Attachment II - Inspection and Repair Procedures
A. VEHICLE INSPECTION PROCEDURE1. Verify that the vehicle is within the following range:
^ 2003 Mazda6 vehicles produced from October 2, 2002 to July 22, 2003 VIN Range: 1YV*P80**3*M00348 - 1YV*P80**3*M57057
- 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 or inventory.
2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Modification Label SSP57 attached to the vehicle's bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table shown.
NOTE:
Be sure to verify SSP number as the vehicle may have multiple SSP labels.
B. INSPECTION AND REPAIR PROCEDURE
NOTE:
^ This Special Service Program supersedes previously released Service Bulletin "09-020103 - Door Sash/Trunk Lid Surface Staining" issued on 11/03/03.
^ All subject vehicles must be inspected for staining on the horizontal & vertical door sash areas as well as under the trunk rubber stoppers.
^ Vehicles that do not exhibit staining are still required to have door sash areas cleaned and sealed according to the repair procedure.
Front Door Sash Inspection:
1. Open front door.
2. Without removing the weather stripping, inspect for staining on the "horizontal" sash area by pulling up the weather stripping.
NOTE:
Stains may or may not be present in this area.
3. Inspect the area near the weather stripping for staining on the "vertical" sash.
NOTE:
^ Stains should be visible without pulling the weather stripping back. Stains may or may not be present in this area.
4. Repeat Steps 1-3 for the other front door.
5. Proceed to "Front Door Sash Repair".
Rear Door Sash Inspection:
1. Open rear door.
2. Without removing the weather stripping, inspect for staining on the "horizontal" sash area by pulling up the weather stripping.
NOTE:
Stains may or may not be present in this area.
3. Inspect the area near the weather stripping for staining on the "vertical" sash.
NOTE:
Stains may or may not be present in this area.
4. Repeat Steps 1 - 3 for the other rear door.
5. Proceed to "Rear Door Sash Repair".
Front Door Sash Repair:
WARNING:
This repair procedure must be performed in a well ventilated area away from direct sunlight. Safety glasses and protective latex rubber gloves must also be worn while performing this procedure.
NOTE:
^ It is strongly recommended that a technician experienced with a caulking gun perform this procedure.
^ The repair requires the use of several 3M products. Obtain the 3M products listed in the 3M Parts Information table before beginning any repairs.
^ The following items are also required to perform this repair: Mazda touch-up paint, caulking gun, latex rubber gloves, utility knife, plastic spatula or spreader, safety glasses, isopropyl alcohol, and terry cloths.
1. Starting at the top left corner of the driver's door, gently detach the plastic molding that is incorporated into the weather stripping from the door.
CAUTION:
Be careful when detaching the plastic molding. Using excessive force may break the clips within the plastic molding, which may not be covered under warranty.
NOTE:
Each door has a plastic molding incorporated into the weather stripping to maintain proper weather stripping placement on the door frame. The plastic moldings are in the following locations:
^ Left Front Door: Molding is at the top left corner of the door frame.
^ Right Front Door: Molding is at the top right corner of the door frame.
2. Remove the upper half portion of the weather stripping by gently pulling it in an upward direction. It is not necessary to remove the lower portion of the weather stripping.
3. Lightly soak a terry cloth with isopropyl alcohol.
4. Using the terry cloth in a side-to-side rubbing motion, remove the stains from the affected areas along the sash.
NOTE:
If no stains are present, cleaning the sash area is still necessary.
5. Using a 3M Scotch Bright pad (white - # 07445), scuff the horizontal and vertical sash cavity areas.
NOTE:
^ If a stain cannot be removed using the methods described in this repair procedure, the vehicle should be taken to a body shop for repair. The current warranty policy allows up to $250.00 of body shop repairs (for the removal of stains) without prior authorization. After the body shop completes the necessary repairs, the remaining repair procedures outlined in this repair procedure must still be performed.
6. Clean the scuffed areas with isopropyl alcohol.
7. Repeat Steps 1 - 6 on other door.
NOTE:
Before proceeding to the next step, make sure the isopropyl alcohol has completely dried.
