01-007-22
Service Bulletin Details
Public Details for: 01-007-22
Some vehicles may have coolant leaks at the cylinder head around the exhaust manifold (as shown below). There may be cracks at the stud bolt hole or at the outside of the exhaust manifold. Cracks may be caused by: - deformation of the exh
- 2020 - 2019 - 2018 - 2017 - 2016 -
Models from 2020
2020 MAZDA CX-5 |
2020 MAZDA CX-9 |
2020 MAZDA MAZDA6 |
Models from 2019
2019 MAZDA CX-5 |
2019 MAZDA CX-9 |
2019 MAZDA MAZDA6 |
Models from 2018
2018 MAZDA CX-9 |
2018 MAZDA MAZDA6 |
Models from 2017
2017 MAZDA CX-9 |
Models from 2016
2016 MAZDA CX-9 |
BULLETIN NOTES This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red text. Previous TSBs: Date(s) Issued: 01-013/21 12/02/21 and 10/15/21 APPLICABLE MODEL(S)/VINS US Spec.: 2019-2020 CX-5 SKYACTIV-G 2.5T vehicles with VINs lower than JM3KF******830243 (produced before Jun. 9, 2020) 2016-2020 CX-9 SKYACTIV-G 2.5T vehicles with VINs lower than JM3TC******422801 (produced before Jun. 9, 2020) 2018-2020 Mazda6 SKYACTIV-G 2.5T vehicles with VINs lower than JM1GL******523967 (produced before Mar. 25, 2020) Mexico Spec.: 2019-2020 Mazda6 SKYACTIV-G 2.5T vehicles with VINs lower than JM1GL******523672 (produced before Mar. 21, 2020) DESCRIPTION Some vehicles may have coolant leaks at the cylinder head around the exhaust manifold (as shown below). There may be cracks at the stud bolt hole (1) or at the outside of the exhaust manifold (2). Page 1 of 13 07/04/2022 08:39 AM cciz Cracks may be caused by: • Deformation of the exhaust manifold during usage causing unexpected force to certain areas of the cylinder head. • Residual stress generated during production in the cylinder head material may be greater than expected. The external force from the exhaust system when driving over bumps may cause unexpected force to certain areas of the cylinder head. To eliminate this concern, the design of the exhaust manifold gasket and the cylinder head has been modified to reduce the force on the cylinder head. Customers having this concern should have their vehicle repaired using the following repair procedure. SI122131 REPAIR PROCEDURE Page 2 of 13 07/04/2022 08:39 AM cciz 1. Verify the customer concern. 2. Confirm the crack(s) and coolant leak(s) are located at the area(s) shown in the "Description" above: - If the coolant leaks are coming from other than the cylinder head itself, this Service Information is not applicable. Diagnose the leaks according to the instructions on MGSS online. - If the coolant leaks are coming from the area(s) shown in the "Description" above, proceed to Step 3. 3. Inspect for DTC P111A: - If DTC P111A is stored in memory, engine overheating is suspected. This Service Information is not applicable. Diagnose the cause and repair, replacing the partial engine according to MGSS online. Contact MASH for partial engine approval. - If DTC P111A is not stored in memory, proceed to Step 4. 4. Drain some engine oil into a container. 5. Inspect the color of the engine oil. Is it a milky light brown color indicating coolant is mixed in with it? - If Yes, this Service Information is not applicable. Contact MASH for partial engine approval. - If No, proceed to Step 6. 6. Replace the cylinder head assembly with a new one using a modified exhaust manifold gasket according to the instructions on MGSS online: NOTE: MASH approval is NOT required for cylinder head assembly replacement. • CX-5: CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.5T] • CX-9: CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.5T] • Mazda6: CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.5T] NOTE: Reuse the water outlet, fuel distributor, fuel injectors, OCV oil filter, rocker arms, HLA, CMP sensors and engine hanger brackets. 