Emissions - Engine Compartment Ticking Noises
Bulletin No: 01-029/11Last Issued: 09/21/2011
Subject:
PURGE VALVE CONTACT / HARD RATTLE NOISE
BULLETIN NOTE
Changes are noted in Red, change bars and asterisks.
APPLICABLE MODEL(S) / VINS
2009 Mazda6 3.7L vehicles built before Oct.17, 2008
DESCRIPTION
Some vehicles may experience a rattle or a loud tick noise from the engine compartment during purge valve operation (the noise is loudest during 30%-60% duty cycle). This may be a hard contact noise caused by mis-alignment of the purge valve, rubber grommets, or attaching hoses forcing contact with the PCM, PCM bracket, metal bracket or an excessive valve tick noise.
Customers having this concern should have their vehicle repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove both windshield wiper arms according to MS3 online instructions or Workshop Manual (section 09-19 WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION).
3. Remove cowl grille assembly according to M53 online instructions or Workshop Manual (section 09-16 COWL GRILLE REMOVAL/INSTALLATION).
4. Remove five (5) fasteners for cowl leaf screen and one (1) fastener for each front fender molding.
5. Remove cowl leaf screen.
6. Remove wiper motor assembly according to M53 online instructions or Workshop Manual (section 09-19
WINDSHIELD WI PER MOTOR REMOVAL/INSTALLATION).
7. Remove center bracket (bulkhead to cowl panel).
WARNING:
When removing parts near the bottom edge of the windshield, be careful not to cut yourself.
8. Unhook power steering reservoir from cowl panel.
9. Remove power steering reservoir by lifting up on reservoir and releasing from bracket.
NOTE:
Verify power steering cap is tight before removing reservoir from bracket.
10. Remove cowl panel.
11. Locate purge valve assembly outboard from power brake unit and rearward of PCM.
12. Verify purge valve body position by looking at top of purge valve assembly. Document the findings (Good or Bad) and proceed to next step.
13. Remove top brace of bracket from purge valve assembly.
14. Remove side support insulator from top brace.
NOTE:
Discard back brace after removal.
15. Remove purge valve grommet from body side support.
16. Pull out lever and disconnect connector.
17. Remove PCM connector from body by releasing from hook.
18. Disconnect connector from purge valve.
19. Replace original purge valve connector with a new one according to steps a - e below.
CAUTION:
Be very careful not to insert the connector in the wrong place, otherwise PCM damage may occur.
a. Using a terminal remover, raise lock cover from original connector.
b. Insert terminal remover into original connector and press-hold the lock-pin, then pull out the terminal.
c. Insert pulled-out terminal into new connector.
NOTE:
Insert the terminal until a click sound is heard. After inserting, lightly pull the harness to ensure it will not pull out.
CAUTION:
In order to prevent the terminal from being inserted in the wrong side, DO NOT pull out both terminals at the same time. Pull terminals out one by one.
d. After inserting terminals into new connector, check the harness color. If they are inserted into the wrong side, correct them.
NOTE:
Verify the green/red is inserted in the left side, and the black/red is inserted in the right side.
e. Fit the lock cover.
20. Cut clip off from original harness.
21. Align positions of original clip and new short cord clip, then tie-wrap harness joint as shown.
22. Connect short cord to original harness.
23. Tie-wrap main harness and short cord.
24. Confirm purge valve connector terminals have been correctly connected to new connector.
a. Set circuit tester to "diode mode".
NOTE:
Some circuit testers have a "diode mode (Di)". Be sure to use a tester with the red terminal on the negative side, and black terminal on the positive side when it is set to diode mode.
b. Face bulge of connector upward, then insert red terminal into right-side and black terminal into left-side.
- If circuit tester shows voltage is 0.5 - 0.7V, this is normal.
- If circuit tester shows voltage is outside of 0.5 - 0.7V range, purge connector terminals have not been connected properly; repair as necessary.
25. Connect the short cord and vehicle side harness connectors together and confirm the same wire colors match each other (A = A and B = B) on both sides of the connector.
NOTE:
If the wire colors do not match, pull the terminals out of the short cord connector and match them to the color of the vehicle side harness connector.
26. Place tie-wrapped position on top and wrap pad protector around main harness, then connect short cord connector (new connector) to purge valve.
27. Install PCM connector.
^ For vehicles that were found to be "BAD" in Step 12, proceed to next step.
^ For vehicles that were found to be "GOOD" in Step 12, proceed to Step 33.
28. Move purge valve assembly to the side.
29. Remove body side bracket.
30. Remove two (2) nuts under dash near steering shaft.
31. Reposition purge valve bracket grommets.
a. Loosen two (2) bottom nuts to relax grommets.
b. Re-torque two (2) nuts while maintaining no touch condition and grommets have little to no twist.
Tightening Torque: 71 in.lbf. {8 Nm, 82 kgf-cm}
32. If bracket still makes contact, replace both bushings and bracket.
33. Reinstall body side bracket to vehicle.
a. Verify that one-time use gasket is in place before putting bracket back into vehicle.
b. Re-torque one (1) nut.
