Mazda Car 2005-06

Crankshaft Damper (Balancer)

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the drive belt.
  8.  
  9. Remove the under cover.
  10.  
  11. Remove the front suspension tower bar.
  12.  
  13. Remove the ignition coil.
  14.  
  15. Remove the OCV connector.
  16.  
  17. Remove the cylinder head cover.
  18.  
  19. Remove the CKP sensor.
  20.  
  21. Remove the crankshaft pulley lock bolt as follows:
    1. Remove the cylinder block lower blind plug.

      Click image to see an enlarged view

      Fig. Remove the cylinder block lower blind plug-MX-5 Miata



      Click image to see an enlarged view

      Fig. Install tool 303-507 in the lower blind plug opening-MX-5 Miata

    2.  
    3. Install tool 303-507.
    4.  
    5. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight contacts tool 303-507).
    6.  
    7. Hold the crankshaft pulley using the tools shown in the illustration.
    8.  
    9. Remove the crankshaft pulley lock bolt.
    10.  

  22.  

To install:

  1. Install the crankshaft pulley lock bolt as follows:
    1. Install tool shown in the illustration on the camshaft.

      Click image to see an enlarged view

      Fig. Install tool shown onto the camshaft-MX-5 Miata

    2.  
    3. Verify that cylinder No.1 is at TDC of the compression stroke. (Crankshaft balance weight contacts tool 303-507)
    4.  
    5. Position the crankshaft pulley by temporarily tightening it and, using a suitable length bolt 25-35mm( 0.99-1.37 in.), fix the crankshaft pulley to the engine front cover.
    6.  
    7. Install the tools illustrated to the crankshaft pulley, lock the crankshaft against rotation.
    8.  
    9. Tighten the crankshaft pulley lock bolt to 96-104 Nm (71-77 ft. lbs.), plus 87-93 degrees.
    10.  
    11. Remove the bolt.

      Click image to see an enlarged view

      Fig. Position the crankshaft pulley by temporarily tightening it using a suitable length bolt-MX-5 Miata



      Click image to see an enlarged view

      Fig. Install the tools shown onto the crankshaft pulley to lock the crankshaft against rotation-MX-5 Miata

    12.  
    13. Remove the tool the camshaft.
    14.  
    15. Remove tool from the cylinder block lower blind plug.
    16.  
    17. Remove the tool from the crankshaft pulley.
    18.  
    19. Rotate the crankshaft clockwise two turns until the TDC position.
    20.  
    21. If not aligned, loosen the crankshaft pulley lock bolt and repeat from the first step.
    22.  
    23. Install the cylinder block lower blind plug and tighten to 18-22 Nm (13-16 ft. lbs.)
    24.  

  2.  
  3. Install the remaining components in the reverse order of removal.
  4.  

  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.  

To install:

  1. Install the crankshaft pulley.
  2.  
  3. Install tool 49 UN30 3465 as illustrated on the camshaft.
  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).
    16.  

  20.  
  21. 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.

  22.  
  23. Assemble the high pressure line pipe.
  24.  
  25. 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).
  26.  
  27. Tighten the water outlet case installation bolts to 13-16 ft. lbs. (18-22 Nm).
  28.  
  29. Install the quick release connector.
  30.  
  31. Install the remaining components in the reverse order of removal.
  32.  
  33. Verify that the high pressure fuel pump is assembled securely.
  34.  
  35. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.
  36.  
  37. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the high pressure fuel pump.
  38.  

 
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