Body - Can't Open Front Doors When Unlocked
Bulletin No: 09-021/10Last Issued: 04/13/2010
Subject:
UNABLE TO OPEN FRONT DOORS IN UNLOCKED POSITION
BULLETIN NOTE
APPLICABLE MODEL(S)/VINS
2010 Mazda3 vehicles with VINS lower than JM1BL1*** **142331 (built before March 23, 2009)
DESCRIPTION
Some customers may complain that the driver's or front passenger's door will not open, even though the door is in the unlocked position. This may be caused by the door opener cable deforming, allowing the cable to bind, and causing the door lock to stick. A return spring has been established to prevent the door opener cable from binding.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
NOTE:
Depending on the severity of the cable deformation, some doors may need to be opened by using an automotive lock out tool.
2. Attempt to unlock the door by verifying the lock is in the unlock position.
3. Attempt to open the door by using the inner and outer door opener levers.
a. If door opens, go to step 8.
b. If door does not open and has keyless entry or advanced keyless, go to step 4.
c. If door does not open and does not have keyless entry or advanced keyless, go to step 5.
4. Attempt to unlock the door by pressing the lock button, then the unlock button several times on the transmitter. Verify door lock is in the unlock position then attempt to open the door using the inner and outer door opener levers.
a. If door opens, go to step 8.
b. If door does not open, go to step 5.
5. Unlock the door using an automotive lockout tool.
a. Lower the window to complete open position.
b. Pull and twist the belt molding upward and outward to unfasten from door, but do not remove from door.
c. Allow the front half of the belt molding to hang outside the door, but do not attempt to remove rear half.
CAUTION:
The belt molding will be damaged if the rear half is removed.
6. Apply tape in the area shown to protect the door body.
NOTE:
USE THE FOLLOWING STEPS TO UNLOCK / OPEN THE DOOR USING A LOCKOUT TOOL.
ALTHOUGH IT IS DIFFICULT TO SEE THROUGH THE WINDOW CHANNEL, LOCATE THE WHITE LOCK LEVER AND THEN PULL UPWARDS USING LOCKOUT TOOL (A) TO UNLOCK / OPEN DOOR.
7. Using a lockout tool between the window and the outer door skin, pull upwards on the white door lock lever to unlock and open door.
a. Using a flashlight, locate the door lock lever.
b. Position the lock out tool (A) under the lock lever (B).
c. Firmly pull upwards on the lock lever to the full upwards position, then attempt to open door.
8. Remove the inner garnish assembly from the door. Refer to MS3 online instructions or Workshop Manual section 09-17 INNER GARNISH REMOVAL/INSTALLATION.
9. Remove the door trim panel assembly from the door. Refer to M53 online instructions or Workshop Manual section 09-17 FRONT DOOR TRIM REMOVAL/INSTALLATION.
NOTE:
Some door trim fasteners may be damaged while removing the door panel. See parts information for replacement part number.
10. Inspect the door cable for kinking / cable deformation.
a. Pull the door opener lever and hold in position.
b. While holding the lever open, inspect the backside of the door lever assembly for cable deformation.
11. Referring to the inspection performed in step 10, is the cable deformed?
YES - Straighten deformed portion of cable using pliers, then go to step 12.
NO - Go to step 12.
12. Remove the front door lock actuator. Refer to MS3 online instructions or Workshop Manual section 09-14 FRONT DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION. In the following steps you will add a return spring to the door lock actuator which has a deformed cable (Driver's door or front passenger's door).
NOTE:
Only add the return spring to the door which could not be opened. EXAMPLE: If the driver's door could not be opened due to cable deformation, only perform this procedure on the driver's door.
13. Add the return spring to the door lock actuator by performing the following.
a. Remove the screws (A) from outer cover.
CAUTION:
Be careful not to damage the the end of the pad (B) where it overlaps the outer cover
b. Carefully pry the outer cover from the lock assembly.
c.
d. Insert the straight end of the spring into the lever opening and position the spring over the screw hole (A) as shown.
14. Reinstall the outer cover to the door lock actuator.
a. Align the screw hole of the outer cover to the return spring hole, then refasten the outer cover to the door lock actuator.
b. Reinstall the outer cover screws (A)
CAUTION:
Be careful not to damage the the end of the pad (B) where it overlaps the outer cover.
15. Install the front door lock actuator. Refer to MS3 online instructions or Workshop Manual section 09-14 FRONT DOOR LATCH AND LOCK ACTUATOR REMOVAL/INSTALLATION.
16. Remove the protective tape from the outer door panel if applied in step 5.
17. Confirm door lock / opener operation.
18.
19. Install the other parts in the reverse order of removal.
20. Verify repair.
PART(S) INFORMATION
WARRANTY INFORMATION
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
^ This repair will be covered under Mazda's New Vehicle Limited Warranty term.
^ Additional diagnostic time cannot be claimed for this repair.
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