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Home >> Mazda >> 2003 >> Protege L4-2.0L DOHC >> Repair and Diagnosis >> Powertrain Management >> Emission Control Systems >> Technical Service Bulletins >> By Symptom >> Recalls >> Recall - Intake Manifold Shutter/Variable Tumble Valves >> Inspection And Repair Procedure

Inspection And Repair Procedure



A. VEHICLE INSPECTION PROCEDURE

NOTE: MAZDASPEED Protege is not subject to this recall campaign because it has a different intake manifold.

1. Verify that the vehicle is within the following range:

- 2003MY Protege VIN Range: (JM1 BJ**** 3*181114 - 219674)

- If the vehicle is within the above range, proceed to step 2.

- If the vehicle is not within the above range, return the vehicle to the customer or inventory.




2. Perform a Warranty Vehicle Inquiry using your eMDCS System and inspect vehicle for a Campaign Label RECALL 3005C attached to the vehicle's hood or bulkhead. Refer to eMDCS System - Warranty Vehicle Inquiry Results table listed below.

NOTE: Verify RECALL number as the vehicle may have multiple RECALL's




eMDCS System - Warranty Vehicle Inquiry Results

B. REPAIR PROCEDURE

WARNING:

- When the engine and intake-air system are hot, Severe Burns Can Occur. Turn off the engine and wait until they are cool before removing the intake-air system.

- Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

- Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See Workshop Manual 01-14 BEFORE REPAIR PROCEDURE.)

REPAIR PROCEDURE "A"

1. Start engine and remove fuel pump relay from main fuse box under hood. Allow engine to stall. This will ensure fuel pressure is relieved before starting any inspections or disassembly.




2. Remove spark plugs and perform a compression test per the procedure in the 03MY Protege WSM page 01-10B-8.

- If the compression test results confirm the engine compression to be in the normal range, reinstall the spark plugs, install a Recall Label in the prescribed location and return the vehicle to the customer.

- If the compression test results confirm the engine compression to be lower than the normal range, contact the National Technical Hotline for further instructions.

REPAIR PROCEDURE "B"

1. Start engine and remove fuel pump relay from main fuse box under hood. Allow engine to stall. This will ensure fuel pressure is relieved before starting any inspections or disassembly.




2. Remove the intake manifold assembly from the vehicle according to the Workshop Manual, page 01-13b-6.




3. Separate the intake manifold from the dynamic chamber.

4. Inspect for missing and or loose Variable Inertia Charging System (VICS) and Variable Tumble Control System (VTCS) shutter valve screws and or plates.

a. If any screws or plates (VICS or VTCS) are found to be missing, inspect the dynamic chamber for loose parts and inspect the intake runners in the cylinder head to determine if the missing parts have become lodged in the head.

- If any parts are found in the dynamic chamber or the head, remove the parts using an appropriate tool, then perform a compression test to determine if any internal engine damage has occurred (the compression test can be performed without reinstalling the intake manifold).

- If NO internal damage is indicated, proceed with the intake manifold replacement. If the compression test indicates internal damage has occurred, contact the National Technical Hotline for instructions.

b. If no loose parts are found in the dynamic chamber or the head, then proceed to testing the compression.

NOTE: The compression test can be performed without reinstalling the intake manifold.

- If the compression test indicates NO internal damage is evident, proceed with the intake manifold replacement.

- If the compression test indicates internal damage has occurred, contact the National Technical Hotline for instructions.




c. If no screws or plates are missing, check the torque condition of the VICS plate retaining screws. To check for looseness of the VICS plates to the shaft, pinch the valve with your fingers then push and pull in an up and down and then a back and forth motion to see if there is any looseness between valve and the shaft.

- If there is no looseness; proceed to the VICS Plate Screw Replacement Procedure.

- If there is looseness; check the valve plates and intake manifold ports to see if there is any visible damage.

- If no damage is observed, proceed to VICS Plate Screw Replacement Procedure.If any damage is observed, replace the intake manifold assembly.

- If any damage is observed, replace the intake manifold assembly.




5. Check the installation condition of Variable Tumble Control System (VTCS) shutter valve and shaft in the intake manifold. To check the torque condition of the VTCS screws, pinch the valve with your fingers (use the same motion procedure as used to check the VICS plates) to see if there is looseness in the valve and shaft.

