Mazda Car 2002-04

Front Crankshaft Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    Be careful not to score the crankshaft or the seal seat.



    Negative battery cable

    Click image to see an enlarged view

    Fig. Remove the front engine seal by cutting the seal lip, then, so as not to damage the crankshaft, carefully pry the seal out with a prybar

     
    Timing belt
     
    Crankshaft damper bolt and damper
     
    Timing belt sprocket
     
    Sprocket key from the crankshaft
     
    Oil seal from the engine block using a prybar
     

  4.  
  5. Clean the seal bore.
  6.  

To install:

  1. Install or connect the following:

    New oil seal lubricated with clean engine oil, drive it into the engine using an installation tool until it seats
     
    Sprocket key onto the crankshaft
     
    Timing belt sprocket
     
    Crankshaft damper
     
    Timing belt
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Install the seal using an appropriate driver, which fits over the crankshaft snout and presses on the outside edge of the seal

     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    WARNING
    Be careful not to score the crankshaft or the seal seat.



    Negative battery cable

    Click image to see an enlarged view

    Fig. Remove the front engine seal by cutting the seal lip, then, so as not to damage the crankshaft, carefully pry the seal out with a prybar-except Mazda 3 and 6 models

     
    Timing belt
     
    Crankshaft damper bolt and damper
     
    Timing belt sprocket
     
    Sprocket key from the crankshaft
     
    Oil seal from the engine block using a prybar
     

  4.  
  5. Clean the seal bore.
  6.  

To install:

  1. Install or connect the following:

    New oil seal lubricated with clean engine oil, drive it into the engine using an installation tool until it seats
     
    Sprocket key onto the crankshaft
     
    Timing belt sprocket
     
    Crankshaft damper
     
    Timing belt
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Install the seal using an appropriate driver, which fits over the crankshaft snout and presses on the outside edge of the seal-except Mazda 3 and 6 models

     

  2.  

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.
  32.  
  33. Cut the seal lip using a suitable knife and using a suitable prytool wrapped in a rag, remove the seal.

    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



    Click image to see an enlarged view

    Fig. Cut the seal lip using a suitable knife and using a suitable prytool wrapped in a rag, remove the seal-2.0L (LF) and 2.3L (L3) engines

  34.  

To install:

Click image to see an enlarged view

Fig. Use seal installer tool 49 H010 401 and a hammer to install the seal-2.0L (LF) and 2.3L (L3) engines



Click image to see an enlarged view

Fig. The seal should be recessed 0-0.019 inch (0-0.5mm) as shown when properly installed-2.0L (LF) and 2.3L (L3) engines

  1. Coat the new seal with clean engine oil.
  2.  
  3. Push the seal in by hand to get it started.
  4.  
  5. Use seal installer tool 49 H010 401 and a hammer to install the seal so that it is recessed 0-0.019 inch (0-0.5mm) as shown in the accompanying illustration.
  6.  
  7. Install the crankshaft pulley.
  8.  
  9. 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

  10.  
  11. Install and hand tighten the M6 x 1.0 bolt as illustrated.
  12.  
  13. Turn the crankshaft clockwise until the crankshaft is in number 1 TDC (the balance weight should be attached to the tool).
  14.  
  15. 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.
  16.  
  17. Remove the M6 x 1.0 bolt.
  18.  
  19. Remove the tools from the camshaft and the cylinder block lower blind plug.
  20.  
  21. 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.
  22.  
  23. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  24.  
  25. 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.  

  26.  
  27. Install the remaining components in the reverse order of removal.
  28.  
  29. Start the vehicle and check for leaks, repair if necessary.
  30.  

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.
  12.  
  13. Remove the front oil seal using a prytool as 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



    Click image to see an enlarged view

    Fig. Remove the front oil seal using a prytool as shown-Mazda 6 with the 3.0L (AJ) engine

  14.  

To install:

  1. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as illustrated.
  2.  
  3. Apply clean oil to the seal and push the seal in by hand.
  4.  
  5. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm).
  6.  
  7. Seal the crankshaft pulley using a silicone sealant.

    Click image to see an enlarged view

    Fig. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm)-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

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

  8.  
  9. Install the pulley using the tools illustrated.
  10.  
  11. 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.  

