RECALL No: 2204H |
DATE: 08/2004 |
MODEL: Mazda MPV |
YEAR: 2002-2003 |
AFFECTED VINs: JM3 LW28** ** 300020 - JM3 LW28** ** 378984 |
MFG.DATE: November 26, 2001 - August 8, 2003 |
SUBJECT: PCV Hose Emission Recall |
Summary:On some 2002-2003 MPV vehicles, the Positive Crankcase Ventilation (PCV) hose may fail, causing rough idling and/or the Malfunction Indicator Lamp (MIL) to illuminate. If this failure occurs, the vehicle may not pass applicable emissions standards. Mazda has decided to conduct an Emission Recall Campaign to replace the PCV hose with a modified hose. |
Letter To Dealers:
August 2004
2002-2003 MPV
PCV Hose Emission Recall
[Recall #2204H]
To: |
Mazda Dealership General Managers, Service Managers, and
Parts Managers |
Subject: |
2002-2003 MPV PCV Hose Emission Recall 2204H |
Dear Mazda Dealer:
Mazda Motor Corporation has decided certain 2002-2003 model year Mazda MPV
vehicles produced from November 26, 2001 through August 8, 2003 may fail to
conform to federal emissions standards.
On some 2002-2003 MPV vehicles, the Positive Crankcase Ventilation (PCV) hose
may fail, causing rough idling and/or the Malfunction Indicator Lamp (MIL) to
illuminate. If this failure occurs, the vehicle may not pass applicable
emissions standards.
Mazda has decided to conduct an Emission Recall Campaign to replace the PCV
hose with a modified hose.
Owners of affected vehicles will be notified by first class mail beginning
August 30, 2004. This Recall will be included with the mailing of SSP 60.
This package contains important information about recall campaign 2204H:
Attachment I |
Dealer Service and Parts information |
Attachment II |
Inspection and Repair procedures |
Attachment III |
Owner notification letter |
Important notice: California Department of Motor Vehicles, Vermont
Department of Motor Vehicles, and the Commonwealth of Massachusetts, in
conjunction with the California Air Resources Board and the Environmental
Protection Agency for the State of Massachusetts and Vermont, have implemented
the Registration Renewal/Recall Tie-In Program, which requires the completion of
Emission Recalls prior to registration renewal. Mazda dealers must provide a
Vehicle Emission Recall – Proof of Correction Certificate upon completion of
the recall. Instruct owners to keep the certificate until needed for
registration renewal.
Failure to perform applicable recalls before sale can result in extensive
dealer fines and penalties from the Federal Government. Therefore, you must
complete this recall for all affected new vehicles in your inventory prior to
sale or lease.
To help you effectively perform this emission recall, Mazda has developed the
following resources:
- Service and Parts recall instructions follow (Attachment I), were
e-mailed to your Service Department, and are also available on the ESI
website.
- Inspection and repair procedures follow (Attachment II), were e-mailed
to your Service Department, and are also available on the ESI website.
- We recommend using the enclosed report of registered owners in the
dealer’s area to encourage customers to come in for the recall (with recall
reminder postcards, for example). Dealers may use such owner information for
the sole purpose of conducting and performing this emission 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 this 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.
In California, privacy laws prevent the release of names and addresses on
this report.
- For technical assistance, call the Technical Assistance Hotline at (888)
832-8477.
- For warranty questions, contact the Corporate Dealer Assistance Group at
(877) 727-6626.
Please make certain that 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 that this recall may cause you and your
customers. Please keep in mind that owners of 2001 and newer models are eligible
to receive a rental car at no charge. Your understanding and support in carrying
out this campaign is greatly appreciated.
Sincerely,
Michael J. Giblin
Director, Technical Services
Mazda North American Operations
|
ATTACHMENT I – DEALER INFORMATION
CONDITION OF CONCERN
On some 2002-2003 MPV vehicles, the Positive Crankcase Ventilation (PCV) hose
may fail, causing rough idling and/or the Malfunction Indicator Lamp (MIL) to
illuminate. If this failure occurs, the vehicle may not pass applicable
emissions standards.
SUBJECT VEHICLES
Model |
VIN Range |
Build Date Range |
2002-2003 MPV |
JM3LW28** ** 300020 – JM3LW28** ** 378984 |
November 26, 2001 through August 8, 2003 |
OWNER NOTIFICATION
Mazda will notify U.S. owners by first class mail beginning August 30, 2004.
PARTS INFORMATION
Description |
Part Number |
Quantity |
|
PCV Hose |
AJ51-13-89YA |
1 |
|
Campaign Label |
9999-95-065A-00 |
1 = sheet of 18 labels |
MStore
(no charge) |
Vehicle Emission Recall – Proof of Correction Certificate* |
9999-95-ERPC-99 |
1 = 50 certificates |
* Important notice: California Department of Motor Vehicles, Vermont
Department of Motor Vehicles, and the Commonwealth of Massachusetts, in
conjunction with the California Air Resources Board and the Environmental
Protection Agency for the State of Massachusetts and Vermont, have implemented
