Repair manual
Mazda 3 BK facelift Repair Manual
Step-by-step repair and maintenance instructions for the Mazda 3 BK facelift (2006–2009): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- Automatic Transaxle - Overhaul (FN4A-EL)
- On-Board Diagnostic - Automatic Transaxle (FN4A-EL)
- On-Board Diagnostic - Automatic Transaxle (FS5A-EL)
- Automatic Transaxle - Service, Removal & Installation (FN4A-EL)
- Automatic Transaxle - Service, Removal & Installation (FS5A-EL)
- Symptom Troubleshooting - Automatic Transaxle (FN4A-EL)
- Symptom Troubleshooting - Automatic Transaxle (FS5A-EL)
- Automatic Transaxle Shift Mechanism
- Technical Data (Transmission)
- Service Tools (Transmission)
- Automatic Transaxle Features & Operation (FS5A-EL)
- Automatic Transaxle General Information (FS5A-EL)
- Automatic Transaxle - Overhaul (FS5A-EL)
- AUTOMATIC TRANSAXLE OUTLINE
- AUTOMATIC TRANSAXLE FEATURES
- POWER FLOW OUTLINE
- POWER FLOW STRUCTURE
- FORWARD CLUTCH, 3-4 CLUTCH, REVERSE CLUTCH, LOW AND REVERSE BRAKE OUTLINE
- CENTRIFUGAL BALANCE CLUTCH OUTLINE
- CENTRIFUGAL BALANCE CLUTCH STRUCTURE
- When clutch pressure is not applied
- When clutch pressure is applied
- 2-4 BRAKE BAND OUTLINE
- 2-4 BRAKE BAND STRUCTURE
- ONE-WAY CLUTCH OUTLINE
- ONE-WAY CLUTCH STRUCTURE
- PLANETARY GEAR OUTLINE
- PLANETARY GEAR STRUCTURE
- Gear ratio of each range
- PARKING MECHANISM OUTLINE
- PARKING MECHANISM STRUCTURE
- OUTPUT GEAR OUTLINE
- OIL PUMP OUTLINE
- OIL PUMP STRUCTURE
- FORWARD CLUTCH, 3-4 CLUTCH HYDRAULIC CIRCUIT OUTLINE
- CONTROL VALVE BODY OUTLINE
- SHIFT SOLENOID A, B AND C (DUTY-CYCLE TYPE) OUTLINE
- SHIFT SOLENOID A, B AND C (DUTY-CYCLE TYPE) FUNCTION
- SHIFT SOLENOID D AND E (ON/OFF TYPE) OUTLINE
- SHIFT SOLENOID D AND E (ON/OFF TYPE) FUNCTION
- PRESSURE CONTROL SOLENOID (LINEAR TYPE) OUTLINE
- Cleaning Notes
- General notes — Part 1
- General notes — Part 2
- Backlash
- TRANSMISSION/TRANSAXLE TECHNICAL DATA
- TRANSMISSION/TRANSAXLE SST
- ACCUMULATORS DISASSEMBLY/ASSEMBLY
- OIL PUMP DISASSEMBLY/ASSEMBLY
- Oil Pump Cover Disassembly Note
- Inner Rotor, Outer Rotor Disassembly Note
- FORWARD CLUTCH DISASSEMBLY/ASSEMBLY
- Snap Ring Disassembly Note
- Forward Clutch Piston Disassembly Note
- SNAP RING (3-4 CLUTCH) DISASSEMBLY NOTE
- 3-4 CLUTCH PISTON DISASSEMBLY NOTE
- SNAP RING (REVERSE CLUTCH) DISASSEMBLY NOTE
- REVERSE PISTON DISASSEMBLY NOTE
- ONE-WAY CLUTCH RETAINER DISASSEMBLY NOTE
- ASSEMBLY PROCEDURE
- LOW AND REVERSE BRAKE PISTON DISASSEMBLY NOTE
- PARKING MECHANISM DISASSEMBLY/ASSEMBLY
- PRIMARY GEAR DISASSEMBLY/ASSEMBLY
- Bearing Disassembly Note
- Bearing Assembly Note
- Control Valve Body Disassembly
- Upper Control Valve Body Disassembly/Assembly
- Main Control Valve Body Disassembly/Assembly
- Roll Pin Disassembly Note
- Sensor Rotor Disassembly Note
- OIL PUMP DISASSEMBLY/ASSEMBLY
- Oil Pump Cover Disassembly Note
- Inner Rotor, Outer Rotor Disassembly Note
- CLUTCH COMPONENT DISASSEMBLY/ASSEMBLY
