2004 MAZDA6 O2 Sensor Failure-No Illumination Recall 3105G (MSP01)
Publication date: 2005-09-01Reference number: MSP01
Supersedes refnos: 01-012/04, 3105G
2004 MAZDA6 O2 SENSOR FAILURE-NO ILLUMINATION RECALL 3105G
SERVICE CAMPAIGN BULLETIN
| MAZDA: | 2004 MAZDA6 |
ATTACHMENT I DEALER INFORMATION
Dear Mazda Dealer:
Mazda Motor Corporation has decided to conduct an Emission Recall 3105G campaign to reprogram the Powertrain Control Module (PCM). This recall campaign supersedes MSP 01 and Service Bulletin 01-012/04.
On some 2004 MAZDA6 vehicles equipped with 2.3 liter engines, the Malfunction Indicator Lamp (MIL) in some vehicles may not illuminate as required in the event of a detected O2 sensor fault. This concern is caused by a Powertrain Control Module (PCM) calibration. If this failure occurs, the vehicle does not meet the OBD-II requirements.
Owners of affected vehicles will be notified by first class mail beginning September 30, 2005.
This package contains important information about recall campaign 3105G:
ATTACHMENT I DEALER INFORMATION
ATTACHMENT II REPAIR PROCEDURES
ATTACHMENT III OWNER NOTIFICATION LETTER
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 vehicles in your inventory prior to delivery.
To help you effectively perform this emission recall, Mazda has developed the following resources:
- Service and Parts recall instructions follow (Attachment I), were e-mailed to your Service Department, and are also available on the ESI website.
- Inspection and repair procedures follow (Attachment II), were e-mailed to your Service Department, and are also available on the ESI website.
- 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 emission 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.
- For technical assistance, call the Technical Assistance Hotline.
- For warranty questions, contact the Corporate Dealer Assistance Group.
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 recall may cause you and your customers.
A rental car may be provided to the customer, if eligible, based on the terms and conditions of the Rental Car Reimbursement Program, policy 12.0. Rental car reimbursements are available only on 2001 and newer vehicles within the mileage and time limitations under the New Vehicle Limited Warranty.
Your understanding and support in carrying out this campaign is greatly appreciated.
Sincerely,
Director, Technical Services
Mazda North American Operations
CONDITION OF CONCERN
On some 2004 MAZDA6 vehicles equipped with 2.3 liter engines, the Malfunction Indicator Lamp (MIL) in some vehicles may not illuminate as required in the event of a detected O2 sensor fault. This concern is caused by a Powertrain Control Module (PCM) calibration. If this failure occurs, the vehicle does not meet the OBD-II requirements.
This recall campaign supersedes MSP 01.
SUBJECT VEHICLES
| Model | VIN Range | Build Date Range |
|---|---|---|
| 2004 | MAZDA6 1YVFP**C*45 N40299-N47633 1YVHP**C*45 N36373-N47490 |
January 14, 2004 through January 23, 2004 |
|
NOTE:
The asterisk symbol "*" can be any letter or number.
|
||
OWNER NOTIFICATION
Mazda will notify U.S. owners by first class mail beginning September 30, 2005.
PARTS INFORMATION
| Description | Part Number | Quantity | |||
|---|---|---|---|---|---|
| Campaign Label | 9999-95-065A-05 | 1 = 50 per pack | MStore (no charge) | ||
| Vehicle Emission Recall - Proof of Correction Certificate(1) | 9999-95-ERPC-99 | 1=50 certificates | MStore (no charge) | ||
|
|||||
PARTS ORDERING
Use MStore to order additional Campaign labels (1=50 per pack) and Vehicle Emission Recall - Proof of Correction certificates (1=50 certificates).
WARRANTY CLAIM PROCESSING INFORMATION
| Inspection & Recalibration | |
|---|---|
| Warranty Type Code | R |
| Symptom Code | 99 |
| Damage Code | 99 |
| Process Number | J0504A |
| Part Number Main Cause | 5555-05-021A |
| Quantity | 00 |
| Labor Operation Code | YY400XRX |
| Labor Hours | 0.4 |
RENTAL CAR
A rental car may be provided to the customer if eligible based on the terms and conditions of the Rental Car Reimbursement Program, policy 12.0. Rental car reimbursements are available only on 2001 and newer vehicles within the mileage and time limitations under the New Vehicle Limited Warranty. If the customer was placed in a rental car while the campaign was being completed, submit a separate claim/problem using the standard rental claim information.
| Warranty Type Code | A | |
| Symptom Code | 99 | |
| Damage Code | 99 | |
| Part Number Main Cause | 5555-RE-NTAL | |
| Part Quantity | 0 | |
| Labor Operation Code | MM012XRX | |
| Labor Hours | 0.0 | |
| Sublet - Rental Car | ||
| Sublet Invoice Number | Number from Rental Invoice or Dealer Purchase Order | |
| Sublet Type Code | Enter "L" | |
| Sublet Amount | Up to $26.00 per day for the number of days customer had rental car | |
Rental expenses that exceed the two-day limit will require prior DCSM Authorization, as outlined in the Rental Car Reimbursement Program policy.
