2004 Mazda 3 Service and Repair Manual

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Covers all 2004 3 trims — i Sedan 4-Door, S Hatchback 4-Door, GS Sedan 4-Door +5 more ·
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2004 Mazda 3 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • i Sedan 4-Door
  • S Hatchback 4-Door
  • GS Sedan 4-Door
  • GT Sedan 4-Door
  • S Sedan 4-Door
  • GT Hatchback 4-Door
  • GX Sedan 4-Door
  • GS Hatchback 4-Door

Engines covered

  • 2.0L 2000CC 122Cu. In. l4 GAS DOHC Naturally Aspirated
  • 2.3L 2260CC l4 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams
NHTSA #21V49400001/07/2021Component: AIR BAGS:FRONTAL

Mazda North American Operations (Mazda) is recalling certain 2004-2007 Mazda3 vehicles. During air bag deployment, the plastic emblem on the steering wheel air bag module cover may shatter, and project plastic fragments into the vehicle.

Consequence

Plastic fragments can hit occupants during air bag deployment, increasing the risk of injury.

Remedy

Dealers will replace the air bag module cover, free of charge. Owner letters were mailed between August 28, 2021 and October 28, 2021. Owners may contact Mazda customer service at 1-800-222-5500 Option 4. Mazda's number for this recall is 4921G.

NHTSA #09E01100002/04/2009Component: EQUIPMENT

THULE, INC. IS RECALLING 2,323 OWNER-INSTALLED ROOF-MOUNTED FIT KITS, MODELS 3068 AND 3069, MANUFACTURED BETWEEN JANUARY 1, 2008 AND FEBRUARY 28, 2009 THAT ARE USED WITH THULE PODIUM FOOT PACKS, MODELS 460 AND 460R. THESE FIT KITS WERE SOLD AS AFTERMARKET EQUIPMENT FOR USE ON THE VEHICLES LISTED ABOVE. THE BOLT(S) USED TO SECURE THE FOOT TO THE VEHICLE WAS MANUFACTURED TO A HARDNESS THAT MAY CAUSE THE BOLT(S) TO BE BRITTLE AND POTENTIALLY BREAK UNDER STRESS.

Consequence

THIS MAY RESULT IN THE BOLT(S) SNAPPING OFF DURING USE OR WITHOUT A LOAD. THE UNSECURED RACK AND LOAD CAN THEN COME LOOSE WHILE DRIVING CREATING A POTENTIAL ROAD HAZARD, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

THULE WILL MAIL A RETRO FIT KIT ALONG WITH REPAIR INSTRUCTIONS TO OWNERS FREE OF CHARGE. THE SAFETY RECALL IS EXPECTED TO BEGIN ON OR BEFORE APRIL 13, 2009. OWNERS MAY CONTACT THULE TOLL-FREE AT 1-800-238-2388.

NHTSA #04V46800024/09/2004Component: AIR BAGS:FRONTAL:SENSOR/CONTROL MODULE-INACTIVE

ON CERTAIN PASSENGER VEHICLES, A CRACK IN THE AIR BAG CRASH ZONE SENSOR HOUSING CAN ALLOW WATER TO ENTER THE SENSOR, CAUSING A SHORT CIRCUIT AND ILLUMINATING THE AIR BAG WARNING LIGHT.

Consequence

IF THIS PROBLEM EXISTS, THE AIR WILL NOT DEPLOY AS DESIGNED IN CERTAIN TYPES OF FRONTAL CRASHES, INCREASING THE RISK OF DEATH OR SERIOUS INJURY TO THE DRIVER AND FRONT SEAT PASSENGER.

Remedy

DEALERS WILL INSPECT THE CRASH ZONE SENSOR AND REPLACE IT, IF NECESSARY. THE RECALL BEGAN ON OCTOBER 28, 2004. OWNERS SHOULD CONTACT MAZDA AT 1-800-222-5500.

