Service Bulletin Mazda North American Operations

Service Bulletin Mazda North American Operations
Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
© 2009 Mazda Motor of America, Inc.
Subject:
Bulletin No:
01-053/09
Last Issued:
12/01/2009
DIAGNOSTIC PROCEDURE FOR ENGINE NOISE REPAIR
MULTI-MODEL - DIAGNOSTIC PROCEDURE FOR ENGINE NOISE REPAIR
APPLICABLE MODEL(S)/VINS
2006 - 2010 MX-5
2004 - 2010 Mazda3
2006 - 2010 Mazda5
2003 - 2010 Mazda6 2.3L/2.5L
DESCRIPTION
Some vehicles may exhibit various types of engine noise such as knocking, ticking, tapping, rattling, grinding,
squealing, squeaking, thumping, whining, creaking, popping, clicking or roaring. If you encounter engine noise,
refer to the following repair procedure. If any parts can be reused after inspection, be sure to reuse them.
REPAIR PROCEDURE
DIAGNOSTIC PROCEDURE
Step
Inspection
Result
Action
1
Verify if the noise is coming from the engine or body.
If Yes to
either
question
Engine mount trouble is suspected. Check torque of engine mount bolt, oil leak from
mount and engine mount
damage according to
Workshop Manual (section
01-10 MECHANICAL).
Listen to the noise with a sound scope or Chassis Ear
at the engine or body then compare. Refer to the
following illustrations for points to measure the noise.
Is the noise only heard on the body side?
2
Is the noise heard on the body side louder than that
heard on the engine side?
No
Go to the next step.
Verify if the noise is coming from the drive belt.
Yes
Go to “Generator Drive Belt
and Related Parts Noise”
procedure.
No
Go to the next step.
Yes
Go to the next step.
No
Go to Step 5.
Using a sound scope, is the noise heard from around
the parts driven by a drive belt, such as generator or
A/C compressor?
3
Verify if the noise is coming from the intake manifold.
Is the noise heard from around the intake manifold?
Page 1 of 14
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: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
4
Verify if the noise is coming from the IMTV or IMRC
(inside intake manifold).
Yes
Replace the intake manifold
according to Workshop
Manual (section 01-13
INTAKE MANIFOLD
REMOVAL/
INSTALLATION).
No
Go to the next step.
Yes
This procedure is not applicable. Exhaust or drive train
system is suspected. Refer
to Workshop Manual
(section 01-15 EXHAUST
SYSTEM, 02
SUSPENSION, 03
DRIVELINE/AXLE, 04
BRAKES or 05
TRANSMISSION/
TRANSAXLE).
No
Go to the next step.
Yes
Go to diagnostic procedure
for “Engine Noise”.
No
2004-2009 Mazda3
Does the noise level change when activating and
deactivating IMTV-IMRC by M-MDS simulation
function?
5
Verify if the noise is coming from the drive train or
exhaust.
Is the noise heard from the drive train or exhaust
system?
6
Verify if the noise is coming from the engine itself.
Is the noise heard from the engine itself?
2006-2010 Mazda5
Go to the next step.
2010 Mazda3
2006-2010 MX-5
2003-2010 Mazda6 (L3/L5
engine)
Go to Step 8.
7
Verify if the noise is coming from the fuel distributor
due to fuel pulsation.
Yes
Contact Mazda Technical
Assistance Hotline and advisde them there is an issue
with the fuel distributor.
No
Go to the next step.
Yes
This procedure is not applicable. Purge system is suspected. Refer to Workshop
Manual (section 01-16
PURGE VALVE
INSPECTION).
No
Contact Mazda Technical
Assistance Hotline.
Does the noise go away or change by adding approx.
200g (7 oz.) of weight on the fuel distributor?
8
Verify if the noise is coming from the purge valve.
Does the noise occur when the purge valve is
activated by M-MDS simulation function, then goes
away when deactivated?
Page 2 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
MAZDA3 AND MAZDA5: POINTS TO MEASURE THE NOISE AROUND THE ENGINE MOUNTS:
No. 1 Engine Mount:
Engine Side: Around transmission case bracket tightening point (A).
Body Side: Around mounting rubber fixing point on crossmember (B).
No. 3 Engine Mount:
Engine Side: No. 20 front cover bolt head located below No. 3 engine mount fixing point (A).
Body Side: No. 3 engine mount tightening bolt (B).
Page 3 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
No. 4 Engine Mount:
Engine Side: Around transmission case mount bracket fixing point (A).
Body Side: Around mount bracket fixing point (vehicle side) (B).
