TSB: 01-041/04

2004 MAZDA3 - ENGINE HARD START

APPLICABLE MODEL(S)/VINS

2004 Mazda3 2.0 and 2.3L engines, both Federal and California specification with VINs lower than JM1BK 161220

DESCRIPTION

Some vehicles may experience an engine with hard starting (cranks but takes 10 seconds or longer to start). The condition is more likely after vehicle sits overnight or for an extended time. Rough idle may occur just after the engine is started.

This may be caused by fouled spark plugs if the vehicle is frequently driven in stop-and-go conditions, such as in heavy traffic. In some cases, foreign debris may get stuck in the pressure regulator valve of the fuel pump, and cause fuel holding pressure to drop below specification.

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

REPAIR PROCEDURE

1. Check fuel hold pressure after turning the engine OFF for 5 minutes or longer. Refer to Workshop Manual (section 01-14 FUEL LINE PRESSURE INSPECTION). Specification is 36.2 psi or more.

• If below specification, check fuel line for clogging. If fuel line is clear, replace fuel pump according to Workshop Manual (section 01-14 FUEL PUMP UNIT REMOVAL/INSTALLATION).

• If fuel hold pressure is okay, check spark plugs for fouling.

1. If fouled, replace spark plugs with modified plugs.

2. If not fouled, perform normal diagnostics according to Workshop Manual (section 01-03 NO.4 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK).

2. Verify repair.

PART(S) INFORMATION

NOTE: Please order only parts needed, based on engine size and emission type.

2.0L (FED), 2.3L (FED/CALIF)

2.0L (CALIF Only)

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.