Automatic Shoulder Belt [Recall Campaign #72803] Door Latch Switch [SSP #31] MX Protégé

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Antony Henderson
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1 Automatic Shoulder Belt [Recall Campaign #72803] Do Latch Switch [SSP #3] MX Protégé To: All Mazda Dealers Attention: All General Managers, Service Managers and Parts Managers Subject: Recall Campaign #72803 and SSP #3 Dear Mazda Dealer: Mazda Mot Cpation has decided to conduct a recall campaign f the automatic shoulder belt on and MX-3 models. In addition, Mazda has decided to conduct a Special Service Program to extend the warranty coverage f the front do latch switch to 2 years on , MX-3 and Protégé models. Mazda has determined that, under certain conditions, the cable that retracts the automatic shoulder belt buckle may bind due to excessive wear of automatic shoulder belt rail. If binding of the cable occurs, the passive restraint system is rendered inoperative. Additionally, Mazda detected that, under certain conditions, the passive shoulder belt buckle may stay at the rearmost position even if the do is opened. This occurs as the grease, on the contact point of the front do latch switch, degrades over time. Detailed infmation regarding these campaigns is provided in Attachment I, the repair procedures are shown in Attachment II, and the owner notifications are Attachment III. The National Traffic and Mot Vehicle Safety Act prohibits selling leasing any subject vehicle without perfming the necessary repairs f defects failures. Therefe, please complete the necessary inspections and/ repairs on all new and used vehicles in your inventy pri to their sell lease. Please make certain that the appropriate personnel in your dealership are familiar with the details of these campaigns f responding to customer inquiries. Should you have any questions, please contact your District Customer Suppt Manager. We apologize f any inconvenience these campaigns may cause you and your staff, and greatly appreciate your understanding and suppt in administrating these recall campaigns. Sincerely, Mazda Nth American Operations

2 ATTACHMENT I CONDITION OF CONCERN [Automatic Shoulder Belt] The cable that retracts the automatic shoulder belt buckle may bind due to dust entering the automatic shoulder belt rail causing excessive wear. If binding of the cable occurs, the passive restraint system is rendered inoperative. [Do Latch Switch] The passive shoulder belt buckle may stay at the rearmost position even if the do is opened. This occurs as the grease, on the contact point of the front do latch switch, degrades over time. SUBJECT VEHICLES [Automatic Shoulder Belt Recall #72803] Model VIN Range Comment JMBG232 LO JMBG232 PO 6590 JMBG234 PO JMBG234 PO 6599 Do Switch SSP Is also applicable MX-3 JMEC JMEC43 PO JMEC JMEC432 PO Do Switch SSP Is also applicable JMBG232 RO JMBG232 RO JMBG234 RO JMBG234 RO Automatic Belt Recall only can be any letter number [Do Latch Switch SSP#3] Model VIN Range Comment JMBG232 LO JMBG232 PO 6590 JMBG234 PO JMBG234 PO 6599 Automatic Belt Recall is also applicable MX-3 JMEC JMEC43 PO JMEC JMEC432 PO Protégé JMBG224 LO JMBG224 PO JMBG226 LO JMBG226 PO JMBG228 LO JMBG228 MO can be any letter number Automatic Belt Recall is also applicable Do Latch Switch SSP only OWNER TIFICATION Mazda will notify subject vehicle owners in three phases, taking into account the availability of replacement parts, as follows. Subject Model & Campaign Contents Kick-off Timing st Automatic Belt and Do Latch Switch The week of March 30 2 nd Automatic Belt and Do Latch Switch End of May Automatic Belt only MX-3 Automatic Belt and Do Latch Switch 3 rd Protégé Do Latch Switch only Middle of June