MAZDA6: POINTS TO MEASURE THE NOISE AROUND THE ENGINE MOUNTS:
No. 1 Engine Mount:
Engine Side: Around transmission case bracket tightening point (A).
Body Side: Around mounting rubber fixing point on crossmember (B).
Page 4 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
No. 3 Engine Mount:
Engine Side: No. 20 front cover bolt head located below No. 3 engine mount fixing point (A).
Body Side: No. 3 engine mount tightening bolt (body side) (B).
No. 4 Engine Mount:
Engine Side: Around transmission case mount bracket fixing point (engine side) (A).
Body Side: Around mount bracket fixing point (vehicle side) (B).
Page 5 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
MX-5: POINTS TO MEASURE THE NOISE AROUND THE ENGINE MOUNTS:
Intake manifold side engine mount:
Engine Side: Engine mount bracket (A).
Body Side: Around mounting rubber fixing point on crossmember (B).
Exhaust manifold side engine mount:
Engine Side: Engine mount bracket (A).
Body Side: Around mounting rubber fixing point on crossmember (B).
Page 6 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
Check the engine mount (A) installed on both sides of the vehicle and verify that the shape of engine mount rubber (B) is symmetrical and not touching its housing (C).
Page 7 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
GENERATOR DRIVE BELT AND RELATED PARTS NOISE
Step
1
Inspection
Verify if the noise is due to a fatigued drive belt.
Result
Yes
Replace the drive belt according to Workshop
Manual (section 01-10
DRIVE BELT REMOVAL/
INSTALLATION).
No
Go to the next step.
Yes
Replace the A/C compressor
according to Workshop
Manual (section 07-11 A/C
COMPRESSOR
REMOVAL/
INSTALLATION).
No
2004-2009 Mazda3
Does the drive belt auto tensioner indicator mark
exceed the limit?
Refer to Workshop Manual (section 01-10 DRIVE
BELT INSPECTION).
2
Verify if the noise is coming from the A/C compressor.
Shift into N range or neutral then turn the A/C on/off
and compare the noise.
Is the noise level greater with the A/C on than it is with
the A/C off?
NOTE: The purpose of this step is to check if
continuous noise occurs when the A/C is on,
not to check the on/off noise of the
compressor magnet clutch.
Action
2010 Mazda3 (except L5 engine)
2006-2010 Mazda5
Go to the next step.
2006-2010 MX-5
2003-2010 Mazda6 (L3/L5
engine)
2010 Mazda3 (L5 engine)
Go to Step 6.
3
Verify if the noise is coming from the A/C compressor
drive belt and/or pulley.
Mazda3 (except 2010 L5 engine) or Mazda5: Does
the noise go away when running the engine without
the A/C belt?
Yes
Go to the next step.
No
Go to Step 6.
Yes
Remove foreign material and
clean the A/C belt or pulley.
No
Go to the next step.
Refer to Workshop Manual (section 01-10 DRIVE
BELT REMOVAL/INSTALLATION).
4
Verify if the noise is due to foreign material.
Mazda3 (except 2010 L5 engine) or Mazda5: Any
foreign material stuck between the A/C drive belt and
pulley?
Page 8 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
5
Verify if the noise is due to a damaged A/C drive belt
and/or pulley.
Yes
Replace the damaged
part(s) according to
Workshop Manual (section
01-10 DRIVE BELT
REMOVAL/
INSTALLATION).
No
A/C belt damage is suspected. Replace the A/C belt according to Workshop
Manual (section 01-10
DRIVE BELT REMOVAL/
INSTALLATION).
Yes
Go to the next step.
No
Issue is not belt related, go
back to “Diagnostic Procedure”.
Verify if the noise is due to foreign material.
Yes
Any foreign material stuck between the pulley and
belt?
Remove foreign material and
clean the belt and pulley.
No
Go to the next step.
Yes
Replace the damaged
part(s) according to
Workshop Manual (section
01-10 DRIVE BELT
REMOVAL/
INSTALLATION).
No
Go to the next step.
Yes
Replace the generator according to Workshop
Manual (section 01-17
GENERATOR REMOVAL/
INSTALLATION).
No
Go to the next step.
Mazda3 (except 2010 L5 engine) or Mazda5: Any
damage found on the A/C drive belt or pulley?
6
Verify if the noise is coming from the drive belt or componenets driven by the belt.
Does the noise go away when running the engine
without the generator drive belt?
Refer to Workshop Manual (section 01-10 DRIVE
BELT REMOVAL/INSTALLATION).
