Technical
Service Bulletin

Mazda North American Operations
Irvine, CA 92618-2922

Subject:
ENGINE MISFIRE DURING ACCELERATION WITH CHECK ENGINE
LIGHT FLASHING AND DTCs P0302:00, P0303:00 AND/OR U0401:00

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted in Red text.

Previous TSBs: Date(s) Issued:
01-010/18

03/29/2018

APPLICABLE MODEL(S)/VINS
2016-2017 CX-9 vehicles with VINs lower than JM3TC******135222 (produced before Dec. 27, 2016)

DESCRIPTION
Some vehicles may exhibit an engine misfire during acceleration with the check engine light flashing and
the following DTC(s).




P0302:00 - Cylinder No.2 misfire detected and/or
P0303:00 - Cylinder No.3 misfire detected

NOTE: Even if a misfire occurred, the DTCs may not be stored because they are set after the continuous
misfire occurred for 2 drive cycles. In this case, check if the following information is available to verify if the
vehicle is applicable to this Service Information.




The customer states that the misfire occurred and at the same time the check engine light started
flashing.
DTC U0401:00 ((ABS) Signal error from PCM) is detected.

Page 1 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

This concern may be caused if the exhaust manifold variable valve shaft (1) is out of alignment and/or the
exhaust manifold variable valve housing (2) is out of shape. The exhaust manifold variable valve (3) then
interferes with the housing and becomes stuck closed when the engine is hot.

To eliminate this concern in the future, the production processes and controls have been improved.

Page 2 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

REPAIR PROCEDURE
1. Verify that DTCs P0302:00 and/or P0303:00 are stored in memory.
NOTE: DTCs P0302:00 and/or P0303:00 may not be stored because they are set after the continuous
misfire for 2 drive cycles. If this is the case, verify that one or both of following conditions are met.




If possible, confirm with the customer that the misfire and the check engine light started flashing at
the same time.
DTC U0401:00 is stored in memory.

NOTE: If there is any other engine related DTC(s) stored, diagnose and repair it accordingly.
2. If one or both of the above conditions are met, remove the exhaust manifold and verify that there are
contact mark(s) on the exhaust manifold variable housing caused by the variable valve, as shown below.

3. If contact mark(s) are found, replace the exhaust manifold with a modified one according to the
instructions on MGSS online (EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]).

Page 3 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

Exhaust Manifold Installation Note
1. Tighten the nuts in the order shown below while watching that the stud bolts are not rotating.
Tightening Torque:
50—57 N·m {5.1—5.8 kgf·m, 37—42 ft·lbf}

CAUTION: When tightening nuts, do not allow the stud bolt to rotate over 270 degrees, otherwise, it could
cause the cylinder head to crack, as shown below. If cylinder head is cracked, replace it with a new one.
(TOP VIEW)

Page 4 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

(SIDE VIEW)

2. To prevent the stud bolt (1) from rotating over 270 degrees, place a mark (2) on the stud bolt (as shown
below) and watch its movement while tightening the nut.

Permissible range of stud bolt
rotation:
270 Degrees

- If the stud bolt is going to rotate over 270 degrees before obtaining the specified tightening torque, hold it
with a torques socket wrench (E10), then temporary tighten the nut using an offset wrench. Lastly, tighten
the nut to the specified torque using a torque wrench.
- If the stud bolt has rotated and was removed during removal of the exhaust manifold, reinstall it to the
following tightening torque.
Tightening Torque:
15—19 N·m (1.5—1.9 kgf·m, 11—14 ft·lbf}

Page 5 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

NOTE: There may be a crack found in the turbocharger housing, as shown below. The crack does not
affect engine performance or cause any noise, so turbocharger replacement is not necessary.

PARTS INFORMATION
Part Number

Description

Qty.

Notes

PY8V-13-450F

Manifold, Exhaust

1

Replace with modified part

PY8V-13-460 Gasket, Exhaust Manifold

1

Replace

PY88-13-465

Nut, Exhaust Manifold

5

Replace

SH01-13-465

Nut, Exhaust Manifold

6

Replace

1

Replace

PY88-13-490 Gasket, Exhaust Manifold
PY8V-13-710B

Gasket, Turbocharger

1

Replace

PE23-40-305

Gasket

2

Replace

9994-61-000

Nut

4

Replace

Page 6 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

Part Location

1

Main silencer

5

HO2S

2

Plate

6

TWC

3

Brace bar

7 Gasket (2) (Replace)

4 Tunnel Member 8

Nut (4) (Replace)

Page 7 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

Page 8 of 9
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.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 01-010/18

Last Issued: 04/27/2018

1

Insulator No.1

7

Insulator No.3

2

A/F sensor

8

Turbocharger

3

Insulator No.2

9

Gasket, Turbocharger (Replace)

4

WU-TWC

10

Exhaust Manifold (Replace)

5 Gasket, WU-TWC (Replace) 11 Gasket, Exhaust Manifold (Replace)
6 Nut, WU-TWC (5) (Replace) 12 Nut, Exhaust Manifold (6) (Replace)

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 Limited Warranty.
• Additional diagnostic time cannot be claimed for this repair.

Warranty Type

A

Symptom Code

6X

Damage Code

9G

Part Number Main Cause
Quantity
Operation Number / Labor
Hours:

PY8V-13-450F
1
XXP34ARX / 4.3 Hrs. (2WD)
XXP34CRX / 4.2 Hrs. (4WD)

NOTE: Enter other replaced parts in Related Parts.

Page 9 of 9
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.

© 2018 Mazda North American Operations, U.S.A.