3 REPAIR PROCEDURES Refer to Attachment II. PARTS INFORMATION [Passive Shoulder Belt Recall #72803] Model Part Number Part Name Side Quantity MX-3 BRY BRY BRY Y BRY Y EAY EAY EAY Y EAY Y Rail & Mot Assembly Rail Assembly Rail & Mot Assembly Rail Assembly [Do Latch Switch SSP#3] Model Part Number VIN/Serial Number Side Quantity BRY Befe L BRY BRY After L BRY LR MX-3 EAY All EAY Protégé BRY Befe L BRY BRY After L BRY LR All BRY Silicon Sealer Both LR LR Campaign labels are supplied at no charge and are available in 8 /2 X sheets containing 8 labels. Please use M-Net f dering these labels. Applicable part number is A-00. The inspection tool is the same as used in Recall #68702 (RX-7 Automatic Shoulder Belt). One additional tool has been included with this bulletin. However, if you need additional tools they may be dered via M- Net. Please use part number R f dering. Mazda will drop ship repair parts to dealers f st campaign of 90MY 323, based on the number of the subject vehicles in their assigned market area, the week of March 30. Please confirm that parts are in stock at the time a customer makes an appointment to have these campaigns perfmed. CUSTOMER REIMBURSEMENT Owners of subjected vehicles who have paid f the replacement of their front do latch switches and/ their automatic shoulder belts, pri to these campaigns, are eligible f reimbursement under the guidelines set fth on the Reimbursement Application Fm. All applications f reimbursement must be submitted to Mazda Nth American Operations.

4 WARRANTY EXTENTION [Automatic Shoulder Belt] The warranty coverage f the automatic shoulder belt rail and mot on subject vehicles has been extended over the lifetime of the vehicle. [Do Latch Switch] The warranty period f the front do latch switches on subject vehicles has been extended to 2 years, unlimited mileage from the iginal warranty start date. Applicable parts f Lifetime Warranty. [Automatic Shoulder Belt] Model Part Number Part Name Side 323 MX-3 BRY BRY BRY Y BRY Y EAY EAY EAY Y EAY Y Rail & Mot Assembly Rail Assembly Rail & Mot Assembly Rail Assembly Applicable parts f 2 years warranty period extension from warranty start date. [Do Catch Switch] Model Part Number VIN serial # Side MX Protégé BRY BRY BRY BRY EAY EAY BRY BRY BRY BRY Befe L Befe L After L After L Any Any Befe L Befe L After L After L LR LR

5 WARRANTY INFORMATION FOR RECALL #72803 Applicable Model: Inspection Only Rail & Mot Replacement (Includes Inspection) Rail Assembly Replacement (Includes Inspection) (Both sides) (One side) (Both sides) (One side) (Both sides) Process Number A84H A84H A84H A84H A84H Warranty Type Code R R R R R Customer Comment Code Damage Code Part Number Main Cause BRY BRY BRY BRY BRY Y BRY Y BRY Y Quantity 0 Lab Operation Code XX999XR XX999XR2 XX999XR3 XX999XR6 XX999XR7 Lab Hours Use Process Number A84J f Lifetime Warranty Inspection Rail & Mot Replacement Rail Assembly Replacement Applicable Model: Only (Includes Inspection) (Include Inspection) MX-3 (Both sides) (One side) (Both sides) (One side) (Both sides) Process Number A84H A84H A84H A84H A84H Warranty Type Code R R R R R Customer Comment Code Damage Code EAY EAY Y Part Number Main Cause EAY EAY (PNMC) EAY EAY Y EAY Y Quantity 0 Lab Operation Code XX999XR8 XX999XR9 XX999XRA XX999XRD XX999XRE Lab Hours Use Process Number A84J f Lifetime Warranty WARRANTY INFORMATIOM FOR SSP#3 - DOOR LATCH SWITCH Applicable model Protege Inspection Only (Buckle Operation) Do Latch Switch Replacement (Includes Inspection) (Both Sides) (One Side) (Both Sides) Process Number A84K A84K A84K Warranty type Code R R R Customer Comment Code Damage Code Part Number Main Cause (PNMC) BRY BRY BRY-58-34, BRY-59-34, BRY BRY BRY BRY Quantity 0 Lab Operation Code XX999XRF XX999XRG XX999X Lab Hours Use Process Number A84L f 2 Year Extended Warranty

