TSB: 03-001/06

2004-2006 MAZDA3, 2006 MAZDA5 - BODY VIBRATION AT CRUISE SPEED

BULLETIN NOTE

This bulletin supersedes the previous bulletin issued on 7/12/2006. The REPAIR PROCEDURE section has been revised.

APPLICABLE MODEL(S) / VINS

2004-2006 Mazda3

2006 Mazda5

DESCRIPTION

Some vehicles may experience a body vibration when driving approximately 55mph. This symptom is due to the characteristics of the No. 3 & No. 4 engine mounts.

Modified No. 3 & No. 4 engine mounts have been established for service only. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

IMPORTANT NOTE:

• This repair should only be performed if all tires and rims are confirmed to be in balance and all suspension components are in proper working condition.

• Notify customers that use of the modified mounts will reduce vibration at cruising speed but may increase vibration at idle.

NOTE: Because idle vibration may increase, it is highly recommended to continue using mass production mounts for all other service concerns.

1. Verify concern.

2. Replace the No. 3 & 4 engine mounts with service parts according to the appropriate Workshop Manual section 01-10 ENGINE REMOVAL/INSTALLATION.

3. Center the new engine mounts as outlined in ENGINE MOUNT CENTERING PROCEDURE.

4. Verify repair.

ENGINE MOUNT CENTERING PROCEDURE

No. 1, No. 3 and No. 4 Engine Mount Adjustment

1. Warm up the engine.

2. Raise and support vehicle on a hoist.

3. Remove engine under cover.

4. Lower the vehicle until the front tires lightly touch the ground.

5. Secure the engine and transaxle using an engine jack and attachment as instructed in No.3 Engine Mount And No.4 Engine Mount Rubber Installation Note in appropriate Workshop Manual, section 01-10 MECHANICAL.

6. Remove two bolts from No. 3 engine mount bracket.

7. Lift engine using jack until No.3 engine mount is lifted slightly from vehicle body.

NOTE:

• Do not raise engine too much or A/C pipe damage may occur.

8. Move the engine mount rubber or engine until installation hole on the vehicle body aligns with hole in the engine mount bracket.

9. Lower the jack and tighten bolts on No. 3 engine mount bracket.Tightening torque: 55.0-77.3 ft-lbf (74.5-04.9 N.m)

NOTE:

• Do not allow the engine mount bracket to be misaligned.

10. With engine supported as described in STEP 5, remove four (4) nuts and two (2) bolts from No. 4 engine mount top plate. Remove top plate.

NOTE:

• To access the mount, remove battery box.

11. Lift engine again using jack until No.4 engine mount is lifted slightly from vehicle body.

NOTE:

• Do not raise engine too much or A/C pipe damage may occur.

12. With top plate of No. 4 engine mount removed, move engine mount bottom plate or engine until all four (4) installation studs on the vehicle align with the engine mount holes.

13. Place top plate back on and tighten No. 4 engine mount bracket nuts and bolts to torque indicated.Tightening torque:

1. 32.5-45.0 ft-lbf (44.0-61.0 N.m)

2. 61.1-86.7 in-lbf (6.9-9.8 N.m)

14. Lift engine again using jack and loosen the two bolts on the No. 1 engine mount rubber until slightly loose on the No. 1 engine mount rubber.

15. Shake/rock the engine back and forth.

16. Tighten bolts in order below.

1. Crossmember-side No. 1 engine mount rubber. Tightening Torque: 68.7-86.1ft-lbf (93.1-116.6 N.m)

2. Engine-side No. 1 engine mount rubber. Tightening Torque: 68.7-86.1ft-lbf (93.1-116.6 N.m)

A/C Pipe Adjustment

NOTE:

• A/C pipes and bracket are located on the right rear of the engine compartment, bolted to the frame rail.

17. Loosen the A/C pipe bracket bolt and/or nut.

18. Position the A/C pipe bracket so A/C pipes are as close to center in the bushings as possible.

NOTE:

• On Mazda5, center both A/C pipes, on Mazda3, center only the rear pipe as the front pipe cannot be centered due to bushing thickness.

19. Tighten the bolt and nut.Tightening torque: 61.0-86.8 in-lb (6.89-9.80 N.m)

PART(S) INFORMATION

WARRANTY INFORMATION

NOTE:

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

• Additional diagnostic time cannot be claimed for this repair.