Mazda 3 Workshop Manual
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Mazda 3 Workshop Manual

Engine + wiring diagrams + diagnostic trouble codes
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Table of Contents

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Mazda 3 Workshop Manual - Engine + Wiring Diagrams + Diagnostic Trouble Codes

Mazda 3 Workshop Manual -
Engine + Wiring Diagrams +
Diagnostic Trouble Codes
Contents
CONTROL SYSTEM WIRING DIAGRAM [Z6] .................................................................................... 23
OBD PENDING TROUBLE CODE [Z6] ................................................................................................ 26
OBD FREEZE FRAME DATA [Z6] ........................................................................................................ 27
OBD ON-BOARD SYSTEM READINESS TEST [Z6] ......................................................................... 28
OBD READ/CLEAR DIAGNOSTIC TEST RESULT [Z6] ................................................................... 29
OBD PARAMETER IDENTIFICATION (PID) ACCESS [Z6] ............................................................. 30
ON-BOARD DIAGNOSTIC TEST [Z6] .................................................................................................. 31
DTC Reading Procedure ..................................................................................................................... 31
Pending Trouble Code Access Procedure ....................................................................................... 31
Freeze Frame PID Data Access Procedure ..................................................................................... 31
On-Board System Readiness Tests Access Procedure ................................................................. 32
PID/DATA Monitor and Record Procedure ....................................................................................... 32
Diagnostic Monitoring Test Results Access Procedure .................................................................. 33
AFTER REPAIR PROCEDURE [Z6] ..................................................................................................... 34
OBD DRIVE MODE [Z6] .......................................................................................................................... 35
PCM Adaptive Memory Produce Drive Mode .................................................................................. 35
HO2S heater, HO2S, and TWC Repair Verification Drive Mode .................................................. 36
DTC TABLE [Z6] ....................................................................................................................................... 38
DTC P0011 [Z6] ........................................................................................................................................ 44
DTC P0012 [Z6] ........................................................................................................................................ 47
DTC P0031 [Z6] ........................................................................................................................................ 50
DTC P0032 [Z6] ........................................................................................................................................ 54
DTC P0037 [Z6] ........................................................................................................................................ 57
DTC P0038 [Z6] ........................................................................................................................................ 61
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Summary of Contents for Mazda 3

  • Page 1: Table Of Contents

    Engine + Wiring Diagrams + Diagnostic Trouble Codes Contents Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ........ 1 CONTROL SYSTEM WIRING DIAGRAM [Z6] ..................23 MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [Z6] ..25 OBD PENDING TROUBLE CODE [Z6] ....................
  • Page 2 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0102 [Z6] ............................64 DTC P0103 [Z6] ............................68 DTC P0111 [Z6] ............................72 DTC P0112 [Z6] ............................75 DTC P0113 [Z6] ............................78 DTC P0117 [Z6] ............................82 DTC P0118 [Z6] ............................
  • Page 3 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0703 [Z6] ............................176 DTC P0704 [Z6] ............................179 DTC P0850 [Z6] ............................182 DTC P1260 [Z6] ............................185 DTC P2006 [Z6] ............................186 DTC P2008 [Z6] ............................188 DTC P2088 [Z6] ............................
  • Page 4 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes AFTER REPAIR PROCEDURE [LF] ....................253 OBD DRIVE MODE [LF] ........................253 Mode 1 (PCM Adaptive Memory Produce Drive Mode) ............... 254 Mode 3 (HO2S heater, HO2S, and TWC Repair Verification Drive Mode) ....... 254 DTC TABLE [LF] .............................
  • Page 5 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0480 [LF] ............................354 DTC P0500 [LF] ............................357 DTC P0505 [LF] ............................358 DTC P0506 [LF] ............................360 DTC P0507 [LF] ............................363 DTC P0511 [LF] ............................365 DTC P0602 [LF] ............................
  • Page 6 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK [Z6] ....451 NO.5 ENGINE STALLS-AFTER START/AT IDLE [Z6] ..............455 NO.6 CRANKS NORMALLY BUT WILL NOT START [Z6] ............. 461 NO.7 SLOW RETURN TO IDLE [Z6] ....................
  • Page 7 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Load compensation inspection ..................... 528 Variable Intake-air Control Operation Inspection ................529 Variable Tumble Control Operation Inspection ................530 Fuel Injector Operation Inspection ....................530 Fuel Cut Control System Inspection ....................531 Fuel Pump Operation Inspection......................
  • Page 8 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes NO.19 EXHAUST SMOKE [LF] ......................601 NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [LF] .............. 604 NO.21 ENGINE NOISE [LF] ......................... 606 NO.22 VIBRATION CONCERNS (ENGINE) [LF] ................608 NO.23 A/C DOES NOT WORK SUFFICIENTLY [LF] ...............
  • Page 9 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DRIVE BELT AUTO TENSIONER INSPECTION [Z6] ..............636 VALVE CLEARANCE INSPECTION [Z6] ................... 637 VALVE CLEARANCE ADJUSTMENT [Z6]..................638 COMPRESSION INSPECTION [Z6] ....................645 TIMING CHAIN REMOVAL/INSTALLATION [Z6] ................646 Crankshaft Pulley Installation Bolt Removal Note .................
  • Page 10 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Spool Valve Operation Inspection ....................676 ENGINE TUNE-UP [Z6] ......................... 677 Engine Tune-up Preparation ......................677 Ignition Timing Inspection ......................... 678 Idle Speed Inspection ........................680 Idle Mixture Inspection ........................681 MECHANICAL .............................
  • Page 11 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Crankshaft Pulley Lock Bolt Removal Note ..................712 Front Oil Seal Removal Note ......................713 Front Oil Seal Installation Note ......................713 Crankshaft Pulley Lock Bolt Installation Note ................714 REAR OIL SEAL REPLACEMENT [LF] ....................
  • Page 12 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes OIL PUMP REMOVAL/INSTALLATION [LF] ..................745 Oil Pump Sprocket Removal/Installation Note ................746 Oil Pump Installation Note ......................... 747 OIL PUMP DISASSEMBLY/ASSEMBLY [Z6] ..................747 Inner Rotor, Outer Rotor Installation Note ..................748 OIL PUMP INSPECTION [Z6] ......................
  • Page 13 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Air Hose Installation Note ........................776 Fresh-air Duct Installation Note ......................776 Strap Installation Note ........................776 PCM Connector Installation Note ..................... 777 AIR CLEANER ELEMENT INSPECTION [Z6] ................... 777 IDLE AIR CONTROL (IAC) VALVE REMOVAL/INSTALLATION [Z6] ...........
  • Page 14 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INTAKE-AIR SYSTEM MANIFOLD VACUUM INSPECTION [LF] ..........790 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF] ..............791 Fresh-air Duct Removal Note ......................793 Intake Manifold Removal Note ......................793 Air Cleaner Case Installation Note ....................793 Strap Installation Note ........................
  • Page 15 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel-filler Pipe Removal Note ......................811 Joint Hose Installation Note ......................811 Breather Hose Installation Note ....................... 811 FUEL TANK INSPECTION ........................812 NONRETURN VALVE INSPECTION ....................813 FUEL PUMP UNIT REMOVAL/INSTALLATION ................
  • Page 16 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel Injector Operation Inspection ....................832 Fuel Cut Control Inspection ......................833 Resistance Inspection ........................834 Circuit Open/Short Inspection [LF] ....................834 Circuit Open/Short Inspection [Z6] ....................835 Leakage Inspection ..........................
  • Page 17 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes EGR VALVE REMOVAL/INSTALLATION [LF] .................. 861 Water Hose Removal Note [LF] ....................... 862 EGR Valve Removal Note [LF] ......................862 EGR VALVE REMOVAL/INSTALLATION [Z6] .................. 862 EGR VALVE INSPECTION ........................863 EGR Control Inspection ........................
  • Page 18 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Generator warning light ........................880 Generator ............................. 881 Voltage ............................. 881 Current ............................. 882 IGNITION SYSTEM ............................883 IGNITION SYSTEM LOCATION INDEX [Z6] ..................883 IGNITION SYSTEM LOCATION INDEX [LF] ..................883 IGNITION COIL REMOVAL/INSTALLATION [Z6]................
  • Page 19 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Not Using the WDS or Equivalent ....................902 PCM terminal voltage table (Reference) ..................902 Inspection Using An Oscilloscope (Reference) ................913 Input/turbine speed sensor (-) signal ................... 913 Input/turbine speed sensor (+) signal ..................
  • Page 20 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Continuity Inspection .......................... 937 Circuit Open/Short Inspection ......................937 Open circuit ............................. 938 Short circuit ............................938 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6] ..938 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [Z6] ......... 939 Continuity Inspection ..........................
  • Page 21 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes MASS AIR FLOW (MAF)/INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION [Z6] ......................951 MASS AIR FLOW (MAF) SENSOR INSPECTION [Z6]..............952 Visual inspection ..........................952 Voltage Inspection ..........................952 Circuit Open/Short Inspection ......................
  • Page 22 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Short circuit ............................964 ENGINE TECHNICAL DATA ........................ 964 SERVICE TOOLS ............................969 ENGINE SST [Z6] ........................... 969 ENGINE SST [LF] ........................... 970 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 23: Control System Wiring Diagram [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes CONTROL SYSTEM WIRING DIAGRAM [Z6] B3E010200102W12 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 24 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 25: Monitoring System And Control System Device Relationship Chart [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [Z6] B3E010200102W13 ×: Applicable Component Input × × × × × ECT sensor × × × × × IAT sensor ×...

  • Page 26: Obd Pending Trouble Code [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes OBD PENDING TROUBLE CODE [Z6] B3E010200102W14 • These appear when a problem is detected in a monitored system. The code for a failed system is stored in the PCM memory in the first drive cycle. This code is called the pending code. If the problem is not found in a second drive cycle, the PCM judges that the system returned to normal or the problem was mistakenly detected, and deletes the pending code (1DC).

  • Page 27: Obd Freeze Frame Data [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes OBD FREEZE FRAME DATA [Z6] B3E010200102W15 • This is the technical data which indicates the engine condition at the time of the first malfunction. This data will remain in the memory even if another emission-related DTC is stored, with the exception of fuel system or misfire DTCs.

  • Page 28: Obd On-Board System Readiness Test [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes OBD ON-BOARD SYSTEM READINESS TEST [Z6] B3E010200102W16 • This shows the OBD systems operating status. If any monitor function is incomplete, WDS or equivalent will identify which monitor function has not been completed. The fuel system, misfire and CCM are continuous monitoring-type functions.

  • Page 29: Obd Read/Clear Diagnostic Test Result [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes OBD READ/CLEAR DIAGNOSTIC TEST RESULT [Z6] B3E010200102W17 • This retrieves all stored DTCs in the PCM and clears the on-board readiness test results, freeze frame data, DTC, diagnostic monitoring test results and pending trouble code.

  • Page 30: Obd Parameter Identification (Pid) Access [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes OBD PARAMETER IDENTIFICATION (PID) ACCESS [Z6] B3E010200102W18 • The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. Since the PID values for output devices are the PCM internal data values, inspect each device to identify which output devices are malfunctioning.

  • Page 31: On-Board Diagnostic Test [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ON-BOARD DIAGNOSTIC TEST [Z6] B3E010200102W19 DTC Reading Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.

  • Page 32: On-Board System Readiness Tests Access Procedure

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Record the freeze frame PID data using the WDS or equivalent. On-Board System Readiness Tests Access Procedure 1. Perform the necessary vehicle preparation and visual inspection.

  • Page 33: Diagnostic Monitoring Test Results Access Procedure

    1. Perform the necessary vehicle preparation and visual inspection. 2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment. 3. Access to the diagnostic monitoring test results and read the test results using the WDS or equivalent. Downloaded from https://carmanualshub.com/...

  • Page 34: After Repair Procedure [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes AFTER REPAIR PROCEDURE [Z6] B3E010200102W20 1. Connect the WDS or equivalent to the DLC-2. 2. Cycle the ignition switch off, then to the ON position (Engine off).

  • Page 35: Obd Drive Mode [Z6]

    3. Idle the engine for more than 120 s. 4. Perform no load racing at the engine speed of 2,800-3,200 rpm for more than 30 s. 5. Idle the engine for more than 30 s after the cooling fan stopped.

  • Page 36: Ho2S Heater, Ho2S, And Twc Repair Verification Drive Mode

    2. Verify that all accessory loads (A/C, headlights, blower fan, rear window defroster) are off. 3. Drive the vehicle as shown in the graph; first drive in zone O, then A or B, followed by C or D, finally E or F.
  • Page 37 4. Stop the vehicle and access the ON BOARD SYSTEM READINESS to inspect the Drive Mode completion status. • If completed, RFC changes from No to Yes. • If not completed, turn the ignition switch off, then go back to Step 3. 5. Verify that no DTCs are available. Downloaded from https://carmanualshub.com/...

  • Page 38: Dtc Table [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC TABLE [Z6] B3E010200102W22 ×: Applicable -: Not applicable Monitor Memory Condition Page item function (See DTC P0011 × P0011 CMP-timing over-advanced [Z6].) (See DTC P0012 ×...
  • Page 39 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See DTC P0123 × P0123 TP sensor circuit high input [Z6].) Insufficient coolant temperature for (See DTC P0125 × P0125 closed loop fuel control [Z6].) (See DTC P0132 ×...
  • Page 40 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Purge solenoid valve circuit (See DTC P0443 × P0443 problem [Z6].) (See DTC P0480 × P0480 Cooling fan control circuit problem Other [Z6].) (See DTC P0500 ×...
  • Page 41 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Transaxle fluid temperature (TFT) P0712 sensor circuit malfunction (short to (See DTC TABLE [FN4A-EL].) ground) Transaxle fluid temperature (TFT) P0713 sensor circuit malfunction (open (See DTC TABLE [FN4A-EL].)
  • Page 42 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Shift solenoid D malfunction P0768 (See DTC TABLE [FN4A-EL].) (electrical) P0771 Shift solenoid E stuck off (See DTC TABLE [FN4A-EL].) P0772 Shift solenoid E stuck on (See DTC TABLE [FN4A-EL].)
  • Page 43 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See DTC P2229 × P2229 BARO sensor circuit high input [Z6].) (See DTC P2502 P2502 Charging system voltage problem [Z6].) (See DTC P2503 P2503 Charging system voltage low [Z6].)

  • Page 44: Dtc P0011 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0011 [Z6] B3E010200001W01 DTC P0011 CMP-timing over-advanced • The actual valve timing is over-advanced from the target valve timing when the OCV is controlled within the maximum valve timing retard condition.
  • Page 45 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION [Z6].) • Inspect the position of the spool valve in the OCV. (See OIL CONTROL VALVE (OCV) INSPECTION [Z6].) • Is the spool valve located at valve retard...
  • Page 46 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "AFTER REPAIR (See DTC TABLE [Z6].) PROCEDURE". (See AFTER REPAIR PROCEDURE [Z6].) No DTC troubleshooting completed.

  • Page 47: Dtc P0012 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0012 [Z6] B3E010200001W02 DTC P0012 CMP-timing over-retarded • The actual valve timing is over-retarded from the target valve timing when the OCV system control is within feed-back range.
  • Page 48 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify related service repair information availability. No Go to the next step. • Is any related repair information available? VERIFY ENGINE OIL PRESSURE Inspect engine oil pressure, then go to Step 7.
  • Page 49 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch to the ON position (Engine off). • Clear the DTC from the PCM memory using WDS or equivalent. • Start the engine.

  • Page 50: Dtc P0031 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0031 [Z6] B3E010200001W03 DTC P0031 Front HO2S heater control circuit low • The PCM monitors front HO2S heater control voltage at PCM terminal 2AM. If PCM turns front HO2S heater off but front HO2S heater circuit has low voltage, PCM determines that front HO2S heater circuit has malfunction.
  • Page 51 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.
  • Page 52 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [Z6].) No Go to the next step. • Is there any malfunction? INSPECT FRONT HO2S HEATER POWER Yes Go to the next step.
  • Page 53 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "AFTER REPAIR PROCEDURE". (See DTC TABLE [Z6].) (See AFTER REPAIR PROCEDURE [Z6].) No DTC troubleshooting completed.

  • Page 54: Dtc P0032 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0032 [Z6] B3E010200001W04 DTC P0032 Front HO2S heater control circuit high • The PCM monitors the front HO2S heater control voltage at PCM terminal 2AM. If the PCM turns the front HO2S heater on but the front HO2S heater circuit has high voltage, the PCM determines that the front HO2S heater circuit has a malfunction.
  • Page 55 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 56 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the front HO2S heater. (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6].) (See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [Z6].) No Go to the next step.

  • Page 57: Dtc P0037 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0037 [Z6] B3E010200001W05 DTC P0037 Rear HO2S heater control circuit low • The PCM monitors the rear HO2S heater control voltage at PCM terminal 2AT. If the PCM turns the rear HO2S heater off but the rear HO2S heater circuit has low voltage, the PCM determines that the rear HO2S heater circuit has a malfunction.
  • Page 58 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.
  • Page 59 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See REAR HEATED OXYGEN SENSOR (HO2S) INSPECTION [Z6].) No Go to the next step. • Is there any malfunction? INSPECT REAR HO2S HEATER POWER Yes Go to the next step.
  • Page 60 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "AFTER REPAIR PROCEDURE". (See DTC TABLE [Z6].)

  • Page 61: Dtc P0038 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0038 [Z6] B3E010200001W06 DTC P0038 Rear HO2S heater control circuit high • The PCM monitors the rear HO2S heater control voltage at PCM terminal 2AT. If the PCM turns the rear HO2S heater on but the rear HO2S heater circuit has high voltage, the PCM determines that the rear HO2S heater circuit has a malfunction.
  • Page 62 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 63 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the voltage B+? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P0038 COMPLETED (See PCM REMOVAL/INSTALLATION [Z6].) • Make sure to reconnect all disconnected connectors.

  • Page 64: Dtc P0102 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0102 [Z6] B3E010200100W01 DTC P0102 MAF sensor circuit low input • The PCM monitors the input voltage from the MAF sensor when the engine is running. If the input voltage at PCM terminal 2AU is less than 0.21 V, the PCM determines that the MAF circuit has a malfunction.
  • Page 65 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 66 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there any malfunction? INSPECT MAF SENSOR CIRCUIT FOR Repair or replace the wiring harness for a SHORT TO GND possible short to GND, then go to Step 8.
  • Page 67 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory No Go to the next step. using the WDS or equivalent.

  • Page 68: Dtc P0103 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0103 [Z6] B3E010200100W02 DTC P0103 MAF sensor circuit high input • The PCM monitors the input voltage from the MAF sensor when the engine is running. If input the voltage at PCM terminal 2AU is more than 4.9 V, the PCM determines that the MAF circuit has a malfunction.
  • Page 69 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 70 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT MAF SENSOR SIGNAL CIRCUIT Repair or replace the wiring harness for a FOR SHORT TO POWER SUPPLY possible short to power supply, then go to Step 8.
  • Page 71 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Are any DTCs present? Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 72: Dtc P0111 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0111 [Z6] B3E010200100W03 DTC P0111 IAT sensor circuit range/performance problem • The PCM compares the IAT with the ECT when the engine is running. If the IAT is higher than the ECT by 40 °C {104 °F}, the PCM determines that there...
  • Page 73 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA Yes Go to the next step. HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 74 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there any malfunction? VERIFY TROUBLESHOOTING OF Replace the PCM, then go to the next step. DTC P0111 COMPLETED (See PCM REMOVAL/INSTALLATION [Z6].) • Make sure to reconnect all disconnected connectors.

  • Page 75: Dtc P0112 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0112 [Z6] B3E010200100W04 DTC P0112 IAT sensor circuit low input • The PCM monitors the IAT sensor signal at PCM terminal 2AQ. If the PCM detects that the IAT sensor voltage is less than 0.16 V, the PCM determines that the IAT sensor circuit has a malfunction.
  • Page 76 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 77 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT IAT SENSOR SIGNAL Repair or replace the wiring harness for a CIRCUIT FOR SHORT TO GND possible short to GND, then go to Step 7.

  • Page 78: Dtc P0113 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0113 [Z6] B3E010200100W05 DTC P0113 IAT sensor circuit high input • The PCM monitors the input voltage from the IAT sensor. If the input voltage at PCM terminal 2AQ is more than 4.8 V, the PCM determines that the IAT sensor circuit has a malfunction.
  • Page 79 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 80 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT IAT SENSOR SIGNAL Repair or replace the wiring harness for a...
  • Page 81 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Clear the DTC from the PCM memory using the WDS or equivalent. • Start the engine. • Is the same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection.

  • Page 82: Dtc P0117 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0117 [Z6] B3E010200100W06 DTC P0117 ECT sensor circuit low input • The PCM monitors the ECT sensor signal at PCM terminal 2J. If the PCM detects that the ECT sensor voltage is less than 0.20 V, the PCM determines that the ECT sensor circuit has a malfunction.
  • Page 83 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 84: Dtc P0118 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT ECT SENSOR SIGNAL Repair or replace the wiring harness for a CIRCUIT FOR SHORT TO GND possible short to GND, then go to Step 7. • Turn the ignition switch off.
  • Page 85 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM monitors the ECT sensor signal at PCM terminal 2J. If the PCM detects that the ECT sensor voltage is more than 4.9 V, the PCM determines that the ECT sensor circuit has a malfunction.
  • Page 86 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 87: Dtc P0121 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT ECT SENSOR CIRCUIT FOR Yes Go to the next step. OPEN CIRCUIT • Turn the ignition switch off. • Inspect for continuity between the following terminals:...
  • Page 88 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - MAF sensor signal is less than 3.3 g/s {0.4 lb/min}. Diagnostic support note • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 89 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Warm up the engine until ECT PID is more than 70 °C {158 °F} • Drive the vehicle. • Read the TP PID while MAF PID is more than 59.5 g/s {7.9 lb/min}.
  • Page 90 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for electrical corrosion on PCM terminals. • Is any electrical corrosion found? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to Step 15. P0121 COMPLETED...

  • Page 91: Dtc P0122 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P0121 COMPLETED (See PCM REMOVAL/INSTALLATION • Make sure to reconnect all disconnected [Z6].) connectors.
  • Page 92 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open circuit in wiring harness between TP sensor terminal A and PCM terminal 2W • Short to GND in wiring harness between TP sensor terminal A and PCM terminal 2W •...
  • Page 93 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is any related repair information available? No Go to the next step. INSPECT TP SENSOR CONNECTOR FOR Repair or replace the terminal, then go to POOR CONNECTION Step 8.

  • Page 94: Dtc P0123 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - TP sensor terminal C (wiring harness-side) and PCM terminal 2AA (wiring harness-side) • Is there continuity? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step.
  • Page 95 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Short to power supply in wiring harness between TP sensor terminal C and PCM terminal 2AA • Open circuit in wiring harness between TP sensor terminal B and PCM terminal 2AE •...
  • Page 96 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch off. • Disconnect the TP sensor connector. No Go to the next step. • Inspect for poor connection (such as damaged/pulled-out pins, corrosion).

  • Page 97: Dtc P0125 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "AFTER REPAIR (See DTC TABLE [Z6].) PROCEDURE". (See AFTER REPAIR PROCEDURE [Z6].)
  • Page 98 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is any related repair information No Go to the next step. available? VERIFY CURRENT INPUT SIGNAL Intermittent concern exists. STATUS: IS CONCERN INTERMITTENT Perform the "INTERMITTENT CONCERNS OR CONSTANT? TROUBLESHOOTING".

  • Page 99: Dtc P0132 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See AFTER REPAIR PROCEDURE [Z6].) • Are any DTCs present? DTC P0132 [Z6] B3E010200100W12 DTC P0132 Front HO2S circuit high voltage • The PCM monitors the input voltage from the front HO2S when the engine is running.
  • Page 100 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 101: Dtc P0133 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch to the ON position (Engine off). • Measure the voltage between front HO2S No Go to the next step. terminal A (wiring harness-side) and body GND.
  • Page 102 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0133 Front HO2S circuit slow response • The PCM monitors the inversion cycle period, lean-to-rich response time and rich-to- lean response time of the sensor. The PCM calculates the average of the inversion cycle period-specified inversion cycles, average response time from lean-to-rich, and from rich-to-lean when the following conditions are met.
  • Page 103 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 104 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the front HO2S installed securely? (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6].) INSPECT GAS LEAKAGE FROM Repair or replace any malfunctioning exhaust EXHAUST SYSTEM part, then go to Step 13.

  • Page 105: Dtc P0134 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If there is any foreign material or stain inside fuel filter (low-pressure side), clean the fuel tank and filter. • If there is no malfunction, replace the fuel pump unit.
  • Page 106 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 0.55 V for 120 s or more, the PCM determines that sensor circuit is not activated. MONITORING CONDITIONS - HO2S, HO2S heater and TWC repair verification drive mode - Following conditions are met: •...
  • Page 107 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 108 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL STATUS • Warm up the engine. • Access O2S11 PID using the WDS or equivalent. • Verify PID while racing engine (in NEUTRAL (MTX) or PARK (ATX)).

  • Page 109: Dtc P0138 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Implement procedure to bleed air from engine coolant, then idle the engine. • Is there any small bubble, which makes engine coolant white at filling opening? Note •...
  • Page 110 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 111 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is any related repair information No Go to the next step. available? INSPECT REAR HO2S CONNECTOR Repair or replace the terminal, then go to Step FOR POOR CONNECTION •...