6 Applicable model: Do Latch Switch Replacement (Includes Inspection) (One Side) (Both Sides) Process Number A84K A84K Warranty type Code R R Customer Comment Code Damage Code Part Number Main Cause (PNMC) BRY , BRY , BRY BRY BRY BRY Quantity Lab Operation Code XX999XRG XX999X Lab Hours Use Process Number A84L f 2 Year Extended Warranty Applicable model : Do Latch Switch Replacement (Includes Inspection) MX-3 (One Side) (Both Sides) Process Number A84K A84K Warranty type Code R R Customer Comment Code Damage Code Part Number Main Cause (PNMC) EAY EAY EAY Quantity Lab Operation Code XX999XRJ XX999XRK Lab Hours Use Process Number A84L f 2 Year Extended Warranty Part Number BRY (Silicone Sealer) can be claimed on the first SSP#3 claim. Dealers should not claim me than tube of silicone f 40 claims. Claims with silicone sealer will be strictly monited.

7 Repair Procedure Chart f Automatic Shoulder Belt Recall Campaign #72803 and Do Latch Switch SSP#3. Applicable models: and MX-3. Customer Inquiry TE: Activities shown below are basic procedures. Refer to the actual instructions when perfming these recall campaigns Has customer experienced the buckle stuck in the locked position? Replace Do Latch Switch Inspect Buckle Operation * * Start from Passenger side. Then proceed to Driver side. Proper Operation? Inspect Rail Within Specification? Replace Do Latch Switch Replace Rail Staying at locked position? Buckle Condition Jammed at other than locked position? Replace Rail and Mot Assembly Inspection and/ repair completed on driver s side? Install Campaign Label TE: Parts needlessly replaced will be subject to charge back. Inspection must be carried out individually on the driver side and passenger side. Do not replace the rail and mot on the Passenger side without inspection when the driver side is replaced.

8 Repair Procedure Chart f Automatic Shoulder Belt Recall Campaign #72803 Applicable model: TE: Activities shown below are basic procedures. Refer to the actual instructions when perfming these recall campaigns Inspect Buckle Operation * * Start from Passenger side. Then proceed to Driver side. Proper Operation? Inspect Rail Within Specification? Replace Rail Replace Rail and Mot Assembly Inspection and/ repair completed on driver s side? Install Campaign Label TE: Parts needlessly replaced will be subject to charge back. Inspection must be carried out individually on the driver side and passenger side. Do not replace the rail and mot on the Passenger side without inspection when the driver side is replaced.

9 Repair Procedure Chart f Do Latch Switch SSP#3. Applicable models: Protégé Customer Inquiry TE: Activities shown below are basic procedures. Refer to the actual instructions when perfming these recall campaigns Has customer experienced the buckle stuck at the locked position? Replace Do Latch Switch Inspect Buckle Operation * * Start from Passenger side. Then proceed to Driver side. Proper Operation? Replace Do Latch Switch Inspection and/ repair completed on driver s side? Install Campaign Label TE: Parts needlessly replaced will be subject to charge back. Inspection must be carried out individually on the driver side and passenger side.

10 and MX-3 Automatic Shoulder Belt [Recall Campaign #72803] [SSP#3] ATTACHMENT III Dear Mazda Owner: This notice is sent to you in accdance with the requirements of the National Traffic and Mot Vehicle Safety Act. Mazda Mot Cpation has decided that a defect, which relates to mot vehicle safety, exists in certain and MX-3 models. Mazda has determined that, under certain conditions, the cable that retracts the automatic shoulder belt buckle may bind due to excessive wear of the automatic shoulder belt rail. If binding of the cable occurs, the passive restraint system is rendered inoperative. Arrangements have been made f you to have your automatic shoulder belt inspected and replaced if necessary. Please schedule an appointment with your Mazda dealer to have this recall perfmed. The inspection and repair will be perfmed free of charge. The wk may take as long as 3 hours to complete. However, it may take longer depending upon the service department s wk schedule. In addition to perfming this recall campaign, Mazda is extending the warranty coverage on the driver and passenger automatic shoulder belt rail and mot f the life of the vehicle. Mazda is also extending the warranty coverage on the front do latch switch, which may affect the operation of the automatic shoulder belt, to 2 years from the manufacturers warranty start date. If you have already paid f the repair replacement of your shoulder belt front do latch switch, due to improper operation of the automatic seat belt retract, Mazda will reimburse you f reasonable expenses based on Mazda s repair standards. Please complete the enclosed Reimbursement Application fm, mail it in the pre-addressed envelope and allow 6-8 weeks f processing. If you are the less of the vehicle and have received this letter, please provide a copy to the lessee. Should you have any questions regarding this recall campaign, please contact our Customer Assistance toll-free number, (800) If your dealer distribut does not remedy this defect without charge and/ within a reasonable amount of time, you may wish to notify the Administrat, National Highway Traffic Safety Administration, Washington, DC 20590, call their toll-free Auto Safety Hotline, (888) (Residents of Washington, DC may call ) If you have moved no longer own your 323 MX-3, please complete the enclosed Change of Address/Ownership pre-paid postcard, as soon as possible. This enables us to update our recds and notify the current owner. Our goal at Mazda is to build and maintain only the highest quality products. Please accept our apology f any inconvenience this recall campaign may cause you. Sincerely, MAZDA RTH AMERICAN OPERATIONS

11 ATTACHMENT II REPAIR PROCEDURE: / PROTEGE/ MX-3 (RECALL#72803 & SSP#3) VEHICLE INSPECTION PROCEDURE. Verify the VIN: MODEL MX Protege VIN JMBG23 2*LO PO 6590 JMBG23 4*PO PO6599 JMBG23 2*RO RO86066 JMBG23 4*RO RO87583 JMEC43 * PO JMEC43 2* PO JMBG22 4*LO PO JMBG22 6*LO PO JMBG22 8*LO MO If the vehicle is within the above range, proceed to step 2. If the vehicle is not within the above range, return the vehicle to the customer inventy. 2. Check the vehicle f the following conditions: Recall #72803 SSP #3 label attached to the driver s side do. Refer to illustration below. Note This issue can be intermittent and difficult to duplicate. Therefe, it is imptant to ask the customer if they have experienced the belt buckle staying in the lock position after the do was opened. B. BUCKLE OPERATION INSPECTION. Turn ON the ignition. 2. Check the automatic shoulder belt by opening and closing the do. SHOULDER BELT BUCKLE INSPECT VEHICLE FOR RECALL OR SSP LABEL The VIN has been registered in the MDCS (Warranty Vehicle Histy) and the repair dates f these campaigns are listed. 3. If the vehicle meets any of the criteria listed in step 2, the repair wk has been completed. Return the vehicle to the customer inventy. If the vehicle does not comply with the criteria listed in step 2, proceed to A. CUSTOMER INQUIRY except F the , proceed to B. BUCKLE OPERATION INSPECTION. A. CUSTOMER INQUIRY Applicable Model: MX Protege Replace the do latch switch if a customer has experienced the buckle staying in the lock (rearmost) position after the do is opened. Proceed to C. DOOR LATCH SWITCH REPLACEMENT. [ & MX-3] - If the buckle stays in the lock (rearmost) position when the do is opened, proceed to C. DOOR LATCH SWITCH REPLACEMENT. - If the buckle is stuck other than in the lock position, proceed to D. RAIL & MOTOR REPLACEMENT. - If the buckle operates properly, proceed to E. RAIL INSPECTION. [ ] - If the buckle is stuck other than in the lock position, proceed to D. RAIL & MOTOR REPLACEMENT. - If the buckle operates properly, proceed to E. RAIL INSPECTION. [ Protege] - If the buckle stays in the lock position when the do is opened, proceed to C. DOOR LATCH SWITCH REPLACEMENT. C. DOOR LATCH SWITCH REPLACEMENT. Remove the do lock assembly per section S of the Wkshop Manual. PAGE OF 5