VERIFY THE VEHICLE NEEDS THE RECALL
- Verify the vehicle is within the following ranges:VEHICLES VIN RANGE
Model VIN Range Build Date Range 2004 MAZDA6 1YVFP**C*45 N40299-N47633
1YVHP**C*45 N36373-N47490January 14, 2004 through January 23, 2004 If the vehicle is within the above ranges, go to step 2.
If vehicle is not within the above ranges, return it to inventory or the customer.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Label RECALL 3105G attached to the vehicle's hood or bulkhead.
eMDCS System - Vehicle Status Inquiry Results
| If eMDCS displays: | Campaign Label is: | Action to perform: |
|---|---|---|
| RECALL 3105G OPEN | Present | Contact the Mazda Corporate Dealer Assistance Group to update vehicle history |
| Not present | Proceed to "REPAIR PROCEDURE " | |
| RECALL 3105G CLOSED | Present | Return vehicle to inventory or customer |
| Not present | Complete a label and apply to vehicle's hood or bulkhead | |
| RECALL 3105G is not displayed | Does not apply | Recall does not apply to this vehicle. Return vehicle to inventory or customer |
ATTACHMENT II REPAIR PROCEDURES
A. VEHICLE INSPECTION PROCEDURE
- Verify that the vehicle is within the following ranges:
- VIN Range:
1YVFP**C*45N40299 - 45N47633
1YVHP**C*45N36373 - 45N47490
- If the vehicle is within either of the above ranges, proceed to step 2.
- If the vehicle is not within either of the above ranges, return the vehicle to the customer or inventory.
- VIN Range:
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for a Campaign Label RECALL 3105G
attached to the vehicle's bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table below.NOTE: Verify Recall number as the vehicle may have multiple recalls.
eMDCS System - Warranty Vehicle Inquiry Results
| If eMDCS displays: | Campaign Label is: | Action to perform: |
|---|---|---|
| RECALL 3105G OPEN | Present | Contact the Mazda Corporate Dealer Assistance Group at (877) 727-6626 to update vehicle history. |
| Not present | Proceed to "B. REPAIR PROCEDURE ". | |
| RECALL 3105G CLOSED | Present | Return vehicle to inventory or customer. |
| Not present | Proceed to "C. CAMPAIGN LABEL INSTALLATION ". Complete a label and apply to vehicle's bulkhead. | |
| RECALL 3105G is not displayed | Does not apply | Recall does not apply to this vehicle. Return vehicle to inventory or customer. |
B. REPAIR PROCEDURE
PCM/TCM CALIBRATION LEVEL INSPECTION PROCEDURE
Using WDS version B39.3 or later software, proceed to "Module Reprogramming" and check the PCM and TCM calibration levels.
- If WDS indicates the PCM and TCM are already at the latest calibration level (refer to "Calibration Information" table), proceed to Step 5 under "PCM/TCM PROGRAMMING" and complete an "Authorized Modifications" label. This label will inform technicians of the PCM/TCM calibration change if future repairs are necessary.
- If WDS indicates that a later calibration is available in either PCM or TCM, proceed to "PCM/TCM PROGRAMMING" below.
PCM/TCM REPROGRAMMING
- Reboot the WDS PTU to clear memory before reprogramming.
- Using WDS B39.3 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.
- 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.NOTE:
- If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.
- After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).
- Perform the TCM reprogramming procedure and reprogram the TCM to the latest available calibration (refer to the "Calibration Information" table). Verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
- Fill out an "Authorized Modifications" label (P/N 9999-95-AMDC-97) with the new PCM/TCM calibration information, your dealer code, and today's date (example below).
- Place the "Authorized Modifications" label on the "A" pillar below the tear tag in the driver door jamb.
C. CAMPAIGN LABEL INSTALLATION
- Fill out a blue "Campaign Label" (9999-95-065A-05) with Campaign No: "3105G", your dealer code, today's date (example below), and affix it to the vehicle's bulkhead as shown in "A. VEHICLE INSPECTION PROCEDURE".
- Return vehicle to customer.
