Interior - Accelerator/Brake Pedal Vibration
Bulletin No.: 01-033/09Last Issued: 07/24/2009
Subject:
ACCELERATOR PEDAL VIBRATION
BULLETIN NOTE
^ *This bulletin supersedes the previous bulletin 01-039/08, issued on 07/23/08. The REPAIR PROCEDURE, PARTS INFORMATION and WARRANTY INFORMATION have been revised.*
^ *Changes are shown with a black line beside the change and asterisks.*
APPLICABLE MODEL(S)/VINS
*2007-2009 CX-9 vehicles with VINs lower than JM3 TB** **9* 172315 (produced through January 14, 2009)*
DESCRIPTION
Some vehicles may exhibit accelerator pedal vibration around 2000 engine RPMs, regardless of speed. The vibration may also be felt at the brake pedal and steering wheel. *Two repair procedures have been developed to address this concern.*
On vehicles with VINs JM3 TB**** ** 149825 through 164651 (produced February 21, 2008 through July 7, 2008), * perform REPAIR PROCEDURE "A" and "B"*. The No.2 dynamic chamber stay (bracket) was deleted on production vehicles. The absence of the No.2 stay can cause pedal vibration. *REPAIR PROCEDURE "A"* details installation of the No. 2 stay. The No. 2 dynamic chamber stay components required are the stay (1), the top fastener (2) and the bottom fastener (3) to resolve concern.
*On 2007-2009 vehicles with VINs lower than JM3 TB** **9* 172315 (produced through January 14, 2009), perform REPAIR PROCEDURE "B". The cause of this is interference between the resonator to the accelerator pedal. The resonator has been eliminated since January 14, 2009. REPAIR PROCEDURE "B" details the rotation of a vacuum hose to increase clearance to resolve concern.*
Customers having this concern should have their vehicle repaired using the following two repair procedures.
REPAIR PROCEDURE "A"
* NOTE:
Perform repair procedure "A" and "B" on vehicles with VINs JM3 TB**** 9* 149825 through 164651 (produced February 21, 2008 through July 7, 2008)*
1. Verify customer concern.
2. Record customer radio station presets.
3. Remove negative battery cable.
4. Remove engine cover. Refer to Workshop Manual section 01-10 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].
5. Remove the air cleaner cover and resonance chamber. Disconnect the MAF/IAT sensor connector. Refer to Workshop Manual section 01-13 INTAKE-AIR SYSTEM REMOVAL / INSTALLATION [3.7L].
6. Remove dynamic chamber assembly (upper intake manifold). Refer to Workshop Manual section 01-13 INTAKE-AIR SYSTEM REMOVAL / INSTALLATION [3.7L].
a. Remove one 8mm fastener from No.1 stay (just underneath throttle body)
b. Remove three (3) harness clips from dynamic chamber using body removal tool (or equivalent).
c. Remove six (6) 8mm bolts from dynamic chamber.
NOTE:
^ When removing dynamic chamber assembly, leave back hose connected and position out of the way.
^ Remove purge valve from mounting bracket to provide additional room to work.
7. Remove two (2) 8mm bolts (A) and loosen one (1) 8mm bolt (B) from the rear exhaust manifold insulator (heat shield) as shown. Refer to Workshop Manual section 01-15 EXHAUST SYSTEM REMOVAL / INSTALLATION [3.7L].
NOTE:
^ An inspection mirror may be helpful to see the bolts.
8. Reposition the heat shield (D) to gain access for No. 2 stay bottom fastener installation.
9. Install bottom fastener (C). Start threads but do not tighten the fastener at this time.
NOTE:
^ Apply Loctite # 272 to bottom fastener threads before installation.
10. Install the No. 2 stay so that slotted side of the stay is placed on top of the bottom fastener installed in the previous step. Do not tighten the fastener at this time.
11. Check that all dynamic chamber gaskets are in place and mounting surfaces are clean.
12. Place dynamic chamber onto the lower intake manifold.
13. Install top fastener through the top bolt hole of the No.2 stay but do not tighten at this time. This will align the No.2 stay properly.
14. Tighten the No. 2 stay bottom fastener.
Fastener Torque: 14.8-20.7 ft-lbf. (20-28 N.m)
NOTE:
^ Use an angled box wrench for best results.
^ Due to limited space, it may not be possible to insert a torque wrench. In this case, tighten bolt snug then another 1/2 turn.
15. Reinstall two 8mm heat shield bolts and tighten Fastener Torque: 15.7-21.2 ft-lbf. (21.2-28.8 N.m)
NOTE:
^ Due to limited space, it may not be possible to insert a torque wrench. In this case, tighten bolt snug then another 1/2 turn.
16. Install the dynamic chamber fasteners. Refer to Workshop Manual section 01-13 INTAKE-AIR SYSTEM REMOVAL / INSTALLATION [3.7L].
- Reinstall hose, pipe, throttle body connector, three (3) engine harness clips, No.1 stay bolt, and six (6) dynamic chamber bolts.
- Ensure the proper torque sequence is followed in the Workshop Manual procedure or vibration may occur.
Fastener Torque: 76-101 in-lbf. (8.5-11.5 N.m)
17. Tighten No. 2 stay top fastener (CA01-13-366)
Fastener Torque: 76-101 in-lbf. (8.5-11.5 N.m)
18. Reinstall purge valve to mounting bracket.
19. Reinstall the air cleaner cover and resonance chamber. Connect the MAF/IAT sensor connector. Refer to Workshop Manual section 01-13 INTAKE-AIR SYSTEM REMOVAL / INSTALLATION [3.7L].
20. Reinstall the engine cover. Refer to Workshop Manual section 01-10 ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].
21. Reconnect the negative battery cable.
22. Reprogram all customer radio station presets.
23. Initialize power windows auto open/close functions. Refer to Workshop Manual section 09-12 POWER WINDOW INITIALIZATION PROCEDURE.
24. Verify repair.
* REPAIR PROCEDURE"B"
NOTE:
Perform on all 2007-2009 vehicles with VINs lower than JM3 TB** **9* 172315 (produced through January 14, 2009)
1. Check the clearance between the intake air duct and the brake booster vacuum hose.
2. If distance between A and B is shorter than 6mm, remove the hose clamps and rotate the vacuum hose to increase clearance.*
3. Verify repair.
PART(S) INFORMATION
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.
^ Additional diagnostic time cannot be claimed for this repair.
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