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Mazda 3 BK 2003 - 2008 First generation Service Manual

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🏷️ Basic Information Identification Make: Mazda Model: 3 Generation: BK (First Generation) Production Years: 2003-2008 Codes Chassis Code: BK 👋 Introduction Market Position Market Segment: Compact Car (C-segment) Target Audience: Younger buyers, families seeking practical and stylish transportation Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Volkswagen Golf Key Features Design Philosophy: Zoom-Zoom driving dynamics, sporty styling, driver-focused cockpit Body Styles: 4-door Sedan, 5-door Hatchback 📋 Manual Details Coverage Areas Manual Type: Service Manual Language: English Format: PDF Download Vehicle Coverage: Mazda 3 BK (2003, 2004, 2005, 2006, 2007, 2008 models) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, component testing, timing systems, lubrication, cooling, fuel delivery, emission controls Engine Electrical: Ignition system, starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators Transmission Manual: Clutch system, gearbox repair, gear ratios, shift mechanism, drive shafts, lubricants Transmission Automatic: Automatic transmission disassembly/assembly, hydraulic control, torque converter, transmission control module (TCM), fluid service Suspension Steering: Front and rear suspension components, shock absorbers, springs, bushings, power steering system, steering gear, alignment specifications Brakes: Hydraulic system, ABS, EBD, brake rotors, pads, calipers, master cylinder, bleeding procedures, parking brake Electrical Chassis: Lighting systems (headlights, taillights, interior), power windows, locks, mirrors, wipers, horn, charging system, battery, fuse box locations Body Interior: Body panel removal/installation, doors, hood, trunk, interior trim, seats, upholstery, HVAC system (heater, air conditioning) Safety Restraint: Airbag system components, seat belt mechanisms, SRS module diagnostics Diagnostics Troubleshooting: Diagnostic Trouble Codes (DTCs), fault finding, wiring diagrams, component testing procedures Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, fluid level checks, tire rotation Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs Component Replacement: Alternator, starter motor, water pump, fuel pump, radiator, exhaust system components Diagnostics: Troubleshooting guides for common symptoms, sensor testing, actuator testing Wiring Diagrams: Detailed electrical schematics for all vehicle systems Specifications: Torque specifications, clearances, tolerances, fluid capacities, electrical values Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete component rebuilds and advanced diagnostics. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes Printable: Yes Quality: High-resolution scans for clarity Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: MZR 1.6L (ZL-DE) Displacement 1: 1.6 liters (1598 cc) Configuration 1: Inline-4, DOHC, 16-valve Horsepower 1: 104 hp (78 kW) @ 6000 rpm Torque 1: 102 lb-ft (138 Nm) @ 4500 rpm Fuel System 1: Electronic Multi-Point Fuel Injection (MPI) Secondary Engine Engine Code 2: MZR 2.0L (LF-DE) Displacement 2: 2.0 liters (1999 cc) Configuration 2: Inline-4, DOHC, 16-valve Horsepower 2: 148 hp (110 kW) @ 6000 rpm Torque 2: 135 lb-ft (183 Nm) @ 4500 rpm Fuel System 2: Electronic Multi-Point Fuel Injection (MPI) Performance Engine Options: Available with 1.6L and 2.0L MZR engines 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Optional Transmission Type 2: 4-speed Automatic (with Activematic) Features Automatic Features: Sport mode, sequential manual shifting capability 📐 Dimensions Exterior Sedan Length: 4415 mm (173.8 in) Width: 1745 mm (68.7 in) Height: 1465 mm (57.7 in) Exterior Hatchback Length: 4340 mm (170.9 in) Width: 1745 mm (68.7 in) Height: 1470 mm (57.9 in) Weights Curb Weight Min: Approx. 