the Registration Renewal/Recall Tie-In Program, which requires the completion of
Emission Recalls prior to registration renewal. Mazda dealers will provide
customers with a Vehicle Emission Recall - Proof of Correction Certificate
upon completion of the recall.
PARTS ORDERING
Order PCV hoses through the normal parts ordering method (eMDCS). Use MStore
to order additional Campaign labels (1=sheet of 18 labels) and Vehicle Emission
Recall – Proof of Correction certificates (1=50 certificates).
PARTS PRICING
As of August 27, 2004, Mazda has revised the price of MPV PCV hose,
AJ51-13-89YA from $35.16 to $21.22. For dealers with parts in inventory,
we will automatically credit the difference of $13.94 on your September
parts statement. Dealer inventory quantities will be calculated by
taking all part purchases of AJ51-13-89YA through 8/26/04, less warranty
claims paid through 8/26/2004. Dealers will be able to view the
associated credit memo along with all other credit memos via web
reporting. If you have any discrepancies with your credits or have any
questions, please send an email to the Corporate Dealer Assistance Group
at: corpdag@mazdausa.com. We
apologize for any inconvenience this may cause, and we thank you for
your support. |
WARRANTY CLAIM PROCESSING INFORMATION
|
PCV Hose Inspection |
OR |
PCV Hose Replacement |
Warranty Type Code |
R |
R |
Symptom Code |
99 |
99 |
Damage Code |
99 |
99 |
Process Number |
A4452J |
A4452H |
Part Number Main Cause |
AJ51-13-89YA |
AJ51-13-89YA |
Quantity |
0 |
1 |
Labor Operation Code |
XX732XR1 |
XX732XRX |
Labor Hours |
0.4 hrs. |
0.4 hrs. |
RENTAL CAR
A rental car may be provided to the customer if eligible based on the terms
and conditions of the Rental Car Reimbursement Program, policy 12.0. Rental car
reimbursements are available only on 2001 and newer vehicles within the mileage
and time limitations under the New Vehicle Limited Warranty. If the customer was
placed in a rental car while the campaign was being completed, submit a separate
claim/problem using the standard rental claim information.
Warranty Type Code |
A |
Symptom Code |
99 |
Damage Code |
99 |
Part Number Main Cause |
5555-RE-NTAL |
Quantity |
0 |
Labor Operation Code |
MM012XRX |
Labor Hours |
0.0 |
Sublet – Rental Car |
|
Sublet Invoice Number |
Number from Rental Invoice or Dealer Purchase Order |
Sublet Type Code |
Enter “L” |
Sublet Amount |
Up to $26.00 per day for the number of days customer
had rental car |
Rental expenses that exceed the two-day limit will require prior DCSM
Authorization, as outlined in the Rental Car Reimbursement Program policy.
VERIFY THE VEHICLE NEEDS THE RECALL
- Verify the vehicle is within the following ranges:
Model |
VIN Range |
Build Date Range |
2002-2003 MPV |
JM3 LW28** ** 300020 – JM3 LW28** ** 378984 |
November 26, 2001 through August 8, 2003 |
If the vehicle is within the above ranges, go to step 2.
If vehicle is not within the above ranges, return it to inventory or the
customer.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect
vehicle for Campaign Label RECALL 2204H attached to the vehicle’s hood or
bulkhead.
eMDCS System - Vehicle Status Inquiry Results
If eMDCS displays: |
Campaign Label is: |
Action to perform: |
RECALL 2204H OPEN |
Present |
Contact the Mazda Corporate Dealer Assistance Group at (877)
727-6626 to update vehicle history |
Not present |
Proceed to “REPAIR PROCEDURE” |
RECALL 2204H CLOSED |
Present |
Return vehicle to inventory or customer |
Not present |
Complete a label and apply to vehicle's hood or bulkhead |
RECALL 2204H is not displayed |
Does not apply |
Recall does not apply to this vehicle. Return vehicle to
inventory or customer |
Note: Verify the recall number as the vehicle may have multiple
labels.
REPAIR PROCEDURES
Please refer to Attachment II.
|
ATTACHMENT II - INSPECTION AND REPAIR PROCEDURES
A. VEHICLE INSPECTION PROCEDURE
- Verify that the vehicle is within the following range:
- 2002 - 2003 MPV vehicles built from November 26, 2001 through August
8, 2003
VIN Range: JM3LW28**2*300020 - JM3LW28**3*378984
- If the vehicle is within the above range, proceed to Step 2.
- If the vehicle is not within the above range, return the vehicle
to the customer or inventory.
- Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect
vehicle for an Authorized Modification Label Recall 2204H attached to
the vehicle’s hood. 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 - Vehicle Status Inquiry Results
If eMDCS displays: |
Campaign Label is: |
Action to perform: |
RECALL 2204H OPEN |
Present |
Contact the Mazda Corporate Dealer Assistance Group at (877)
727-6626 to update vehicle history |
Not present |
Proceed to “REPAIR PROCEDURE” |
RECALL 2204H CLOSED |
Present |
Return vehicle to inventory or customer |
Not present |
Complete a label and apply to vehicle's hood or bulkhead |
RECALL 2204H is not displayed |
Does not apply |
Recall does not apply to this vehicle. Return vehicle to inventory
or customer |
B. REPAIR PROCEDURE
WARNING: Allow the engine to sufficiently cool down before performing
this repair.
PCV HOSE REMOVAL:
- Record customer’s pre-set radio stations.
- Remove the Battery, Air Cleaner Case, and Intake Air Hose to gain access
to the PCV hose.

