Mazda 3 2008 (1st Generation) Workshop Service Repair Manual
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Basic Information Identification Make: Mazda Model: Mazda3 Year: 2008 Generation: 1st Generation (BK) Codes Chassis Code: BK Introduction Market Position Segment: Compact/Small Family Car Positioning: Known for its sporty handling, upscale interior feel, and engaging driving dynamics within its class. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Ford Focus, Volkswagen Golf, Nissan Sentra. Key Features Design Philosophy: Zoom-Zoom philosophy emphasizing driving pleasure and responsiveness. Body Styles: Available as a 4-door sedan and a 5-door hatchback. Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Secondary Coverage: Diagnostics, Maintenance, Troubleshooting, Overhaul Page Count Estimated Page Count: Approximately 2000+ pages (typical for full workshop manuals of this era) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, and overhaul procedures for all engine variants, including cylinder head, block, pistons, crankshaft, camshafts, timing systems. Engine Management And Emissions: Fuel injection, ignition system, sensor data, diagnostic trouble codes (DTCs), evaporative emission control (EVAP), exhaust gas recirculation (EGR). Transmission Manual: Service and repair of the manual gearbox, clutch system, gearbox fluid, internal components. Transmission Automatic: Service and repair of the automatic transmission, torque converter, transmission fluid, valve body, solenoids, electronic control. Drivetrain: Front-wheel drive (FWD) system, axles, CV joints, differential components, prop shaft (if AWD variant covered). Suspension: Front and rear suspension components, struts, shocks, springs, control arms, bushings, anti-roll bars, alignment specifications. Steering: Power steering system, steering rack, power steering pump, steering column, universal joints, tie rods. Brakes: Hydraulic system, brake fluid, master cylinder, brake lines, calipers, pads, rotors, ABS system, parking brake. Electrical System: Battery, alternator, starter motor, fuses, relays, wiring diagrams, lighting system, horn, wipers, power windows. Body And Chassis: Body panels, doors, hood, trunk, bumpers, glass, interior trim, seat removal, chassis structure. HVAC System: Air conditioning, heater core, blower motor, refrigerant system, climate control panel, cabin filter replacement. Safety Systems: Airbag system, seat belt pre-tensioners, SRS module, diagnostic procedures for safety components. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, DTC lookup and interpretation. Repair And Overhaul: Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Diagnostics: Procedures for using diagnostic tools, reading live data, performing actuator tests, and diagnosing electronic control modules (ECMs). Wiring And Schematics: Detailed electrical wiring diagrams for all vehicle systems, component location charts, connector pinouts. Specifications And Tolerances: Precise torque values, clearance measurements, wear limits, and other critical specifications for proper assembly and repair. Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) User Level: Professional technicians and advanced DIY enthusiasts Manual Specifications File Format Format: PDF Searchability: Text-searchable (allows quick finding of specific terms) Print Quality Printability: Printable (allows users to print specific sections or the entire manual) Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper: N/A (Digital Download - PDF) Engine Specifications Primary Engine Engine Code: LF-DE (2.0L) Engine Type: Inline 4-cylinder, DOHC, 16-valve, VVT-i (Variable Valve Timing with intelligence) Displacement: 1998 cc (2.0 Liters) Bore X Stroke: 87.5 mm x 83.1 mm Compression Ratio: 9.7:1 Horsepower Net: Approx. 148 hp @ 6000 rpm Torque Net: Approx. 135 lb-ft (183 Nm) @ 4500 rpm Secondary Engine Engine Code Optional: MZR DISI Turbo (2.3L) Engine Type Optional: Inline 4-cylinder, DOHC, 16-valve, Turbocharged, Direct Injection, VVT Displacement Optional: 2261 cc (2.3 Liters) Horsepower Net Optional: Approx. 263 hp @ 5500 rpm (MazdaSpeed3) Torque Net Optional: Approx. 280 lb-ft (380 Nm) @ 3000 rpm (MazdaSpeed3) Performance Fuel Type: Unleaded gasoline (87 octane recommended for 2.0L, premium recommended for 2.3L Turbo) Fuel System Injection Type: Electronic Fuel Injection (EFI) / Direct Injection (for Turbo) Cooling System Coolant Type: Mazda Long Life Antifreeze/Coolant (or equivalent with 50/50 mix with distilled water) Oil Specifications Engine Oil Viscosity: SAE 5W-20 (recommended for 2.0L, check manual for 2.3L Turbo) Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 5-speed Activematic Automatic Transmission (with Sport Mode/Sequential Shift) Features Clutch Type: Dry, single-plate, coil spring diaphragm type (Manual) Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (specific Mazda fluid recommended) Automatic Transmission Fluid: Mazda ATF-SP III or equivalent Dimensions Exterior Length: Sedan: 4580 mm (180.3 in), Hatchback: 4415 mm (173.8 in) Width: 1745 mm (68.7 in) Height: 1465 mm (57.7 in) Sedan, 1470 mm (57.9 in) Hatchback Wheelbase: 2640 mm (103.9 in) Front Track: 1505 mm (59.3 in) Rear Track: 1495 mm (58.9 in) Weights Curb Weight: Approx. 1300-1450 kg (2866-3197 lbs), varies by trim and body style. Cargo Cargo Volume Sedan: Approx. 13.2 cu ft Cargo Volume Hatchback: Approx. 20.0 cu ft (seats up) Safety Features Ratings NHTSA Frontal Crash Driver: 5-Star (2008 model year) NHTSA Frontal...
Approximately 2000+ pages (typical for full workshop manuals of this era)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, and overhaul procedures for all engine variants, including cylinder head, block, pistons, crankshaft, camshafts, timing systems.
