List of Mazda RX-8 Technical Service bulletins:
http://www.finishlineperformance.com....php?pageid=11

 

In order to keep the TSB link easily accesible and not buried under hundreds of posts we have split the discussion of the TSBs to a seperate thread. this one will remain locked so no normal replies can be made. Whenever a new TSB is issued a post will be made here to alert you.

TSB Discussion can be found here.

 

Fixed the link - sorry folks!!

 

the Recall bulletins are starting to show up. click the link in the first post. of course you can find them in the recall thread also

 

wow a long time since a TSB for the RX-8. here's the new one

there is a repair procedure of course but you'll have to wait for Rosenthal to host the PDF

also there is a new Service Tip about rmoving the shifter Panel- seems they have been seen alot of broken tabs Richard must be selling alot of short shift kits
again- the full pdf will be available from rosenthal shortly

 

Here's the new PDI step for RX-8s calle FQI - Final Quality Inspection

TSB: 00-001/06
2005-2006 RX-8 - FINAL QUALITY INSPECTION PROGRAM
BULLETIN NOTE

This bulletin supersedes the previous bulletin 00-001/06, issued on 03/08/06. The PART(S) and WARRANTY INFORMATION has been revised.
APPLICABLE MODEL(S)/VINS

2005-2006 RX-8
DESCRIPTION

As a part of our ongoing commitment to product excellence and customer satisfaction, Mazda Motor Corporation has decided to initiate a Final Quality Inspection (FQI) Program. This program consists of an inspection of the vehicle at time of customer delivery.

A critical element of this inspection is replacement of the spark plugs. Repeated short engine cycles encountered during the transportation process and when moved during dealer inventory may prematurely foul the spark plugs. The FQI is not limited to spark plug replacement. However, important inspection items that may require attention from the effects of storage are necessary. (Battery condition, tire pressure etc.…).

Please refer to the inspection procedure for details.
INSPECTION PROCEDURE

1. Verify vehicle has been retailed.

NOTE:

*

Procedure must not be performed more than 3 days prior to vehicle retail delivery.
*

Procedure must be performed within 7 days after vehicle retail delivery.

2. Refer to Final Quality Inspection Form, perform all inspections / procedure as instructed.

NOTE:

*

Make sure to place a copy of the FQI sheet in the glove compartment after performing inspection. Place the FQI tag on vehicle's shifter for 2005 MY. (See 2005 MY note under "PARTS INFORMATION").

BATTERY INSPECTION

NOTE:

*

After wholesale delivery, it is the dealer's responsibility to maintain the condition of the batteries in new Mazda vehicles while in inventory and at the time of new car delivery.
*

This procedure should be performed using a Micro491 battery tester.
*

Battery test results MUST be documented on battery tag.

1. Using the Mazda Micro491 Battery Tester (162-00017), attach the red probe to the positive battery terminal and the black probe to the negative terminal.

NOTE:

*

The tester's display screen will automatically activate for batteries above 1 volt. For batteries that are below 1 volt, it may be necessary to charge the battery for 30 minutes to raise the battery above 1 volt for testing and DTC retrieval.

2. Select "IN-VEHICLE" test by scrolling with the UP and DOWN arrows, then press ENTER.

NOTE:

*

When performing an "In-Vehicle" battery test, make certain that the key is in the OFF position and all electrical accessories and lights are turned off. Be sure that no diagnostic equipment is attached to the vehicle or DLC.

3. Select the correct rating system for the battery by identifying the correct JIS or CCA code.

4. Enter the correct battery rating by using the UP and DOWN arrows to scroll to the correct rating, then press ENTER to start the battery test.

NOTE:

*

For JIS batteries, the tester will only display the first five digits of the six-digit JIS number. Select the JIS number which represents the first five digits of the battery JIS code.

5. The battery tester will display one of the five possible results listed below. Review the results and follow the Action Step for the displayed result.

Battery Tester Display


Action Step

"BATTERY GOOD"


Go to "SPARK PLUG INSTALLATION"

"GOOD - RECHARGE"


Fully charge battery by normal recharging method.

See SLOW CHARGE (REGULAR CHARGE) under "BATTERY CHARGING"

NOTE:

*

If battery tester displays one of the three results listed below, perform a one (1) time quick recharging for 30 minutes. See QUICK CHARGE (BOOST CHARGE) under BATTERY CHARGING. Keep headlights on for 15 seconds to remove surface charge. Turn headlights off and let vehicle sit for 1 minute. Then repeat Steps 1 - 5, retest, then follow the Action Step for the displayed result.


Battery Tester Display


Action Step

"CHARGE & RETEST"


Fully charge battery by normal recharging method one (1) time.

See SLOW CHARGE (REGULAR CHARGE) under "BATTERY CHARGING". Repeat Steps 1 - 5.

NOTE:

*

If same result is displayed on 2nd test attempt, replace battery.

"BAD CELL" Replace Battery

"REPLACE BATTERY" Replace Battery

6. Generate a 6 character DTC code by performing the following steps:

NOTE: These steps are required when submitting a Mazda warranty claim for battery replacement.

1.

Press the "i" icon.
Enter the Warranty RO number by using the UP and DOWN buttons to scroll to the correct character, then press ENTER to select each character.

Enter the RO Line Number by using the UP and DOWN buttons to scroll to the correct character, then press ENTER to select each character.

Press ENTER when complete to view the Warranty Approval Code.

Press ENTER again to view the DTC Code.
7. Attach the printout to the repair order hard copy.