7. Perform “Engine Oil Data Reset” according to the instructions on MGSS online: • CX-5: ENGINE OIL DATA RESET [SKYACTIV-G 2.5T] • CX-9: ENGINE OIL DATA RESET [SKYACTIV-G 2.5T] • Mazda6: ENGINE OIL DATA RESET [SKYACTIV-G 2.5T] 8. Verify the repair. PARTS INFORMATION Parts Number Description Qty. Notes PYY1-10-SJ0A HEAD SET, CYLINDER 1 --- PYY1-10-S50 GASKET KIT A 1 --- PYY1-13-S50 GASKET KIT B 1 --Page 3 of 13 07/04/2022 08:39 AM cciz PYY1-13-SRZ GASKET KIT C 1 --- PYY1-13-W8Z GASKET KIT D 1 --- Dealers can now utilize the Limited Parts Ordering (LPO) page on eMDCS to order the repair parts for 2.5L (with cylinder deactivation) and 2.5L turbo cylinder head repairs. There is no longer a need to contact hotline for part ordering. If there are any questions on part ordering or part status, contact the DAG group for assistance. NOTE: It is necessary to order Gasket Kit A, B, C & D for each vehicle repair. Non-reusable parts locations: • Gasket for cylinder head cover • Gaskets for EGR cooler and EGR valve component • Gaskets for intake-air system Page 4 of 13 07/04/2022 08:39 AM cciz • Gasket and nuts for TWC Page 5 of 13 07/04/2022 08:39 AM cciz • Joint bolt A for Intermediate shaft • Snap pin for Tie-rod end • Lock nut for Driveshaft • Clip for Drive shaft (LH) • Grease (L2Y1-33-247) for knuckle Page 6 of 13 07/04/2022 08:39 AM cciz • Transfer oil seals (RH) [4WD] • Gasket and nuts for WU-TWC • Gasket and nuts for exhaust manifold Page 7 of 13 07/04/2022 08:39 AM cciz • Gaskets for turbocharger • O-ring for vacuum pump Page 8 of 13 07/04/2022 08:39 AM cciz • Gaskets and pipe for high pressure fuel pump • Gasket and O-rings for water pipes and cylinder head gasket Page 9 of 13 07/04/2022 08:39 AM cciz • Gasket for water outlet • O-ring for electric variable valve timing motor/driver • Sealing washer for bolt • Front oil seal • Spacer and O-rings for fuel injector • O-rings for CMP sensor Page 10 of 13 07/04/2022 08:39 AM cciz • Pressure detection square head plug NOTE: For information only, DO NOT order the parts shown below. They are already included with the Cylinder Head Set (PYY1-10-SJ0). Page 11 of 13 07/04/2022 08:39 AM cciz No. Description Qty. 1 VALVE, INLET 8 2 VALVE, EXHAUST 8 3 SEAT, VALVE SPG-UP 16 4 COTTER, VALVE 32 5 SPRING, VALVE 8 6 SPRING, OUTER-EX. VALVE 8 8 SEAL, INLET VALVE 8 9 SEAL, EXHAUST VALVE 8 10 SEAT, VALVE SPG.-LWR 16 11 GUIDE, VALVE 8 12 GUIDE, VALVE 8 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 Powertrain Warranty. • Additional diagnostic time cannot be claimed for this repair. Warranty Type A Symptom Code 77 Damage Code 9A Part Number Main Cause Quantity Operation Number / Labor Hours: PYY1-10-SJ0 1 XXS82BRX / 11.2 Hr. (CX-5 2WD) XXS82CRX / 11.1 Hr. (CX-5 4WD) XXS82FRX / 11.3 Hr. (CX-9) XXS82ARX / 10.9 Hr. (Mazda6) NOTE: • Claim engine oil (5.9 L {6.2 US qt, 5.2 Imp qt} maximum), ATF (4.9 L {5.1 US qt, 4.3 Imp qt} maximum), gear oil (0.45 L {0.48 US qt, 0.40 Imp qt} maximum) and coolant (9.9 L {10.5 US qt, 8.7 lmp qt} maximum) as related parts. • If Wheel Alignment Check and Adjust is performed at outside shop, claim the actual invoice amount with sublet code “C1”. Page 12 of 13 07/04/2022 08:39 AM cciz Page 13 of 13 07/04/2022 08:39 AM cciz