  • Page 112: Dtc P0140 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "AFTER REPAIR (See DTC TABLE [Z6].) PROCEDURE". (See AFTER REPAIR PROCEDURE [Z6].) No DTC troubleshooting completed.
  • Page 113 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 114 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL STATUS • Warm up engine. • Access O2S12 PID using WDS or equivalent. No Go to the next step. • Verify PID while racing engine at least 10 times (in NEUTRAL (MTX) or PARK (ATX)).

  • Page 115: Dtc P0300 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Note • Large bubbles are normal since they are remaining air coming out from engine coolant passage. INSPECT ENGINE COMPRESSION Yes Go to the next step. • Inspect engine compression.
  • Page 116 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 117 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next step. • Has FREEZE FRAME DATA been...
  • Page 118 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Retighten the CKP sensor, then go to Step 22. VERIFY CKP SENSOR INSTALLATION CONDITION (See CRANKSHAFT POSITION (CKP) • Inspect for the CKP sensor looseness. SENSOR REMOVAL/INSTALLATION [Z6].)
  • Page 119 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Between MAF sensor and throttle body - Between throttle body and intake manifold • Is there any malfunction? Yes Go to step 16. INSPECT FUEL LINE PRESSURE If the fuel line pressure is too low, go to the next step.
  • Page 120 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT OPERATION OF PURGE Yes Go to the next step. SOLENOID VALVE • Turn the ignition switch off. • Connect vacuum pump to the purge solenoid valve and apply vacuum to the purge solenoid valve.

  • Page 121: Dtc P0301, P0302, P0303, P0304 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Perform "ENGINE COOLANT LEAKAGE Then go to the next step. INSPECTION". (See ENGINE COOLANT LEAKAGE INSPECTION.) No Go to the next step. • Is there any malfunction? VERIFY TROUBLESHOOTING OF Replace the PCM, then go to the next step.
  • Page 122 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 123 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Access BOO, ECT, IAT, MAF, RPM, TP and VSS PIDs using WDS or equivalent. (See PCM INSPECTION [Z6].) No Go to the next step. • Is there any signal that is far out of...
  • Page 124 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Remove the intake air system parts. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) • Disconnect the fuel injector connector on Inspect for fuel injector wiring harnesses. suspected cylinder.

  • Page 125: Dtc P0327 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "AFTER REPAIR (See DTC TABLE [Z6].)
  • Page 126 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 127: Dtc P0328 [Z6]

    KS circuit high input • The PCM monitors the input signal from the KS when the engine is running. If the input voltage at PCM terminal 2BA is more than 3.75 V, the PCM DETECTION determines that the KS circuit has a malfunction.
  • Page 128 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle. • PENDING CODE is available if the PCM detects the above malfunction condition.
  • Page 129 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Perform repair or diagnosis according to the VERIFY RELATED REPAIR INFORMATION available repair information. AVAILABILITY • If the vehicle is not repaired, go to the next • Verify related service repair information step.

  • Page 130: Dtc P0335 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P0328 COMPLETED (See PCM REMOVAL/INSTALLATION • Make sure to reconnect all disconnected [Z6].) connectors.
  • Page 131 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Short to GND in wiring harness between CKP sensor terminal B and PCM terminal 2P • Open circuit in wiring harness between CKP sensor terminal C and PCM terminal 2BF •...
  • Page 132 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT CKP SENSOR CONNECTOR Repair or replace the terminal, then go to FOR POOR CONNECTION Step 9. • Turn the ignition switch off. • Disconnect the CKP sensor connector.

  • Page 133: Dtc P0340 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT CKP SENSOR CIRCUIT FOR Yes Go to the next step. OPEN CIRCUIT • Turn the ignition switch off. • Inspect for continuity between the following terminals:...
  • Page 134 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction condition in the first drive cycle. • PENDING CODE is available if the PCM detects the above malfunction condition.
  • Page 135 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 136 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT CMP SENSOR CIRCUIT FOR Repair or replace the wiring harness for a SHORT TO GND possible short to GND, then go to Step 9. • Turn the ignition switch off.

  • Page 137: Dtc P0403 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - CMP sensor terminal A (wiring harness-side) and PCM terminal 2T (wiring harness-side) - CMP sensor terminal B (wiring harness-side) and PCM terminal 2BB (wiring harness-side) - CMP sensor terminal C (wiring...
  • Page 138 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory. • EGR valve malfunction • Connector or terminal malfunction • Open circuit in wiring harness between EGR valve terminal C and PCM terminal 2BG •...
  • Page 139 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 140 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there any malfunction? INSPECT EGR VALVE CIRCUIT FOR Repair or replace wiring harness for short to SHORT TO GND GND, then go to Step 9.
  • Page 141 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch off. • Disconnect the PCM connector. No Go to the next step. • Inspect for poor connection (such as damaged/pulled-out pins, corrosion).

  • Page 142: Dtc P0420 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Are any DTCs present? DTC P0420 [Z6] B3E010200400W02 DTC P0420 Catalyst system efficiency below threshold • The PCM compares the number of the front HO2S and rear HO2S inversions for a predetermined time.
  • Page 143 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next step. • Has FREEZE FRAME DATA been...

  • Page 144: Dtc P0443 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Clear the DTC from the PCM memory using the WDS or equivalent. • Perform the "HO2S heater, HO2S, and TWC Repair Verification Drive Mode". (See OBD DRIVE MODE [Z6].)
  • Page 145 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Short to GND in wiring harness between purge solenoid valve terminal B and PCM terminal 2AV • PCM malfunction Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step.
  • Page 146 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT PURGE SOLENOID VALVE Repair or replace wiring harness for short to CIRCUIT FOR SHORT TO GND GND, then go to Step 9.

  • Page 147: Dtc P0480 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Purge solenoid valve terminal A (wiring harness-side) and PCM terminal 2T (wiring harness-side) - Purge solenoid valve terminal B (wiring harness-side) and PCM terminal 2AV (wiring harness-side) •...
  • Page 148 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Short to power supply in wiring harness between fan control module terminal C and PCM terminal 1AP • Short to GND in wiring harness between fan control module terminal C and PCM terminal 1AP •...
  • Page 149 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT FAN CONTROL MODULE SIGNAL Repair or replace the wiring harness for a CIRCUIT FOR SHORT TO GND possible short to GND, then go to Step 9.

  • Page 150: Dtc P0500 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC (See PCM REMOVAL/INSTALLATION P0480 COMPLETED [Z6].) • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory using the WDS or equivalent.

  • Page 151: Dtc P0505 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next step. • Has FREEZE FRAME DATA been...
  • Page 152 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0505 IAC system problem • The PCM cannot control idle speed toward target idle speed while KOER DETECTION self test. CONDITION • IAC valve circuit malfunction •...

  • Page 153: Dtc P0506 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes next step for vehicles without A/C. • Turn the A/C switch off. • Is magnetic clutch still on? INSPECT GENERATOR CONTROL Yes Go to the next step.
  • Page 154 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010200500W03 DTC P0506 IAC system RPM lower than expected • The PCM compares the actual idle speed with the target idle speed when the engine is running. If the actual idle speed is lower than the targeted by 100 rpm for 14 s, the PCM determines that the IAC system RPM is lower than expected.
  • Page 155 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next step. • Has FREEZE FRAME DATA been...
  • Page 156 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT THROTTLE BODY PASSAGE Clean the throttle body passage or replace the throttle body, then go to Step 19. • Remove the throttle body. (See INTAKE-AIR SYSTEM...
  • Page 157 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the engine oil condition. Replace the engine oil. • Is the engine oil condition normal? Inspect the ECT sensor and related wiring harnesses. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [Z6].)

  • Page 158: Dtc P0507 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0507 [Z6] B3E010200500W04 DTC P0507 IAC system RPM higher than expected • The PCM compares the actual idle speed with the target idle speed when the engine is running.
  • Page 159 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY RELATED PENDING CODE OR Go to the applicable DTC inspection. STORED DTC (See DTC TABLE [Z6].) • Turn the ignition switch off, then to the ON position (Engine off).

  • Page 160: Dtc P0511 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR No Go to the next step. INSPECTION [Z6].) • Is there any malfunction? INSPECT CKP SENSOR Replace the CKP sensor, then go to the next step.
  • Page 161 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PENDING CODE is available if the PCM detects the above malfunction condition. • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory.
  • Page 162 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 163: Dtc P0550 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the IAC valve. (See IDLE AIR CONTROL (IAC) VALVE REMOVAL/INSTALLATION [Z6].) (See IDLE AIR CONTROL (IAC) VALVE INSPECTION [Z6].) No Go to the next step.
  • Page 164 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0550 PSP switch circuit problem • The PCM monitors the input signal from the PSP switch. If the input signal does not change for 1 min, the PCM determines that the PSP switch circuit problem.
  • Page 165 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 166 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT PSP SWITCH SIGNAL CIRCUIT Repair or replace the wiring harness for a FOR SHORT TO GND possible short to GND, then go to Step 9. • Turn the ignition switch off.

  • Page 167: Dtc P0602 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Start the engine. • Access the ECT PID. • Warm up the engine until the ECT PID is more than 60 °C {140 °F}. • Drive the vehicle more than 60 km/h {37.3 mph} for 1 min.

  • Page 168: Dtc P0610 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Perform repair or diagnosis according to the VERIFY RELATED REPAIR available repair information. INFORMATION AVAILABILITY • If the vehicle is not repaired, go to the next • Verify related service repair information step.

  • Page 169: Dtc P0660 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 170 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM could not perform the self-test for the variable intake-air control circuit. Diagnostic support note • This is a continuous monitor (Other). • The MIL does not illuminate.
  • Page 171 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.
  • Page 172 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, and corrosion). • Is there any malfunction? INSPECT VARIABLE INTAKE-AIR SHUTTER Repair or replace the wiring harness for a...

  • Page 173: Dtc P0668 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, and corrosion). • Is there any malfunction? INSPECT VARIABLE INTAKE-AIR SHUTTER Yes Go to the next step. VALVE ACTUATOR CIRCUIT FOR OPEN CIRCUIT •...
  • Page 174 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM monitors the PCM temperature sensor (integrated in the PCM) signal. If the PCM detects that the PCM temperature sensor voltage is 0.10 V or less, the PCM determines that the PCM temperature sensor has a malfunction.

  • Page 175: Dtc P0669 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Are any DTCs present? DTC P0669 [Z6] B3E010200600W05 DTC P0669 PCM temperature sensor circuit high input • The PCM monitors the PCM temperature sensor (integrated the PCM) signal. If the PCM detects that the PCM temperature sensor voltage is 4.98 V or more, the PCM...

  • Page 176: Dtc P0703 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Clear the DTC from the PCM memory using the WDS or equivalent. • Start the engine. • Is same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC troubleshooting.
  • Page 177 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open circuit in wiring harness between brake switch terminal D and PCM terminal 1V • Short to power supply in wiring harness between brake switch terminal D and PCM terminal 1V •...
  • Page 178 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT BRAKE SWITCH CIRCUIT FOR Repair or replace the wiring harness for a SHORT TO GND possible short to GND, then go to Step 10. • Turn the ignition switch off.

  • Page 179: Dtc P0704 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for continuity between brake switch terminal D (wiring harness-side) and PCM terminal 1V (wiring harness-side). • Is there continuity? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step.
  • Page 180 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PENDING CODE is available if the PCM detects the above malfunction condition during the first drive cycle. • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory.
  • Page 181 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT CPP SWITCH CONNECTOR FOR Repair or replace the terminal, then go to POOR CONNECTION Step 9. • Turn the ignition switch off. • Disconnect the CPP switch connector.

  • Page 182: Dtc P0850 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there continuity? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P0704 COMPLETED (See PCM REMOVAL/INSTALLATION • Make sure to reconnect all disconnected [Z6].)
  • Page 183 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Connector or terminal malfunction • Open circuit in wiring harness between neutral switch terminal A and PCM terminal 1AB • Short to GND in wiring harness between neutral switch terminal A and PCM terminal 1AB •...
  • Page 184 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT NEUTRAL SWITCH GND CIRCUIT Yes Go to the next step. FOR OPEN CIRCUIT • Turn the ignition switch off. Repair or replace the wiring harness for a •...

  • Page 185: Dtc P1260 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Vehicle speed: 30 km/h {19 mph} or more • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection.

  • Page 186: Dtc P2006 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY STORED DTC IN INSTRUMENT (See DTC TABLE [IMMOBILIZER SYSTEM].) CLUSTER • Turn the ignition switch to the ON position (Engine off). • Verify stored DTCs in instrument cluster.
  • Page 187 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.

  • Page 188: Dtc P2008 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT FOR EXCESSIVE AIR SUCTION Repair or replace source of air suction, then OF INTAKE-AIR SYSTEM OR IMPROPER go to the next step. ROUTING OF INTAKE-AIR SYSTEM HOSE •...
  • Page 189 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 190 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.
  • Page 191 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged, pulled-out pins, and corrosion). • Is there any malfunction? INSPECT VARIABLE TUMBLE SHUTTER Yes Go to the next step.

  • Page 192: Dtc P2088 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT VARIABLE TUMBLE SHUTTER Repair or replace for short to power VALVE ACTUATOR CONTROL CIRCUIT FOR supply, then go to the next step. SHORT TO POWER • Turn the ignition switch to the ON position.
  • Page 193 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory. • OCV malfunction • Connector or terminal malfunction • Open circuit in wiring harness between OCV terminal A and PCM terminal •...
  • Page 194 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Perform repair or diagnosis according to the VERIFY RELATED REPAIR available repair information. INFORMATION AVAILABILITY • If the vehicle is not repaired, go to the next • Verify related service repair information step.

  • Page 195: Dtc P2089 [Z6]

    Variable valve timing control circuit high • If the PCM detects that the OCV drive current is as specified or more when the OCV control duty target is 3 % or less, the PCM determines that the variable valve timing control circuit high.
  • Page 196 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Short to power supply in wiring harness between OCV terminal B and PCM terminal 2AG • PCM malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step.

  • Page 197: Dtc P2096 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, and corrosion). • Is there any malfunction? INSPECT OCV CONTROL CIRCUIT FOR Repair or replace the wiring harness for a...
  • Page 198 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010202000W10 DTC P2096 Target A/F feedback system too lean • The PCM monitors the target A/F fuel trim when under the target A/F feedback control. If the fuel trim is more than the specification, the PCM determines that the target A/F feedback system is too lean.
  • Page 199 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify related service repair information • If the vehicle is not repaired, go to the next availability. step. • Is any related repair information No Go to the next step.
  • Page 200 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - TP - VSS • Are the PIDs normal? VERIFY CURRENT INPUT SIGNAL Yes Go to the next step. STATUS UNDER FREEZE FRAME DATA CONDITION • Connect the WDS or equivalent to the DLC-2.
  • Page 201 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the PID normal? INSPECT INTAKE-AIR SYSTEM FOR Repair or replace the malfunctioning part, then EXCESSIVE AIR SUCTION go to Step 17. • Visually inspect hoses in intake-air system for looseness, cracks or damages No Go to the next step.

  • Page 202: Dtc P2097 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there any malfunction? No Go to the next step. VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P2096 COMPLETED (See PCM REMOVAL/INSTALLATION [Z6].)
  • Page 203 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Front HO2S malfunction • Excessive fuel line pressure • Fuel pump unit malfunction • Purge solenoid valve malfunction • Insufficient engine compression • PCM malfunction Diagnostic procedure...
  • Page 204 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Read the O2S12 PID under following accelerator pedal condition (in PARK or NEUTRAL). - More than 0.45 V when suddenly depressing accelerator pedal (rich condition) - Less than 0.45 V just after...
  • Page 205 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Access the O2S11 PID. (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6] • Read the O2S11 PID under following accelerator pedal condition (in PARK or Then go to Step 11.

  • Page 206: Dtc P2177 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See AFTER REPAIR PROCEDURE [Z6].) • Are any DTCs present? DTC P2177 [Z6] B3E010202100W07 DTC P2177 System too lean off idle • The PCM monitors short term fuel trim (SHRTFT) and long term fuel trim (LONGFT) during closed loop fuel control during off-idle.
  • Page 207 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 208 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify PID under following accelerator Then go to Step 17. pedal condition (in PARK (ATX) or NEUTRAL (MTX)). • Is PID normal? - Above 0.45 V when suddenly...
  • Page 209 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Replace suspected fuel line, then go to Step INSPECT FUEL LINE FROM FUEL PUMP TO FUEL DELIVERY PIPE Inspect for foreign materials or stain inside fuel filter (low pressure).

  • Page 210: Dtc P2178 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Perform the "PCM Adaptive Memory Produce Drive Mode". (See OBD DRIVE MODE [Z6].) • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection.
  • Page 211 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Purge solenoid hoses improper connection • Variable valve timing control system improper operation • PCV valve malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step.
  • Page 212 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there any signal which causes drastic changes? VERIFY CURRENT INPUT SIGNAL Yes Go to the next step. STATUS OF FRONT HO2S • Access O2S11 for P2177 PID using WDS or equivalent.
  • Page 213 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Does the EGR control system work properly? INSPECT VARIABLE TUMBLE Yes Go to the next step. SHUTTER VALVE ACTUATOR OPERATION • Perform the "Variable Tumble Control Operation Inspection".

  • Page 214: Dtc P2187 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory using the WDS or equivalent. • Perform the "PCM Adaptive Memory No Go to the next step.
  • Page 215 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel filter clogged or restricted • Fuel leakage on fuel line from fuel delivery pipe and fuel pump • Leakage exhaust system • Purge solenoid valve malfunction •...
  • Page 216 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL Inspect suspected sensor and related wiring STATUS UNDER TROUBLE CONDITION harnesses repair or replace it. • Inspect same PIDs as Step 4 while Then go to Step 17.
  • Page 217 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch off. Note If the fuel pressure is too high, replace the fuel • If the engine will not start, inspect pump unit, then go to Step 17.

  • Page 218: Dtc P2188 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the fuel injector (resistance, injection amount). (See FUEL INJECTOR INSPECTION.) • Is the fuel injector normal? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step.
  • Page 219 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Front HO2S deterioration • Front HO2S heater malfunction • MAF sensor malfunction • Pressure regulator (built-in fuel pump unit) malfunction • Fuel pump malfunction • EGR valve stuck open •...
  • Page 220 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL Inspect suspected sensor and excessive STATUS (IGNITION SWITCH TO ON/IDLE) resistance in related wiring harnesses. • Access ECT, MAF, TP and VSS PIDs Repair or if necessary.
  • Page 221 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the PCV valve operation. Replace the PCV valve, then go to Step 16. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE (See INTAKE-AIR SYSTEM HOSE ROUTING INSPECTION.) DIAGRAM [Z6].)

  • Page 222: Dtc P2195 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Remove the EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [Z6].) (See EGR VALVE REMOVAL/INSTALLATION [Z6].) No Go to the next step. • Does the EGR valve stuck open? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step.
  • Page 223 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory. • Front HO2S malfunction • Fuel injector malfunction • Insufficient fuel line pressure •...
  • Page 224 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL STATUS • Connect the WDS or equivalent to the DLC-2. • Verify the following PIDs. Inspect the malfunctioning part according to the (See PCM INSPECTION [Z6].)
  • Page 225 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT FRONT HO2S Replace the front HO2S, then go to Step 13. • Inspect the front HO2S. (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6].) (See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [Z6].)

  • Page 226: Dtc P2196 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P2196 [Z6] B3E010202100W12 DTC P2196 Front HO2S signal stuck rich • The PCM monitors the front HO2S output voltage when the following conditions are met. If output voltage is more than 0.45 V for 46 s, the PCM determines that the front HO2S signal remains rich.
  • Page 227 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify related service repair information availability. No Go to the next step. • Is any related repair information available? VERIFY RELATED PENDING CODE Go to the appropriate DTC inspection.
  • Page 228 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Are the PIDs normal? VERIFY CURRENT INPUT SIGNAL Yes Go to the next step. STATUS OF MAF SENSOR • Connect the WDS or equivalent to the DLC-2.

  • Page 229: Dtc P2228 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Perform the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE No DTC troubleshooting completed. [Z6].) • Are any DTCs present? DTC P2228 [Z6] B3E010202200W01 DTC P2228 BARO sensor circuit low input •...
  • Page 230 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 231 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - BARO sensor terminal C (wiring harness-side) and body GND - BARO sensor terminal B (wiring harness-side) and body GND • Is there continuity? INSPECT BARO SENSOR Replace the BARO sensor, then go to Step •...

  • Page 232: Dtc P2229 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Perform the "AFTER REPAIR PROCEDURE". No DTC troubleshooting completed. (See AFTER REPAIR PROCEDURE [Z6].) • Are any DTCs present? DTC P2229 [Z6] B3E010202200W02 DTC P2229 BARO sensor circuit high input •...
  • Page 233 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 234: Dtc P2502 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Measure the voltage between BARO sensor terminal B (wiring harness-side) and body GND. • Is the voltage B+? INSPECT BARO SENSOR Replace the BARO sensor, then go to Step •...
  • Page 235 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P2502 Charging system voltage problem • The PCM determines that the generator output voltage is more than 17 DETECTION V or the battery voltage is less than 11 V while the engine running.
  • Page 236 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the repair • Has FREEZE FRAME DATA been order, then go to the next step.

  • Page 237: Dtc P2503 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is same DTC present? VERIFY AFTER REPAIR Go to the applicable DTC inspection. PROCEDURE (See DTC TABLE [Z6].) • Perform the "AFTER REPAIR PROCEDURE". (See AFTER REPAIR PROCEDURE No DTC troubleshooting completed.
  • Page 238 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 239 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT DRIVE BELT CONDITION Yes Go to the next step. • Verify that the drive belt auto tensioner indicator mark does not exceed the limit. Replace and/or adjust the drive belt, then go to Step 8.

  • Page 240: Dtc P2504 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Generator terminal P (wiring harness-side) and PCM terminal 2AR (wiring harness-side) • Is there continuity? VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step.
  • Page 241 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 242 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT GENERATOR CONNECTOR Repair or replace the terminal, then go to Step FOR POOR CONNECTION • Turn the ignition switch off. • Disconnect the generator connector. • Inspect for poor connection (such as No Go to the next step.

  • Page 243: Dtc P2507 [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Are any DTCs present? DTC P2507 [Z6] B3E010202500W04 DTC P2507 PCM power input signal low • The PCM monitors the voltage of the backup battery positive at PCM terminal 1AX.
  • Page 244 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 245 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT PCM POWER MONITOR Yes Go to the next step. CIRCUIT FOR OPEN CIRCUIT •...

  • Page 246: On-Board Diagnostic[Engine Control System (Lf)]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ON-BOARD DIAGNOSTIC[ENGINE CONTROL SYSTEM (LF)] CONTROL SYSTEM WIRING DIAGRAM [LF] B3E010200102W01 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 247 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 248: Monitoring System And Control System Device Relationship Chart [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes MONITORING SYSTEM AND CONTROL SYSTEM DEVICE RELATIONSHIP CHART [LF] B3E010200102W02 x: Applicable Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 249: Obd Pending Trouble Code [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Component Input A/C switch, refrigerant pressure switch (high, low pressure) TP sensor ECT sensor IAT sensor MAF sensor HO2S (front) HO2S (rear) BARO sensor MAP sensor CMP sensor...

  • Page 250: Obd Freeze Frame Data [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (2DC). If the problem is found in a second drive cycle too, the PCM judges that the system has failed, and the DTC is stored. OBD FREEZE FRAME DATA [LF] B3E010200102W04 •...

  • Page 251: Pending Trouble Code Access Procedure

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Retrieve the DTCs using the WDS or equivalent. Pending Trouble Code Access Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.

  • Page 252: On-Board System Readiness Tests Access Procedure

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes On-Board System Readiness Tests Access Procedure 1. Perform the necessary vehicle preparation and visual inspection. 2. Connect the WDS or equivalent to the vehicle DLC-2 16-pin connector located in the driver compartment.

  • Page 253: After Repair Procedure [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Access to the diagnostic monitoring test results and read the test results using the WDS or equivalent. AFTER REPAIR PROCEDURE [LF] B3E010200102W09 1. Connect the WDS or equivalent to the DLC-2.

  • Page 254: Mode 1 (Pcm Adaptive Memory Produce Drive Mode)

    2. Verify that all accessory loads (A/C, headlights, blower fan, rear window defroster) are off. 3. Drive the vehicle as shown in the graph; first drive in zone O, then A or B, followed by C or D, finally E or F.

  • Page 255: Dtc Table [Lf]

    4. Stop the vehicle and access the ON BOARD SYSTEM READINESS to inspect the Drive Mode completion status. • If completed, RFC changes from No to Yes. • If not completed, turn the ignition switch off, then go back to Step 3. 5. Verify that no DTCs are available. DTC TABLE [LF] B3E010200102W11 ×: Applicable...
  • Page 256 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Front HO2S heater circuit high HO2S × P0032 (See DTC P0032 [LF]) input heater Rear HO2S heater circuit low HO2S × P0037 (See DTC P0037 [LF]) input...
  • Page 257 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 or × P0302 Cylinder No.2 misfire detected Flash/ON Misfire (See DTC P0301, 1 or × P0303 Cylinder No.3 misfire detected Flash/ON Misfire P0302, P0303, P0304 [LF]) 1 or ×...
  • Page 258 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Neutral switch input circuit × P0850 (See DTC P0850 [LF]) problem × P1260 Immobilizer system problem Other (See DTC P1260 [LF]) Variable tumble shutter valve × P2006...

