01-006-21-3779a

BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted below in Red.
Previous TSBs:
Date(s) Issued:
Previous TSBs
Date(s) Issued:
01-006/21
02/08/21
01-017/12
05/23/12
01-001/19
01/02/19
01-003/11
01/12/11
01-008/18
03/26/18
01-009/10
08/24/10, 06/11/10, 02/15/10, and 02/02/10
01-004/16
02/15/16
01-029/06
07/28/06
APPLICABLE MODEL(S)/VINS
1995-2009 B-Series
1997-2002 626
2004-2021 Mazda3
2007-2012 CX-7
2016-2021 CX-3
1997-2003 Protege
1997-2006 MPV
2006-2015 Mazda5
2007-2021 CX-9
2020-2021 CX-30
1997-2005 Miata
2001-2011 Tribute
2003-2021 Mazda6
2006-2021 MX-5
2022 MX-30
1997-2002 Millenia
2011-2014 Mazda2
2013-2021 CX-5
2004-2011 RX-8
DESCRIPTION
This service bulletin provides testing and charging procedures in order to promote proper battery maintenance, to deliver
new vehicles with fully charged batteries, and to reduce unnecessary battery replacement cost.
For new vehicles in stock at the dealer, inspect and maintain the battery periodically according to the repair procedure.
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ADDITIONAL INFORMATION FOR MX-30:
The MX-30 is equipped with 2 batteries:
• A lead-acid battery (1) which feeds the features consuming less power, such as ECU, lights or audio.
• A high-voltage battery (2), which supplies the power for high-voltage systems such as the motor and the inverter.
Lead-acid battery (1)
High-voltage battery (2)
The high-voltage battery (1) is located under the vehicle’s floor.
The lead-acid battery is charged by the high-voltage battery when the EV system is activated. If the power is turned ON
many times without activating the EV system, the lead-acid battery may discharge completely, making it impossible to
turn the ignition ON and to activate the EV system.
The table below describes the situations in which charging the battery is necessary.
Lead-acid battery
Showroom vehicles with ignition OFF
The doors are opened and closed at least 10 times/hour.
Activate the EV system at least 1 hour every morning, after
noon and night.
The doors are opened and closed 2 or 3 times/hour.
Activate the EV system at least 1 hour every morning and
afternoon.
The doors are opened and closed 2 or 3 times a day.
Activate the EV system at least 1 hour every morning.
Stored vehicles
The doors are opened and closed 2 or 3 times per month.
Activate the EV system at least 1 hour every month.
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High-voltage battery
Verify the State-of-charge (SOC) in the instrument cluster. If the SOC is lower than 26%, charge it to 50% (either by
normal charging or quick charging).
NOTE:
• While explaining the vehicle functionalities to a customer using a showroom vehicle, have the EV system
activated.
• The READY indication (1) is displayed in the instrument cluster when the EV system is activated.
• If the vehicle has value other than 90% set for the maximum charge limit, reset it to 90% on Mazda Connect
before handing the vehicle to the customer.
Prevention of high voltage battery discharging
• Before leaving the vehicle, make sure that the power switch is switched OFF (READY indication is not displayed).
• When the high voltage battery charge display shows “---” (2) in the instrument cluster, charge the battery
immediately just after you notice the indication without performing “READY ON” operation. If the vehicle has to be
moved, minimize the frequency of “READY ON” operation and record how many times it has been done.
NOTE: When the high voltage battery charge display shows “---”, the charge level is 0% or less. If “READY ON”
operation is done several times in this situation, the high voltage battery may not keep in a good condition and,
in the worst case, it will need to be replaced.
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REPAIR PROCEDURE
BATTERY VISUAL INSPECTION
Visually check battery for the following:
• The surface of the battery should be dry and clean (no dirt). If it is not, wipe away the dirt and moisture with a
damp cloth. If a dry cloth is used, static electricity could ignite the battery vapor gas.
• Ensure there is no corrosion (rust) or dirt on the battery terminals and that the connections are tight.
If the battery terminals are loose, tighten them.
If there is any corrosion (rust), use a wire brush to remove it.
• Check the liquid level (non-sealed battery).
Make sure that the liquid level in each cell is between the upper and lower level.
If the liquid level is low, remove the cap and fill with distilled water to the upper level.
If any other water than distilled is used, it could cause the battery to discharge.
