NHTSA ID Number: 11003352
Manufacturer Communication Number: 01-007-24
TSB/Document Date: 2024-07-05
Summary
All Mazda
Dealers: Follow the Special Service Program SSPD5 – Valve Stem Seal Class Action for determination if valve stem seals should be replaced.
(1) There is a threaded hole to
lift the tool by turning the bolt.
(2) Bolt: 8mm thread (12mm head)
Valve Seal Installation Tools
(#9) and (#10) of the SST kit
(1) Valve seal installation tool B (#9)
(2) Valve seal installation tool A (#10)
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Valve Keeper Installation Tools
(#11), (#12) and (#18) of the SST kit
(1) Valve keeper installation tool (#11, #12, #18) A: Mark a point on the
attachment (1) to identify the slit of the keeper mating surface.
(2) Valve keeper installation tool (#11, #12, #18) B: Insert a wire (3) into the
hole of the keeper guide (2).
(3) Wire
Valve Seal Height Checker
(#16) and (#17) of the SST kit
1. Slide the inner cylinder (2) into the outer cylinder (1) to measure the seal height after installing the new seals.
(1) Outer Cylinder
(2) Inner Cylinder
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(C) Related Parts Removal (before replacing the valve seal)
Related Parts Removal
1. Remove the right front splash shield so that the crankshaft can be rotated.
NOTE: Turn the steering wheel to the right for easier access to the crankshaft bolt.
(1) Fastener
(2) Front splash shield
2. Disconnect the negative battery (-) terminal according to the instructions on MGSS (NEGATIVE BATTERY TERMINAL
DISCONNECTION / CONNECTION).
3. Remove the plug hole plate in according to the instructions on MGSS (PLUG HOLE PLATE REMOVAL/
INSTALLATION).
4. On the top engine, disconnect the harness and connector shown in the figure.
(1) Purge solenoid valve assembly
(2) Connector
(3) Hose (vacuum pipe side)
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5. Remove the four bolts shown in red.
(1) Purge solenoid valve assembly
(2) Bolt: 5.9 - 7.38 lbf·ft (8 - 10 N·m, 0.82 - 1.02 kgf·m)
(3) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
6. Disconnect the two connectors and five clips shown in red and move the harness aside.
(1) Harness clip
(2) Purge solenoid valve connector
(3) Solenoid valve connector
(4) Vehicle Front
7. Remove the hose as shown, then remove the purge solenoid bracket assembly.
(1) Purge solenoid bracket assembly
(2) Vehicle front
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8. Remove the bolts shown in red, then remove the bracket.
(1) Cylinder head cover
(2) Bracket
(3) Bolt: 6.64 - 8.85 lbf·ft (9 - 12 N·m, 0.92 - 1.22 kgf·m)
(4) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(5) Vehicle front
9. Remove the bolts and clips as shown in red, then remove the harness bracket.
(1) Harness clip
(2) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(3) Harness bracket
(4) Vehicle front
10. Move the engine harness aside for the following steps.
a. Disconnect or remove the parts shown in red.
(1) Harness clip
(2) OCV connector
(3) Vehicle front
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b. Place the engine harness aside where it will not interfere with the work.
(1) Harness clip
(2) Fuel pressure sensor connector
(3) High-pressure fuel pump connector
(4) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(5) Camshaft position sensor connector
(6) Vehicle front
11. Remove the hoses shown and remove the bolts shown in red, then remove the vacuum pipe assembly.
(1) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(2) Vacuum pipe assembly
(3) Vehicle front
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12. Remove the vacuum hose (1) and remove the clip (2).
(1) Vacuum hose
(2) Clip
(3) Vehicle front
13. Remove the bolt (2), then disconnect the clip (3) and hose and set aside (avoid interfering with connected water
hose).
(1) Air pipe assembly
(2) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(3) Clip
(4) Vehicle front
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14. Remove the bolt and the harness bracket.
(1) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(2) Harness bracket
(3) Vehicle front
15. Remove the breather hose.
[For the US specification]
Remove the breather hose with the turbocharger air inlet hose (5) and the
head cover assembly (1) since they are clamped together.
(1) Cylinder head cover
(2) Breather hose
(3) Clip
(4) Vehicle front
(5) Air inlet hose
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16. Remove the ignition coil/ion sensor with bolts and connectors.
(1) Bolt: 5.9 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(2) Ignition coil/ion sensor
(3) Connector
17. Remove the spark plugs.
18. Remove the cylinder head cover and oil shower pipe on the exhaust side.
NOTE: The cylinder head cover gasket is non-reusable.
