Mazda Car 2002-04

Alternator

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Installation



  1. Install or connect the following:

    Alternator
     
    Alternator bolts. Tighten the lower bolts to 38 ft. lbs. (51 Nm) and the upper bolt 18 ft. lbs. (25 Nm).
     
    Electrical connectors to the alternator
     
    Intake manifold bracket
     
    Negative battery cable
     

  2.  

  1. Install or connect the following:

    Alternator with the pivot bolt
     
    Alternator electrical connectors
     
    Drive belt
     
    Upper mounting bolt
     

  2.  
  3. Adjust the belt tension. Torque the lower through bolt to 28-38 ft. lbs. (38-51 Nm) and the upper mounting bolt to 14-18 ft. lbs. (19-26 Nm).

    Negative battery cable
     

  4.  

  1. Install or connect the following:

    Alternator. Torque the upper bolt to 14-18 ft. lbs. (19-25 Nm) and the lower bolt to 28-38 ft. lbs. (38-51 Nm).
     
    A/C compressor. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
     
    Right splash shield
     
    Drive belt
     
    Electrical connectors to the alternator
     
    Intake air system on 2.4 (KL) engine
     

  2.  
  3. If equipped with the 2.3L engine, install the condenser fan assembly, radiator upper seal board and the front charge air cooler using new O-rings. Torque the mounting bolts to 12-16 ft. lbs. (16-22 Nm).
  4.  
  5. Connect the negative battery cable.
  6.  

  1. Install or connect the following:

    Alternator with the pivot bolt
     
    Alternator bracket
     
    Alternator electrical connectors
     
    Drive belt
     
    Upper mounting bolt
     

  2.  
  3. Adjust the belt tension. Torque the lower through bolt to 27-38 ft. lbs. (37-52 Nm) and the upper mounting bolt to 12-19 ft. lbs. (16-26 Nm)
  4.  
  5. Install or connect the following:

    Pressure pipe bracket and the EGR solenoid valve bracket
     
    Negative battery cable
     

  6.  

  1. Install or connect the following:

    Alternator. Torque the through bolt to 38 ft. lbs. (51 Nm)
     
    A/C compressor, if removed. Torque the bolts to 26 ft. lbs. (35 Nm)
     
    Right splash shield
     
    Drive belt. Adjust the drive belt tension
     
    Alternator upper mounting bolt. Torque the bolt to 18 ft. lbs. (25 Nm)
     

  2.  
  3. Tighten the belt tensioner locknut and tension adjusting bolt.
  4.  
  5. Install or connect the following:

    Electrical connectors to the alternator
     
    Condenser fan, if removed
     
    Radiator upper bracket
     
    Fresh air duct
     
    Negative battery cable
     

  6.  

  1. Install or connect the following:

    Alternator. Torque the through bolt to 24-33 ft. lbs. (32-46 Nm) and the upper bolt to 12-16 ft. lbs. (16-22 Nm)
     
    A/C compressor. Torque the bolts to 12-16 ft. lbs. (16-22 Nm)
     
    Right splash shield
     
    Drive belt
     
    Electrical connectors to the alternator
     

  2.  
  3. If equipped with the 2.3L engine, install the condenser fan assembly, radiator upper seal board and the front charge air cooler using new O-rings. Torque the mounting bolts to 12-16 ft. lbs. (16-22 Nm)
  4.  
  5. Connect the negative battery cable.
  6.  

2.0L (Fs) Engines

Install or connect the following:



Alternator
 
Alternator bolts. Tighten the lower bolt to 28-38 ft. lbs. (38-51 Nm) and the upper bolt to 14-18 ft. lbs. (19-25 Nm).
 
Drive belt, check the belt deflection by applying moderate pressure 22 lbs. (98 N) between the alternator and the water pump pulley. The deflection on a new belt should be 6.5-7 inch (0.26-0.27mm) or on a used belt, 7.0-9.0 inch (0.28-0.35mm). Loosen the alternator mounting bolts and use the adjusting bolt to adjust the belt tension to the correct specification.
 
