Technical Service Bulletins are "Car-speak" for design flaws in a car that have been noted and for which fixes exist.
Lists of TSBs to any vehicle can be obtained through AllData Corporation. Check out the AllData Technical Service Bulletins web site for more details.
The list below is not an official Mazda list so it might not be 100% accurate - I don't think Mazda wants you to know all this anyway. This version was last updated November 1, 1996. Regular updates to this TSB list may be obtained by sending an email request to Troy Wilson (tcw@amicus.com)
TSB LIST FOLLOWS: (Listed in the order Dave wrote them up, NOT in the order they were released by Mazda.)
Summary of running changes on the Mazda assembly line:
Service bulletin #04293 Category S, issued 10/21/93
Replace lamp cover with modified design part # FD0164170A
Service bulletin #031/93 Category S, issued 6/16/93
Replace rubber stopper with modified design part # FD0158565
The steering or suspension makes a clunking sound at low speeds or when wheel turned lock to lock. There are three service bulletins which address this problem:
Service bulletin #056/92, Category S, Issued 12/15/92
Applies to vehicles with a VIN of JM1FD331**P0207441 or lower produced through August 4, 1992. Some vehicles may experience the black finish peeling from the following interior trim parts:
(Note from DSZ: Owner Rob Zeitinger experienced this problem on his car with VIN#JM1FD3311**P0207925. Thus the problem may affect more vehicles than Mazda indicates in the TSB)
Replace the parts under warranty. The adhesive has been strengthened.
For 1994 models, the parts were redesigned again so there is no extra layer to peel off.
Service bulletin #010/93, Category S, issued 2/26/93
Applies to vehicles with a VIN of JM1FD****P0210513 or lower produced through November 30, 1992.
Noise may be heard from the rear hatch hinges when driving over bumps or rough roads. Replace both the rear hatch hinges with a modified part under warranty.
New Part#: FD01 62 210C Old Part#: FD01 62 210A
Service bulletin #057/92, Category S, issued 12/15/92
Applies to vehicles with a VIN of JM1FD33**P0208750 or lower produced through July 2, 1992. After July 2, the hood was modified to eliminate this condition.
Install a washer (part# FDY1 56 788) under both cushion rubbers under the front of the hood. If the hood is replaced with a modified part (like if you crashed!) then the washers do not need to be installed.
Service bulletin #049/92, Category S, Issued 10/5/92
Applies to vehicles with a VIN of JM1FD331*P0207061 or lower produced through May 31, 1992.
Some RX-7s may emit a whistling noise around the windshield area when being driven at high speeds.
Caused by air being pulled through the space between the molding and the windshield. A repair seal foam kit has been designed to fix this. Simply slide the foam under the windshield molding.
Later RX-7s have the sealing foam attached to the windshield molding at the factory.
Repair Seal Foam Kit - Part# B001 77 739
Service bulletin # 002/93, Category S, Issued 2/5/93
Applies to vehicles with a VIN of JM1FD3***P0205708 or lower produced through April 30, 1992.
Wind noise from the right and left door windows (near the outside door handles). This is due to air entering the cabin because the windows do not fit flush against the glass channel. Replace front glass guides with modified part under warranty.
Front Glass Guide (R) - New Part# FD01 58 601B
Old
Part# FD01 58 601A
Front Glass Guide (L) - New Part# FD01 59 601B
Old
Part# FD01 59 601A
Service bulletin # 003/93, Category AD, Issued 3/8/93
Applies to 1993 RX-7 with VIN of JM1FD331*P0207440 or lower
Rather than fix a bug in the RX-7 alarm system, Mazda decided to issue a sticker to be placed in your owner's manual.
Dealership is supposed to put the following stickers in your owner's manual:
{Attach sticker to lower right side of page 2-10}
How to Arm the System.
For vehicles produced up to June 7, 1992 the following procedures apply
NOTE: If any of the doors, hood and/or hatch are opened prior to removing the key from the ignition switch, the theft deterrent system will not arm. The following procedure should be done to arm the system:
{Attach sticker to Page 2-11}
Same as above with different note to apply to vehicles made after June 7, 1992.
To order stickers (if your dealer doesn't have them), send fax to
MAZDA MOTOR OF AMERICA, INC.
SUPPORT SERVICES DEPARTMENT
ATTN: SERVICE
PUBLICATIONS COORDINATOR
FAX# (714) 454-7010
Be sure to list bulletin # 003/93 Category AD and specify how many stickers you want (probably just 1 set!)
