NHTSA

15V382

SUMMARY:

Mazda North American Operations (Mazda) is recalling certain model year 2003-2008 Mazda6 vehicles manufactured May 29, 2002, to May 5, 2008, 2004-2008 RX-8 vehicles manufactured April 10, 2003, to February 18, 2008, and 2006-2007 Mazdaspeed6 vehicles manufactured August 4, 2005, to June 29, 2007.

The affected vehicles are equipped with a dual-stage driver frontal air bag that may be susceptible to moisture intrusion and other factors, including manufacturing variability that, over time, could cause the inflator to rupture.

CONSEQUENCE:

In the event of a crash necessitating deployment of the driver’s frontal air bag, the inflator could rupture with metal fragments striking the driver or other occupants resulting in serious injury or death.

REMEDY:

Mazda will notify owners, and dealers will replace the driver’s frontal air bag inflator, free of charge.

The recall began on November 20, 2015.

Owners may contact Mazda customer service at 1-800-222-5500. Mazda’s number for this recall is 8215F.

Note: This recall supersedes 15V345.

Owners who had their vehicle’s interim repair completed under recall 15V-345 still need to have their vehicles remedied again under this recall.

NOTES:

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

Check if your Mazda Has a Recall

 

TO: All Mazda Dealership General Managers, Service Managers, and Parts Managers

DATE: November 2015

SUBJECT: Driver Air Bag Inflator Final Repair – Safety Recall 8215F

 

Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists in 2003-2008 Mazda6, 2004-2008 RX-8, and 2006-2007 Mazdaspeed6 vehicles.

 

In the subject vehicles, continued exposure to high levels of absolute humidity may cause the front air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the driver side frontal air bag. An inflator rupture could result in metal fragments striking and potentially seriously injuring vehicle occupants.

 

Safety Recall 8215F supersedes Safety Recall 7914J.  Recall 7914J has been replaced by Safety Recall 8215F.  The 7914J replacement driver air bag inflators were interim replacement parts; therefore, all vehicles that had Recall 7914J performed will still need to have Recall 8215F completed.  Recall 8215F requires installation of a permanent remedy driver air bag inflator.

Note: Some vehicles in 8215F are also included in Safety Recall 8114L, which requires passenger air bag inflator replacement.

 

Due to the current limited supply of permanent remedy inflators, the subject owners will be notified of 8215F parts availability in phases:

Phase	Mailing to:	Approx. mailing date
Phase 1	Owners of subject vehicles registered in high absolute humidity (HAH) states of Florida, Hawaii, Texas, Alabama, Mississippi, Georgia and Louisiana that did not complete the interim repair under recall 7914J.	November 20, 2015
Phase 2	Owners of 2003-2004 model year subject vehicles in non-HAH states that did not complete the interim repair under recall 7914J.	January 2016
Phase 3	Owners of 2005-2008 model year subject vehicles in non-HAH states that did not complete the interim repair under recall 7914J.	1st quarter 2016
Phase 4	Owners of subject vehicles that already received the interim repair under recall 7914J.	1st  quarter 2016

 

Dealers are to replace the driver air bag inflators of subject vehicles with a new, permanent remedy inflator. The original inflator must be returned to the manufacturer according to the instructions in Attachment IV.

 

This package contains important information about Safety Recall 8215F:

Attachment I	Dealer Service and Parts Information
Attachment II	Repair procedure
Attachment III	Owner notification letter
Attachment IV	Air Bag Inflator Return Instructions

 

Important Safety Notice: The National Traffic and Motor Vehicle Safety Act prohibits the delivery of any subject vehicle without performing the necessary repair for defects or failures. Failure to perform applicable recalls before delivery can result in extensive dealer fines and penalties from the Federal Government. Therefore, you must complete this recall for all affected vehicles in your inventory prior to delivery.

 

To help you effectively perform this recall, Mazda has developed the following resources:

 

1. The attached service information, repair procedure, parts information, and air bag inflator return instructions are available on eMDCS and MS3 (Mazda Service Support System) websites via MXConnect.
2. For technical assistance, contact the Technical Assistance Hotline at (888) 832-8477, Option 3.
3. For parts questions, contact the Corporate Dealer Assistance Group at (877) 727-6626, Option 2.
4. For warranty questions, contact the Warranty Hotline at (877) 727-6626, Option 3.
5. We recommend using the special Recall Reminder Report #JS30R***-1 and Recall Reminder Labels available in Web Reporting to encourage customers who received a notice of parts availability to come in for the recall (with recall reminder postcards). Dealers may use such owner information for the sole purpose of conducting and performing this recall, and for no other purpose. Using it for marketing activities is strictly prohibited and could subject your dealership to serious fines. The information in the report is protected by state privacy and other applicable laws regarding disclosure of personal and/or confidential, restricted or blocked information. It is the dealer’s responsibility to protect the confidentiality of owner records and prevent the release of information to other parties.