8. Pull off the metal cover from the bottom of the 3M Windo-Weld Super Fast Urethane Sealer (# 08609) cartridge and insert it into the caulking gun.
9. Pierce a small hole into the top of the urethane sealer cartridge.
10. Install the plastic cartridge nozzle.
NOTE:
Do not cut the top of the plastic cartridge nozzle. The nozzle is already cut to the proper size.
11. In order to keep a "factory-like" bead appearance, apply 3M Scotch Masking Tape (# 26334) to the edge of the horizontal surface of the door. Leave approximately 1/8" gap between the edge of the masking tape and the door sash.
12. Apply a small bead of urethane sealer to the horizontal door sash area starting near the exterior mirror. It is important to ensure the urethane sealer enters the sash cavity.
CAUTION:
Apply urethane sealer at room temperature of approx. 70 degrees F. Sealer will not cure properly if applied in cold temperature.
13. After the urethane sealer bead is applied, "tool the bead" by running your finger along the bead while applying light pressure. If excessive urethane sealer accumulates on your finger, wipe it off before continuing.
NOTE:
By applying sealer to the repair area, corrosion can be prevented as the sealer isolates the area (especially at sash edge and between sash and sash rail) from atmosphere/moisture. Ensure that the sealer fully covers these areas.
14. Repeat Steps 11 - 13 on the vertical area of the door sash.
15. Inspect the bead quality and penetration into the door sash cavity.
16. Carefully remove the masking tape from the horizontal and vertical door sash areas.
17. Apply 3M General Purpose Adhesive Cleaner (# 08987) to a terry cloth and remove any excess urethane sealer that may have been applied to the door sash rail.
NOTE:
Do not remove any urethane sealer from the door sash cavity.
18. Shake the Mazda touch-up paint thoroughly.
19. Touch up the outer top corners of the door sash rails, and any other areas that were previously stained and cleaned.
NOTE:
Do not apply touch-up paint to the horizontal or vertical door sash areas where the urethane sealer was applied.
20. Wait approximately 1-1/2 hours for the urethane sealer and touch-up paint to dry to the touch (ambient temperature of approximately 70 degrees F at 50% relative humidity).
NOTE:
The urethane sealer will fully dry in 24 hours.
21. Reinstall the door weather stripping.
NOTE:
A weather stripping that is not installed correctly may cause wind noise and water leaks. While the weather stripping may appear to be fully installed inside the sash rail, some areas may not be.
22. After installing the weather stripping, lift it upward to inspect for proper fit.
23. Repeat Steps 11 - 22 on other side door.
Rear Door Sash Repair:
WARNING:
This repair procedure must be performed in a well ventilated area away from direct sunlight. Safety glasses and protective latex rubber gloves must also be worn while performing this procedure.
NOTE:
^ It is strongly recommended that a technician experienced with a caulking gun perform this procedure.
^ The repair requires the use of several 3M products. Obtain the 3M products listed in the 3M Parts Information table before beginning any repairs.
^ The following items are also required to perform this repair: Mazda touch-up paint, caulking gun, latex rubber gloves, utility knife, plastic spatula or spreader, safety glasses, isopropyl alcohol, and terry cloths.
1. Starting at the top right corner of the left rear door, detach the plastic molding that is incorporated into the weather stripping from the door.
CAUTION:
Be careful when detaching the plastic molding. Using excessive force may break the clips within the plastic molding, which may not be covered under warranty.
NOTE:
Each door has a plastic molding incorporated into the weather stripping to maintain proper weather stripping placement on the door frame. The plastic moldings are in the following locations:
^ Left Rear Door: Molding is at the top right corner of the door frame.
^ Right Rear Door: Molding is at the top left corner of the door frame.
2. Remove the upper half portion of the weather stripping by gently pulling it in an upward direction. It is not necessary to remove the lower portion of the weather stripping.
3. Lightly soak a terry cloth with isopropyl alcohol.
4. Using the terry cloth in a side-to-side rubbing motion, remove the stains from the affected areas along the sash.
NOTE:
If no stains are present, cleaning the sash area is still necessary.
