POP NOISE OVER BUMPS

Applicable Models

Model Starting S/N Ending S/N Model Spec
  MAZDA3 2004-2007   000000   ZZZZZZ  
  MAZDA5 2006-2007   000000   ZZZZZZ  
  MAZDA6 2003-2007   000000   ZZZZZZ  

Related Category/Subcategory/Symptoms

SUSPENSION / FRONT / UNUSUAL NOISE(EXCL. PINGING,SQUEAKING,OPERATION,RESONANCE)
BODY AND ACCESSORY / ON-BOARD TROUBLESHOOTING / UNUSUAL NOISE(EXCL. PINGING,SQUEAKING,OPERATION,RESONANCE)

MTOL - 4948 Dealer Repair Information

Symptom and Conditions

Some customers may complain of a 'POP' noise that is heard in the front
of the vehicle, particularly when going over large bumps.  The noise   
comes from the under the hood in the upper front strut tower area,     
but can easily be mistaken for a Front Suspension Noise.  Upon further 
investigation, the front suspension components are not the cause of the
noise.                                                                 
                                                                       
The source may be the mounting bolts for the Cowl Panel need to be     
re-torqued.  The contact and movement between the cowl panel and vehicle
body may be the cause of the noise.

Repair Procedure

1.  Pinpoint the noise to the cowl area.                               
                                                                       
2.  Remove the windshield wiper arms and blades.  Refer to appropriate 
    Workshop Manual section 09-19 (WINDSHIELD WIPER ARM AND BLADE      
    REMOVAL/INSTALLATION).                                             
                                                                       
3.  Remove the cowl grille.  Refer to appropriate Workshop Manual      
    section 09-16 (COWL GRILLE REMOVAL/INSTALLATION).                  

4.  Loosen and re-torque all the cowl panel bolts to specification.
    Refer to appropriate Workshop Manual section 09-10 (COWL PANEL 
    REMOVAL/INSTALLATION).

                                         
    MAZDA3: 62-86 in-lbf. (6.9-9.8 N.m)                            
    MAZDA5: 62-86 in-lbf. (6.9-9.8 N.m)                            
    MAZDA6: 60.8-86.7 in-lbf. (6.87-9.8 N.m)                       
                                                                   
5.  Install cowl grille, wiper arms and blades in reverse order.   
                                                                   
6.  Verify repair.  If noise is still present, continue with normal
    diagnosis.


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