RECALL No: 0502A DATE: 02/01/2002
MODEL: Mazda MPV YEAR: 2000-2001
AFFECTED VINs: JM3 LW28** Y0 100395 - JM3 LW28** 10 214772 MFG.DATE: March 31, 1999 - November, 2001
SUBJECT: Brakeline Proportioning Valve Replacement on vans NOT equipped with ABS
Summary:
Certain mini vans without anti-lock braking systems (ABS) fail to comply with the requirements of Federal Motor Vehicle Safety standard No. 135, "Passenger Car Brake Systems." Due to inappropriate brake pipe layout, these vehicles do not meet the brake stopping distance with partial failure requirements of the standard.

If partial failure occurred in the braking system, the stopping distance of the vehicle could increase, increasing the risk of a crash.

Dealers will modify the brake system to correct the problem.
Letter To Dealers:
N/A
Attachment I
N/A
Attachment II

A. VEHICLE VERIFICATION PROCEDURE

  1. Verify the vehicle is within the following ranges:
    • Build Date: 04/01/99 - 11/14/01.
    • VIN Range: JM3 LW28*** 0100395 - 0214772.
      • If the vehicle is within the above ranges, proceed to STEP 2.
      • If vehicle is not within the above range, return it to the customer or inventory.
  2. Perform a Vehicle Status Inquiry using your MDCS System and inspect vehicle for an Authorized Modification Label RECALL #0502A attached to the drivers side door. Refer to illustration below.
    NOTE: Be sure to verify the recall number as the vehicle may have multiple labels.

     
    • If MDCS displays RECALL: 0502A N and an Authorized Modification Label is not present, the recall has not been performed. Proceed to “B. REPAIR PROCEDURE.”
    • If MDCS displays RECALL: 0502A N and an Authorized Modification Label is present, contact the Warranty Department at (800) 662-6779. They will update the vehicle history.
    • If MDCS displays RECALL: 0502A D and an Authorized Modification Label is not present, proceed to “C. AUTHORIZED MODIFICATION LABEL INSTALLATION.”
    • If MDCS displays RECALL: 0502A D and an Authorization Modification Label is present, the recall has already been completed. Return the vehicle to the customer or inventory.
    • If MDCS does not display RECALL: 0502A N or RECALL: 0502A D, this recall does not apply to the vehicle. Return vehicle to the customer or inventory.

B. REPAIR PROCEDURE

Brake Line and Proportioning Valve Removal:

CAUTION: Do not allow brake fluid to leak on the paint, or rubber components. Otherwise, damage may occur.

  1. Retrieve and record the customer’s radio station pre-sets.
  2. Lift vehicle on a hoist and remove the right front tire and splash shield.
  3. Place a drain pan under the brake line where it is connected to the flex hose and another drain pan directly under the area below the proportioning valve.
  4. Disconnect the right front brake line fitting (use a 10 mm flare nut wrench) from the flex hose connection and unsnap the brake line from brake line clip “A”.

  5. Open the hood and protect the grill and fenders with fender covers.
  6. Disconnect the negative battery terminal.
  7. Remove one bolt holding the bracket for the Pressure Regulator Control (PRC) solenoid to the intake manifold and move the PRC to gain access to the proportioning valve.

  8. Disconnect the spark plug wires from the Ignition Coil and completely remove the Ignition Coil from the engine.
  9. Remove the three nuts holding the Cruise Control Actuator to the spring tower and move the actuator aside for access to the right front brake line.
  10. Disconnect brake line fittings “1”, “2”, “3”, “4” from the proportioning valve, leaving fitting “5” connected.

  11. Unsnap the right front brake line from the two white brake line clips “B” mounted on the bulkhead and clip “A” mounted on the engine side fender well.

     
  12. Remove the two bolts holding the proportioning valve to the bulk head, and pull the valve and attached line forward (bending the line).
  13. Cut the right front brake line at the bend allowing you to remove the brake line from the vehicle in two pieces. Discard the removed brake lines and proportioning valve.
  14. Remove the two white brake line clips “B” mounted on the bulkhead and discard.

Brake Line and Proportioning Valve Installation:

  1. Install two new (black) brake line clips “B” into their mounting holes located on the bulkhead.
    NOTE: New clips are used because brake line diameter has changed.

     
  2. Attach joint connector to brake line “A” and torque the fitting.
    Tightening torque: 12.8 - 21.5 N·m (1.3 - 2.2 kgf·m, 9.4 -15.9 ft·lbf)
  3. Install brake line “A” from inside the right front inner fender well and be sure to route the line under A/C lines.
  4. Snap brake line “A” into the two (original) clips “A”, but do not tighten or attach the fitting to the flex hose yet. 
    NOTE: If clips “A” are broken, replace them with new parts provided.
  5. Install brake line “B” into the revised proportioning valve and finger tighten the fitting.
  6. Mount the proportioning valve to the bulkhead with line “B” attached and finger tighten the bolts.
  7. Install brake line “B” to joint connector and finger tighten the fitting.
  8. Install and torque brake line fittings “1”, “2”, “3”, “4”, “5” for the proportioning valve and joint connector.
    Tightening torque: 12.8 - 21.5 N·m (1.3 - 2.2 kgf·m, 9.4 - 15.9 ft·lbf)
  9. Tighten and torque the proportioning valve mounting bolts.
    Tightening torque: 8.9 - 12.7 N·m (90 - 130 kgf·cm, 79 - 112 in·lbf)

     
  10. Snap brake line “B” into clips “B”.
  11. Install brake line into the flex hose connection and torque the brake line fitting.
    Tightening torque: 12.8 - 21.5 N·m (1.3 - 2.2 kgf·m, 9.4 - 15.9 ft·lbf)

     
  12. Bleed the brake system using the 2001 MPV Workshop Manual procedure on page 04-11-3 and INSPECT ALL FITTINGS FOR SIGNS OF LEAKAGE.
  13. Reinstall the Ignition Coil, Cruise Control Actuator, PRC solenoid and negative battery cable.
  14. Reinstall the right front splash shield and right front tire.
  15. Clean any brake fluid from the underside of the vehicle using water or shop rags.
  16. Road test the vehicle and confirm braking operation is normal. Reset customer’s radio station pre-sets.
  17. Reinspect all brake line fittings for leakage. Retighten and re-bleed system if necessary.

C. AUTHORIZED MODIFICATION LABEL INSTALLATION

Complete an “Authorized Modification Label” with the recall number on it and affix it to driver’s side door under the door latch. Refer back to illustration under “A. VEHICLE VERIFICATION PROCEDURE.”

D. PARTS RETURN POLICY

Unless Mazda has requested a parts return, retain parts as required by Mazda Warranty Policy & Procedures. Parts may be discarded 30 days after claim payment.

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