- Locate the PCV hose on the back of the intake manifold.
- Pull the end of the PCV hose from the plastic joint connector.

- Obtain a hose clamp removal tool (i.e. Snap-on - Hose Clamp Pliers,
#YA28650) or other suitable tool.

- Using the tool, squeeze and release the large hose clamp at the back of
the intake manifold.

- Remove the PCV hose from intake manifold.
- Remove and discard the tie-wrap.
- Remove the PCV hose from the vehicle and proceed to “C. INSPECTION
PROCEDURE” to identify the type of PCV hose found on the vehicle.
C. INSPECTION PROCEDURE
PCV HOSE INSPECTION:
- Identify the type of PCV hose installed on the vehicle by comparing the
shape of the PCV hoses below.

NOTE: The new style hose is approx. 20” in length, is not pre-formed,
and has a larger outer diameter than the old style hose.
- Inspect the hose for damage (heat marks, cut, split, etc.).
- After identifying the type and condition of the PCV hose, use the “PCV
Hose Inspection Results” table below to determine the required action.
CAUTION: IF A NEW STYLE HOSE IS FOUND ON THE VEHICLE, IT MUST BE
REPLACED IF IT IS
DAMAGED.
PCV Hose Inspection Results:
If Vehicle Has: |
Result: |
Required Action: |
Old Style PCV Hose |
Vehicle has “DEFECTIVE” PCV Hose |
Replace PCV Hose according to “D. REPAIR PROCEDURE” |
New Style PCV Hose |
New style PCV Hose is “DAMAGED” |
Replace PCV Hose according to “D. REPAIR PROCEDURE” |
New Style PCV Hose |
New style PCV Hose is “NOT DAMAGED” |
No repair is required. Reinstall hose according to “D. REPAIR
PROCEDURE” |
D. REPAIR PROCEDURE
PCV HOSE INSTALLATION:
NOTE: DO NOT remove the “retaining clip” from the new PCV hose clamp
at this time. If the new style hose was already installed on the vehicle, the
retaining clip will not be present.

- Attach the large hose end to the intake manifold.
- Twist the large hose end counter-clockwise so the hose clamp faces the
driver side of the vehicle, and the hose is routed away from the EGR pipe.
NOTE: It is very important to twist the hose to provide the necessary
clearance between the PCV hose and the EGR Pipe.

