19
7755 Irvine Center Drive Irvine, CA 92618-2922 Telephone 949.727.1990 PO Box 19734 Irvine, CA 92623-9734 Facsimile 949.727.6101 Internet http://www.MazdaUSA.com Mazda North American Operations TO: Mazda Dealership General Managers, Service Managers, and Parts Managers DATE: December 2005 SUBJECT: 2003 Protegé Intake Manifold Shutter and Variable Tumble Control Valves Emission Recall 3005C Dear Mazda Dealer: Mazda Motor Corporation has decided that certain 2003 model year Mazda Protegé vehicles produced from March 3, 2003 through July 31, 2003 may fail to conform to California and federal emission standards. On certain 2003 Protegé vehicles, the tightening torque of the screws used for mounting the intake manifold shutter valve may have been lower than the specification. Engine vibration, air pulsation and normal action of the valve may cause the mounting screws to loosen or fall out. This may cause rough idling, noise and/or Malfunction Indicator Lamp (MIL) illumination to engine misfiring adversely affecting the exhaust emissions. Note: This excludes the Mazda Speed Protégé models. Mazda has decided to conduct an Emission Recall Campaign to inspect and replace the intake manifold shutter and variable tumble control valves mounting screws and gaskets or, if necessary, the intake manifold assembly. Owners of affected vehicles will be notified by first class mail beginning December 16, 2005. This package contains important information about recall campaign 3005C: Attachment I Dealer Service and Parts information Attachment II Repair procedures Attachment III Owner notification letter Important notice: California Department of Motor Vehicles, Vermont Department of Motor Vehicles, and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts and Vermont, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers must provide a Vehicle Emission Recall – Proof of Correction Certificate upon completion of the recall. Instruct owners to keep the certificate until needed for registration renewal.

TO: Mazda Dealership General Managers, Service Managers

  • Upload
    others

  • View
    6

  • Download
    0

Embed Size (px)

Citation preview

7755 Irvine Center Drive Irvine, CA 92618-2922 Telephone 949.727.1990 PO Box 19734 Irvine, CA 92623-9734 Facsimile 949.727.6101 Internet http://www.MazdaUSA.com

Mazda North American Operations

TO: Mazda Dealership General Managers, Service Managers, and Parts Managers DATE: December 2005 SUBJECT: 2003 Protegé Intake Manifold Shutter and Variable Tumble Control Valves Emission Recall 3005C Dear Mazda Dealer: Mazda Motor Corporation has decided that certain 2003 model year Mazda Protegé vehicles produced from March 3, 2003 through July 31, 2003 may fail to conform to California and federal emission standards. On certain 2003 Protegé vehicles, the tightening torque of the screws used for mounting the intake manifold shutter valve may have been lower than the specification. Engine vibration, air pulsation and normal action of the valve may cause the mounting screws to loosen or fall out. This may cause rough idling, noise and/or Malfunction Indicator Lamp (MIL) illumination to engine misfiring adversely affecting the exhaust emissions. Note: This excludes the Mazda Speed Protégé models. Mazda has decided to conduct an Emission Recall Campaign to inspect and replace the intake manifold shutter and variable tumble control valves mounting screws and gaskets or, if necessary, the intake manifold assembly. Owners of affected vehicles will be notified by first class mail beginning December 16, 2005. This package contains important information about recall campaign 3005C: Attachment I Dealer Service and Parts information Attachment II Repair procedures Attachment III Owner notification letter Important notice: California Department of Motor Vehicles, Vermont Department of Motor Vehicles, and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts and Vermont, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers must provide a Vehicle Emission Recall – Proof of Correction Certificate upon completion of the recall. Instruct owners to keep the certificate until needed for registration renewal.

