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.
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• If the seal height is too high, remove the checker, install the seal installation tools A and B and the valve spring
compression tool and tighten the 12mm bolt to 2Nm (torque specs), then recheck the seal height.
• If the seal height is still too high, remove the seal and inspect the valve guide for debris or other blockage. Once
the obstruction has been removed, install a new seal.
[Determination of the height check]
(1) Good
(2) No good
(3) Valve seal
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Valve Spring Installation
1. Place the valve spring on the lower valve spring seat with the smaller spring diameter facing up.
NOTE: To make valve keeper installation easier, the spring end should be at 9 o'clock position.
(1) The end of spring
(2) Spring diameter
(3) Engine front
2. Place the keepers in the upper valve spring seat with the separations at 12 o'clock and 6 o'clock positions.
(1) Valve seat
(2) Keeper
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3. Place the valve keeper installation tool (#11, #12, #18) on top of the upper valve spring seat.
NOTE:
• Align the white dot on the valve keeper installation tool (#11, #12, #18) with the slit of the keepers.
• The tool as it is shipped does not have a white dot on the face (2), a paint marker must be used to add the white
dot.
(1) Slit of the keeper
(2) White dot for slit identification
4. Insert the valve keeper installation guide into the hole of the keeper installation tool.
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5. Hold the assembled valve keeper installation tools (#11, #12, #18) between your index finger and thumb and install
them on the valve spring.
NOTE: To make placing the assembled valve keeper installation tools (#11, #12, #18) easier, press the valve down into
the engine and tilt the spring toward you.
(1) Valve keeper installation tool (#11, #12, #18) and guide
(2) Spring
(3) Valve
(4) Vehicle front
(5) To free the spring, push the valve in with your finger until it hits the piston.
(6) Tilt the spring toward the front of the vehicle.
(7) Insert the valve keeper installation tool (#11, #12, #18) and guide.
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6. Place the valve spring compression tool on top of the valve keeper installation tools (#11, #12, #18).
CAUTION: DO NOT remove the valve keeper installation guide (1) before the valve stem pushes it out.
Pass the wire (1) of the valve keeper installation guide between the valve spring compression tool.
7. With a finger pushing down on the valve keeper installation guide, slowly tighten the 12mm bolt (17mm hex head)
(#15) with the torque wrench.
CAUTION: DO NOT exceed 1.48 lbf·ft (2 N·m, 0.20 kgf·m) of torque or SST damage will occur.
NOTE:
• The valve keeper installation guide is pushed out of the installation tool as the bolt is tightened.
• As the 12mm bolt is tightened the valve keeper installation guide will contact the top of the valve stem and will be
pushed up and out to the valve keeper installation tool. Once the guide is pushed out, remove it.
CAUTION:
• If the torque increases while tightening the 12mm bolt (17mm hex head), the valve keeper installation tool (#12)
may be interfering with the valve stem.
• If the bolt is continued to be tighten with this condition, the valve spring compression tool and valve will be
damaged. Stop and loosen the bolt and move the valve keeper installation tool (#12) back and forth or left and
right until the valve stem in the center of the tool. Then, slowly tighten the bolt again.
• If the valve keeper installation guide does not get pushed up and out of the tool, loosen the bolt, remove the valve
spring compression attachment and verify that the piston is at top dead center.
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8. Once the valve keeper installation guide is pushed up and out, keep tightening the bolts until the tip of the valve stem
rises about 1/8 - 3/16 in (3 - 5 mm) from the top of the valve keeper installation tool (#12).
NOTE: If the valve stem tip does not protrude more than 1/8 - 3/16 in (3 - 5 mm) above the valve keeper installation
tool after the valve spring is fully compressed (torque wrench indicates 0.74 - 1.48 lbf·ft (1 to 2 N·m, 0.10 - 0.20 kgf·m),
the valve may be too low due to the cylinder not being exactly at top dead center of compression. In this case, remove
each tool, pull the valve stem up to close the valve with your fingers and start over.
(1) 1/8 - 3/16 in (3 - 5 mm)
9. Loosen the 12mm bolt (17mm hex head) and remove the spring compressor tool.
10. Remove the valve keeper installation tool (#11, #12, #18).
11.Inspect and verify the valve keepers are correctly installed in the upper valve spring seat.