Tightening Torque: 71 in.lbf. {8 Nm, 82 kgf-cm}
c. Re-torque two (2) nuts.
Tightening Torque: 13ft. lbf. {18 Nm, 1.8 kgf-m}
34. Adjust purge valve hose assembly.
a. Adjust orientation of quick connector so tube and solenoid valve are aligned.
b. Check if the bulge of rubber aligns with the protrusion on the purge valve. If not aligned, adjust to align them.
35. Reinstall purge valve hose assembly to bracket.
36. Verify purge valve grommet is fully seated.
37. Reinstall purge valve assembly bracket top brace.
a. Torque two (2) nuts at bulkhead.
Tightening Torque: 71 in. lbf. {8 Nm, 82 kgf-cm}
b. Torque one (1) nut to at PCM bracket.
Tightening Torque: 71 in. lbf. {8 Nm, 82 kgf-cm}
38. Verify both purge valve hose inboard from assembly are sitting squarely in power brake unit support bracket.
39. Adjust and check clearance using fiber stick between:
a. Purge valve and upper bracket.
b. Purge valve grommet and PCM bracket.
c. Quick connector and PCM.
d. Lower hose quick connector and lower PCM bracket.
40. Reprogram PCM according to Steps 40 - 42.
41. Reboot the IDS to clear memory before reprogramming.
42. Using IDS B60.13 or later OR B61.04 or later software, reprogram the PCM to the latest calibration (refer to Calibration Information" table) by following the Module Reprogramming" procedure.
NOTE:
^ Always update the IDS tool first, then follow on-screen instructions to download the needed calibration file for PCM reprogramming.
^ It is not necessary to remove any fuses or relays during PCM reprogramming when the IDS screen prompts you to do so. You may accidentally stop power to one of the PCM terminals and cause the PCM to be blanked, or you may receive error messages during the IDS reprogramming procedure.
^ IDS shows the calibration part numbers after programming the PCM.
^ Please be aware that PCM calibration part numbers and file names listed in any Service Bulletin may change due to future releases of IDS software, and additional revisions made to those calibrations for service related concerns.
^ When reprogramming a PCM, IDS will always display the "latest" calibration P/N available for that vehicle. If any calibration has been revised/updated to contain new information for a new service concern/issue, it will also contain all previously released calibrations.
^ When performing this procedure, we recommend that a battery charger be installed on the vehicle battery and turned ON to a maximum charge of no more than 20 AMPS to keep the vehicle battery up to capacity. If you exceed 20 AMPS, it could damage the VCM.
43. After performing the PCM reprogramming procedure, verify the repair by starting the engine and making sure there are no MIL illumination or abnormal warning lights present.
NOTE:
^ If any DTCs should remain after performing DTC erase, diagnose the DTCs according to the appropriate Troubleshooting section of the Workshop Manual.
^ After PCM reprogramming, it is no longer necessary to road test the vehicle to "relearn" KAM (Keep Alive Memory).
CALIBRATION INFORMATION
NOTE:
It is not necessary to order a PCM part for this repair procedure.
44. Verify noise from purge valve using M-MDS.
NOTE:
When running test, sit in passenger side seat with all windows closed.
a. Using M-MDS DATAlogger, Select EVAPCV# and continue to data screen.
b. Select # to control output state control.
c. Increase on time % in 10% increments (10, 20, 30, etc.) up to 100%, checking for purge valve noise in vehicle at each increment (normally loudest is 30-60%).
NOTE:
Noise concerns heard outside the vehicle or with the windows down are considered to be normal.
- If rattle/loud tick noise is not present (or it is very faint while sitting in passenger seat with windows closed), purge valve contact inspection is complete. Proceed to next step.
- If rattle/loud tick noise is present, repeat Steps 33-38.
45. Reinstall cowl panel.
Tightening Torque: 17-22 ft.lbf. {22-30 Nm, 2.3-3.0 kgf-m}
46. Reinstall power steering reservoir.
47. Reinstall center bracket (bulkhead to cowl panel).
Tightening Torque: 17-22 ft.lbf. {22-30 Nm, 2.3-3.0 kgf-m}
48. Reinstall windshield wiper motor assembly according to MS3 online instructions or Workshop Manual (section 09-19 WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION).
NOTE:
Verify wiper motor cover is installed correctly.
49. Verify washer fluid lines are not twisted and are in proper position.
50. Verify center joint is assembled correctly and place assembly back into position.
51. Install cowl leaf screen.
52. Verify outer edges of cowl leaf screen are tucked under front fender moldings.
53. Reinstall five (5) fasteners for cowl leaf screen and one (1) fastener for each front fender molding.
54. Reinstall cowl grille assembly according to MS3 online instructions or Workshop Manual (section 09-16 COWL GRILLE REMOVAL/INSTALLATION).
55. Reinstall both windshield wiper arms according to MS3 online instructions or Workshop Manual (section 09-19 WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION).
56. Verify windshield wiper functions: W~per blade alignment, wiper arm movement when activated, windshield washer fluid nozzles.
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.
Disclaimer