  • Page 259: Dtc P0031 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Communication error to U0155 (See DTC TABLE [MULTIPLEX COMMUNICATION SYSTEM]) instrument cluster DTC P0031 [LF] B3E010201084W01 DTC P0031 Front HO2S heater circuit low input • The PCM monitors the front HO2S heater control signal at PCM terminal 2G.
  • Page 260 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.
  • Page 261 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the front HO2S heater. (See FRONT HEATED OXYGEN SENSOR No Replace the front HO2S, then go to Step 9. (HO2S) INSPECTION [LF].) • Is the front HO2S heater normal? INSPECT POWER CIRCUIT OF FRONT HO2S Yes Go to the next step.

  • Page 262: Dtc P0032 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC troubleshooting. • Perform the "After Repair Procedure". (See DTC TABLE [LF].) (See AFTER REPAIR PROCEDURE [LF].) No Troubleshooting completed.
  • Page 263 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 264: Dtc P0037 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [LF].) • Is the front HO2S heater normal? INSPECT PCM TERMINAL Yes Repair the terminal, then go to Step 7.
  • Page 265 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic support note • This is a continuous monitor (HO2S heater). • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 266 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 267: Dtc P0038 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for continuity between rear HO2S terminal D (wiring harness-side) and body ground. • Is there continuity? INSPECT HREAR HO2S HEATER CONTROL Yes Go to the next step.
  • Page 268 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory. • Short to power supply in wiring harness between rear HO2S terminal D and PCM terminal 2C •...
  • Page 269 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT REAR HO2S TERMINAL Repair or replace the terminal, then go to Step 7. • Turn the ignition switch off. • Disconnect the rear HO2S connector. • Inspect for poor connection (such as No Go to the next step.

  • Page 270: Dtc P0101 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0101 [LF] B3E010201084W05 DTC P0101 MAF sensor circuit range/performance problem • The PCM compares actual MAF amount with expected MAF amount when the engine is running.
  • Page 271 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is any related repair information available? VERIFY CURRENT INPUT SIGNAL Make sure that the throttle position sensor STATUS: IS CONCERN resistance changes smoothly while gradually INTERMITTENT OR CONSTANT? opening the throttle valve.
  • Page 272 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (damaged/pulled-out pins, corrosion, etc.). • Is there any malfunction? VERIFY TROUBLESHOOTING OF DTC Yes Replace the PCM, then go to Step 11.

  • Page 273: Dtc P0102 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Clear the DTC from the memory using the WDS or equivalent. • Start the engine. • Warm up the engine until ECT PID is above 80 °C {176 °F}.
  • Page 274 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 275 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT Inspect for open circuit in wiring harness • Turn the ignition switch to the ON position between MAF/IAT sensor terminal A (wiring (Engine off).

  • Page 276: Dtc P0103 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See AFTER REPAIR PROCEDURE [LF].) No Troubleshooting completed. • Are any DTC present? DTC P0103 [LF] B3E010201084W07 DTC P0103 MAF sensor circuit high input • The PCM monitors the input voltage from the MAF sensor when the engine running.
  • Page 277 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 278: Dtc P0107 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Measure the voltage between MAF/IAT sensor terminal C (wiring harness-side) and body ground. • Is the voltage 0 V? INSPECT POOR CONNECTION OF PCM Yes Repair the terminal, then go to Step 7.
  • Page 279 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle. • PENDING CODE is available if the PCM detects the above malfunction condition.
  • Page 280 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next step. • Has FREEZE FRAME DATA been...

  • Page 281: Dtc P0108 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT MAP SENSOR SIGNAL AND GROUND CIRCUIT FOR SHORT EACH OTHER • Inspect for continuity between MAP No Go to the next step. sensor terminals D and A (wiring harness- side).
  • Page 282 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • MAP sensor malfunction • Connector or terminal malfunction • Open circuit in wiring harness between MAP sensor terminal A and PCM terminal 2AA POSSIBLE CAUSE • Open circuit in wiring harness between MAP sensor terminal D and PCM terminal 2AL •...
  • Page 283 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT CONNECTION OF MAP Yes Go to the next step. SENSOR CONNECTOR • Turn the ignition switch off. • Verify that the MAP sensor No Reconnect the connector, then go to Step 9.

  • Page 284: Dtc P0111 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Make sure to reconnect all disconnected connectors. • Turn the ignition switch to the ON position (Engine off). No Go to the next step. • Clear the DTC from the memory using the WDS or equivalent.
  • Page 285 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.

  • Page 286: Dtc P0112 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Perform the "After Repair Procedure". (See DTC TABLE [LF].) (See AFTER REPAIR PROCEDURE [LF].) No Troubleshooting completed. • Are any DTC present? DTC P0112 [LF] B3E010201084W11...
  • Page 287 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 288: Dtc P0113 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify IAT value when disconnecting the MAF/IAT sensor connector. • Does IAT value change? INSPECT IAT SIGNAL CIRCUIT FOR Repair or replace the wiring harness for SHORT TO GROUND short to ground, then go to Step 7.
  • Page 289 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction condition during first drive cycle. • PENDING CODE is available if the PCM detects the above malfunction condition.
  • Page 290 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Perform repair or diagnosis according to VERIFY RELATED REPAIR INFORMATION the available repair information. AVAILABILITY • If the vehicle is not repaired, go to the • Verify related service repair information next step.

  • Page 291: Dtc P0117 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for continuity between MAF/IAT sensor terminal D (wiring harness-side) and PCM terminal 1AH. • Is there continuity? INSPECT IAT SENSOR GROUND CIRCUIT Yes Go to the next step.

  • Page 292: Ect Sensor

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • ECT sensor malfunction • Connect or terminal malfunction • Short to ground in wiring harness between ECT sensor terminal A and PCM POSSIBLE CAUSE connector terminal 2AK •...

  • Page 293: Dtc P0118 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for bent of ECT sensor terminals A and B (part-side). • Is there any malfunction? CLASSIFY ECT SENSOR MALFUNCTION Yes Replace the ECT sensor, then go to Step 7.
  • Page 294 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0118 ECT sensor circuit high input • The PCM monitors the ECT sensor signal at PCM terminal 2AK. If the PCM detects the ECT sensor voltage is above 4.6 V, the PCM determines that the ECT sensor circuit has malfunction.
  • Page 295 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 296: Dtc P0121 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT ECT SENSOR SIGNAL CIRCUIT Yes Go to the next step. FOR OPEN CIRCUIT • Inspect the continuity between ECT sensor terminal A (wiring harness-side) and PCM Repair or replace the wiring harness for terminal 2AK.

  • Page 297: Maf Sensor

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - MAF sensor signal below 5 g/s {0.7 lb/min.} Diagnostic support note • This is a continuous monitor (CCM). • MIL illuminates if PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 298 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Access ECT, TP and MAF PIDs using the WDS or equivalent. • Warm up the engine until ECT PID is above 70 °C {158 °F} • Drive the vehicle.
  • Page 299 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is any electrical corrosion? INSPECT CONSTANT VOLTAGE SUPPLY Yes Go to the next step. AND TP SIGNAL CIRCUITS FOR VOLTAGE DROP • Turn the ignition switch to the ON position (Engine off).

  • Page 300: Dtc P0122 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the resistance between TP sensor • Repair or replace the terminal. terminal A (wiring harness-side) and body Go to Step 16. ground. • Is the resistance approx. 0 ohm ? VERIFY TP SENSOR Yes Go to the next step.
  • Page 301 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction conditions in first drive cycles. • PENDING CODE is available if the PCM detects the above malfunction condition.
  • Page 302 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY RELATED REPAIR Perform repair or diagnosis according to the INFORMATION AVAILABILITY available repair information. • Verify related service repair information • If the vehicle is not repaired, go to the next availability.

  • Page 303: Dtc P0123 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC (See PCM REMOVAL/INSTALLATION [LF].) P0122 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory No Go to the next step.
  • Page 304 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA Yes Go to the next step. HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 305 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT TP SENSOR Yes Go to the next step. • Perform TP sensor inspection.

  • Page 306: Dtc P0125 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there continuity? VERIFY TROUBLESHOOTING OF Replace the PCM, then go to the next step. DTC P0123 COMPLETED (See PCM REMOVAL/INSTALLATION [LF].) • Make sure to reconnect all disconnected connectors.
  • Page 307 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.

  • Page 308: Dtc P0132 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC (See PCM REMOVAL/INSTALLATION [LF].) P0125 COMPLETED • Make sure to reconnect all disconnected connectors. • Clear the DTC from the PCM memory using the WDS or equivalent.
  • Page 309 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Front HO2S or PCM terminal shorted • PCM malfunction Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN...

  • Page 310: Dtc P0133 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes IDENTIFY TRIGGER DTC FOR FREEZE Go to troubleshooting procedures for DTC FRAME DATA on FREEZE FRAME DATA. • Is DTC P0132 on FREEZE FRAME DATA? (See DTC TABLE [LF].)
  • Page 311 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010201084W20 DTC P0133 Front HO2S circuit problem • The PCM monitors inversion cycle period, lean-to-rich response time and rich-to-lean response time of the sensor. The PCM calculates the average of the inversion cycle period-specified inversion cycles, average response time from lean-to-rich, and from rich-to-lean when following conditions are met.

  • Page 312: Ho2S (Front)

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 313 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the sensor installed securely? INSPECT GAS LEAKAGE FROM Repair or replace malfunctioning faulty EXHAUST SYSTEM exhaust part, then go to Step 13. • Visually inspect if there is any gas leakage is found between the exhaust manifold and front HO2S.

  • Page 314: Dtc P0134 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Then go to Step 13. INSPECT SEALING OF ENGINE Yes Go to the next step. COOLANT PASSAGE • Perform inspection engine coolant leakage. Repair or replace the malfunctioning part according to inspection result.
  • Page 315 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • This is a continuous monitor (HO2S). • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.

  • Page 316: Ho2S (Rear)

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY RELATED REPAIR Perform repair or diagnosis according to the INFORMATION AVAILABILITY available repair information. • Verify related service repair information • If the vehicle is not repaired, go to the next availability.
  • Page 317 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Repair or replace any malfunctioning exhaust part, then go to Step 10. • Inspect the following harnesses for open circuit or short to ground, repair or replace INSPECT GAS LEAKAGE FROM wiring harness if necessary.

  • Page 318: Dtc P0138 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0138 [LF] B3E010201084W22 DTC P0138 Rear HO2S circuit high input • The PCM monitors input voltage from rear HO2S. If the input voltage from the rear HO2S sensor is above 1.2 V for 0.8 s, the PCM determines that circuit input is high.
  • Page 319 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 320: Dtc P0140 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC (See PCM REMOVAL/INSTALLATION P0138 COMPLETED [LF].) • Make sure to reconnect all disconnected connectors. • Turn the ignition switch to the ON position (Engine off).
  • Page 321 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Rear HO2S deterioration • Rear HO2S heater malfunction • Leakage exhaust system • Open circuit or short to ground in wiring harness between rear HO2S POSSIBLE CAUSE terminal A and PCM terminal 2AH •...
  • Page 322 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Note • If fuel monitor DTC, DTC P0132 is retrieved, ignore it until P0140 is fixed. • Turn the ignition switch off, then to the ON No Go to the next step.
  • Page 323 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT SEALING OF ENGINE COOLANT Air gets in from poor sealing on head gasket PASSAGE or other areas between combustion chamber and engine coolant passage. Warning Repair or replace the malfunctioning part, •...

  • Page 324: Dtc P0300 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0300 [LF] B3E010201085W01 DTC P0300 Random misfire detected • The PCM monitors CKP sensor input signal interval time. The PCM calculates change of interval time for each cylinder. If change of interval time exceeds preprogrammed criteria, the PCM detects misfire in the corresponding cylinder.
  • Page 325 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PCV valve malfunction • EGR valve malfunction • Vacuum hoses damages or improper connection • Related connector and terminal malfunction • Related wiring harness malfunction • Insufficient compression...
  • Page 326 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect the same PIDs as in Step 4 Then go to Step 21. while simulating FREEZE FRAME DATA condition. No Go to the next step. • Is there any signal which causes drastic changes? Yes Go to the next step.
  • Page 327 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See IGNITION COIL INSPECTION [LF].) • Is coil resistance normal? INSPECT MAF PID Yes Go to the next step. • Start the engine. • Access MAF PID using the WDS or equivalent.
  • Page 328 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is it normal? INSPECT OPERATION OF PURGE Yes Go to the next step. CONTROL SOLENOID VALVE • Turn the ignition switch off. • Connect the vacuum pump to purge control solenoid valve and apply vacuum to solenoid.

  • Page 329: Dtc P0301, P0302, P0303, P0304 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF Replace the PCM, then go to the next step. MISFIRE DTC COMPLETED (See PCM REMOVAL/INSTALLATION [LF].) • Make sure to reconnect all disconnected connectors.

  • Page 330: Fuel Injector

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PENDING CODE is available if the PCM detects the misfire which affects emission performance during first drive cycle. • FREEZE FRAME DATA is available. • DTC is stored in the PCM memory.
  • Page 331 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL Inspect suspected circuit and/or part according STATUS UNDER TROUBLE CONDITION to inspection results. Then go to Step 13. • Inspect same PIDs as in Step 4 while...

  • Page 332: Dtc P0327 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT SEALING OF ENGINE Repair or replace the malfunctioning part COOLANT PASSAGE according to inspection result. • Perform ENGINE COOLANT LEAKAGE Then go to Step 13. INSPECTION.
  • Page 333 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0327 KS circuit low input • The PCM monitors input signal from the KS when the engine is running. If the input voltage at PCM terminals between 2Q and 2R is below 0.9 V, the PCM determines that the KS circuit has malfunction.
  • Page 334 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN Record the FREEZE FRAME DATA on the RECORDED repair order, then go to the next step. • Has FREEZE FRAME DATA been recorded?

  • Page 335: Dtc P0328 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Are there continuities? INSPECT FOR SHORT CIRCUITS Repair or replace the wiring harness, then go to Step 9. • Inspect for continuity between KS female terminals A and B (wiring harness-side).
  • Page 336 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • FREEZE FRAME DATA is available. • The DTC is stored in the PCM memory. • KS malfunction • Connector or terminal malfunction • Short to power supply in wiring harness between KS terminal A and PCM...

  • Page 337: Dtc P0335 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Disconnect KS connector. • Inspect for poor connection at terminals A and B (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT KS Yes Go to the next step.
  • Page 338 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P0335 CKP sensor circuit problem • If the PCM does not receive input voltage from the CKP sensor for 4.2 s while MAF is 2.0 g/s {0.26 lb/min} or above, the PCM determines that the CKP sensor circuit has malfunction.
  • Page 339 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 340 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify that the CKP sensor connector is connected securely. • Is the connector normal? INSPECT CKP CIRCUIT FOR SHORT Repair or replace the wiring harness, then go to TO POWER Step 11.

  • Page 341: Dtc P0340 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - CKP sensor terminal A (wiring harness-side) and PCM terminal 2Y (wiring harness-side) - CKP sensor terminal B (wiring harness-side) and PCM terminal 2Z (wiring harness-side) • Is there continuity? INSPECT CKP SENSOR Yes Go to the next step.
  • Page 342 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM monitors input voltage from CMP sensor when engine is running. If the PCM does not receive input voltage from CMP sensor while the PCM receives input signal from CKP sensor, PCM determines that CMP circuit has malfunction.
  • Page 343 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 344 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify that the CMP sensor connector is connected securely. • Is the connector normal? INSPECT CMP CIRCUIT FOR SHORT TO Repair or replace the wiring harness, then go to POWER Step 11.

  • Page 345: Dtc P0403 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - CMP sensor terminal B (wiring harness-side) and PCM terminal 2U (wiring harness-side) • Is there continuity? INSPECT CMP SENSOR Yes Go to the next step. • Turn the ignition switch off.
  • Page 346 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction conditions in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
  • Page 347 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 348: Egr Valve

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT POWER CIRCUIT FOR OPEN Yes Go to the next step. CIRCUIT • Turn the ignition switch to the ON position (Engine off). • Measure the voltage following terminal Repair or replace harness for open circuit then and body ground.

  • Page 349: Dtc P0420 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there any malfunction? INSPECT CONTROL CIRCUIT FOR Yes Go to the next step. OPEN CIRCUIT •...
  • Page 350 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Engine speed is 1,410- 3,100 rpm. - Calculated TWC temperature in PCM is above 574 °C {1065 °F}. - Calculated load is 15- 50% (at 2,000 rpm) Diagnostic support note •...

  • Page 351: Dtc P0443 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there gas leakage? INSPECT INSTALLATION OF FRONT AND Yes Go to the next step. REAR OXYGEN SENSORS • Inspect for looseness of front and rear oxygen sensors.
  • Page 352 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic support note • This is a continuous monitor (CCM). • The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.

  • Page 353: Purge Solenoid Valve

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY RELATED REPAIR Perform repair or diagnosis according to the INFORMATION AVAILABILITY available repair information. • Verify related service repair information • If the vehicle is not repaired, go to the next step.

  • Page 354: Dtc P0480 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch to the ON position (Engine off). • Measure the voltage between purge solenoid valve terminal B and body ground. • Is the voltage B+? INSPECT PCM CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 10.
  • Page 355 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM monitors the input voltages from the fan control module. If the voltage at PCM terminal 1W remains low or high, the PCM determines that fan control circuit has malfunction.
  • Page 356 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN Record the FREEZE FRAME DATA on the RECORDED repair order, then go to the next step. • Has FREEZE FRAME DATA been recorded?

  • Page 357: Dtc P0500 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is there continuity? INSPECT FAN CONTROL MODULE Yes Go to the next step. • Perform fan control module inspection. Replace the fan control module, then go to •...

  • Page 358: Dtc P0505 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 359 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM cannot control idle speed toward target idle speed while KOER DETECTION self test. CONDITION • IAC valve circuit malfunction • Air cleaner element clogged •...

  • Page 360: Dtc P0506 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the magnetic clutch still on? INSPECT GENERATOR CONTROL Yes Go to the next step. CIRCUIT MALFUNCTION • Apply electrical load. Repair short to power supply in generator control circuit, then go to Step 9.
  • Page 361 (brake switch is on) and steering wheel is held straight ahead (power steering pressure switch is off). Note • If atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or intake air temperature is below -10 °C {14 °F}, the PCM cancels diagnosis of P0506.
  • Page 362 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY RELATED PENDING OR (See DTC TABLE [LF].) STORED DTC • Turn the ignition switch to off then to the ON position (Engine off). • Verify pending code or stored No Go to the next step.

  • Page 363: Dtc P0507 [Lf]

    (brake switch is on) and the steering wheel is held straight ahead (power steering pressure switch is off). Note DETECTION • If atmospheric pressure is less than 72.3 kPa {542 mmHg, 21.3 inHg} or CONDITION intake air temperature is below -10 °C {14 °F}, the PCM cancels diagnosis of P0507.
  • Page 364 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The MIL illuminates if the PCM detects the above malfunction conditions in two consecutive drive cycles or in one drive cycle while the DTC for the same malfunction has been stored in the PCM.

  • Page 365: Dtc P0511 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT ACCELERATOR CABLE FREE Yes Go to the next step. PLAY • Turn the ignition switch off. Adjust accelerator cable free play, then go to Step 9.
  • Page 366 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the PCM detects that PCM terminal 2E voltage is above or below threshold when the IAC control duty target is within 16-30%, the PCM determines that the IAC valve circuit has malfunction.
  • Page 367 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 368 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See IDLE AIR CONTROL (IAC) VALVE INSPECTION [LF].) • Is IAC valve normal? INSPECT CONTROL CIRCUIT FOR SHORT Repair or replace wiring harness, then go to TO POWER Step 9.

  • Page 369: Dtc P0602 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Make sure to reconnect all disconnected connectors. • Clear the DTC using the WDS or No Go to the next step. equivalent. • Start the engine.

  • Page 370: Dtc P0610 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC P0602 Replace the PCM, then go to the next COMPLETED step. • Make sure to reconnect all disconnected (See PCM REMOVAL/INSTALLATION connectors. [LF].) •...

  • Page 371: Dtc P0661 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P0610 COMPLETED (See PCM REMOVAL/INSTALLATION [LF].) • Make sure to reconnect all disconnected connectors.
  • Page 372 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PCM malfunction Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next •...
  • Page 373 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See VARIABLE INTAKE-AIR SOLENOID VALVE INSPECTION [LF].) • Is variable intake-air solenoid valve normal? INSPECT VARIABLE INTAKE-AIR SOLENOID Yes Go to the next step. VALVE POWER SUPPLY CIRCUIT FOR OPEN CIRCUIT •...

  • Page 374: Dtc P0662 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC troubleshooting. • Perform the "After Repair Procedure". (See DTC TABLE [LF].) (See AFTER REPAIR PROCEDURE [LF].)
  • Page 375 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 376: Dtc P0703 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the variable intake-air solenoid valve normal? INSPECT PCM CONNECTOR FOR POOR Yes Repair the terminal, then go to Step 7. CONNECTION • Turn the ignition switch off.
  • Page 377 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM monitors changes in input voltage from the brake switch. If the PCM does not detect PCM terminal 1AU voltage changes while alternately accelerating and decelerating 8 times, the PCM determines that brake switch circuit has malfunction.
  • Page 378 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 379 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT PCM CONNECTOR FOR POOR Repair or replace the terminal, then go to Step CONNECTION • Turn the ignition switch off. • Disconnect the PCM connector. • Inspect for poor connection (such as No Go to the next step.

  • Page 380: Dtc P0704 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Make sure to reconnect all disconnected connectors. • Clear the DTC from the memory using the WDS or equivalent. • Drive the vehicle 30 km/h {18.6 mph} or No Go to the next step.
  • Page 381 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PCM malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair •...
  • Page 382 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection (such as damaged/pulled-out pins, corrosion). • Is there malfunction? CLASSIFY CPP SWITCH OR CIRCUIT Yes Go to the next step. • Connect the WDS or equivalent to DLC-2.

  • Page 383: Dtc P0850 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes CLASSIFY CPP SWITCH OR CIRCUIT Yes Go to the next step. • Connect the WDS or equivalent to DLC-2. • Access CPP PID. • Verify that CPP PID changes from ON to No Go to Step 13.
  • Page 384 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The PCM monitors changes in input voltage from the neutral switch. If the PCM does not detect PCM terminal 1S voltage changes while running vehicle with vehicle speed above 30 km/h {19 mph} and clutch pedal turns press and...
  • Page 385 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS BEEN Yes Go to the next step. RECORDED Record the FREEZE FRAME DATA on • Has FREEZE FRAME DATA been repair order, then go to the next step.
  • Page 386 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for continuity between neutral switch terminal A and ground. • Is there continuity? INSPECT PCM CONNECTOR FOR POOR Repair or replace the terminal, then go to CONNECTION Step 14.

  • Page 387: Dtc P1260 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY TROUBLESHOOTING OF DTC Replace the PCM, then go to the next step. P0850 COMPLETED (See PCM REMOVAL/INSTALLATION [LF].) • Make sure to reconnect all disconnected connectors.

  • Page 388: Dtc P2006 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the repair order, then go to the next step. • Has FREEZE FRAME DATA been...
  • Page 389 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes The PCM determines that the variable tumble shutter valve has been stuck closed. MONITORING CONDITIONS - Engine coolant temperature is above 70 °C {158 °F}. - Engine speed is 3,500 rpm or more.
  • Page 390 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on repair • Has FREEZE FRAME DATA been order, then go to the next step.
  • Page 391 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the variable tumble shutter valve actuator normal? INSPECT VTCS SOLENOID VALVE Yes Go to the next step. • Perform "VTCS solenoid valve airflow inspection". Replace the variable tumble solenoid valve,...

  • Page 392: Dtc P2009 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P2009 [LF] B3E010202000W02 DTC P2009 Variable tumble solenoid valve circuit low input • The PCM monitors variable tumble solenoid valve control signal at PCM terminal 2AI. If the PCM turns variable tumble solenoid valve off but voltage at PCM terminal 2AI still remains low, the PCM determines that variable tumble solenoid valve circuit has malfunction.
  • Page 393 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 394: Dtc P2010 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect for poor connection at PCM terminal 2AI. (such as damaged/pulled-out pins, corrosion). • Is there malfunction? INSPECT VARIABLE TUMBLE SOLENOID Repair or replace the wiring harness for VALVE CONTROL CIRCUIT FOR SHORT TO short to ground, then go to Step 9.
  • Page 395 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes voltage at PCM terminal 2AI still remains high, the PCM determines that the variable tumble solenoid valve circuit has malfunction. Diagnostic support note • This is a continuous monitor (CCM).
  • Page 396 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify related service repair information • If the vehicle is not repaired, go to the next availability. step. • Is any related repair information available? No Go to the next step.

  • Page 397: Dtc P2096 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Start the engine. • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC troubleshooting. • Perform the "After Repair Procedure".
  • Page 398 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PCM malfunction Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the •...
  • Page 399 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL Yes Go to the next step. STATUS • Connect the WDS or equivalent to the DLC- • Verify the following PIDs. (See PCM INSPECTION [LF].)
  • Page 400 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL STATUS OF MAF SENSOR • Connect the WDS or equivalent to the DLC- • Start the engine. Replace the MAF/IAT sensor, then go to Step •...

  • Page 401: Dtc P2097 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See COMPRESSION INSPECTION [LF].) • Is there any malfunction? Replace suspected fuel injector, then go to INSPECT FUEL INJECTOR the next step. • Inspect fuel injector. (See...
  • Page 402 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The DTC is stored in the PCM memory. • Leakage exhaust gas • Rear HO2S malfunction • IAT sensor malfunction • ECT sensor malfunction • Front HO2S malfunction POSSIBLE •...
  • Page 403 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Connect the WDS or equivalent to the • If there is no leakage, replace rear HO2S. DLC-2. (See HEATED OXYGEN SENSOR (HO2S) • Start the engine and warm it up REMOVAL/INSTALLATION [LF].)
  • Page 404 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL STATUS OF FRONT HO2S • Connect the WDS or equivalent to the DLC-2. • Start the engine and warm it up Visually inspect for exhaust gas leakage completely.