Electrical connector and terminal wire
 
Front exhaust pipe
 
Transverse pipe
 
Negative battery cable
 



Click image to see an enlarged view

Fig. Adjust the alternator belt tension using the adjustment bolt C-626 4 cylinder models

2.3L (L3) Engine
  1. Install the alternator, tighten bolt A temporarily, then tighten the bolts in the following order; B, A and C to 29-41 ft. lbs. (40-55 Nm).
  2.  
  3. Vonnect the alternator electrical connections.
  4.  
  5. Install the heat insulator and tighten the bolt to 18-47 inch lbs. (2-5 Nm).
  6.  
  7. Install the alternator duct
  8.  
  9. Install the under cover.
  10.  
  11. Install the drive belt.
  12.  
  13. Connect the negative battery cable.
  14.  

2.5L (Kl) Engines
  1. Install or connect the following:

    Alternator. Torque the lower bolt to 28-38 ft. lbs. (38-51 Nm) and the upper bolt to 14-18 ft. lbs. (19-25 Nm).
     
    A/C compressor, if removed. Torque the bolts to 11-15 ft. lbs. (15-21 Nm).
     
    Drive belt, check the belt deflection by applying moderate pressure 22 lbf. (98 N) between the alternator and the crankshaft pulley to check the alternator belt or midway between the A/C compressor and the crankshaft pulley to check the Air conditioning/alternator belt. The deflection on a new belt should be 6.0-7 inch (0.24-0.27mm) or on a used belt, 7.0-8.0 inch (0.28-0.31mm) on the alternator belt. On models with a air conditioning/alternator belt; the deflection on a new belt should be 5.5-6.5 inch (0.22-0.25mm) or on a used belt, 6.5-7.5 inch (0.26-0.29mm) Loosen the alternator mounting bolts and use the adjusting bolt to adjust the belt tension to the correct specification.
     


    Click image to see an enlarged view

    Fig. Adjust the alternator belt tension using the adjustment bolt B-626 6 cylinder models

    Negative battery cable
     

  2.  

3.0L (Aj) Engine
  1. Install the alternator and tighten the bolts to 29-41 ft. lbs. (40-55 Nm).
  2.  
  3. Connect the alternator electrical connections.
  4.  
  5. Install the right hand three way catalytic converter and front pipe.
  6.  
  7. Install the drive belt.
  8.  
  9. Install the under cover.
  10.  
  11. Connect the negative battery cable.
  12.  

Removal



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Vacuum hose
     
    Solenoid bracket, if equipped
     
    Pressure pipe bracket and the Exhaust Gas Recirculation (EGR) solenoid valve bracket
     
    Electrical connectors from the alternator
     
    Alternator drive belt
     
    Alternator bracket
     
    Alternator pivot and adjusting bar bolts
     
    Alternator
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Alternator upper mounting bolt
     
    Alternator adjusting bolt
     
    Drive belt from the alternator pulley
     
    Transverse member
     
    Electrical connectors from the alternator
     
    Front exhaust pipe at the catalytic converter and suspend it on a piece of wire
     
    Oxygen (O 2 S) sensor
     
    3 exhaust manifold flange nuts and the hold-down bracket clamp
     
    Exhaust pipe
     
    Alternator lower through-bolt
     
    Alternator
     

  4.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If equipped with the 2.3L engine, remove the front charge air cooler, radiator upper seal board and the condenser fan assembly.
  6.  
  7. Remove or disconnect the following:

    Electrical connectors from the alternator
     
    Right splash shield
     
    Drive belt from the alternator pulley
     
    A/C compressor and support it aside, leaving the refrigerant lines connected
     
    Upper and lower alternator mounting bolts
     
    Alternator
     

  8.  

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold bracket
     
    Electrical connectors from the alternator
     
    Alternator bolts
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Alternator bolts. Tighten the lower bolts to 38 ft. lbs. (51 Nm) and the upper bolt 18 ft. lbs. (25 Nm).
     