Page -2- Failure to perform applicable recalls before delivery can result in extensive dealer fines and penalties from the Federal Government. Therefore, you must complete this recall for all affected new and pre-owned vehicles in your inventory prior to delivery. To help you effectively perform this emission recall, Mazda has developed the following resources: 1. Service and Parts recall instructions follow (Attachment I), were e-mailed to your Service

Department, and are also available on eMDCS and the ESI website. 2. Inspection and repair procedures follow (Attachment II), were e-mailed to your Service

Department, and are also available on eMDCS and the ESI website. 3. We recommend using the enclosed report of registered owners in the dealer’s area to encourage

customers to come in for the recall (with recall reminder postcards, for example). Dealers may use such owner information for the sole purpose of conducting and performing this emission recall, and for no other purpose. Using it for marketing activities is strictly prohibited and could subject your dealership to substantial fines and other penalties. The information in this report is protected by state privacy and other applicable laws regarding disclosure of personal and/or confidential, restricted or blocked information. It is the dealer’s responsibility to protect the confidentiality of owner records and prevent the release of information to other parties. In California, privacy laws prevent the release of names and addresses on this report.

4. For technical assistance, call the Technical Assistance Hotline at (888) 832-8477. 5. For warranty questions, contact the Corporate Dealer Assistance Group at (877) 727-6626. Please make certain that the appropriate personnel in your dealership are aware of these resources and are familiar with the details of this recall before responding to customer inquiries. We apologize for any inconvenience that this recall may cause you and your customers. Please keep in mind that owners of 2001 and newer models are eligible to receive a rental car at no charge. Your understanding and support in carrying out this campaign is greatly appreciated. Sincerely,

Michael J. Giblin Director, Technical Services Mazda North American Operations

ATTACHMENT I – DEALER INFORMATION

CONDITION OF CONCERN On certain 2003 Protegé vehicles, the tightening torque of the screws used for mounting the intake manifold shutter valve may have been lower than the specification. Engine vibration, air pulsation and normal action of the valve may cause the mounting screws to loosen or fall out. This may cause rough idling, noise and/or Malfunction Indicator Lamp (MIL) illumination to engine misfiring adversely affecting the exhaust emissions. SUBJECT VEHICLES Model VIN Range Build Date Range 2003 Protegé JM1BJ**** 3* 181114 - 219674 March 3, 2003 through July 31, 2003

Note: This excludes the Mazda Speed Protégé Models. OWNER NOTIFICATION Mazda will notify U.S. owners by first class mail beginning December 16, 2005. PARTS INFORMATION Description Part Number Quantity GASKET SET FSY1-13-SRZ 1 MANIFOLD SET FSY3-13-SRY 1 if needed Campaign Label 9999-95-065A-00 1=sheet of 18

labels MStore (no charge)

Vehicle Emission Recall – Proof of Correction Certificate*

9999-95-ERPC-99 1=50 certificates MStore (no charge)

* Important notice: California Department of Motor Vehicles, Vermont Department of Motor Vehicles, and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts and Vermont, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers must provide customers with a Vehicle Emission Recall - Proof of Correction Certificate upon completion of the recall. PARTS ORDERING An initial shipment of Gasket Sets will be shipped to dealers based on the number of vehicles registered in their area. If, after December 16 you require additional Gasket Sets, they can be ordered through the normal eMDCS parts ordering process. If you require a manifold set, it too can be ordered through eMDCS. Use MStore to order additional Campaign labels (1=sheet of 18 labels) and Vehicle Emission Recall – Proof of Correction certificates (1=50 certificates).

Page 1 of 3

SPECIAL SERVICE TOOL Torque Driver Set MT05-A1-001 1 Jig FS7N-20-150 5 Jig FS8N-20-150 5

An initial shipment of a Torque Driver Set and Jigs will be shipped to dealers directly from the vendor. Additional Torque Driver Sets and Jigs can be ordered through M-Store. They cannot be ordered on the eMDCS Parts Ordering system. These parts are not inventoried at the PDCs. WARRANTY CLAIM PROCESSING INFORMATION

Labor Operation Code

XXB216R1 XXB048R1 XXB048R2 XXB048R3 XXB048R4

Labor Hours 0.7 hrs. (includes

compression test and attachment of

recall label)

1.8 hrs. (without

inspection for engine

compression or spark plug)

2.4 hrs. (includes inspection for engine

compression and spark

plug)

1.6 hrs. (without

inspection for engine

compression or spark plug)

