Mazda3 Haynes Repair Manual 2004-2011

The 2004-2011 Mazda3 repair manual by Haynes, covers models indicated, powered by 2.0L DOHC, 2.3L DOHC and 2.5L DOHC in-line, four-cylinder engines. Note: this manual DOES NOT include information specific to all-wheel drive or turbocharged Mazda 3 models.
Book Excerpt: 2004-2011 Mazda3 Repair Manual FUEL AND EXHAUST SYSTEMS

FUEL RAIL AND INJECTORS - REMOVAL AND INSTALLATION
(Refer to illustrations 11.4, 11.6a and 11.6b) WARNING: Gasoline is extremely flammable. See Fuel system warnings in Section 1.

1. Disconnect the cable from the negative battery terminal (see Chapter 5, Section 3).
2. Remove the upper engine cover, pull the cover up from each side and lift the cover off the mounting posts in the center of the cover. Relieve the fuel system pressure (see Section 3).
3. Disconnect the fuel supply line quick-connect fitting from the fuel rail (see Disconnecting Fuel Line Fittings on page 4-5).
4. Disconnect the electrical connectors for all wiring that shares the harness with the fuel injectors, and then disconnect the four fuel injector electrical connectors (see illustration).
5. Remove the fuel rail mounting fasteners, and then remove the fuel rail and injectors as an assembly.
6. Remove each fuel injector retaining clip with a pair of needle-nose pliers and remove the injector from its bore in the fuel rail (see illustration). Remove and discard the upper and lower injector O-rings (see illustration). Repeat this procedure for each injector.
NOTE: Even if you only removed the fuel rail assembly to replace a single injector or a leaking O-ring, it's a good idea to remove all of the injectors from the fuel rail and replace all of the O-rings at the same time.
7. Coat the new upper O-rings with clean engine oil and slide them into place on each of the fuel injectors. Coat the new lower O-rings with clean engine oil and install them on the lower ends of the injectors.
8. Coat the outside surface of each upper O-ring with clean engine oil, and then insert each injector into its bore in the fuel rail.
9. Install the injectors and fuel rail assembly on the intake manifold. Tighten the fuel rail mounting fasteners securely.
10. The remainder of installation is the reverse of the removal.

BRAKES

METAL BRAKE LINES

9. When replacing brake lines, be sure to use the correct parts. Don't use copper tubing for any brake system components. Purchase steel brake lines from a dealer parts department or auto parts store.
10. Prefabricated brake line, with the tube ends already flared and fittings installed, is available at auto parts stores and dealer parts departments. These lines can be bent to the proper shapes using a tubing bender.
11. When installing the new line make sure it's well supported in the brackets and has plenty of clearance between moving or hot components.
12. After installation, check the master cylinder fluid level and add fluid as necessary. Bleed the brake system as outlined in Section 9 and test the brakes carefully before placing the vehicle into normal operation.

BRAKE HYDRAULIC SYSTEM | BLEEDING
(Refer to illustration 9.8 NOTE: Bleeding the brake system is necessary to remove any air that's trapped in the system when it's opened during removal and installation of a hose, line, caliper, wheel cylinder or master cylinder.

1. It will probably be necessary to bleed the system at all four brakes if air has entered the system due to low fluid level, or if the brake lines have been disconnected at the master cylinder.
2. If a brake line was disconnected only at a wheel, then only that caliper or wheel cylinder must be bled.
3. If a brake line is disconnected at a fitting located between the master cylinder and any of the brakes, that part of the system served by the disconnected line must be bled.
4. Remove any residual vacuum (or hydraulic pressure) from the brake power booster by applying the brake several times with the engine off.

Subject: 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 Mazda 3 service, maintenance, repair. ISBN-10: 1563929155 | ISBN-13: 978-1-56392-915-1 | Haynes 61012