Attachment II - Procedure
ATTACHMENT IIA. VEHICLE INSPECTION PROCEDURE
1. Verify that the vehicle is within the following range:
VIN Range:
Mazda6
2003 Model Year - 1YVFP****35 M00348 - M49928
2003 Model Year - 1YVHP****35 M00394 - M49862
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.
2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for an Authorized Modification Label RECALL 1203F attached to the vehicle's bulkhead. Refer to illustration.
NOTE:
Be sure to verify RECALL number as the vehicle may have multiple RECALL labels.
- If eMDCS displays RECALL 1203F OPEN and an Authorized Modification Label is not present, the RECALL has not been performed. Proceed to "B. CORRECTION PROCEDURE".
- If eMDCS displays RECALL 1203F OPEN and an Authorized Modification Label is present, contact the Warranty Department. They will update the vehicle warranty.
- If eMDCS displays RECALL 1203F CLOSED and an Authorized Modification Label is not present, proceed to "C. AUTHORIZED MODIFICATION LABEL INSTALLATION".
- If eMDCS displays RECALL 1203F CLOSED and an Authorized Modification Label is present, the RECALL has already been completed. Return the vehicle to the customer.
- If eMDCS does not display RECALL 1203F OPEN or RECALL 1203F CLOSED, this RECALL does not apply to the vehicle. Return vehicle to the customer.
B. INSPECTION PROCEDURE:
WARNING:
Please observe the following points before proceeding with the inspection/repair procedure.
^ Use tire chocks (or equivalent) to hold vehicle in place
^ Use safety goggles
^ Use fender covers to prevent brake fluid from contacting vehicle paint, which can be easily damaged.
1. Put tire chocks (or equivalent) in place to hold vehicle stationary.
2. Remove the cap and filter from the brake reservoir tank.
3. Place cap and filter on a clean shop towel.
4. Turn the IG key to ON position.
5. Release parking brake lever.
6. Confirm status of "Brake" warning light in instrument panel.
^ If the brake warning light is illuminated with the parking brake released, you must first fix any problems with the parking brake warning system (Refer to Parking Brake System, Section 04-12 of the 2003 Mazda6 Workshop Manual).
^ If the brake warning light goes off when you release the paring brake, go to Step 7.
7. Wipe SST (4900-M6-TL0) with clean shop towel.
8. Insert SST (hook side down) approx. 2" into brake reservoir tank opening through center slot (as shown).
9. Gently push the SST downward until the float bottoms out (total float travel is approx. 1"). Leave the float in the bottomed-out position.
10. Confirm status of "Brake" warning light in instrument panel.
^ If warning light is illuminated, move SST upward and ensure the float moves smoothly upward, go to Step 5 of "C. CORRECTION PROCEDURE".
^ If warning light does not illuminate and/or float does not move smoothly upward, go to Step 1 of "C. CORRECTION PROCEDURE".
C. CORRECTION PROCEDURE:
The objective of the repair is to reposition the float into the correct position. The grooves on the float must be inside the "rails" of the brake reservoir tank.
1. Insert the SST into brake reservoir tank opening through center slot until SST contacts the reservoir wall.
2. Move SST downward until it hooks onto the float.
3. Gently pull the SST (towards front of vehicle) until a "click" noise is heard. A "click" noise confirms that the float grooves" are correctly positioned on the reservoir tank rails".
4. Confirm repair by repeating Steps 9 - 10 of "B. INSPECTION PROCEDURE".
5. Check the fluid level of the reservoir tank and add if necessary.
6. Reinstall the filter and cap.
7. Clean the top of the brake reservoir tank.
8. Place a new Caution label (GJ6A-43-403) onto the top of the brake reservoir tank.
Note:
Be sure the orientation of the Caution label is placed as shown above.
D. AUTHORIZED MODIFICATION LABEL INSTALLATION
Complete an "Authorized Modification Label" with the RECALL number written on the sticker and affix it to the vehicle's bulkhead. Refer back to the illustrations under "A. VEHICLE INSPECTION".