- Snap Ring (3-4 clutch) Disassembly Note
- 3-4 Clutch Piston Disassembly Note
- Reverse Piston Disassembly Note
- One-Way Clutch Retainer Disassembly Note
- Assembly Procedure
- Low and Reverse Brake Piston Disassembly Note
- DIRECT CLUTCH DISASSEMBLY/ASSEMBLY
- Reduction Brake Piston Disassembly Note
- PARKING MECHANISM DISASSEMBLY/ASSEMBLY
- SECONDARY GEAR AND OUTPUT GEAR DISASSEMBLY/ASSEMBLY
- PRIMARY GEAR DISASSEMBLY/ASSEMBLY
- Bearing Disassembly Note
- Bearing Assembly Note
- PRIMARY CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY Primary Control Valve Body Disassembly
- Upper Control Valve Body Disassembly/Assembly
- Main Control Valve Body Disassembly/Assembly
- Primary Control Valve Body Assembly
- SECONDARY CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY Secondary Control Valve Body Disassembly
- Secondary Main Control Valve Body Disassembly/Assembly
- Differential Disassembly
- Roll pin disassembly note
- Differential Assembly
- TIMING CHAIN REMOVAL/INSTALLATION [L3 WITH TC]
- Oil Pump Driven Sprocket installation Note
- CYLINDER HEAD GASKET REPLACEMENT [L3 WITH TC]
- Camshaft Removal Note
- Crankshaft Pulley Lock Bolt Removal Note
- ENGINE REM0VAL/INSTALLATION [L3 WITH TC]
- VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [L3 WITH TC]
- ENGINE OVERHAUL SERVICE WARNING
- TIMING CHAIN DISASSEMBLY
- Crankshaft Pulley Lock Bolt Disassembly Note
- Front Oil Seal Disassembly Note
- Oil Pump Driven Sprocket Disassembly Note
- CYLINDER HEAD (I) DISASSEMBLY
- Camshaft Sprocket, Variable Valve Timing Actuator Disassembly Note
- Camshaft Cap Disassembly Note
- Tappet Disassembly Note
- Cylinder Head Disassembly Note
- CYLINDER HEAD (II) DISASSEMBLY
- Valve Keeper Disassembly Note
- Valve Seal Disassembly Note
- CYLINDER BLOCK (I) DISASSEMBLY
- Oil Pan Disassembly Note
- Flywheel Disassembly Note
- CYLINDER BLOCK (II) DISASSEMBLY
- Pilot Bearing Disassembly Note
- Connecting Rod Cap Disassembly Note
- Connecting Rod, Piston Disassembly Note
- Piston Pin Disassembly Note
- Main Bearing Cap Disassembly Note
- CYLINDER BLOCK (I) ASSEMBLY
- Main Bearing Cap Assembly Note
- Piston Pin Assembly Note
- Piston Ring Assembly Note
- Connecting Rod Bearing Assembly Note
- Connecting Rod Cap Assembly Note
- Pilot Bearing Assembly Note
- CYLINDER BLOCK (II) ASSEMBLY
- Flywheel Assembly Note
- CYLINDER HEAD (I) ASSEMBLY
- Water Outlet Case Assembly Note
- Valve Seal Assembly Note
- Valve Keeper Assembly Note
- CYLINDER HEAD (II) ASSEMBLY
- Cylinder Head Assembly Note
- Camshaft Assembly Note
- Camshaft Sprocket, Variable Valve Timing Actuator Assembly Note
- TIMING CHAIN ASSEMBLY
- Drive Sprocket Assembly Note
- Oil Pump Driven Sprocket Assembly Note
- Camshaft Sprocket Lock Bolt Assembly Note
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information
- Waveforms - Injector Pattern Tutorial - General Information
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- PRECAUTION