Engine Management And Emissions:
Fuel injection, ignition system, sensor data, diagnostic trouble codes (DTCs), evaporative emission control (EVAP), exhaust gas recirculation (EGR).
Transmission Manual:
Service and repair of the manual gearbox, clutch system, gearbox fluid, internal components.
Transmission Automatic:
Service and repair of the automatic transmission, torque converter, transmission fluid, valve body, solenoids, electronic control.
Unleaded gasoline (87 octane recommended for 2.0L, premium recommended for 2.3L Turbo)
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) / Direct Injection (for Turbo)
Cooling System
Coolant Type:
Mazda Long Life Antifreeze/Coolant (or equivalent with 50/50 mix with distilled water)
Oil Specifications
Engine Oil Viscosity:
SAE 5W-20 (recommended for 2.0L, check manual for 2.3L Turbo)
Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
5-speed Activematic Automatic Transmission (with Sport Mode/Sequential Shift)
Features
Clutch Type:
Dry, single-plate, coil spring diaphragm type (Manual)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (specific Mazda fluid recommended)
Automatic Transmission Fluid:
Mazda ATF-SP III or equivalent
Dimensions
Exterior
Length:
Sedan: 4580 mm (180.3 in), Hatchback: 4415 mm (173.8 in)
Width:
1745 mm (68.7 in)
Height:
1465 mm (57.7 in) Sedan, 1470 mm (57.9 in) Hatchback
Wheelbase:
2640 mm (103.9 in)
Front Track:
1505 mm (59.3 in)
Rear Track:
1495 mm (58.9 in)
Weights
Curb Weight:
Approx. 1300-1450 kg (2866-3197 lbs), varies by trim and body style.
Cargo
Cargo Volume Sedan:
Approx. 13.2 cu ft
Cargo Volume Hatchback:
Approx. 20.0 cu ft (seats up)
Safety Features
Ratings
NHTSA Frontal Crash Driver:
5-Star (2008 model year)
NHTSA Frontal Crash Passenger:
5-Star (2008 model year)
NHTSA Side Crash Driver:
5-Star (2008 model year)
NHTSA Side Crash Rear Passenger:
5-Star (2008 model year)
IIHS Front Offset Crash Test:
Good (2008 model year)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Electronic Stability Control:
Available Dynamic Stability Control (DSC)
Passive Features
Airbags Front:
Advanced front airbags (driver and passenger)
Airbags Side:
Front side-impact airbags
Airbags Curtain:
Available front and rear side-curtain airbags
Seatbelts:
3-point height-adjustable front seat belts with pretensioners and load limiters, 3-point rear seat belts.
Technology Features
Infotainment
Audio System:
Standard AM/FM/CD audio system with auxiliary input jack. Optional Bose premium audio system available on higher trims.
Navigation:
Optional factory navigation system available on select trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Keyless Entry:
Standard keyless remote entry.
Connectivity
Bluetooth:
Not widely available on standard 2008 models; may be an aftermarket addition or specific dealer option.
Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 12 months, whichever comes first (under normal driving conditions). Refer to manual for severe conditions.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. Replace at 45,000 miles (72,000 km) or sooner if dirty.
Cabin Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. Replace at 30,000 miles (48,000 km) or sooner if airflow is reduced.
Spark Plug Replacement:
Typically at 75,000 miles (120,000 km) for standard spark plugs, consult manual for specific type.
Coolant Flush:
First flush at 105,000 miles (168,000 km), then every 50,000 miles (80,000 km) thereafter.
Transmission Fluid Change Auto:
Inspect every 30,000 miles (48,000 km), change as needed. Some sources recommend changing around 60,000 miles (96,000 km).
Transmission Fluid Change Manual:
Inspect condition, typically no fixed interval but recommended inspection at 60,000 miles (96,000 km).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (check owner's manual for specific recommendation)
Fluid Capacities
Engine Oil Capacity 2.0L:
Approx. 4.7 US quarts (4.4 liters) with filter change
Engine Oil Capacity 2.3L:
Approx. 5.1 US quarts (4.8 liters) with filter change
Coolant Capacity:
Approx. 6.1 US quarts (5.8 liters)
Known Issues
Engine Mounts:
Premature wear of engine mounts, leading to vibrations, is a common complaint.
Clutch Wear:
Manual transmission clutches can wear out faster than expected with aggressive driving.
Rust Corrosion:
Areas prone to road salt exposure can experience rust, particularly on the undercarriage and wheel wells.
Catalytic Converter:
Some reports of catalytic converter failures, potentially due to engine misfires or oil consumption.
Power Steering Pump:
Occasional reports of power steering pump leaks or failures.
Vehicle History
Brand Heritage
Mazda Focus:
Mazda has a long history of producing engaging and reliable vehicles, with a focus on driving dynamics since its inception.
Model Evolution
First Generation Launch:
The first generation Mazda3 (BK) was introduced for the 2004 model year, replacing the Mazda Protégé.
2008 Update:
The 2008 model year represented a mid-cycle refresh for the first-generation Mazda3, featuring revised exterior styling (grille, headlights, taillights), updated interior trim, and improved features.
Production
Manufacturing Location:
Primarily produced in Japan (Hofu) and also in North America (Fremont, California, and Salamanca, Mexico).
Awards & Recognition
Recognitions
Car And Driver Best 10:
Mazda3 named to Car and Driver's 10Best list for 2004 and 2005.
Consumers Report Ratings:
Generally received good ratings for reliability and performance from Consumer Reports during its production run.
Certifications
California Emisiones:
Vehicles sold in California and other states adopting California emissions standards would meet these requirements.
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