01-007-14

Tony Lawrence
From:
Sent:
To:
Subject:
Daniel Gonza lez
Monday, March 17, 2014 3:36 PM
All Dlrs All Rg ns - PT; All Dlrs All Rgns - SR
MAZDA DEALER NOTICE - SERVICE BULLETIN RELEASE
SERVICE BULLETIN RELEASE - 03/17/2014
2014 INDEX: http://www.mstore2000.com/PDF Files/index03-17-14.pdf
The following Service Bulletin has just been issued.
- For latest MS3 postings, click here: https://portal.mazdausa.com/m173/service/esi/MazdaServiceShop
- For printable PDF files from MStore, click on the link below each TSB title:
* If the links do not automatically take you directly to the document, cut and paste the link into your internet
browser address window and press enter.
UPDATED BULLETIN
01 -007/14-2009-2013 MAZDA6 2.SL (A/T)- UNUSUAL NOISE FROM EXHAUST PIPE SEAL RING
http://www.mstore2000.com/PDF Files/01-007-14-2899.pdf
•
Please distribute this information to all parts and service personnel.
•
If you no longer wish to receive Mazda bulletins, please contact the IT Administrator at your dealership and ask them
to remove your email address from under the EMDCS application.
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Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
© 2014 Mazda Motor of America, Inc.
Subject:
Bulletin No:
01-007/14
Last Issued:
03/17/2014
UNUSUAL NOISE FROM EXHAUST PIPE SEAL RING
BULLETIN NOTE
• This bulletin supersedes the previous bulletins 01-016/12 issued 04/27/12 , 06/27/12 and 10/19/12, 01-022/
11 issued 06/07/11, 01 -044!10 issued 08/06/10, 08/13/ 10, and 10/15/10, and 01-052/08 issued 11/26/08. The
APPLICABLE MODEL(S)NINS, PARTS INFORMATION and WARRANTY INFORMATION have been
revised .
• Changes are noted below in Red beside the change bar.
APPLICABLE MODEL(S)NINS
2009-2013 Mazda6 2.5L with automatic transmission
DESCRIPTION
Some vehicles may exhibit an unusual squeak noise when the engine is idling, or just at the moment when the
engine is shut off. The noise may be audible from inside the vehicle if one or more windows are open , or if any
passenger is opening a door to exit the vehicle.
Due to engine vibration and a lack of seal ring lubrication, the mesh in the seal ring (A) rides in the flared portion
(B) of the catalytic converter (C) resulting in a slight noise from the exhaust system while the engine is running .
The friction between the exhaust system parts and the resulting slight noise are normal. This friction
does not cause breakage, gas leakage, or other functional problems with the vehicle's exhaust system .
During normal vehicle aging, the noise level may change as the surface of the metal flange deteriorates. Usually this noise cannot be heard when the engine is running, however the noise may be heard in a quiet environment when the customer is outside the vehicle or when a door or window is open.
25170
Customers having this concern should have their vehicle repaired using the following repair procedure.
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 .
Last Issued: 03/17/2014
Bulletin No: 01-007/14
© 2014 Mazda Motor of America, Inc.
REPAIR PROCEDURE '
WARNING: A hot engine and exhaust system can cause severe burns. Wait until they are cool before beginning the repair.
· ·
NOTE: ' Be sure to follcfw the re.pair procedure precisely,, incl~ding all not~s arid caution~: qtherwise, the symptom will recur. Recommend to the customer that they drive gently for approximately. 125 miles (200 km)
in order to properly seat the seal ring to the round surface of the exhaust manifold flange.
1. Verify customer concern.
2. Safely lift vehicle on hoist.
3. Remove the catalytic._converter and mi.ddle pipe together as an assembly. Refer to the MS3 online instructions or Workshop Mam1al (section 01·~ 15A EXHAUST SYSTEM.REMOVAL/INSTALLATION [MZR 2.5]) .
NOTE: Failure to follow the instructions on MS3 or the Workshop Manual may result in rattle noise due to
misalignment of the exhaust system .
4. Remove the exhaust studs and washers (if any) and discard them .
5. Remove seal ring from exhaust manifold . Refer to the MS3 online instructions or Workshop Manual (section
01-15A EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.5]) .
6. Stuff a cloth into exhaust manifold and catalytic converter to prevent dust or debris from entering.
7. Polish the flared portion (A) of catalytic converter-side (B) using a nylon brush or sandpaper (#60) for twenty
(20) minutes, then use (#600) for three (3) minutes until bare metal is exposed.
8. Degrease (A) using ethanol for thirty (30) seconds.
9. Remove stains from the seal ring installed locatio'n (C) in exhaust ma~ifold (D) .
10. Degrease (C) using ethanol for thirty (30) seconds.
NOTE: Make sure· the polished surface is free from seal ring residue , debris, or wear marks.
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2401 c
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11 . Run your finger over seal ring installed location (flange) of exhaust manifold . If surface feels rough, use #80
sandpaper Ul'ltil rough surface is gone, themuse fine sandpaper until bare metal is exposed .
NOTE: Do not use air tools.
Page 2 of 9
Bulletin No: 01-007/14
Last Issued: 03/17/2014
© 2014 Mazda Motor of Ameri ca, Inc.