12 REPAIR PROCEDURE: / PROTEGE/ MX-3 (RECALL#72803 & SSP#3) 2. Cut all tie-wraps holding the latch switch wiring harness to the lock assembly and make a note of their locations as shown on the following illustration. 3. Remove the protective rubber cover to the latch switch and then remove the latch switch by removing the two (2) screws illustrated below. REMOVE RUBBER COVER CUT TIE-WRAPS 4. Select the applicable do latch switch using the Part Infmation below. PARTS INFORMATION MODEL SPECIFICATION SIDE VIN/SERIAL# PART NUMBER QTY. 323 Manual Lock Befe BRY Manual Lock Befe BRY Manual Lock After BRY Manual Lock After BRY Power Lock Befe BRY Power Lock Befe BRY Power Lock After BRY Power Lock After BRY MX-3 Any Any EAY Any Any EAY PROTEGE Manual Lock Befe BRY Manual Lock Befe BRY Manual Lock After BRY Manual Lock After BRY Power Lock Befe BRY Power Lock Befe BRY Power Lock After BRY Power Lock After BRY ALL Silicon Sealer Both Any BRY PAGE 2 OF 5

13 REPAIR PROCEDURE: / PROTEGE/ MX-3 (RECALL#72803 & SSP#3) 5. Install the new latch switch onto the do lock assembly using the two (2) screws. 6. Apply silicon sealer (BRY 58 37) to the latch where the wiring harness is soldered to the switch. This is to prevent water entry into the switch after the top rubber cover is installed. 3. Pull seaming welt back to expose body seam as illustrated. DUST SEAL APPLY SILICON SEALER BODY SEAM REMOVE SEAMING WELT 4. Align and clip the dust seal on the body seam as shown in the above illustration and the detail illustration below. 7. Secure top rubber cover over the latch switch and tie-wrap the harness back to the do lock assembly. Refer to the locations noted in the removal of the tiewraps back in step Install the do lock assembly into the do per the Wkshop Manual. D. RAIL & MOTOR ASSEMBLY REPLACEMENT. Disconnect negative battery cable. 2. Replace the malfunctioning rail and mot assembly with the new part. Refer to section S of the Wkshop Manual. See Parts Infmation. BODY SEAM CLIP THE DUST SEAL TO THE SEAM PARTS INFORMATION MODEL PART NUMBER PART NAME QTY. ALIGN TCH IN DUST SEAL WITH BUCKLE STAY BRY Rail & Mot Assy. () BRY Rail & Mot Assy. () MX-3 EAY Rail & Mot Assy. () EAY Rail & Mot Assy. () 5. Re-connect the negative battery cable. 6. Confirm that the automatic shoulder belt buckle stays in the locked (rearmost) position when the do is closed. 7. Re-install seaming welt. 8. Repeat step B. BUCKLE OPERATION INSPEC- TION on the other front do if has not already been done. 9. Proceed to step G. AUTOMATIC SHOULDER BELT OPERATION INSPECTION. PAGE 3 OF 5

REPAIR PROCEDURE: 990-94 323/990-93 PROTEGE/992-93 MX-3 (RECALL#72803 & SSP#3) E. RAIL INSPECTION. Check and recd the vehicle mileage. 2. Close the front do. 3. Turn ON the ignition to move the automatic shoulder belt to the center pillar.