  12.  
  13. Install the A/C compressor.
  14.  
  15. Install the accessory drive belt.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the vehicle and check for leaks, repair if necessary.
  20.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the right side front tire.
  6.  
  7. Remove the under cover.
  8.  
  9. Remove the right side splash shield.
    NOTE
    If the high pressure fuel pump is removed, replace the O-ring with a new one.

  10.  
  11. Remove the charge air cooler cover.
  12.  
  13. Disconnect the spill valve control solenoid valve connector.
  14.  
  15. Disconnect the quick release connector on the high pressure fuel pump.
  16.  
  17. Remove the battery and battery tray.
    WARNING
    If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When removing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump joint nut has rotated, replace the high pressure fuel pump with a new one.

  18.  
  19. Disconnect the high pressure line pipe of the high pressure fuel pump.
  20.  
  21. Fix the joint nut with a wrench on the high pressure fuel pump side.
  22.  
  23. Loosen the high pressure line pipe installation nut.
  24.  
  25. Drain and recycle the engine coolant.
  26.  
  27. Loosen the water outlet case installation bolts securing the high pressure line pipe.
  28.  
  29. Remove the high pressure fuel pump.
  30.  
  31. Remove the high pressure fuel pump cover.
  32.  
  33. Remove the ignition coils, spark plugs, valve cover and accessory drive belt.
  34.  
  35. Remove the right hand halfshaft from the joint shaft.
  36.  
  37. Remove the Crankshaft Position (CKP) sensor.
  38.  
  39. Remove the crankshaft pulley bolt and pulley.
  40.  
  41. Remove the cylinder block lower blind plug.
  42.  
  43. Install tool 49 JE01 061.
  44.  
  45. 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).
  46.  
  47. Hold the crankshaft pulley using the tools illustrated and remove the bolt.
  48.  
  49. Remove the crankshaft pulley.
  50.  
  51. Cut the seal lip using a suitable knife and using a suitable prytool wrapped in a rag, remove the seal.
  52.  

To install:

  1. Coat the new seal with clean engine oil.
  2.  
  3. Push the seal in by hand to get it started.
  4.  
  5. Use seal installer tool 49 H010 401 and a hammer to install the seal so that it is recessed 0-0.019 inch (0-0.5mm) as shown in the accompanying illustration.
  6.  
  7. Install the crankshaft pulley.
  8.  
  9. Install tool 49 UN30 3465 as illustrated on the camshaft.
  10.  
  11. Install and hand tighten the M6 x 1.0 bolt as illustrated.
  12.  
  13. Turn the crankshaft clockwise until the crankshaft is in number 1 TDC (the balance weight should be attached to the tool).
  14.  
  15. 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.
  16.  
  17. Remove the M6 x 1.0 bolt.
  18.  
  19. Remove the tools from the camshaft and the cylinder block lower blind plug.
  20.  
  21. 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.
  22.  
  23. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  24.  
  25. 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).
    16.  

  26.  
  27. Install the high pressure fuel pump cover and tighten to 13-16 ft. lbs. (18-22 Nm).
    CAUTION
    If the high pressure fuel pump installation bolts are tightened with the high pressure fuel pump tilted, the high pressure fuel pump may not operate correctly. Tighten the high pressure fuel pump installation bolts in a few passes with equal torque. Tighten to 76-101 inch lbs. (8.5-11.5 Nm).


    WARNING
    If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When installing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump joint nut has rotated, replace the high pressure fuel pump with a new one.

  28.  
  29. Assemble the high pressure line pipe.
  30.  
  31. Fix the joint nut with a wrench on the high pressure fuel pump side. Tighten the high pressure line pipe installation nut to 17-26 ft. lbs. (23-35 Nm).
  32.  
  33. Tighten the water outlet case installation bolts to 13-16 ft. lbs. (18-22 Nm).
  34.  
  35. Install the quick release connector.
  36.  
  37. Install the remaining components in the reverse order of removal.
  38.  
  39. Verify that the high pressure fuel pump is assembled securely.
  40.  
  41. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.
  42.  
  43. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the high pressure fuel pump.
  44.  

 
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