 

Please make certain the appropriate personnel in your dealership are aware of these resources and are familiar with the details of this recall before responding to customer inquiries. We apologize for any inconvenience this recall may cause you and your customers. Your understanding and support in carrying out this campaign is greatly appreciated.

 

Sincerely,

 

Satoshi Takahashi
Director, Technical Services Division
Mazda North American Operations

 

 

CONDITION OF CONCERN

In certain vehicles with continued exposure to high levels of humidity over long periods, the driver air bag inflator could produce excessive internal pressure in the event of a crash where the front air bag is designed to deploy. The excessive internal pressure may cause the inflator housing to rupture with metal fragments, which may increase the risk of injury to the vehicle occupants.

 

Dealers are to replace the driver side frontal air bag inflator with a new and permanent remedy inflator.  Parts for 8215F are ordered to repair a specific VIN. Therefore these parts are nonreturnable.

 

Note: Some vehicles in this recall are also included in Safety Recall 8114L, which applies to passenger air bag inflator replacement.

 

MANDATORY AIR BAG INFLATOR RETURN

Upon receiving the replacement air bag inflator, the original air bag inflator should be returned the same day the repair is performed. Do not wait for Warranty Claim Entry or Warranty Parts Requests. Failure to return the original inflator will result in a Warranty Claim Debit. Detailed air bag inflator return instructions are provided in Attachment IV.

 

SUBJECT VEHICLES

Model	VIN Range
2004-2008 RX-8	All
2003-2008 Mazda6	All
2006-2007 Mazdaspeed6	All

 

OWNER NOTIFICATION

Due to the current limited supply of permanent remedy inflators, the subject owners will be notified of 8215F parts availability in phases:

Phase	Mailing to:	Approx. mailing date
Phase 1	Owners of subject vehicles registered in high absolute humidity (HAH) states of Florida, Hawaii, Texas, Alabama, Mississippi, Georgia and Louisiana that did not complete the interim repair under recall 7914J.	November 20, 2015
Phase 2	Owners of 2003-2004 model year subject vehicles in non-HAH states that did not complete the interim repair under recall 7914J.	January 2016
Phase 3	Owners of 2005-2008 model year subject vehicles in non-HAH states that did not complete the interim repair under recall 7914J.	1st quarter 2016
Phase 4	Owners of subject vehicles that already received the interim repair under recall 7914J.	1st  quarter 2016

 

PARTS INFORMATION

Parts for 8215F are ordered to repair a specific VIN. Therefore these parts are non-returnable.

Description	Part Number	Quantity	Notes
Driver Side Front Air Bag Inflator	F1Y2-57-K80	1	RX-8
	GPYA-57-K80	1	Mazda6, Mazdaspeed6
Campaign Label	9999-95-065A-06	1=50 labels	Obtain in Mazda e-Store (no charge)

 

PARTS ORDERING

Parts orders for 8215F must be placed on the web page in MXConnect. A complete VIN is needed to process the order. For each VIN order request, the appropriate parts will be automatically selected and ordered based on the VIN.  Please use VIN inquiry on eMDCS to confirm the vehicle is involved in the recall and in OPEN status for recall 8215F.

 

WARRANTY CLAIM PROCESSING INFORMATION

	Replacement of Driver Side Front Air Bag Inflator
Process Number	AF037A
Symptom Code	99
Damage Code	99
Causal Part Number	F1Y2-57-K80 GPYA-57-K80
Quantity	1
Labor Operation Number	XXL83ARX
Labor Hours	0.3 H

 

RENTAL CAR INFORMATION

Mazda will authorize rental and service loaner vehicles on a limited basis. We are requesting dealer understanding and partnership regarding rental and loaner vehicle utilization. Please make every effort to utilize alternative transportation solutions in place of rental use. Rental is covered if customer has no alternative means of transportation.

