Cara Key + Two or more keys clearing key IDs eee posers All kays forthe vehicle must be collected and programmed. Perform the following procedure with M-MDS: Ignition Key Code Erase + One or more card keys [tearing cars key bs [ne more cme Al card keys forthe vehicle must be collected and programmed. Perform the folowing procedure with M-MDS: Care Key Code Erase |. New PCM, + Keys to be programmed {two or more). Replacing PCM All keys forthe vehicle must be collected and programmed. Perform the folowing procedure with M-MDS: Parameter Reset |. New steering lock unit Replacing steering ock |» One programmed card key. lunit + Keys to be programmes {two or more). - Perform the folowing procedures with M-MDS in the incicates order: 1. Ignition Key Code Erase 2. Steering Lock Unt Programming + Now keyless control modula, + Card keys to be Replacing keyless contd | oe Aer ee + Keys to be programmed {two or more) + All keys and card keys for the vehicie must be collected ang programmed. . Perform the folowing procedures with M-MDS in the insicatee order 1. nition Key Code Erase 2. Parameter Reset 3. Caro Key Code Erase 4. Steering Lock Unit Programming Replacing insvumen jeentes |. New instrument cluster. No immobilizer system programming or resating necessary. Replacing coll antenna |+ New col antenna. No immobilizer systom programming or reseting necessary Mt ‘T09005 Service Training Mazda3 F/L 09-17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. To do this connect M-MDS to the vehicle and select the option Toolbox» Self Test-»Modules-»RKE. PID Monitor + The PID monitor function allows the PIDs for the Advanced Keyless Entry and Start System to be monitored. To do this connect M-MDS to the vehicle and select the option ‘Toolbox->Datalogger->Modules->RKE. sw p eo sch vrs coun oN nsw Ait [besa atows adit oN Rea Sire —— [pecan uth geste a Snot fruc sw rr tg lth switch OPEN Key romincer switch we. a ee pie ue Pet STF Sir 09-18 Service Training Mazda3 F/LBody & Accessories ‘Simulation Test © The simutatio Security and Locks st function allows certain PIDs for the Advanced Keyless Entry and Start System to be activated. To do this connect M-MDS to the vehiole and select the option Toolbox-»Datalogger-»Modules->RKE. Uni PID Applicable Component condition azALOUT, Exterior keyless buzzer ‘Onvort 7A IN iteror buzzer ‘OniOft NP_RED, Keyless waming igh ‘On/Off LNP_GREEN [Keyless indicator ight ‘OniOrt DR_LOCK [All doors lock Lock Off [DR_UNLOCK [Al coors unlook Unload OF [SUPERLOCK. [All doors doublelock Lock’ Off MaFL_To9003 Service Training Mazda3 F/L 09-19Exterior Trim Body & Accessories Exterior Trim Features ‘The design of the exterior trim is essentially carried over from that of the current Mazda 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) New aluminium alloy wheel designs for 15-, 16-, and 17-inch wheels = Seven new exterior colours (True Red (A4A), Aurora Blue (34), Galaxy Grey (82S) Icy Blue (33Y), Phantom Blue (32C), Phantom Purple (34N), Crystal White Pear! (34k) Modified boot opening design and new boot lid recess for improved accessibility (only 48D vehicles) — New underbody tyre deflectors and centre floor cover for improved aerodynamics 09-20 Service Training Mazda3 F/LBody & Accessories Exterior Trim Parts Location MSFL_09017, 1 Front mud flap 5 Radiator grile (Sports type) 2 Rear spoiler 6 Side step moulding 3 Radiator grile (standard type) 7 With Sports Appearance Package 4 Rear mud flap Service Training Mazda3 F/L 09-21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) — New white driver meters with indirect blue lighting for better readability (depending on vehicle grade) — New steering wheel adjustment lever design and energy absorbing padding added to steering column to reduce risk of knee injury New sound insulation under the bonnet and in the cabin roof Parts Location MBFL_09018 ‘Audio unit 5 Center console Glove box 6 Ashtray Storage box 7 Door pocket Cup holder 09-22 Service Training Mazda3 F/L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 lighttaillight has been added for 4SD vehicles (depending on vehicle grade), — Headlight auto-leveling contr Mazdas) | module connected to the DLC-2 (similar to that of the — Initialization procedure for the headlight auto-leveling control module has been added (similar to that of the Mazdas). Headlight Auto-leveling System Parts Location MBFL_09008 1 Auto-leveling control module 4 Auto-leveling sensor 2 