Mazda 3 (BK, 2003 - 2009) Workshop Service Manual
Mazda 3 (BK, 2003–2009) Workshop Service Manual & EWD
This detailed service and repair manual for the first generation Mazda 3 (BK) includes:
Full instructions for diagnosing and repairing all vehicle systems.
Electrical diagrams (EWD) for all trim levels, simplifying troubleshooting.
Description of engines, transmissions, suspension, brake system and electrical equipment.
Recommendations for maintenance and replacement of consumables.
1st generation (BK)
Years of production: 2003–2009
Bodies: Sedan, hatchback (5-door)
Engines:
Petrol:
- 1.4L (MZR) — 84 hp
- 1.6L (MZR) — 105 hp
- 2.0L (MZR) — 150 hp
- 2.3L (MZR) — 156-260 hp (Mazdaspeed 3 / MPS)
Diesel:
- 1.6L (HDi, shared with Ford/PSA) — 109 hp
- 2.0L (MZR-CD) — 143 hp
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| Mazda 3 MPS / Workshop Manual (BK Series) [2007 - 2009] | Download |
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| Repair manual in English, German, French and other languages .nrg | Download |
| Workshop Manual Mazda 3 2007 MAZDASPEED (BK) | Download |
Mazda 3 (BK, 2003 - 2009) Typical problems
1. Suspension
Noises and knocks:
Wear of stabilizer struts and stabilizer bushings is a common problem, causing knocks when driving on uneven roads.
Rapid wear of shock absorbers and support bearings.
Rust on suspension elements:
Levers and bolts often suffer from corrosion.
2. Body corrosion
Problem areas:
Lower edges of doors, rear wheel arches and underbody.
Edges of the hood and trunk.
A feature of the first batches of cars is insufficient anti-corrosion treatment.
3. Electrical equipment
Electric windows:
Problems with the motor or cables of the mechanisms.
Failures in the operation of electronics:
Malfunctions of the central lock, ABS sensors and airbags.
Headlights:
Rapid burnout of lamps, as well as cloudy plastic of the headlights.
4. Engines
Increased oil consumption (2.0L and 2.3L):
Due to wear of piston rings and valve stem seals.
1.6L MZR:
Oil leaks through gaskets.
Problems with alternator belt tensioner.
2.0L and 2.3L:
Oil leak through rear crankshaft oil seal.
5. Brake system
Squeaking brakes:
Rapid wear of brake pads and discs.
Rear calipers:
Jamming due to corrosion of handbrake mechanism.
6. Gearbox
Automatic transmission (4AT):
Jerking when shifting, especially when cold.
Need for regular oil changes.
Manual transmission (5MT):
Noises when shifting gears, especially 2nd and 3rd.
7. Problems with the air conditioning system
Freon leaks due to wear of seals and corrosion of the air conditioning radiator.