[Correct Installation]
CAUTION: Starting the engine with the keepers NOT installed correctly will cause catastrophic engine failure,
NOT covered under Warranty.
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[Incorrect installation]
One (or both) of the keepers are floating.
• If the keepers are not installed correctly, reinstall the valve keeper installation tool without the guide and tighten it
to 1.48 ft-lbs (2 Nm).
• If the keepers are still not installed correctly, remove the tools, keepers, and upper spring seat, then pull the valve
stem up by hand and verify the piston in the cylinder you are working on is exactly at TDC of the compression
stroke and start over.
CAUTION: DO NOT attempt to raise the valve by rotating the engine, otherwise damage to the valve will occur.
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Rocker Arm Installation
1. Install the valve spring compression tool on the upper valve spring seat.
2. Push down on the valve stem with a finger to prevent the valve keepers from separating from the upper spring seat
while tightening the 12mm bolt to compress the valve spring.
3. Continue pressing down on the valve stem while tightening the 12mm bolt approximately 5 complete turns.
CAUTION: DO NOT exceed 1.48 lbf·ft (2 N·m, 0.20 kgf·m) of torque or SST damage will occur.
4. Inspect the rocker arm HLA clip and make sure the clip is securely attached. Replace any clip that is damaged or bent.
NOTE: The new HLA assembly comes with a rocker arm and clip.
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5. Insert the rocker arm.
a. Valves 3 and 6: will require the rocker arm to be installed from the side of the valve spring compression tool.
Refer to Rocker Arm Removal for details.
b. All other valves: The rocker arm can be in installed between the valve spring compression tool arms using a
magnet.
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6. Push the rocker arm on to the HLA ball using the fastener remover tool or finger, until the clip is locked on to the HLA
ball.
NOTE: A click will be heard when the metal clip locks onto the HLA ball. To verify if the rocker is properly secured to the
HLA, use a pick and gently lift the rocker. If clip takes the HLA up with it, it is securely attached
(1) Clip
(2) HLA
(3) Rocker arm
7. Loosen the 12mm bolt (17mm hex head) and verify that the rocker arm is installed correctly.
NOTE: Put a mark on the masking tape next to the valve worked on.
8. Rotate the crankshaft clockwise and follow the same procedure to replace the valve seals on the remaining cylinders.
9. Remove the SST and painters tape.
10. Remove the oil drain back plugs and rag (if previously installed over timing chain area).
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(E) Related Parts Reassembly
1. Install the spark plug.
Tightening torque for spark plug: 11.06 - 14.75 lbf·ft (15 - 20 N·m, 1.53 - 2.04 kgf·m)
2. Tighten the mounting bolts (2) of the oil shower pipe (3) and the oil feed banjo bolt (1) on the exhaust side in the order
of the numbers shown in the figure.
NOTE:
• Wipe off the oil before tightening, as oil adhesion will cause over-torque.
• Hand tighten the oil feed banjo bolt (1) and oil feed pipe mounting bolts (2). Torque the oil feed banjo bolt to spec
then torque the feed pipe mounting bolts to spec.
Tightening torque spec:
(1) Oil feed banjo bolt: 6.64 - 8.85 lbf·ft (9 -12 N·m, 0.92 - 1.22 kgf·m)
(2) Oil feed pipe mounting bolts: 0.92 - 6.64 lbf·ft 8 -9 N·m (0.82 - 1.22 kgf·m)
(3) Oil shower pipe
3. Install a new cylinder head cover gasket into the groove of the cylinder head cover.
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4. Apply liquid gasket (TB1217D) at the locations shown in the figure.
(1) Engine-front side
(2) 0.23 - 0.31" (6 - 8mm)
(3) 0.04 - 0.12" (1 - 3mm)
(4) 0.12 - 0.51" (3 - 13mm)
(5) Engine front cover
(6) Cylinder head
(7) Arrow A
(8) Mating surface of the engine front cover
(1) Engine-rear side
(2) 0.23 - 0.31" (6 - 8mm)
(3) 0.04 - 0.12" (1 - 3mm)
(4) 0.08 - 0.23" (2 - 6mm)
(5) Rear camshaft cap at the exhaust side
(6) Cylinder head
(7) Arrow B
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5. Install the cylinder head cover.