8. To print test results for attachment to RO, perform the following steps:

1.

Turn off the battery tester by disconnecting the battery test leads from the battery.
2.

Align the infrared ports of the battery tester and the printer.
3.

With the tester off, press and hold the print button to activate the OPTION menu.
4.

Use the UP and DOWN arrows to scroll to PRINT RESULTS, then press the ENTER button.

NOTE:

*

The tester will print the results from the last battery test completed.
*

If the tester results do not print, verify that the infrared IR port of the tester is pointing correctly at the infrared IR port of the printer.

9. Write the 6 character DTC code on the RO and attach the printed results to the RO Hardcopy (do not attach with tape due to reaction with the printer paper).

NOTE: Warranty Approval Code and DTC is required for warranty claim submission and must be typed in the Text field of the warranty claim.

10. Perform appropriate repair to vehicle.

11. Verify repair.

BATTERY CHARGING

There are 2 ways to properly charge a battery.

*

Slow Charge (Regular Charge)
*

Quick Charge (Boost Charge)

WARNING:

*

During any battery charge procedure, remove the caps and charge in a well ventilated area. If battery acid comes in contact with your skin, wash away with large amount of water, then go to the doctor immediately.

NOTE:

*

Before disconnecting battery, record radio station presets.

When performing quick or slow charge procedures, make sure the following precautions are adhered to:

*

It is recommended to remove the battery from the vehicle and place battery in a pan of water during charging to avoid the increase of the battery heat.
*

If charging the battery on the vehicle, disconnect the negative battery cable.
*

If equipped, remove the battery caps.
*

When electrolyte liquid level has fallen below the lower level, it can cause the battery to explode. When electrolyte liquid level is below half line of lower and upper level, add electrolyte liquid and fill to the upper level before charging.
*

Avoid the risk of sparks and explosion by connecting up the charger cables before you turn on the charger. If battery cables are connected in reverse order, sparks could appear.
*

Near the end of the charge cycle, hydrogen gas might be produced in large quantities - it has explosive potential so keep all flames away from it. Hydrogen gas can react with the vehicle"s surface, so be sure to wash any possibly affected area with lots of soap and water immediately after you shut the charging down.

SLOW CHARGE (REGULAR CHARGE)

NOTE:

*

You can recover the full charge with a slow charge with 1/10 of the 5 hours ratio capacity.

1. Connect battery charger to battery and adjust current.

2. Charge battery.

3. After completing slow charge, make sure battery has the standard voltage and specific gravity (more than 1.27 for 20°C) and battery has the same voltage and specific gravity 1 hour later.

CAUTION:

*

During slow charge, keep the battery cool (under 45°C (113°F)) as outlined in . If battery gets hotter than 45°C (113°F) (hot to the touch), stop charging temporarily and allow to cool. Resume charging at a decreased current.

QUICK CHARGE (BOOST CHARGE)

WARNING:

*

During any battery charge procedure, remove the caps and charge in a well ventilated area. If battery acid comes in contact with your skin, wash away with large amount of water, then go to the doctor immediately.

NOTE:

*

Quick charge can temporarily recover the battery enough to start the engine but it will not charge the battery completely.

4. Connect the battery charger to the battery and adjust the current.

5. Charge the battery for 30 minutes.

CAUTION:

*

Do not perform quick charge for longer than 30 minutes. The heavy current creates high battery temperature. During quick charge, keep the battery cool (under 55°C (131°F)) as outlined in . If battery gets hotter than 55°C (131°F) (hot to the touch), stop charging temporarily and allow to cool. Resume charging at a decreased current. Do not perform a quick charge on a completely discharge battery as it will damage the battery.

SPARK PLUG INSTALLATION

1. Install spark plugs.

1.

Raise vehicle on hoist.
2.

Remove the driver's side front wheel (spark plugs may be removed with wheel in place, wheel removal provides more working space).
3.

Remove inner splash shield.
4.

Use a ratchet, long extension and spark plug socket to remove / replace spark plugs.

NOTE:

*

Ensure leading / trailing spark plugs are installed in the proper location.

IMPORTANT:

*

Vehicle's original spark plugs will be collected for warranty inspection. Make sure to retain original spark plugs with proper documentation. A warranty parts return request referencing Part Number Main Cause under WARRANTY INFORMATION will be issued.

PART(S) INFORMATION

IMPORTANT: Although the spark plug part numbers are different between 2005 RX-8 (N3Y3-18-S30) and 2006 RX-8 (N3M1-18-1BX), the spark plugs contained in the kits are the same.

 

Voluntary Emissons Recall 4206f

Its "Officially" on folks here are the PDFs.

Its Explained in the Info that some 2006s are included for aDIFFERENT issue. They just threw them in to take care of a glitch while they were adding it instead of having a seperate bulletin/ recall.

 

and of course the warranty extension program

http://www.finishlineperformance.com.../pdf/ad-18.pdf

 

new TSB for the Visor Breaking

 

ok here is the newest lack of power TSB

 

Msp16

 

TSB 01-050/06

milky dipstick and oil in the intake

 

WOW. Been awhile since there was something to update this thread with.

NHTSA has completed its investigation of the Clutch Pedal Bracket Failure

Mazda thought the problem happened in about 1% of cars. NHTSA investigation foudn it in about 3% statistically. Mazda has extened the warranty for the clutch pedal for 04-09 cars to 8 years.

Letters will be going out to all owners of record. If you bought yours used you might want to get to a dealer and make sure you are the owner of record in Mazda's system.