2.2 hrs. (includes

inspection for engine

compression and spark

plug)

NOTE: * Inspection Only: For the vehicle where the intake manifold has previously been replaced during a prior repair. Refer to Repair Procedure “A”. RENTAL CAR A rental car may be provided to the customer if eligible based on the terms and conditions of the Rental Car Reimbursement Program, policy 12.0. Rental car reimbursements are available only on 2001 and newer vehicles within the mileage and time limitations under the New Vehicle Limited Warranty. If the customer was placed in a rental car while the campaign was being completed, submit a separate claim/problem using the standard rental claim information. Warranty Type Code A Symptom Code 99 Damage Code 99 Part Number Main Cause 5555-RE-NTAL Part Quantity 0 Labor Operation Code MM012XRX Labor Hours 0.0 Sublet – Rental Car Sublet Invoice Number Number from Rental Invoice or Dealer Purchase Order Sublet Type Code Enter “L” Sublet Amount Up to $30.00 per day for the number of days customer had rental car

Page 2 of 3

Inspection Only*

Replacement of Screws & Gaskets

Replacement of Intake Manifold

Warranty Type Code

R R R

Symptom Code 99 99 99 Damage Code 99 99 99 Process Number A0503L A0503H A0503H Part Number Main Cause

FS7N-13-100E or FS7N-13-100F FSY1-13-SRZ FSY3-13-SRY

Quantity 0 1 1

Rental expenses exceeding the two-day limit will require prior DCSM Authorization, as outlined in the Rental Car Reimbursement Program policy. VERIFY THE VEHICLE NEEDS THE RECALL 1. Verify the vehicle is within the following ranges: Model VIN Range Build Date Range 2003 Protegé JM1BJ**** 3* 181114 – 219674 March 3, 2003 through July 31, 2003

If the vehicle is within the above ranges, go to step 2. If vehicle is not within the above ranges, return it to inventory or the customer. 2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for Campaign Label RECALL 3005C attached to the vehicle’s hood or bulkhead. eMDCS System - Vehicle Status Inquiry Results

If eMDCS displays: Campaign Label is: Action to perform:

Present Contact the Mazda Corporate Dealer Assistance Group at (877) 727-6626 to update vehicle history

RECALL 3005C OPEN

Not present Proceed to “REPAIR PROCEDURE” Present Return vehicle to inventory or customer RECALL 3005C

CLOSED Not present Complete a label and apply to vehicle's hood or bulkhead

RECALL 3005C is not displayed Does not apply Recall does not apply to this vehicle.

Return vehicle to inventory or customer Note: Verify the recall number as the vehicle may have multiple labels. REPAIR PROCEDURES: Please refer to Attachment II

Page 3 of 3

7755 Irvine Center Drive Irvine, CA 92618-2922 PO Box 19734 Irvine, CA 92623-9734 Internet http://www.MazdaUSA.com

Mazda North American Operations

December 2005 2003 Protegé Intake Manifold Shutter Valve Emission Recall 3005C Dear Mazda Owner: Mazda Motor Corporation has decided that certain 2003 model year Mazda Protegé vehicles produced from March 3, 2003 through July 31, 2003 may fail to conform to California and federal emission standards. If you are a recipient of this notice, your vehicle is included in this campaign. What is the problem? On certain 2003 Protegé vehicles, the tightening torque of the screws used for mounting the intake manifold shutter valve may have been lower than the specification. Engine vibration, air pulsation and normal action of the valve may cause the mounting screws to loosen or fall out. This may cause rough idling, noise and/or Malfunction Indicator Lamp (MIL) illumination to engine misfiring adversely affecting the exhaust emissions. What will Mazda do? Your Mazda dealer will inspect the intake manifold shutter valves, and , if necessary, replace the intake manifold shutter valve mounting screws and gaskets with new ones, or replace the intake manifold assembly, free of charge. The repair should take approximately 4 hours to complete. However, it may take longer depending on the service workload at your Mazda dealership. As a reminder, the Mazda Driver’s Assurance Plan may provide alternate transportation when your vehicle is at an authorized Mazda dealership for a warranty repair. To be eligible for alternate transportation, your vehicle must be within the mileage and time limitations under the Mazda New Vehicle Limited Warranty and adhere to the Rental Car Reimbursement policy. Ask your dealer for details about the Mazda Rental Car Reimbursement Program. What should you do? We encourage you to make an appointment with any authorized Mazda dealer to have the intake manifold shutter valves inspected/repaired as soon as possible. You do not need to bring this notice to the dealer, but it may assist in the check-in process. Important notice to owners registering vehicles in California, Massachusetts, and Vermont: California Department of Motor Vehicles, Vermont Department of Motor Vehicles, and the Commonwealth of Massachusetts, in conjunction with the California Air Resources Board and the Environmental Protection Agency for the State of Massachusetts and Vermont, have implemented the Registration Renewal/Recall Tie-In Program, which requires the completion of Emission Recalls prior to registration renewal. Mazda dealers will provide a Vehicle Emission Recall - Proof of Correction Certificate upon completion of the recall. Be sure to keep the proof of correction certificate provided by the Mazda Dealer until needed for the registration renewal process.