NOTE: To run the engine without the belts, follow
the conditions below.
- Keep engine at 1,500 rpm or lower during
the stall test in D range.
- Keep the engine at 2,000 rpm or lower
when in N range.
- Running period should be less than ten
(10) seconds (from engine start to engine
stop).
- For continuous test, run the engine at
intervals of thirty (30) minutes or more,
cooling the engine with a large shop fan.
7
8
Verify if the noise is due to a damaged belt and/or pulley.
Any damage found on the drive belt or pulley?
9
Verify if the noise is due to a generator malfunction.
Any unusual resistance felt when turning the
generator by hand?
Page 9 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
10
Verify if the noise is due to an auto tensioner malfunction.
Yes
Replace the drive belt auto
tensioner according to
Workshop Manual (section
01-10 DRIVE BELT AUTO
TENSIONER REMOVAL/
INSTALLATION).
No
Go to the next step.
Yes
If the drive belt auto tensioner has not been replaced
yet, replace it according to
Workshop Manual (section
01-10 DRIVE BELT AUTO
TENSIONER REMOVAL/
INSTALLATION).
Any unusual resistance felt or squeak noise heard
when moving the drive belt auto tensioner by hand?
Refer to Workshop Manual (section 01-10 DRIVE
BELT AUTO TENSIONER INSPECTION).
11
Verify if the noise is coming from the auto tensioner.
Install the generator drive belt and A/C belt according
to Workshop Manual (section 01-10 DRIVE BELT
AUTO TENSIONER REMOVAL/INSTALLATION).
Compare the noise level of “N range with A/C ON” and
“D range with A/C ON”.
Is the noise level greater in “D range with A/C ON”
than it is in “N range with A/C ON”?
No (or
M/T
equip.)
2004-2010 Mazda3
2006-2010 Mazda5
Go to Step 13.
2006-2010 MX-5
2003-2010 Mazda6 (L3/L5
engine)
Go to the next step.
12
Verify if the noise is due to a power steering system
malfunction.
Yes
Refer to power steering
diagnostics according to
Workshop Manual (section
06-14 POWER STEERING).
Does the noise become worse?
NOTE: The noise can be easily checked by
touching the “eye bolt” which is connected to
the high pressure side pipe to power
steering pump.
No
Go to the next step.
Verify if the noise is coming from the water pump.
Yes
Replace the water pump according to Workshop
Manual (section 01-12
WATER PUMP REMOVAL/
INSTALLATION).
No
Go to the next step.
Verify if the noise is due to a damaged drive belt.
Yes
Completed.
If the drive belt has not been replaced yet, replace it
according to Workshop Manual (section 01-10
DRIVE BELT REMOVAL/INSTALLATION).
No
Contact Mazda Technical
Assistance Hotline.
Shift to N range or neutral, then perform static
steering.
13
Is the noise heard just from around the water pump
area?
14
Is the noise gone?
Page 10 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
ENGINE NOISE
Step
1
Inspection
Verify if the noise only occurs when starting the engine.
Does the noise only occur when starting the engine
after the vehicle sits overnight?
2
Verify if the noise is due to a VVT lock function malfunction.
When rotating the intake camshaft, does the intake
cam sprocket slip?
Result
Yes
Go to the next step.
No
Go to Step 3.
If Yes to
either
question
Any cracks or damage visually found around the VVT
lock pin stopper?
For illustration purposes, refer to the following TSBs:
Action
No
Replace the VVT according
to Workshop Manual
(section 01-10 VARIABLE
VALVE TIMING
ACTUATOR REMOVAL/
INSTALLATION).
Contact Mazda Technical
Assistance Hotline.
01-026/09 - “VARIABLE VALVE TIMING (VVT)
NOISE WHEN STARTING ENGINE”
AND
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
3
Roughly verify the noise location.
Where is the noise heard the most?
Around
the
valve
cover or
cylinder
head
Valve noise, cam journal
damage or the noise is due
to piston hitting cylinder
head are suspected.
Around
the
engine
block
Piston slap or the noise is
due to piston hitting cylinder
head are suspected.
Around
the oil
pan
Go to Steps 4~7.
Go to Steps 8~11.
Connecting rod material
damage and/or balancer
unit trouble is suspected.
Go to Step 12~16.
4
Verify if the noise is due to an out-of-spec valve clearance.
Inspect the valve clearance.
Yes
Go to Step 6.
No
Go to the next step.
Is it within specification?
Standard of inspection (engine cold):
IN: 0.22-0.30mm
EX: 0.27-0.37mm
Refer to Workshop Manual (section 01-10 VALVE
CLEARANCE INSPECTION).