CALIBRATION INFORMATION
2.3L PCM
| Trans. | Spec. | New PCM Calibration Part Number | File Name |
|---|---|---|---|
| M/T | Calif. | L392-18-881E | SW-L392EE030 |
| A/T | Calif. | L393-18-881E | SW-L393EE030 |
| M/T | Fed. | L3M1-18-881C | SW-L3M1EC020 |
| A/T | Fed. | L3M2-18-881C | SW-L3M2EC020 |
2.3L TCM
| Trans. | Spec. | New TCM Calibration Part Number | File Name |
|---|---|---|---|
| A/T | All | L322 K | SW-L322TK000 |
| A/T | All | L3YW | SW-L3YWT0000 |
ATTACHMENT III OWNER NOTIFICATION LETTER
September 2005
2004 MAZDA6 O2 Sensor Failure-No Illumination Recall 3105G
Dear Mazda Owner:
Mazda Motor Corporation has decided that a defect exists on certain 2004 MAZDA6 vehicles. If you are a recipient of this notice, your vehicle is included in this recall.
What is the problem?
On some 2004 MAZDA6 vehicles equipped with 2.3 liter engines, the Malfunction Indicator Lamp (MIL) in some vehicles may not illuminate as required in the event of a detected O2 sensor fault. This concern is caused by a Powertrain Control Module (PCM) calibration. If this failure occurs, the vehicle does not meet the OBD-II requirements.
What will Mazda do?
Your Mazda dealer will reprogram the PCM to include the latest calibration free of charge. The repair should take approximately one-half day to complete. However, it may take longer depending on the service workload at your Mazda dealership.
As a reminder, the Mazda Driver's Assurance Plan may provide alternate transportation when your vehicle is at an authorized Mazda dealership for a warranty repair. To be eligible for alternate transportation, your vehicle must be a 2001 or newer and within the mileage and time limitations under the Mazda New Vehicle Limited Warranty and adhere to the Rental Car Reimbursement policy. Ask your dealer for details about the Mazda Rental Car Reimbursement Program.
What should you do?
We encourage you to make an appointment with any authorized Mazda dealer to have the PCM reprogrammed. You do not need to bring this notice to the dealer, but it may assist in the check-in process.
Important notice to owners registering vehicles in California, Massachusetts, and Vermont:
California Department of Motor Vehicles, Vermont Department of Motor Vehicles, and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts and Vermont, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers will provide a Vehicle Emission Recall - Proof of Correction Certificate upon completion of the recall. Be sure to keep the proof of correction certificate provided by the Mazda Dealer until needed for the registration renewal process.
Emission Law Information:
To ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended you have your vehicle or engine serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not completed.
What if you have already paid for reprogramming the Powertrain Control Module (PCM)?
If you have already paid for the reprogramming of the PCM to correct a defect, you may be eligible for reimbursement of reasonable repair expenses based on Mazda's repair standards. Please complete the enclosed "Reimbursement Application Form," including the necessary documentation, and mail it to us in the pre-addressed envelope provided, allowing 6-8 weeks for processing.
Where is the closest Mazda dealer?
To locate your nearest Mazda dealer, visit our web site and try our "Locate a Dealer" feature at www.MazdaUSA.com or consult your local yellow pages.
Moved or no longer own this vehicle?
If you have moved or no longer own your MAZDA6, please complete the enclosed prepaid Information Change Card as soon as possible. This enables us to update our records and notify the current owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Still have questions?
If you have any questions regarding this campaign, please contact our Customer Assistance Center at (800) 222-5500, option #4.
If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 400 Seventh Avenue, SW, Washington, D.C. 20590. You may also call their toll-free Auto Safety Hotline at (888) 327-4236.
We actively work to improve our products and search for solutions to improve your ownership experience. Please accept our apologies for any inconvenience this program may have caused you.
Sincerely,
Mazda North American Operations
September 2005
2004 MAZDA6 O2 Sensor Failure-No Illumination Recall 3105G
Dear Mazda Owner:
Mazda Motor Corporation has decided that a defect exists on certain 2004 MAZDA6 vehicles. If you are a recipient of this notice, your vehicle is included in this recall.
What is the problem?
On some 2004 MAZDA6 vehicles equipped with 2.3 liter engines, the Malfunction Indicator Lamp (MIL) in some vehicles may not illuminate as required in the event of a detected O2 sensor fault. This concern is caused by a Powertrain Control Module (PCM) calibration. If this failure occurs, the vehicle does not meet the OBD-II requirements.
What will Mazda do?
