Mazda Car 2002-04

Crankshaft Damper (Balancer)

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Front suspension lower bar
     
    Air pipe
     
    Drive belt
     
    Crankshaft Position (CKP) sensor
     
    High tension lead and the ignition coil
     
    Spark plugs
     
    Upper radiator hose
     
    Water hose
     
    Oil pipe
     
    Oil Control Valve (OCV)
     
    Rocker arm cover and discard the gasket
     
    Water pump pulley
     
    Crankshaft pulley and plate
     
    Pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation

    Click image to see an enlarged view

    Fig. Remove pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation-1.8L (BP) engines

     

  6.  

To install:

  1. Install or connect the following:

    Crankshaft plate and pulley. Tighten the bolt to 13 ft. lbs. (17 Nm).
     
    Water pump pulley
     
    Rocker arm cover with a new gasket
     
    Remaining components in the reverse of removal
     

  2.  

1.6L (Zm) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Camshaft Position (CMP) sensor
     
    Ignition coils
     
    Drive belt
     
    Crankshaft pulley and plate
     
    Water pump pulley
     
    Rocker arm cover and discard the gasket
     

  6.  
  7. Support the engine with a suitable support device and remove the number 3 engine mount.

    Timing belt cover
     
    Pulley using tool 49 D011 102 to prevent crankshaft rotation and remove the pulley boss

    Click image to see an enlarged view

    Fig. Remove pulley bolt and boss by using tool 49 D011 102 to prevent crankshaft rotation-1.6L (ZM) engines

     

  8.  

To install:

  1. Install or connect the following:

    Crankshaft pulley and tighten the bolts to 109-151 inch lbs. (12-17 Nm)
     
    Drive belt
     
    Ignition coils
     
    CMP sensor and check the air gap between the sensor and the plate teeth using a brass feeler gauge. If the gap is not 0.020-0.059 inch (0.5-1.5mm) adjust the sensor until the proper gap is reached.
     
    Negative battery cable
     

  2.  

2.0L (Fs) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor on Protégé models
     
    Spark plugs
     
    Power steering pump and bracket, leave the lines attached and position the pump aside on 2.0L (FS) engines
     
    Drive belt
     
    Water pump pulley
     



    Crankshaft pulley using special tools 49 G011 103, 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 G011 v103, 49 E011 1A1 and 49 S120 710-1.8L (FP) and 2.0L (FS) engines

     

  6.  

To install:

  1. Install or connect the following:

    Crankshaft pulley using special tools 49 G011 v103, 49 E011 1A1 and 49 S120 710 and tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
     
    Water pump pulley. Refer to the exploded view of the timing belt components for torque specifications.
     
    Drive belt
     
    Power steering bracket and pump, if removed
     
    Spark plugs
     
    CKP sensor
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Crankshaft Position (CKP) sensor
     
    Camshaft Position (CMP) sensor on Protégé models
     
    Spark plugs
     
    Power steering pump and bracket, leave the lines attached and position the pump aside on 2.0L (FS) engines
     
    Drive belt
     
    Water pump pulley
     



    Crankshaft pulley using special tools 49 G011 103, 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.
     
    Guide plate from behind the crankshaft pulley

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 G011 v103, 49 E011 1A1 and 49 S120 710-1.8L (FP) and 2.0L (FS) engines

     

  6.  

To install:

  1. Install or connect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not installed carefully.



    Guide plate
     



    Crankshaft pulley using special tools 49 G011 v103, 49 E011 1A1 and 49 S120 710 and tighten the bolt to 116-122 ft. lbs. (157-166 Nm).
     
    Water pump pulley. Refer to the exploded view of the timing belt components for torque specifications.
     
    Drive belt
     
    Power steering bracket and pump, if removed
     
    Spark plugs
     
    CKP sensor
     
    Negative battery cable
     

  2.  

2.3L (Kj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The Crankshaft Position (CKP) sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Right front wheel
     
    Splash shield from the right hand side
     
    Dust cover
     
    Drive belt
     

  6.  
  7. Turn the crankshaft pulley clockwise until the pin on the pulley is facing down.

    Crankshaft pulley using special tools 49 E120 710. Refer to the illustration for tool positioning.

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 E120 710-2.3L (KJ) engines

     

  8.  

To install:

  1. Install or connect the following:


  2.  
  3. Install the crankshaft pulley. Hand tighten bolts A and B . Tighten the bolt A to 116-122 ft. lbs. (157-166 Nm) and bolt B to 22 ft. lbs. (30 Nm).

    Drive belt
     
    Dust cover
     
    Splash shield from the right hand side
     
    Right front wheel
     
    Negative battery cable
     

  4.  

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the plug hole plate and bracket.
  4.  
  5. Remove the battery cover.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Disconnect the wiring harness.
  10.  
  11. Remove the ignition coils, spark plugs, valve cover and accessory drive belt.
  12.  
  13. Remove the front wheels.
  14.  
  15. Remove the under cover and splash shield, if equipped.
  16.  
  17. On Mazda 6 models, remove the right hand halfshaft from the joint shaft.
  18.  
  19. Remove the Crankshaft Position (CKP) sensor.
  20.  
  21. Remove the crankshaft pulley bolt and pulley.
  22.  
  23. Remove the cylinder block lower blind plug.
  24.  
  25. Install tool 49 JE01 061.
  26.  
  27. Turn the crankshaft clockwise until the crankshaft is in the number 1 cylinder Top Dead Center position (the balance weight should be attached to tool 49 JE01 061).
  28.  
  29. Hold the crankshaft pulley using the tools illustrated and remove the bolt.
  30.  
  31. Remove the crankshaft pulley.

    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061-2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061 Hold the crankshaft pulley using the tools illustrated and remove the bolt-2.0L (LF) and 2.3L (L3) engines

  32.  