  • Page 405: Dtc P2177 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform the "After repair procedure". (See DTC TABLE [LF].)
  • Page 406 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Insufficient engine compression Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the •...
  • Page 407 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INUPUT SIGNAL STATUS OF FRONT HO2S • Access O2S11 for P2177 PID using WDS or equivalent. • Check PID under following accelerator Visually inspect for any gas leakage between pedal condition (in NEUTRAL).
  • Page 408 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Replace suspected fuel line, then go to Step INSPECT FUEL LINE FROM FUEL PUMP TO FUEL DELIVERY PIPE Inspect for foreign materials or stain inside fuel filter (low-pressure).

  • Page 409: Dtc P2178 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes DTC P2178 [LF] B3E010202100W02 DTC P2178 Fuel system too rich at off idle • PCM monitors short term fuel trim (SHRTFT), long term fuel trim (LONGFT) during closed loop fuel control at off-idle.
  • Page 410 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY RELATED REPAIR Perform repair or diagnosis according to the INFORMATION AVAILABILITY available repair information. • Verify related service repair information • If the vehicle is not repaired, go to the next availability.
  • Page 411 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Below 0.45 V just after release of accelerator pedal (lean condition) VERIFY CURRENT INPUT SIGNAL Yes Go to the next step. STATUS OF MAF SENSOR • Connect the WDS or equivalent to the DLC-2 •...

  • Page 412: Dtc P2187 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FUEL LINE PRESSURE If fuel line pressure is low, go to the next step. INSPECTION.) • Is fuel line pressure normal? Replace suspected fuel line, then go to the next step.
  • Page 413 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PENDING CODE is available if PCM detects the above malfunction conditions during first drive cycle. • FREEZE FRAME DATA is available. • DTC is stored in the PCM memory.
  • Page 414 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes IDENTIFY TRIGGER DTC FOR FREEZE Yes Go to the next step. FRAME DATA Go to troubleshooting procedures for DTC on • Is DTC P2177 on FREEZE FRAME FREEZE FRAME DATA.
  • Page 415 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Visually inspect for loosen, cracks or damages hoses on intake-air system. No Go to the next step. • Is there any malfunction? INSPECT PURGE SOLENOID VALVE Replace purge solenoid valve.

  • Page 416: Dtc P2188 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is fuel injector normal? VERIFY TROUBLESHOOTING OF DTC Replace PCM, then go to the next step. P2187 COMPLETED (See PCM REMOVAL/INSTALLATION [LF].) • Make sure to reconnect all disconnected connectors.
  • Page 417 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel pump malfunction • EGR valve stuck open • VTCS improper operation • Purge solenoid valve improper operation • Purge solenoid valve malfunction (stuck open) • Purge solenoid hoses improper connection •...
  • Page 418 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Inspect same PIDs as Step 5 while Then go to Step 15. simulating FREEZE FRAME DATA condition. No Go to the next step. • Is there any signal which causes drastic...

  • Page 419: Dtc P2195 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Carry out Variable Tumble Control System (VTCS) Operation Inspection. Repair or replace malfunctioning part (See Variable Tumble Control Operation according to inspection result, then go to Step Inspection.)
  • Page 420 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010202100W05 DTC P2195 Front HO2S signal stuck lean • The PCM monitors the front HO2S output voltage when the following conditions are met. If output voltage is less than 0.45 V for 41 s, the PCM determines that the front HO2S signal remains lean.
  • Page 421 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is any related repair information available? No Go to the next step. VERIFY RELATED PENDING CODE OR Go to applicable DTC troubleshooting. STORED DTC (See DTC TABLE [LF].)
  • Page 422 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY CURRENT INPUT SIGNAL STATUS Yes Go to the next step. OF MAF SENSOR • Connect the WDS or equivalent to the DLC-2. • Start the engine.

  • Page 423: Dtc P2196 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is the PENDING CODE for this DTC present? VERIFY AFTER REPAIR PROCEDURE Go to the applicable DTC inspection. • Perform "After Repair Procedure". (See DTC TABLE [LF].)
  • Page 424 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been recorded? repair order, then go to the next step.

  • Page 425: Dtc P2228 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT FRONT HO2S Replace front HO2S, then go to Step 10. • Inspect the front HO2S. (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [LF].) (See FRONT HEATED OXYGEN SENSOR (HO2S) INSPECTION [LF].)
  • Page 426 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic support note • This is a continuous monitor (CCM). • MIL illuminates if PCM detects the above malfunction condition during first drive cycle. • PENDING CODE is available if PCM detects the above malfunction condition.
  • Page 427 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Verify related service repair information • If the vehicle is not repaired, go to the next availability. step. • Is any related repair information available? No Go to the next step.

  • Page 428: Dtc P2229 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT PCM CONNECTOR FOR POOR Yes Repair terminal, then go to Step 9. CONNECTION • Disconnect PCM connector. • Inspect for poor connection at terminals No Go to the next step.
  • Page 429 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open circuit in wiring between BARO sensor terminal A and PCM terminal • Open circuit in wiring between BARO sensor terminal B and PCM terminal • Short to power circuit in wiring between BARO sensor terminal A and PCM terminal 1AG •...
  • Page 430 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT BARO SENSOR CONNECTOR Repair or replace suspected terminal, then FOR POOR CONNECTION go to Step 9. • Disconnect the BARO sensor connector. • Inspect for poor connection No Go to the next step.

  • Page 431: Dtc P2502 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Is same DTC present? VERIFY AFTER REPAIR PROCEDURE Go to applicable DTC troubleshooting. • Perform "After Repair Procedure". (See DTC TABLE [LF].) (See AFTER REPAIR PROCEDURE [LF].)
  • Page 432 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the repair • Has FREEZE FRAME DATA been order, then go to the next step.

  • Page 433: Dtc P2503 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VERIFY AFTER REPAIR PROCEDURE Go to applicable DTC troubleshooting. • Perform "After Repair Procedure". (See DTC TABLE [LF].) (See AFTER REPAIR PROCEDURE [LF].) No Troubleshooting completed. • Is there any DTC present?
  • Page 434 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Yes Go to the next step. VERIFY FREEZE FRAME DATA HAS BEEN RECORDED Record the FREEZE FRAME DATA on • Has FREEZE FRAME DATA been recorded? the repair order, then go to the next step.

  • Page 435: Dtc P2504 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INSPECT GENERATOR CONTROL CIRCUIT FOR OPEN • Inspect for continuity between generator Repair or replace wiring harness for open terminal D (wiring harness-side) and PCM circuit, then go to Step 10.
  • Page 436 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION ACTION VERIFY FREEZE FRAME DATA HAS Yes Go to the next step. BEEN RECORDED Record the FREEZE FRAME DATA on the • Has FREEZE FRAME DATA been repair order, then go to the next step.

  • Page 437: Dtc P2507 [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Measure voltage between generator terminal D (wiring harness-side) and body ground. • Is the voltage B+? INSPECT POOR CONNECTION OF PCM Yes Repair or replace pins, then go to Step 8.
  • Page 438 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010201083W06 DTC P2507 PCM B+ voltage low • The PCM monitors the voltage of back-up battery positive terminal at PCM terminal 1BA. If the PCM detected battery positive terminal voltage below DETECTION 2.5 V for 2 s, the PCM determines that the backup voltage circuit has...
  • Page 439 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Turn the ignition switch to off. • If EEC fuse has been melt down, then go to the next step. • Inspect EEC fuse for failure and proper.

  • Page 440: Symptom Troubleshooting[Engine Control System (Z6)]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes SYMPTOM TROUBLESHOOTING[ENGINE CONTROL SYSTEM (Z6)] ENGINE SYMPTOM TROUBLESHOOTING [Z6] B3E010318881W32 • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. Diagnostic Index...
  • Page 441 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes The engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stalls/quits. Acceleration/cruise The engine stops unexpectedly while cruising. The engine speed fluctuates during acceleration or Engine runs rough.

  • Page 442: Quick Diagnosis Chart [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Upshift/downshift/ 28 ATX concerns ATX concerns not related to engine performance engagement QUICK DIAGNOSIS CHART [Z6] B3E010318881W33 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 443 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 444 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 445: 1 Melting Of Main Or Other Fuses [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes NO.1 MELTING OF MAIN OR OTHER FUSES [Z6] B3E010318881W34 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse. Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 446 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Damaged fuse Related wiring harness IG KEY1 fuse IG KEY1 • Ignition switch (30 A) - ENGINE fuse ENGINE fuse ENGINE (20 A) • Main relay IG KEY2 fuse IG KEY2 •...

  • Page 447: 2 Mil Illuminates [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PCM (10 A) • Fuel pump relay FUEL PUMP fuse FUEL PUMP (15 A) • Fuel pump relay FAN fuse (40 A) • FAN control module...

  • Page 448: 3 Will Not Crank [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If normal, return to diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [Z6].) • If malfunction remains, inspect related Service information perform repair or diagnosis.
  • Page 449 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Is the coil connector securely connected to Connect the coil connector securely. the coil? Return to Step 1. Go to the next step.
  • Page 450 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is clicking sound heard from the starter when the ignition switch is turned to START Go to Step 11. position? Inspect for seized/hydrolocked the engine, flywheel or drive plate.

  • Page 451: 4 Hard To Start/Long Crank/Erratic Start/Erratic Crank [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes No DTC is displayed: Inspect following: • START circuit in ignition switch • Open circuit in wiring harness between ignition switch and starter DTC is displayed: Go to the appropriate DTC inspection.
  • Page 452 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Spark plug malfunction • Air leakage from intake-air system • Erratic signal from CKP sensor • Erratic signal from CMP sensor • Improper air/fuel mixture ratio control •...
  • Page 453 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Proper fuel quality (such as proper octane, contamination, winter/summer blend) • Loose bands on intake-air system • Cracks on intake-air system parts • Air cleaner restriction...
  • Page 454 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is the gap within specification? Go to the next step. Remove and shake the PCV valve. Does the PCV valve rattle? Replace the PCV valve. Go to the next step.

  • Page 455: 5 Engine Stalls-After Start/At Idle [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect engine condition while tapping Replace EGR valve. the EGR valve housing. Go to the next step. Does the engine condition improve? Inspect for loose connectors or poor terminal contact.
  • Page 456 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Air cleaner restriction • Restriction in exhaust system • Electrical connector disconnection • Open or short circuit in fuel pump body and related wiring harness • No battery power supply to PCM or poor GND •...
  • Page 457 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The following test should be performed for vehicles with immobilizer system. Go to Step 8 for vehicles without immobilizer system. Either or other condition appears: Connect the WDS or equivalent to the DLC-2.
  • Page 458 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Verify the following: Go to the next step. • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system •...
  • Page 459 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Inspect for the following: • Open or short circuit in CKP sensor • Open or short circuit between CKP Connect the WDS or equivalent to the sensor terminal A and PCM terminal 2T DLC-2.
  • Page 460 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Install the spark plugs on original cylinders. Go to the next step. Go to the next step. Remove and shake the PCV valve. Does the PCV valve rattle? Replace the PCV valve.

  • Page 461: 6 Cranks Normally But Will Not Start [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Condenser fan operation (See REFRIGERANT PRESSURE CHECK.) Disconnect the vacuum hose between Inspect if the purge solenoid valve is stuck the purge solenoid valve and the intake open mechanically.
  • Page 462 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes CRANKS NORMALLY BUT WILL NOT START • The starter cranks the engine at normal speed but the engine will not run. • Refer to symptom troubleshooting "No.5 Engine stalls" if this symptom appears after the engine stall.
  • Page 463 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Pressure regulator malfunction Warning The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services: •...
  • Page 464 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect the instrument cluster and wiring harness. (See INSTRUMENT CLUSTER INSPECTION.) Connect the WDS equivalent to the DLC-2 Go to the appropriate DTC inspection. and retrieve DTC.
  • Page 465 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Are all items normal? DTC is displayed: Go to the appropriate DTC inspection. (See DTC TABLE [Z6].) Communication error message is displayed: Inspect for following: • Open circuit in wiring harness between...
  • Page 466 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open or short circuit in CKP sensor wiring harnesses If the CKP sensor and wiring harness are normal, go to the next step. Visually inspect the CKP sensor and teeth Go to the next step.
  • Page 467 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Zero or low: Inspect the fuel pump relay and the fuel pump related circuit. Install fuel pressure gauge between fuel pipe and the fuel distributor. (See FUEL PUMP UNIT INSPECTION.)

  • Page 468: 7 Slow Return To Idle [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect variable valve timing control system operation. (See Variable Valve Timing Control System Repair or replace the malfunctioning Operation Inspection.) part. Does variable valve timing control work...

  • Page 469: 8 Engine Runs Rough/Rolling Idle [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Retrieve any continuous memory, (See DTC TABLE [Z6].) KOEO and KOER DTCs using WDS or equivalent. No DTC is displayed: Are there DTCs displayed? Go to the next step.
  • Page 470 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • A/C system operation is improper • Erratic signal to ignition coil • Spark plug malfunction • Purge solenoid valve malfunction • IAC valve improper operation • Idle learning of IAC system is not completed •...
  • Page 471 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION"...
  • Page 472 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to symptom troubleshooting "No.17 Cooling system concerns - Overheating". (See NO.17 COOLING SYSTEM Is the engine overheating? CONCERNS-OVERHEATING [Z6].) Go to the next step. Connect WDS or equivalent to DLC-2.
  • Page 473 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Measure gap between the CKP sensor Go to the next step. and teeth of crankshaft pulley. Specification Replace the crankshaft pulley. 0.5-1.5 mm {0.02-0.05 in} Is gap within specification? Inspect the ignition coil related wiring Go to the next step.
  • Page 474 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If condition is normal, inspect the fuel Does fuel line pressure hold after the ignition switch is turned off? injector. (See FUEL LINE PRESSURE (See FUEL INJECTOR INSPECTION.)

  • Page 475: 9 Fast Idle/Runs On [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect variable valve timing control system operation. (See Variable Valve Timing Control Repair or replace the malfunctioning part. System Operation Inspection.) Does variable valve timing control system work properly? Remove EGR valve and visually inspect for mechanically stuck EGR valve.
  • Page 476 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. ECT PID is more than 112°C {234°F}: Connect the WDS or equivalent to the Go to symptom troubleshooting "No.17 DLC-2. Cooling system concerns - Overheating".

  • Page 477: 10 Low Idle/Stalls During Deceleration [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes PSP PID: Inspect the PSP switch. (See POWER STEERING PRESSURE (PSP) SWITCH INSPECTION [Z6].) Repair or replace part if necessary. Is there air leakage felt or heard at the Verify accelerator cable free play.
  • Page 478 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Improper A/C magnetic clutch operation Diagnostic procedure STEP INSPECTION RESULTS ACTION Go to symptom troubleshooting "No.8 Engine runs rough/rolling idle". (See NO.8 ENGINE RUNS Does the engine idle rough? ROUGH/ROLLING IDLE [Z6].)
  • Page 479 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes manifold from the purge solenoid valve side. Plug the opening end of vacuum hose. Go to the next step. Drive the vehicle. Does the engine condition improve? Intermittent concern exists.

  • Page 480: 11 Engine Stalls/Quits, Engine Runs Rough, Misses, Buck/Jerk, Hesitation/Stumble, Surges [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See TRANSAXLE RANGE (TR) SWITCH INSPECTION.) Verify test results. • If normal, return to diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [Z6].) • If malfunction remains, inspect related Service information perform repair or diagnosis.
  • Page 481 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Erratic signal from CKP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Main relay intermittent malfunction • Throttle body malfunction • Engine overheating •...
  • Page 482 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes this, always complete the "BEFORE SERVICE PRECAUTION" and "AFTER SERVICE PRECAUTION" described in this manual. (See BEFORE SERVICE PRECAUTION.) (See AFTER SERVICE PRECAUTION.) Caution • If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe.
  • Page 483 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Go to the next step. RPM PID: Inspect the CKP sensor and related harness for such as vibration, intermittent open/short circuit. VPWR PID: Inspect for open circuit intermittently.
  • Page 484 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Install spark plugs on original cylinders. Go to the next step. Go to the next step. Remove and shake the PCV valve. Does the PCV valve rattle? Replace the PCV valve.
  • Page 485 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Note • Following test is for engine If the A/C is always on, go to symptom stalling with the A/C on. If other troubleshooting "No.24 A/C is always on or symptom exists, go to the next A/C compressor runs continuously".

  • Page 486: 12 Lack/Loss Of Power-Acceleration/Cruise [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect the EGR system. Go to the next step. (SeeEGR Control System Inspection.) Replace or replace the malfunctioning parts. Is the EGR system normal? Inspect the following: •...
  • Page 487 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Brake dragging • Erratic signal from CKP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Erratic signal to ignition coil • Engine overheating •...
  • Page 488 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.
  • Page 489 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect for intermittent open circuit of the MAF sensor and related wiring harness. TP PID: Inspect if the TP sensor output increases smoothly. IAT PID: Inspect for air suction in the intake-air system.
  • Page 490 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is there any deformed exhaust system part? Go to the next step. Zero or low: Install fuel pressure gauge between the Inspect the fuel pump relay and the fuel fuel pipe and the fuel distributor.
  • Page 491 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See A/C Cut-off Control System Inspect the A/C cut-off system components. Inspection.) (See A/C Cut-off Control System Does A/C cut-off function properly? Inspection.) Disconnect the vacuum hose between...

  • Page 492: 13 Knocking/Pinging-Acceleration/Cruise [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) NO.13 KNOCKING/PINGING-ACCELERATION/CRUISE [Z6] B3E010318881W46 KNOCKING/PINGING - ACCELERATION/CRUISE Sound is produced when air/fuel mixture is ignited by something other than spark plug DESCRIPTION (e.g.
  • Page 493 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Connect the WDS or equivalent to the DLC-2. Inspect cooling system for cause of Access ECT PID. overheating. Verify ECT PID is less than 116°C (See NO.17 COOLING SYSTEM {241°F} during driving.

  • Page 494: 14 Poor Fuel Economy [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FUEL LINE PRESSURE (See FUEL PUMP UNIT INSPECTION.) REMOVAL/INSTALLATION.) High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) Verify test results. • If normal, return to diagnostic index to service any additional symptoms.
  • Page 495 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Improper valve timing due to jumping out of timing belt • Contaminated MAF sensor • Improper engine compression • Exhaust system clogging Warning The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures.
  • Page 496 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Access ECT PID. Go to the next step. Drive vehicle while monitoring PID. Inspect for coolant leakage, cooling fan (See PCM INSPECTION [Z6].) operations or thermostat operation.

  • Page 497: 15 Emission Compliance [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Does the PCV valve rattle? Replace the PCV valve. Visually inspect the exhaust system part. Replace the suspected part. Is there any deformed exhaust system Go to the next step.
  • Page 498 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Exhaust system clogging • Fuel tank ventilation system malfunction • Charcoal canister damage • Air cleaner element clogging or restriction • Throttle body malfunction • Spark leakage from high-tension leads •...
  • Page 499 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness Are all items normal? DTC is displayed: Connect the WDS or equivalent to the DLC-2.

  • Page 500: 16 High Oil Consumption/Leakage [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If normal, replace fuel pump unit. Measure fuel line pressure during idle. (See FUEL PUMP UNIT Is fuel line pressure correct during REMOVAL/INSTALLATION.) idle? High: (See FUEL LINE PRESSURE INSPECTION.)

  • Page 501: 17 Cooling System Concerns-Overheating [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • PCV valve malfunction • Improper dipstick POSSIBLE CAUSE • Improper engine oil viscosity • Engine internal parts malfunction Diagnostic procedure STEP INSPECTION RESULTS ACTION Remove and shake Go to the next step.
  • Page 502 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Coolant leakage • Excessive A/C system pressure • A/C system operation is improper. • Improper water/anti-freeze mixture • Fans reverse rotation • Poor radiator condition • Thermostat malfunction •...
  • Page 503 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Turn the A/C switch on. Inspect for the following and repair or replace if necessary: Does A/C compressor engage? • Refrigerant charging amount • Open circuit in wiring harness between A/C relay and PCM terminal 1AL •...

  • Page 504: 18 Cooling System Concerns-Runs Cold [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the temperature gauge on the instrument (See THERMOSTAT INSPECTION [Z6].) cluster indicates normal range but ECT PID is not same as the temperature gauge Is the thermostat normal? reading, inspect the ECT sensor.

  • Page 505: 19 Exhaust Smoke [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Remove the thermostat and inspect operation. (See THERMOSTAT Replace the thermostat. REMOVAL/INSTALLATION [Z6].) (See THERMOSTAT REMOVAL/INSTALLATION (See THERMOSTAT [Z6].) INSPECTION [Z6].) Is the thermostat normal? Access ECT PID.
  • Page 506 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Cooling system malfunction (coolant loss) • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted.
  • Page 507 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Damaged valve guide, stems or valve seals • Blocked oil drain passage in cylinder head • Piston ring is not seated, seized or worn. Remove and shake the PCV •...

  • Page 508: 20 Fuel Odor (In Engine Compartment) [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Replace fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) Inspect the CMP sensor. Perform the spark test. (See CAMSHAFT POSITION (CMP) SENSOR (See Spark Test.) INSPECTION [Z6].)
  • Page 509 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See AFTER SERVICE PRECAUTION.) Caution • If there is foreign material on the connecting area of the quick release connector, it might damage the connector or fuel pipe. To prevent this, disconnect the connector and clean the connecting area before connecting.

  • Page 510: 21 Engine Noise [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If normal, return to diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [Z6].) • If malfunction remains, inspect related Service information perform repair or diagnosis.
  • Page 511 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Camshaft friction gear noise or MLA noise • Timing chain noise Diagnostic procedure STEP INSPECTION RESULTS ACTION Inspect for following: • Engine oil • Drive belt tension...

  • Page 512: 22 Vibration Concerns (Engine) [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See ENGINE SYMPTOM TROUBLESHOOTING [Z6].) • If malfunction remains, inspect related Service information perform repair or diagnosis. - If vehicle repaired, troubleshooting completed. - If vehicle not repaired or additional diagnostic information not available, replace the PCM.
  • Page 513 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010318881W56 A/C DOES NOT WORK SUFFICIENTLY. The A/C compressor magnetic clutch does not engage when the A/C switch is DESCRIPTION turned on. • Improper refrigerant charging amount •...

  • Page 514: 24 A/C Is Always On Or A/C Compressor Runs Continuously [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open circuit in wiring harness between Access AC_REQ PID. refrigerant pressure switch and PCM Turn the ignition switch to the ON terminal 1Q position position. • Open circuit of blower motor fan switch...
  • Page 515 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION RESULTS ACTION DTC is displayed: Go to the appropriate DTC Connect the WDS or equivalent to the DLC-2. inspection. Retrieve any continuous memory, KOEO and...

  • Page 516: 25 A/C Is Not Cut Off Under Wide Open Throttle Conditions [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • AC_REQ PID should read Off when turning A/C switch off. If AC_REQ PID Inspect for stuck closed the A/C remains On, short to GND may be switch.

  • Page 517: 26 Exhaust Sulphur Smell [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Are there any DTCs displayed? No DTC is displayed: Inspect the TP sensor for proper adjustment. Verify test results. • If normal, return to diagnostic index to service any additional symptoms.
  • Page 518 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION RESULTS ACTION Go to appropriate flow chart. Are any drive ability or exhaust smoke concerns present? Go to the next step. Inspect following: Go to the next step.

  • Page 519: 27 Spark Plug Condition [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See ENGINE SYMPTOM TROUBLESHOOTING [Z6].) • If malfunction remains, inspect related Service information perform repair or diagnosis. - If vehicle repaired, troubleshooting completed. - If vehicle not repaired or additional diagnostic information not available, replace the PCM.
  • Page 520 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE SERVICE PRECAUTION"...
  • Page 521 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect compression pressure at suspected malfunctioning cylinder. Repair or replace the malfunctioning Is compression pressure correct? part. (See COMPRESSION INSPECTION [Z6].) Install all spark plugs. Go to the next step.
  • Page 522 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Turn the ignition switch off. Inspect the fuel injector for following: Disconnect the PCM connector. (See FUEL INJECTOR INSPECTION.) Measure resistance between suspected the • Resistance fuel injector terminal B and the PCM connector following terminal: •...
  • Page 523 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Perform the purge control inspection. (When engine can be started) Repair or replace the malfunctioning (See Purge Control System Inspection.) part. Is purge control correct? Inspect for deformed exhaust system part.

  • Page 524: Intermittent Concern Troubleshooting [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - If vehicle not repaired or additional diagnostic information not available, replace PCM. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) INTERMITTENT CONCERN TROUBLESHOOTING [Z6] B3E010318881W61 Vibration Method 1. If malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform the steps below.

  • Page 525: Inspection Method For Sensor Connectors Or Wiring Harnesses

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspection Method for Sensor Connectors or Wiring Harnesses 1. Connect the WDS or equivalent to the DLC-2. 2. Turn the ignition switch to the ON position (Engine off).

  • Page 526: Inspection Method For Actuators Or Relays

    3. Prepare the Output State Control for actuators or relays that you are inspecting. 4. Vibrate the actuator or relay with your finger for 3 s are Output State Control is activated. • If variable click sound is heard, inspect for poor connection and/or poorly mounted actuator or relay.