Service bulletin #001/93, Category F
Applies to all fuel injected models
To improve fuel injection performance, Mazda has tested and approved a highly effective fuel injector cleaner. The kit and cleaner is recommended for all Mazda fuel injection systems.
Mazda's fuel injector cleaner uses a chemical reducing agent rather than the common solvent used in typical aftermarket cleaners. As a result, in tests against aftermarket competitors, Mazda's cleaner outperformed all others and was the only one to restore the fuel injector's flow rate to original factory specs.
Mazda recommends cleaning injectors every 15,000 miles.
DESCRIPTION PART# REMARKS
Fuel Injector Cleaner
0000 77 2019 case of 12 cans
Tool kit 0000 77 2026
w/ instructions
(req'd for use with the cleaner)
Service brochures 9999 95 043N 92 QTY: 1 package = 50 brochures
Service bulletin # 005/93, Category F, issued 4/28/93
Applies to all RX-7s
Some vehicles with properly functioning emission control systems may fail emission inspections. In order to avoid this, the following must be done prior to the test:
Service bulletin #032/92, Category F, issued 12/23/92
Applies to 1993 RX-7 5-spd models with VIN of JM1FD3312P0208703 or lower produced through July 2, 1992. Applies to 1993 RX-7 automatics with VIN of JM1FD331XP0210513 or lower produced through September. 30, 1992.
Some 1993 RX-7 vehicles may experience stalling during deceleration with the throttle released approaching a stop. This occurs during initial warm-up and, sometimes after the car has reached operating temperature. Also, when idling with the A/C on, engine speed decreases as the A/C compressor engages and idle fluctuation may occur. The ECU has been modified as a countermeasure. The modified ECU is designed to:
WARNING from DZ: The following parts may have been superseded by a more recent TSB. Have your Mazda dealer check their own TSB list which should be more up to date.)
Replace ECU under warranty with following part:
Service bulletin # 001/93, Category H, issued 12/17/93
Applies to 1993 RX-7 with a VIN of JM1FD333*P0200001 through JM1FD333*P0299999.
Applies to 1994 RX-7 with a VIN of JM1FD333*R0300001 through JM1FD333*R0300031.
Customers with the following driving habits may experience clutch slippage or premature clutch wear:
To improve the clutch for these conditions, the facing material of the clutch disk has been changed. These changes have been used in production since October 8, 1993.
Old Part# N315 16 460A
New Part# N315 16 460B
Service bulletin #012/92, Category K, issued 7/15/92
Applies to 1993 RX-7 built prior to May 11, 1992
If the hold light starts flashing while the vehicle is running, and torque reduction control fail code is 57, replace ECU under warranty.
New part# N3A2 18 9E1B
Old part# N3A2 18 9E1
Service bulletin #003/92, category Q, issued 9/14/92
Applies to vehicles built prior to Feb. 10, 1992 up to VIN JM1FD331*P0201892
Some vehicles may have aluminum wheel center caps that do not fit flush with the wheel. This is caused by contact between the cap and the axle flange. Replace center cap with modified part under warranty.
New part# FD01 37 191B
Old Part# FD01 37 191A
Service bulletin #050/92, Category S, issued 10/19/92
Tie-down hole plugs need to be installed on vehicles produced after May 20, 1992. These tie-down holes are used during transport. The plugs will prevent water from penetrating the body which will result in rust. These plugs should have been installed by your dealer. The 4 holes are located behind the front wheels about 10 inches from the side of the car and in front of the rear wheels about 4 inches from the side of the car (underneath the car).
Not a TSB. Published in January 1994 Mazda Tips (Dealer newsletter)
A kink in the turbo charger relief valve vacuum hose may also cause the engine to lack power or hesitate during acceleration. Check the hose and replace it with a modified one if it is kinked. The new part is available at the PDC (part # N3A3-20-341A)
Not a TSB. Published in January 1994 Mazda Tips (Dealer newsletter)
Turbo pressure can cause the air duct to come loose. Result: the vehicle loses power or the engine produces a sucking noise. Mazda has made the following modifications to correct this condition:
These modified parts are available at the PDC. If you encounter this condition, replace the existing parts with the modified ones.
Service bulletin #010/94 Category S, issued 2/11/94
Applies to vehicles with a VIN of JM1FD33**P0200001 through P0210664
(No date specified, but this was probably fixed in February 1993)
When opening or closing the door a squeaking sound may be heard. This is caused by the door checker. To correct this problem, the checker has been modified. Replace part under warranty.
