Electrical - Engine No Start Condition
TSB: 01-009/072003 - 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 shown.
NOTE:
2006 - 2007 Mazda6 vehicles already have a modified Fuel Pump Relay.
Main Relay Kit Installation Procedure:
3. Record customer's pre-seat radio stations.
4. Disconnect negative battery cable.
5. Disconnect air flow sensor connector
6. (3.0L Engine Only): Disconnect VAD three-way solenoid connector.
7. Remove air cleaner.
8. Remove fuse box lid.
9. Disconnect main relay from fuse box, and install an intermediate harness between fuse box and main relay.
10. Tie-wrap intermediate harness and emission harness together.
11. Tie-wrap intermediate harness and B-terminal harness together.
12. Install intermediate harness bracket at bottom of fuse box installed location.
13. Reinstall air cleaner.
14. Reconnect air flow sensor connector.
15. (3.0L Engine Only): Reconnect VAD three-way solenoid connector.
16. 2003 - 2005 Mazda6: Proceed to "Fuel Pump Relay Kit Installation Procedure" and install Fuel Pump Relay Kit.
2006 - 2007 Mazda6: Proceed to next step.
17. Reconnect negative battery cable.
18. 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.
Fuel Pump Relay Kit Installation Procedure (2003 - 2005 Mazda6 Only):
19. Secure intermediate harness bracket together with PCM installation bracket.
20. Tie-wrap intermediate harness and harness together at three locations. Make sure intermediate harness passes over main relay bracket.
21. Disconnect fuel pump relay from relay box, and connect intermediate harness to fuel pump relay connector.
22. Connect ground terminal on body panel with existing M8 screw.
23. Reconnect negative battery cable.
24. Re-enter customer's preset radio stations.
25. Verify repair.
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.
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.
5. Move to front passenger seat and repeat Steps 3 - 4 on passenger window switch.
6. Verify proper window operation using each door switch.
PARTS INFORMATION
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.
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