-Page 2- Emission Law Information: To ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle or engine serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not completed. What if you already paid for a repair of the Intake Manifold? If you have already paid for the inspection/repair of the intake manifold shutter valves, you may be eligible for reimbursement of reasonable repair expenses based on Mazda’s repair standards. Please complete the enclosed “Reimbursement Application Form,” include the necessary documentation, and mail it to us in the pre-addressed envelope provided, allowing 6-8 weeks for processing. Where is the closest Mazda dealer? To locate your nearest Mazda dealer, visit our web site and try our “Locate a Dealer” feature at www.MazdaUSA.com or consult your local yellow pages. Moved or no longer own this vehicle? If you have moved or no longer own your Protegé, please complete the enclosed prepaid Information Change Card as soon as possible. This enables us to update our records and notify the current owner. Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days. Still have questions? If you have any questions regarding this campaign, please contact our Customer Assistance Center at (800) 222-5500, option #4. We actively work to improve our products and search for solutions to improve your ownership experience. Please accept our apologies for any inconvenience this program may have caused you. Sincerely, Mazda North American Operations

Page 1 of 10

2003 PROTEGE INTAKE MANIFOLD RECALL 3005CATTACHMENT II

SSP/RECALL TEMPLATEA. VEHICLE INSPECTION PROCEDURENOTE: MAZDASPEED Protege is not subject to this recall campaign because it has a different intake mani-

fold.

1. Verify that the vehicle is within the following range:• 2003MY Protege VIN Range: (JM1 BJ**** 3*181114 - 219674)- If the vehicle is within the above range, proceed to step 2.- If the vehicle is not within the above range, return the vehicle to the customer or inventory.

2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for a Campaign Label RECALL 3005C attached to the vehicle’s hood or bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table below.

NOTE: Verify RECALL number as the vehicle may have multiple RECALLs.

CAMPAIGNLABEL

c_label2

CAMPAIGNLABEL

c_label1

1326b

CAMPAIGN LABEL

CAMPAIGN NO:_____________

DATE:

P/N 9999-95-065A-05

DEALER CODE:_____________

Page 2 of 10

ATTACHMENT IIRECALL 3005C

eMDCS System - Warranty Vehicle Inquiry Results

If eMDCS displays: Campaign Label is: Action to perform:

RECALL 3005C OPEN

Present Contact the Mazda Corporate Dealer Assistance Group at (877) 727-6626 to update vehicle history.

Not present Review vehicle warranty history in eMDCS to determine if any previous replacement of the intake manifold is indicated. PNMC FS7N-13-100E or F, Quantity 1.- If the warranty history shows the intake manifold

has been replaced with either an FS7N-13-100E or FS7N-13-100F part number intake manifold, proceed to REPAIR PROCEDURE “A”.

- If the warranty history shows the intake manifold has not been replaced or it has been replaced with a part number that is not an FS7N-13-100E or FS7N-13-100F part number intake manifold, proceed to REPAIR PROCEDURE “B”.

