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RECALL No: 1604B DATE: 02/2004
MODEL: Mazda MPV YEAR: 2004
AFFECTED VINs: JM3 LW28** 40 500013 - JM3 LW28** 40 519303 MFG.DATE: August 20, 2003 - February 4, 2004
SUBJECT: 2004 MPV & 2004 RX-8 Front Passenger-Side Airbag Recall
Summary:
Certain 2004 MPV and 2004 RX-8 vehicles were produced with improperly wired front passenger-side airbags. The result of this problem is that the airbag will not provide adequate protection in the event of a crash. Mazda has decided to conduct a recall campaign to correct the wiring by installing a new wiring harness in the front passenger-side airbag system on all affected vehicles.
Letter To Dealers:

February 2004

2004 MPV & 2004 RX-8
Front Passenger-Side Airbag
[Recall #1604B]

To: All Mazda Dealers
Attention: All General Managers, Service Managers, and Parts Managers
Subject: 2004 MPV & 2004 RX-8 Front Passenger-Side Airbag Recall 1604B-a & 1604B-b and STOP DELIVERY

This is to notify you of a recall and STOP DELIVERY on the 2004 MPV and 2004 RX-8. This recall and stop delivery notification is for dealer inventory vehicles and provides dealers with detailed parts information and warranty claim processing information. Repair procedures can be found on ESI and M-Store.

Mazda Motor Corporation has decided that 2004 MPV vehicles produced from August 20, 2003 through February 4, 2004 fail to conform to requirements of Federal Motor Vehicle Safety Standard No. 208, Occupant Crash Protection. Also, Mazda Motor Corporation has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 RX-8 vehicles produced from April 10, 2003 through January 28, 2004.

Certain 2004 MPV and 2004 RX-8 vehicles were produced with improperly wired front passenger-side airbags. The result of this problem is that the airbag will not provide adequate protection in the event of a crash. Mazda has decided to conduct a recall campaign to correct the wiring by installing a new wiring harness in the front passenger-side airbag system on all affected vehicles.

Owners of affected vehicles will be notified by first class mail beginning February 27, 2004.

Attachment I (enclosed) provides dealer service and parts information. Attachment II (available on the ESI website under SSP/Recalls and on M-Store under Bulletins, Forms & E-Documents) contains inspection and repair procedures for recall campaign 1604B-a and 1604B-b.

The National Traffic and Motor Vehicle Safety Act prohibits selling or leasing any subject vehicles without performing the necessary repair for defects or failures. Failure to perform applicable recalls before sale can result in extensive dealer fines and penalties from the Federal Government. Therefore, you must complete this recall for all affected new vehicles in your inventory prior to sale or lease.

To help you effectively perform this recall, Mazda has developed the following resources:

  1. Service and Parts recall instructions follow (Attachment I), were e-mailed to your Service Department, are available on the ESI website and M-Store, and are also available on the eMDCS Warranty Vehicle Inquiry Detail screen.
  2. Inspection and repair procedures are available on ESI and M-Store.
  3. For technical assistance, call the Technical Assistance Hotline at (888) 832-8477.
  4. For warranty questions, contact the Corporate Dealer Assistance Group at (877) 727-6626.

Please make certain that the appropriate personnel in your dealership are familiar with the details of this recall campaign and are aware of these resources.

We apologize for any inconvenience that this program may cause. Your understanding and support in carrying out this campaign is greatly appreciated.

Sincerely,

Michael J. Giblin
Director, Technical Services
Mazda North American Operations

ATTACHMENT I

CONDITION OF CONCERN

Certain 2004 MPV and 2004 RX-8 vehicles were produced with improperly wired front passenger-side airbags. The result of this problem is that the airbag will not provide adequate protection in the event of a crash.

SUBJECT VEHICLES

Model VIN Range Build Date Range
2004 MPV JM3LW28**40 500013 - 519303 August 20, 2003 – February 4, 2004
2004 RX-8 JM1FE17**40 100053 - 131563 April 10, 2003 – January 28, 2004

Note: The asterisk symbol “*” can be any letter or number.

