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Mil Comes On With DTC P2006/Variable Tumble Shutter Valve Cannot Completely Close (01-024/08)

Publication date: 2011-02-03
Reference number: 01-024/08
Supersedes refnos: 01-006/11

MIL COMES ON WITH DTC P2006/VARIABLE TUMBLE SHUTTER VALVE CANNOT COMPLETELY CLOSE

MIL COMES ON WITH DTC P2006/VARIABLE TUMBLE SHUTTER VALVE CANNOT COMPLETELY CLOSE

TECHNICAL SERVICE BULLETIN

Reference Number(s): CAT. 01, NO. 006/11, 01-006/11, Date of Issue:  February 3, 2011
MAZDA: 2004-2009 Mazda3; 2006-2009 Mazda5
SECTION: 01 Engine
BULLETIN NO.: 006/11
Superceded Bulletin(s): 01-024/08, Date of Issue:  April 11, 2008, 01-022/10, Date of Issue:  April 16, 2010

BULLETIN NOTE

NOTE:
  • This bulletin supersedes the previous bulletin 01-024/08 issued on 04/11/08 and 01-022/10 issued on 4/16/10. The APPLICABLE MODEL(S)/VINS, DESCRIPTION, PART(S) INFORMATION, and WARRANTY INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS

2004-2009 Mazda3 vehicles (2.3L)

2006-2009 Mazda5 vehicles

DESCRIPTION

On some vehicles, the MIL may come on with DTC P2006 stored in memory because the variable tumble shutter valve (VTSV) gets stuck causing the valve not to close enough. The clearance between the VTSV actuator and the lever is not enough for smooth movement in cold weather.

G07246772

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

  1. Verify concern.
  2. Record customer's radio presets.
  3. Disconnect the negative battery cable.
  4. Remove the air cleaner cover and case along with the air hose disconnected from the throttle body. Refer to MS3 online instructions section 01-13 Mazda3 INTAKE AIR SYSTEM REMOVAL/INSTALLATION or Mazda5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION .
  5. Remove the four bolts from the throttle body and carefully move it out of the way to gain access to the top screw for the VTSV actuator.
    NOTE: Do not disconnect the coolant hose from throttle body.
  6. Remove the screws from the VTSV actuator, then slowly remove the VTSV actuator with lever and seal assembled.
    G07246773
    CAUTION: DO NOT pry the lever out of the intake manifold. If the lever does not want to come out of the intake manifold, separate the lever from the VTSV actuator at the ball socket with a screwdriver. Then remove the lever from the intake manifold by moving it up and down and pulling out on it.
    G07246774
    CAUTION: If the old seal on the lever is left in the intake manifold, remove it using a pick or pin, being careful not to scratch the interior walls.
  7. Disconnect the vacuum hose and electrical connector from the VTSV actuator.
  8. Before installing the new VSTV actuator, install the lever from the old actuator without the seal to confirm that it can move all the way between the stops.
    NOTE:
    • If the lever does not move all the way between the stops, remove it reinstall it at a different angle. The lever must move all the way between the stops.
    • When the lever moves between the stops, move it to the top of the range and remove it.
      G07246775
  9. Apply mild soap around the seal at the actuator lever, then install a new VTSV actuator on the intake manifold with the lever at the top of the range.
  10. Install the three bolts and tighten them to mount the VTSV actuator.
    NOTE: Three bolts are used to install the modified VTSV actuator. The three bolts consists of two original bolts plus one other bolt in the repair kit.
  11. Connect the vacuum hose and electrical connector to the VTSV actuator.
  12. Verify the mounting surface is clean, then install the throttle body with the four bolts and tighten them to mount the throttle body.

    Tightening torque: 8.0 - 11.5 N.m (6 - 8 ft.lbf) 

  13. Connect the air hose to the throttle body and install the air cleaner case and cover. Refer to MS3 online instructions or Workshop Manual section 01-13 Mazda3 INTAKE AIR SYSTEM REMOVAL/INSTALLATION or Mazda5 INTAKE AIR SYSTEM REMOVAL/INSTALLATION
  14. Connect the negative battery cable.
  15. Enter customer's radio presets.
  16. Delete DTC and verify repair.

PART(S) INFORMATION

PART(S) INFORMATION

Part Number Description Qty. Note
L3Y4-13-TJ0 Repair Kit 1 Kit includes variable tumble shuttle valve and a package of three bolts.
L3G2-13-655 Throttle body gasket 1 Gasket needs to be replaced since it cannot be reused.

WARRANTY INFORMATION

NOTE:
  • This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
  • This repair will be covered under Mazda's New Vehicle Limited Warranty term where applicable coverage will be California Emission Defect/Performance Warranty or PZEV (Partial Zero Emissions) Warranty.
  • Additional diagnostic time cannot be claimed for this repair.
WARRANTY CLAIM INFORMATIONS

Warranty Type A
Symptom Code 6X
Damage Code 92
Part Number Main Cause L3Y4-13-TJ0
Quantity 1
Operation Number/Labor Hours: XXF4ZXRX/0.7 Hrs.
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