- If there is NO looseness in any of the plates; proceed to VTCS Screw Replacement Procedure.

- If there is looseness, check the valve and intake manifold port to see if there is any damage.

- If NO damage is observed, proceed to VTCS Screw Replacement Procedure.

- If any damage is observed, replace the intake manifold assembly.

VICS SCREW REPLACEMENT PROCEDURE




To keep the valves closed during the screw replacement procedure, fit a retaining jig part number FS7N-20-150 in the lever as shown.

NOTE: Fitting the jig can be simplified by applying vacuum to the actuator with a hand vacuum pump.

1. Replace each valve's screw with a new one according to the following procedures.

- If NO looseness is observed between the valve and shaft; remove and replace each valve's screws with new screws, one by one. Tighten them as you install them to the specified torque using the SST P/N MT05-A1-001 (torque screwdriver Set torque: 1.0 N.m).

CAUTION: Please be careful if the two screws are loosened at the same time, the valve shaft's location will vary and will come into contact with the port. This will cause the valve to get damaged or stuck.

- If looseness IS observed between the valve and shaft, perform the following procedure.




a. Using a flat screwdriver, move the play of the shaft toward the lever.

b. Loosen the two screws until the valve is just free to move.




c. First, remove one screw, then move the valve toward the lever, install and tighten a new screw using the SST (torque screwdriver). Repeat the same procedure for the other new screw.

CAUTION: Make sure the valve is in the correct position. Otherwise, the valve will come into contact with the port. This will cause the valve to get damaged or stuck.




2. Remove the jig from the lever. Move the lever by hand to confirm it functions normally.

a. Make sure all the valves move smoothly.

b. Move the lever by hand to firmly close the valve. With the valve closed, move the lever toward the shaft back and forth and make sure the shaft and valves move together.

CAUTION: If they do not move together, there is a possibility that valves are touching the port. Loosen the screws until the valves are just free to move, and then re-adjust the location of each valve according to the VICS Screw Replacement Procedure "B"

VTCS SCREW REPLACEMENT PROCEDURE




1. To close the valve, fit a jig part number FS8N-20-150 in the lever.

NOTE: Fitting the jig can be simplified by applying vacuum to the actuator with a hand vacuum pump.

2. Replace each valve's screw with a new one according to the following procedure.

- If no looseness is observed in the valve and shaft; replace each valve's screw with a new one, one by one, tightening each screw as it is replaced using the SST (torque screwdriver).

CAUTION: Please be careful if the two screws are loosened at the same time, the valve shaft's location will vary and will come into contact with the port. This will cause the valve to get damaged or stuck.




- If looseness is observed in the valve and shaft, perform the following procedure.

a. Using a flat screwdriver, move the play of the shaft toward the lever.

b. Loosen the two screws until the valve is just free to move.




c. First remove one screw. Then, by moving the valve toward the lever, tighten a new screw using an SST (torque screwdriver). Do the same on the other new screw.


CAUTION: Make sure the valve is in position. Otherwise, the valve will come into touch with the port. This will cause the valve to get damaged or stuck.

3. Remove the jig from the lever. Move the lever by hand to confirm it functions normally.

a. Make sure the valves moves smoothly.




b. Move the lever by hand to firmly close the valve. With the valve closed, move the lever toward the shaft back and forth and make sure the shaft and valves move together.

CAUTION: If they do not move together, there is a possibility that a valve is touching the port. Loosen the screws until valves are just free to move, and then re-adjust the location of each valve according to the Step 2 "If looseness is observed in the valve and shaft".

4. Reinstall the parts in the reverse order of the removal.

5. Make sure each part is installed in the correct position and functions properly according to the Workshop
Manual.


6. Reinstall fuel pump relay into main fuse box.

7. Start engine and check for leaks in the fuel system.

C. CAMPAIGN LABEL INSTALLATION

Complete a "Campaign Label" with the RECALL number written on the sticker and affix it to the vehicle's hood or bulkhead. Refer back to the illustration under "A. VEHICLE INSPECTION PROCEDURE".
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