14 REPAIR PROCEDURE: / PROTEGE/ MX-3 (RECALL#72803 & SSP#3) E. RAIL INSPECTION. Check and recd the vehicle mileage. 2. Close the front do. 3. Turn ON the ignition to move the automatic shoulder belt to the center pillar. Insert the inspection tool P/N R (OTC P/N T97C-660B45-A) between the dust shields of the rail assembly at position X as shown below. IF MILEAGE IS LESS THAN 80,000 (28,000KM), USE THE 3.2MM END OF THE INSPECTION TOOL. INSPECTION TOOL X IF MILEAGE IS MORE THAN 80,000 (28,000KM), USE THE 3.4MM END OF THE INSPECTION TOOL. 4. If the inspection tool s depth does not increase (tool s scribe line does not move closer to the dust shield), proceed to B. BUCKLE OPERATION INSPECTION f the other front do. Proceed to G. AUTOMATIC SHOULDER BELT OPERATION INSPECTION if the necessary inspection and repair has been completed on both sides. If the inspection tool s depth increases anywhere between X and Y, Proceed to F. RAIL ASSEM- BLY REPLACEMENT. F. RAIL ASSEMBLY REPLACEMENT. Remove the automatic shoulder belt from the vehicle. Refer to section S of the Wkshop Manual. 2. Remove the rail assembly from the locking device. A. Push the dowel pin through to the outside bracket. B. Lift the plastic lever (on the locking device) with a flat screwdriver and remove the rail assembly. LIFT PLASTIC LEVER (LOCKED POSITION SHOWN) REMOVE RAIL Y DO T SLIDE TOOL ALONG RAIL STOPS HERE PASS RAILS STOPS HERE FAIL RAIL ASSEMBLY PUSH DOWEL PIN THROUGH OTHER SIDE OF BRACKET DUST SHIELD INSPECTION TOOL - Tool must be inserted until it stops in the rail assembly. - Recd the distance between the scribe line on the tool and dust shields. - Insert and inspect every /2 inch from point X to point Y along the rail assembly. Note Wear of the dust shield may cause the depth measurement distance to the scribe line to vary. Caution Do not slide the inspection tool along the shield; lubricate grease will be removed. Remove and reinsert the inspection tool every /2 inch. Note If the cable and rail assembly stick together, wk the cable back and fth in the rail assembly to free the two pieces. 3. Insert new rail assembly into the locking device of the mot assembly. A. Insert the edge of the cable coming from the locking device into the rail assembly. B. Insert the rail assembly into the locking device. C. Confirm that the plastic lever is locked into the rail assembly. PAGE 4 OF 5

15 REPAIR PROCEDURE: / PROTEGE/ MX-3 (RECALL#72803 & SSP#3) D. Install new dowel pin. RAIL ASSEMBLY CABLE PLASTIC CLIP BUCKLE ASSEMBLY INSPECT THIS ENTIRE AREA FOR GREASE OR DIRT DOWEL PIN 4. Install shoulder belt assembly in the vehicle. 5. Confirm that the buckle is permanently fixed in the locked position. 6. Repeat the necessary steps (starting with B. BUCKLE OPERATION INSPECTION ) on the other front do if it has not already been done. 7. Proceed to G. AUTOMATIC SHOULDER BELT OPERATION INSPECTION. PARTS INFORMATION MODEL PART NUMBER PART NAME QTY BRY Y Rail Assembly () BRY Y Rail Assembly () MX-3 EAY Y Rail Assembly () EAY Y Rail Assembly () G. AUTOMATIC SHOULDER BELT OPERATION INSPECTION. Turn ignition ON. 2. Close and open the do to check the automatic shoulder belt operation. 3. Repeat on other front do. Note If any problems are found, repair accding to the Wkshop Manual. 4. Proceed to H. CAMPAIGN LABEL ATTACHMENT. H. CAMPAIGN LABEL INSTALLATION Install campaign label (recall #72803 f the automatic shoulder belt SSP#3 f the do latch switch) on the driver s side do. Refer back to the illustration under A. VEHICLE INSPECTION PROCEDURE. PAGE 5 OF 5

Automatic Shoulder Belt Recall Campaign [72803] Door Latch Switch [SSP31] MX Protege

Recall Start March 989 Automatic Shoulder Belt Recall Campaign [72803] Door Latch Switch [SSP3] 990-994 323 992-993 MX-3 990-993 Protege TO: ATTENTION: SUBJECT: All Mazda Dealers All General Managers,