New Part#: FD01 58 270B
Old Part# FD01 58 270A
If both door checkers are replaced, 2 warranty claims will be required.
Service bulletin # 001/94 Cat. J, issued 1/7/94, revised 1/27/94
Applies to vehicles with a Vin of JM1FD332*P0100001 through 210508
If grinding occurs when shifting to 5th gear, a 5th gear synchronizer ring, damaged by mis-shifting, may be the cause. To correct this concern, the shift select spindle has been modified to increase the accuracy of the shift pattern.
(Note from DZ: they raised the spring force from 6.7 kg to 8.9 kg on the shift select spindle)
Replace shift select spindle with part# R503 17 550 and replace 5th gear synchronizer with part# W501 17 725B. Inspect related parts for damage and replace as necessary. Applies to all vehicles under normal warranty.
This is not a TSB yet but I suspect it will become one soon. A number of 1993 RX-7 owners have reported hearing a rattle or vibration under the car which is more pronounced at certain RPMs. The problem is that the bolts which retain the heat shield to the catalytic converter have corroded resulting in a loose shield. Mazda sells the cat/heat shield assembly only as a unit, so the entire catalytic converter must be replaced. This is a warranty item.
Affects 1993-1994 RX-7 models manufactured before Dec. 21, 1994.
Beginning in 1993, a number of RX-7s burst into flames without warning. The NHTSA investigated and concluded in a report by Jeff Quandt that turbocharger malfunctions were to blame for the fires. (A free copy of report #PE94-009 may be obtained by calling the NHTSA hotline on 1-800-424-9393) Mazda redesigned the turbo charger housings on August 1, 1993 but claimed in a letter to the NHTSA that the redesign was simply to make the turbocharger housings easier to manufacture. Mazda conducted their own investigation on four test cars and concluded that the fires were caused by leaks in the cooling system. They claimed that coolant pooled on top of the engine, became concentrated by boiling, and then caught fire as it dripped onto a hot exhaust. The fact that a recall involving the cooling system cost Mazda a few hundred dollars per car versus a few thousand dollars for turbo charger replacement may have had something to do with their claim. The text of the recall letter follows:
1993-94 RX-7 Coolant Leak [Recall Campaign #54407]
Dear RX-7 Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.
Mazda has determined that a defect which relates to motor vehicle safety exists in certain 1993-94 RX-7 models. We have decided to conduct Recall Campaign #54407 for replacement of selected engine cooling system components in those vehicles, beginning August 8, 1994.
If your RX-7 has been subjected to high-speed operation and then parked before cooling down, the residual engine heat combined with build-up of pressure in the cooling system can raise the temperature of the coolant to levels where the integrity of the cooling system can be compromised. Repeated operation of the vehicle in this manner may produce cooling system leaks.
Under some circumstances, the leaking coolant mixture can collect on top of the engine, where some of the water can evaporate, increasing the concentration of the coolant. If coolant then leaks onto the exhaust manifold, an engine compartment fire could be the result.
Your RX-7 is equipped with a water level sensor that warns you of low coolant levels with both a warning light and accompanying buzzer. In most cases, you would be warned of a low water level prior to the point where enough coolant had been leaked to present any serious risk of fire.
Please make an appointment at your Mazda dealer to have the required repairs performed at no charge to you.
If you have moved or no longer owned the vehicle, please complete the enclosed "Change of Address/Ownership" pre-paid postcard as soon as possible, so we may update our records and/or notify the current owner.
Should you have any questions regarding this program, please contact our Customer Relations toll-free number (800) 222-5500.
If your dealer or distributor does not remedy the defect without charge within a reasonable amount of time, you may wish to notify the Administrator, National Highway Traffic Safety Administration,
Washington, D.C. 20590, or you can call their toll-free Auto Safety Hotline at (800) 424-9393, (residents of Washington, D.C. may call 366-0123).
Our goal at Mazda is to build and maintain only the highest quality products. please accept our apologies for any inconvenience this may cause you.
Sincerely,
Mazda Motor of America, Inc.
Editorial Comments: Despite the assurances in the recall letter, none of the RX-7 fires which the NHTSA investigated involved automobiles "subjected to high-speed operation" nor were the owners warned by a light or buzzer that the coolant level was low. At least two fires resulted in the loss of the owners' homes although to this date, no injuries or deaths have been reported. Until your RX-7 has had the recall service performed, it would be advisable NOT to park it in an attached garage or next to anything valuable.