    Electrical connectors to the alternator
     
    Intake manifold bracket
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery cover and disconnect the negative battery cable.
  4.  
  5. Remove the under cover and splash shield as an assembly.
  6.  
  7. Remove the plug hole plate.
  8.  
  9. Remove the drive belt.
  10.  
  11. Disconnect the alternator electrical connections.
  12.  
  13. Position the coolant overflow tank to one side to facilitate alternator removal.
  14.  
  15. Remove the bolts A, B, C, and D in order and the alternator. Refer to the illustration for bolt location.

    Click image to see an enlarged view

    Fig. Location of alternator mounting bolts A, B, C, and D-Mazda 3 models

  16.  

To install:

  1. Place the alternator in position matching the fixing and engine side holes and hand tighten the bolts A, B, C and D in alphabetical order. Refer to the illustration for bolt locations.
  2.  
  3. Attach the alternator electrical connections. Tighten bolts A, B, C and D in alphabetical order to 16-22 ft. lbs. (21-30 Nm). Refer to the illustration for bolt locations.
  4.  
  5. Install the drive belt.
  6.  
  7. Install the under cover and splash shield.
  8.  
  9. Install the plug hole plate.
  10.  
  11. Connect the negative battery cable and install the battery cover.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Electrical connectors from the alternator
     
    Alternator drive belt
     
    Alternator pivot and adjusting bar bolts
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator with the pivot bolt
     
    Alternator electrical connectors
     
    Drive belt
     
    Upper mounting bolt
     

  2.  
  3. Adjust the belt tension. Torque the lower through bolt to 28-38 ft. lbs. (38-51 Nm) and the upper mounting bolt to 14-18 ft. lbs. (19-26 Nm).

    Negative battery cable
     

  4.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. If equipped with the 2.3L (KJ) engine, remove the front charge air cooler, radiator upper seal board and the condenser fan assembly.
  6.  
  7. Remove or disconnect the following:

    Intake air system on 2.4 (KL) engine
     
    Electrical connectors from the alternator
     
    Right splash shield
     
    Drive belt from the alternator pulley
     
    A/C compressor and support it aside, leaving the refrigerant lines connected
     
    Upper and lower alternator mounting bolts
     
    Alternator
     

  8.  

To install:

  1. Install or connect the following:

    Alternator. Torque the upper bolt to 14-18 ft. lbs. (19-25 Nm) and the lower bolt to 28-38 ft. lbs. (38-51 Nm).
     
    A/C compressor. Torque the bolts to 12-16 ft. lbs. (16-22 Nm).
     
    Right splash shield
     
    Drive belt
     
    Electrical connectors to the alternator
     
    Intake air system on 2.4 (KL) engine
     

  2.  
  3. If equipped with the 2.3L engine, install the condenser fan assembly, radiator upper seal board and the front charge air cooler using new O-rings. Torque the mounting bolts to 12-16 ft. lbs. (16-22 Nm).
  4.  
  5. Connect the negative battery cable.
  6.  

2.0L (Fs) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Alternator upper mounting bolt
     
    Alternator adjusting bolt
     
    Drive belt from the alternator pulley
     
    Transverse member
     
    Electrical connectors from the alternator
     
    Front exhaust pipe at the catalytic converter and suspend it on a piece of wire
     
    Oxygen Sensor (O 2 S)
     
    3 exhaust manifold flange nuts and the hold-down bracket clamp
     
    Exhaust pipe
     
    Alternator lower through-bolt
     
    Alternator
     

  4.  

To install:



Alternator
 
Alternator bolts. Tighten the lower bolt to 28-38 ft. lbs. (38-51 Nm) and the upper bolt to 14-18 ft. lbs. (19-25 Nm).
 
Drive belt, check the belt deflection by applying moderate pressure 22 lbs. (98 N) between the alternator and the water pump pulley. The deflection on a new belt should be 6.5-7 inch (0.26-0.27mm) or on a used belt, 7.0-9.0 inch (0.28-0.35mm). Loosen the alternator mounting bolts and use the adjusting bolt to adjust the belt tension to the correct specification.
 
Electrical connector and terminal wire
 
Front exhaust pipe
 
Transverse pipe
 
Negative battery cable

Click image to see an enlarged view

Fig. Adjust the alternator belt tension using the adjustment boltC-626 4 cylinder models

 

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the under cover.
  8.  
  9. Remove the drive belt.
  10.  
  11. Remove the alternator duct and heat insulator.
  12.  
  13. Disconnect the alternator electrical connections.
  14.  
  15. Remove the bolts A, B and C. Refer to the illustration for bolt location.

