09-017/04 2004 MAZDA3 - SPLASHING SOUND FROM INSIDE DASH DURING COLD START

Note: This bulletin contains revised sections. Please update your records accordingly.

BULLETIN NOTE

• This bulletin supersedes last issued 05/07/2004. The REPAIR PROCEDURE has been revised.

APPLICABLE MODEL(S)/VINS

2004 MAZDA3

DESCRIPTION

Some vehicles may exhibit an unusual noise (like splashing) from inside the dashboard during a cold start. The noise sounds as if water is running. This may be caused by insufficient air-bleeding of the cooling system during assembly.

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

REPAIR PROCEDURE

1. Check the reservoir tank and, if low on coolant, fill up to the MAX mark.

2. Fully install the cooling system cap.

3. Start the engine and let it idle until the temperature gauge indicator is at the center. The engine should be below 1500 rpm.

   CAUTION: If the water temperature gauge indicator goes into the red zone, stop the engine and allow the coolant to cool to prevent overheating.

4. After the engine warms up, perform the following steps to bleed the cooling system. Make sure the temperature gauge indicator does not go into the red zone.
   1. Run the engine at 2,500 rpm for 5 minutes.
   2. Run the engine at 3,000 rpm for 5 seconds, then idle.
   3. Repeat steps (a) and (b) two times.

5. Stop the engine and wait until the coolant temperature decreases, then check the coolant level.
   • If it is low, refill the coolant into the coolant reserve tank up to the MAX mark on the tank.

   CAUTION: Allow coolant to cool sufficiently, otherwise severe injury or burns can occur.

6. Make sure there is no water leakage and the work is completed.

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.
• Additional diagnostic time cannot be claimed for this repair.