  • Page 527: Engine Control System Operation Inspection [Z6]

    1. Verify the air intake hoses are installed properly. 2. Start the engine and idle it. 3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve from the intake manifold side. 4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.

  • Page 528: Idle Air Control System Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Fuel injector insulator - Engine compression (See COMPRESSION INSPECTION [Z6].) Idle Air Control System Inspection Engine coolant temperature compensation inspection 1. Connect the WDS or equivalent to the DLC-2.

  • Page 529: Variable Intake-Air Control Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Excludes temporary idle speed drop just after the loads are turned on. 7. Verify that the engine speed is within the specification under each load condition.

  • Page 530: Variable Tumble Control Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Turn the ignition switch to the ON position (Engine off). 5. Turn variable intake-air shutter valve actuator from on to off and from off to on using the IMTV PID and verify that operation sound of the actuator is heard.

  • Page 531: Fuel Cut Control System Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes All cylinders no heard: While cranking engine, inspect for fuel injector Go to the next step. operation sound at each cylinder using a soundscope. Some cylinders no heard: Is operation sound heard? Go to Step 3.

  • Page 532: Fuel Pump Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - TR switch and related wiring harness (ATX) (See TRANSAXLE RANGE (TR) SWITCH INSPECTION.) Fuel Pump Operation Inspection 1. Connect the WDS or equivalent to the DLC-2.

  • Page 533: Egr Control System Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test.

  • Page 534: Purge Control System Inspection

    [Z6].) 2. Start the engine and idle it. 3. Increase the step value of EGR valve from 0 to 40 using SEGRP PID. 4. Operate the EGR valve and inspect if the engine speed becomes unstable or the engine stalls.

  • Page 535: A/C Cut-Off Control System Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the WDS or equivalent indicates 60 °C {140 °F} or less, perform out the ECT sensor inspection. 5. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister.

  • Page 536: Cooling Fan Motor Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Open circuit or short to GND in wiring harness and connectors (Ignition switch-A/C relay-PCM terminal 1AL) - A/C related parts Cooling Fan Motor Operation Inspection 1. Verify that the battery voltage is above 12.4 V.

  • Page 537: Variable Valve Timing Control System Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Fan control module power supply circuit (open or short circuit) - Fan control module GND circuit (open or short circuit) - Fan control module control signal circuit (open or short circuit between fan control module...
  • Page 538 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Connect the WDS or equivalent to the DLC-2. 3. Idle the engine. 4. Access VT DUTY1 PID. 5. Set the OCV duty valve to 100% and verify that the engine idles roughly or stalls.

  • Page 539: Symptom Troubleshooting [Engine Control System (Lf)]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes SYMPTOM TROUBLESHOOTING [ENGINE CONTROL SYSTEM (LF)] ENGINE SYMPTOM TROUBLESHOOTING [LF] B3E010318881W01 • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. Diagnostic Index...

  • Page 540: Quick Diagnostic Chart [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Misses Acceleration/cruise Engine misses during acceleration or cruising. Acceleration/cruise/ Vehicle bucks/jerks during acceleration, cruising, or Buck/jerk deceleration deceleration. Momentary pause at beginning of acceleration or Hesitation/stumble Acceleration...
  • Page 541 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E010318881W02 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 542 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 543 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 544: 1 Melting Of Main Or Other Fuses [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes NO.1 MELTING OF MAIN OR OTHER FUSES [LF] B3E010318881W03 MELTING OF MAIN OR OTHER FUSES [TROUBLESHOOTING HINTS] Inspect condition of fuse. Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 545 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Damaged fuse Related wiring harness IG KEY1 fuse IG KEY1 • Ignition switch (30 A) - ENGINE fuse ENGINE fuse • Main relay • Ignition coil No.1 ENGINE •...

  • Page 546: 2 Mil Illuminates [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel injector No.3 • Fuel injector No.4 EGI INJ2 fuse EGI INJ2 (10 A) • PCM ENG BAR1 fuse • EGR valve • Variable intake-air solenoid valve ENG BAR1 •...

  • Page 547: 3 Will Not Crank [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the MIL blinks at steady rate, misfire condition could possibly exist. Diagnostic procedure STEP INSPECTION RESULTS ACTION DTC is displayed: • Go to the appropriate DTC inspection.
  • Page 548 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STEP INSPECTION RESULTS ACTION Both conditions appear: Note • The following test should be performed Go to Step 4. for vehicles with immobilizer system. Go to Step 7 for vehicles without immobilizer system.
  • Page 549 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Battery condition Repeat Step 7. • Fuses Are all items normal? Go to the next step. Is clicking sound heard from starter when the ignition switch is turned to START? Go to Step 13.

  • Page 550: 4 Hard To Start/Long Crank/Erratic Start/Erratic Crank [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open circuit in wiring harness between ignition switch and starter DTC is displayed: Go to the appropriate DTC inspection. Retrieve any KOEO DTCs using WDS or...
  • Page 551 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Erratic signal from CMP sensor • Improper air/fuel mixture ratio control • Air cleaner restriction • IAC valve malfunction • PCV valve malfunction • Inadequate fuel pressure •...
  • Page 552 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Intake-air system restriction (e.g. air cleaner element, fresh air duct.) Are all items normal? DTC is displayed: Connect the WDS or equivalent to the DLC-2. Go to the appropriate DTC inspection.
  • Page 553 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Does the PCV valve rattle? Replace the PCV valve. Go to the next step. Zero or low: Install fuel pressure gauge between Inspect the fuel pump and fuel pump relay the fuel pipe and the fuel distributor.

  • Page 554: 5 Engine Stalls-After Start/At Idle [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect engine condition while tapping the EGR valve housing. Go to the next step. Does engine condition improve? Inspect for loose connectors or poor terminal contact. Inspect the starting system.
  • Page 555 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Restriction in exhaust system • Electrical connector disconnection • Open or short circuit in fuel pump body and related wiring harness • No battery power supply to PCM or poor GND •...
  • Page 556 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Connect the WDS or equivalent to the Go to the next step. DLC-2. Do the following conditions appear? • The engine is not completely started. • DTC P1260 is displayed.
  • Page 557 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold: EGR valve, IAC valve •...
  • Page 558 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Open or short circuit between CKP sensor terminal A and PCM terminal 2Y • Open or short circuit in between CKP sensor terminal B and PCM terminal 2Z •...
  • Page 559 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is there any deformed exhaust system Go to the next step. part? Go to the next step. Zero or low: Install the fuel pressure gauge between Inspect the fuel pump and fuel pump relay the fuel pipe and fuel distributor.

  • Page 560: 6 Cranks Normally But Will Not Start [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is air leakage felt or heard at the intake- Repair or replace the malfunctioning part. air system components while racing the engine to higher speed? Go to the next step.
  • Page 561 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Engine overheating • Vacuum leakage • Erratic signal to ignition coil • Improper air/fuel mixture ratio control • Poor fuel quality • PCV valve malfunction • Restriction in intake-air system •...
  • Page 562 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Diagnostic procedure STEP INSPECTION RESULTS ACTION Note Both conditions appear: • Following test should be Go to Step 3. performed for vehicles with immobilizer system. Go to Step 8 for vehicles without immobilizer system.
  • Page 563 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Between PCM terminal 1AI and instrument cluster terminal 1O • Between PCM terminal 1AM and Go to the next step. instrument cluster terminal 1M Is there any malfunction? Verify following: Go to the next step.
  • Page 564 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Go to Step 29. Does the engine start with the throttle valve closed? Go to the next step. Inspect the IAC valve and wiring Will the engine start and run smoothly at harness.
  • Page 565 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Spark plug is grayish white: Inspect the fuel injector for clogging. Install the spark plugs on original cylinders. Go to the next step. Go to the next step.

  • Page 566: 7 Slow Return To Idle [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Repair or replace the malfunctioning Is air leakage felt or heard at the intake-air part. system components while racing the engine to higher speed? Go to the next step.

  • Page 567: 8 Engine Runs Rough/Rolling Idle [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. ECT sensor and thermostat are normal. Go to the next step. Access ECT PID on the WDS or Remove thermostat and inspect equivalent.
  • Page 568 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Spark plug malfunction • Purge valve malfunction • IAC valve improper operation • Idle learning of IAC system is not completed • EGR valve malfunction • Erratic or no signal from CMP sensor •...
  • Page 569 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Caution • Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
  • Page 570 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Connect the WDS or equivalent to the Go to the next step. DLC-2. Access MAF PID. Drive vehicle with monitoring PID. Inspect for open or short circuit of MAF sensor and related wiring harness.
  • Page 571 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 0.5-1.9 mm {0.020-0.75 in} Is the gap within the specification? Inspect the ignition coil related wiring Go to the next step. harness condition (intermittent open or short circuit) for all cylinders.
  • Page 572 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Connect the WDS or equivalent to the Go to the next step. DLC-2. Warm up the engine and idle it. Access O2S11 PID. Inspect and repair or replace the front...

  • Page 573: 9 Fast Idle/Runs On [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See PCM REMOVAL/INSTALLATION [LF].) NO.9 FAST IDLE/RUNS ON [LF] B3E010318881W11 FAST IDLE/RUNS ON • The engine speed continues at fast idle after warm-up. DESCRIPTION • The engine runs after the ignition switch is turned off.

  • Page 574: 10 Low Idle/Stalls During Deceleration [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes AC_REQ PID: Inspect the A/C switch, refrigerant pressure switch and the fan switch. CPP PID: Connect the WDS or equivalent to the DLC-2. Inspect the clutch pedal position switch.
  • Page 575 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • IAC valve malfunction • Air leakage from intake-air system • Improper air/fuel mixture ratio control • Evaporative emission control system malfunction • TP sensor misadjustment • TP sensor or related circuit malfunction •...
  • Page 576 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Go to the next step. Inspect the following: Does the idle speed drop or stall when • Circuit from IAC valve to the PCM...

  • Page 577: 11 Engine Stalls/Quits, Engine Runs Rough, Misses, Buck/Jerk, Hesitation/Stumble, Surges [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If normal, return to diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [LF].) • If malfunction remains, inspect related Service information perform repair or diagnosis.
  • Page 578 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Vacuum leakage • Poor fuel quality • Main relay intermittent malfunction • Throttle body malfunction • Engine overheating • Erratic signal to ignition coil • Improper air/fuel mixture ratio control operation •...
  • Page 579 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See AFTER SERVICE PRECAUTION.) Caution • Disconnecting/connecting quick release connector without cleaning it may possibly cause damage to fuel pipe and quick release connector. Always clean quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material.
  • Page 580 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Access RPM, VPWR, MAF, TP and Inspect the CKP sensor and related wiring VSS PIDs. harness for such as vibration, intermittent open/short circuit. Drive the vehicle with monitoring PIDs.
  • Page 581 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is the lever in correct position? Visually inspect deformed exhaust Replace the suspected part. system part. Is there any deformed exhaust system Go to the next step.
  • Page 582 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Connect the WDS or equivalent to the DLC-2. Warm up the engine and idle it. Inspect and repair or replace the front HO2S, Access O2S11 PID. wiring harness, connector or terminal, then go to the next step.

  • Page 583: 12 Lack/Loss Of Power-Acceleration/Cruise [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Engine mounts • Check valve (two-way) Inspect for cause. Verify test results. • If normal, return to diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [LF].)
  • Page 584 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Throttle body malfunction • Spark plug malfunction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system •...
  • Page 585 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold; such as EGR valve, IAC valve • Fuel quality (such as proper octane,...
  • Page 586 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect for intermittent open circuit of VSS and related wiring harness. Visually inspect CKP sensor and teeth Go to the next step. of crankshaft pulley. Are CKP sensor and teeth of Replace the malfunctioning part.
  • Page 587 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) Inspect the variable tumble control Go to the next step. operation. (See Variable Tumble Control Operation Inspection.) Repair or replace the malfunctioning part.

  • Page 588: 13 Knocking/Pinging-Acceleration/Cruise [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect the EGR system. Go to the next step. (See EGR Control System Inspection.) Replace the malfunctioning part. Is the EGR system normal? Inspect the following: • Valve timing •...
  • Page 589 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes The following troubleshooting flow chart contains the fuel system diagnosis and repair procedures. Read the following warnings before performing the fuel system services: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.

  • Page 590: 14 Poor Fuel Economy [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect ignition timing. Low: Install fuel pressure gauge between the fuel Inspect the fuel line for clogging. pipe and fuel distributor. • If there is no malfunction, replace the Start the engine and idle it.
  • Page 591 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Spark plug malfunction • PCV valve malfunction • Brake dragging • Improper valve timing due to jumping out of timing belt • Contaminated MAF sensor • Improper engine compression •...
  • Page 592 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Retrieve any continuous memory, KOEO No DTC is displayed: and KOER DTCs using WDS or equivalent. Go to the next step. Are there any DTCs displayed? Access ECT PID.

  • Page 593: 15 Emission Compliance [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Visually inspect the exhaust system part. Replace the suspected part. Is there any deformed exhaust system Go to the next step. part? Go to the next step.
  • Page 594 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Charcoal canister damage • Air cleaner element clogging or restriction • Throttle body malfunction • Erratic signal to ignition coil • Improper air/fuel mixture ratio control operation •...
  • Page 595 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Intake-air system and air cleaner element concerns: obstructions, leakage or dirtiness Are all items normal? DTC is displayed: Connect the WDS or equivalent to the DLC-2.

  • Page 596: 16 High Oil Consumption/Leakage [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If normal, replace fuel pump unit. Measure fuel line pressure during idle. (See FUEL PUMP UNIT Is fuel line pressure correct during REMOVAL/INSTALLATION.) idle? High: (See FUEL LINE PRESSURE INSPECTION.)

  • Page 597: 17 Cooling System Concerns-Overheating [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes HIGH OIL CONSUMPTION/LEAKAGE Oil consumption is excessive. DESCRIPTION • PCV valve malfunction • Improper dipstick POSSIBLE CAUSE • Improper engine oil viscosity • Engine internal parts malfunction...
  • Page 598 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Improper coolant level • Blown fuses • Coolant leakage • Excessive A/C system pressure • A/C system operation is improper • Improper water/anti-freeze mixture • Fans reverse rotation •...
  • Page 599 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Go to Step 5. Inspect for following and repair or replace if necessary: Start the engine and idle it. • Refrigerant charging amount Turn the A/C switch on.

  • Page 600: 18 Cooling System Concerns-Runs Cold [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See THERMOSTAT Access ECT PID. REMOVAL/INSTALLATION [LF].) Inspect for both ECT PID and temperature (See THERMOSTAT INSPECTION gauge readings. [LF].) • If temperature gauge on instrument cluster...

  • Page 601: 19 Exhaust Smoke [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Remove thermostat and inspect Go to the next step. operation. (See THERMOSTAT REMOVAL/INSTALLATION [LF].) Replace the thermostat. (See THERMOSTAT INSPECTION [LF].) Is thermostat normal? Access ECT PID.
  • Page 602 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes White smoke (Water in combustion): • Cooling system malfunction (coolant loss) • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted.
  • Page 603 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to Step 4. Inspect for the following: • Damaged valve guide, stems or valve seals • Blocked oil drain passage in cylinder head • Piston ring is not seated, seized or worn.

  • Page 604: 20 Fuel Odor (In Engine Compartment) [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FUEL LINE PRESSURE (See FUEL PUMP UNIT INSPECTION.) REMOVAL/INSTALLATION.) High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) Inspect spark plugs and CMP sensor.
  • Page 605 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes The following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system services: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.

  • Page 606: 21 Engine Noise [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the appropriate DTC inspection. (See DTC TABLE [LF].) Connect the WDS or equivalent to the DLC- No DTC is displayed: Retrieve any continuous memory, KOEO and KOER DTCs using WDS or equivalent.
  • Page 607 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Improper drive belt tension • Improper P/S fluid level Rap or roar sound noise: • Dynamic dumper looseness • Exhaust system looseness • Intake-air system looseness Other noise: •...

  • Page 608: 22 Vibration Concerns (Engine) [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to the next step. Go to symptom troubleshooting "No.11 Knocking/pinging". (See NO.13 KNOCKING/PINGING- Is a knocking sound ACCELERATION/CRUISE [LF].) present? If the noise comes from the engine internal, inspect for friction gear, timing chain or MLA noise.

  • Page 609: 23 A/C Does Not Work Sufficiently [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If normal, return to diagnostic index to service any additional symptoms. (See ENGINE SYMPTOM TROUBLESHOOTING [LF].) • If malfunction remains, inspect related Service information perform repair or diagnosis.

  • Page 610: 24 A/C Is Always On Or A/C Compressor Runs Continuously [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Is there correct voltage A/C compressor magnetic clutch terminal? Go to the next step. Specification More than 10.5 V Disconnect the refrigerant pressure Inspect refrigerant pressure switch switch connector.
  • Page 611 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY. A/C compressor magnetic clutch does not disengage. DESCRIPTION • Stuck engagement A/C compressor magnetic clutch • A/C relay is stuck closed.

  • Page 612: 25 A/C Is Not Cut Off Under Wide Open Throttle Conditions [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes remains On, short to GND may be present. Does AC_REQ PID remain On? Inspect the following: Reconnect refrigerant pressure switch connector. • Short to GND in wiring harness Read AC_REQ PID while turning off A/C switch.

  • Page 613: 26 Exhaust Sulphur Smell [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to symptom troubleshooting "No.24 A/C is always on or A/C compressor runs continuously". Does A/C compressor disengage when the A/C switch is turned off? (See NO.24 A/C IS ALWAYS ON OR A/C COMPRESSOR RUNS CONTINUOUSLY [LF].)
  • Page 614 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.

  • Page 615: 27 Spark Plug Condition [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) Replace the charcoal canister. Inspect the fuel tank vent system. Inspect the charcoal canister for fuel saturation.
  • Page 616 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Malfunction spark plug Wet/carbon is stuck on all plugs: • Spark-Spark weak • Air/fuel mixture-Too rich • Compression-Low compression • Clogging in intake/exhaust system Grayish white with all plugs: •...
  • Page 617 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Go to Step 15. Inspect all areas related to oil, working up and Are the spark plug wet/covered with down. carbon by engine oil? Go to the next step.
  • Page 618 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Inspect the spark plug for following. Go to the next step. • Heat range • Air gap Replace the spark plug. Is the spark plug normal? Remove the suspected fuel injector.
  • Page 619 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • O2S11 (When engine can be started) • O2S12 (When engine can be started) • MAF (See PCM INSPECTION [LF].) Are PIDs normal? Perform the purge control Go to the next step.

  • Page 620: Intermittent Concern Troubleshooting [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) High: Replace the fuel pump unit. (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) Verify test results. • If normal, return to diagnostic index to service any additional symptoms.

  • Page 621: Inspection Method For Sensor Connectors Or Wiring Harnesses

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If engine starts and runs, perform the following steps at idle. 3. Access PIDs for the switch you are inspecting. 4. Turn switch on manually. 5. Slightly shake each connector or wiring harness vertically and horizontally while monitoring the PID.

  • Page 622: Inspection Method For Actuators Or Relays

    3. Prepare the Output State Control for actuators or relays that you are inspecting. 4. Vibrate the actuator or relay with your finger for 3 s are Output State Control is activated. • If variable click sound is heard, inspect for poor connection and/or poorly mounted actuator or relay.

  • Page 623: Engine Control System Operation Inspection [Lf]

    1. Verify air intake hoses are installed properly. 2. Start the engine and run it at idle. 3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve from the intake manifold side. 4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.

  • Page 624: Idle Air Control System Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Air suction at throttle body, intake manifold and PCV valve installation points - Accelerator cable free play - Fuel injector insulator - Engine compression (See COMPRESSION INSPECTION [LF].)

  • Page 625: Variable Intake-Air Control Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • RPM Note • Excludes temporary idle speed drop just after the loads are turned on. 7. Verify that the engine speed is within the specification under each load condition.

  • Page 626: Variable Tumble Control Operation Inspection

    [LF].) (2) Turn the ignition switch to the ON position. (3) Turn the variable tumble solenoid valve from on to off using the IMRC PID and verify that operation sound of the solenoid valve is heard. • If the operation sound is heard, inspect the following.

  • Page 627: Fuel Injector Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Vacuum hose and vacuum chamber for looseness or damage - Shutter valve actuator (See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [LF].) - Shutter valve stuck open or close •...

  • Page 628: Fuel Pump Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Access RPM and FUELPW1 PIDs. 5. Monitor both PIDs while performing the following steps. (1) Depress the accelerator pedal and increase the engine speed to 4,000 rpm.

  • Page 629: Spark Test

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the fuel pump relay is normal, inspect the following. - Wiring harnesses and connectors (Main relay-fuel pump relay-PCM) Spark Test 1. Remove the fuel pump relay.

  • Page 630: Egr Control System Inspection

    2. Start the engine and run it at idle. 3. Increase the step value of EGR valve from 0 to 40 using SEGRP PID. 4. Operate the EGR valve and inspect if the engine speed becomes unstable or the engine stalls.

  • Page 631: Purge Control System Inspection

    2. Disconnect the vacuum hose between the purge valve and the charcoal canister. 3. Put a finger to the purge valve and verify that there is no vacuum applied when the engine is cold. • If there is a vacuum, inspect the following.

  • Page 632: Cooling Fan Motor Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (4) Access ACCS PID. (5) Turn the A/C relay from off to on and inspect if the operation sound of the relay is heard. • If the operation sound is heard, inspect TP PID.
  • Page 633 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 8. Turn the A/C switch to on. 9. Verify that the cooling fan is operating while the ECT PID is below 98 °C {209 °F}. • If the cooling fan does not operate, inspect for the following:...

  • Page 634: Mechanical[Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes MECHANICAL[Z6] ENGINE LOCATION INDEX [Z6] B3E011015800W01 Drive belt (See DRIVE BELT INSPECTION [Z6].) (See DRIVE BELT REPLACEMENT [Z6].) Drive belt auto tensioner (See DRIVE BELT AUTO TENSIONER INSPECTION [Z6].)

  • Page 635: Drive Belt Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See VALVE CLEARANCE INSPECTION [Z6].) (See VALVE CLEARANCE ADJUSTMENT [Z6].) Timing chain (See TIMING CHAIN REMOVAL/INSTALLATION [Z6].) Cylinder head gasket (See CYLINDER HEAD GASKET REPLACEMENT [Z6].) Front oil seal...

  • Page 636: Drive Belt Replacement [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If it exceeds the limit, replace the drive belt. (See DRIVE BELT REPLACEMENT [Z6].) 3. Install the under cover and splash shield (RH). DRIVE BELT REPLACEMENT [Z6] B3E011015800W03 1.

  • Page 637: Valve Clearance Inspection [Z6]

    • If it does not move smoothly, replace the drive belt auto tensioner. 3. Rotate the drive belt auto tensioner pulley by hand and verify that it rotates smoothly. • If it does not move smoothly, replace the drive belt auto tensioner.

  • Page 638: Valve Clearance Adjustment [Z6]

    Note • Make sure to note down the measured values for choosing the suitable replacement tappets. (3) Rotate the crankshaft clockwise 360° so that the No.4 cylinder is at TDC of the compression stroke. (4) Measure the valve clearance at B shown in the figure.
  • Page 639 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6].) 6. Disconnect the ventilation hose. 7. Remove the cylinder head cover.
  • Page 640 • The timing chain presses the tensioner arm by the rotation of the crank pulley backwards (counterclockwise). (3) Rotate the bolt (M10 × 1.25) installed to the front cover by hand and insert it to the position where it catches the inside of the rib on the tensioner arm.
  • Page 641 13. Remove the camshaft sprocket installation bolt. 14. Remove the timing sprocket on the exhaust side with the timing chain positioned out of the way. 15. Loosen the camshaft cap installation bolts in 2-3 passes in the order shown in the figure. Downloaded from https://carmanualshub.com/...
  • Page 642 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 16. Remove the camshaft caps. 17. Remove the intake and exhaust camshafts. 18. Remove the tappets. 19. Select a proper tappet according to the result of the valve clearance inspection and install it.
  • Page 643 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 23. Tighten the camshaft installation bolts in 2-3 passes uniformly in the order shown in the figure. Tightening torque 11.3-14.2 N·m {1.16-1.44 kgf·m, 8.4-10.4 ft·lbf} 24. Align the sprocket timing marks on the intake and exhaust camshafts so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.
  • Page 644 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 26. Tighten the camshaft sprocket installation bolt. Tightening torque 49.6-60.8 N·m {5.06-6.19 kgf·m, 36.6-44.8 ft·lbf} 27. Remove the bolt (M10 × 1.25) holding the tensioner arm. 28. Verify that there is no slack in the timing chain, and then verify that the marks on the camshaft sprocket and the crank pulley are aligned.

  • Page 645: Compression Inspection [Z6]

    1. Verify that the battery is fully charged. (See BATTERY INSPECTION.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and leave it for approx.10 min to cool down the exhaust system. 4. Remove the fuel pump relay. (See BEFORE SERVICE PRECAUTION.) 5.

  • Page 646: Timing Chain Removal/Installation [Z6]

    , 28.5 psi} or more perform Steps (1) to (3) adding a small quantity of engine oil from the spark plug hole. • If the pressure increases by adding the engine oil, the piston ring or the cylinder surface is worn, or they are damaged.
  • Page 647 ENGINE OIL LEVEL INSPECTION [Z6].) (2) Pulley and belt for runout and contact (3) Ignition timing and idle speed. Verify the amount of CO and HC. (See ENGINE TUNE-UP [Z6].) 10. Perform a road test and verify that there is no abnormal vibration or noise.
  • Page 648 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Cylinder head cover (See Cylinder Head Cover Installation Note.) Crankshaft pulley installation bolt (See Crankshaft Pulley Installation Bolt Removal Note.) (See Crankshaft Pulley Installation Bolt Installation Note.)