 

Rental Car Warranty Claim Information

Please submit rentals on a separate claim problem number as follows: 

	Rental Agency Vehicle	Dealer Loaner Car Fleet Vehicle
Warranty Type Code	A	A
Symptom Code	99	99
Damage Code	99	99
Part Number Main Cause	5555-82-15FR	5555-82-15FL
Part Quantity	0	Number of days loaner car was used Mazda pays $35.00/day
Labor Operation Code	MM024XRX	MM024XRX
Labor Hours	0.0	0.0
Sublet – Rental Car
Sublet Invoice Number	Number from Rental Invoice or Dealer Purchase Order
Sublet Type Code	Enter “Z9” (other)
Sublet Amount	Up to $30.00 per day for the number of days customer had rental car
Sublet Text	Number of days rental car was supplied to customer

 

Rental expenses exceeding the two-day limit will require prior DSM Authorization, as outlined in the Mazda Rental Car Reimbursement Program policy.

 

VERIFY THE VEHICLE NEEDS THE RECALL

Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect the vehicle for an Authorized Campaign Label RECALL 8215F attached to the vehicle’s hood or bulkhead.

eMDCS System – Warranty Vehicle Inquiry Results:

If eMDCS displays:	Campaign Label is:	Action to perform:
RECALL 8215F OPEN	Present	Contact the Warranty Hotline at (877) 727- 6626, option 3, to update vehicle history.
	Not present	Proceed to “REPAIR PROCEDURE”.
RECALL 8215F PRELIM LTR	Present	Contact the Warranty Hotline at (877) 727- 6626, option 3, to update vehicle history.
	Not present	Customer has not received the “parts available” letter
RECALL 8215F CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Complete a label and apply to vehicle’s hood or bulkhead.
RECALL 8215F is not displayed	Does not apply	Recall does not apply to this vehicle. Return vehicle to customer.

 

REPAIR PROCEDURE

Please refer to Attachment II.

 

ATTACHMENT II 2003-08 MAZDA6, 2006-07 MAZDASPEED6, 2004-08 RX-8 – DRIVER AIR BAG INFLATOR FINAL REPAIR – SAFETY RECALL 8215F                                                                         

 

A. VEHICLE INSPECTION PROCEDURE

1. Verify that the vehicle is within the following ranges:

Model	VIN Range
2003-2008 Mazda6	All
2006-2007 Mazdaspeed6	All
2004-2008 RX-8	All

 

• If the vehicle is within the above ranges, proceed to Step 2.
• If the vehicle is not within the above ranges, return vehicle to the customer or inventory.

2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Labels Recall 8215F 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:

If eMDCS displays:	Campaign Label is:	Action to perform:
RECALL 8215F OPEN	Present	Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
	Not present	Proceed to “B. REPAIR PROCEDURE”.
RECALL 8215F PRELIM LTR	Present	Contact the Warranty Hotline at (877) 727-6626 option 3 to update vehicle history.
	Not present	Customer has not received the “parts available” letter.
RECALL 8215F CLOSED	Present	Return vehicle to inventory or customer.
	Not present	Complete a label and apply to vehicle’s hood or bulkhead.
RECALL 8215F is not displayed	Does not apply	Recall does not apply to this vehicle. Return vehicle to customer.

 

B. REPAIR PROCEDURE

2003-2008 Mazda6, 2006-2007 Mazdaspeed6:

Driver-Side Air Bag Inflator Replacement Procedure:

Parts Information: The service parts are available in one box [Inflator (A), Diffuser (B) and 4 Nuts (C)].

 

Outline:

1. Remove the inflator (A) from the air bag module.

2. Install a diffuser (A) to the module, then install a modified inflator (B).

3. Pack and return the removed inflator as follows:

IMPORTANT: Be sure to follow the packing and shipping instructions provided in the carton and in Attachment IV, Air Bag Inflator Return Instructions.

CAUTION:

• All the removed Inflators must be returned to a designated location. Be sure to keep the carton box which was used to deliver the new inflator, and use it for the part returning. This authorized box must be mandatory used for shipping special goods like airbag inflator.
• Pack the old inflator in the box exactly in the same manner as the new inflator was packed.

 

Air Bag Module Removal:

WARNING:

• Perform the replacement in a clean environmental. Oil, grease, water, etc. on components may cause the air bag modules to fail to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., to spill or make 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 electrical power to the module and the inflator.
• Keep the module facing of the pad surface upwards at all times, except during replacement.
• Do not use the module and new inflator if they were dropped on the ground.
• Avoid module and inflator exposure to temperatures of 194 degrees F (90 degrees C) or more.

1. Turn the ignition switch to the LOCK position.
2. Record the customer’s preset radio stations.
3. Disconnect the negative battery cable and wait for one (1) minute or more.
4. Remove the driver-side air bag module.
   1. Remove the covers (A).
   2. Remove the bolts (B).
   3. Disconnect the connectors (C). Using a flathead screwdriver, pry out the connector’s stopper plate.