RECALL 3005C CLOSED

Present Return vehicle to inventory or customer.

Not present Complete a label and apply to vehicle’s hood or bulk-head.

RECALL 3005C is not displayed

Does not apply RECALL does not apply to this vehicle. Return vehicle to inventory or customer.

Page 3 of 10

ATTACHMENT IIRECALL 3005C

B. REPAIR PROCEDUREWARNING:

• When the engine and intake-air system are hot, Severe Burns Can Occur. Turn off the engine and wait until they are cool before removing the intake-air system.

• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See Workshop Manual 01-14 BEFORE REPAIR PROCEDURE.)

REPAIR PROCEDURE “A”1. Start engine and remove fuel pump relay from main fuse box under hood. Allow engine to stall. This will

ensure fuel pressure is relieved before starting any inspections or disassembly.

2. Remove spark plugs and perform a compression test per the procedure in the 03MY Protégé WSM page 01-10B-8.

- If the compression test results confirm the engine compression to be in the normal range, reinstall the spark plugs, install a Recall Label in the prescribed location and return the vehicle to the customer.

- If the compression test results confirm the engine compression to be lower than the normal range, con-tact the National Technical Hotline for further instructions.

FRONT OFVEHICLE

FUELPUMPRELAY

ENGINECOOLANTRESERVOIR

Page 4 of 10

ATTACHMENT IIRECALL 3005C

REPAIR PROCEDURE “B”1. Start engine and remove fuel pump relay from main fuse box under hood. Allow engine to stall. This will

ensure fuel pressure is relieved before starting any inspections or disassembly.

2. Remove the intake manifold assembly from the vehicle according to the Workshop Manual, page 01-13b-6.

3. Separate the intake manifold from the dynamic chamber.

FRONT OFVEHICLE

FUELPUMPRELAY

ENGINECOOLANTRESERVOIR

INTAKEMANIFOLDGASKET

INTAKEMANIFOLD

DYNAMICCHAMBERGASKET

DYNAMICCHAMBER

3005Ca

Page 5 of 10

ATTACHMENT IIRECALL 3005C

4. Inspect for missing and or loose Variable Inertia Charging System (VICS) and Variable Tumble Control Sys-tem (VTCS) shutter valve screws and or plates.

- If any screws or plates (VICS or VTCS) are found to be missing, inspect the dynamic chamber for loose parts and inspect the intake runners in the cylinder head to determine if the missing parts have become lodged in the head.• If any parts are found in the dynamic chamber or the head, remove the parts using an appropriate

tool, then perform a compression test to determine if any internal engine damage has occurred (the compression test can be performed without reinstalling the intake manifold).

- If NO internal damage is indicated, proceed with the intake manifold replacement. If the compres-sion test indicates internal damage has occurred, contact the National Technical Hotline for instruc-tions.

- If no loose parts are found in the dynamic chamber or the head, then proceed to testing the compression.

NOTE: The compression test can be performed without reinstalling the intake manifold.

• If the compression test indicates NO internal damage is evident, proceed with the intake manifold replacement.

• If the compression test indicates internal damage has occurred, contact the National Technical Hot-line for instructions.

- If no screws or plates are missing, check the torque condition of the VICS plate retaining screws. To check for looseness of the VICS plates to the shaft, pinch the valve with your fingers then push and pull in an up and down and then a back and forth motion to see if there is any looseness between valve and the shaft.• If there is no looseness; proceed to the VICS Plate Screw Replacement Procedure.• If there is looseness; check the valve plates and intake manifold ports to see if there is any visible

damage.- If no damage is observed, proceed to VICS Plate Screw Replacement Procedure.- If any damage is observed, replace the intake manifold assembly.

SHAFT

SCREW

SHAFT

3005Cb

Page 6 of 10

ATTACHMENT IIRECALL 3005C

5. Check the installation condition of Variable Tumble Control System (VTCS) shutter valve and shaft in the intake manifold. To check the torque condition of the VTCS screws, pinch the valve with your fingers (use the same motion procedure as used to check the VICS plates) to see if there is looseness in the valve and shaft.