  • Page 649: Crankshaft Pulley Installation Bolt Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Engine front cover (See Engine Front Cover Removal Note.) (See Engine Front Cover Installation Note.) 9 Chain tensioner (See Chain Tensioner Removal Note.) 10 Chain tensioner arm...

  • Page 650: Chain Tensioner Removal Note

    2. Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down. 3. Release the link plate with the plunger still pressed down. 4. Release the pressure slightly from the plunger, and move the plunger back and forth 2-3 mm {0.08- 0.11 in).

  • Page 651: Timing Chain Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Timing Chain Removal Note 1. Rotate the crankshaft clockwise and align the key groove of the crankshaft sprocket with the timing mark, and then position the No.1 cylinder to TDC.

  • Page 652: Engine Front Cover Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Align the timing marks on the camshaft sprockets so that they form a straight line in alignment with the upper horizontal surface of the cylinder head.
  • Page 653 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Caution • Install the engine front cover within 10 min of applying the silicone sealant. Thickness 2-4 mm {0.08-0.15 in) 2. Tighten the engine front cover installation bolts in the order shown in the figure.

  • Page 654: 3 Engine Mount Installation Note

    Tightening torque 7-13 N·m {0.8-1.3 kgf·m, 5.2-9.5 ft·lbf} 2. Install the No.3 engine mount and temporarily tighten the installation bolts and nuts. 3. Tighten the installation bolts in the order shown in the figure. Tightening torque Downloaded from https://carmanualshub.com/...

  • Page 655: Crankshaft Pulley Installation Bolt Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 (nuts) : 44-61 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf} 2 (bolts) : 74.5-104.9 N·m {7.60-10.70 kgf·m, 55.0-77.3 ft·lbf} Crankshaft Pulley Installation Bolt Installation Note 1. Fix the crankshaft pulley using the SSTs.

  • Page 656: Cylinder Head Gasket Replacement [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Tightening torque 6.9-10.8 N·m {70-110 kgf·cm, 61.1-95.5 in·lbf} CYLINDER HEAD GASKET REPLACEMENT [Z6] B3E011010271W01 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

  • Page 657: Camshaft Cap Removal Note

    Cylinder Head Removal Note) (See Cylinder Head Installation Note) 4 Cylinder head gasket Camshaft Cap Removal Note 1. Loosen the camshaft cap installation bolts in 2-3 passes in the order shown in the figure. Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 658: Cylinder Head Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Remove the camshaft caps. Cylinder Head Removal Note 1. Loosen the cylinder head installation bolts in 2-3 passes in the order shown in the figure, and remove them. Cylinder Head Installation Note 1.

  • Page 659: Camshaft Cap Installation Note

    2. Install the camshaft caps in the positions numbered as shown in the figure, and then temporarily tighten the No.2 and No.7 camshaft cap installation bolts. 3. Tighten the camshaft cap installation bolts in 2-3 passes uniformly in the order shown in the figure. Tightening torque 11.3-14.2 N·m {116-144 kgf·cm, 101-125 in·lbf}...

  • Page 660: Crankshaft Pulley Installation Bolt Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1. Remove the battery cover. 2. Disconnect the negative battery cable. 3. Remove the drive belt. (See DRIVE BELT REPLACEMENT [Z6].) 4. Remove in the order indicated in the table.

  • Page 661: Front Oil Seal Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Front Oil Seal Removal Note 1. Remove the oil seal lip using a cutting knife. 2. Remove the oil seal using a flathead screwdriver with the tip protected by a rag to prevent crankshaft oil seal damage.

  • Page 662: Crankshaft Pulley Installation Bolt Installation Note

    3. Flywheel (See CLUTCH UNIT REMOVAL/INSTALLATION.) 2. Remove the oil seal lip using a cutting knife. 3. Remove the oil seal using a flathead screwdriver with the tip protected by a rag to prevent crankshaft oil seal damage. Downloaded from https://carmanualshub.com/...

  • Page 663: Engine Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Apply clean engine oil to a new rear oil seal. 5. Insert the oil seal into the cylinder block by hand. 6. Install the rear oil seal using the SST.
  • Page 664 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage.
  • Page 665 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. Caution • Do not tighten the No.1 engine mount rubber installation bolt before installing the No.3 engine mount. (See No.3 Engine Mount Installation Note.)

  • Page 666: Main Fuse Block Connector Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Main fuse block connector (See Main Fuse Block Connector Removal Note.) No.3 Engine mount (See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.) (See No.3 Engine Mount Installation Note.)

  • Page 667: No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Pull the lock lever up and remove the connector. No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note 1. Secure the engine and the transaxle using an engine jack and attachment.

  • Page 668: No.3 Engine Mount Installation Note

    1. Tighten the No.3 engine mount installation stud bolts. Tightening torque 7-13 N·m {0.8-1.3 kgf·m, 5.2-9.5 ft·lbf} 2. Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts. 3. Tighten the installation bolts in the order shown in the figure. Downloaded from https://carmanualshub.com/...

  • Page 669: Engine Disassembly/Assembly [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Tightening torque 1 (nuts) : 44-61 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf} 2 (bolts) : 74.5-104.9 N·m {7.60-10.70 kgf·m, 55.0-77.3 ft·lbf} 4. Remove the engine jack and attachment.

  • Page 670: Variable Valve Timing Actuator Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • When attaching the SST in the engine rear side, install a suitable nut between the engine and the SST. Tightening torque 38-51 N·m {3.9-5.2 kgf·m, 29-37 ft·lbf} 2.

  • Page 671: Variable Valve Timing Actuator Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Disconnect the negative battery cable. 3. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 4. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [Z6].) 5.

  • Page 672: Oil Control Valve (Ocv) Removal/Installation [Z6]

    2. Secure the camshaft in a vise and fix the camshaft using a wrench on the cast hexagon as shown in the figure. 3. Loosen the variable valve timing actuator installation bolt, and then remove the variable valve timing actuator.
  • Page 673 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1. Remove the battery cover. 2. Disconnect the negative battery cable. 3. Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 4. Remove the accelerator cable and bracket.
  • Page 674 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Note • Wood slab height 4SD: approx. 35 mm {1.4 in} 5HB: approx. 60 mm {2.4 in} • Cut the wood slab into two pieces and insert.

  • Page 675: Oil Control Valve (Ocv) Inspection [Z6]

    18. Tighten the No.3 engine mount installation stud bolts. Tightening torque 7-13 N·m {0.8-1.3 kgf·m, 5.2-9.5 ft·lbf} 19. Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts. 20. Tighten the installation bolts and nuts in the order shown in the figure. Tightening torque 1 (nuts) : 44-61 N·m {4.5-6.2 kgf·m, 33-44 ft·lbf}...

  • Page 676: Spool Valve Operation Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Disconnect the negative battery cable. 3. Disconnect the OCV connector. 4. Measure the coil resistance between terminals A and B using a tester. • If not within the specification, replace the OCV.

  • Page 677: Engine Tune-Up [Z6]

    Engine Tune-up Preparation 1. Warm up the engine to normal operating temperature. (1) Increase the engine speed to 2,500-3,000 rpm until the cooling fan starts running. (2) When the cooling fan starts running, release the accelerator pedal and wait until the cooling fan stops running.

  • Page 678: Ignition Timing Inspection

    • Use a timing light that can detect the primary ignition signal. 2. Remove the PCM connector cover. 3. By referring to the following procedure, connect the timing light to the PCM terminal 2A wire. Caution • To prevent poor contact at the connector terminal, be careful not to pull the wire on the connector side.
  • Page 679 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Pull out the wire 20-30 mm so that the pickup clip of the timing light can be connected. After the ignition timing inspection, bundle the pulled out wire back together with other wires using tape.

  • Page 680: Idle Speed Inspection

    Ignition Timing Inspection.) 3. Verify that the idle speed is within the specification using the RPM DATA MONITOR function. • If not within the specification, adjust the idle speed to within the specification by turning the AAS after verifying that the ignition timing is within the specification.

  • Page 681: Idle Mixture Inspection

    Idle Mixture Inspection 1. Warm up the engine to normal operating temperature. (1) Increase the engine speed to 2,500-3,000 rpm until the cooling fan starts running. (2) When the cooling fan starts running, release the accelerator pedal and wait until the cooling fan stops running.

  • Page 682: Mechanical

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes MECHANICAL ENGINE LOCATION INDEX [LF] B3E011001002W01 Drive belt (See DRIVE BELT INSPECTION [LF].) (See DRIVE BELT REPLACEMENT [LF].) (See DRIVE BELT AUTO TENSIONER INSPECTION [LF].) Tappet (See VALVE CLEARANCE INSPECTION [LF].)

  • Page 683: Drive Belt Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See VALVE CLEARANCE ADJUSTMENT [LF].) Engine (See COMPRESSION INSPECTION [LF].) (See ENGINE REMOVAL/INSTALLATION [LF].) (See ENGINE DISASSEMBLY/ASSEMBLY [LF].) Timing chain (See TIMING CHAIN REMOVAL/INSTALLATION [LF].) Cylinder head gasket...

  • Page 684: A/C Drive Belt

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes A/C Drive Belt Note • Drive belt deflection/tension inspection is not necessary because of the use of the maintenance- free type A/C drive belt. • Replace the drive belt if it is found to be damaged during visual inspection, or if there is a malfunction or noise in the A/C compressor.
  • Page 685 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Set a new A/C drive belt and jig as shown in the figure. Caution • The A/C drive belt cannot be reused. Do not reinstall the A/C drive belt that was installed to the engine.

  • Page 686: Generator Drive Belt

    PLUG HOLE PLATE REMOVAL/INSTALLATION [LF].) 2. Remove the A/C drive belt. 3. Turn the center of the auto tensioner pulley counterclockwise to release tension to the drive belt tension. 4. Remove the generator drive belt. 5. Install a new generator drive belt.

  • Page 687: Drive Belt Auto Tensioner Inspection [Lf]

    • If it does not move smoothly, replace the generator drive belt auto tensioner. 3. Turn the generator drive belt auto tensioner pulley by hand and verify that it rotates smoothly. • If it does not move smoothly, replace the generator drive belt auto tensioner.

  • Page 688: Valve Clearance Adjustment [Lf]

    Standard [Engine cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0107-0.0129 in} (3) Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke. (4) Measure the valve clearance at B in the figure.
  • Page 689 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1. Remove the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF].) 2. Remove the battery cover (See BATTERY REMOVAL/INSTALLATION [LF].) 3. Disconnect the negative battery cable.
  • Page 690 (2) Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain. (3) Placing the suitable bolt (M6 X 1.0 length 25mm-35mm {0.99-1.37in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
  • Page 691 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 10. Remove the exhaust camshaft sprocket. 11. Loosen the camshaft cap bolts in 2-3 passes in the order shown in the figure. Note • The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly.
  • Page 692 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes EX: 0.27-0.33 mm {0.0107-0.0129 in} 15. Install the camshaft with No.1 cylinder aligned with the TDC position. 16. Tighten the camshaft cap bolt with the following 2 steps.
  • Page 693 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 22. Tighten the exhaust camshaft sprocket lock bolt. Tightening torque 69-75 N·m {7.1-7.6 kgf·m, 50.9-55.3 ft·lbf} 23. Remove the SST from the camshaft. 24. Remove the SST from the block lower blind plug.

  • Page 694: Compression Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (2) Cylinder block lower blind plug. Tightening torque 18-22 N·m {1.9-2.2 kgf·m, 14-16 ft·lbf} (3) Engine front cover lower blind plug. Tightening torque 10-14 N·m {1.1-1.4 kgf·m, 7.4-10.3 ft·lbf} (4) Cylinder head cover.
  • Page 695 INSPECTION.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool down for about 10 min. 4. Perform "Fuel Line Safety Procedures". Leave the fuel pump relay removed. (See BEFORE SERVICE PRECAUTION.)

  • Page 696: Timing Chain Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Engine type Item Standard 1,720 {17.54, 246.8} [300] Minimum 1,204 {12.28, 174.6} [300] Maximum difference between cylinders 196.1 {2.0, 28.5} 12. Disconnect the compression gauge. 13. Install the following parts.
  • Page 697 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (6) A/C compressor with the oil hose still connected and position the A/C compressor so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [LF].) (7) Coolant reserve tank with the hose still connected and position the coolant reserve tank so that it is out of the way.
  • Page 698 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Cylinder head cover (See Cylinder Head Cover Installation Note.) Crankshaft pulley lock bolt (See Crankshaft Pulley Lock Bolt Removal Note.) (See Crankshaft Pulley Lock Bolt Installation Note.)

  • Page 699: Crankshaft Pulley Lock Bolt Removal Note

    Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST. 3. Turn the crankshaft clockwise the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST). Downloaded from https://carmanualshub.com/...

  • Page 700: No.3 Engine Mount Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Hold the crankshaft pulley using the SSTs. No.3 Engine Mount Removal Note 1. Install the suitable wood slabs between the front fender panel and apron reinforcement upper.

  • Page 701: Chain Tensioner Removal Note

    1. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem using a thin screwdriver. 2. Slowly compress the tensioner piston. 3. Hold the tensioner piston using a 1.5 mm {0.059 in} wire or paper clip. Oil Pump Sprocket Removal Note 1.

  • Page 702: Timing Chain Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Timing Chain Installation Note 1. Install the SST to the camshaft as shown in the figure. 2. Install the timing chain. 3. Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain.

  • Page 703: Front Oil Seal Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Install the engine front cover within 10 min of applying the silicone sealant. Thickness A: 2.2-3.2 mm {0.087-0.125 in} B: 1.5-2.5 mm {0.059-0.098 in} 2. Install the engine front cover bolts in the order shown in the figure.

  • Page 704: 3 Engine Mount Rubber And No.3 Engine Mount Bracket Installation Note

    • If the No.3 engine mount bracket remove to the engine 2. Hand-tighten the No.3 engine mount rubber and No.3 engine mount bracket. 3. Tighten the bolts and nuts in the order as shown in the figure. Crankshaft Pulley Lock Bolt Installation Note 1.
  • Page 705 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Install the M6 x 1.0 bolt in by hand. 3. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST).

  • Page 706: Cylinder Head Cover Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (2) 87°-93° 6. Remove the M6 x 1.0 bolt. 7. Remove the SST from the camshaft. 8. Remove the SST from the cylinder block lower blind plug.

  • Page 707: Cylinder Head Gasket Replacement [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Tightening torque 8.0-10.5 N·m {81.6-107.1 kgf·cm, 70.9-94.4 in·lbf} CYLINDER HEAD GASKET REPLACEMENT [LF] B3E011010271W02 Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Page 708 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Inspect the compression. (See COMPRESSION INSPECTION [LF].) Downloaded from https://carmanualshub.com/...

  • Page 709: Camshaft Removal Note

    When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps. 1. Loosen the camshaft cap bolts in 2-3 passes in the order shown in the figure. Cylinder Head Removal Note 1.

  • Page 710: Camshaft Installation Note

    1. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft. 2. Temporarily tighten the camshaft bearing caps evenly in 2-3 passes. 3. Tighten the camshaft cap bolts in the order shown with the following two steps. Downloaded from https://carmanualshub.com/...

  • Page 711: Front Oil Seal Replacement [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Tighten torque (1) 5.0-9.0 N·m {51.0-91.7 kgf·cm, 44.3-79.6 in·lbf} (2) 14.0-17.0 N·m {1.5-1.7 kgf·m, 10.4-12.5 ft·lbf} FRONT OIL SEAL REPLACEMENT [LF] B3E011010602W02 1. Remove the plug hole plate (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF].)

  • Page 712: Crankshaft Pulley Lock Bolt Removal Note

    Crankshaft Pulley Lock Bolt Removal Note 1. Remove the cylinder block lower blind plug. 2. Install the SST. 3. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST). Downloaded from https://carmanualshub.com/...

  • Page 713: Front Oil Seal Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Hold the crankshaft pulley using the SSTs. Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver wrapped with a rag.

  • Page 714: Crankshaft Pulley Lock Bolt Installation Note

    2. Install the M6 x 1.0 bolt in by hand. 3. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST). 4. Hold the crankshaft pulley using the SSTs.

  • Page 715: Rear Oil Seal Replacement [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 5. Tighten the crankshaft pulley lock bolt in the order shown following 2 steps using the SST (49 D032 316). Tightening torque (1) 96-104 N·m {9.8-10.6 kgf·m, 70.9-76.7 ft·lbf} (2) 87°-93°...

  • Page 716: Rear Oil Seal Installation Note

    2. Apply clean engine oil to the new oil seal lip. 3. Install the rear oil seal using the installer as shown in the figure. 4. Tighten the rear oil seal bolts in the order as shown in the figure.

  • Page 717: Engine Removal/Installation [Lf]

    [LF].) 2. Remove the air hose and air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF].) 3. Remove the battery cover, battery duct, battery clamp, battery and battery tray (See BATTERY REMOVAL/INSTALLATION [LF].) 4. Disconnect the fuel hose (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)
  • Page 718 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 8. Disconnect the brake vacuum hose. 9. Remove the following parts. (1) Member (See EXHAUST SYSTEM REMOVAL/INSTALLATION [Z6].) (2) Front crossmember, front stabilizer, lower arm, steering gear and No.1 engine mount rubber...
  • Page 719 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Main fuse block connector (See Main Fuse Block Connector Removal Note.) No.1 engine mount rubber (See No.1 Engine Mount Rubber Installation Note.) No.3 Engine mount (See No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note.)

  • Page 720: Main Fuse Block Connector Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note.) (See No.3 Engine Mount and No.4 Engine Mount Rubber Installation Note.) 6 Engine, transaxle Main Fuse Block Connector Removal Note 1.
  • Page 721 • Do not tighten the bolt and nut for the No.1 engine mount rubber and No.4 engine mount rubber during this step. 3. Tighten the No.4 engine mount rubber installation bolt as shown in the figure. Tightening torque 66.6-93.1 N·m {6.8-9.4 kgf·m, 49.2-68.6 ft·lbf}...

  • Page 722: No.1 Engine Mount Rubber Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Tightening torque 7.0-13 N·m {71.4-132.5 kgf·cm, 62.0-115.0 in·lbf} 6. Tighten the No.3 engine joint bracket bolts and nuts in the order as shown in the figure. Tightening torque 74.5-104.9 N·m {7.60-10.6 kgf·m, 55.0-77.3 ft·lbf} No.1 Engine Mount Rubber Installation Note...

  • Page 723: Engine Disassembly/Assembly [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ENGINE DISASSEMBLY/ASSEMBLY [LF] B3E011001001W05 1. Disconnect the engine and manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].) 2. Remove the following part: (1) the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF].)

  • Page 724: Engine Tune-Up [Lf]

    1. Turn off all electrical loads. 2. Warm up the engine as follows. (1) Start the engine. (2) Maintain the engine speed 2,500-3,000 rpm until the cooling fans start to operate. (3) Release the accelerator pedal. (4) Wait until the cooling fans stop.

  • Page 725: Idle Mixture Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Condition Engine speed (rpm)* No load 600-700 Electrical loads* 650-750 (38-48A) Electrical loads* 700-800 (Above 42A) A/C ON and refrigerant pressure switch (middle) OFF 700-800 A/C ON and refrigerant pressure switch (middle) ON 700-800 *1 : Excludes temporary idle speed drop just after the electrical loads are turned on.

  • Page 726: Lubrication

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes LUBRICATION LUBRICATION SYSTEM LOCATION INDEX [Z6] B3E011101003W01 Oil pressure switch (See OIL PRESSURE INSPECTION [Z6].) Oil filter (See OIL FILTER REPLACEMENT [Z6].) Oil pan (See OIL PAN REMOVAL/INSTALLATION [Z6].)

  • Page 727: Oil Pressure Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E011101003W02 Oil pressure switch (See OIL PRESSURE INSPECTION [LF].) Oil filter (See OIL FILTER REPLACEMENT [LF].) Oil pan (See OIL PAN REMOVAL/INSTALLATION [LF].) Oil strainer (See OIL PUMP REMOVAL/INSTALLATION [LF].)
  • Page 728 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled. 1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6].)

  • Page 729: Oil Pressure Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 11. Install the oil pressure switch. Tightening torque 1217 Nm {1.2-1.8 kgf·m, 9-13 ft·lbf} 12. Install the under cover. 13. Connect the negative battery cable. 14. Install the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6].)
  • Page 730 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 6. Warm up the engine to normal operating temperature. 7. Run the engine at the specified speed, and note the gauge readings. • If the pressure is not as specified, inspect for the cause and repair or replace if necessary.

  • Page 731: Engine Oil Level Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 12. Install the under cover. 13. Connect the negative battery cable. 14. Install the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF].) 15. Start the engine and inspect for oil leakage.

  • Page 732: Engine Oil Replacement [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the oil level is below the MIN mark, add engine oil. ENGINE OIL REPLACEMENT [Z6] B3E011114001W03 Warning • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

  • Page 733: Engine Oil Replacement [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Specifications Item Europe Except Europe Grade API SL, ACEA A3 API SG, SH, SJ, SL, ILSAC GF-2, GF-3 Viscosity 40, 30, 20, 20W-20, 10W-30, 10W-40, 10W-50, 20W-40,...

  • Page 734: Oil Filter Replacement [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Remove the oil pan drain plug. 4. Drain the engine oil into a container. 5. Install the oil pan drain plug with a new washer. Oil pan drain plug tightening torque 30-41 N·m {3.1-4.1 kgf·m, 23-30 ft·lbf}...
  • Page 735 1. Remove the under cover. 2. Remove the oil filter using the SST. 3. Use a clean rag to wipe off the mounting surface on the cylinder block. 4. Apply clean oil to the O-ring of a new oil filter.

  • Page 736: Oil Filter Replacement [Lf]

    1. Remove the under cover. 2. Remove the oil filter using a commercially available, cap-type oil filter wrench (76 mm {3.0 in} diameter, 15 sided). 3. Use a clean rag to wipe off the mounting surface.

  • Page 737: Oil Pan Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 9. Install the under cover. OIL PAN REMOVAL/INSTALLATION [Z6] B3E011110040W01 Warning • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

  • Page 738: Oil Pan Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3 O-ring 6. Install in the reverse order of removal. 7. Add engine oil. (See ENGINE OIL REPLACEMENT [Z6].) 8. Start the engine and confirm that there is no oil leakage from areas worked on.

  • Page 739: Oil Pan Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Thickness 2.06.0 mm {0.080.24 in} 4. Tighten the bolts in the order shown. Tightening torque 7.810.8 N·m {80-110 kgf·cm, 69.1-95.5 in·lbf} OIL PAN REMOVAL/INSTALLATION [LF] B3E011110040W02 Warning •...
  • Page 740 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 6. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [LF].) 7. Remove the drive belt. (See DRIVE BELT REPLACEMENT [LF].) 8. Position the coolant reserve tank out of the way.

  • Page 741: Oil Pan Removal Note

    2. When reusing oil pan installation bolts, clean any old sealant from the bolts. 3. Use a square ruler to align the oil pan and the cylinder block junction side on the engine front cover side.

  • Page 742: Oil Pump Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Apply silicone sealant to the oil pan along the inside of the bolt holes as shown. Thickness 2.5 mm {0.098 in} 5. Tighten the bolts in the order shown.
  • Page 743 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Continuous exposure to used engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.

  • Page 744: Oil Pump Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Oil pump (See Oil Pump Installation Note.) 2 Oil pump gasket 13. Install in the reverse order of removal. 14. Add the engine coolant. (See ENGINE COOLANT REPLACEMENT.)

  • Page 745: Oil Pump Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Install the oil pump and the oil pump gasket to the engine as a single unit. OIL PUMP REMOVAL/INSTALLATION [LF] B3E011119220W02 Warning • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.

  • Page 746: Oil Pump Sprocket Removal/Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 19. Start the engine and inspect for oil leakage. • If the oil leaks, specify the faulty part and repair or replace it. 20. Inspect the oil level. (See ENGINE OIL LEVEL INSPECTION [LF].)

  • Page 747: Oil Pump Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Oil Pump Installation Note 1. Tighten the oil pump bolts in two steps in the order indicated in the figure. Tightening torque: 1) 8-10 N·m {82-101 kgf·cm, 71-88 in·lbf} 2) 20-25 N·m {2.1-2.5 kgf·m, 15.2-18.4 ft·lbf}...

  • Page 748: Inner Rotor, Outer Rotor Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Oil pump cover Inner rotor, outer rotor (See Inner Rotor, Outer Rotor Installation Note.) 3 Plunger plug 4 Plunger spring 5 Control plunger 6 Oil pump body 2.
  • Page 749 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If it exceeds the maximum specification, replace the inner rotor or the outer rotor, or the both. Standard tip clearance 0.020.18 mm {0.00080.0070 in} Maximum tip clearance 0.20 mm {0.0079 in}...
  • Page 750 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If it is less than the specification, replace the plunger spring. Free length 45.94 mm {1.8087 in} Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 751: Cooling System

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes COOLING SYSTEM COOLING SYSTEM LOCATION INDEX [Z6] B3E011201004W01 Cooling system cap (See COOLING SYSTEM CAP INSPECTION.) Radiator (See RADIATOR REMOVAL/INSTALLATION.) Thermostat (See THERMOSTAT REMOVAL/INSTALLATION [Z6].) (See THERMOSTAT INSPECTION [Z6].)

  • Page 752: Cooling System Location Index [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes COOLING SYSTEM LOCATION INDEX [LF] B3E011201004W02 Cooling system cap (See COOLING SYSTEM CAP INSPECTION.) Radiator (See RADIATOR REMOVAL/INSTALLATION.) Thermostat (See THERMOSTAT REMOVAL/INSTALLATION [LF].) (See THERMOSTAT INSPECTION [LF].)