5. Using a 3M Scotch Bright pad (white - # 07445), scuff the horizontal and vertical sash cavity areas.
NOTE:
^ If a stain cannot be removed using the methods described in this repair procedure, the vehicle should be taken to a body shop for repair. The current warranty policy allows up to $250.00 of body shop repairs (for the removal of stains) without prior authorization. After the body shop completes the necessary repairs, the remaining repair procedures outlined in this repair procedure must still be performed.
6. Clean the scuffed areas with isopropyl alcohol.
7. Repeat Steps 1 - 6 on other door.
NOTE:
Before proceeding to the next step, make sure the isopropyl alcohol has completely dried.
8. Pull off the metal cover from the bottom of the 3M Windo-Weld Super Fast Urethane Sealer (# 08609) cartridge and insert it into the caulking gun.
9. Pierce a small hole into the top of the urethane sealer cartridge.
10. Install the plastic cartridge nozzle.
NOTE:
Do not cut the top of the plastic cartridge nozzle. The nozzle is already cut to the proper size.
11. In order to keep a "factory-like" bead appearance, apply 3M Scotch Masking Tape (# 26334) to the edge of the horizontal surface of the door. Leave approximately 1/8" gap between the edge of the masking tape and the door sash.
12. Apply a small bead of urethane sealer to the horizontal door sash area starting near the exterior mirror. It is important to ensure the urethane sealer enters the sash cavity.
CAUTION:
Apply urethane sealer at room temperature of approx. 70 degrees F. Sealer will not cure properly if applied in cold temperature.
13. After the urethane sealer bead is applied, "tool the bead" by running your finger along the bead while applying light pressure. If excessive urethane sealer accumulates on your finger, wipe it off before continuing.
NOTE:
By applying sealer to the repair area, corrosion can be prevented as the sealer isolates the area (especially at sash edge and between sash and sash rail) from atmosphere/moisture. Ensure that the sealer fully covers these areas.
14. Repeat Steps 11 - 13 on the vertical area of the door sash.
15. Inspect the bead quality and penetration into the door sash cavity.
16. Carefully remove the masking tape from the horizontal and vertical door sash areas.
17. Apply 3M General Purpose Adhesive Cleaner (# 08987) to a terry cloth and remove any excess urethane sealer that may have been applied to the door sash rail.
NOTE:
Do not remove any urethane sealer from the door sash cavity.
18. Shake the Mazda touch-up paint thoroughly.
19. Touch up the outer top corners of the door sash rails, and any other areas that were previously stained and cleaned.
NOTE:
Do not apply touch-up paint to the horizontal or vertical door sash areas where the urethane sealer was applied.
20. Touch-up the "opening" along the upper edge of the door sash rail (rear doors only).
21. Wait approximately 1-1/2 hours for the urethane sealer and touch-up paint to dry to the touch (ambient temperature of approximately 70 degrees F at 50% relative humidity).
NOTE:
The urethane sealer will fully dry in 24 hours.
22. Reinstall the door weather stripping.
NOTE:
A weather stripping that is not installed correctly may cause wind noise and water leaks. While the weather stripping may appear to be fully installed inside the sash rail, some areas may not be.
23. After installing the weather stripping, lift it upward to inspect for proper fit.
24. Repeat Steps 11 - 23 on other door.
Trunk Lid Rubber Stopper Inspection:
1. Open the trunk lid.
2. Grasp the trunk lid rubber stoppers and inspect the area around them for staining.
- If stains are found, proceed to, "Trunk Lid Rubber Stopper Repair".
- If stains are not found, reinstall rubber stoppers. No repair is necessary.
Trunk Lid Rubber Stopper Repair:
1. Remove the rubber stopper from the trunk lid by gently pulling it outward.
2. Lightly soak a terry cloth with isopropyl alcohol.
3. Using the terry cloth, gently rub off the stain from the affected area.
4. Clean the backside of the rubber stopper with the terry cloth.
5. Repeat Steps 1 - 4 on the other rubber stopper.
6. Reinstall both rubber stoppers and close the trunk lid.
C. AUTHORIZED MODIFICATION LABEL INSTALLATION
Complete an "Authorized Modification Label" with the SSP number written on the sticker and affix it to the vehicle's bulkhead. Refer back to the illustration under "A. VEHICLE INSPECTION PROCEDURE."