1290 kg (2844 lbs) Curb Weight Max: Approx. 1390 kg (3064 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (Driver), 5-Star (Passenger) IIHS Front Offset: Good Active Features ABS: Standard Ebd: Standard Traction Control: Optional on some trims Passive Features Airbags Front: Standard Airbags Side Curtain: Optional Seatbelts: Front pretensioners, 3-point rear seatbelts 💡 Technology Features Infotainment Audio System: Optional Bose premium audio system on higher trims, standard AM/FM/CD player with auxiliary input. Navigation: Optional dealer-installed or aftermarket navigation units. Driver Assistance Cruise Control: Standard on most trims Connectivity Bluetooth: Optional on later models 🔧 Maintenance Service Intervals Oil Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Fluid Specifications Engine Oil Type Gasoline: API SN or higher, ILSAC GF-5 or higher, SAE 0W-20 or 5W-20 (refer to owner's manual for specific engine) Coolant Type: Mazda Super Long Life Coolant (Blue) Brake Fluid Type: DOT 3 or DOT 4 Transmission Fluid Automatic: Mazda ATF JWS3317 (or equivalent) Transmission Fluid Manual: GL-4 75W-90 gear oil Known Issues Common Issue 1: Rust on rear wheel arches and rocker panels, especially in rust-belt regions. Common Issue 2: Worn rear sway bar bushings, leading to clunking noises. Common Issue 3: Facelift models (2006 onwards) addressed some earlier quality concerns. Common Issue 4: Potential for ignition coil failure (can cause misfires). Common Issue 5: Clutch wear on manual transmission models, particularly with aggressive driving. 📚 Vehicle History Brand Heritage Brand Focus: Mazda is known for its focus on driving enjoyment ('Zoom-Zoom') and innovative engineering. Model Evolution Predecessor: Mazda 323 (Familia) Successors: Mazda 3 (2nd...
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Mazda 3 BK 2003 - 2008 First generation Service Manual
🏷️ Basic Information
Identification
Make:
Mazda
Model:
3
Generation:
BK (First Generation)
Production Years:
2003-2008
Codes
Chassis Code:
BK
👋 Introduction
Market Position
Market Segment:
Compact Car (C-segment)
Target Audience:
Younger buyers, families seeking practical and stylish transportation
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Volkswagen Golf
Key Features
Design Philosophy:
Zoom-Zoom driving dynamics, sporty styling, driver-focused cockpit
Body Styles:
4-door Sedan, 5-door Hatchback
📋 Manual Details
Coverage Areas
Manual Type:
Service Manual
Language:
English
Format:
PDF Download
Vehicle Coverage:
Mazda 3 BK (2003, 2004, 2005, 2006, 2007, 2008 models)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine overhaul, component testing, timing systems, lubrication, cooling, fuel delivery, emission controls
Engine Electrical:
Ignition system, starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators
Transmission Manual:
Clutch system, gearbox repair, gear ratios, shift mechanism, drive shafts, lubricants
Transmission Automatic:
Automatic transmission disassembly/assembly, hydraulic control, torque converter, transmission control module (TCM), fluid service
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, bushings, power steering system, steering gear, alignment specifications
Brakes:
Hydraulic system, ABS, EBD, brake rotors, pads, calipers, master cylinder, bleeding procedures, parking brake
Electrical Chassis:
Lighting systems (headlights, taillights, interior), power windows, locks, mirrors, wipers, horn, charging system, battery, fuse box locations
Body Interior:
Body panel removal/installation, doors, hood, trunk, interior trim, seats, upholstery, HVAC system (heater, air conditioning)
Safety Restraint:
Airbag system components, seat belt mechanisms, SRS module diagnostics
Diagnostics Troubleshooting:
Diagnostic Trouble Codes (DTCs), fault finding, wiring diagrams, component testing procedures
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug service, fluid level checks, tire rotation
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs
Component Replacement:
Alternator, starter motor, water pump, fuel pump, radiator, exhaust system components
Diagnostics:
Troubleshooting guides for common symptoms, sensor testing, actuator testing
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems
Specifications:
Torque specifications, clearances, tolerances, fluid capacities, electrical values
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete component rebuilds and advanced diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes
Printable:
Yes
Quality:
High-resolution scans for clarity
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
MZR 1.6L (ZL-DE)
Displacement 1:
1.6 liters (1598 cc)
Configuration 1:
Inline-4, DOHC, 16-valve
Horsepower 1:
104 hp (78 kW) @ 6000 rpm
Torque 1:
102 lb-ft (138 Nm) @ 4500 rpm
Fuel System 1:
Electronic Multi-Point Fuel Injection (MPI)
Secondary Engine
Engine Code 2:
MZR 2.0L (LF-DE)
Displacement 2:
2.0 liters (1999 cc)
Configuration 2:
Inline-4, DOHC, 16-valve
Horsepower 2:
148 hp (110 kW) @ 6000 rpm
Torque 2:
135 lb-ft (183 Nm) @ 4500 rpm
Fuel System 2:
Electronic Multi-Point Fuel Injection (MPI)
Performance
Engine Options:
Available with 1.6L and 2.0L MZR engines
🔧 Transmission
Standard
Transmission Type 1:
5-speed Manual
Optional
Transmission Type 2:
4-speed Automatic (with Activematic)
Features
Automatic Features:
Sport mode, sequential manual shifting capability
📐 Dimensions
Exterior Sedan
Length:
4415 mm (173.8 in)
Width:
1745 mm (68.7 in)
Height:
1465 mm (57.7 in)
Exterior Hatchback
Length:
4340 mm (170.9 in)
Width:
1745 mm (68.7 in)
Height:
1470 mm (57.9 in)
Weights
Curb Weight Min:
Approx. 1290 kg (2844 lbs)
Curb Weight Max:
Approx. 1390 kg (3064 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (Driver), 5-Star (Passenger)
IIHS Front Offset:
Good
Active Features
ABS:
Standard
Ebd:
Standard
Traction Control:
Optional on some trims
Passive Features
Airbags Front:
Standard
Airbags Side Curtain:
Optional
Seatbelts:
Front pretensioners, 3-point rear seatbelts
💡 Technology Features
Infotainment
Audio System:
Optional Bose premium audio system on higher trims, standard AM/FM/CD player with auxiliary input.
Navigation:
Optional dealer-installed or aftermarket navigation units.
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Bluetooth:
Optional on later models
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Fluid Specifications
Engine Oil Type Gasoline:
API SN or higher, ILSAC GF-5 or higher, SAE 0W-20 or 5W-20 (refer to owner's manual for specific engine)
Coolant Type:
Mazda Super Long Life Coolant (Blue)
Brake Fluid Type:
DOT 3 or DOT 4
Transmission Fluid Automatic:
Mazda ATF JWS3317 (or equivalent)
Transmission Fluid Manual:
GL-4 75W-90 gear oil
Known Issues
Common Issue 1:
Rust on rear wheel arches and rocker panels, especially in rust-belt regions.
Common Issue 2:
Worn rear sway bar bushings, leading to clunking noises.
Common Issue 3:
Facelift models (2006 onwards) addressed some earlier quality concerns.
Common Issue 4:
Potential for ignition coil failure (can cause misfires).
Common Issue 5:
Clutch wear on manual transmission models, particularly with aggressive driving.
📚 Vehicle History
Brand Heritage
Brand Focus:
Mazda is known for its focus on driving enjoyment ('Zoom-Zoom') and innovative engineering.
Model Evolution
Predecessor:
Mazda 323 (Familia)
Successors:
Mazda 3 (2nd generation - BL)
Production
Manufacturing Locations:
Japan (Hofu), Thailand, China, Malaysia, Russia, South Africa, Ukraine, Vietnam
🏆 Awards & Recognition
Recognitions
Car Of The Year:
Named MotorTrend's Car of the Year for 2004.
Safety Awards:
Consistently received good safety ratings from NHTSA and IIHS.
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