  • Page 753: Engine Coolant Level Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. • Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.

  • Page 754: Engine Coolant Replacement

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ENGINE COOLANT REPLACEMENT B3E011215001W04 Warning • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. • Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap.
  • Page 755 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Remove the under cover. 3. Remove the radiator drain plug and drain the engine coolant into a container. 4. Flush the cooling system with water until all traces of color are gone.

  • Page 756: Engine Coolant Leakage Inspection

    1. Inspect the engine coolant level. 2. Remove the cooling system cap. 3. Clean the installation parts of the cooling system cap and the upper radiator hose. 4. Install the SST and a radiator cap tester to the coolant reserve tank filler port.

  • Page 757: Coolant Reserve Tank Removal/Installation

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 5. Apply pressure using the radiator cap tester. Caution • Applying more than Z6: 100 kPa {1.0 kgf/cm , 14.5 psi}, LF: 145 kPa {1.5 kgf/cm , 21 psi} can damage the hoses, fittings, and other components, and cause leakage.

  • Page 758: Cooling System Cap Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Hose 2 Coolant reserve tank 3. Install in the reverse order of removal. 4. Add engine coolant. (See ENGINE COOLANT REPLACEMENT.) 5. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION.)

  • Page 759: Radiator Removal/Installation

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Hold the cooling system cap downward and apply pressure gradually. Verify that the pressure holds for 10 s. • If the pressure is not held stable within the specification, replace the cooling system cap.

  • Page 760: Radiator Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Fan control module connector Cooling fan component (See Cooling Fan Component Installation Note.) 3 Radiator lower hose 4 Radiator upper hose 5 Radiator mount Radiator (See Radiator Removal Note.)
  • Page 761 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Remove the condenser from the radiator with the pipes still connected, by pressing the radiator side tab to unlock the tab B on the condenser. 3. Remove rubber mount A from the mount installation hole.

  • Page 762: Radiator Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Radiator Installation Note 1. Install the condenser to the radiator by aligning lower side tab B with the radiator side tab, install upper tab B, then install lower side tab B.

  • Page 763: Thermostat Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes THERMOSTAT REMOVAL/INSTALLATION [Z6] B3E011215171W01 Warning • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury. 1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6].)

  • Page 764: Thermostat Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 7. Install in the reverse order of removal. 8. Add engine coolant. (See ENGINE COOLANT REPLACEMENT.) 9. Inspect the system for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION.)

  • Page 765: Thermostat Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Hose 2 Lower radiator hose 3 Thermostat component 4 Gasket THERMOSTAT INSPECTION [Z6] B3E011215171W03 1. Inspect the thermostat for the following. Warning • During inspection, the thermostat and water are extremely hot and they can cause burns. Do not touch the thermostat and water.

  • Page 766: Thermostat Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes THERMOSTAT INSPECTION [LF] B3E011215171W04 1. Inspect the thermostat for the following. Warning • During inspection, the thermostat and water are extremely hot and they can cause burns. Do not touch the thermostat and water.

  • Page 767: Water Pump Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Water pump component 2 O-ring 10. Install in the reverse order of removal. 11. Add engine coolant. (See ENGINE COOLANT REPLACEMENT.) 12. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION.)

  • Page 768: Cooling Fan Motor Component Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 8. Remove in the order indicated in the table. 9. Install in the reverse order of removal. 10. Add engine coolant. (See ENGINE COOLANT REPLACEMENT.) 11. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION.)
  • Page 769 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Due to the cooling fan protection function, there is a time lag until the fan control signal reaches the specified duty value. (Example: If a fan control signal with a 90 % duty value is input while the cooling fan is stopped, it takes approx.

  • Page 770: Intake-Air System[Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INTAKE-AIR SYSTEM[Z6] INTAKE-AIR SYSTEM LOCATION INDEX [Z6] B3E011300113W01 Air cleaner (See AIR CLEANER ELEMENT INSPECTION [Z6].) IAC solenoid valve (See IDLE AIR CONTROL (IAC) VALVE REMOVAL/INSTALLATION [Z6].)

  • Page 771: Intake-Air System Diagram [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Accelerator pedal (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [Z6].) Accelerator cable (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [Z6].) Intake-air system (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) INTAKE-AIR SYSTEM DIAGRAM [Z6] B3E011300113W02 INTAKE-AIR SYSTEM HOSE ROUTING DIAGRAM [Z6]...

  • Page 772: Intake-Air System Manifold Vacuum Inspection [Z6]

    1.• Verify that the intake air hoses are installed securely. 2. Warm up the engine. 3. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (purge solenoid valve side) and install the vacuum gauge. 4. Measure the intake manifold vacuum while idling (no load) using the vacuum gauge.

  • Page 773: Intake-Air System Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes MTX: -72.0 kPa {-541 mmHg, -21.3 inHg} or more 5. After measuring the intake manifold vacuum, install the vacuum hose to the purge solenoid valve as shown in the figure.
  • Page 774 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 PCM connector cover PCM connector (See PCM Connector Installation Note.) 3 Air cleaner cover 4 Air cleaner element 5 Air cleaner case 6 Fresh-air duct cover...

  • Page 775: Throttle Body Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Air hose (See Air Hose Installation Note.) Throttle body (See Throttle Body Removal Note.) EGR pipe (Intake manifold side) (See EGR Pipe Installation Note.) Fuel distributor (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6].)

  • Page 776: Air Hose Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Air Hose Installation Note 1. Align the alignment marks on the throttle body and the air hose. Fresh-air Duct Installation Note Note • Before installing the fresh-air duct, verify that the rubber mounts on the battery support bracket have not fallen off.

  • Page 777: Pcm Connector Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes PCM Connector Installation Note 1. Insert the PCM connector fully into the air cleaner and push the lever until a click is heard. AIR CLEANER ELEMENT INSPECTION [Z6] B3E011313300W01 1.

  • Page 778: Idle Air Control (Iac) Valve Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 5. Install in the reverse order of removal. IDLE AIR CONTROL (IAC) VALVE INSPECTION [Z6] B3E011320661W02 Resistance Inspection 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector.

  • Page 779: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Circuit Open/Short Inspection 1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check) Open circuit • If there is no continuity, the circuit is open. Repair or replace the wiring harness.

  • Page 780: Variable Intake-Air Shutter Valve Actuator Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Do not pull out the intake manifold side gear. - Do not allow foreign material to contact the intake manifold side gear. - Keep the inside of the actuator away from foreign material.

  • Page 781: Retainer Removal Note

    1. Verify that the retainer installation position has not shifted. 2. Verify that the gasket is installed. 3. Verify that intake manifold side gear and actuator side gear are engaged properly so that the actuator can be installed without any excessive force.

  • Page 782: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If there is no malfunction, carry out the "Circuit Open/Short Inspection". • If there is any malfunction, replace the variable intake-air shutter valve actuator. Terminal Gear rotation direction...

  • Page 783: Variable Tumble Shutter Valve Actuator Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Variable intake-air shutter valve actuator terminal A and body GND - Variable intake-air shutter valve actuator terminal B and power supply - Variable intake-air shutter valve actuator terminal B and body GND...

  • Page 784: Variable Tumble Shutter Valve Actuator Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Variable tumble shutter valve actuator (See Variable Tumble Shutter Valve Actuator Removal Note) (See Variable Tumble Shutter Valve Actuator Installation Note) Retainer (See Retainer Removal Note) (See...

  • Page 785: Variable Tumble Shutter Valve Actuator Installation Note

    1. Verify that the retainer installation position has not shifted. 2. Verify that the gasket is installed. 3. Verify that intake manifold side gear and actuator side gear are engaged properly so that the actuator can be installed without any excessive force.

  • Page 786: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Circuit Open/Short Inspection 1. Inspect the following wiring harnesses for an open or short circuit. (Continuity check) Open circuit • If there is no continuity, the circuit is open. Repair or replace the wiring harness.

  • Page 787: Accelerator Cable Inspection/Adjustment [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Accelerator pedal 2 Accelerator cable 2. Install in the reverse order of removal. 3. Adjust the accelerator cable. (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [Z6].) ACCELERATOR CABLE INSPECTION/ADJUSTMENT...

  • Page 788: Intake-Air System[Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INTAKE-AIR SYSTEM[LF] INTAKE-AIR SYSTEM LOCATION INDEX [LF] B3E011300113W06 Air cleaner (See AIR CLEANER ELEMENT INSPECTION [LF].) IAC solenoid valve (See IDLE AIR CONTROL (IAC) VALVE INSPECTION [LF].)

  • Page 789: Intake-Air System Diagram [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Variable tumble shutter valve actuator (See VARIABLE TUMBLE SHUTTER VALVE ACTUATOR INSPECTION [LF].) Accelerator pedal (See ACCELERATOR PEDAL REMOVAL/INSTALLATION [LF].) Accelerator cable (See ACCELERATOR CABLE INSPECTION/ADJUSTMENT [LF].)

  • Page 790: Intake-Air System Manifold Vacuum Inspection [Lf]

    1.• Verify that the intake air hoses are installed securely. 2. Warm up the engine. 3. Disconnect the vacuum hose connecting the intake manifold and the purge solenoid valve (intake manifold side) and install the vacuum gauge. 4. Using the vacuum gauge, measure the intake manifold vacuum in the idling condition (no load).

  • Page 791: Intake-Air System Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - Compression pressure (See COMPRESSION INSPECTION [LF].) - Air suction (throttle body, fuel injector, PCV valve, intake manifold) Note • If any air suction exists, the change in engine speed can be made apparent by spraying penetrant lubricating spray on the applicable part.
  • Page 792 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Intake-air cover Air hose (See Air Hose Installation Note.) 3 Air cleaner cover 4 Resonance chamber (Air cleaner side) 5 Air cleaner element Strap (See Strap Installation Note.)

  • Page 793: Fresh-Air Duct Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fresh-air duct (See Fresh-air Duct Removal Note.) 9 Throttle body 10 Variable intake air solenoid valve 11 Variable tumble solenoid valve Fuel distributor (See FUEL INJECTOR REMOVAL/INSTALLATION [LF].)

  • Page 794: Strap Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Strap Installation Note 1. Using the strap, secure the shroud panel and the air cleaner case as shown in the figure. Air Hose Installation Note 1. Align the alignment marks on the throttle body and the air hose.

  • Page 795: Operation Test

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Perform the following inspection only when directed. Operation Test 1. Carry out the "Idle Air Control Inspection". (See Idle Air Control System Inspection.) • If not as specified, perform the further inspection for the IAC valve.

  • Page 796: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E011318740W01 1. Remove the variable intake-air solenoid valve. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF].) 2. Inspect airflow between the ports under the following conditions. • If not as specified, replace the variable intake-air solenoid valve.

  • Page 797: Variable Intake-Air Shutter Valve Actuator Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes VARIABLE INTAKE-AIR SHUTTER VALVE ACTUATOR INSPECTION [LF] B3E011320130W05 1. Remove the air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [LF].) 2. Disconnect the vacuum hose from the variable intake-air shutter valve actuator.

  • Page 798: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Circuit Open/Short Inspection 1. Disconnect the PCM connector. (See REMOVAL/INSTALLATION [LF].) 2. Inspect the following wiring harness for open or short (continuity check). Open circuit • If there is no continuity, the circuit is open. Repair or replace the wiring harness.

  • Page 799: Accelerator Pedal Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Connect a vacuum pump to the variable tumble shutter valve actuator. 4. Apply vacuum and verify that the rod moves. • If the rod dose not move, replace the intake manifold.

  • Page 800: Accelerator Cable Inspection/Adjustment [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ACCELERATOR CABLE INSPECTION/ADJUSTMENT [LF] B3E011341660W02 1. Verify that the throttle valve is fully closed. 2. Move the accelerator cable in the directions of A and B, and verify that the accelerator cable play is within the specification.

  • Page 801: Fuel System

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes FUEL SYSTEM FUEL SYSTEM LOCATION INDEX B3E011401006W01 Engine Compartment Side Fuel injector (See FUEL INJECTOR REMOVAL/INSTALLATION [LF].) (See FUEL INJECTOR INSPECTION.) Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)
  • Page 802 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3 Fuel pump relay Fuel injector (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6].) (See FUEL INJECTOR INSPECTION.) Quick release connector (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.) 3 Fuel pump relay Downloaded from https://carmanualshub.com/...

  • Page 803: Fuel Tank Side

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel Tank Side Fuel tank (See FUEL TANK REMOVAL/INSTALLATION.) (See FUEL TANK INSPECTION.) Fuel pump unit (See FUEL PUMP UNIT REMOVAL/INSTALLATION.) (See FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY.) (See FUEL PUMP UNIT INSPECTION.)

  • Page 804: Before Service Precaution

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Fuel-filler cap 2 Fuel filter (high-pressure) 3 Pressure regulator 4 Fuel pump unit 5 Fuel pump 6 Fuel filter (low-pressure) 7 Fuel tank 8 Fuel injector...

  • Page 805: Fuel Line Safety Procedure

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel Line Safety Procedure 1. Remove the fuel-filler cap to release the pressure inside the fuel tank. 2. Remove the fuel pump relay. 3. Start the engine.

  • Page 806: Fuel Line Pressure Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Turn the ignition switch to the ON position. 3. Using the simulation function "FP", start the fuel pump. 4. Verify that there is no fuel leakage from the pressurized parts.
  • Page 807 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 5. Insert the SST quick release connector into the fuel pipe until a click is heard. 6. Verify that the quick release connector is firmly connected by pulling it by hand.

  • Page 808: Fuel Tank Removal/Installation

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 350-410 kPa {3.57-4.18 kgf/cm , 50.8-59.4 psi} 13. Stop the fuel pump. 14. Measure the fuel hold pressure after 5 min. • If not within the specification, inspect the following:...
  • Page 809 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (3) Connect the WDS or equivalent to the DLC-2. (4) Turn the ignition switch to the ON position. (5) Using the simulation function "FP", start the fuel pump.
  • Page 810 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Insulator Quick release connector (fuel tank front) (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.) Quick release connector (on rollover valve) (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.) Quick release connector (on charcoal canister, purge solenoid valve side)

  • Page 811: Fuel-Filler Pipe Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 10 Fuel-filler cap Fuel-filler pipe (See Fuel-filler Pipe Removal Note.) Fuel-filler Pipe Removal Note 1. Remove the rear tire (RH). 2. Remove the rear mudguard (RH). 3. Support the rear crossmember using a transmission jack.

  • Page 812: Fuel Tank Inspection

    7. Apply a pressure of 3 kPa {22 mmHg, 0.8 inHg} to port A and wait for a while. 8. With the pressure still applied, verify that there is airflow from port C and the pressure is 0-3 kPa {0-22 mmHg, 0-0.8 inHg}.

  • Page 813: Nonreturn Valve Inspection

    • If there is no airflow, replace the fuel tank. 9. Apply a pressure of -0.5 kPa {-3.7 mmHg, -0.1 inHg} to port A and wait for a while. 10. With the pressure still applied, verify that there is airflow from port C and the pressure is 0- -0.5 kPa {0- -3.7 mmHg, 0- -0.1 inHg}.

  • Page 814: Fuel Pump Unit Removal/Installation

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes FUEL PUMP UNIT REMOVAL/INSTALLATION B3E011413350W01 Warning • Fuel is very flammable liquid. If fuel spills or leaks from the pressurized fuel system, it will cause serious injury or death and facility breakage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure", while referring to "BEFORE SERVICE...

  • Page 815: Fuel Pump Cap Removal Note

    1. Align the fuel tank and fuel pump unit alignment marks as shown in the figure. 2. Set the SST as shown in the figure. 3. Using the SST, tighten the fuel pump cap within the specified tightening torque without shifting the alignment marks.

  • Page 816: Fuel Leakage Inspection After Pump Unit Installation

    REMOVAL/INSTALLATION.) 3. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed. 4. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the fuel pump unit.

  • Page 817: Continuity Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If the operation sound cannot be verified, measure the voltage at fuel pump wiring harness-side connector terminal A. - If as specified, inspect the following: • Fuel pump continuity - If not within the specification, inspect the following: •...

  • Page 818: Fuel Static Pressure Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. - Fuel pump unit terminal A and fuel pump relay terminal D...

  • Page 819: Type A Removal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Engine compartment side 2 Fuel tank side 3 Only on LF 4 Only on Z6 Type A Removal 1. Follow "BEFORE SERVICE PRECAUTION" before performing any work operations to prevent fuel from spilling from the fuel system.

  • Page 820: Type B Removal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Pull out the fuel hose straight from the fuel pipe and disconnect it. 4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

  • Page 821: Without Using The Sst

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt. Without using the SST Caution •...

  • Page 822: Type C Removal

    2. Push the release tab on the retainer to unlock. 3. Pull out the fuel hose straight from the fuel pipe and disconnect it. 4. Cover the disconnected quick release connector and fuel pipe with vinyl sheeting or a similar material to prevent it from scratches or dirt.

  • Page 823: Type A Installation

    • If there is any malfunction, replace it with a new one. 2. Apply a small amount of clean engine oil to the sealing surface of the fuel pipe. 3. Reconnect the fuel hose straight to the fuel pipe until a click is heard. Note •...

  • Page 824: Using The Sst

    • If there is any malfunction, replace it with a new one. 2. Reconnect the fuel hose straight to the fuel pipe until a click is heard. 3. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

  • Page 825: Type D Installation

    • If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe. 3. Reconnect the fuel hose straight to the fuel pipe until a click is heard. 4. Lightly pull and push the quick release connector a few times by hand, and then verify that it is connected securely.

  • Page 826: Fuel Injector Removal/Installation [Lf]

    • If the metal pipe protrudes from the resin pipe, insert it flush with the end of the resin pipe. 3. Insert the fuel pipe straight to the end of the quick release connector. 4. Push down the retainer using a finger.

  • Page 827: Fuel Injector Removal Note [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel injector (See Fuel Injector Installation Note [LF].) 7. Install in the reverse order of removal. 8. Inspect all related parts by performing "AFTER SERVICE PRECAUTION". (See AFTER SERVICE PRECAUTION.)

  • Page 828: Fuel Injector Installation Note [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (2) Pull the clip parallel to the injector groove and remove it from the injector. Fuel Injector Installation Note [LF] 1. Verify that the O-ring is not damaged.

  • Page 829: Injector Clip Removal Note [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [Z6].) 3. Disconnect the negative battery cable. 4. Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 5. Disconnect the fuel injector connector.
  • Page 830 2. While holding one side of the injector clip removed in Step 1 to prevent it shifting, release the other side of injector clip. 3. Detach the injector clip by sliding it in the axial direction of the fuel injector. Downloaded from https://carmanualshub.com/...

  • Page 831: Fuel Injector Installation Note [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel Injector Installation Note [Z6] 1. Apply a small amount of clean oil to a new O-ring. Caution • A damaged O-ring could cause fuel leakage. Be careful not to damage the O-ring when installing the fuel injector.

  • Page 832: Fuel Injector Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Verify that the injector port flange is completely inserted into the groove. FUEL INJECTOR INSPECTION B3E011413250W03 Fuel Injector Operation Inspection Warning • To prevent serious injury or damage, always perform diagnosis while referring to the warnings and cautions in each procedure when inspecting or repairing the fuel system.

  • Page 833: Fuel Cut Control Inspection

    (2) Depress the accelerator pedal and increase the engine speed to 4,000 rpm. (Loaded range) (3) With the accelerator pedal released (without depressing the brake pedal), verify that the injector actuation time of 0 ms is indicated until the engine speed decreases to approx. 1,200 rpm, and then the actuation time 2-5 ms is indicated when the engine speed decreases to approx.

  • Page 834: Resistance Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If it cannot be verified, inspect the PCM input signal circuit. - Load/no load detection signal (neutral/CPP switch (MTX), TR switch (ATX)) Resistance Inspection 1. Turn the ignition switch to the LOCK position.

  • Page 835: Circuit Open/Short Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. - Fuel injector No.1 terminal A and PCM terminal 2BB - Fuel injector No.2 terminal A and PCM terminal 2BC...

  • Page 836: Leakage Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. - Fuel injector No.1 terminal A and PCM terminal 2E - Fuel injector No.2 terminal A and PCM terminal 2F...
  • Page 837 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Remove the fuel injector and fuel distributor as a single unit. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF].) (See FUEL INJECTOR REMOVAL/INSTALLATION [Z6].) 4. Fix the fuel injector to the fuel distributor with a wire or the equivalent.

  • Page 838: Injection Volume Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If not within the specification, replace the fuel injector. Standard 1 drop or less/2 min 11. Turn the ignition switch to the LOCK position and stop the fuel pump.
  • Page 839 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 5. Remove the fuel injector and fuel distributor as a single unit. (See FUEL INJECTOR REMOVAL/INSTALLATION [LF].) 6. Fix the fuel injector to the fuel distributor with a wire or the equivalent.

  • Page 840: Injection Volume Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel injector No. PCM terminal 13. Turn the ignition switch is to the LOCK position and stop the fuel pump. 14. Remove the wire or the equivalent securing the fuel injector.

  • Page 841: Atomization Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 8. Turn the ignition switch to the ON position. 9. Using the simulation function "FP", start the fuel pump. 10. Measure the fuel injection volume. • If not within the specification, replace the fuel injector.

  • Page 842: Exhaust System[Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes EXHAUST SYSTEM[Z6] EXHAUST SYSTEM INSPECTION [Z6] B3E011500115W01 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. • If there is leakage, repair or replace the appropriate component.
  • Page 843 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Rear tunnel member 2 Front tunnel member 3 Main silencer Rear heated oxygen sensor (See REAR HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6].) Front heated oxygen sensor...

  • Page 844: Exhaust Manifold/Exhaust Manifold Insulator Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes EGR pipe (Exhaust manifold side) (See EGR Pipe Installation Note.) 7 Member 8 Exhaust manifold bracket 9 Clip WU-TWC (See Exhaust Manifold/Exhaust Manifold Insulator Removal Note.) (See Exhaust Manifold Installation Note.)

  • Page 845: Exhaust Manifold Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 12. Support the flexible pipe with a support wrap or splint as shown in the figure. 13. Remove the exhaust manifold together with the insulator by lowering it to the underside of the vehicle.

  • Page 846: Exhaust System[Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes EXHAUST SYSTEM[LF] EXHAUST SYSTEM INSPECTION [LF] B3E011500115W03 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. • If there is leakage, repair or replace the appropriate component.
  • Page 847 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Rear tunnel member 2 Front tunnel member Main silencer (See Main Silencer Removal Note.) Rear heated oxygen sensor (See HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [LF].) Front heated oxygen sensor...

  • Page 848: Main Silencer Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 7 Exhaust manifold bracket WU-TWC (See Exhaust Manifold Removal Note.) (See Exhaust Manifold Installation Note.) 9 Exhaust manifold insulator 10 Exhaust manifold gasket Main Silencer Removal Note 1.
  • Page 849 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 850: Emission System

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes EMISSION SYSTEM EMISSION SYSTEM LOCATION INDEX B3E011601074W01 Engine Compartment Side Positive crankcase ventilation (PCV) valve (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION.) EGR valve (See EGR VALVE REMOVAL/INSTALLATION [LF].)
  • Page 851 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Positive crankcase ventilation (PCV) valve (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION.) EGR valve (See EGR VALVE REMOVAL/INSTALLATION [Z6].) (See EGR VALVE INSPECTION.) Purge solenoid valve (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [Z6].)

  • Page 852: Fuel Tank Side

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel Tank Side Charcoal canister (See CHARCOAL CANISTER REMOVAL/INSTALLATION.) (See CHARCOAL CANISTER INSPECTION.) Rollover valve (See ROLLOVER VALVE REMOVAL/INSTALLATION.) (See ROLLOVER VALVE INSPECTION.) EMISSION SYSTEM DIAGRAM B3E011601074W02 Downloaded from https://carmanualshub.com/...

  • Page 853: Positive Crankcase Ventilation (Pcv) Valve Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 854: Purge Solenoid Valve Removal/Installation [Lf]

    1. Remove the intake manifold. 2. Remove the PCV valve. 3. Verify that there is no airflow when pressure is applied to port A. • If there is airflow, replace the PCV valve. 4. Verify that there is airflow when vacuum is applied to port A.

  • Page 855: Evaporative Hose Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (2) Pull the vacuum tube from the intake manifold. 5. Install in the reverse order of removal. Evaporative Hose Installation Note 1. Install the evaporative hose and clamp as shown in the figure.

  • Page 856: Purge Solenoid Valve Inspection

    1. Warm up the engine and idle it. 2. Disconnect the vacuum hose which is connected to the charcoal canister from purge solenoid valve. 3. Place your finger onto the purge solenoid valve as shown in the figure and verify that vacuum is applied.

  • Page 857: Using Wds Or Equivalent

    2. Warm up the engine and idle it. 3. Disconnect the vacuum hose which is connected to the charcoal canister from purge solenoid valve. 4. Place your finger onto the purge solenoid valve as shown in the figure and verify that vacuum is applied.

  • Page 858: Airflow Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If vacuum is not applied, inspect the following: - PID: EVAPCP - Purge solenoid valve 5. Disconnect the vacuum hose. 6. Using the "EVAPCP" simulation function, set the present 0% duty value of the purge solenoid valve to the 100% duty value and verify that the engine idles roughly or stalls.

  • Page 859: Circuit Open/Short Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Verify that the airflow is as indicated in the table. • If as specified in the table, perform the "Circuit Open/Short Inspection". • If not as specified in the table, inspect the purge solenoid valve.