Do not overfill the battery. If the battery is overfilled, liquid will leak.
• Verify the battery case is not damaged or deformed. If the battery case is deformed, it is recommended to replace
the battery, as the inside of the battery may also be damaged.
• Install the battery securely in the vehicle using the battery clamp.
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The following are indications the battery is nearly dead and may need to be replaced soon:
•
•
•
•
•
•
•
The battery liquid level requires topping off more often.
The need to recharge the battery becomes more frequent.
The engine cranking speed is insufficient to start engine.
When you press/depress the accelerator pedal, the intensity of the headlight/interior lights changes.
The electrolyte liquid levels between the cells varies.
The electrolyte liquid becomes dirty.
The turn signals blink slower than normal.
BATTERY INSPECTION AND RECHARGE PROCEDURE
NOTE:
• Some batteries may be equipped with a "battery eye". The battery eye color simply indicates the battery state-ofcharge, not its condition. Do not replace a battery based solely on the indication given by the battery eye. Always
follow the procedure shown below for proper inspection of the battery condition.
• This procedure should be performed using the Mazda DCA-8000PM battery management system. Refer to TSB
BATTERY TEST PROCEDURE REQUIREMENTS USING THE DCA-8000PM.
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Step
Inspection
Result
Action
1
Inspect the battery with the D
CA-8000PM.
“GOOD BATTERY”
“GOOD-RECHARGE”
Return vehicle to inventory
Refer to the following “Discha
rged Battery Inspection” and “
Discharged Battery Troubles
hooting Procedure” and chec
k if there is any problem on v
ehicle side. If not, perform “B
attery Diagnostics” on the bat
tery using the DCA-8000PM.
“CHARGE AND RETEST” Refer to the following “Discha
rged Battery Inspection” and “
Discharged Battery Troubles
hooting Procedure” and chec
k if there is any problem on v
ehicle side. If not, perform “B
attery Diagnostics” on the bat
tery using the DCA-8000PM.
“REPLACE BATTERY”
Replace battery.
DISCHARGED BATTERY INSPECTION
Possible Factors
• Battery discharging current is exceeding charging current.
Engine idling too long with high electric load (i.e. traffic jam at night or in the rain).
Excessive use of electric devices with engine off (generator not working).
Generator problem (i.e. loose drive belt, internal failure, damage).
Poor or no contact between battery and generator.
Generator control problem (i.e. short circuit or contact loss of field coil control circuit / generator output
voltage signal circuit).
Electric load too high, especially due to aftermarket equipments.
• Too much electric consumption while vehicle is not in use.
Electric devices left on.
Excessive use of electric devices with engine off (generator not working).
Vehicle not in use for long periods of time.
Excessive parasitic draw, especially due to aftermarket equipments.
• Weak battery.
Low electrolyte, electrode plate deterioration.
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DISCHARGED BATTERY TROUBLESHOOTING PROCEDURE
NOTE: If needed, use the “Battery Diagnostics” of the Mazda DCA-8000PM to test the charging and starting systems by
following the on-screen instructions to enter the appropriate information. Refer to the Mazda DCA-8000PM Quick Start
Guide or Midtronics online Instruction Manual for more information.
Step
Inspection
Result
Action
1
Measure the parasitic draw of
the vehicle. Refer to MGSS (
BATTERY INSPECTION/Par
asitic Draw.)
Is it within spec?
Note: The following are consi
dered normal parasitic draw v
alues for aftermarket accesso
ries.
YES
Go to next step.
NO
Repair or replace the malfunc
tioning part.
YES
Go to next step.
NO
Repair or replace the malfunc
tioning part.
• Remote
engine st
arter - up
to 15 mA
• Radar de
tector - u
p to 15 m
A
• Anti-theft
alarm - u
p to 15 m
A
• Navigatio
n system
- up to 1
5 mA
• Cell pho
ne charg
er - 0-60
mA
• DVD pla
yer - up t
o 5 mA
2
Check the connection of harn
ess & connectors between P
CM field coil control and gene
rator.
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Are all items OK?
Refer to MGSS (BATTERY I
NSPECTION/ GENERATOR
INSPECTION)
3
4
Measure the generator voltag
e.
Is it within spec?
Refer to MGSS (BATTERY I
NSPECTION/ GENERATOR
INSPECTION)
YES
Go to next step.
NO
Inspect generator according t
o MGSS (BATTERY INSPEC
TION/ GENERATOR INSPE
CTION). If anything is wrong,
repair or replace the malfunct
ioning part.
Ask customer’s usage of elec
tric devices and check if any
of following conditions apply.
- Engine idling too long with h
igh electric load (i.e. traffic ja
m at night or in the rain).
- Excessive use of electric de
vices with engine off (generat
or not working).
- Electric devices left on.
- Vehicle not in use for long p
eriods.
Do they apply?
NOTE: Even if the battery is
dead, it may be recovered jus
t with normal driving after a ju
mp start as long as the chargi
ng system is working properly
.
YES
Advise customer of proper us
age of electric devices.
NO
Refer to the appropriate troub
leshooting procedure on MG
SS. (It may not be a “dead ba
ttery”).
Refer to MGSS (SYMPTOM
TROUBLESHOOTING / NO.
3 WILL NOT CRANK and NO
.4 HARD TO START/LONG
CRANK/ERRATIC START/E
RRATIC CRANK).
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BATTERY MAINTENANCE PROCEDURE AND WARRANTY POLICY
NOTE:
• Remove the room fuse while the vehicle is in inventory.
• Disconnect the battery negative cable if the vehicle is in inventory for more than 1 month.
• Remember, batteries continue discharging by parasitic draw and self-discharging even though the
vehicle is in inventory.
• If the battery discharges for a long period of time and becomes sulfated, the battery may be difficult
to recover.
• If the battery is discharged, the battery is hard to recover by road driving.
• In some cases, even if the battery is discharged (less than 12.4 V voltage and 1.22 specific gravity),
cranking is still possible. Therefore, do not judge the battery as good/bad by cranking only.
• It is the dealer’s responsibility to maintain batteries on inventory vehicles. Failure to provide
documentation that proper maintenance was performed may result in denial of battery warranty
claims.
• Battery failure due to lack of maintenance is not a warrantable repair. Refer to Mazda Warranty
Policies and Procedures 2.5 and 2.6 for details.
1. For DEALER INVENTORY vehicles, follow the appropriate procedure below.
• Vehicles Arriving from Port:
Battery should be inspected and recharged (if necessary) within 2 days from date of delivery to dealer.
Refer to the BATTERY INSPECTION AND RECHARGE PROCEDURE. Recharge and replace battery as
necessary.
Recharging and replacement for vehicles arriving from ports IS covered by warranty (within 2 days). To be
covered by warranty, the following information is required to be completed and submitted with the claim:
Properly documented Section 1 of the New Vehicle Inventory Battery Maintenance Record
DCA-8000PM Test Result Printout
10 character Warranty code is required in the text field of the claim
• Inventory Vehicles:
As PDI step 2 indicates, inspect battery voltage every 10 days for showcase or forefront vehicles and every
30 days for inventory vehicles. Refer to the BATTERY INSPECTION AND RECHARGE PROCEDURE.
Make sure to properly document Section 2 of the New Vehicle Inventory Battery Maintenance Record.
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2. For RETAIL vehicles within 90 days of in-service, follow the appropriate procedure below.
• Retail Vehicles (Within Warranty Period):
Battery should be inspected and recharged (if necessary). Refer to the BATTERY INSPECTION AND
RECHARGE PROCEDURE. Recharge and replace battery as necessary.
If battery tests GOOD, diagnose charging and electrical system for problem.
Recharging and replacement for customer retail vehicles IS covered by warranty. To be covered by
warranty, the following information is required to be completed and submitted with the claim:
Authorization approval from the DCSM
Properly documented Sections 1, 2, and 3 of the New Vehicle Inventory Battery Maintenance
Record attached to the repair order
DCA-8000PM Test Result Printout attached to the repair order
10 character Warranty code is required in the text field of the warranty claim
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3. For RETAIL vehicles after 90 days of in-service, follow the appropriate procedure below.
• Retail Vehicles (Within Warranty Period):
Battery should be inspected and recharged (if necessary). Refer to the BATTERY INSPECTION AND
RECHARGE PROCEDURE. Recharge and replace battery as necessary.
If battery tests GOOD, diagnose charging and electrical system for problem.
Recharging and replacement for customer retail vehicles IS covered by warranty. To be covered by
warranty, the following information is required to be completed and submitted with the claim:
DCA-8000PM Test Result Printout attached to the repair order
10 character Warranty code is required in the text field of the warranty claim
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