OWNER NOTIFICATION

Mazda will notify U.S. owners by first class mail beginning February 27, 2004.

PARTS INFORMATION

Description Part Number Quantity  
Short Harness Kit FEY0-67-SH0 1  
Campaign Label 9999-95-065A-00 1 = sheet of 18 labels

MStore (no charge)

PARTS ORDERING

The majority of dealers will automatically receive a quantity of parts for dealer inventory on Tuesday, February 17, 2004. For dealers with the Richmond, VA PDC as their facing PDC, Short Harnesses will arrive on Wednesday. For dealers with the Norton, MA PDC as their facing PDC, Short Harnesses will arrive on Thursday. If dealers need additional parts for dealer inventory after receiving the initial parts shipment, order them by faxing an order form (found on ESI and MX Connect) to Mazda Corporate Dealer Assistance Group at (866) 366-2061. Mazda will ship these parts as CSO orders, and freight will be reimbursed as a sublet on warranty claims. Please repair dealer inventory as soon as possible.

Use MStore to order additional Campaign labels (1 = sheet of 18 labels).

WARRANTY CLAIM PROCESSING INFORMATION

  Short Harness Installation
Warranty Type Code R
Symptom Code 99
Damage Code 99
Process Number A4417H

Part Number Main Cause

FEY0-67-SH0
Quantity 1
Labor Operation Code XX643XRX
Labor Hours 0.2

CSO Freight Charge Reimbursement

Parts ordered from Corporate Dealer Assistance Group will be shipped as a CSO order. Dealer may claim reimbursement by adding a sublet to the recall claim using the following format:

Sublet Invoice Number CSOXX
Sublet Type Code Enter “F”
Sublet Amount Amount of CSO Freight Charge

Submit CSO Freight with the recall repair claim. Do not submit separate claims for sublet.

VERIFY THE VEHICLE NEEDS THE RECALL

  1. Verify the vehicle is within the following ranges:

    Model VIN Range Build Date Range
    2004 MPV JM3LW28**40 500013 - 519303 August 20, 2003 – February 4, 2004
    2004 RX-8 JM1FE17**40 100053 - 131563 April 10, 2003 – January 28, 2004

    If the vehicle is within the above ranges, go to step 2.
    If vehicle is not within the above range, return it to inventory or the customer.

  2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Modification Label RECALL 1604B attached to the vehicle’s bulkhead.
    Note: Verify the recall number as the vehicle may have multiple labels.

    • If eMDCS displays “RECALL: 1604B Open” and an Authorized Modification Label is not present, the recall has not been performed. Proceed to “REPAIR PROCEDURES.”
    • If eMDCS displays “RECALL: 1604B Open” and an Authorized Modification Label is present, contact the Warranty Department at (800) 662-6779. They will update the vehicle history.
    • If eMDCS displays “RECALL: 1604B Closed” and an Authorized Modification Label is not present, complete a label and apply it to the vehicle’s bulkhead.
    • If eMDCS displays “RECALL: 1604B Closed” and an Authorization Modification Label is present, the recall has already been completed. Return the vehicle to inventory or the customer.
    • If eMDCS does not display “RECALL: 1604B Open” or “RECALL: 1604B Closed,” this recall does not apply to the vehicle. Return vehicle to inventory or the customer.
ATTACHMENT II

2004 MPV

PARTS / TOOLS REQUIRED - MPV

  • Harness Kit FEY0-67-SHO Includes:
    • Short Harness
    • Foam (Urethane) Pad
    • Gray Fastener “A” For Connector
  • Flat-Blade Screwdriver

A. VEHICLE PRE-INSPECTION PROCEDURE - MPV

  1. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Modification Label RECALL 1604B or Port Campaign Label REWORK# 04B01 attached to the vehicle’s hood [or bulkhead]. Refer to illustration below.
    Note: Be sure to verify RECALL number as the vehicle may have multiple RECALL labels.