This is another one of those RX-7 problems which is not documented in an official TSB but is being treated by Mazda on a case by case basis. RX-7 models painted Vintage Red, Montego Blue, or Black are most susceptible to this problem. Small paint chips start to appear on the hood, around the headlight openings, on the leading edge of the roof, and around the wheel arches. The problem is caused by a lack of adhesion between the paint and the primer and is made worse by the fact that the primer is white in color. In order to properly fix this problem, the entire car must be stripped down to bare metal, reprimed, and then repainted. In most cases Mazda can be convinced to pick up the tab for this expensive job ($5,000 - $7,000) without having to hire a lawyer. What follows are general guidelines for getting this problem fixed:
If power is removed from the radio in the 3rd generation RX-7 and the antitheft feature has been activated, the radio will blink "CODE". If three attempts to enter the code fail, the radio locks up and blinks "ERR" and becomes unusable. Bugs in the radio software may cause it to go directly to the "ERR" state. A "secret" code is available which will allow the radio to be unlocked. For obvious reasons, I will not post this code to the internet. If your radio ever locks up and you need assistance getting it unlocked, send me email with the following information:
Name
Address
Phone Number
VIN# of RX-7
I will contact you and provide you with instructions for unlocking your radio. I will also keep a record of who I give this information to. Please do not forward it to anyone or post it to the internet. If you do not agree to these terms, you may go to your Mazda dealer and have them unlock the radio for you for a nominal charge (unless the car is under warranty).
Applicable Models: 1993-95 RX-7
Bulletin No. 006/95
Issued: 4/5/95
Installing non-genuine air cleaners may lead to air pump failure. Unlike the original design, non-genuine air cleaners draw heated, engine compartment air into the air pump. This air increases pump temperature which may result in lubrication loss and bearing failure. Customers should be informed that the vehicle warranty prohibits alteration of the emission control system as well as other components. Recommend that the customer have the original air cleaner installed to prevent non-warrantable component failure.
CAMPAIGN #60504
The problem is that fuel lines become brittle because of excessive engine compartment temperatures. Eventually, they leak fuel and the car catches fire. The recall involves replacing the fuel lines with a different material and adding a fan control relay which runs the cooling fan for 10 minutes after the engine is shut off.
Affects: All 1993 RX-7 models manufactured beginning December 1, 1991 and 1994 RX-7 models manufactured through September, 1994.
VINs affected: JM1FD33**P0200001 - JM1FD33**R0303550
Total number of affected vehicles: 13,400
Repair Time: 3.8 hours
Install Part Nos.
N3A1-18-SE0 Fan Control Kit
N3A1-13-S70 Fuel Hose Kit
The following is a portion of a letter from the Vice President of Mazda North America to the NHTSA dated March 30, 1995:
Mazda first learned of an engine compartment fire in an RX-7 which
had the recall remedy conducted in November, 1994. In January, 1995, Mazda
engineers investigated seven RX-7 engine fires in the United States and in the
same month, NHTSA's information request on the completion rate for the on-going
safety recall campaign was issued.
Mazda submitted a partial response on February 8, 1995 and a complete
response on February 22, 1995 in which Mazda reported that it knew of 18 fire
cases in which investigations in the U.S. found evidence of fuel seepage from
the fuel hoses on those vehicles.
In order to identify the cause of the fuel seepage, thorough
investigations and analyses have been conducted. In March, 1995, Mazda
identified the cause of fuel seepage and reported it to NHTSA on March 22,
1995. Mazda concluded on March 24, 1995 that a defect existed and that a
recall was required.
Mazda Motor Corporation will notify all subject vehicle owners by letter
and will install an additional control unit for the electric cooling fan. The
fan activates after the engine is turned off when the coolant exceeds a
specified temperature. Mazda will also replace the fuel hoses with modified
hoses in all these vehicles without charge.
Sincerely yours,
Shintaro Nakatsuka
Vice President and General Manager
The following is the text of the recall letter which should be going out to owners in May 1995:
1993 and 1994 RX-7 Fuel Leakage [Recall Campaign #60504]
Dear Mazda Owner:
This notice is sent to you in accordance with the requirements of the
National Traffic and Motor Vehicle Safety Act.
Mazda Motor Corporation has determined that a defect which relates to
motor vehicle safety exists in certain 1993 and 1994 Mazda RX-7 models.
If an RX-7 is driven under severe conditions (e.g. high speed and uphill
driving), and the engine is turned off, the temperature of the engine
compartment rises due to the residual engine heat. This condition may cause
premature deterioration of the fuel hoses' elasticity. Repeated vehicle
operation in this manner may lead to a reduction in the sealing performance of
the fuel hoses and in rare cases can result in engine compartment fires.