CAUTION:

• Be careful when prying out the stopper plate (A). Otherwise, damage to the stopper plate could occur. Or if it pops off and is lost, it is not available as a separate part.
• The stopper plate must be pryed up before disconnecting the connector. Otherwise, the connector could be damaged if trying to disconnect it with the stopper plate engaged.
• Use extreme care when disconnecting the connector. Otherwise, damage to the connector could occur.

4. Remove the air bag module.

 

Inflator Replacement:

1. Set the airbag face down onto a surface that will not scratch or damage the airbag face.
2. Remove the 4 nuts, then remove the inflator (A) from the air bag body. Discard the original nuts.

NOTE: DO NOT use an impact wrench.

CAUTION:

• DO NOT touch the bolts or the cloth.
• DO NOT drop nuts or foreign materials in the air bag body.

3. Install the diffuser (A) to the module (B) aligning the notch of the diffuser with the hole of the module (C).

CAUTION: Verify that the notch of the diffuser is engaged in the hole of the module for sure. If the diffuser is not installed in the correct position, the air bag will not develop sufficient deployment performance.

4. Peel off the dust-proof seal and confirm the two terminals of red (R) and yellow (Y) layouts correctly as shown.

5. Tighten the new nuts (with self-lock) finger tight first, then to the specified torque in the order shown.

Tightening Torque: 34 – 112 in-lbf. {3.9 +/- 3.5 Nm}

 

Air Bag Module Reinstallation:

1. Install the driver-side air bag module.
   1. Re-connect the connectors (A) to air bag module, securely locking the connectors by depressing the stoppers on the connector back.

2. Install the air bag module (B).
3. Install the bolts (C).

Tightening Torque: 78 – 112 in-lbf. {8.9 – 12.7 Nm}

4. Install the covers (D).

2. Reconnect the negative battery cable.
3. Turn the ignition switch to the ON position.
4. Verify that the air bag system warning light illuminates for approx. 6 sec., then goes out.

NOTE:   If the air bag system warning light does not operate in the manner described above, there is a malfunction in the system. Inspect the system following the on-board diagnostic system procedure according to MS3 online or the Workshop Manual (section 08 Restraints).

5. Re-enter the customer’s preset radio stations.
6. Proceed to “C. CAMPAIGN LABEL INSTALLATION”.

 

2004-2008 RX-8:

Driver-Side Air Bag Inflator Replacement Procedure:

Parts Information: The service parts are available in one box [Inflator (A) and 4 Nuts (B)].

 

Outline:

1. Remove the inflator (A) from the air bag module.

2. Pack and return the removed inflator as follows:

 

IMPORTANT: Be sure to follow the packing and shipping instructions provided in the carton and in Attachment IV, Air Bag Inflator Return Instructions.

CAUTION:

• All the removed Inflators must be returned to a designated location. Be sure to keep the carton box which was used to deliver the new inflator, and use it for the part returning. This authorized box must be mandatory used for shipping special goods like airbag inflator.
• Pack the old inflator in the box exactly in the same manner as the new inflator was packed.

 

Air Bag Module Removal:

WARNING:

• Perform the replacement in a clean environmental. Oil, grease, water, etc. on components may cause the air bag modules to fail to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., to spill or make 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 electrical power to the module and the inflator.
• Keep the module facing of the pad surface upwards at all times, except during replacement.
• Do not use the module and new inflator if they were dropped on the ground.
• Avoid module and inflator exposure to temperatures of 194 degrees F (90 degrees C) or more.

1. Turn the ignition switch to the LOCK position.
2. Record the customer’s preset radio stations.
3. Disconnect the negative battery cable and wait for one (1) minute or more.
4. Remove the driver-side air bag module.
   1. Remove the covers (A).
   2. Remove the bolts (B).
   3. Disconnect the connectors (C). Using a flathead screwdriver, pry out the connector’s stopper plate.

CAUTION:

• Be careful when prying out the stopper plate (A). Otherwise, damage to the stopper plate could occur. Or if it pops off and is lost, it is not available as a separate part.
• The stopper plate must be pryed up before disconnecting the connector. Otherwise, the connector could be damaged if trying to disconnect it with the stopper plate engaged.
• Use extreme care when disconnecting the connector. Otherwise, damage to the connector could occur.

4. Remove the air bag module.

 

Inflator Replacement:

1. Set the airbag face down onto a surface that will not scratch or damage the airbag face.
2. Remove the 4 nuts, then remove the inflator (A) from the air bag body. Discard the original nuts.