6. Tighten the cylinder head cover bolts in numerical order, as shown in the figure.
Tightening torque: 3.32 - 5.16 lbf·ft (4.5 7.0 N·m, 0.46 - 0.71 kgf·m)
7. Install the ignition coil/ion sensor.
(1) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(2) Ignition coil/ion sensor
(3) Connector
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8. Connect the breather hose.
For the US specification]
Install 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
9. Install the harness bracket.
(1) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(2) Harness bracket
(3) Vehicle front
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10. Connect the hose and attach the air pipe assembly.
(1) Air pipe assembly
(2) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m) (0.82 - 1.12 kgf·m)
(3) Clip
(4) Vehicle front
11. Install the vacuum hose.
(1) Vacuum hose
(2) Clip
(3) Vehicle front
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12. Connect the hose of the vacuum pipe assembly and install the vacuum pipe assembly.
(1) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(2) Vacuum pipe assembly
(3) Vehicle front
13. Connect the parts shown in the figure.
(1) Harness clip
(2) Fuel pressure sensor connector
(3) High-pressure fuel pump connector
(4) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(5) Camshaft position sensor connector
(6) Vehicle front
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(1) Harness clip
(2) OCV connector
(3) Vehicle front
14. Install the bolts, clips, and harness bracket shown in the figure.
(1) Harness clip
(2) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(3) Harness bracket
(4) Vehicle front
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15. Install the bolts and bracket.
(1) Bracket
(2) Cylinder head cover
(3) Bolt: 6.64 - 8.85 lbf·ft (9-12 N·m, 0.92 - 1.22 kgf·m)
(4) Bolt: 5.90 - 8.11 lbf·ft (8-11 N·m, 0.82 - 1.12 kgf·m)
(5) Vehicle front
16. Connect the hose and install the purge solenoid bracket assembly.
(1) Purge solenoid bracket assembly
(2) Vehicle front
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17. Connect the connectors and four clips.
(1) Harness clip
(2) Purge solenoid valve connector
(3) Solenoid valve connector
(4) Vehicle front
18. Install the bolts shown in the figure.
(1) Bolt: 5.90 - 7.38 lbf·ft (8 - 10 N·m, 0.82 - 1.02 kgf·m)
(2) Bolt: 5.90 - 8.11 lbf·ft (8 - 11 N·m, 0.82 - 1.12 kgf·m)
(3) Purge solenoid valve assembly
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19. Connect the connector.
(1) Purge solenoid valve assembly
(2) Connector
20. Attach the plug hole plate.
21. Connect the negative battery (-) terminal.
22. Perform the steps after connecting the negative battery (-) cable according to the instructions on MGSS (NEGATIVE
BATTERY TERMINAL DISCONNECTION / CONNECTION).
PARTS INFORMATION
Parts Number
Description
Qty.
PY8W-10-1F5
8
PY8W-10-235
Gasket, Head Cover
1
Notes
[R]: Replacement Part
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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 Powertrain Warranty term. If Powertrain Warranty has expired, use the
Warranty Information from SSPD5.
• Additional diagnostic time cannot be claimed for this repair.
• This repair can only be performed by Senior and Master Technicians.
Warranty Type
A
Symptom Code
16
Damage Code
99
Part Number Main Cause
PY8W-10-1F5
Quantity
8 (Replacing valve seals with new ones)
Operation Number / Labor Hours:
Conditions
See the following table.
Operation No. &
Labor
Hours
Repair performed
Replacing valve stem
seals
with new ones at the first
customer visit.
1. Checking for engine oil leak due to
oil consumption and valve stem seals
replacement.
2. Use claim information in SSPD5 for oil change during valve stem
seal
replacemen
XXW3TCRX / 4.4
Hrs.
Replacing valve stem
seals
with new ones at the
second customer visit.
Valve stem seals replacement
XXW3TGRX / 4.2
Hrs.
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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
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