12. If severe damage appears on round surface of catalytic converter-side flared flange .(A) , replace catalytic
converter.
,
NOTE: If the catalytic converter is replaced and a black coating (B) remains on the round ·surface of the
flared flange , the white coating of the s~al ring will stick to the black cqating , which may cause .
noise. Be._sure . ~ci suffidentiv. polish the flang~ (C) .
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In case where catalytic converter: is NOT replaceq: .
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a. Install a new exhaust stud .
b. Confirm if patch (A) e~ists behind the catalytic converter flange .
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2640.
If YES (patch exists) - Install washer listed in the Part(s) Information to reduce spring tension.
NEVER use an originally equipped washer.
If NO (patch does not exist) - Washer installation is NOT necessary.
In case where catalytic converter is replaced :
a. Install a new exhaust stud .
b. Washer installation is NOT necessary (as no patch· exists on ·new catalytic converter listed ·irrthe
Part(s) Information.
13. Using a piece of cloth including organic solvent (acetone, methanol) or a piece of cloth free of oil content,
wipe off any debris or grease from polished area.
Page 3 of 9
Bulletin No: 01-007/14
Lastlssued: 03/17/2014
© 2014 Mazda Motor of America , Inc.
14. Remove cloth from exhaust manifold .
NOTE: During cloth removal , be careful not to allow any foreign substances· into the pipe.
15. Replace old seal ring (A) with new seal ring (B) . Push new seal ring (with green identification marking (C))
onto manifold flange by hand .
0
2517b
Pay attention so as not to drop the seal ring on the floor as it can be easily damaged.
NOTE:
Make sure seal ring fits straight and does not fall off when you remove your hand from the ring .
Make sure seal ring ·fits straight, if not, there is a possibility the lubrication on the inner surface
will be damaged when the seal ring is press-fitted with the special service tool.
CAUTION:
DO NOT APPLY any type of grease to the seal ring as it will harmfully effect the lubricant performance originally applied on the seal ring and the noise will recur.
'
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2401 0
Page 4 of 9
Bulletin No: 01-007/14
Last Issued: 03/17/2014
© 2014 Mazda Motor of America , Inc.
16. Install the special service tool (SST) to the seal ring so that the SST is even witl:Ythe flange .
A: Installer (49 ~0,40 004)
B: Handle (49 G040 001)
·!
2401f
17. Seat seal ring by lightly tapping end of special service tool with a rubber hammer.
18. Push in seal ring (A) until edge of it contacts flange (B).
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19. If the seal ring is NOT installed straight, mesh
tact the exhaust pipe flange.
wi~e
(A) will come out fro.m the seal ring which will then con1t' .,.
0
2640b
Page 5 of 9
Last Issued: 03/17/2014
Bulletin No: 01-007/14
© 2014 Mazda Motor of America, Inc.
a. Insert a 0.3mm thickness gauge at four different'tocations and confirm that the gauge'Stops at 5mm or
less.
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..
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b. If the gauge can be inserted more than 5mm in one or more locations, perform the following :
1. Place the used original seal ring (A) upside down to the new seal ring (B) .
2. Tap it around carefully against the exhaust manifold (C) with a rubber hammer so as not to damage
the seal ring .
3. Do this ur:itil the O}mm thickne~~ 9auge st9ps at !)mm, or le~s .
B
.,
20. Assemble converter to seal ring according to the Workshop Manual or MS3 online instructions (section 0115A EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.5L]) .
NOTE: Failure to follow the instructions may result in rattle noise due to misalignment of exhaust system .
Page 6 of 9
Bulletin No: 01-007/14
CC>
Last Issued: 03/17/2014
2014 Mazda Motor of America, Inc.
21 . Install springs, washers (when necessary accord..ing·to Step 11), and he~ nuts in .order.
· ·
A - Exhaust Stud
B - Spring
C - Washer - (washer fits inside spring against stud shoulder)
D - Hex Nut
E- Seal Ring
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NOTE: It is NOT necessary to install wash.ers wheri thecatalYtic converter is replaced with"a-new one.
22 . Tighten the stud nuts.
Tightening torque: 41-51 Nm (4.2-5.2 kgf-m, 31-37 ft-lbf)
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Page 7 of 9
Bulletin No: 01-007/14
Last Issued: 03/17/2014
© 2014 Mazda Motor of America, Inc.
23. Measure the length and clearance between the flanges of the exhaust manifold and U/F catalytic converter.
Verify that they are within the specification shown.
A
Upper
9-12 mm
B
Lower
7-10 mm
c
Right
D
6-9 mm
6-9 mm
E
F
Left
Spring length (end-to-end)
Vehicle ·upper
G
Vehicle lower
29-31 mm
NOTE: If the clearance or spring length is out of. range , verify the cause and repair.
'(.
VIEW A-A
24. Verify repair.
WARNING: Exhaust leaks can allow carbon monoxide into the vehicle and cause injury or death, p1ease go
over the system and be sure there are no gas leaks at any point before returning the vehicle to
..
.
the customer.
Page 8 of 9
Bulletin No: 01-007/14
Lastlssued: 03/17/2014