NOTE: DO NOT use an impact wrench.

CAUTION:

• DO NOT touch the bolts or the cloth.
• DO NOT drop nuts or foreign materials in the air bag body.

3. Peel off the dust-proof seal and confirm the two terminals of red (R) and yellow (Y) layouts correctly as shown.

4. Tighten the new nuts (with self-lock) finger tight first, then to the specified torque in the order shown.

Tightening Torque: 34 – 112 in-lbf. {3.9 +/- 3.5 Nm}

 

Air Bag Module Reinstallation:

1. Install the driver-side air bag module.
   1. Re-connect the connectors (A) to air bag module, securely locking the connectors by depressing the stoppers on the connector back.

2. Install the air bag module (B).
3. Install the bolts (C).

Tightening Torque: 78 – 112 in-lbf. {8.9 – 12.7 Nm}

4. Install the covers (D).

2. Reconnect the negative battery cable.
3. Turn the ignition switch to the ON position.
4. Verify that the air bag system warning light illuminates for approx. 6 sec., then goes out.

NOTE:   If the air bag system warning light does not operate in the manner described above, there is a malfunction in the system. Inspect the system following the on-board diagnostic system procedure according to MS3 online or the Workshop Manual (section 08 Restraints).

5. Re-enter the customer’s preset radio stations.
6. Proceed to “C. CAMPAIGN LABEL INSTALLATION”.

 

C.  CAMPAIGN LABEL INSTALLATION

1. Fill out a blue “Campaign Label” (9999-95-065A-06) with Campaign No: “8215F”, your dealer code, today’s date.

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

3. Return the vehicle to customer.

 

IMPORTANT SAFETY RECALL

 

Driver Air Bag Inflator Final Repair – Safety Recall 8215F
NHTSA Campaign No. 15V-382

 

November 2015

 

This notice applies to your vehicle, VIN _______________

 

Dear Mazda Owner:

 

This notice is sent to you in accordance with the National Traffic and Motor Vehicle Safety Act.

 

Mazda Motor Corporation has decided that a defect which relates to motor vehicle safety exists  in 2004-2008 RX-8, 2003-2008 Mazda6, and 2006-2007 Mazdaspeed6 vehicles.

 

If you are a recipient of this notice, your vehicle is included in this Safety Recall. 

 

What is the problem? 

In the subject vehicles, continued exposure to high levels of absolute humidity may cause the driver’s front air bag inflator housing to rupture and deploy abnormally in the event of a crash necessitating deployment of the driver’s side frontal air bag. An inflator rupture could result in metal fragments striking the driver or other vehicle occupants, resulting in serious injury or death.

 

You may have had an interim air bag inflator installed under Safety Recall 7914J. However, you  still need to have the final repair completed and the permanent remedy inflator installed.

 

What will Mazda do?

Your Mazda dealer will replace the driver air bag inflator with the permanent remedy air bag  inflator, free of charge. The repair should take less than one hour to complete; however, it may  take longer depending on the service workload at your Mazda dealership.

 

What should you do?

Even if you already had the interim replacement part previously installed under Safety Recall 7914J, please make an appointment with an authorized Mazda dealer to have the permanent remedy repair completed. Making an appointment provides the dealer the opportunity to reserve  the necessary part for your repair and plan their service activity, thus minimizing your wait time and inconvenience. You do not need to bring this notice to the dealer, but it may assist in the check-in process.

 

Where is the closest Mazda dealer?

To locate your nearest Mazda dealer, visit our web site and try our “Locate a Dealer” feature at  www.MazdaUSA.com or consult your local yellow pages.

 

Moved or no longer own this vehicle?

If you have moved or no longer own your Mazda vehicle, please complete the enclosed prepaid Information Change Card as soon as possible. This enables us to update our records and notify  the current owner.

 

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this  notice to the lessee within ten days.

 

Still have questions?

If you have any questions regarding this campaign, please contact our Customer Experience  Center at (800) 222-5500, option #6.

 

If Mazda or its dealers do not repair the defect free of charge and within a reasonable amount of time, you may notify the Administrator of the National Highway Traffic Safety Administration, 1200 New Jersey Ave., SE., Washington, DC 20590; or call the toll-free Vehicle Safety Hotline at 1-888 327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov.

 

Your safety is our first priority at Mazda. Please accept our apology for any inconvenience this  recall may have caused you.

 

Sincerely,

 

Mazda North American Operations