01-003-15-3014

Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
© 2015 Mazda Motor of America, Inc.
Subject:
Bulletin No:
01-003/15
Last Issued:
02/27/2015
OXYGEN / AIR FUEL RATIO SENSOR REMOVAL CAUTION
MULTI MODEL - OXYGEN / AIR FUEL RATIO SENSOR REMOVAL CAUTION
BULLETIN NOTE
• This bulletin supersedes the previous bulletins 01-032/10 issued 05/27/10, 01-051/09 issued 11/19/09, 01006/08 issued 02/11/08 and 10/10/08 and 01-019/07 issued 05/10/07. The APPLICABLE MODEL(S)/VINS
and REPAIR PROCEDURE has been revised.
• Changes are noted below in Red beside the change bar.
APPLICABLE MODEL(S)/VINS
2000-2003 Protege
2000-2005 Miata
2000-2002 626
2000-2002 Millenia
2000-2006 MPV
2001-2006 Tribute
2008-2011 Tribute
2008-2010 Tribute Hybrid
2011-2015 Mazda2
2004-2015 Mazda3
2006-2014 Mazda5
2003-2016 Mazda6
2006-2015 MX-5
2004-2011 RX-8
2013-2016 CX-5
2007-2012 CX-7
2007-2015 CX-9
DESCRIPTION
Use the following repair procedure to minimize the need to replace the catalyst converter/exhaust pipe when
removing oxygen sensors and/or air fuel ratio sensors.
REPAIR PROCEDURE
Oxygen Sensor Removal Procedure:
WARNING: To avoid personal injury, allow exhaust system to cool down before removing oxygen sensor.
NOTE: In some cases oxygen sensor and/or air fuel ratio sensor seizure will occur during this removal procedure. If seizure occurs, remove the converter or exhaust pipe from the vehicle and re-attempt removal
with the assembly placed in a vise. This will maximize your positioning and ability to apply adequate
torque to remove the sensor.
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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.
Bulletin No: 01-003/15
Last Issued: 02/27/2015
© 2015 Mazda Motor of America, Inc.
1. If reusing oxygen sensor, mask it with masking tape (A) to prevent lubrication soaking.
2. Spray CRC Freeze-Off (or equivalent) around the oxygen sensor flange (B).
CAUTION: Avoid excess spraying. Remaining flammable substance could catch fire.
3. Allow lubricant to reach sensor threads for a minimum of 1 - 2 minutes.
NOTE: FOLLOW ALL PENETRANT MANUFACTURER INSTRUCTIONS LISTED ON THE PRODUCT
LABEL.
4. Turn 30 degrees counter-clockwise with SST (49 L018 001).
5. Remove SST and spray lubricant again in the same place.
6. Allow lubricant to reach sensor threads for a minimum of 1 - 2 minutes.
7. Use SST to loosen sensor.
NOTE: If sensor begins to bind, it may be necessary to work the sensor in a tightening and loosening
motion to slowly work the sensor out.
8. Wipe off all excess lubricant.
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Bulletin No: 01-003/15
Last Issued: 02/27/2015
© 2015 Mazda Motor of America, Inc.
9. Clean O2 sensor threads in converter or pipe with SST J-43897-18.
NOTE: If the converter or exhaust pipe threads cannot be correctly cleaned on the vehicle, remove the
converter or exhaust pipe from the vehicle to perform thread cleaning procedure. If the threads
cannot be adequately cleaned to correctly install the sensor, then converter or exhaust pipe can be
replaced. However, replaced catalytic converters are collected, the threads are cleaned and a new
sensor is installed and torqued to spec. to confirm the converter replacement was necessary.
The claim is subject to debit if a new sensor can be installed and torqued to spec.
10. Coat O2 sensor threads with “NEVER-SEEZ” (or equivalent) high temperature nickel based anti-seize
grease.
WARNING: If reusing the oxygen sensor, completely remove the masking tape to prevent vehicle fire.
11. Install O2 sensor and tighten to:
Tightening Torque: 29 - 49 Nm (22 - 36 ft. lbs.)
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