TSB #11032103

This Service Alert supersedes the previously issued SA listed below: The changes are noted in Red. SA-011/24 02/12/24, 06/06/24, 07/29/24 DESCRIPTION Mazda has developed factory recommended scheduled maintenance services that support all ma

TSB #11026904

A musty/mildew type odor may come from the vents when the air conditioning (A/C) system is operating. It is most noticeable when the A/C is first turned ON. This odor is the result of mold growth in the A/C evaporator/cooling unit which is

TSB #11022742

Some vehicles may experience exterior trim heat damage such (melted, separating, etc.) when parked near a glass building or Low-E windows. This may be caused by the sun's reflection. If a structure's windows create enough of a curve, the co

TSB #11020039

Some customers may complain about a noisy HVAC blower motor or odor after a cabin air filter replacement. Foreign debris on the blower motor after servicing the cabin air filter may be the cause. During the removal of the cabin air filter,

TSB #11017699

A musty/mildew type odor may come from the vents when the air conditioning (A/C) system is operating. It is most noticeable when the A/C is first turned ON. This odor is the result of mold growth in the A/C evaporator/cooling unit which is

TSB #11007022

Some vehicles may experience exterior trim heat damage such (melted, separating, etc.) when parked near a glass building or Low-E windows. This may be caused by the sun's reflection.

TSB #11006987

In accordance with Federal regulations, follow the procedure listed below when replacing a speedometer. NOTE: Tampering with a motor vehicle odometer is strictly prohibited by Federal, and State laws. It is the dealers responsibility to com

TSB #11005671

Mazda has developed factory recommended scheduled maintenance services that support all major vehicle systems. Mazda recommends dealers follow the scheduled maintenance tables as cited in the vehicle-specific workshop manual or owner's manu

Showing the 8 most recent of 191 technical service bulletins on file with NHTSA.

07/22/20Component: STEERING,AIR BAGSCrash reported2 injured

TL* THE CONTACT OWNS A 2004 MAZDA3. THE CONTACT STATED THAT WHILE TRAVELING APPROXIMATELY 45 MPH AND MAKING A TURN, THE STEERING WHEEL SEIZED AND THE CONTACT LOST CONTROL OF THE VEHICLE. AS A RESULT, THE CONTACT CRASHED INTO A CURB, A TREE, AND THE VEHICLE ROLLED OVER. THE AIRBAGS DID NOT DEPLOY. A POLICE REPORT WAS FILED. THE DRIVER SUSTAINED MINOR INJURIES AND THE FRONT PASSENGER SUSTAINED MAJOR INJURIES THAT REQUIRED MEDICAL ATTENTION. THE VEHICLE WAS DESTROYED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 04V468000 (

05/25/20Component: AIR BAGS,EQUIPMENTCrash reported2 injured

WE WERE BROADSIDED BY A VEHICLE THAT RAN A RED LIGHT AT FULL SPEED. THE IMPACT WAS ON THE PASSENGER SIDE. THE CAR FLIPPED OVER AND SKIDDED ONTHE PASSENGER SIDE THEN FLIPPED BACK ONTO THE DRIVERS SIDE AND SKIDDED BEFORE ROLLING OVER AT LEAST ONCE. NOT ONE AIR BAG DEPLOYED. THANK GOD FOR THE SEAT BELTS. THEY SAVED OUR LIVES. INJURIES WERE CONCUSSIONS, SPRAINED NECK, INJURIES TO LOWER NECK, BACK AND SHOULDER OF PASSENGER. WE LANDED UPSIDE DOWN, RELEASED OUR SEAT BELTS AND CRAWLED TO SAFETY WITH THE HELP OF POLICE AND FIRE. OUR SPEED WAS ABOUT 25-30 MILES /HOUR. OUR CAR WAS TOTALLED. THE OTHER DRI

02/02/20Component: AIR BAGSCrash reported2 injured

THE PASSENGER'S SIDE AIR BAG FAILED TO DEPLOY IN THE 2004 MAZDA 3 UPON IMPACT. *TS ***NO ANSWER REQUIRED*** THE PASSENGER SUSTAINED AN EYE INJURY. THE VEHICLE WAS A TOTAL LOSS. A FEW MONTHS AFTER THE VEHICLE WAS PURCHASED THE CONSUMER RECEIVED A RECALL FOR THE CRASH ZONE SENSOR. JAN 2005 THE VEHICLE WAS TAKEN TO THE DEALER AND THE SENSOR WAS REPLACED. SINCE THE ACCIDENT THE CONSUMER IS SKEPTICAL AS TO WHETHER THE RECALL REPAIRS PERFORMED. *NM