  • Page 860: Circuit Open/Short Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. - Purge solenoid valve terminal A and PCM terminal 2AN...

  • Page 861: Egr Valve Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, the circuit is open. Repair or replace the harness. - Purge solenoid valve terminal A and PCM terminal 2T...

  • Page 862: Water Hose Removal Note [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Water hose (See Water Hose Removal Note [LF].) EGR valve (See EGR Valve Removal Note [LF].) 6. Install in the reverse order of removal. Water Hose Removal Note [LF] 1.

  • Page 863: Egr Valve Inspection

    1. Connect the WDS or equivalent to the DLC-2. 2. Start the engine. 3. Using the "SEGRP" simulation function, operate with Steps 0 (idling) to 52 and verify that the engine speed becomes unstable or the engine stalls. • If the engine speed does not change, perform the following procedure: (1) Stop the engine.

  • Page 864: On-Vehicle Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (3) Connect the EGR valve connector. (4) Turn the ignition switch to the ON position. (5) Using the "SEGRP" simulation function, verify that it operates with Steps 0 (idling) to 52.

  • Page 865: Circuit Open/Short Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Measure the resistance between the EGR valve terminals. • If within the specification, perform out the "Circuit Open/Short Inspection". • If not within the specification, replace the EGR valve.

  • Page 866: Circuit Open/Short Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If there is no continuity, the circuit is open. Repair or replace the wiring harness. - EGR valve terminal A and PCM terminal 2AR - EGR valve terminal B and PCM terminal 2AY...

  • Page 867: Charcoal Canister Removal/Installation

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - EGR valve terminal E and PCM terminal 2Z - EGR valve terminal F and PCM terminal 2N Short circuit • If there is continuity, the circuit is short. Repair or replace the wiring harness.

  • Page 868: Rollover Valve Removal/Installation

    1. Remove the charcoal canister. 2. Plug the atmosphere side and purge solenoid valve side of the charcoal canister. 3. Inspect for air leakage when blowing air by mouth from the fuel tank side. • If air leaks, replace the charcoal canister.

  • Page 869: Charging System

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes CHARGING SYSTEM CHARGING SYSTEM LOCATION INDEX [Z6] B3E011701098W01 Battery (See BATTERY REMOVAL/INSTALLATION [Z6].) (See BATTERY INSPECTION.) (See BATTERY RECHARGING.) Generator (See GENERATOR REMOVAL/INSTALLATION [Z6].) (See GENERATOR INSPECTION.)

  • Page 870: Battery Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Battery (See BATTERY REMOVAL/INSTALLATION [LF].) (See BATTERY INSPECTION.) (See BATTERY RECHARGING.) Generator (See GENERATOR REMOVAL/INSTALLATION [LF].) (See GENERATOR INSPECTION.) BATTERY REMOVAL/INSTALLATION [Z6] B3E011718520W01 1. Remove in the order indicated in the table.

  • Page 871: Battery Box Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Battery cover (See Battery Cover Installation Note.) 2 Negative battery cable 3 Positive battery cable Battery box (See Battery Box Installation Note.) 5 Battery clamp 6 Battery...

  • Page 872: Battery Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Install with the battery cover hooks D aligned with the battery tray flange at two points. 3. Set the battery cover to the battery tray hooks C at two points. BATTERY REMOVAL/INSTALLATION [LF] B3E011718520W02 1.

  • Page 873: Pcm Cover Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Battery cover (See Battery Cover Installation Note.) 2 Negative battery cable 3 Positive battery cable Battery duct (See Battery Duct Installation Note.) Battery box (See Battery Box Installation Note.)

  • Page 874: Battery Box Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 2. Install the PCM cover to the PCM box hook. Battery Box Installation Note 1. Assemble with the battery box hooks E aligned with the battery tray holes at two points.

  • Page 875: Battery Cover Installation Note

    2. Install with the battery cover hooks A aligned with the battery tray holes at two points. 3. Install with the battery cover hooks D aligned with the battery tray flange at two points. 4. Set the battery cover to the battery tray hooks C at two points.

  • Page 876: Battery Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes BATTERY INSPECTION B3E011718520W03 Warning • Since battery acid is toxic, be careful when handling the battery. • Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.

  • Page 877: Back-Up Current

    1. Verify that the ignition switch is off and that the key has been removed. 2. Disconnect the negative battery cable. 3. Measure the back-up current between the negative battery terminal and the negative battery cable. • If not within the specification, measure the back-up current while removing the fuses one by one from the inside of the main fuse block and the inside of the fuse block.

  • Page 878: Generator Removal/Installation [Z6]

    75D26L (52) 5.0-6.0 80D26L (55) 5.5-6.5 3. After the battery is recharged, verify that the voltage is within the specification and remains at the same value for 1 h or more after the recharging was completed. • If not within the specification, replace the battery.

  • Page 879: Generator Removal Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 7. Remove in the order indicated in the table. 8. Install in the reverse order of removal. 1 Terminal B cable 2 Generator connector Generator (See Generator Removal Note.)

  • Page 880: Generator Installation Note

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 6. Position the coolant reserve tank out of the way. 7. Remove in the order indicated in the table. 8. Install in the reverse order of removal.

  • Page 881: Generator

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. With the ignition switch at ON, verify that the generator warning light illuminates. • If it does not illuminate, inspect the generator warning light and the wiring harness.

  • Page 882: Current

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Current 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (See DRIVE BELT INSPECTION [Z6].) (See DRIVE BELT INSPECTION [LF].)

  • Page 883: Ignition System

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes IGNITION SYSTEM IGNITION SYSTEM LOCATION INDEX [Z6] B3E011801009W01 Ignition coil (See IGNITION COIL REMOVAL/INSTALLATION [Z6].) (See IGNITION COIL INSPECTION [Z6].) Spark plug (See SPARK PLUG REMOVAL/INSTALLATION [Z6].)

  • Page 884: Ignition Coil Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Ignition coil (See IGNITION COIL REMOVAL/INSTALLATION [LF].) (See IGNITION COIL INSPECTION [LF].) Spark plug (See SPARK PLUG REMOVAL/INSTALLATION [LF].) (See SPARK PLUG INSPECTION.) IGNITION COIL REMOVAL/INSTALLATION [Z6] B3E011801009W03 1.

  • Page 885: Ignition Coil Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Connector 2 Ignition coil IGNITION COIL REMOVAL/INSTALLATION [LF] B3E011801009W04 1. Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [LF].) 2. Disconnect the negative battery cable. 3. Remove the plug hole plate.

  • Page 886: Ignition Coil Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Connector 2 Ignition coil IGNITION COIL INSPECTION [Z6] B3E011801009W05 IGNITION COIL WITH BUILT-IN POWER SWITCH INSPECTION 1. Remove the ignition coil connector. 2. Measure the resistance between each terminal on the ignition coil connector.

  • Page 887: Ignition Coil Inspection [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes IGNITION COIL INSPECTION [LF] B3E011801009W06 Primary Coil Winding 1. Disconnect the ignition coil connector. 2. Measure the resistance between the following terminals using an ohmmeter: • A and B - If not as specified, replace the ignition coil.

  • Page 888: Insulation Resistance Of Case

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Measure the resistance between the following using an ohmmeter. • Terminal A to coil boot socket - If not as specified, replace the ignition coil. Resistance (Reference) 5.0-6.0 kilohms [25 °C {77 °F}]...

  • Page 889: Spark Plug Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E011801009W07 Caution • If a spark plug that is not as specified is installed, sealing performance will be deteriorated. Install only the specified spark plug when replacing.

  • Page 890: Plug Gap Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ITR6F13 Type DENSO SK16PR-E11 - Plug Gap Inspection Caution • To avoid possible damage to the tip, do not adjust the plug gap. • To prevent damaging the tip, use wire type plug gap gauge when inspecting the plug gap.
  • Page 891 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If not within the specification, replace the spark plug. Resistance 3.0-7.5 kilohms [25°C {77 °F}] Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 892: Starting System

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes STARTING SYSTEM STARTING SYSTEM LOCATION INDEX [Z6] B3E011918400W01 Starter (See STARTER REMOVAL/INSTALLATION [Z6].) (See STARTER INSPECTION.) STARTING SYSTEM LOCATION INDEX [LF] B3E011918400W02 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 893: Starter Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Starter (See STARTER REMOVAL/INSTALLATION [LF].) (See STARTER INSPECTION.) STARTER REMOVAL/INSTALLATION [Z6] B3E011918400W03 Warning • When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks.

  • Page 894: Starter Removal/Installation [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Terminal B cable 2 Terminal S connector 3 Wiring harness clip 4 Starter STARTER REMOVAL/INSTALLATION [LF] B3E011918400W04 Warning • When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks.

  • Page 895: Starter Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1 Terminal B cable 2 Terminal S connector 3 Wiring harness bracket 4 Starter STARTER INSPECTION B3E011918400W05 On-vehicle Inspection 1. Verify that the battery is fully charged.
  • Page 896 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Operate the starter and verify that it rotates smoothly. • If the starter does not rotate smoothly, inspect the starter unit. 4. Measure the voltage and current while the starter is operating.

  • Page 897: Control System[Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes CONTROL SYSTEM[Z6] CONTROL SYSTEM LOCATION INDEX [Z6] B3E014018880W04 (See PCM REMOVAL/INSTALLATION [Z6]) (See PCM INSPECTION [Z6]) (See PCM CONFIGURATION [Z6]) Downloaded from https://carmanualshub.com/ - automotive repair manuals website...
  • Page 898 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Neutral switch (See NEUTRAL SWITCH INSPECTION [Z6]) CPP switch (MTX) (See CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [Z6]) PSP switch (See POWER STEERING PRESSURE (PSP) SWITCH INSPECTION...

  • Page 899: Control System Diagram [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes (See BAROMETRIC PRESSURE (BARO) SENSOR INSPECTION [Z6]) (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION [Z6]) (See KNOCK SENSOR (KS) INSPECTION [Z6]) CONTROL SYSTEM DIAGRAM [Z6] B3E014018880W05 CONTROL SYSTEM WIRING DIAGRAM [Z6]...
  • Page 900 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 901: Pcm Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes PCM REMOVAL/INSTALLATION [Z6] B3E014018880W07 Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

  • Page 902: Pcm Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Note • The PCM is integrated with the air cleaner cover and cannot be removed. 1. When replacing the PCM, perform the following: • PCM configuration (See PCM CONFIGURATION [Z6].)
  • Page 903 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Input/turbine • Related wiring Internal GND speed sensor Under any condition 1.0 or less harness shield wire • Input/turbine Input/turbine speed sensor Input/turbine (See Inspection Using An Oscilloscope...
  • Page 904 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Instrument Because this terminal is for CAN, good/no cluster, ABS CAN_L good judgment by terminal voltage is not HU/CM, DSC possible. HU/CM, DLC-2 Refrigerant pressure is 1.52 MPa {15.5...
  • Page 905 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Detects down-shift Ignition operation of 1.0 or less • Selector lever switch is selector lever in M Manual Down switch turned to • Related wiring range down...
  • Page 906 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Fan control module Fan control Test mode 1.0 or less module is on. • Related wiring harness Ignition M range 1.0 or less • Selector lever...
  • Page 907 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Battery Battery Ignition switch is turned to the • Related wiring voltage ON position. harness • Related wiring VSS power Ignition switch is turned to the supply ON position.
  • Page 908 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Fuel injector • Related wiring Fuel injector Ignition switch is turned to the No.1 power No.1 ON position. harness supply Fuel injector • Related wiring Fuel injector Ignition switch is turned to the No.2 power...
  • Page 909 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Related wiring harness • EGR valve EGR control EGR valve Idle (EGR control operating) • Related wiring harness Altitude:0 m {0 ft}) 2.3-2.8 Altitude:500 m 2.2-2.8...
  • Page 910 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Related wiring harness • EGR valve EGR control EGR valve Idle (EGR control operating) 1.0 or less • Related wiring harness Ignition 0.3-1.0 • TP sensor...
  • Page 911 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • OCV Variable (See Inspection Using An Oscilloscope valve timing • Related wiring (Reference).) control (+) harness • Front HO2S Front HO2S Front HO2S (See Inspection Using An Oscilloscope heater •...
  • Page 912 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Purge solenoid valve Purge solenoid (See Inspection Using An Oscilloscope Purge control valve (Reference).) • Related wiring harness ECT sensor, • Related wiring front HO2S, Internal GND Under any condition 1.0 or less...

  • Page 913: Inspection Using An Oscilloscope (Reference)

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes The voltage may vary excessively depending on the weather or battery conditions. The voltage changes for a specified time. Inspection Using An Oscilloscope (Reference) Input/turbine speed sensor (-) signal PCM terminals •...

  • Page 914: Vehicle Speed Output Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Idle after warm-up Vehicle speed output signal PCM terminals • 1Z (+)-Negative battery terminal (-) Oscilloscope setting • 5 V/DIV (Y), 20 ms/DIV (X), DC range Vehicle condition •...

  • Page 915: Pressure Control Solenoid (-) Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Pressure control solenoid (-) signal PCM terminals • 1AV (+)-Negative battery terminal (-) Oscilloscope setting • 200 mV/DIV (Y), 1 ms/DIV (X), DC range Vehicle condition • All of the following conditions are met.

  • Page 916: Shift Solenoid A Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Shift solenoid A signal PCM terminals • 1AZ (+)-Negative battery terminal (-) Oscilloscope setting • 5 V/DIV (Y), 5 ms/DIV (X), DC range Vehicle condition • 4GR...

  • Page 917: Shift Solenoid B Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Shift solenoid B signal PCM terminals • 1BH (+)-Negative battery terminal (-) Oscilloscope setting • 5 V/DIV (Y), 5 ms/DIV (X), DC range Vehicle condition • 1GR (except L range (HOLD))

  • Page 918: Esa Control Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ESA control signal PCM terminals • No.1: 2Y (+)-Negative battery terminal (-) • No.2: 2U (+)-Negative battery terminal (-) • No.3: 2Q (+)-Negative battery terminal (-) • No.4: 2M (+)-Negative battery terminal (-) Oscilloscope setting •...

  • Page 919: Iac (+) Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes IAC (+) signal PCM terminals • 2X (+)-Negative battery terminal (-) Oscilloscope setting • 2 V/DIV (Y), 2 ms/DIV (X), DC range Vehicle condition • Idle after warm-up...

  • Page 920: Oxygen Concentration Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Oxygen concentration signal PCM terminals • 2AI (+)-Negative battery terminal (-) Oscilloscope setting • 0.2 V/DIV (Y), 1 s/DIV (X), DC range Vehicle condition • Idle after warm-up...

  • Page 921: Ho2S Heater Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes HO2S heater signal PCM terminals • 2AM (+)-Negative battery terminal (-) Oscilloscope setting • 2 V/DIV (Y), 0.1 s/DIV (X), DC range Vehicle condition • Idle after warm-up...

  • Page 922: Generator Output Voltage Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Generator output voltage signal PCM terminals • 2AR (+)-Negative battery terminal (-) Oscilloscope setting • 2 V/DIV (Y), 1 ms/DIV (X), DC range Vehicle condition • Idle after warm-up...

  • Page 923: Cmp Signal

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes CMP signal PCM terminals • 2BB (+)-Negative battery terminal (-) Oscilloscope setting • 1 V/DIV (Y), 20 ms/DIV (X), DC range Vehicle condition • Idle after warm-up...
  • Page 924 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Refrigerant pressure is more AC_REQ than the specification or less • Refrigerant pressure than the specification. (Refrigerant switch (low pressure (Refrigerant pressure switch pressure switch On/Off...
  • Page 925 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • E/L on (42 A or more): 750 • A/C on (low load): 750 • A/C on (high load): 750 • P/S on: 750 RPM • Ignition switch is turned to...
  • Page 926 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Clutch pedal is depressed: • CPP switch On/Off (Clutch pedal • Clutch pedal is released: Off position) CPP/PNP • Neutral: Neutral • Neutral switch Drive/Neutral (Shift lever •...
  • Page 927 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Cranking: On • The following PIDs - CPP, CPP/PNP, PSP, ECT, FUELPW IAT, RPM, TP, 2B, 2C, • Idling: Approx. 2.0 ms (Fuel injector MAF, O2S11,...
  • Page 928 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Idling (ECT is 88 °C {190 °F}, MAF, BARO, no load condition): Approx. 25 VSS, AC_REQ, COLP • Ignition switch is turned to °C °F the ON position: Indicate the •...
  • Page 929 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Ignition switch is turned to KNOCKR the ON position: 0 ° ° • KS (Knocking retard) • Idling: 0 ° LINEDES (See PID/DATA MONITOR INSPECTION [FN4A-EL]) •...
  • Page 930 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Idling (after warm-up): O2S12 Alternates between 0 and 1.0 • Rear HO2S (Rear HO2S) OP_SW_B (See PID/DATA MONITOR INSPECTION [FN4A-EL]) PCM_T • Ignition switch is turned to...
  • Page 931 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Vehicle driving when engine - MAF, TP, speed is 1,000-4,700 rpm: 0- ECT, RPM, 100 % • The following PIDs - CPP, CPP/PNP, PSP, ECT, SHRTFT1 •...
  • Page 932 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes SSC/SS3 (See PID/DATA MONITOR INSPECTION [FN4A-EL]) (See PID/DATA MONITOR INSPECTION [FN4A-EL]) • During test mode: On test On/Off • Other than test mode: Off (Test mode) (See...

  • Page 933: Pcm Configuration [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • The following PIDs VT ACT1 • Idling: 0 ° - ECT, RPM, 2AG, ° (Actual valve TP, MAF • Racing: 025 ° timing) • OCV VT DIFF1 •...

  • Page 934: Neutral Switch Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 4. Select "Programmable Module Installation". 5. Select "PCM" and perform procedures according to directions on the WDS or equivalent screen. Note • If the PCM is replaced with a new one, the PCM stores DTC P0602 and illuminates the MIL even though no malfunction is detected.

  • Page 935: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - Neutral switch terminal A and PCM terminal 1AB...

  • Page 936: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Circuit Open/Short Inspection 1. Remove the PCM connector cover. 2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 3. Inspect the following wiring harness for open or short circuit (continuity check).

  • Page 937: Continuity Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure.) Continuity Inspection 1. Inspect the following items: •...

  • Page 938: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - PSP switch terminal A and PCM terminal 2AC Short circuit •...

  • Page 939: Engine Coolant Temperature (Ect) Sensor Inspection [Z6]

    ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6].) 3. Place the ECT sensor in the water and while increasing water temperature, measure the resistance between terminals A and B. • If not within the specification, replace the ECT sensor. (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [Z6].)

  • Page 940: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ECT sensor characteristics graph (reference) Circuit Open/Short Inspection 1. Remove the PCM connector cover. 2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 3. Inspect the following wiring harness for open or short circuit (continuity check).

  • Page 941: Intake Air Temperature (Iat) Sensor Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION [Z6] B3E014018840W06 Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure.)

  • Page 942: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Circuit Open/Short Inspection 1. Remove the PCM connector cover. 2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 3. Inspect the following wiring harness for open or short circuit (continuity check).

  • Page 943: Crankshaft Position (Ckp) Sensor Removal/Installation [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes - MAF/IAT sensor terminal E and power supply CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6] B3E014018220W01 Caution • When replacing the CKP sensor, make sure there is no foreign material on it such as metal shavings.

  • Page 944: Visual Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Visual inspection 1. Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6].) 2. Verify that there are no metal shavings on the sensor. 3. Install the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6].)

  • Page 945: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If not within the specification, replace the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [Z6].) • If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".

  • Page 946: Short Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Short circuit • If there is continuity, there is a short circuit. Repair or replace the wiring harness. - CKP sensor terminal A and body GND - CKP sensor terminal B and power supply...

  • Page 947: Visual Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes B3E014018200W02 Note • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure.) Visual inspection 1. Remove the CMP sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [Z6].)

  • Page 948: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Circuit Open/Short Inspection 1. Remove the PCM connector cover. 2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) 3. Inspect the following wiring harness for open or short circuit (continuity check).

  • Page 949: Throttle Position (Tp) Sensor Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Perform the following procedure for easier access. • Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].) • Remove the air hose. 4. Remove the TP sensor.

  • Page 950: Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Verify that the resistance between terminals B and C changes moderately corresponding to the throttle valve openings. • If the resistance change is verified, go to the next step.

  • Page 951: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - TP sensor terminal A and PCM terminal 2W...

  • Page 952: Mass Air Flow (Maf) Sensor Inspection [Z6]

    1. Remove the MAF/IAT sensor without disconnecting the MAF/IAT sensor connector. 2. Turn the ignition switch to the ON position. 3. As the air gradually approaches the MAF detection part of the MAF/IAT sensor, verify that the MAF sensor output voltage (WDS PID: MAF) varies.

  • Page 953: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 3. Inspect the following wiring harness for open or short circuit (continuity check). Open circuit • If there is no continuity, there is an open circuit . Repair or replace the wiring harness.

  • Page 954: Front Heated Oxygen Sensor (Ho2S) Inspection [Z6]

    1. Warm up the engine to normal operating temperature. 2. Disconnect the front HO2S connector. 3. Connect the positive probe of the tester (digital type) to front HO2S terminal A, and the negative probe to front HO2S terminal B and measure the voltage.

  • Page 955: Front Heated Oxygen Sensor (Ho2S) Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • If it cannot be verified, replace the front HO2S. (See FRONT HEATED OXYGEN SENSOR (HO2S) REMOVAL/INSTALLATION [Z6].) • If the monitor item condition/specification (reference) is not within the specification, even though there is no malfunction, perform the "Circuit Open/Short Inspection".

  • Page 956: Front Heated Oxygen Sensor (Ho2S) Heater Resistance Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Front Heated Oxygen Sensor (HO2S) Heater Resistance Inspection 1. Disconnect the front HO2S connector. 2. Measure the resistance between front HO2S terminals C and D. • If not within the specification, replace the front HO2S. (See...

  • Page 957: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - Front HO2S terminal C and PCM terminal 2T...

  • Page 958: Rear Heated Oxygen Sensor (Ho2S) Voltage Inspection

    1. Warm up the engine to normal operating temperature. 2. Disconnect the rear HO2S connector. 3. Connect the positive probe of the tester (digital type) to rear HO2S terminal A, and the negative probe to rear HO2S terminal B and measure the voltage.

  • Page 959: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - Rear HO2S terminal A and PCM terminal 2K...

  • Page 960: Rear Heated Oxygen Sensor (Ho2S) Heater Circuit Open/Short Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Rear HO2S heater resistance 14.1-18.9 ohms [20 °C {68 °F}] Rear Heated Oxygen Sensor (HO2S) Heater Circuit Open/Short Inspection 1. Remove the PCM connector cover. 2. Disconnect the PCM connector. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [Z6].)

  • Page 961: Voltage Inspection

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes • Before performing the following inspection, make sure to follow the procedure as indicated in the troubleshooting flowchart. (See Troubleshooting Procedure.) Voltage Inspection 1. Remove the BARO sensor with the connector still connected.

  • Page 962: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - BARO sensor terminal C and PCM terminal 2W...

  • Page 963: Knock Sensor (Ks) Inspection [Z6]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 5. Remove the KS. 6. Install in the reverse order of removal. KS tightening torque 19.6-34.3 N·m {2.0-3.4 kgf·m, 14.5-24.5 ft·lbf} KNOCK SENSOR (KS) INSPECTION [Z6] B3E014018920W04 Note •...

  • Page 964: Open Circuit

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Open circuit • If there is no continuity, there is an open circuit. Repair or replace the wiring harness. - Knock sensor terminal A and PCM terminal 2BA Short circuit •...
  • Page 965 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1.204 1,029 {10.49, Minimum {12.28, 149.2} [250] 174.6} [300] Maximum difference 196.1 {2.0, 196.1 {2.0, between cylinders 28.5} 28.5} 145.2-145.8 128.9-129.5 Standard {5.075-5.098} {5.72-5.74} Cylinder head bolt length...
  • Page 966 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes D position 650-750 load Neutral 650-750 700-800 position High load 700-800 P/S ON 700-800 CO concentration Within the regulation HC concentration LUBRICATION SYSTEM 330-380 234-521 Oil pressure (approx. quantity) {3.36-3.87,...
  • Page 967 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 64-84 {64-84, 46-66 {46-66, Injection volume (ml {cc, cu in}/15 s) 3.9-5.1} 2.8-4.0} CHARGING SYSTEM 1.22-1.29 [20 °C {68 °F}] Electrolyte gravity Back-up current* (mA) Max. 20...
  • Page 968 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes ITR6F13 Plug gap Standard (mm {in}) 1.0-1.1 1.25-1.35 Resistance [25°C {77°F}] (kilohm) 3.0-7.5 STARTING SYSTEM Voltage Starter No load test Current 90 or less Recommended engine oil...

  • Page 969: Service Tools

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes SERVICE TOOLS ENGINE SST [Z6] B3E016001001W01 1: Mazda SST number 2: Global SST number Example 1:49 UN30 3050 2:303-050 Engine lifting bracket 1:49 UN30 49 E017 1:49 H010...

  • Page 970: Engine Sst [Lf]

    Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes 1:49 N013 1:49 0187 1A0C 280A 1: - 2: - 2: - Fuel pressure pressure gauge set gauge 1:49 L018 1:49 D015 1: 49 F042 2: -...
  • Page 971 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Engine Oil seal Adjusting support set installer wrench 1:49 JE01 1:49 UN20 1:49 B011 5072 2:303-507 2:205-072 2: - Crankshaft TDC setting Holder Adapter 1:49 UN30 1:49 JE01...
  • Page 972 Mazda 3 Workshop Manual – Engine + Wiring Diagrams + Diagnostic Trouble Codes Downloaded from https://carmanualshub.com/ - automotive repair manuals website...

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