(1) Cylinder head cover
(2) Bolt: 3.32 - 5.16 lbf·ft (4.5 - 7.0 N·m, 0.46 - 0.71 kgf·m)
(3) Bolt: 0.92 - 6.64 lbf·ft (8 - 9 N·m, 0.82 - 1.22 kgf·m)
(4) Bolt: 6.64 - 8.85 lbf·ft (9 - 12 N·m, 0.92 - 1.22 kgf·m)
(5) Oil shower pipe
(6) Oil level gauge
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Blockage of the oil drain holes with a suitable material to prevent parts from falling into the engine
CAUTION: Failure to install the oil drain back plugs and protective tape could allow an accidently dropped
keeper or foreign object to enter the engine. Any object dropped into the engine must be retrieved before the
engine is rotated. Labor/parts required to retrieve dropped objects or damage to the engine are not covered
under warranty.
1. Cover the oil holes in the cylinder head with a thin 6" x 6" (150mm x 150mm) rag wrapped around about 0.2" (0.5 mm)
diameter wire or any other suitable material.
(1) Insert a wire for easy bending and inserting easily.
NOTE: There are three holes on the exhaust side, one hole on the intake side, and one near the timing chain (hole is
sideways).
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2. When taping over openings, attach 2-1/2" wide painters tape (or equivalent) from the top of the cam tower (8) and over
the spark plug holes (7).
NOTE:
• It is recommended to use tape that can be easily applied and removed since the long screwdriver will be inserted
to verify the upper top dead center of compression for each cylinder.
• Placing a rag (6) over the timing chain area is optional as you will not be working in this area.
(D) Valve seal replacement of the exhaust side
NOTE: The figure of the SST shown in the following images may change.
SST Main Body Installation
1. Apply painters tape (or equivalent) to the four lower parts of the SST main body where it makes contact with the
cylinder head to prevent scratches.
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2. Attach the SST main body to the oil shower pipe mounting bolts holes on the exhaust side using the included 6mm
flange bolts.
Tightening torque: 3.32 - 3.84 lbf·ft (4.5 - 5.2 N·m, 0.46 - 0.53 kgf·m)
NOTE: The following procedure is shown on cylinder # 3 as an example, however, the valve stem seal
replacement procedure MUST be performed on all exhaust valves.
Rocker Arm Removal
1. Insert the long screwdriver (with the length marking on the shank from the assembly instructions ) into the spark plug
hole of the #3 cylinder to determine top dead center.
(1) Long screwdriver
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2. Rotate the crankshaft clockwise to bring cylinder #3 to top dead center of compression stroke. When the 143mm mark
(1) on the screwdriver is even with the cylinder head surface and the nose of the exhaust cam lobes lean toward the
spark plug hole, the cylinder is at top dead center.
NOTE: Rotate the crankshaft slightly clockwise and counterclockwise to bring the marking on the screwdriver to the
highest position.
CAUTION: Place a rag over the oil shower pipe feed port (circled in the image) before rotating the crankshaft since
engine oil may be pumped out. If oil should spill out onto the exhaust system, carefully clean it off.
(1) Marking
NOTE: At top dead center of compression stroke, the exhaust cam lobe nose is located approximately 30° from vertical
towards the spark plug holes.
(1) Vehicle front
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3. Install the valve spring compression tool (#8) with the 12mm bolt (17mm hex head) (#15) onto the upper spring seat.
4. Inspect the clearance between the valve spring compression tool and the cam lobe - the space between each side of
the tool and the cam lobe should be the same.
• If the tool is not centered on the cam lobe, loosen the 4 main body mounting bolts and shift the main body left or
right until the tool is centered on the cam lobe, then retighten the main body mounting bolts.
5. Push down on the rocker arm with a finger to prevent the valve keepers from separating from the upper spring seat
while compressing the valve spring.
6. Compress the spring by tightening the 12mm bolt (17mm hex head) approximately 4 complete turns.
CAUTION: DO NOT exceed 1.48 lbf·ft (2 N·m, 0.20 kgf·m) of torque or SST damage will occur.
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7. Detach the rocker arm from the Hydraulic Lash Adjuster (HLA) by inserting a small panel clip removal tool or flat blade
screwdriver between the HLA (1) and the rocker arm (2) and applying a small twist.
8. [For all valves except 3 and 6] Take out the rocker arm from between the spring compression tool arms by using a
magnet and verify that the rocker arm HLA retaining clip is still attached to the rocker arm and is not damaged.NOTE:
• Check the top of the HLA if the retaining clip is missing.
• If the retaining clip is damaged, a new HLA assembly will need to be ordered because the clip is currently not
available separately. The new HLA assembly comes with a rocker arm and clip.
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9. [For the two rocker arms 3 and 6 of #2 and #3 cylinder circled] Remove the rocker arms from the side using the
following steps because the shape of the cylinder head casting prevents the rocker arms from being removed through
the front of the spring compression tool.
a. While detaching the rocker arm from the HLA, move the rocker arm backward off the valve stem.
b. Insert a magnet behind the compression tool to raise the rear of the rocker arm to remove it and verify that the
rocker arm HLA retaining clip is still attached to the rocker arm and is not damaged.
