Mazda2004–2009

3 1.6 90 hp: Common faults & known problems

Common faults & known problems

11 known faults documented in workshop bulletins. Of these, two concern the engine and fuel system and two the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Technical specifications

Engine & fuel system

2 documented faults — symptoms, causes and workshop fixes.

Engine intermittently fails to crank

Affects All models except 2.3 MPS.Repair kit

Cause

Poor electrical connection between starter motor solenoid and harness connector.

Repair

Repair starter motor wiring harness using harness repair kit.

Parts1 part

Parts listed in the bulletin
Part	Part number	Qty
Harness repair kit	BAY0-67-SH0	1

Data: Motorwise Workshop. Bulletin 4.

Lack of power

Internal failure of turbocharger (TC) due to build up of sludge in oil supply pipe. Fix: fit a new part.

Overview

Affects: All models with 1.6 turbocharged engine.
Remedy: Fit new part

Symptoms

Excessive exhaust smoke. Rattling noise from turbocharger (TC).

Repair steps

Inspect engine for internal damage. Repair as necessary.
Flush engine oil system with a suitable flushing oil.
Fit new turbocharger (TC).

Data: Motorwise Workshop. Bulletin 11.

Electrical & ignition

2 documented faults — symptoms, causes and workshop fixes.

SRS warning lamp illuminated

Affects All models with side airbags.B1998Fit new part

Symptoms

Trouble code stored in SRS control module fault memory: B1998.

Cause

Front side airbag faulty.

Repair

Fit new front side airbag.

Data: Motorwise Workshop. Bulletin 7.

SRS warning lamp illuminated. Trouble code stored: B1885

Overview

Affects: All models.
Fault codes: B1885
Remedy: Fit new part

Cause

SRS control module faulty.

Repair

Carry out electrical, mechanical and component tests (as applicable) to eliminate any other possible cause(s).
If no fault(s) found: Fit new SRS control module.

Data: Motorwise Workshop. Bulletin 10.

Brakes

1 documented fault — symptoms, causes and workshop fixes.

Squeaking noise from rear brakes

Vibration between brake pads and discs. Fix: fit a modified part.

Overview

Affects: All models, →2005.
Remedy: Fit modified part

Repair steps

Remove rear brake pads.
Clean and lubricate rear brake caliper carrier.
Fit modified rear brake pads.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Rear brake pads	B3YP-26-48Z	1

Data: Motorwise Workshop. Bulletin 3.

Suspension & drivetrain

2 documented faults — symptoms, causes and workshop fixes.

Squeaking noise from front suspension when driving over rough roads or speed humps

Overview

Affects: All models, →01/06.
Remedy: Fit new part
Parts: 2 parts

Cause

Front suspension lower arm bushes faulty.

Repair

Fit new front suspension lower arm(s).
Check front wheel alignment and adjust if necessary.

Parts2 parts

Parts listed in the bulletin
Part	Part number	Qty
Front suspension lower arm - RH	B32H-34-300D	1
Front suspension lower arm - LH	B32H-34-350D	1

Data: Motorwise Workshop. Bulletin 1.

Clicking noise from driveshaft when moving off or changing from forward gear to reverse gear

Movement between front hub and driveshaft. Fix: fit a new part.

Overview

Affects: All models, →01/05.
Remedy: Fit new part

Repair steps

Remove driveshaft from front hub.
Remove dust cover from driveshaft.
Thoroughly clean all mating surfaces.
Ensure modified dust cover/washer fitted with black coloured side facing driveshaft.
Refit driveshaft to front hub.
Fit new driveshaft retaining bolt and hand tighten.
Rotate driveshaft and check correct alignment of dust cover/washer.
If dust cover/washer alignment is correct, tighten driveshaft retaining bolt. Tightening torque: 32 - 38 Nm + 90 °.

Parts

Parts listed in the bulletin
Part	Part number	Qty
Dust cover/washer	BPYK-33-044	2
Driveshaft retaining bolt	9YA0-21-083D	2

Data: Motorwise Workshop. Bulletin 2.

Steering

1 documented fault — symptoms, causes and workshop fixes.

Stored trouble code cannot be erased after replacement of power steering pump

Affects All models.B2477Software update

Symptoms

Trouble code stored in power steering control module fault memory: B2477.

Cause

Software incompatibility between power steering control module and power steering pump.

Repair

Re-program power steering control module with upgraded software.

Data: Motorwise Workshop. Bulletin 6.

Clutch & gearbox

2 documented faults — symptoms, causes and workshop fixes.

Whining noise from transmission in 3rd gear

Overview

Affects: All models with 5-speed G35M-R transmission, →06/05/08.
Parts: 4 parts

Symptoms

Transmission jumps out of 3rd gear.

Cause

Worn transmission components.

Repair

Remove transmission from vehicle and dismantle.
Replace parts as listed.

Parts4 parts

Parts listed in the bulletin
Part	Part number	Qty
Synchroniser hub sleeve	G501-17-242E	1
Synchroniser ring	GC01-17-26YA	2
Synchroniser spring	G601-17-724	2
Transmission 3rd gear	G511-17-230	1

Data: Motorwise Workshop. Bulletin 5.

Engine runs in limp home mode

Affects All models with automatic transmission (AT).P0715

Symptoms

Trouble code stored in transmission control module (TCM) fault memory: P0715.

Cause

Transmission input shaft speed sensor faulty.

Repair

Replace transmission input shaft speed sensor.

Data: Motorwise Workshop. Bulletin 8.

Air conditioning & heating

1 documented fault — symptoms, causes and workshop fixes.

Air conditioning (AC) inefficient

Affects All models with air conditioning (AC).

Cause

Foreign objects and/or debris in expansion valve.

Repair

Check AC system for debris. Replace component(s) as necessary.

Data: Motorwise Workshop. Bulletin 9.

Glossary

Technical terms used in this guide.

Nm: Newton-metres — the standard unit for how tightly a bolt is done up
AC: Air conditioning — the system that cools the cabin
SRS: Supplementary restraint system — the airbags and seat-belt pretensioners
TC: Turbocharger — the exhaust-driven compressor that boosts engine power
TCM: Transmission control module — the electronic unit that manages the gearbox
Caliper: The part that squeezes the brake pads onto the disc
Control Module: A control unit for one of the vehicle's systems (engine, gearbox, brakes, body, and so on)
Driveshaft: The shaft that takes drive from the differential out to a wheel
Expansion Valve: The air-conditioning valve that lets refrigerant drop in pressure so it can absorb heat
Fault Memory: The list of stored trouble codes in a control module
Re-Program: Update the software on a control module using the manufacturer's diagnostic tool
Solenoid: An electrically operated valve or actuator
Trouble Code: A standardised fault code stored by a control module, read with a diagnostic tool
Wiring Harness: The bundled cables that carry power and signals around the vehicle
Bushes: Rubber mountings that let a suspension or body joint move without metal-to-metal contact
Lower Arm: A suspension link that locates the wheel at the bottom of the hub

Frequently asked questions

What are the common faults with the Mazda 3 1.6?

This guide contains 11 workshop bulletins for the Mazda 3 1.6. Of these, two concern the engine and fuel system and two the electrical and ignition. Symptoms, causes, repair steps and part numbers are shown where supplied.

Does every Mazda 3 1.6 have these faults?

No. These are patterns documented across the model by workshops, not predictions for an individual vehicle. Where a fault applies only to certain vehicles or VIN ranges, that is listed with the fault.

Can I check for Mazda 3 1.6 faults myself?

Many of them. The documented symptoms can be seen, heard or felt during a test drive.