NHTSA ID Number: 10154529
Manufacturer Communication Number: 09-003-19-3555a
TSB/Document Date: 2019-03-20
Summary
Some customers may complain of condensation/fog inside the front (headlamp/headlight) or rear (taillamp/taillight) combination lights. The recent new models have been fitted with a clear lens which can cause the symptom to be more noticeable, however, it does not affect the performance of the light. This condensation/fog is a natural phenomenon that occurs when there is a fairly large temperature difference between the inside and the outside of the light housing. It is normal for very small water drops to appear in certain locations on the light units where the air is stagnant (condensation), making the lens look whitish (fog). This happens mostly in the corners and narrow spaces, and will typically clear during warmer ambient temperatures, or when the lights have been on for some time.
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TSB/Document ID: 09-003-19-3555a
Replacement Service Bulletin Number:
MFR Communication Date: 2019-03-15
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EXTERIOR LIGHTING
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
Technical
Service Bulletin
Mazda
North American Operations
Irvine, CA 92618-2922
Subject:
CONDENSATION / FOG IN FRONT AND REAR COMBINATION LAMPS
(HEADLAMP AND TAILLAMP ASSEMBLIES)
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted below in Red
beside the change bars.
Previously Issued
TSBs:
Date(s) Issued
Previously Issued
TSBs:
Date(s) Issued
09-003/19
09-011/18
01/03/2019
03/22/2018
09-003/2013
09-046/12
03/04/2013
12/21/2012
09-005/11
02/07/2011
09-001/17
08/09/2017 and
01/13/2017
09-013/16
01/26/2016
09-057/10
12/23/2010
09-003/16
01/25/2016
09-016/09
09-049/14
09-007/14
11/24/2014
01/24/2014
09-007/08
11/19/2009, 03/20/2009 and
03/26/2009
02/11/2008
APPLICABLE MODEL(S)/VINS
2011-2014 Mazda2 2003-2019 Mazda6 2007-2012 CX-7 2016-2019 CX-3
2004-2019 Mazda3 2006-2019 MX-5 2007-2019 CX-9
2006-2015 Mazda5 2013-2019 CX-5* 2004-2011 RX-8
* For additional repair information regarding rear combination light fogging on 2017-2018 CX-5 vehicles with
VINs lower than JM3KF******356208 (produced before Feb. 6, 2018), refer to TSB 09-014/19 - REAR
COMBINATION LIGHT(S) ARE FOGGY. Ensure that the appropriate repairs found in TSB 09-014/19 are
completed before returning the vehicle to the customer.
Page 1 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Replacement headlamp assembly applicable to this bulletin
Halogen Headlamp
+
Bulb Type Turn Signal lamp
Discharge Headlamp
+
Bulb Type Turn Signal lamp
LED Headlamp
+
Bulb Type Turn Signal lamp
Replacement headlamp assembly not applicable to this bulletin
LED Headlamp
+
LED Turn Signal lamp
Page 2 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
DESCRIPTION
Some customers may complain of condensation/fog inside the front (headlamp/headlight) or rear
(taillamp/taillight) combination lights. The recent new models have been fitted with a clear lens which can
cause the symptom to be more noticeable, however, it does not affect the performance of the light. This
condensation/fog is a natural phenomenon that occurs when there is a fairly large temperature difference
between the inside and the outside of the light housing. It is normal for very small water drops to appear in
certain locations on the light units where the air is stagnant (condensation), making the lens look whitish
(fog). This happens mostly in the corners and narrow spaces, and will typically clear during warmer ambient
temperatures, or when the lights have been on for some time.
Page 3 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
When dealing with customer complaints of excessive condensation and/or water within the headlamp unit,
first determine if all the bulb sockets (including O-ring), seals and covers are present and correctly installed.
In most cases you will find that the Bulb Seal No. 1 (A) or HID Bulb Seal No. 1 (B) and Bulb Seal No. 2 (C)
socket covers have not been correctly installed or are missing due to improper prior repairs (i.e., customer
replacing the headlamp bulbs or body shop not transferring them when replacing the headlamp unit(s) due
to a collision). Any damage caused by missing socket covers, HID module seal (D), or missing bumper
brackets (E) is not covered by warranty policy. If none of these issues exists, explain to the customer that
this is a natural phenomenon and not a quality defect. DO NOT attempt repairs as this is considered
normal, and is NOT covered under Warranty. Replacing the light unit will not correct this symptom.
NOTE: LED headlamp assembly with LED turn signal lamp replacement part include seals. Seal transfer is
not required.
DETERMINATION / TESTING
NOTE:
The location where the bulbs are fitted has a high air volume with good air circulation, therefore, if a
large or heavy amount of condensation appears here, the light unit should be replaced. A small
amount of condensation here is considered normal and should clear after the lights have been on
for some time and the light unit should not be replaced. Refer to the following pictures for examples.
If the outside conditions are unfavorable (cold and damp), even fog (dew concentration) as shown
in the following pictures will take some time to clear up. Therefore, be careful in making a decision.
A picture will be required with every claim for Warranty. If a light unit is found with no problem, and
no picture is sent in, the claim may be later debited. You can also perform the following test to
determine if the light unit should be replaced.
Page 4 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
In certain situations, it is normal for a light on one side to have condensation/fog and the other side
not to. This would be due to differences in conditions (temperature, humidity, etc.) between the left
and right sides. For example, one side may be exposed to direct sunlight and the other side may be
in the shade.
1. In sunny weather or inside a warm garage, remove a bulb/socket and add cold/cool (not hot) air with a
hair dryer for approximately 5-10 minutes.
If the condensation/fog clears, it is normal, and the light unit should not be replaced.
If the condensation/fog does not clear, it is abnormal (water entry is suspected), and the light unit
should be replaced.
Water entry is where rain water comes into the inner light and stays as waterdrops on the inside of
the lens. The possible causes of "water entry" because of a part issue are:
Poor sealing joint between the lens and housing.
Missing or poor sealing of gasket. (NOTE: If the light unit was previously repaired and any
seals are missing, this is not covered under Warranty. Contact your DSM in this situation
before replacing the light.)
Cracked lens and/or housing.
Poor installation of respiration tube at ventilation hole.
NOTE: Causes of water entry from owner/operator treatment of vehicle (that should be avoided and are not
covered under Warranty) are:
The light and the surrounding area receive too much water in high-pressure washing.
The lens cracks from using a special cleaning agent with solvent.
Examples of Light Units With Condensation/Fog That Should NOT Be Replaced:
Condensation/fogging along the edges and in the corners is considered normal.
Page 5 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 6 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 7 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Some condensation/fogging on the lens is considered normal.
Page 8 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 9 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 10 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 11 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Examples of Light Units With Condensation/Fog That Should Be Replaced:
Heavy/large amount of condensation on the lens is not normal.
Page 12 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 13 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
Bulletin No.: 09-003/19
Last Issued: 03/15/2019
Page 14 of 14
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2019 Mazda North American Operations, U.S.A.
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