NOTE:
• Check the top of the HLA if the retaining clip is missing.
• If the retaining clip is damaged, you will need to order a new HLA assembly. The clip is currently not
available separately. The new HLA assembly comes with a rocker arm and clip.
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Valve Spring Removal
1. After removing the rocker arm, loosen the 12 mm bolt (17 mm hex head) (#15) on the valve spring compression tool
two to three complete turns.
2. Then tighten the 12 mm bolt (17 mm hex head) (#15) again to release the valve keepers from the upper valve spring
seat. Use a magnet to remove the keepers.
CAUTION: DO NOT exceed 1.48 lbf·ft (2 N·m, 0.20 kgf·m) of torque or SST damage will occur.
3. Loosen the 12 mm bolt (17 mm hex head) (#15), then remove the bolt and the valve spring compression tool.
NOTE: Loosen the 12mm bolt the full 4 turns that it was compressed.
4. Use a magnet to remove the upper valve spring seat and valve spring.
NOTE: Press down on the valve stem to make valve spring removal easier. The valve will rest on the piston if properly
set at top dead center of the compression stroke.
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Valve Seal Removal
1. Place the valve seal removal tool (#7, #13, #14) under the valve seal as shown.
(1) Press lightly into place.
(2) Hook the lower end of the valve seal to the step of the inner wall.
2. Put the valve seal removal attachment tightening bolt 8mm thread (12mm head) (#14) with the M10 washer (#13)
through the SST main body.
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3. Tighten the 8mm bolt to remove the valve seal in the direction of the arrow shown.
NOTE: Once the valve seal is released, the tightening torque will become light.
CAUTION: The SST could be damaged if not placed properly under the valve seal.
(1) Good
(2) Not Good
4. Clean and degrease the valve guide and surrounding area with a rag and inspect the valve guide groove and valve
guide to remove any remaining rubber residuals from the old oil seal.
(1) Valve seal
(2) Inner rubber
(3) Valve guide
(4) Residuals
5. Remove valve seal removal tool along with the 8mm bolt and washer.
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Valve Seal Installation
1. Gently lubricate the lip of the new valve seal with clean engine oil.
NOTE: DO NOT lubricate the inside of the valve seal.
(1) Valve seal
(2) Lubrication
(3) DO NOT lubricate.
2. Install the new oiled valve seal on the valve stem and press down until the seal is seated on top of the valve guide.
(1) New valve seal
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3. Place the valve seal installation tool A over the valve guide and seal and verify the tool is sitting on the lower valve
spring seat.
(1) Valve seal installation tool A (#10)
4. Place the valve seal installation tool B (#9) on the valve seal and make sure the valve stem is in the center of
installation tool B.
[Image of the set of the valve seal installation tools A and B]
(1) Good
(2) No good
(3) Valve seal
(4) Valve seal installation tool A (#10)
(5) Valve seal installation tool B (#9)
5. Place the valve spring compression tool on the valve seal installation tool B (#9).
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6. Install the 12mm bolt until it makes contact with the valve spring compression tool.
7. Using a torque wrench, tighten the 12mm bolt to 0.74 - 1.48 lbf·ft (1 - 2 N·m, 0.10 - 0.20 kgf·m) to install the new valve
guide seal on to the valve guide.
NOTE: The valve guide seal will be properly seated when tool B contacts tool A.
CAUTION: DO NOT exceed 1.48 lbf·ft (2 N·m, 0.20 kgf·m) of torque or SST damage will occur.
8. Remove the valve spring compression tool and the valve seal installation tools A and B.
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9. Prepare the valve seal height checker (#16, #17).
NOTE: If it is difficult to confirm the height of the SST because of its black exterior, mark the 5mm from the top of the
inner cylinder with a white pen.
(1) Outer Cylinder
(2) Inner Cylinder
10. Attach the valve seal height checker (#16, #17) on top of the valve seal installed in step 5.
NOTE: Install the height checker with the notch facing the camshaft side (1). If it is difficult to install by hand, use a
magnet.
11. Rotate the height checker 180 degrees so the open side faces the front of the vehicle.
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12. Verify the height of the inner cylinder is within the OK level of the outer cylinder (within the notch difference).
Good
No Good
(1) Good
(2) Not good
(3) The inner cylinder is within the step (OK range) of the outer cylinder (same height is also acceptable).
(4) The inner cylinder exceeds beyond the step of the outer cylinder.
(5) Remove the height checker and proceed to "Valve spring installation".
(6) Remove the valve seal height checker and inspect the valve seal.
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TSB/Document ID: 01-007-24
Replacement Service Bulletin Number:
MFR Communication Date: 2024-06-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem: Lubrication System
Previous TSB | Next TSB |
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