Instrument cluster 5 Headlight leveling actuator 3 Auto-leveling waming light Service Training Mazda3 F/L 09-23Lighting Systems Body & Accessories Wiring Diagram ad M3FL_o9009 09-24 Service Training Mazda3 F/L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. ‘+ The auto-leveling control module must be initialized when any of the following procedures has been performed: = Front combination light replacement = Auto leveling control module replacement = Auto leveling sensor removaliinstallati n = Instrument cluster replacement — PUB replacement Replacement of suspension components or work that effects vehicle height * In order to activate the initialization procedure for the auto-leveling control module, connect M-MDS to the vehicle and select the option Toolbox-rElectrical-rExterior Lighting>Headlamp—Auto-leveling Sensor Re-zero Procedure. NOTE: in case the initialization procedure using M-MDS is not possiple, it can also be performed by connecting terminal B in the DLC-2 to ground (refer to the workshop manual for the detailed procedure). Service Training Mazda3 F/L 09-25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) Audio System Music Hard Disc Drive Specifications Tem Specification [HDD capacity 20 GB. [Playback signal compression method Eneypled MPS [Maximum recordable vacks 3000. [Maximum recordable aloums 999 Favourite track repistration capacity Number of favoria Tater 4 Number of reisterable racks per list: 100, category registration capacity ‘Number of categories: 5 Number of registarabe albums per category: 999 MaFL_Tos008 09-26 Service Training Mazda3 F/LBody & Accessories Entertainment Parts Location MBFL_99014 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 10 Remote contro! 5HB vehicles) Service Training Mazda3 F/L 09-27Entertainment Body & Accessories System Overview ® ? —— 1® ® 1® ® Leq@ Ot; a@ ® 1® S| ® PP -1@ LSI L@ | L@ CoH) © I), /tas O-H| |}_1@ or }—1@) 1 Antenna 10 Front tweeter (right) 2 Center panel module (integrated in audio 11 Front door speaker (right) unit) 4 Audio control switches 13 Front tweeter (left) 5 TNS signal 14 Rear door speaker (right) 09-28 Service Training Mazda3 F/LBody & Accessories Entertainment Audio Uni ‘+ 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 Mazdas. NOTE: Further information can be found in the Training Manual “Mazdas” (NMT-007). ‘+ Depending on whether or not the audio unit is equipped with music HDD, the base unit is different, MaFL_09011 1 Center pane! module 5 Lower module 2 Information display 6 Cover (with lower module) 3 Base unit (without music HDD) 7 Cover (without lower module) 4 Base unit (with music HDD) 8 Cover Service Training Mazda3 F/L 09-29Instrumentation/Driver Info Body & Accessories Instrumentation/Driver Info Features ‘+ The construction and operation of the instrumentation/criver information system is, essentially carried over trom that of the current Mazda except for the following features: — Odometer write procedure for the instrument cluster has been added (similar to that, of the Mazdas), = Freeze frame data providing information about the instrument cluster control status at the occurrence of a fault have been added = Driver-side seat belt reminder system replaced by front seat belt reminder system — Rear sear belt reminder system has been introduced (similar to that of the Mazdaé FIL). Instrument Cluster Overview MaFL_09015 09-30 Service Training Mazda3 F/LBody & Accessories Instrumentation/Driver Info No] Tem Taput signal source | CAN system Note 1 [EXPAS waming Wht FEHPAS contol module x. [Gi pressure switch Win 137 B2ONZR engine 2 [oi pressure warning Hight pow x Wh L6H CO engine 5 [Tomine pe x 4 [ass waring tight Bee uc x — = [arvana igh pow x WRATE 6 [green neater rus x = 7 ]pst ndeatoriart scrum x [Setesoriionr gh pow x WAT [bag ston waring [SAS cone moa x = 10 oor air warn atts x 11 ns indstor igh TNS op = = 12 [ontop nator ight Fron on ey = = 13 arog nator tnt Poa fo ig crite redesign Cae 1 [Ore nda ow x Withers contol system 5 [et eve wring i Fue gauge sondorunt | = = 16 [Generar waring ight [Pom x 17 [Seat ba waving ig SAS cont meas x = > Colarera x |W sarees oy 18 [Security light pbs Seen PRevessconrarmoaie | | Wit Avanced KeveasEnRy us 2d Sat Syaom 72 [bSC.OFF nakatorign osc HuicM x = 2 [ashore evel wring gh Washor oval sane 21 oyosswarinpinacatoriont |keyoss convmeaue | x | Wi AbancedKaylssEnty OSC RUC 22 roe stem waringtan [ABS HLCM x - Sua 3 | Sowa pow x Wik