Stains Found On Paint During PDI – 2014-2016 Mazda

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Bulletin No: 09-010/16
Last Issued: 02/17/2016



This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red beside the change bars.

Previous TSBs: Date(s) Issued:
09-009/15 02/27/15
09-004/14 01/14/14
09-011/12 03/12/12
09-036/09 07/17/09, 07/27/09 and 11/12/09
09-004/05 02/18/05 09/23/05
09-015/04 04/26/04 and 05/14/04



2014-2016 MX-5

2016 CX-3

2014-2016 CX-5

2014-2016 CX-9

2014-2016 Mazda2

2014-2016 Mazda3

2014-2015 Mazda5

2014-2016 Mazda6



Some vehicles may experience stains appearing on the hood, roof and/or trunk of the vehicle. This concern is most likely to be found in a cold weather areas just after the RAPGARD is removed at PDI. This may be caused by moisture which has been trapped and condensed between the paint and the RAPGARD. These types of stains can be removed with a heat gun or an infrared drier.

If you encounter this concern during PDI, use a heat gun or an infrared drier to apply heat to the affected area to remove the stain(s).



  1. Visually inspect the top coat surface for stains.

If stains are found, use a heat gun (for smaller stains) or an infrared drier (for larger stains) to heat the affected area and remove the stains.

  1. Insulate all plastic and rubber parts (as shown below) using heat insulation materials (C ~ F) prior to beginning the application of heat.

A – Body Panel
B – Molding
C – Aluminum foil covering all area
D – Wet towel
E – Folded aluminum foil
F – Aluminum foil tape



  • Since this repair procedure requires the use of heat from a heat gun or infrared drier, be sure to insulate all rubber or plastic parts which are easily affected by heat from near the affected stain area.
  • Use extreme care to ensure the top coat surface temperature stays below 2840F (1400C). To protect materials inside the cabin area (i.e. carpet, seats, etc.), also place insulation over the glass as necessary.



NOTE: Ensure the aluminum foil tape (F) is inserted into the edges of the molding (B) as shown below.



CAUTION: Refer to “PLASTIC PARTS HEAT RESISTING TEMPERATURE” section of the applicable Body Shop Manual before the repair. Repair and replacement of damaged plastic parts due to over-heating is not covered under warranty.


PROCEDURE FOR USING HEAT GUN (for smaller stains):

  1. Place a 1000 W (AC-100V) heat gun approx. 2 inches (5 cm) from the surface of the stain area and apply heat for only 20 seconds.
  2. Adjust heat gun approx. 4 inches (10 cm) away from the surface of the stain area and apply heat for a maximum of 20 minutes.

CAUTION: DO NOT apply heat for more than 20 minutes or damage to the body panel surface, plastic or rubber parts may occur.

  1. Verify the repair.



  1. Mount an infrared drier approx. 31.5 inches (80 cm) away from the surface of the stained area.
  2. Set the temperature of the infrared drier to 140-158 0F (60—70 0C) and apply heat for a maximum of 60 minutes.

CAUTION: DO NOT apply heat for more than 60 minutes or damage to the body panel surface, plastic or rubber parts may occur.

  1. Verify the repair.




  • 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. Please note that the “Period Covered” is for PDI only.
Warranty Type
Symptom Code 98
Damage Code
Part Number Main Cause 7777-PT-002
Operation Number / Labor Hours: XX666XR1 / 0.5 Hrs.
Period Covered: PDI ONLY




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