Recall - PCM/TCM Reprogramming for I/M Failure
01-024/052003 - 2005 MAZDA6 - MAZDA SPECIAL
PROGRAM (MSP10) - CAN COMMUNICATION
BULLETIN NOTE
This bulletin supersedes the previous bulletin issued on 09/21/05. The WARRANTY INFORMATION has been revised
APPLICABLE MODEL(S)/VINS
2003 - 2004 Mazda6 3.0L vehicles built from May 16, 2002 through August 23, 2004
2003 - 2005 Mazda6, 2.3L - Non-PZEV (Non-Partial Zero Emission Vehicle) vehicles built from May 20, 2002 through July 2, 2005
VIN Range:
^ 2.3L Engines
^ 1YV FP**C* 35 M00003 -) M56997
^ 1YV HP**C* 35 M00030 -) M54604-
^ 1YV FP**C* 45 N00001 -) N99310
^ 1YV HP**C* 45 N00004 -) N99307
^ 1YV FP**C* 55 M00014 -) M76942
^ 1YV HP**C* 55 M00024 -) M77535
^ 3.0L Engines
^ 1YV FP**D* 35 M00227 -) M57077
^ 1YV HP**D* 35 M00005 -) M55980
^ 1YV FP**D* 45 N04304 -) N99312
^ 1YV HP**D* 45 N00002 -) N99286)
DESCRIPTION
The MIL (Malfunction Indicator Light) may illuminate during OBD II check at I/M (Inspection/Maintenance) station. This will cause the vehicle to fail the I/M test, although the vehicle itself has no problem.
Customers having this concern should have their vehicle repaired using the following repair procedure.
NOTE:
^ UNDER THE MAZDA SPECIAL PROGRAM (MSP10), ALL CURRENT DEALER
INVENTORY AND RETAILED VEHICLES FOUND TO BE WITHIN THE ABOVE VIN
AND PRODUCTION RANGES, MUST BE INSPECTED AND REPAIRED ACCORDING TO
THE INSTRUCTIONS CONTAINED IN THIS SERVICE BULLETIN.
^ BEFORE PERFORMING ANY REPAIR, VALIDATE THAT THE VEHICLE IS APPLICABLE TO THIS PROGRAM BY PERFORMING AN "eMDCS WARRANTY VEHICLE INQUIRY" AND VERIFYING THE VEHICLE DISPLAYS CAMPAIGN "MSP10". SEE "VEHICLE
INSPECTION PROCEDURE" BELOW.
DEALER INVENTORY:
Inspect and repair all current dealer inventory according to the procedures contained in this service
bulletin.
RETAIL VEHICLES:
When a retail vehicle is brought into the dealer for any type of repair or scheduled maintenance, inspect and repair the vehicle according to the procedures contained in this service bulletin.
VEHICLE INSPECTION PROCEDURE
1. Verify the vehicle is within one of the following VIN and production ranges:
2003 - 2004 Mazda6 3.0L vehicles built from May 16, 2002 through August 23, 2004
2003 - 2005 Mazda6, 2.3L - Non-PZEV (Non-Partial Zero Emission Vehicle) vehicles built from May 20, 2002 through July 2, 2005
VIN Range:
^ 2.3L Engines
^ 1YV FP**C* 35 M00003 -) M56997
^ 1YV HP**C* 35 M00030 -) M54604
^ 1YV FP**C* 45 N00001 -) N99310
^ 1YV HP**C* 45 N00004 -) N99307
^ 1YV FP**C* 55 M00014 -) M76942
^ 1YV HP**C* 55 M00024 -) M77535
^ 3.0L Engines
^ 1YV FP**D* 35 M00227 -) M57077
^ 1YV HP**D* 35 M00005 -) M55980
^ 1YV FP**D* 45 N04304 -) N99312
^ 1YV HP**D* 45 N00002 -) N99286
^ If the vehicle is within one of the above VIN and production ranges, proceed to Step 2.
^ If the vehicle is not within one of the above VIN and production ranges, return the vehicle to the customer or inventory.
2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect the vehicle for a Campaign Label MSP10 attached to the vehicle's bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table below.
NOTE:
Verify the campaign number as the vehicle may have multiple labels.
eMDCS System - Warranty Vehicle Inquiry Results
REPAIR PROCEDURE
PCM / TCM CALIBRATION LEVEL INSPECTION PROCEDURE
Using WDS version B39.3 or later software, proceed to "Module Reprogramming" and check the PCM and TCM calibration levels.
^ If WDS indicates the PCM and TCM are already at the latest calibration level (refer to "Calibration Information" table), proceed to Step 5 under "PCM/TCM PROGRAMMING" and complete an "Authorized Modifications" label. This label will inform technicians of the PCM/TCM calibration change if future repairs are necessary.
^ If WDS indicates that a later calibration is available in either PCM or TCM, proceed to "PCM/TCM PROGRAMMING" below.
PCM / TCM REPROGRAMMING
1. Reboot the WDS PTU to clear memory before reprogramming.
2. Using WDS B39.3 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure.
NOTE:
^ Always update the WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If the PTU is not updated to the latest WDS calibration level, the calibration file will
not install into the PTU.
^ It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the
WDS reprogramming procedure.
^ WDS shows the calibration part numbers after programming the PCM.
^ Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns.
^ When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
^ When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU. Also the external battery power supply cable should be connected to the vehicle battery and the
PTU.
3. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
NOTE:
^ If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.
^ After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).
4. Perform the TCM reprogramming procedure and reprogram the TCM to the latest available calibration (refer to the "Calibration Information" table). Verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
5. Fill out an "Authorized Modifications" label (P/N 9999-95-AMDC-97) with the new PCM/TCM calibration information, your dealer code, and today's date (example below).
6. Place the "Authorized Modifications" label on the "A" pillar below the tear tag in the driver door jamb.
7. Fill out a blue "Campaign Label" (9999-95-065A-05) with Campaign No: "MSP10", your dealer code, today's date (example below), and affix it to the vehicle's bulkhead.
8. Return the vehicle to the customer.
CALIBRATION INFORMATION
2.3L PCM
3.0L PCM
3.0L TCM
NOTE:
The PCM and TCM Calibration Part Numbers listed above are provided for PCM and TCM reprogramming purposes only. These are not necessarily the same Mazda part numbers used to order an actual PCM or TCM through the Mazda Parts System. It is not necessary to order a PCM or TCM as part of this repair procedure.
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.