AirbagTSB - PDF Rx8
AirbagTSB - PDF Rx8
AirbagTSB - PDF Rx8
Irvine, CA 92618-2922
2004-2005 RX-8 - AIRBAG WARNING LIGHT ILLUMINATED - DTC B1994 AND / OR B1998 SET
APPLICABLE MODEL(S)/VINS
2004-2005 RX-8 built before April 15, 2005 with VINs of JM1FE******154081 or lower
DESCRIPTION
Some 2004-2005 RX-8 vehicles may experience an illuminated air bag warning light with one or both of the fol-
lowing DTCs stored in memory.
• B1994 - Driver’s-side side air bag module circuit resistance high
• B1998 - Passenger’s-side side air bag module circuit resistance high
This may indicate a poor contact between the terminals and the harness in the side air bag module connector. A
revised overlay harness has been developed to repair this issue. This overlay harness will be installed over the
existing main harness. Overlay harness installation requires cutting off existing air bag harness connectors and
plugging in connectors from overlay harness and routing harness accordingly.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
WARNING:
• Consult Workshop Manual section 08-10 SERVICE WARNINGS and SERVICE CAUTIONS
before servicing the air bag system. Failure to do so may result in injury.
1. Verify customer concern.
2. Prepare vehicle for installation of overlay harness.
a. Record customer radio station presets.
b. Turn ignition switch off and disconnect negative battery cable. Wait at least 1 minute for air bag system to
power down before proceeding to step c.
WARNING:
•
Wait a minimum of 1 minute for air bag system to power down. Failure to do so
may result in injury.
c. Remove floor covering (carpet). See appropriate Workshop manual section 09-17 - FLOOR COVERING
REMOVAL / INSTALLATION.
WARNING:
• Use care when cutting off connectors. Be sure that only the wires for the air bag connector
are cut. If air bag harness and another vehicle harness is cut at the same time, the air bag
could deploy and cause serious injury. Double check where and what wires to cut.
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CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
CLOCK
SPRING
PASSENGER-SIDE
AIR BAG MODULE
SAS
CONTROL CURTAIN AIR
MODULE BAG MODULE
CRASH
ZONE
SENSOR
1507a
Page 2 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
c. Route overlay harness exactly as original SAS module. Connect overlay harness connector to SAS mod-
ule and secure overlay harness to body anchor.
1507c
SECURE OVERLAY
HARNESS USING
BODY ANCHOR
Page 3 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
d. Place overlay harness onto floor of vehicle and route connectors to the proper location.
NOTE:
• Follow original vehicle harness routing as close as possible. Use component location image at
beginning of bulletin to aid in overlay.
DRIVER SIDE
SAS UNIT 1507d
REAR DOOR
CONNECTIONS.
DRIVER SIDE,
PASSENGER SEAT
CONNECTIONS DRIVER SEAT SIDE IMPACT
CONNECTIONS SENSOR
CONNECTION.
Page 4 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
SIDE IMPACT
SENSOR
1507e
b. Disconnect sensor and remove harness anchors from body up to branch point.
c. Cut side impact sensor harness at branch point.
SIDE IMPACT
SENSOR
CUT HARNESS CONNECTOR
AT THIS POINT
1507f
Page 5 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
• Driver’s side overlay harness side impact sensor connector wire colors: Y/B and W/R.
• Passenger’s side overlay harness side impact sensor connector wire colors: G and G/R.
e. Fasten overlay harness body anchors to body.
DRIVER SIDE SHOWN,
PASSENGER SIDE SIMILAR
1507g
f. Install metal protector to impact sensor. Torque bolts to 7.9-11.7 N.m (70-103 in. lb).
g. Open original body harness protector and place overlay harness rear branch inside.
DRIVER SIDE SHOWN,
PASSENGER SIDE SIMILAR
1507h
Page 6 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
1507i
5. Route and connect overlay harness to driver’s and passenger’s seats harness connector.
a. Starting at driver’s side, locate original Yellow two-pin connector on vehicle harness (driver’s side = Y and
LG wires, passenger’s side = R/Y and L/W wires). Cut original vehicle harness at branch point.
Page 7 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
b. Connect the White 14-pin male overlay harness connector to the existing seat connector (white 14-pin
female). Wrap this connection in electrical tape.
1507k
1507l
Page 8 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
c. Using cloth tape, secure tape-wrapped connection to the vehicle floor in area shown.
d. Tape and plastic tie overlay harness into position as shown. Repeat step 5 for passenger’s side.
NOTE:
• The overlay harness White 14-pin female connector and Yellow 2-pin connector will plug into
seat when seat is re-installed.
BAND
1507m
DRIVER SIDE
SHOWN, INSTALL WIRE TAPE OVERLAY
PASSENGER TIE AT THIS HARNESS TO
SIDE SIMILAR POINT TUNNEL.
IF THE TAPE IS ADHERED OUTSIDE THIS RANGE,
THE HARNESS MAY COME INTO CONTACT WITH
THE SEAT WHEN THE SEAT IS SLID.
Page 9 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
1507n
1507o
Page 10 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
b. Peel back weather seal from connector and disconnect door connector from original harness connector.
1507p
ORIGINAL BODY
CONNECTOR
AND HARNESS
1507q
Page 11 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
e. Disconnect original harness anchor from body, then place tape wrapped connection into body cavity.
NOTE:
• When placing tape-wrapped connection into body cavity, insulate the connection using foam
or other insulation materials to prevent rattles.
1507r
DISCONNECT BODY
ANCHOR FOR ORIGINAL
HARNESS FROM BODY
1507s
Page 12 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
f. Snap overlay harness connector into hole in door jamb, then reconnect door harness connector.
NOTE:
• Ensure weather seal is returned to proper position to prevent leaks and/or damage to connec-
tor.
1507t
Page 13 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
• DO NOT cut the connector for the side curtain air bag module. Side curtain air bag mod-
ule harness will have a Yellow sleeve.
DISCONNECT SIDE
SIDE CURTAIN
CURTAIN AIR BAG
AIR BAG MODULE
CONNECTOR AND
HARNESS (YELLOW
REMOVE ANCHOR
WIRE PROTECTOR)
FROM BODY
1507u
Page 14 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
d. Connect overlay harness connector to side curtain air bag module connector and secure harness
anchors to body.
1507v
e. Secure overlay harness with plastic ties as shown. Repeat step 7 for passenger’s side.
1507w
Page 15 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
1507x
PART(S) INFORMATION
Page 16 of 17
Bulletin No: 08-008/05 Last Issued: 10/21/2005
© 2005 Mazda Motor of America, Inc.
WARRANTY INFORMATION
NOTE:
• This warranty information applies only to verified customer complaints on vehicles eligible for war-
ranty repair. Refer to the Warranty Wizard for warranty term information.
• Additional diagnostic time cannot be claimed for this repair.
Warranty Type A
Symptom Code 62
Damage Code 9S
Quantity 1
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