- Secondary shaft (No. 1) gear thrust clearance
- Secondary shaft (No. 1) gear radial clearance
- Secondary shaft (No. 2) gear thrust clearance
- Secondary shaft (No. 2) gear radial clearance
- Reverse idler gear thrust clearance
- Reverse idler gear radial clearance
- Synchronizer ring clearance
- Clutch hub sleeve and shift fork clearance
- Primary shaft snap ring clearance
- Secondary shaft (No. 1) snap ring clearance
- Secondary shaft (No. 2) snap ring clearance
- Gear backlash
- SERVICE TOOLS
- SHIFT COMPONENT DISASSEMBLY/ASSEMBLY
- Shift Lever Shaft Oil Seal Disassembly Note
- Shift Lever Shaft Bearing Disassembly Note
- Breather Plug Disassembly Note
- Breather Plug Assembly Note
- Shift Lever Shaft Bearing Assembly Note
- Shift Lever Shaft Oil Seal Assembly Note
- Spring Pin Assembly Note
- PRIMARY SHAFT COMPONENTS DISASSEMBLY
- Rear Bearing and 6th Gear Disassembly Note
- 3rd Gear Disassembly Note
- 4th Gear Disassembly Note
- Front Bearing Inner Race Disassembly Note
- PRIMARY SHAFT COMPONENTS ASSEMBLY
- Front Bearing Inner Race Assembly Note
- 4th Gear Assembly Note
- 3rd Gear Assembly Note
- 6th Gear Assembly Note
- Rear Bearing Assembly Note
- Rear Bearing Snap Ring Assembly Note
- SECONDARY SHAFT (NO. 1) COMPONENTS DISASSEMBLY
- Rear Bearing and 3rd Gear Disassembly Note
- 3rd/4th Clutch Hub Component and 4th Gear Disassembly Note
- 1st/2nd Clutch Hub Component and 1st Gear Disassembly Note
- SECONDARY SHAFT (NO. 1) COMPONENTS ASSEMBLY
- 2nd Synchronizer Ring and 2nd Gear Assembly Note
- SECONDARY SHAFT (NO. 2) COMPONENTS DISASSEMBLY
- 5th Gear and 5th/6th Clutch Hub Disassembly Note
- Reverse Gear and Reverse Clutch Hub Disassembly Note
- Front Bearing Disassembly Note
- SECONDARY SHAFT (NO. 2) COMPONENTS ASSEMBLY
- Reverse Clutch Hub Snap Ring Assembly Note
- 6th Synchronizer Ring Assembly Note
- Front Bearing Assembly Note
- DIFFERENTIAL DISASSEMBLY
- Bearing (Ring Gear Side) Disassembly Note
- DIFFERENTIAL ASSEMBLY
- Ring Gear Assembly Note
- Bearing (Ring Gear-Opposite Side) Assembly Note
- Bearing (Ring Gear Side) Assembly Note
- CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS DISASSEMBLY
- OIL SEAL (PRIMARY SHAFT) DISASSEMBLY NOTE
- BEARING RACE (SECONDARY SHAFT) DISASSEMBLY NOTE
- ROLL PIN DISASSEMBLY NOTE
- OIL SEAL (CHANGE ROD COMPONENT) DISASSEMBLY NOTE
- OIL SEAL (DIFFERENTIAL) DISASSEMBLY NOTE
- BEARING RACE (DIFFERENTIAL) DISASSEMBLY NOTE
- BEARING RACE (TRANSAXLE CASE) DISASSEMBLY NOTE
- PRIMARY SHAFT COMPONENTS DISASSEMBLY
- BEARING (4TH GEAR END) DISASSEMBLY NOTE
- 3RD/4TH CLUTCH HUB COMPONENT, 3RD SYNCHRONIZER RING AND 3RD GEAR DISASSEMBLY NOTE
- PRIMARY SHAFT COMPONENTS ASSEMBLY
- BEARING (PRIMARY SHAFT END) ASSEMBLY NOTE
- 3RD GEAR, 3RD SYNCHRONIZER RING, AND 3RD/4TH CLUTCH HUB COMPONENT ASSEMBLY NOTE
- SECONDARY SHAFT COMPONENTS DISASSEMBLY
- BEARING AND SECONDARY 4TH GEAR DISASSEMBLY NOTE
- SECONDARY 3RD GEAR AND 2ND GEAR DISASSEMBLY NOTE
