On certain minivans equipped with cruise control, the cruise control actuator cable may be broken due to insufficient strength. Also included are certain 2000-2001 minivans equipped with cruise control built between march 31, 1999 and march 31, 2001, that have had the cruise control repaired and possibly had a defective cable installed during that repair.

It is possible that the broken actuator cable may be out of position and could interfere with the operation of the accelerator cable, preventing a decrease in engine speed while driving, increasing the risk of a crash.

Dealers will replace the actuator cable. Owner notification is expected to begin during June 2004. Owners should contact Mazda at 1-800-222-5500.

July 2004

2000-2001 MPV
Actuator Cable Recall
[Recall #2004F]

To:	Mazda Dealership General Managers, Service Managers, and Parts Managers
Subject:	2000-2001 MPV Actuator Cable Recall 2004F

Mazda Motor Corporation has decided that a defect, which relates to motor vehicle safety, exists in certain 2000-2001 MPV vehicles produced from March 31, 1999 through November 15, 2001.

On certain 2000-2001 MPV vehicles, it is possible that the auto cruise control system actuator cable may break. If the actuator cable breaks, it may interfere with the accelerator cable, preventing the engine speed from decreasing during driving, which could result in a crash without warning.

The subject MPV vehicles are divided into two groups:

Group 1
Certain 2001 MPV vehicles produced from April 1, 2001 through November 15, 2001 were equipped with a defective actuator cable when assembled at the Mazda factory. All vehicles in this group need to have the cable replaced.

Group 2
Certain 2000-2001 MPV vehicles produced from March 31, 1999 through March 31, 2001 were not equipped with a defective actuator cable when assembled at the Mazda factory. However, a defective cruise control cable could have been installed as a replacement part during a service repair at a Mazda dealer or other repair shop. All vehicles in this group need to have the cable inspected; however, only a very small number of vehicles in this group will need to have the cable replaced.

Owners of affected vehicles in Group 1 will be notified by first class mail beginning July 7, 2004. Group 2 owners will be notified at a later date.

The first phase of this recall covers Group 1. This package contains important information about recall campaign 2004F:

Attachment I	Dealer Service and Parts information
Attachment II	Inspection and Repair procedures
Attachment III	Owner notification letter – Group 1 Dealer Report

The National Traffic and Motor Vehicle Safety Act prohibits the delivery of any subject vehicle without performing the necessary repair for defects or failures. Failure to perform applicable recalls before delivery 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 delivery.

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, and are also available on the ESI website.
2. Inspection and repair procedures follow (Attachment II), were e-mailed to your Service Department, and are also available on the ESI website.
3. We recommend using the enclosed report of registered owners in the dealer’s area to encourage customers to come in for the recall (with recall reminder postcards, for example). Dealers may use such owner information for the sole purpose of conducting and performing this safety recall, and for no other purpose. Using it for marketing activities is strictly prohibited and could subject your dealership to serious fines. The information in this report is protected by state privacy and other applicable laws regarding disclosure of personal and/or confidential, restricted or blocked information. It is the dealer’s responsibility to protect the confidentiality of owner records and prevent the release of information to other parties.
   In California, privacy laws prevent the release of names and addresses on this report.
4. For technical assistance, call the Technical Assistance Hotline at (888) 832-8477.
5. For warranty questions, contact the Corporate Dealer Assistance Group at (877) 727-6626.

Please make certain that the appropriate personnel in your dealership are aware of these resources and are familiar with the details of this recall before responding to customer inquiries.

We apologize for any inconvenience that this program may cause you and your customers. Please keep in mind that owners of 2001 and newer models are eligible to receive a rental car at no charge if the vehicle is within the mileage and time limitations under Mazda New Vehicle Limited Warranty and adheres to the Rental Car Reimbursement policy. Your understanding and support in carrying out this campaign is greatly appreciated.

