Recall - Headlight Switch Replacement
BULLETIN NUMBER:87004
DATE:
April 2000
TITLE:
Headlight Switch [Recall #87004]
MODELS:
1994 626/MX-6
Dealer Letter - Recall 87004:
CONDITION OF CONCERN
Mazda has determined that while the turn signal lever is being used, there is a possibility for the headlight wire that runs through the turn signal lever to fail at the point where it is soldered to the headlight switch. This could result in the loss of headlights without any prior warning.
SUBJECT VEHICLES
OWNER NOTIFICATION
Mazda will notify owners of subject vehicles by mail on April 07, 2000.
REQUIRED PARTS
Replacement parts will be drop-shipped to dealers one week before the owner notifications. The quantity shipped to each dealer will be based on the number of vehicles registered in each dealer's area.
Campaign labels are supplied at no charge and are available in 8 1/2" X 11" sheets containing 18 labels. Please use M-Net to order labels.
WARRANTY CLAIM PROCESSING INFORMATION
REPAIR PROCEDURE
CUSTOMER REIMBURSEMENT FOR PREVIOUS REPAIRS OR REPLACEMENT OF THE HEADLIGHT SWITCH OR THE COMBINATION SWITCH.
All affected vehicle owners will receive a reimbursement application form.
A. VEHICLE INSPECTION PROCEDURE
1. Verify VIN is within the following range:
- 1YVGE****R5 150619 - 206336
If vehicle is within the above range, proceed to STEP 2.
If vehicle is not within the above range, return it to the customer or inventory.
2. Check vehicle for Recall Label #87004 attached to the driver side door.
Note:
Be sure to verify recall number as the vehicle may have multiple recalls.
- If Recall Label #87004 is present and the vehicle history shows the recall as not done, contact the Warranty Department. They will update the vehicle history.
- If Recall Label #87004 is not present, proceed to "B. SWITCH REPLACEMENT PROCEDURE."
B. SWITCH REPLACEMENT PROCEDURE
Warning:
This procedure requires the removal and installation of the air bag module. Be sure to observe all "Service Warnings" in the BETM (section S DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION) when handling air bag modules.
1. Refer to the BETM (section S DRIVER-SIDE AIR BAG MODULE INSTALLATION/REMOVAL and Z4 COMBINATION SWITCH REMOVAL/INSTALLATION) and remove the following:
- Air Bag Module
- Steering Wheel
- Column Cover
- Clock Spring
- Combination Switch
2. Remove the two (2) screws securing the headlight switch to the combination switch.
Note:
Be sure not to misplace the spring and check ball. These parts will be reused.
3. Open both pin lock gates on the back of the 14-pin connector.
4. Remove the black, red and green wires from the 14- pin connector using a suitable tool.
5. Detach the headlight switch harness by removing the two (2) pieces of electrical tape and one tie-wrap.
6. Apply small amount of grease provided in the kit to the following components.
- End of new headlight switch lever
- Spring
- Check ball
7. Assemble headlight switch into combination switch.
Note:
Be sure to install check ball and spring.
8. Verify that the new switch operates smoothly and does not bind.
9. Route the headlight switch harness behind tabs as shown below. Install a tie-wrap through the housing hook and secure the headlight harness (at white mark) with other two harnesses. Refer to side view illustration below.
Caution:
- Be sure to first route the tie-wrap through the housing hook before securing harnesses.
- Headlight switch harness must be secured at white mark. Otherwise, the harness may be too tight to permit smooth turn signal lever movement.
10. Measure the following distances from the tie-wrap toward the connectors and wrap one (1) piece of electrical tape around the harness at those locations. Refer to following illustration.
- 30 mm ± 3 mm
- 110 mm ± 5 mm
- 220 mm ± 5 mm
Note:
When complete, three (3) locations on the harness will be wrapped instead of the original two (2) locations.
11. Install red, green and black wires into the correct locations and secure inside the connector. Close gate on connector.
Note:
Ensure that the wires are in the correct locations and secure inside the connector. Refer back to STEP 4 for correct locations.
12. Install the following components. Refer to the BETM "Installation Notes" in section Z4.
- Combination Switch
- Clock Spring
- Column Covers
- Steering Wheel
- Air Bag Module
Caution:
When installing the column covers, be sure the wire harness is not pinched between the top and bottom halves.
13. Verify repair.
D. CAMPAIGN LABEL INSTALLATION
Complete an "Authorized Modification Label" with the recall number written on the sticker and affix it to driver's side door under the door latch. Refer back to the illustration under "A. VEHICLE INSPECTION PROCEDURE" on page one (1).
Owner Letter - Recall 87004:
Owner Letter (Continued) - Recall 87004:
REIMBURSEMENT PLAN:
REIMBURSEMENT APPLICATION FORM:
