TSB: 01-004/06 2006 MAZDA6 2.3L - MAZDA SPECIAL PROGRAM (MSP11) - O2 SENSOR DTC ERROR APPLICABLE MODEL(S)/VINS 2006 Mazda6 2.3L Automatic Transmission - California Spec. (Green State) - PZEV (Partial Zero Emission Vehicle) vehicles built from July 30, 2005 through October 1, 2005 VIN Range: 1YVFP**C*65M00403 - M13266 VIN Range: 1YVHP**C*65M00415 - M13489 DESCRIPTION It is possible for the O2 sensor failure DTCs to be incorrectly displayed. DTC P2195 (Front HO2S Signal Stuck Lean) and DTC P2196 (Front HO2S Signal Stuck Rich) may be displayed in reverse (i.e. DTC P2195 Signal Stuck Rich and/or DTC P2196 Signal Stuck Lean). NOTE: - UNDER THE MAZDA SPECIAL PROGRAM (MSP11), ALL CURRENT DEALER INVENTORY AND RETAILED VEHICLES FOUND TO BE WITHIN THE ABOVE VIN RANGES, AND PRODUCED BETWEEN JUL. 30, 2005 THROUGH OCT. 1, 2005, MUST BE INSPECTED AND REPAIRED ACCORDING TO THE INSTRUCTIONS CONTAINED IN THIS SERVICE BULLETIN. - BEFORE PERFORMING ANY REPAIR, VALIDATE THAT THE VEHICLE IS APPLICABLE TO THIS PROGRAM BY PERFORMING AN "eMDCS WARRANTY VEHICLE INQUIRY" AND VERIFYING THE VEHICLE DISPLAYS CAMPAIGN "MSP11" AND ITS CAMPAIGN STATUS DISPLAYS "OPEN". SEE "VEHICLE INSPECTION PROCEDURE" BELOW. DEALER INVENTORY: Inspect and repair if necessary, all applicable vehicles currently in dealer inventory according to the procedures contained in this service bulletin. RETAIL VEHICLES: When an applicable retail vehicle is brought into the dealer for any type of repair or scheduled maintenance, perform an eMDCS Warranty Vehicle Inspection and check the status of MSP11. If status of MSP11 is "OPEN" inspect and repair if necessary, the vehicle according to the procedures contained in this service bulletin. VEHICLE INSPECTION PROCEDURE 1. Verify the vehicle is within the following VIN and production range. - 2006 Mazda6 2.3L A/T - PZEV (Partial Zero Emission Vehicle) vehicles built from July 30, 2005 through October 1, 2005. VIN Range: 1YVFP**C*65M00403 - M13266 VIN Range: 1YVHP**C*65M00415 - M13489 - If the vehicle is within the above VIN and production ranges, proceed to Step 2. - If the vehicle is not within the above VIN and production ranges, return the vehicle to the customer or inventory. 2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect the vehicle for a Campaign Label MSP11 attached to the vehicle's bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table below. REPAIR PROCEDURE 1. When a subject vehicle within the VIN range is brought into the dealer for MIL illumination with DTC P2195 or P2196 stored in memory, carry out the following operations. - If the DTC P2195 is stored in memory, perform the necessary diagnosis or repair according to the "On-Board Diagnostic" section of the Workshop Manual for DTC P2196 instead of P2195. Proceed to Step 2. - If the DTC P2196 is stored in memory, perform the necessary diagnosis or repair according to the "On-Board Diagnostic" section of the Workshop Manual for DTC P2195 instead of P2196. Proceed to Step 2. NOTE: Be sure to reprogram the PCM after performing the diagnostic/repair for the DTC P2195/P2196, so as to identify the actual malfunction condition from the data stored. 2. Verify vehicle is within VIN range and has not been previously reprogrammed to the "E" calibration level. NOTE: Current calibration level can be checked using WDS. After identifying vehicle, select "Log Viewer" icon (center icon) at the lower left section of the screen. Scroll down on WDS screen and locate "Filename:". The last digit of the "Filename" is the current calibration identifier. For example: SW-L3R3EE020. Vehicles that are not at the "E" calibration or later need to be programmed using this repair procedure. 3. Reboot the WDS PTU to clear memory before reprogramming. 4. Using WDS B39.7 or later software, reprogram the PCM to the latest calibration (refer to "Calibration Information" table) by following the "Module Reprogramming" procedure. NOTE: - Always update the WDS PTU first, then install the needed calibration file that WDS shows during PCM reprogramming. Go to "WDS Calibration" on ESI and download the "update" file. If the PTU is not updated to the latest WDS calibration level, the calibration file will not install into the PTU. - It is not necessary to remove any fuses or relays during PCM reprogramming when the WDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the WDS reprogramming procedure. - WDS shows the calibration part numbers after programming the PCM. - Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of WDS software, and additional revisions made to those calibrations for service related concerns. - When reprogramming a PCM, WDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations. - When performing this procedure, if the WDS PTU is not docked and connected to 115V-120V, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it will damage the WDS PTU. Also the external battery power supply cable should be connected to the vehicle battery and the PTU. 5. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present. NOTE: - If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual. - After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory). 6. Fill out an "Authorized Modifications" label (P/N 9999-95-AMDC-97) with the new PCM calibration information, your dealer code, and today's date. 7. Place the "Authorized Modifications" label on the "A" pillar below the tear tag in the driver door jamb. 8. Fill out a blue "Campaign Label" (9999-95-065A-05) with Campaign No.: "MSP11", your dealer code, today's date, and affix it to the vehicle's bulkhead. 9. Return the vehicle to the customer.