Service Bulletin Mazda North American Operations Irvine, CA 92618-2922 Subject: ENGINE NO START DUE TO FROZEN MAIN RELAY / FUEL PUMP RELAY Bulletin No: 01-009/07 2003-2007 MAZDA6 - ENGINE NO START DUE TO FROZEN MAIN RELAY / FUEL PUMP RELAY APPLICABLE MODEL(S)/VINS 2003-2007 Mazda6 vehicles produced before Feb. 28, 2007 NOTE: This Service Bulletin is not applicable to MAZDASPEED6 vehicles. DESCRIPTION In extremely cold weather (approx. minus 30C), a customer may experience an engine no start/no crank condition due to a frozen main relay and/or fuel pump relay. Due to the design, moisture can enter the relays and freeze the contact points after driving a short distance and may shut off the engine. Customers having this concern should have their vehicle repaired using the following repair procedure. REPAIR PROCEDURE 1. Verify customer concern. 2. Replace relay(s) with modified kits according to table below: NOTE: 2006-2007 Mazda6 vehicles already have a modified Fuel Pump Relay. Model Year Repair Procedure 2003-2005 Replace Main Relay and Fuel Pump Relay with modified kits 2006-2007 Replace Main Relay with modified kit Main Relay Kit Installation Procedure: 1. Record customer s pre-seat radio stations. 2. Disconnect negative battery cable. 3. Disconnect air flow sensor connector 4. (3.0L Engine Only): Disconnect VAD three-way solenoid connector. 5. Remove air cleaner. 6. Remove fuse box lid. Page 1 of 5 CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/ equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by do-it-yourselfers. Customers should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies, customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means, electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in writing.
7. Disconnect main relay from fuse box, and install an intermediate harness between fuse box and main relay. 8. Tie-wrap intermediate harness and emission harness together. 9. Tie-wrap intermediate harness and B-terminal harness together. 10. Install intermediate harness bracket at bottom of fuse box installed location. CONNECT INTERMEDIATE HARNESS COUPLER TO LOCATION WHERE MAIN RELAY WAS ORIGINALLY FITTED TIE-WRAP THESE TWO LOCATIONS 1753a INSTALL SERVICE MAIN RELAY HERE 11. Reinstall air cleaner. 12. Reconnect air flow sensor connector. 13. (3.0L Engine Only): Reconnect VAD three-way solenoid connector. - 2003-2005 Mazda6: Proceed to Fuel Pump Relay Kit Installation Procedure and install Fuel Pump Relay Kit. - 2006-2007 Mazda6: Proceed to next step. 14. Reconnect negative battery cable. 15. Re-enter customer s pre-seat radio stations. - 2006-2007 Mazda6: Proceed to Power Window Initialization Procedure to restore anti-pinch and auto open/close window features before returning vehicle to customer or dealer inventory. Page 2 of 5
Fuel Pump Relay Kit Installation Procedure (2003-2005 Mazda6 Only): 1. Secure intermediate harness bracket together with PCM installation bracket. 2. Tie-wrap intermediate harness and harness together at three locations. Make sure intermediate harness passes over main relay bracket. 3. Disconnect fuel pump relay from relay box, and connect intermediate harness to fuel pump relay connector. 4. Connect ground terminal on body panel with existing M8 screw. SECURE FUEL PUMP RELAY WITH BRACKET CONNECT GROUND TERMINAL ON BODY PANEL WITH EXISTING M8 SCREW 5. Reconnect negative battery cable. 6. Re-enter customer s preset radio stations. 7. Verify repair. 1753b CONNECT INTERMEDIATE HARNESS COUPLER TO LOCATION WHERE FUEL PUMP RELAY WAS ORIGINALLY FITTED Page 3 of 5
POWER WINDOW INITIALIZATION PROCEDURE (2006-2007 Mazda6 Only) 1. Turn ignition to ON position. 2. From driver s seat ensure window lockout switch is NOT depressed. POWER WINDOW MAIN SWITCH 1601a ENSURE WINDOW LOCKOUT SWITCH IS NOT DEPRESSED 3. Press window switch down to fully open door window. 4. Pull window switch up to fully close door window; hold switch up for two (2) seconds; release switch. OPEN WINDOW FULLY, CLOSE WINDOW FULLY HOLDING SWITCH UP FOR TWO(2) SECONDS, RELEASE SWITCH 1601b 5. Move to front passenger seat and repeat Steps 3-4 on passenger window switch. 6. Verify proper window operation using each door switch. Page 4 of 5
PARTS INFORMATION Part Number Description Qty. Note L3Y1-18-8BX Main Relay Kit 1 --- L3Y2-18-8BX Fuel Pump Relay Kit 1 2003-2005 Mazda6 Only WARRANTY INFORMATION NOTE: This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information. Additional diagnostic time cannot be claimed for this repair. Main Relay and Fuel Pump Relay Kit Replacement: (2003-2005 Mazda6) Main Relay Kit Replacement Only: (2006-2007 Mazda6) Warranty Type A A Symptom Code 01 01 Damage Code 92 92 Part Number Main Cause L3Y1-18-8BX L3Y1-18-8BX Quantity 1 1 Operation Number / Labor Hours: XXC005R1 / 0.5 Hrs XXC005R2 / 0.3 Hrs Page 5 of 5