TSB: 01-008/06

2004-2005 MAZDA3 - 2.0L MT - FED / CAN ONLY - CRUISE SURGE

BULLETIN NOTE

This bulletin supersedes the previous bulletin 01-008/06, issued on 03/17/06. The WARRANTY INFORMATION has been revised.

APPLICABLE MODEL(S)/VINS

2004-2005 Mazda3 - 2.0L (LF) engine w/Manual Transmission (MT), Federal & Canadian Spec vehicles only

DESCRIPTION

Some customers may complain a light surging may be felt when cruise control is set and the vehicle is cresting a hill or going downhill. The speedometer stays constant, and the light surge is felt when the throttle adjusts to maintain a constant speed.

The cause is throttle valve versus fuel-cut system strategy depending on inclination of the slope in order to maintain vehicle speed. The PCM logic has been changed to fix the concern starting Job #1 of 2006MY.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Reboot the WDS PTU to clear memory before reprogramming.

2. Using WDS B40.13 or PDS/IDS 41.6 or later software, reprogram the PCM to the latest calibration (refer to “Calibration Information” table) by following the “Module Reprogramming” procedure.

NOTE:

• Always update the PDS/IDS tool first, then follow on-screen instructions to download the needed calibration file for PCM reprogramming.

• It is not necessary to remove any fuses or relays during PCM reprogramming when the PDS/IDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the PDS/IDS reprogramming procedure.

• PDS/IDS shows the calibration part numbers after programming the PCM.

• Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of PDS/IDS software, and additional revisions made to those calibrations for service related concerns.

• When reprogramming a PCM, PDS/IDS will always display the “latest” calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.

• When performing this procedure, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it could damage the VCM.

3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.

NOTE:

• If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.

• After PCM reprogramming, it is no longer necessary to road test the vehicle to “relearn” KAM (Keep Alive Memory).

4. Fill out an “Authorized Modifications” label (P/N 9999-95-AMDC-97) with the new PCM calibration information, your dealer code, and today's date.

5. Place the “Authorized Modifications” label on the “A” pillar below the tear tag in the driver door jamb.

CALIBRATION INFORMATION

NOTE: The PCM Calibration Part Numbers listed above are provided for PCM reprogramming purposes only. These are not necessarily the same Mazda part numbers used to order an actual PCM through the Mazda Parts System. It is not necessary to order a PCM as part of this repair procedure.

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.

• Additional diagnostic time cannot be claimed for this repair.