- If there is NO looseness in any of the plates; proceed to VTCS Screw Replacement Procedure.- If there is looseness, check the valve and intake manifold port to see if there is any damage.

• If NO damage is observed, proceed to VTCS Screw Replacement Procedure.• If any damage is observed, replace the intake manifold assembly.

3005Cg

Page 7 of 10

ATTACHMENT IIRECALL 3005C

VICS Screw Replacement Procedure

To keep the valves closed during the screw replacement procedure, fit a retaining jig part number FS7N-20-150 in the lever as shown.

NOTE: Fitting the jig can be simplified by applying vacuum to the actuator with a hand vacuum pump.

1. Replace each valve’s screw with a new one according to the following procedures.- If NO looseness is observed between the valve and shaft; remove and replace each valve’s screws

with new screws, one by one. Tighten them as you install them to the specified torque using the SST P/N MT05-A1-001 (torque screwdriver – Set torque: 1.0 N.m).

CAUTION: Please be careful if the two screws are loosened at the same time, the valve shaft’s location will vary and will come into contact with the port. This will cause the valve to get damaged or stuck.

- If looseness IS observed between the valve and shaft, perform the following procedure.a. Using a flat screwdriver, move the play of the shaft toward the lever.

b. Loosen the two screws until the valve is just free to move.

JIG (FS7N-20-150)

3005Cc

30005Cd

Page 8 of 10

ATTACHMENT IIRECALL 3005C

c. First, remove one screw, then move the valve toward the lever, install and tighten a new screw using the SST (torque screwdriver). Repeat the same procedure for the other new screw.

CAUTION: Make sure the valve is in the correct position. Otherwise, the valve will come into contact with the port. This will cause the valve to get damaged or stuck.

2. Remove the jig from the lever. Move the lever by hand to confirm it functions normally.a. Make sure all the valves move smoothly.b. Move the lever by hand to firmly close the valve. With the valve closed, move the lever toward the shaft

back and forth and make sure the shaft and valves move together.

CAUTION: If they do not move together, there is a possibility that valves are touching the port. Loosen the screws until the valves are just free to move, and then re-adjust the location of each valve according to the VICS Screw Replacement Procedure “B “

LEVERSIDE

GAP APPEARS BETWEENTHE VALVE AND PORT

PLACE THE VALVECLOSE TO THE PORT

3005Ce

3005Cf

Page 9 of 10

ATTACHMENT IIRECALL 3005C

VTCS Screw Replacement Procedure

1. To close the valve, fit a jig part number FS8N-20-150 in the lever.

NOTE: Fitting the jig can be simplified by applying vacuum to the actuator with a hand vacuum pump.

2. Replace each valve’s screw with a new one according to the following procedure.- If no looseness is observed in the valve and shaft; replace each valve’s screw with a new one, one by

one, tightening each screw as it is replaced using the SST (torque screwdriver).

CAUTION: Please be careful if the two screws are loosened at the same time, the valve shaft’s location will vary and will come into contact with the port. This will cause the valve to get damaged or stuck.

- If looseness is observed in the valve and shaft, perform the following procedure.

a. Using a flat screwdriver, move the play of the shaft toward the lever.b. Loosen the two screws until the valve is just free to move.

JIG (FS8N-20-150)

3005Ch

3005Ci

Page 10 of 10

ATTACHMENT IIRECALL 3005C

c. First remove one screw. Then, by moving the valve toward the lever, tighten a new screw using an SST (torque screwdriver). Do the same on the other new screw.

CAUTION: Make sure the valve is in position. Otherwise, the valve will come into touch with the port. This will cause the valve to get damaged or stuck.

3. Remove the jig from the lever. Move the lever by hand to confirm it functions normally.a. Make sure the valves moves smoothly.b. Move the lever by hand to firmly close the valve. With the valve closed, move the lever toward the shaft

back and forth and make sure the shaft and valves move together.

CAUTION: If they do not move together, there is a possibility that a valve is touching the port. Loosen the screws until valves are just free to move, and then re-adjust the location of each valve according to the Step 2 “If looseness is observed in the valve and shaft”.

