2004-2011 Mazda RX-8 Passenger Air Bag Inflator Concern – Safety Recall 2618F

2004-2011 RX-8 Passenger Air Bag Inflator Concern – Safety Recall 2618F

A. VEHICLE INSPECTION PROCEDURE

Verify that the vehicle is within the 2004-2005 or 2006-2011 Model/Year range: 

–If the vehicle is within the 2004-2005 Model/Year range, proceed to Repair Procedure B Page 2.  

-If the vehicle is within the 2006-2011 Model/Year range, proceed to Repair Procedure C Page 14.  

– Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Label Recall 2618F attached to the vehicle’s hood or bulkhead. Refer to eMDCS System – Warranty Vehicle Inquiry Results table below.

NOTE:  Be sure to verify Recall number as the vehicle may have multiple Recall labels.

eMDCS System – Warranty Vehicle Inquiry Results:

1. REPAIR PROCEDURE: Air Bag inflator Replacement Procedure

RX-8(FE): 2004-2005MY ONLY (Part Number: F1Z2-57-K80)

Parts Information: The service parts are available in one box.

Inflator APPS-7

Nuts(x4)

Collar C

Collar A

Stopper Plate

Felt Tape(x2)

CE Label Discard

Outline: 

1. Remove the inflator from Air Bag Module, then replace it with a modified one.

2. Return the removed inflator with the following manner and caution.

Caution: 

• Replaced Inflators must be returned. Be sure to keep the carton box which was used to deliver the new inflator. This box is a mandatory for shipping special goods like airbag related parts / inflator.
• Pack the removed inflator in this box exactly in the same manner as the new inflator was packed.

Repair Procedure B:

Warning: 

• Perform the replacement in a clean environment. Oil, grease, water, etc on components may cause the air bag modules to fail to deploy in the event of an accident, which may cause serious injury. Do not allow oil, grease, water, etc., spill or get in contact with the airbag components. * Inserting a screwdriver, etc., into the connector of an air bag module may damage the connector and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connectors.
• Do not disassemble the vehicle part other than instructed here.
• Do not make an attempt to directly supply electric power to the module and the inflator.
• Keep the module facing of the pad surface upwards anytime, except while performing replacement work.
• Do not use the module and new inflator if they happen to fall on the ground.
• Avoid exposing the module and inflator to temperatures exceeding 194 degrees Fahrenheit.

Remove the air bag module assembly.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.

3. Remove the glove compartment.

(1) Pull the stay damper in the direction shown in the figure, and detach the connecting part between the glove compartment and the stay damper.

(2) Press the stopper in and remove it.

(3) Lower the glove compartment.

(4) Detach the clips from the dashboard and remove the glove compartment.

4. Remove the Air Bag Module.

Note: The Air Bag Module cover in many vehicles may be sun damaged, however this is not covered under the recall. Be careful when handling so that any crack does not get worse.

(1) Remove the bolts

(2) Disconnect the connector

(3) Remove the Air Bag Module

Replace the Inflator:

1. Using a flathead screwdriver, pry out the connector stopper plate. Then disconnect the connector.

2. Loosen the four nuts with non-power tools until the upper surface of the nuts is aligned with the top edge of the screw thread of bolts.

3. If necessary, for easier inflator removal, depress the four nuts to make a gap between the inflator and air bag module.

Note: Do not depress exessively as the module body may be damaged.

4. Remove the nuts(X4), then move the stopper plate from the air bag module. Discard the removed four nuts and stopper plate.

5. Push the inflator end by thumbs then remove it sliding in the direction as shown.

Caution: Return the removed inflator with required information and pack it in the same carton which the replacement part was sent in. 

6. Paste the felt tape to Straight area (Orange area) the retainer. (Paste in two places)

Note: Do not extend outside the Red line (bolt side), in order to prevent tool contact when tightening the nut.

7. Fold it in half and paste it inside the retainer. Make it the same on both sides.

8. Attach the collar A and C to replacement inflator.

(Location of the collar A: The position is the 1st stage side of the  inflator.)

(Location of the collar C: The position is the 2nd stage side of the  inflator.)

9. Insert to align the side of the retainer and guide line (Black line) of replacement inflator.

Align guide line (Black line) with retainer edge.

10. Insert the inflator up to the position where it touches the stopper.

The connector direction is 15 ° from the bottom of the retainer.