- Attach the other end of the new PCV hose to the plastic joint connector.
NOTE: Ensure the hose is fully seated onto the connector. Confirm the
connector hose is fully seated onto the PCV valve.
- Pull off the “retaining clip” from the hose clamp to secure the new PCV
hose; discard the retaining clip.
- Install a tie-wrap (not supplied) around the new hose as shown.
CAUTION: A TIE-WRAP MUST BE INSTALLED TO KEEP THE NEW PCV HOSE IN
PROPER POSITION AND AWAY FROM THE EGR PIPE. CONFIRM THERE IS A MINIMUM OF
1/2” CLEARANCE BETWEEN THE PCV HOSE AND THE EGR PIPE. IF THE PCV HOSE
CONTACTS THE EGR PIPE, THE PCV HOSE MAY BE DAMAGED.

- Reinstall the Intake Air Hose, Air Cleaner Case, and Battery.
- Start the engine and confirm no vacuum leaks are present.
- Re-enter the customer’s pre-set radio stations.
- Proceed to “E. AUTHORIZED MODIFICATION LABEL INSTALLATION.”
E. AUTHORIZED MODIFICATION LABEL INSTALLATION
Complete an “Authorized Modification Label” with the Recall number written on
the sticker and affix it to the vehicle’s hood. Refer back to the illustration
under “A. VEHICLE INSPECTION PROCEDURE”.
|
ATTACHMENT III – OWNER NOTIFICATION LETTER
August 2004
2002-2003 MPV PCV Hose Emission Recall 2204H
Dear Mazda Owner:
Mazda Motor Corporation has decided that a defect exists on certain 2002-2003
model year Mazda MPV vehicles produced from November 26, 2001 through August 8,
2003. Affected vehicles may fail to conform to federal emissions standards.
If you are a recipient of this notice, your vehicle is included in this
campaign.
What is the problem?
On some 2002-2003 MPV vehicles, the positive crankcase ventilation (PCV) hose
may fail, causing rough idling and/or the malfunction indicator lamp (MIL) to
illuminate. If this failure occurs, your vehicle may not pass applicable
emissions standards.
What will Mazda do?
Your Mazda dealer will replace the PCV hose with a modified one free of
charge. The repair should take approximately one hour to complete. However,
it may take longer depending on the service workload at your Mazda dealership.
As a reminder, the Mazda Driver’s Assurance Plan may provide alternate
transportation when your vehicle is at an authorized Mazda dealership for a
warranty repair. To be eligible for alternate transportation, your vehicle must
be within the mileage and time limitations under the Mazda New Vehicle Limited
Warranty and adhere to the Rental Car Reimbursement policy. Ask your dealer for
details about the Mazda Rental Car Reimbursement Program.
What should you do?
We encourage you to make an appointment with any authorized Mazda dealer to
have the PCV hose replaced as soon as possible. You do not need to bring this
notice to the dealer, but it may assist in the check-in process.
Important notice to owners registering vehicles in California,
Massachusetts, and Vermont: California Department of Motor Vehicles, Vermont
Department of Motor Vehicles, and the Commonwealth of Massachusetts, in
conjunction with the California Air Resources Board and the Environmental
Protection Agency for the State of Massachusetts and Vermont, have implemented
the Registration Renewal/Recall Tie-In Program, which requires the completion of
Emission Recalls prior to registration renewal. Mazda dealers will provide a
Vehicle Emission Recall - Proof of Correction Certificate upon completion of
the recall. Be sure to keep the proof of correction certificate provided by the
Mazda Dealer until needed for the registration renewal process.
Emission Law Information:
To ensure your full protection under the emission warranty made applicable to
your vehicle by State or Federal Law, and your right to participate in future
recalls, it is recommended that you have your vehicle or engine serviced as soon
as possible. Failure to do so could be determined as lack of proper maintenance
of your vehicle. Also, your vehicle may fail a state or local emission
inspection if this recall is not completed.
What if you already paid for a repair of the PCV hose?
If you have already paid for the inspection/repair of the PCV hose, you may
be eligible for reimbursement of reasonable repair expenses based on Mazda’s
repair standards. Please complete the enclosed “Reimbursement Application Form,”
include the necessary documentation, and mail it to us in the pre-addressed
envelope provided, allowing 6-8 weeks for processing.
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 MPV, 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 Assistance Center at (800) 222-5500, option #4.
We actively work to improve our products and search for solutions to improve
your ownership experience. Please accept our apologies for any inconvenience
this program may have caused you.
Sincerely,
Mazda North American Operations
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