Bulletin No.: 01-024/08 Last Issued: 4/11/2008 Subject: MIL COMES ON WITH DTC P2006 / VARIABLE TUMBLE SHUTTER VALVE CANNOT COMPLETELY CLOSE APPLICABLE MODEL(S)/VINs 2004-2008 Mazda3 vehicles (2.3L) with VINs lower than JM1 BK**** ** 872056 (produced before December 14, 2007) 2006-2008 Mazda5 vehicles with VINs lower than JM1 CR**** ** 308293 (produced before December 14, 2007) 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. This is due to product variation of the actuator and lever where the clearance between them is not enough for smooth movement. The production process of the actuator has now been improved. 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 or Workshop Manual section 01-13 INTAKE AIR SYSTEM REMOVAL/INSTALLATION. 5. Remove the bottom screw from the VTSV actuator. 6. Remove the four bolts from the throttle body and carefully move it out of the way to gain access to the top bolt for the VTSV actuator. 7. Remove the top screw from the VTSV actuator, then slowly remove the VTSV actuator with lever and seal assembled. 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. 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 wall. 8. Disconnect the vacuum hose and electrical connector from the VTSV actuator. NOTE: Carefully disconnect the vacuum hose from the top of the intake manifold to make it easier to disconnect the vacuum hose from the VTSV actuator. 9. 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. 10. 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. 11. Install the two bolts and tighten them to mount the VTSV actuator. Tightening torque: 2.8 - 3.8 Nm (2.1 - 2.8 ft-lbf) 12. Connect the vacuum hose and electrical connector to the VTSV actuator. NOTE: Connect the vacuum hose to the top of the intake manifold if disconnected. 13. 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 Nm (6 - 8 ft-lbf) 14. 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 INTAKE AIR SYSTEM REMOVAL/INSTALLATION. 15. Connect the negative battery cable. 16. Enter customer's radio presets. 17. Verify repair.