11. Set the new stopper plate (A) by gently pushing until it touches with the inflator side (B).

12. Keeping the condition above, tighten the new nuts by fingers first, then to the specified torque by hand tool in the order of (1) – (2) – (3) – (4) shown in the figure. DO NOT USE ANY POWER TOOL AS YOU MAY

SHEAR THE STUDS

Tightening Nut Torque: 3.9 ± 0.4 Nm

13. Connect the wire harness connecter to the inflator at 2 locations.

14. Ensure the connectors are fitted properly.

Install the Air Bag Module:

1. Re-connect the connector, then install the Air Bag Module.

(1) Tighten the bolts.

Tightening Torque: 7.9 – 11.7 Nm

2. Install the glove box.

3. Connect the negative battery cable.

4. Turn the ignition switch to the ON position.

5. Verify that the air bag system warning light illuminates for approximately 6 seconds, and goes out.

• If the air bag system warning light does not operate, refer to the onboard diagnostic system (air bag system) and perform inspection of the system.

C. CAMPAIGN LABEL INSTALLATION

1. Fill out a blue “Campaign Label” (9999-95-065A-06) with:

CAMPAIGN NO:  2618F

DEALER CODE:  Your dealer code DATE: Today’s Date.

2. Affix it to the hood or bulkhead as shown:

3. Return the vehicle to customer.

C. REPAIR PROCEDURE: Air Bag Module Replacement Procedure

RX-8(FE): 2006-2011 MY ONLY (Part Number: FEZ8-57-K70) Parts Information: The service parts are available in one box.

Air Bag Module APPS-7

Outline: 

1. Remove the air bag module, then replace it with a modified one.

2. Return the removed inflator with the following manner and caution.

Caution: 

• Replaced Inflators must be returned. Be sure to keep the carton box which was used to deliver the new inflator. This box is a mandatory for shipping special goods like airbag related parts / inflator.
• Pack the removed inflator in this box exactly in the same manner as the new inflator was packed.

Repair Procedure C:

Warning: 

• Perform the replacement in a clean environment. Oil, grease, water, etc on components may cause the air bag modules to fail to deploy in the event of an accident, which may cause serious injury. Do not allow oil, grease, water, etc., spill or get in contact with the airbag components.
• Inserting a screwdriver, etc., into the connector of an air bag module may damage the connector and cause the air bag module to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connectors.
• Do not disassemble the vehicle part other than instructed here.
• Do not make an attempt to directly supply electric power to the module and the inflator.
• Keep the module facing of the pad surface upwards anytime, except while performing replacement work.
• Do not use the module and new inflator if they happen to fall on the ground.
• Avoid exposing the module and inflator to temperatures exceeding 194 degrees Fahrenheit.

Remove the Air Bag Module Assembly.

1. Turn the ignition switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 min or more.

3. Remove the glove compartment.

(1) Pull the stay damper in the direction shown in the figure, and detach the connecting part between the glove compartment and the stay damper.

(2) Press thePress the stopper in and remove it.

(3) Press theLower the glove compartment.

(4) Press theDetach the clips from the dashboard and remove the glove compartment.

4. Remove the Air Bag Module Assembly.

Note: The Air Bag Module cover in many vehicles may be sun damaged, however this is not covered under the recall. Be careful when handling so that any crack does not get worse.

(4)Remove the bolts

(5)Disconnect the connector

(6)Remove the Air Bag Module Assembly

Replace the air bag module:

1. Remove the nuts (X2).

(This photo is without INFLATOR)

2. Remove Plate and Air Bag Module.

3. Remove webbings from Air Bag Module.

4. Attach the both webbings to the retainer hooks of new replacement module.

5. Install the replacement module.

(1) Set the webbing below.

(2) Set the webbing on the below.

(3) Pass the retainer hook through the hole in the LID.

(4) Attach the plate to the retainer hook.

Fasten the M6 replacement Nuts in 2 locations with hand tools only. (Red circle)

Install the Air Bag Module Assembly:

1. Re-connect the connector, then install the air bag module.

(1) Tighten the bolts.

Tightening Torque: 7.9 – 11.7 Nm

2. Install the glove box.

3. Connect the negative battery cable.

4. Turn the ignition switch to the ON position.

5. Verify that the air bag system warning light illuminates for approximately 6 seconds and goes out.

• If the air bag system warning light does not operate, refer to the onboard diagnostic system (air bag system) and perform inspection of the system.

C. CAMPAIGN LABEL INSTALLATION

1. Fill out a blue “Campaign Label” (9999-95-065A-06) with:

CAMPAIGN NO:  2618F

DEALER CODE:  Your dealer code

DATE:  Today’s Date.

5. Affix it to the hood or bulkhead as shown:

6. Return the vehicle to customer.

Remedy Instructions and TSB

RCRIT-19V781-3586.pdf 1352.749KB

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Last update on 2021-09-12 / Affiliate links / Images from Amazon Product Advertising API