Lenz OO anaes 2a Pox x eaaigh ao ovaingwaring [A ovo 2s fen ewaring [Aeon — | winters easton WGFL_T090T7 Service Training Mazda3 F/L 09-31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->1C. ‘+ The odometer write procedure can only be conducted once. However, the new instrument cluster must display less than 100 km for the mileage data to be uploaded. If a cluster with 100 km or more is configured, M-MDS will display an error message after configuring, inaicating that the procedure failed. In this situation, all data other than the mileage will have been uploaded into the new instrument cluster, so that the configuration is actually successful ‘+ Inorder to upload the mileage data to anew instrument cluster with an odometer setting of 100 km or more, perform the odometer write procedure after completing the instrument cluster configuration. To do this select the option Toolbox-»Module Programming->Programmable Parameters—>Odometer Write. During this procedure M-MDS will request the user to input As-built data (VIN and Vehicle Data) NotI Do NOT delete the M-MDS session until the odometer write procedure is completed. Otherwise it is not possible anymore to upload the mileage data to the new instrument cluster NOTE: In case the old instrument cluster is electrically damaged and therefore the configuration data cannot be read, the odometer write procedure cannot be performed. 09-32 Service Training Mazda3 F/L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. ‘+ The FFD is very helpful to diagnose the potential causes of a malfunction, especially when the malfunction is currently not present, * When a fault is detected, the following data is stored in the instrument cluster memory: Tair FFD Description Condition [Type of malfunction that oocurred: + Communication errs of ether modules Mattunetion type + Abnormal messages trom the POM = + Waring ight illumination request signal from other moaules [Warning ight that was iluminated due to the malfunction. + Alrbag system warning light + Generator warring light, r MIL Waring font contol status | 7 ening ght 7 + Brake system warning light + AT warning light + Keyless warning light Meter/Gauge that fallee due tothe malfunction: + Speedometer Tachometer + Water temperature gauge [Traveled cistance when DTC was recorded (only the last Tour digits are recorded) MeteriGauge contol status Traveled distance km Cleared! Dre status Status of the DTC that was stored due to the malfunction eres MaFL_To2010 * The FFD can be read out using M-MDS via the option Toolbox-rElectrical-vIC Service Functions. NOTE: he FFD will not be cleared even if the corresponding DTC is cleared using M-MDS, In this case, only the DTC status will be set to “Cleared” Service Training Mazda3 F/L 09-33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 waming light and warning chime (the latter two are integrated in the instrument cluster). OO® rear AMM MaFL_09016 1 Seat belt reminder indicator 4 Rear center seat belt indicator light 2 Passenger seat belt warning light 5 Rear right seat belt indicator ight 3 Rear left seat belt indicator light, Buckle Switches ‘* The buckle switches are integrated in the seat belt buckles and detect, whether or not the seat belts are buckled. When the seat belt is unbuckled, the switch supplies ground to the SAS control module (driver-side/passenger-side buckle switch) or to the seat belt reminder indicator (rear buckle switches). Occupancy Sensor ‘+ The occupancy sensor is integrated in the passenger seat cushion and detects, whether or not the passenger seat is occupied. When a weight of approx. 15 kg or more acts on. the passenger seat, the sensor supplies ground to the SAS control module. 09-34 Service Training Mazda3 F/LBody & Accessories Instrumentation/Driver Info Microcomputer Buzzer Driver seat belt warning light Generator warning ight Instrument cluster Passenger seat belt warning light Red (seat belt unfastened) Green (seat belt fastened) Rear left seat belt indicator light Rear center seat belt indicator light " 12 13 “4 15 16 7 18 19 MaFL_09013 Rear right seat belt incicator light Buckle switch (rear left) Buckle switch (rear center) Buckle switch (rear right) ‘Seat belt reminder indicator SAS control module Buckle switch (driver side) Buckle switch (passenger side) (Occupancy sensor Service Training Mazda3 F/L 09-35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" signal via the mid-speed CAN bus to the instrument