    Click image to see an enlarged view

    Fig. Location of alternator mounting bolts A, B and C-Mazda 6 models with 2.3L (L3) engine

  16.  

To install:

  1. Install the alternator, tighten bolt A temporarily, then tighten the bolts in the following order; B, A and C to 29-41 ft. lbs. (40-55 Nm).
  2.  
  3. Connect the alternator electrical connections.
  4.  
  5. Install the heat insulator and tighten the bolt to 18-47 inch lbs. (2-5 Nm).
  6.  
  7. Install the alternator duct
  8.  
  9. Install the under cover.
  10.  
  11. Install the drive belt.
  12.  
  13. Connect the negative battery cable.
  14.  

2.5L (Kl) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct
     
    Radiator upper bracket
     
    Condenser fan, if equipped
     
    Electrical connectors from the alternator
     
    Loosen the belt tensioner locknut and tension adjusting bolt
     
    Alternator upper mounting bolt
     
    Right splash shield
     
    Drive belt from the alternator pulley
     
    A/C compressor and support it aside, leaving the refrigerant lines connected, if necessary
     
    Alternator through-bolt
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator. Torque the lower bolt to 28-38 ft. lbs. (38-51 Nm) and the upper bolt to 14-18 ft. lbs. (19-25 Nm).
     
    A/C compressor, if removed. Torque the bolts to 11-15 ft. lbs. (15-21 Nm).
     
    Drive belt, check the belt deflection by applying moderate pressure 22 ft. lbs. (98 N) between the alternator and the crankshaft pulley to check the alternator belt or midway between the A/C compressor and the crankshaft pulley to check the Air conditioning/alternator belt. The deflection on a new belt should be 6.0-7 inch (0.24-0.27mm) or on a used belt, 7.0-8.0 inch (0.28-0.31mm) on the alternator belt. On models with a air conditioning/alternator belt; the deflection on a new belt should be 5.5-6.5 inch (0.22-0.25mm) or on a used belt, 6.5-7.5 inch (0.26-0.29mm) Loosen the alternator mounting bolts and use the adjusting bolt to adjust the belt tension to the correct specification.

    Click image to see an enlarged view

    Fig. Adjust the alternator belt tension using the adjustment boltB-626 6 cylinder models

     
    Negative battery cable
     

  2.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the under cover.
  8.  
  9. Remove the drive belt.
  10.  
  11. Remove the right hand three way catalytic converter and front pipe.
  12.  
  13. Disconnect the alternator electrical connections.
  14.  
  15. Remove the bolts and the alternator.

    Click image to see an enlarged view

    Fig. Alternator mounting-Mazda 6 models with 3.0L (AJ) engine

  16.  

To install:

  1. Install the alternator and tighten the bolts to 29-41 ft. lbs. (40-55 Nm).
  2.  
  3. Connect the alternator electrical connections.
  4.  
  5. Install the right hand three way catalytic converter and front pipe.
  6.  
  7. Install the drive belt.
  8.  
  9. Install the under cover.
  10.  
  11. Connect the negative battery cable.
  12.  

Mazdaspeed6
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 under cover.
  6.  
  7. Remove the drive belt.
  8.  
  9. Remove the right hand three way catalytic converter and front pipe.
  10.  
  11. Disconnect the alternator electrical connections.
  12.  
  13. Remove the bolts and the alternator.

    Click image to see an enlarged view

    Fig. Alternator mounting-Mazda6 models with 3.0L (AJ) engine

  14.  

To install:

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Install the alternator and tighten the bolts to 29-41 ft. lbs. (40-55 Nm).
  4.  
  5. Connect the alternator electrical connections.
  6.  
  7. Install the right hand three way catalytic converter and front pipe.
  8.  
  9. Install the drive belt.
  10.  
  11. Install the under cover.
  12.  
  13. Connect the negative battery cable.
  14.  

 
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