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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:

  1. Service and Parts recall instructions follow (Attachment I), were e-mailed to your Service Department, and are also available on the ESI website.
  2. Inspection and repair procedures follow (Attachment II), were e-mailed to your Service Department, and are also available on the ESI website.
  3. 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.
  4. For technical assistance, call the Technical Assistance Hotline at (888) 832-8477.
  5. 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

  1. 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.

  2. 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

  1. 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.
  2. 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:

  1. Record customer’s pre-set radio stations.
  2. Remove the Battery, Air Cleaner Case, and Intake Air Hose to gain access to the PCV hose.
  3. Locate the PCV hose on the back of the intake manifold.
  4. Pull the end of the PCV hose from the plastic joint connector.
  5. Obtain a hose clamp removal tool (i.e. Snap-on - Hose Clamp Pliers, #YA28650) or other suitable tool.
  6. Using the tool, squeeze and release the large hose clamp at the back of the intake manifold.
  7. Remove the PCV hose from intake manifold.
  8. Remove and discard the tie-wrap.
  9. 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:

  1. 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.
  2. Inspect the hose for damage (heat marks, cut, split, etc.).
  3. 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.

  1. Attach the large hose end to the intake manifold.
  2. 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.
  3. 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.
  4. Pull off the “retaining clip” from the hose clamp to secure the new PCV hose; discard the retaining clip.
  5. 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.
  6. Reinstall the Intake Air Hose, Air Cleaner Case, and Battery.
  7. Start the engine and confirm no vacuum leaks are present.
  8. Re-enter the customer’s pre-set radio stations.
  9. 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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