cluster. When the vehicle speed is 20 km/h or more, the SAS control module additionally sends “seat belt warning chime on request’ signal to the instrument cluster. Depending on the signals from the 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 warming chime, , Condition Vehicle speed less than 20 km/h Vehicle speed 20 kmih or more Driver seat bet ° ° x x ° ° x x Passenger seat belt ° x ° x ° x ° x pias ala % Pasconge seal bat warning igre & & * Waring chime D{+ ° Fastened SE Flashing x Untastened Dp A Mluminatos Se MaFL_Toao09 ‘+ The instrument cluster deactivates the warning chime 90 s after the last activation, even if the vehicle speed drops below 20 km/h before the 90 s have elapsed. NOTE: The driveripassenger seat belt warning chime can be deactivated using M-MDS via the option Toolbox->Module Programming-»Programmable Parameters—> Warning LampsiChimes. 09-36 Service Training Mazda3 F/L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. The colour of the indicator light provides information about the status of the seat belts: = Ifthe indicator light is illuminated in red, the corresponding seat belt is unfastened (seat belt is unbuckled). = Ifthe indicator light is illuminated in green, the corresponding seat belt is fastened (seat belt is buckled) + In addition, the warning chime of the seat belt reminder indicator sounds for 0.5 s, when. a seat belt is unfastened while the engine is running, * The seat belt reminder indicator deactivates all rear seat belt indicator lights either 40 s after engine start (i.e. after the generator warning light is off) or 40 s after the last activation (in case the indicator lights have been activated while the engine is running). Service Training Mazda3 F/L 09-37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 Mazdas) Controller Area Network * On vehicles with Advanced Keyless Entry and Start System the keyless control module is connected to the high-speed CAN bus. MaFL_09012 09-38 Service Training Mazda3 F/LBody & Accessories Control System High-speed CAN bus PCM (ZiIZ6 engine) POM (LF engine) POM (1.6 MZ-CD engine) EHPAS control module With 2.0 MZR/1.6 MZ-CD engine ‘ABS HUICM DSC HU/CM Keyless control module With Advanced Keyless Entry and Start System 10 Twisted pair 11 Instrument cluster worennens> 12 13 14 16 16 7 18 19 20 a1 22 Mid-speed CAN bus DLo-2 Fuel adaitive control module With 1.6 MZ-CD high-power engine Climate control unit With full-auto A/C. SAS control module Information display PUB Audio unit (base unit) CAN high CAN low Service Training Mazda3 F/L 09-39Control System Body & Accessories High-speed CAN Signal Chart ‘+ The following signals are transmitted via the high-speed CAN bus. Wutiplex module Signal ERPAS | assnurom | Feve8 | cramom rou | racucn | contol conve | Heures mmadue2) [oscHUCM | medue (3) a aed OOF W W i W WT Weise our W W = W rN Erin rue our x = RE SOT okra pal poston 2) = — = =o = | Throttle position (4) ouT - = ix - = rake position KU — our ("ty [Brake Pedal ‘OUT 1N [car poten i = — = Sar tx oear pre Saeco = lever position (ATX) our — " N — " rasa epecteaione our = Era spectators our = - = = = fcc wane oon out = — = = = iran OTTER [xn out — = — = ww fom eon eqs WN = — = = = Fame eticion wick our = [Immobiizer-related inormation x _ _ _ — OUT [3 oor rs iota orator [Tk = = = oo = = OUT W rome coomTeapeaia [our = = = = W fraeaastrce OUT i Fotos noo OUT ie W 7 = a onreuest af on — — — = Sara wa ToT os = = = = . erence iN = — our = = i ex = a itn 16 §zCO Nh some erie “2. wih 20 Mair eMz0D ene “2: Wh Advanced Kegess Enty ard Stan Siem “As twih ane 2A wg “5: th sankey ery stem “e:min euzcD ence vars_ros08 09-40 Service Training Mazda3 F/LBody & Accessories Control System Maplex module Signal ERPAS | aasnuem | RFPS 1 cimon pom | Fact) | contol conirot_ | Imstumer module (2) [ BSCHUCM | module (3) [ERPAS waring Herron eaves o — = our = = N [race anton sats EBD 7 7 JaasiDso) N oy Wheel sees (UF, AF,LR.AR) | IN = — our — — [Bake aren waning ighon or N [ABs warming tht on request = = = our = Nw lose inscatrigteonreqest | — = = x = W [OSC OFF scat tgieo = N roves omr Secury TaFton eae or w Keyias waringincestr Doe our WN on request) rtror buzz on requesti'3) | = = = our W [ruse conto systr-eated 7 lnormation C8) N our [cuse/Cnise man ndewor our = = = = n ign on request Fuctiank ove w my = = = our setae ssconareat [5 our ave Wssion ahs w ou = = = = [oc onreaves w = = = = our Hansa in reverse postion