- 1ST/2ND CLUTCH HUB COMPONENT, 1ST SYNCHRONIZER RING, AND 1ST GEAR DISASSEMBLY NOTE
- BEARING (SECONDARY SHAFT END) DISASSEMBLY NOTE
- SECONDARY SHAFT COMPONENTS ASSEMBLY
- BEARING (SECONDARY SHAFT END) ASSEMBLY NOTE
- 1ST GEAR, 1ST SYNCHRONIZER RING, AND 1ST/2ND CLUTCH HUB COMPONENT ASSEMBLY NOTE
- 2ND SYNCHRONIZER RING, 2ND GEAR, AND SECONDARY 3RD GEAR ASSEMBLY NOTE
- DIFFERENTIAL DISASSEMBLY
- BEARING (SIDE OPPOSITE RING GEAR) DISASSEMBLY NOTE
- BEARING (RING GEAR SIDE) DISASSEMBLY NOTE
- DIFFERENTIAL ASSEMBLY
- BEARING (RING GEAR SIDE) ASSEMBLY NOTE
- Bearing (Side Opposite Ring Gear) Assembly Note
- CLUTCH HOUSING AND TRANSAXLE CASE COMPONENTS ASSEMBLY
- OIL SEAL (DIFFERENTIAL) ASSEMBLY NOTE
- BEARING RACE (DIFFERENTIAL) ASSEMBLY NOTE
- BEARING RACE (TRANSAXLE CASE) ASSEMBLY NOTE
- OIL SEAL (CHANGE ROD COMPONENT) ASSEMBLY NOTE
- OIL SEAL (PRIMARY SHAFT) ASSEMBLY NOTE
- 5TH/REVERSE GEAR AND HOUSING PARTS ASSEMBLY
- PRIMARY SHAFT GEAR COMPONENT AND SECONDARY SHAFT GEAR COMPONENT ASSEMBLY NOTE
- CRANK LEVER COMPONENT AND CRANK LEVER SHAFT ASSEMBLY NOTE
- 5TH/REVERSE SHIFT ROD END AND 5TH/REVERSE SHIFT ROD ASSEMBLY NOTE
- REVERSE IDLE GEAR AND REVERSE IDLE SHAFT ASSEMBLY NOTE
- TRANSAXLE CASE COMPONENT ASSEMBLY NOTE
- SECONDARY 5TH GEAR ASSEMBLY NOTE
- 5TH/REVERSE CLUTCH HUB COMPONENT AND 5TH/REVERSE SHIFT FORK ASSEMBLY NOTE
- DRIVE CYCLE PROCEDURE
- Drive Cycle-Mode 1
- Drive Cycle-Mode 2
- Drive Cycle-Mode 3
- Drive Cycle-Mode 4
- Preparation
- Drive Mode
- Comprehensive Component Monitor Repair Verification Drive Mode
- EGR Monitor Repair Verification Drive Mode
- Catalyst Monitor Repair Verification Drive Mode
- Fuel Monitor, Oxygen Sensor Monitor or Oxygen Sensor Heater Monitor Repair Verification Drive Mode
- Misfire Monitor Repair Verification Drive Mode
- Vehicle Preparation For OBD-II Or Monitor Repair Verification Drive Cycle
- Comprehensive Component Monitor Repair Verification Drive Cycle
- EGR Monitor Repair Verification Drive Cycle
- EVAP Running Loss System Repair Verification Drive Cycle
- Catalyst Monitor Repair Verification Drive Cycle
- Fuel Monitor Or HO2S Monitor Repair Verification Drive Cycle
- Misfire Monitor Repair Verification Drive Cycle
- Secondary Air Monitor Repair Verification Drive Cycle
- Verification Drive Cycle
- HO2S/TWC Monitor Repair Verification Drive Cycle
- EVAP Monitor Repair Verification Drive Cycle
- 1999: B2500, B3000, B4000
- Vehicle Preparation For Drive Cycles
- EVAP System Monitor Repair Verification Drive Cycle
- HO2S Monitor Repair Verification Drive Cycle
- OBDII DRIVE MODE
- Mode 1 (PCM adaptive memory produce drive mode)
- Mode 2 (EGR system repair verification drive mode)
- Mode 3 HO2S heater, HO2S, and TWC repair verification drive mode)
- Mode 4 (EVAP system repair verification drive mode)
- Drive Cycle Recommendations
- Vehicle Preparation
- OBD II Drive Cycle
- 2000: MPV
- Mode 1 (PCM Adaptive Memory)
- Mode 2 (EGR Verification)
- Mode 3 (HO2S/TWC Verification)
- Mode 4 (EVAP Verification)
