TSB: 05-010/05
2004-2005 MAZDA3 - 1 - 2 SHIFT SHOCK
APPLICABLE MODEL(S)/VINS
2004 2005 Mazda3 (Automatic transmission only)

DESCRIPTION
Some vehicles may exhibit intermittent shift shock during 1-2 upshift. The symptom is due to improper PCM calibration. A revised PCM calibration is now available to correct this issue.

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

REPAIR PROCEDURE
1. Reboot the WDS PTU to clear memory before reprogramming.
2. Using WDS B39.11 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.
NOTE:

Always update the WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If the PTU is not updated to the latest WDS calibration level, the calibration file will not install into the PTU.

It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the WDS reprogramming procedure.

WDS shows the calibration part numbers after programming the PCM.

Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns.

When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.

When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU. Also the external battery power supply cable should be connected to the vehicle battery and the PTU.


3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.

 

another great TSB AFTER I sell the 3S....this was a big headache with ours.

Hey Mark, we had the 3S for about 5 months and had MASSIVE problems with detonation regardless of octane and weather (it was an alabama summer though). We sold the car and were contacted about a month later by the new owners who said the engine blew and had to be replaced. They wanted to know what I had done to it. It was driven daily by my wife...bone stock. Any ideas?

 

With no car to look at that would be a tough one to diagnose. We have had some fuel pressure issues and of course lean=heat=detonation.

 

yeah...the car felt real sluggish even for a 2.3L auto...it may have just been a poor runner all along. That's ultimately why the wife didn't want it anymore...the power was so anemic.

The detonation was LOUD...only noticeable at parking lot speeds with the windows down. Slow rolls just give it a little gas and it would ping like hell. I stepped it up to 93octane and it toned down some but it was an obvious problem.

Thanks for your help.

 

I have an idea what the noise was now that I think about it.

Some of the early 2.3's had a clatter in the intake. I swear it sounded exactly like a rod knocking. The set-up is similar to the 3rd Gen except the butterflies are actually molded to the rod.

 

Found this M-tip

TAPPING NOISE FROM ENGINE AT IDLE
Applicable Models
2004 - Mazda3 VIN Range: 000000 - ZZZZZZ;
2005 - Mazda3 VIN Range: 000000 - ZZZZZZ;
Symptoms
110 PINGING
800 EXCESSIVE OPERATION NOISE
810 RESONANCE NOISE
820 UNUSUAL NOISE(EXCL. PINGING,SQUEAKING,OPERATION,RESONANCE)
MTOL - 4556 Dealer Repair Information
A tapping/clatter type noise might be heard from engine at operating
temperature and when warm. The noise may come from the inside of the
intake manifold.

To verify, close the Intake Manifold Tuning Valve (IMTV #) PID using
WDS. The workshop manual calls this the variable intake-air shutter
valve actuator. For procedure, see following instructions. If noise
goes away with IMTV # = OFF, replace intake manifold assembly.

1. ID vehicle (Note - select "automatic" if A/T equipped, not ASM.)
2. Select TOOLBOX
3. Select DATALOGGER. Press Tick
4. Select POWERTRAIN
5. Select ENGINE. Press Tick
6. Select IMTV # PID. Press Tick
7. At Datalogger screen, select IMTV #
8. Press # button on right side of screen
9. Press button with icon showing hand. IMTV # changes to IMTV =
10. Press "-" button. IMTV changes from ON to OFF
11. Verify tapping/clatter noise stops with IMTV = OFF, then comes
back with IMTV = ON, by toggling "+" and "-" buttons.
12. If verified, replace intake manifold assembly by following
procedure outlined in WSM section 01-13, INTAKE-AIR SYSTEM.

 

EXACTLY!!! damn...I wish I knew this then. I was worried the motor was going south.