 

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

A. VEHICLE INSPECTION PROCEDURE

1. Verify that the vehicle is within the following ranges:
   • 2001 MPV vehicles equipped with cruise control (ACC) built between April 1, 2001 and November 15, 2001
     VIN Range: JM3LW28**10197856 - JM3LW28**10214775
   • 2000-2001 MPV vehicles equipped with cruise control (ACC) built between March 31, 1999 and March 31, 2001 that have had their cruise control repaired and possibly had a defective cable installed during that repair.
     VIN Range: JM3LW28**Y0100036 - JM3LW28**10198685
     • If the vehicle is within either of the above ranges, proceed to step 2.
     • If the vehicle is not within the above ranges, return the vehicle to the customer or inventory.
2. Perform a Vehicle Status Inquiry using your eMDCS System and inspect vehicle for an Authorized Modification Label Recall 2004F attached to the vehicle’s hood. Refer to eMDCS System - Vehicle Status Inquiry Results table below.
   NOTE: Be sure to verify RECALL number as the vehicle may have multiple Recall labels.
   
   

eMDCS System - Vehicle Status Inquiry Results:

If eMDCS displays:	Campaign Label is:	Action to perform:
RECALL 2004F OPEN	Present	Contact the Mazda Corporate Dealer Assistance Group at (877) 727-6626 to update vehicle history.
	Not present	Proceed to “B. INSPECTION PROCEDURE”.
RECALL 2004F CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Complete a label and apply to vehicle’s hood.
RECALL 2004F is not displayed	Does not apply	Recall does not apply to this vehicle. Return vehicle to inventory or customer.

B. INSPECTION PROCEDURE

1. Identify the type of Cruise Control Actuator Cable installed on the vehicle by comparing the shape of Cable Type “A” and Cable Type “B” below.
   
   
   NOTE: A “Good” actuator cable has a larger outer diameter and a molded rib.
    
2. Use the “Cruise Control Actuator Cable Inspection Results” table below to determine if any action is required.
   
   Cruise Control Actuator Cable Inspection Results:

   If Vehicle Has:	Result:	Required Action:
   Cable Type “A”	Vehicle has a “DEFECTIVE” Cruise Control Actuator Cable	Replace Cruise Control Actuator Cable according to “C. REPAIR PROCEDURE”
   Cable Type “B”	Vehicle has a “GOOD” Cruise Control Actuator Cable	No repair is required, proceed to “D. AUTHORIZED MODIFICATION LABEL INSTALLATION”

C. REPAIR PROCEDURE

ACTUATOR CABLE REMOVAL

1. Squeeze the hooks of the grommet and remove the actuator cable from its bracket. Unhook the cable from the actuator.
   
   
    
2. Remove the end fitting of the actuator cable from the arm of the throttle.
   
   
    
3. Squeeze the hooks of the grommet, and remove it from the cable bracket.
   
   
    
4. Remove the actuator cable clip from the body.
   
   
    
5. Remove the actuator cable and discard.

ACTUATOR CABLE INSTALLATION

1. Press the grommet into the cable bracket ensuring the grommet is secure/tight in the bracket.
   
   
    
2. Insert the cable end fitting to the arm of the throttle.
   
   
    
3. Press the actuator cable clip (attached to the cable) into the body.
   
   
    
4. Pass the actuator cable end fitting through the bracket and attach to the actuator.
5. Press the grommet into the actuator bracket ensuring the rubber boot is installed into the actuator.
   
   
    
6. Adjust the free play by pushing or pulling the actuator cable directly behind the spring two (2) times.
   
   
    
7. Turn the ratchet ring in the direction shown by the arrow to lock it.
   
   
    
8. Slide the lock lever in the direction shown by the arrow to lock the adjuster.
   
   
    
9. Road test the vehicle and confirm the cruise control operates normally.

D. AUTHORIZED MODIFICATION LABEL INSTALLATION

Complete an “Authorized Modification Label” with the Recall number written on the sticker and affix it to the vehicle’s hood. Refer back to the illustration under “A. VEHICLE INSPECTION PROCEDURE”.