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Mazda 3 BK 2003 - 2008 First generation Service Manual

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The Mazda 3, first generation (BK chassis), produced from 2003 to 2008, is a sporty and practical compact car available as a 4-door sedan or 5-door hatchback. Embodying a sporty...
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Mazda 3 BK 2003 - 2008 First generation Service ManualMazda 3 BK 2003 - 2008 First generation Service ManualMazda 3 BK 2003 - 2008 First generation Service ManualMazda 3 BK 2003 - 2008 First generation Service Manual
The Mazda 3, first generation (BK chassis), produced from 2003 to 2008, is a sporty and practical compact car available as a 4-door sedan or 5-door hatchback. Embodying a sporty driving philosophy, it offers engaging driving dynamics and a driver-focused cockpit. Available with either a 1.6L engine producing 104 hp or a more powerful 2.0L engine delivering 148 hp, and paired with a 5-speed manual or optional 4-speed automatic transmission, the Mazda 3 was designed for younger buyers and families seeking stylish and reliable transportation. It garnered significant recognition, including Car of the Year for 2004, and consistently achieved strong safety ratings. This comprehensive service manual provides detailed information for the maintenance and repair of the Mazda 3 BK generation. It covers a wide range of systems, including engine mechanical and electrical components, manual and automatic transmissions, suspension, steering, brakes, and electrical chassis systems. The manual also details body and interior work, safety restraint systems, and offers in-depth diagnostics and troubleshooting guidance. Owners, mechanics, and technicians will find essential information on routine maintenance procedures, major repair processes, component replacement, diagnostic codes, wiring diagrams, and precise technical specifications, ensuring the longevity and optimal performance of the vehicle.
🏷️ 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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