Page 11 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
5
Verify if the out-of-spec valve clearance is due to damage of camshaft journal.
Yes
Remove the camshaft.
No
Any damage and/or sign of burnt or seizure found?
Contact MASH for head replacement authorization.
Valve noise is suspected.
Adjust valve clearance according to Workshop
Manual (section 01-10
VALVE CLEARANCE
ADJUSTMENT).
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
Standard of adjustment
(engine cold):
IN: 0.22-0.28mm
EX: 0.27-0.33mm
6
Yes
Go to the next step.
No
Contact Mazda Technical
Assistance Hotline.
Yes
A partial engine may be
needed. Contact MASH for
authorization.
No
Contact MASH for short
block authorization.
Verify if the noise depends on combustion pressure.
Yes
Go to the next step.
Does the noise decrease when halting cylinder
ignition?
No
Go to Steps 10~11.
Verify if the noise is due to piston hitting cylinder head
caused by seized and/or damaged connecting rod
bearing.
Remove the oil pan and check the connecting rod
bearings.
Any damage and/or sign of burnt or seizure found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
7
Verify if the cylinder head can be reused.
Is there any sign of contact between the piston and
cylinder head found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
8
Refer to Service Highlights (section 01-02
SIMULATION TEST) and perform the procedure
below.
1. Connect M-MDS, then select “Data Logger”.
2. Using simulation function, intentionally cause
misfire one by one.
(On and Off INJ_1, INJ_2, INJ_3, INJ_4)
Page 12 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
9
Yes
Go to Step 11.
No
Replace the piston according
to Engine Workshop Manual
(section 01-10
MECHANICAL).
Yes
Go to the next step.
No
Contact Mazda Technical
Assistance Hotline.
Yes
A partial engine may be
needed. Contact MASH for
authorization.
No
Contact MASH for short
block authorization.
Verify if the noise depends on combustion pressure.
Yes
Go to the next step.
Does the noise decrease when halting cylinder
ignition?
No
Go to Step 14.
Yes
Go to Step 15.
No
Contact Mazda Technical
Assistance Hotline.
Verify if the noise is due to piston hitting cylinder head
caused by seized and/or damaged connecting rod
bearing.
Remove the oil pan and check the connecting rod
bearings.
Is there any damage and/or sign of burnt or seizure
found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
10
Verify if the noise is due to piston hitting cylinder head
caused by seized and/or damaged connecting rod
bearing.
Remove the oil pan and check the connecting rod
bearings.
Is there any damage and/or sign of burnt or seizure
found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
11
Verify if the cylinder head can be reused.
Is there any sign of contact between the piston and
cylinder head found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
12
Refer to Service Highlights (section 01-02
SIMULATION TEST) and perform the procedure
below.
1. Connect M-MDS, then select “Data Logger”.
2. Using simulation function, intentionally cause
misfire one by one.
(On and Off INJ_1, INJ_2, INJ_3, INJ_4)
13
Verify if the noise is due to piston hitting cylinder head
caused by seized and/or damaged connecting rod
bearing.
Remove the oil pan and check the connecting rod
bearings.
Is there any damage and/or sign of burnt or seizure
found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
Page 13 of 14
Bulletin No: 01-053/09
Last Issued: 12/01/2009
© 2009 Mazda Motor of America, Inc.
14
Verify if the noise is due to piston hitting cylinder head
caused by seized and/or damaged connecting rod
bearing.
Yes
Go to next step.
No
Go to Step 16.
Yes
A partial engine may be
needed. Contact MASH for
authorization.
No
Contact MASH for short
block authorization.
Yes
Adjust the balancer unit and
crankshaft gear backlash
according to Engine
Workshop Manual (section
01-10 CYLINDER BLOCK
ASSEMBLY / Balancer Unit
Assembly Note).
No
Contact Mazda Technical
Assistance Hotline.
Remove the oil pan and check the connecting rod
bearings.
Is there any damage and/or sign of burnt or seizure
found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
15
Verify if the cylinder head can be reused.
Is there any sign of contact between the piston and
cylinder head found?
Refer to the following TSB:
01-042/09 - “SERVICE POINTS FOR ENGINE
REPLACEMENT DUE TO ENGINE NOISE.”
16
Verify if the noise is due to improper gear backlash of
balancer unit.
Any problem found with gear backlash of balancer
unit?
Refer to Engine Workshop Manual (section 01-10
CYLINDER BLOCK ASSEMBLY / Balancer Unit
Assembly Note).
Page 14 of 14
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