Mazda 6 Service Manual: Service warnings

Component Disassembly

• Disassembling and reassembling the components of the air bag system can render the system inoperative, which may result in serious injury or death in the event of an accident. Do not disassemble any air bag system components.

Wiring Harness Repair

• Incorrectly repairing an air bag system wiring harness can accidentally deploy the air bag module or pre-tensioner seat belt, which can cause serious injury. If a problem is found in the system wiring, replace the wiring harness. Do not try to repair it.

Air Bag Module Inspection

• Inspecting an air bag module using an ohmmeter can deploy the air bag module, which may cause serious injury. Do not use an ohmmeter to inspect an air bag module. Always use the on-board diagnostic to diagnose the air bag module for malfunctions.

Air Bag Module Handling

• A live (undeployed) air bag module may accidentally deploy when it is handled and cause serious injury. When carrying a live (undeployed) air bag module, point the front surface away from your body to lessen the chance of injury in case it deploys.

• A live (undeployed) air bag module placed face down on a surface is dangerous. If the air bag module deploys, the motion of the module can cause serious injury. Always face the front surface up to reduce the motion of the module in case it accidentally deploys.

Side Air Bag Module Handling

• When the side air bag module deploys due to a collision, the interior of the seat back (pad, frame, etc.) may become damaged. If the seat back is reused and the side air bag module does not deploy properly, a serious accident may result. When the side air bag module deploys, always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After service, confirm that the seat operates normally and that the harness is positioned properly.

SAS Unit Handling

• Disconnecting the SAS unit connector or removing the SAS unit with the ignition switch at ON position can cause the air bag modules to deploy, which may seriously injure you. Before disconnecting the SAS unit connector or removing the SAS unit, turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS unit to deplete its stored power.

• Connecting the SAS unit connector without firmly installing the SAS unit to the vehicle is dangerous. The crash sensor inside the control module may send an electrical signal to the air bag modules. This will deploy the air bag modules, which may result in serious injury. Therefore, before connecting the connector, firmly mount the control module to the vehicle.

• For vehicles with a single point sensor, once an air bag module is deployed due to an accident or other causes, the SAS unit must be replaced with a new one even if the used one does not have any external signs of damage. The used SAS unit may have been damaged internally which may cause improper operation, resulting in major injuries or even death. The used single point SAS unit cannot be bench-checked or self-checked.

Crash Zone Sensor Handling

• Disconnecting the crash zone sensor connector or removing the crash zone sensor with the ignition switch at ON position can cause the crash zone sensor to operate and the air bag modules and pre-tensioner seat belts to deploy, which may seriously injure you. Before disconnecting the crash zone sensor connector or removing the crash zone sensor, always turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete its stored power.

• If the crash zone sensor is subjected to shock or the sensor is disassembled, the air bag modules and pre-tensioner seat belts may operate (deploy) suddenly and cause injury, or it may fail to operate normally and cause a serious accident. Do not subject the crash zone sensor to shock or disassemble the sensor.

• Because a sensor is built into the crash zone sensor, when the air bag modules and pre-tensioner seat belts operates (deploys), there may be a problem, such as an internal malfunction, even if there is not any external damage or deformation. If the crash zone sensor is reused, the air bag modules and pre-tensioner seat belts may fail to operate normally and cause a serious injury. Always replace the crash zone sensor with a new part. The crash zone sensor cannot be bench-checked or self-checked.

Side Air Bag Sensor Handling

• Disconnecting the side air bag sensor connector or removing the side air bag sensor with the ignition switch at ON position can cause the side air bag sensor to operate and the side air bag module to deploy, which may seriously injure you. Before disconnecting the side air bag sensor connector or removing the side air bag sensor, always turn the ignition switch to LOCK position, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS control module to deplete its stored power.

• If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag module may operate (deploy) suddenly and cause injury, or it may fail to operate normally and cause a serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.

• Because a sensor is built into the side air bag sensor, when the side air bag module operates (deploys), there may be a problem, such as an internal malfunction, even if there is not any external damage or deformation. If the side air bag sensor is reused, the side air bag module may fail to operate normally and cause a serious injury. Always replace the side air bag sensor with a new part. The side air bag sensor cannot be bench-checked or self-checked.

Pre-tensioner Seat Belt Inspection

• Inspecting a pre-tensioner seat belt using an ohmmeter can deploy the pre-tensioner seat belt, which can cause serious injury. Do not use an ohmmeter to inspect the pre-tensioner seat belt. Always use the on-board diagnostic to diagnose the pre-tensioner seat belt for malfunctions.

Component Handling

• Oil, grease, water, etc on components may cause the air bag modules and pre-tensioner seat belts to fall to deploy in an accident, which may cause serious injury. Do not allow oil, grease, water, etc., on components.

• Inserting a screwdriver, etc., into the connector of an air bag module or a pre-tensioner seat belt may damage the connector and cause the air bag module or the pre-tensioner seat belt to deploy improperly, which may cause serious injury. Do not insert any foreign objects into the connector.

Component Reuse

• Even if an air bag module or a pre-tensioner seat belt does not deploy in a collision and does not have any external signs of damage, it may have been damaged internally, which may cause improper operation. Improper operation may cause serious injury. Always self-check the undamaged air bag module or pre-tensioner seat belt to determine whether it can be reused.