4. Reinstall the parts in the reverse order of the removal.

5. Make sure each part is installed in the correct position and functions properly according to the Workshop Manual.

6. Reinstall fuel pump relay into main fuse box.

7. Start engine and check for leaks in the fuel system.

C. CAMPAIGN LABEL INSTALLATIONComplete a “Campaign Label” with the RECALL number written on the sticker and affix it to the vehicle’s hood or bulkhead. Refer back to the illustration under “A. VEHICLE INSPECTION PROCEDURE”.

GAP APPEARSBETWEEN THEVALVE AND PORT

PLACE THE VALVEALONG THE PORT

LEVERSIDE

3005Cj

3005Ck

REIMBURSEMENT PLAN Requirements for Reimbursement If you meet all of the following requirements, you are eligible to receive reimbursement under this plan: 1. An authorized Mazda dealer has inspected your vehicle and completed the 2003 Protegé Intake Manifold Shutter

Valve Emission Recall 3005C. 2. You own or have owned a subject 2003 Protegé within the VIN ranges:

Model VIN Range Build Date Range 2003 Protegé JM1BJ**** 3* 181114 - 219674 March 3, 2003 through July 31, 2003

Note: The asterisk “*” can be any number or letter. 3. You have paid for the inspection/repair or replacement of the intake manifold or shutter valve screws. 4. You have an original or legible copy of the paid repair order or invoice receipt showing:

• Description of the concern reported • Inspection/Repair or replacement of the intake manifold or shutter valve screws • Itemized part(s) and labor charges • Vehicle model and year, and vehicle identification number (chassis number) • Repair date • Repair mileage • Name, address, and telephone number of the authorized Mazda Dealer or a licensed repair shop where such

repairs were performed • Your name and address at the time of repair

5. Mail this reimbursement application form in the enclosed envelope to:

Mazda North American Operations PO Box 5049 Lake Forest, CA 92609-8549

Procedure for Reimbursement Request Once your vehicle has been inspected, repaired or the intake manifold or shutter valve screws replaced by an authorized Mazda dealer, you may apply for reimbursement by doing the following: 1. Complete the Reimbursement Application Form found on the reverse side of this page. 2. Mail the Reimbursement Application Form with a legible copy of the paid repair order and/or invoice using the

enclosed envelope. 3. Retain copies of the paid repair order or invoice and this application form for your records. If you wish to correspond with Mazda regarding this reimbursement plan, please write to the above address and refer to your vehicle identification number (VIN). Any reimbursement application form that is incomplete, illegible, or sent without the legible copy of the paid repair order or invoice will be returned for completion. If Mazda has any questions concerning your application for reimbursement, you may be contacted. Please allow 6-8 weeks for processing.

(SEE REVERSE SIDE FOR APPLICATION FORM)

REIMBURSEMENT APPLICATION FORM

2003 Protegé Intake Manifold Shutter Valve Emission Recall 3005C

(Please type or print)

Name:

First Middle Last

Address:

Street Address

City State Zip Code

Home:

Phone Number: Work:

Vehicle Identification Number (VIN):

(17 digits in length)

Total Amount of Reimbursement Requested: .

Dollars Cents

General Release I am submitting to Mazda Motor Corporation (“Mazda”) a claim for reimbursement for all inspection, repair or part replacement performed to date in connection with the intake manifold, or shutter valves/screws. The vehicle identification number (VIN) is:

VIN: In exchange for Mazda’s payment of that claim, I hereby release Mazda, its agents, and its related entities from all claims for such inspection/repair costs. This release shall benefit Mazda and its authorized agent Mazda North American Operations, its regions/distributors (foreign and domestic), its authorized dealerships, and all their respective directors, officers, agents, employees, divisions, subsidiaries, and affiliated companies. This release shall bind my heirs, successors and assigns.

Dated: Signed:

(SEE REVERSE SIDE FOR REIMBURSEMENT PLAN DETAILS)

INSTRUCTIONS FOR GENERAL RELEASE DESCRIBED BELOW:

• Please read thoroughly • Fill in vehicle identification number • Sign the General Release (below)