Tt = = = = ‘our Parang brake postion im ‘our Brace tudlevel im ‘our [noir emperatre ir ‘our [Fon wipe aus i ‘Our FINS sas ih = = = = ‘OUT [PTC heatoron eases) in = = = = ‘our igrrseew an rene | our = = = = N [i presre waring Ta on = 7 request (6) ov " [Generator nad TO) our = = = = iw [Generar contol ry eyee 8] OUT = = = = N +1 With 162.60 high ome onoine “2: With 20 MZAVI.S M200 ersine “3 Wi Advarced Keyless Enty and Stan Syston 4 With 1371.6 MZR engine *5: Wh standardkeyees ery systom 8: With 18MZ-CD engine aF_Tosoo6a Service Training Mazda3 F/L 09-41Control System Body & Accessories Mid-speed CAN Signal Chart ‘+ The following signals are transmitted via the mid-speed-CAN bus. Taper noe signa po | ota] as conv] Ato unt | ttormaton | tnsvument rotont | trode | eeeount | euply” | ster soa a T 7 octamer sans oor} — i = = = i fur rdcatrighonveaass | our | — = = = " Say Ta aT OOF im faamormaest oT = = = = i oe ar wang Ton a = = = T ect Sea taiear oO H rage aaa TOT request our = = = = N Frac Rave poate [OUT in Pac bas pom oF i iar ore oroearor is or [eave oT wc on request a Sut = = = = (C on venues ‘OUT = 1 = 5 iW oF x [Froteowroreqesit | = Cea aay waaeT ons = = x 8 fsbag eytonwariegonron | = . = ~ n request out ig nom aS] —— =p = T ote sea = orf = = in eatateares on - . request ~ ~ oul Seat bat wary ozo] = - = = a request out : oT im Teme — Se iRroaior eae = = = sir} coin orgy eae —[—— = oe = [ssgreeel i = = = Bar fetabst i m 7 7 OF (engreroarcompears —| Wh it = = =r eae eee = = = =r iat ey Soo = = = H oT icy or Mao = r status N our Diverioraioneren can | — — = = w [om Soma rm OF wera cono yoo 2] N our + inte AC “2. Win te Mz engre art toe? 09-42 Service Training Mazda3 F/LAppendix Mazda3 Product Changes History ‘+ This section describes the product changes introduced during the cost reduction FiL of, the Mazda 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) Engine ‘+ Fuel filter with separate fuel warmer replaced by fiter wth integrated fuel warmer (only vehicles with 1.6 MZ-CD engine) Steering ‘+ Steering angle sensor integrated in the steering gear replaced by steering angle sensor at the steering wheel (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 & Accessories * Black leather seats and seat warmer added for left-hand drive vehicles (optional) ‘+ Separate key and transmitter replaced by retractable key with integrated transmitter. ‘+ Body-coloured outer door handles, side mouldings and outer mirrors replaced by black coloured components (only for Base grade) * Rear ash tray, subtrunk box and trunk hooks deleted (the latter two only on SHB: vehicles). ‘* Door trim material modified. '* Red-coloured rear combination lamp bezel replaced by black-coloured bezel (except for Sports grade). Service Training Mazda3 F/L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). ‘+ Navigation system without TMC replaced by navigation system with TMC. ‘+ Information display connected to the audio unit replaced by information display connected to the mid-speed CAN bus. Exterior colour Carbon Grey (288) added. Service Training Mazda3 F/LList of Abbreviations ABS AIC AT ATX BDC CAN cp pe DLC D-PATS DPF psc pTc EBD EGR Anti-lock Brake System Air Conditioning Automatic Transmission Automatic Transaxle Bottom Dead Center Controller Area Network Compact Disc Direct Current Data Link Connector Distributed PATS Diesel Particulate Filter Dynamic Stability Control Diagnostic Trouble Code Electronic Brakeforce Distribution Exhaust Gas Recirculation EHPAS FACM FFD FL GR HDD HUICM. aT Isv LED MAF MIL Electro-Hydraulic Power Assist Steering Fuel Additive Control Module Freeze Frame Data Face Lift Gear Ratio Hard Disk Drive Hydraulic UnitiControl Module Intake Air Temperature Instrument Cluster Identification Intake Shutter Valve Light Emitting Diode Mass Air Flow Malfunction Indicator Light Service Training Mazda3 F/LList of Abbreviations M-MDS MP3 PAD PATS Pom PID PUB PTC RKE SAS Tec Toc ™c TNS Mazda-Modular Diagnostic System Music Picture Experts Group Layer-3 Passenger Airbag Deactivation Passive Anti-Theft System Powertrain Control Module Parameter ID Passenger Junction Box Positive Temperature Coefficient Remote Keyless Entry Sophisticated Airbag Sensor Torque Converter Clutch Top Dead Center Traffic Message Channel Tail Number-/Sidelights vec vIN vss 4sD 5HB Variable Boost Control Vehicle Identification Number Vehicle Speed Sensor 4-door Sedan 5-door Hatchback Service Training Mazda3 F/L