We have made arrangements for you to have the engine fuel hoses replaced
and the engine cooling fan control system modified, free of charge, at an
authorized Mazda dealer. The necessary work takes approximately three hours to
perform. To minimize your inconvenience, we recommend that you schedule an
appointment with a Mazda dealer to have this work performed.
If you have moved or no longer own the vehicle, please complete the
enclosed Change of Address/Ownership pre-paid postcard as soon as possible.
This enables us to update our records and notify the current owner, if
necessary.
Please note the following change in the operation of the cooling fan after
the recall repair is performed:
Once the engine coolant exceeds a preset temperature, the cooling fan will
come on and continue running for about 10 minutes after the ignition switch is
turned off. Before the service, the cooling fan would stop when the ignition
switch was turned off.
Should you have any questions regarding this program, please contact our
Customer Relations toll-free number (800) 222-5500.
If your dealer or distributor does not remedy this defect without charge
and/or within a reasonable amount of time, you may wish to notify the
Administrator, NHTSA, Washington, DC 20590 or you can call their toll-free Auto
Safety Hotline at (800) 424-9393. (Residents of Washington, DC may call
366-0123).
Our goal at Mazda is to build and maintain only the highest quality
products. Please accept our apologies for any inconvenience this program may
cause you.
Sincerely,
MAZDA MOTOR OF AMERICA, INC.
There are numerous "fixes" out there including Engine Control Unit (ECU) replacements, check valve replacement, kinked vacuum hoses (See TSB item #17), replacement of the EGR valve with the California EGR valve, etc. While these may help reduce the symptoms, on most RX-7s the problem will remain. There was even an internal Mazda fix which included the adjustment of a rod that controls the "transition" between the primary and secondary turbos, but again, just a bit of help, not a true "fix".
The problem seems to be the programming in the factory computer. The RX-7 has two secondary injectors which turn on at aprox 2,700 RPM. While the engine RPMs are rising under light acceleration, the secondary injectors will turn off for a fraction of a second, then turn back on. This seems to be causing a momentary lean condition which we experience as the famous "3,000 RPM hesitation".
The secondary injectors are controlled by the ECU at terminals 4 X and 4 Z. By hooking up a digital multi-meter to these terminals and observing the voltages going to the injectors, we may observe this problem directly. At about. 12.5 Volts, the injectors are off. At lower voltages, they are being switched on at varying rates based upon the programming of the ECU. Every time the engine hesitates while going through the 3000 RPM range, we may observe the secondary injectors being switched off, engine hesitation, then injectors back on; hesitation gone, and normal acceleration.
It is possible that the only true fix is to reprogram the ECU to keep the secondary injectors from switching off in the 3,000 RPM range. Will Mazda address this problem in an upcoming release of the ECU? Possibly, but only if enough customers continue to complain about the 3,000 RPM hesitation. Contact your dealer service department and also call the Mazda Customer Relations number on (800) 222-5500.
Affects all 93-95 RX-7s. A problem with a check valve in the brake booster vacuum line can cause the brakes to fail when cold.
The campaign # for the recall is 65609.
For more information, call the following number 1-800-222-5500 (Mazda's customer service). Be ready to give the VIN number of you vehicle.
Here is the AP press release:
BC-Mazda Recall
Mazda RX-7s Recalled
IRVINE, Calif. (AP) + Mazda recalled 13,900 RX-7s Tuesday because of a brake problem.
Owners of the affected sports cars are being asked to bring them to a Mazda dealer for the replacement of the brake vacuum hoses.
The company said that on some RX-7s, from the 1993 through 1995 model years, accumulations of engine oil mist may prevent the brake vacuum check valve from opening at the specified pressure.
This could keep the brakes from working right on the first through third attempts after the RX-7s are started in the morning, Mazda said.
(Assembly month/year printed inside driver's door)
ALL CARS BUILT BEFORE THIS DATE ARE SUBJECT TO A FACTORY RECALL TO PREVENT ENGINE COMPARTMENT FIRES.
ALL CARS BUILT BEFORE THIS DATE ARE SUBJECT TO A FACTORY RECALL TO PREVENT ENGINE COMPARTMENT FIRES.
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All of the information on these pages is to my knowledge either an accurate summary of events and facts or is my opinion. It doesn't represent the views of Mazda (duh), my employer, my Internet service provider, or anyone else.