Your Mazda dealer will reprogram the PCM to include the latest calibration free of charge. The repair should take approximately one-half day to complete. However, it may take longer depending on the service workload at your Mazda dealership.
As a reminder, the Mazda Driver's Assurance Plan may provide alternate transportation when your vehicle is at an authorized Mazda dealership for a warranty repair. To be eligible for alternate transportation, your vehicle must be a 2001 or newer and within the mileage and time limitations under the Mazda New Vehicle Limited Warranty and adhere to the Rental Car Reimbursement policy. Ask your dealer for details about the Mazda Rental Car Reimbursement Program.
What should you do?
We encourage you to make an appointment with any authorized Mazda dealer to have the PCM reprogrammed. You do not need to bring this notice to the dealer, but it may assist in the check-in process.
Important notice to owners registering vehicles in California, Massachusetts, and Vermont: California Department of Motor Vehicles, Vermont Department of Motor Vehicles, and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts and Vermont, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers will provide a Vehicle Emission Recall - Proof of Correction Certificate upon completion of the recall. Be sure to keep the proof of correction certificate provided by the Mazda Dealer until needed for the registration renewal process.
Emission Law Information:
To ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended you have your vehicle or engine serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not completed.
What if you have already paid for reprogramming the Powertrain Control Module (PCM)?
If you have already paid for the reprogramming of the PCM to correct a defect, you may be eligible for reimbursement of reasonable repair expenses based on Mazda's repair standards. Please complete the enclosed "Reimbursement Application Form," including the necessary documentation, and mail it to us in the pre-addressed envelope provided, allowing 6-8 weeks for processing.
Where is the closest Mazda dealer?
To locate your nearest Mazda dealer, visit our web site and try our "Locate a Dealer" feature at www.MazdaUSA.com or consult your local yellow pages.
Moved or no longer own this vehicle?
If you have moved or no longer own your MAZDA6, please complete the enclosed prepaid Information Change Card as soon as possible. This enables us to update our records and notify the current owner.
Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.
Still have questions?
If you have any questions regarding this campaign, please contact our Customer Assistance Center at (800) 222-5500, option #4.
If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 400 Seventh Avenue, SW, Washington, D.C. 20590. You may also call their toll-free Auto Safety Hotline at (888) 327-4236.
We actively work to improve our products and search for solutions to improve your ownership experience. Please accept our apologies for any inconvenience this program may have caused you.
Sincerely,
Mazda North American Operations
REIMBURSEMENT PLAN
Requirements for Reimbursement
If you meet all of the following requirements, you are eligible to receive reimbursement under this plan:
- An authorized Mazda dealer has inspected your vehicle and completed the 2004 MAZDA6 O2 Sensor Failure - No Illumination Recall 3105G.
- You own or have owned a subject 2004 MAZDA6 within the VIN ranges:VEHICLES VIN RANGE
Model VIN Range Build Date Range 2004 MAZDA6 1YVFP****45 N40299-N47633
1YVHP****45 N36373-N47490January 14, 2004 through January 23, 2004 NOTE: The asterisk "*" can be any number or letter. - You have paid for the inspection/reprogramming of the Powertrain Control Module (PCM).
- You have an original or legible copy of the paid repair order or invoice receipt showing:
- Description of the concern reported
- Inspection/Reprogramming of the Powertrain Control Module (PCM)
- Itemized part(s) and labor charges
- Vehicle model and year, and vehicle identification number (VIN)
- Repair date
- Repair mileage
- Name, address, and telephone number of the authorized Mazda Dealer or a licensed repair shop where such repairs were performed
- Your name and address at the time of repair
- Mail this reimbursement application form in the enclosed envelope to:
Mazda North American Operations
PO Box 5049
Lake Forest, CA 92609-8549
Procedure for Reimbursement Request
Once your vehicle has been inspected and/or the Powertrain Control Module (PCM) has been reprogrammed by an authorized Mazda dealer, you may apply for reimbursement by doing the following:
- Complete the Reimbursement Application Form found on the reverse side of this page.
- Mail the Reimbursement Application Form with a legible copy of the paid repair order and/or invoice using the enclosed envelope.
- Retain copies of the paid repair order or invoice and this application form for your records.
If you wish to correspond with Mazda regarding this reimbursement plan, please write to the above address and refer to your vehicle identification number (VIN).
Any reimbursement application form that is incomplete, illegible, or sent without the legible copy of the paid repair order or invoice will be returned for completion. If Mazda has any questions concerning your application for reimbursement, you may be contacted. Please allow 6-8 weeks for processing.
(SEE REVERSE SIDE FOR APPLICATION FORM)