TSB: 01-011/07

2003 - 2003.5 MAZDASPEED PROTEGE - CONVERTER ASSEMBLY BREAKS AT WELD

APPLICABLE MODEL(S)/VINS

2003 MAZDASPEED Protege VIN Range JM1BJ227630641217 to JM1BJ227*30644072

2003.5 MAZDASPEED Protege VIN Range JM1BJ227730644627 to JM1BJ227730650248

DESCRIPTION

Some vehicles may experience breakage of the catalytic converter assembly just after the first converter. Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.

2. Inspect and replace only "broken" engine mounts.

NOTE:

• If engine mounts require replacement refer to Workshop Manual Section 01-10B ENGINE REMOVAL / INSTALLATION [FS] - No.3, No.4 Engine Mount Installation Note.

3. Remove and replace exhaust system components only with the parts included in the kit.

The Modified Catalyst Kit includes the following:

• Catalytic Converter Assembly

• Pre-Silencer

• Hanger Bracket Assembly

• Flange Nut (2)

• Exhaust Pipe Gaskets (2)

• Self-Locking Nuts (4)

• Exhaust Pipe Spring (2)

• Hanger Bracket Bolt (3)

• Rubber Hanger (2)

The following item is part of the Modified Catalyst Kit but shipped in a seperate box:

• Main Silencer

NOTE:

• The front pipe is not replaced and shown for information purposes only.

• Transfer existing O2 sensor to new catalytic converter assembly.

  O2 Sensor Torque: 22-36 ft-lbf (30-49 N.m)

1. Verify repair.

PART(S) INFORMATION

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the Warranty Wizard for warranty term information.

• Additional diagnostic time cannot be claimed for this repair.