To install:

  1. Install the crankshaft pulley.
  2.  
  3. Install tool 49 UN30 3465 as illustrated on the camshaft.

    Click image to see an enlarged view

    Fig. Install tool 49 UN30 3465 on the camshaft-2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Install and hand tighten the M6 x 1.0 bolt-2.0L (LF) and 2.3L (L3) engines

  4.  
  5. Install and hand tighten the M6 x 1.0 bolt as illustrated.
  6.  
  7. Turn the crankshaft clockwise until the crankshaft is in number 1 TDC (the balance weight should be attached to the tool).
  8.  
  9. Hold the crankshaft pulley and tighten the lock bolt in two steps. First tighten to 71-77 ft. lbs. (96-104 Nm). Then final tighten an additional 87-93 degrees.
  10.  
  11. Remove the M6 x 1.0 bolt.
  12.  
  13. Remove the tools from the camshaft and the cylinder block lower blind plug.
  14.  
  15. Rotate the crankshaft clockwise 2 turns until you reach TDC. If not aligned properly, loosen the crankshaft pulley lock bolt and reinstall the lock bolt again using the above procedure and special tools.
  16.  
  17. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  18.  
  19. When installing the CKP sensor perform the following:
    1. Remove the cylinder block lower blind plug.
    2.  
    3. Install tool 49 JE01 061.
    4.  
    5. Turn the crankshaft clockwise until the crankshaft is in the number 1 cylinder Top Dead Center position (the balance weight should be attached to tool 49 JE01 061).
    6.  
    7. Using a ruler, mark the center line on the pulse wheel teeth on the crank pulley which is located at the 9th tooth counting counterclockwise from the empty space. Refer to the illustration for more detail.
      CAUTION
      If you do not mark the center line correctly this will cause improper engine control for the ignition and fuel system, so be sure to mark the line carefully.

    8.  
    9. Install the CKP sensor making sure the mark on the sensor is aligned with the mark on the pulse wheel. Tighten the sensor bolt to 49-66 inch lbs. (5.5-7.5 Nm)and attach the electrical connector.
    10.  
    11. Remove the tool from the cylinder block lower blind plug.
    12.  
    13. Rotate the crankshaft clockwise 2 turns until you reach TDC. If not aligned properly, loosen the crankshaft pulley lock bolt and reinstall the lock bolt.
    14.  
    15. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).

      Click image to see an enlarged view

      Fig. Using a ruler, mark the center line on the pulse wheel teeth on the crank pulley which is located at the 9th tooth counting counterclockwise from the empty space-2.0L (LF) and 2.3L (L3) engines

    16.  

  20.  
  21. Install the remaining components in the reverse order of removal.
  22.  
  23. Start the vehicle and check for leaks, repair if necessary.
  24.  

2.5L (Kl) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The CKP sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Crankshaft Position (CKP) sensor
     
    Spark plugs
     
    Power steering pump, leave the lines attached and position the pump aside
     
    Drive belt
     
    Water pump pulley
     
    Idler pulley bracket
     



    Crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710-2.5L (KL) engines

     

  6.  

To install:

  1. Install or connect the following:

    Crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning. Tighten the bolt to 16-122 ft. lbs. (157-166 Nm).
     
    Idler pulley bracket.
     
    Water pump pulley.
     
    Drive belt
     
    Power steering pump
     
    Spark plugs
     
    CKP sensor
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Refer to the illustration of the exploded view of the timing belt assembly for component location and torque specifications.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    The Crankshaft Position (CKP) sensor rotor is on the rear of the crankshaft pulley and can be damaged if the pulley is not removed carefully.



    Negative battery cable
     
    Splash shield from the right hand side
     
    Drive belt
     
    Water pump pulley
     
    Idler pulley and bracket
     
    Power steering pump, leave the lines attached and position the pump aside
     



    Crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning.

    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710-2.5L (KL) engines

     

  6.  

To install:

  1. Install or connect the following:

    Crankshaft pulley using special tools 49 E011 1A1 and 49 S120 710. Refer to the illustration for tool positioning. Tighten the bolt to 16-122 ft. lbs. (157-166 Nm).
     
    Power steering pump
     
    Idler pulley bracket. Refer to the exploded view of the timing belt components for torque specifications.
     
    Water pump pulley. Refer to the exploded view of the timing belt components for torque specifications.
     
    Drive belt
     
    Splash shield
     
    Negative battery cable
     

  2.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the accessory drive belt.
  6.  
  7. Hold the crankshaft pulley using the tools illustrated and remove the pulley bolt.
  8.  
  9. Remove the A/C compressor and set aside with the lines still attached.
  10.  
  11. Remove the crankshaft pulley using a suitable puller such as the one illustrated.

    Click image to see an enlarged view

    Fig. Hold the crankshaft pulley using the tools illustrated and remove the pulley bolt-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Remove the crankshaft pulley using a suitable puller such as the one shown-Mazda 6 with the 3.0L (AJ) engine

  12.  

To install:

Click image to see an enlarged view

Fig. Install the pulley using the tools shown-Mazda 6 with the 3.0L (AJ) engine

  1. Install the pulley using the tools illustrated.
  2.  
  3. While holding the pulley, tighten the crankshaft pulley bolt as follows:
    1. Tighten to 88 ft. lbs. (120 Nm).
    2.  
    3. Loosen one full turn.
    4.  
    5. Tighten to 35-39 ft. lbs. (47-53 Nm).
    6.  
    7. Tighten 85-95 degrees.
    8.  

  4.  
  5. Install the A/C compressor.
  6.  
  7. Install the accessory drive belt.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the vehicle and check for leaks, repair if necessary.
  12.  

 
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