     
    • If eMDCS displays RECALL 1604B OPEN and an Authorized Modification Label is not present, the RECALL has not been performed. Proceed to “B. REPAIR PROCEDURE - MPV”.
    • If eMDCS displays RECALL 1604B OPEN and an Authorized Modification Label or a Port Campaign label with Rework# 04B01 is present, contact the Mazda Corporate Dealer Assistance Group at (877) 727-6626. They will update the vehicle history.
    • If eMDCS displays RECALL 1604B CLOSED and an Authorized Modification Label is not present, proceed to “C. AUTHORIZED MODIFICATION LABEL INSTALLATION - MPV”.
    • If eMDCS displays RECALL 1604B CLOSED and an Authorized Modification Label or a Port Campaign label with Rework# 04B01 is present, the RECALL has already been completed. Return the vehicle to inventory or the customer.
    • If eMDCS does not display RECALL 1604B OPEN or RECALL 1604B CLOSED, this RECALL does not apply to the vehicle. Return vehicle to inventory or the customer.
  2. Open RF passenger door and look for a YELLOW mark (paint or seal) on the door hinge.
    • If a YELLOW mark IS present, the vehicle HAS already been fitted with updated harness. No repairs are necessary.
    • If a YELLOW mark IS NOT present, go to next step.


     
  3. Remove glove compartment (box) using the following procedure:
    1. Open the glove box and bend stoppers inward allowing the box to drop down slightly.
    2. Pull the left side of the glove box toward rear of vehicle to unsnap the pivots from bottom of dash.
    3. Slide the glove box toward driver’s side of vehicle to disengage pin on right side. Remove glove box from dash and set aside.
    Note: If glove box is damaged during removal, order a new part from Mazda PDC. See “PARTS IDENTIFICATION - MPV”.




     
  4. Before continuing with repair, verify if there is GREEN tape on the harness as shown:
    • If GREEN tape IS on the harness near the air bag connector, no repairs are necessary. Reinstall glove box.
    • If GREEN tape IS NOT on the harness near the air bag connector, repairs are necessary. Proceed to “B. REPAIR PROCEDURE - MPV”.

B. REPAIR PROCEDURE - MPV

  1. Remove ignition key from ignition switch and wait for 1 minute or more before continuing to next step.
    Warning: Failure to remove ignition key from ignition switch and waiting 1 minute could result in unexpected air bag deployment and possible injury.
  2. Using a small screwdriver, carefully pry under Gray fastener to remove the Yellow air bag connector from the metal bracket. Leave Gray fastener attached to back side of connector.


     
  3. Unlock the Yellow connector from the harness as shown.


     
  4. Attach new Gray fastener “A” from the harness kit to the short harness connector on vehicle harness side.


     
  5. Connect short harness to the air bag harness connector and the vehicle harness connector. Ensure a click is heard when connecting both connectors. Push Gray connector fastener “A” into mounting bracket hole that original harness connector fastener was removed from.


     
  6. Wrap the harness and connector with the foam (urethane) pad.
    Note: When wrapping, place connector in center of foam pad.


     
  7. Place the wrapped harness behind the speaker (tweeter) harness on top of blower case. Push the wrapped harness forward and tuck under the speaker harness.


     
  8. Reinstall glove box in reverse order as detailed in “A. VEHICLE PRE-INSPECTION PROCEDURE - MPV”.
  9. Turn ignition switch to ON position and verify the air bag system warning light illuminates for approximately 6 seconds, then turns off. Go to “C. AUTHORIZED MODIFICATION LABEL INSTALLATION - MPV”.

C. AUTHORIZED MODIFICATION LABEL INSTALLATION - MPV

Record the VIN of the updated vehicle and complete an “Authorized Modification Label” with the recall number, dealer code and date written on the label and affix it to the underside of the hood. Refer back to the illustration under “A. VEHICLE PRE-INSPECTION PROCEDURE - MPV”.

PARTS IDENTIFICATION - MPV

Description Part No.
Harness Kit FEY0-67-SHO
Gray Glove Box LD47-64-030-72
Beige Glove Box LD47-64-030-80

2004 RX-8

RX-8 specific repair information is omitted

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