Engine - Component/Engine Replacement Guidelines

Bulletin No: 01-042/09

Last Issued: 09/22/2009

Subject:
SERVICE POINTS FOR ENGINE REPLACEMENT DUE TO ENGINE NOISE

APPLICABLE MODEL(S)/VINS
2004-2009 Mazda3
2006-2009 Mazda5
2003-2008 Mazda6 with L3 Engine
2006-2009 MX-5

DESCRIPTION

This bulletin provides guidelines for repairing internal engine noise issues (such as Knocking, Ticking, Tapping, Rattling, Grinding, Squealing, Squeaking, Thumping, Whining, Creaking, Popping, Clicking, Roaring, Loud, High-pitched etc). When engine replacement is necessary, use short block or long block according to following guideline. Do not replace long block assembly if short block assembly or cylinder head assembly will resolve concern.





Guideline for Short Engine/Cylinder Head Replacement

The following service points will assist you in determining correct repair.

SERVICE POINTS TO DETERMINE PARTS REUSABILITY

1. Cylinder Head

^ Check for contact mark between the cylinder head (A) and piston (B). Check for carbon peeling or valve to piston interference.

- If OK, flush cylinder head (with valves assembled) with kerosene and blow oil passages with regulated shop air.

- If no good, contact MASH for authorization to replace cylinder head assembly and related damaged components.





2. Oil Control Valve Filter

^ Check for any visual damage.

- If OK, remove foreign material and clean.

- If no good, replace.

3. Oil Pump

^ Check for any unusual resistance felt when turning the oil pump by finger.

- If OK, Remove foreign material and clean.

- If no good, replace.

4. Timing Chain and Oil Pump Chain

^ Though Workshop Manual suggests reusing, replace both chains because there is a possibility that foreign material may get wedged into links.

- Replace

5. Variable Valve Timing Actuator (OCV)

^ Check for Damage or cracks near lock pin stopper. Check for a locked VVT at the most retarded position (Refer to TSB 01-002/08).

- If OK, Remove foreign material and clean.

- If no good, replace.





NOTE:
If piece of VVT is broken off, locate piece in oil pan or chain area.

6. Chain Tensioner

^ Check for any visual damage.

- If OK, remove foreign material and clean.

- If no good, replace.

7. Oil Filter

^ Always replace with any internal engine repair.

- Replace

8. Oil Filter Body

^ Check for any visual damage.

- If OK, clean and blow oil passages with regulated shop air.

- If no good, replace.

9. Oil Strainer

^ Check for any visual damage.

- If OK, clean and blow oil passages with regulated shop air.

- If no good, replace.

10. Oil Pan

^ Check for any visual damage.

- If OK, clean to reuse.

- If no good, replace.

11. Cam Shaft (journal)





^ Check for any visual damage. Cam surface should be smooth.

- If OK, clean to reuse.

- If no good, contact MASH for authorization to replace cylinder head assembly and camshafts.

12. Cylinder Head





^ Check for any visual damage. Surface should be smooth.

- If OK, clean to reuse.

- If no good, contact MASH for authorization to replace cylinder head assembly and camshafts.