Final Quality Inspection Program (00-002/06)

FINAL QUALITY INSPECTION PROGRAM

TECHNICAL SERVICE BULLETIN

APPLICABLE MODEL(S)/VINS

2007 CX-7

DESCRIPTION

As a part of our ongoing commitment to product excellence and customer satisfaction, Mazda Motor Corporation has decided to initiate a Mazda CX-7 Final Quality Inspection (FQI) Program. This program consists of an inspection of the vehicle at time of customer delivery.

It is mandatory to conduct a two (2) minute 4,000 RPM sustained throttle "Decarbon Spark Plug Procedure". Repeated short engine run cycles encountered during the transportation process and dealer inventory vehicle movement may prematurely foul the spark plugs. Completion of the FQI is not limited to performing the spark plug decarbon procedure. Possible long-term storage require inspection of other important items (battery condition, tire pressure, fluid levels, 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.

BATTERY INSPECTION

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.
   Fig 1: Identifying Mazda Micro491 Battery Tester

   Courtesy of MAZDA MOTORS CORP.
   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 code.
   NOTE: Mazda CX-7JIS Code: 55D23L9
   Fig 2: Locating JIS Code

   Courtesy of MAZDA MOTORS CORP.
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 Tester Display	Action Step
   "BATTERY GOOD"	Go to "DECARBON SPARK PLUG PROCEDURE "
   "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
   
   

   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

   NOTE: If replacing (or disconnecting) battery, first record customer's preset radio stations.
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.
   2. 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.
   3. 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.
   4. Press ENTER when complete to view the Warranty Approval Code.
   5. Press ENTER again to view the DTC Code.
      Fig 3: Battery Tester Display

      Courtesy of MAZDA MOTORS CORP.
7. Record the Warranty Approval Code and DTC Code on the Repair Order and attach the tester 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.
     Fig 4: Identifying Battery Test Result

     Courtesy of MAZDA MOTORS CORP.
9. 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. After repair, reconnect battery and perform the following steps:
    1. Re-enter customer's preset radio stations.
    2. Perform "Power Window Initialization" procedure to restore "anti-pinch" and "auto open/close" window features.

BATTERY CHARGING

There are 2 ways to properly charge a battery.

• Slow Charge (Regular Charge)
• Quick Charge (Boost Charge)

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.
  Fig 5: Connecting Battery Charger To Battery

  Courtesy of MAZDA MOTORS CORP.
• 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.

AFTER CHARGING AND RECONNECTING BATTERY

1. After charging and reconnecting the battery, always remember to perform the following steps: 
   1. Re-enter customer's preset radio stations.
   2. Perform "Power Window Initialization" procedure (below) to restore "anti-pinch" and "auto open/close" window features.

POWER WINDOW INITIALIZATION PROCEDURE

1. Turn ignition to ON position.
2. From driver's seat ensure window lockout switch is NOT depressed.
   Fig 6: Locating Window Lockout Switch

   Courtesy of MAZDA MOTORS CORP.
3. Press window switch down to fully open door window.
4. Pull window switch up to fully close door window; hold switch up for two (2) seconds; release switch.
   Fig 7: Locating Window Switch

   Courtesy of MAZDA MOTORS CORP.
5. Move to front passenger seat and repeat Steps  3 -  4 on passenger window switch.
6. Verify proper window operation using each door switch.

DECARBON SPARK PLUG PROCEDURE

1. Conduct a two (2) minute 4,000 RPM sustained throttle "Decarbon Spark Plug Procedure".
   1. Move vehicle to ventilated area.
   2. Start vehicle and leave transmission selector in PARK position.
   3. Allow engine to achieve proper operating temperature.
   4. Depress the accelerator and hold at 4,000 RPM for two (2) minutes.
   5. At end of two (2) minute period, allow engine to idle momentarily to cool down turbocharger.
      NOTE:

      • Failure to conduct procedure may cause starting concerns after customer delivery as the vehicle's original spark plugs may become prematurely fouled from repeated short drive cycles encountered during transportation and/or dealer storage.
      • To prevent engine overheating, engine RPM will lower automatically after two (2) minutes.

WARRANTY INFORMATION