05/17/20Component: AIR BAGSCrash reported2 injured

INVOLVED IN A HEAD ON COLLISON ON APRIL 18 2005 AIR BAGS DID NOT DEPLOY HAVE CALLED AND EMAILS MAZDA ABOUT THIS AND THEY WILL NOT HELP ME. THE CAR WAS IN THE SHOP PRIOR TO THE ACCIDENT FOR THE AIR BAG LIGHTS FLASHING. I WAS TRAVING AT 25 TO 30MPH AND THE OTHER CAR ( THERE FAULT ) WAS GOING ABOUT 20MPH. I SUFFERD HEAD, BACK, GROIN INJURYS. I VERY UNHAPPY WITH THE WAY MAZDA IS TREATING ME ON THIS!!!

12/21/20Component: TIRESCrash reported1 injured

The contact owns a 2004 Mazda 3 equipped with Hankook Tires, Tire Line: Ventus S1 Noble2, Tire Size: 205/50/R17, DOT Number: N/A. The contact stated that while driving at approximately 45 MPH, a loud explosion was heard. The contact's wife alerted him that the rear driver's side tire had blown out. The contact's vehicle was then rear-ended by another vehicle, causing his vehicle to turn 360 degrees. The air bags did not deploy. The contact was not injured, but his wife suffered from neck pain. Medical attention was not received. A police report was filed. The vehicle was towed to the contact's

11/04/20Component: AIR BAGSCrash reported1 injured

WAS IN ACCIDENT HIT DITCH AND TREE HEAD ON AND AIRBAGS DID NOT DEPLOY, CAUSING INJURY TO FACE FROM HITTING STEERING WHEEL. WAS ON CITY STREET AND IN MOTION.

03/15/20Component: ENGINE AND ENGINE COOLING,AIR BAGSCrash reported1 injured

I AM VERY CONCERNED ABOUT THE SAFETY OF THE CAR THAT I HAVE HAD SINCE 2004 MAZDA 3. ON SUNDAY, I WAS HIT BY A CAR AT ABOUT A 20 TO 30 DEGREE ANGLE AND THE IMPACT HIT MY PASSENGER DOOR. NEITHER ONE OF US WAS GOING AT A SPEED THAT SHOULD HAVE HAD A RESULT IN THE DAMAGE THAT OCCURRED. WHEN HE HIT US AND THE CAR CAME TO REST, THE POLICE AND TOWING PEOPLE DISCOVERED THAT THE ENGINE HAD SNAPPED OFF ITS' MOUNTING. MY AIRBAGS DID NOT DEPLOY EITHER. HE TOLD ME THAT BOTH HE AND THE TOWING AGENT HAD EVER SEEN THIS HAPPEN BEFORE TO A CAR WITH AS LITTLE DAMAGE TO IT. I WENT TO THE TOW PLACE WHERE THEY

01/12/20Component: AIR BAGSCrash reported1 injured

TL*THE CONTACT OWNS A 2004 MAZDA 3. WHILE DRIVING 35 MPH THE VEHICLE SLID ON BLACK ICE AND HIT THE GUARD RAIL. THE AIR BAGS DID NOT DEPLOY. THE CONTACT WAS TRANSPORTED TO THE HOSPITAL AND SUSTAINED INJURIES TO HER BACK. THE VEHICLE WAS TOWED TO HER RESIDENCE. THE FRONT AND REAR FENDER WERE DAMAGED. THE MANUFACTURER WAS NOTIFIED. A POLICE REPORT IS AVAILABLE. THE FAILURE MILEAGE WAS 77,000. UPDATED 02/18/10

Showing the 8 most serious of 170 complaints filed with NHTSA.

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