- 2000: PROTEGE
- Standard Drive Mode
- HO2S/TWC Monitor Repair Verification Drive Mode
- EVAP Monitor Repair Verification Drive Mode
- 2001: B2300, B2500, B3000, B4000, TRIBUTE
- OBD-II Drive Cycle Vehicle Preparation
- OBD-II Drive Cycle Procedures
- PCM Adaptive Memory Drive Mode
- Mode 1 (PCM Adaptive Memory Drive Mode)
- Mode 2 (EGR Monitor Repair Verification Drive Mode)
- Mode 3 (HO2S/TWC Monitor Repair Verification Drive Mode)
- Mode 4 (EVAP Monitor Repair Verification Drive Mode)
- OBD-II Drive Cycle Procedure
- 2002: MILLENIA
- Mode 1: PCM Adaptive Memory Procedure
- Mode 2: EGR System Repair Verification
- Mode 3: HO2S & TWC Repair Verification
- Mode 4: EVAP System Repair Verification
- Mode 1 - PCM Adaptive Memory Produce Drive Mode
- Mode 2 - EGR System Repair Verification Drive Mode
- Mode 3 - HO2S Heater, HO2S & TWC Repair Verification Drive Mode
- Mode 6 - EVAP System Repair Verification Drive Mode
- Mode 4 - EVAP System Repair Verification Drive Mode
- Drive Mode 1 - PCM Adaptive Memory
- Drive Mode 2 - EGR Monitor Repair Verification
- Drive Mode 3 - HO2S, HO2S Heater & TWC Repair Verification
- Drive Mode 4 - EVAP System Repair Verification
- Drive Mode 5 - EVAP System Very Small Leak Repair Verification
- OBD-II DRIVE MODES
- 2004-06: MAZDA3 & 2006: MAZDA5 & 2007-09: MAZDA3 (W/O TURBO)
- PCM Adaptive Memory Production Drive Mode
- EVAP System Repair Verification Drive Mode
- 2004-05: MAZDA6
- MODE 6 (EVAP SYSTEM REPAIR VERIFICATION DRIVE MODE)
- 2004: MPV
- 2004: MX-5 MIATA
- MODE 1 (PCM ADAPTIVE MEMORY PRODUCTION DRIVE MODE)
- 2004: RX-8
- 2005-06: MPV
- With rear HO2S model
- 2005: MX-5 MIATA
- 2005-08: RX-8
- 2006-08: MAZDA6
- EVAP System Repair Verification Drive Mode (4 Cylinder W/O Turbo & V6)
- EVAP System Repair Verification Drive Mode (4 Cylinder W/Turbo)
- 2006-08: MX-5 MIATA
- 2007-09: MAZDA3 (W/TURBO)
- 2007: MAZDA5
- 2007-08: CX-7
- PCM Adaptive Memory Production, EGR, HO2S heater, HO2S, TWC, and EVAP System Repair Verification Drive Mode
- 2007-10: CX-9
- 2008-09: MAZDA5
- Mode 06 (EVAP System Repair Verification Drive Mode)
- Single Drive Mode
- 2009-10: MAZDA6 (4 CYLINDER)
- Mode 02 (EGR System Repair Verification Drive Mode)
- 2009-10: MAZDA6 (V6)
- 2009: CX-7
- Mode 03 (A/F Sensor Heater, HO2S Heater, A/F Sensor, HO2S, and TWC Repair Verification Drive Mode)
- 2009: MX-5 MIATA
- 2009-11: RX-8
- Mode 5 (AIR System Repair Verification Drive Mode)
- 2010-13: MAZDA3 (W/TURBO)
- 2010: MAZDA5
- 2010-12: CX-7 (W/TURBO)
- 2010-12: CX-7 (W/O TURBO)
- 2010-13: MX-5 MIATA
- Mode 03 (PCM Adaptive Memory Production, EGR System, A/F Sensor Heater, HO2S Heater, A/F Sensor, HO2S, and TWC Repair Verification Drive Mode)
- 2011-13: CX-9
- 2010-13: MAZDA3 (W/O TURBO)
- 2012-13: MAZDA5
- 2011-13: MAZDA6 (4 CYLINDER)
- Mode 03 (EGR System, A/F Sensor Heater, HO2S Heater, A/F Sensor, HO2S and TWC Repair Verification Drive Mode)
- 2011-13: MAZDA6 (V6)
- 2012-13: MAZDA2
- 2013: CX-5