Mazda Trucks 1994-1998 Repair Guide

Belts

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INSPECTION



See Figures 1, 2, 3, 4 and 5

Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. All worn or damaged drive belts should be replaced immediately. It is best to replace all drive belts at one time, as a preventive maintenance measure, during this service operation.



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Fig. Fig. 1: There are typically 3 types of accessory drive belts found on vehicles today



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Fig. Fig. 2: An example of a healthy drive belt



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Fig. Fig. 3: Deep cracks in this belt will cause flex, building up heat that will eventually lead to belt failure



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Fig. Fig. 4: The cover of this belt is worn, exposing the critical reinforcing cords to excessive wear



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Fig. Fig. 5: Installing too wide a belt can result in serious belt wear and/or breakage

ADJUSTMENT



See Figure 6

Belt tension can be checked by pressing on the belt at the center point of its longest straight run. The belt should give about 1 / 4 - 1 / 2 in. If the belt is loose, it will slip. If the belt is too tight it will damage bearings in the driven unit. Those units being driven, such as the alternator, power steering pump or compressor, have a bolt which when loosened allows the unit to move for belt adjustment. Sometimes it is necessary to loosen the pivot bolt also, to make the adjustment.



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Fig. Fig. 6: Checking ribbed belt alignment

REMOVAL & INSTALLATION



Non-serpentine (MPV)

See Figure 7



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Fig. Fig. 7: (A) Alternator belt, (B) Power steering pump belt, (C) A/C compressor belt-MPV with 3.0L engine shown

POWER STEERING PUMP BELT

See Figures 8, 9 and 10

  1. Turn the ignition OFF and remove the key. Allow the engine to cool.
  2.  
  3. Loosen the idler pulley locknut to release the drive belt tension.
  4.  
  5. Remove the power steering belt.
  6.  



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Fig. Fig. 8: Using a boxwrench, loosen the power steering pump belt idler pulley lockbolt



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Fig. Fig. 9: Loosen the power steering pump belt by turning the idler pulley adjusting bolt



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Fig. Fig. 10: Remove the power steering pump belt

To install:
  1. Install the power steering belt and make sure it is correctly seated on the pulleys.
  2.  
  3. Adjust the power steering belt tension/deflection by turning the adjusting bolt. A new belt should deflect 0.26-0.28 in. (6.6-7.2mm) and a used belt should deflect 0.28-0.31 in. (7-8mm).
  4.  
  5. Tighten the idler pulley locknut to 27-38 ft. lbs. (37-52 Nm).
  6.  
  7. Run the engine for 5 minutes and then recheck the belt deflection.
  8.  

ALTERNATOR BELT

See Figures 11, 12, 13, and 14

  1. Turn the ignition OFF and remove the key. Allow the engine to cool.
  2.  
  3. Remove the power steering pump belt and A/C compressor belt, if necessary.
  4.  
  5. Loosen the alternator upper bracket adjusting bolt.
  6.  
  7. Loosen the lower through-bolt.
  8.  
  9. Remove the alternator belt.
  10.  



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Fig. Fig. 11: To access the alternator pivot bolt, you must first remove the power steering pump pulley



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Fig. Fig. 12: Loosen the alternator pivot bolt located just below the alternator assembly



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Fig. Fig. 13: Loosen the alternator adjuster lockbolt (A), then turn the adjustment nut (B) to loosen the slack on the belt ...



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Fig. Fig. 14: ... then remove the alternator belt

To install:
  1. Install the alternator belt and make sure it is correctly seated on the pulleys.
  2.  
  3. Turn the adjusting bolt to adjust the belt deflection. New belts should deflect 0.39-0.47 in. (10-12mm). Used belts should deflect 0.43-0.51 in. (11-13mm).
  4.  
  5. Once the correct deflection has been reached, tighten the upper bracket lock bolt to 14-19 ft. lbs. (19-25 Nm).
  6.  
  7. Tighten the lower through-bolt to 28-38 ft. lbs. (38-51 Nm).
  8.  
  9. Install and tension the power steering pump belt and A/C compressor belt, if necessary.
  10.  
  11. Run the engine for 5 minutes and then recheck the belt deflection.
  12.  

A/C COMPRESSOR BELT

See Figures 15, 16 and 17

  1. Turn the ignition OFF and remove the key. Allow the engine to cool.
  2.  
  3. Remove the power steering pump belt and alternator belt, if necessary.
  4.  
  5. Loosen the tensioner bracket adjusting bolt and tensioner pulley center locknut to release the drive belt tension.
  6.  
  7. Remove the A/C belt.
  8.  



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Fig. Fig. 15: Loosen the A/C compressor belt idler pulley lockbolt using an open end wrench



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Fig. Fig. 16: Loosen the A/C compressor belt idler pulley adjusting bolt just enough to be able to remove the belt



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Fig. Fig. 17: Remove the A/C compressor belt

To install:
  1. Install the A/C belt, and make sure it is correctly seated on the pulleys.
  2.  
  3. Adjust the A/C belt tension/deflection by turning the tensioner bracket adjusting bolt. A new belt should deflect 0.33-0.39 in. (8.5-10mm), and a used belt should deflect 0.39-0.45 in. (10-11.5mm).
  4.  
  5. Tighten the tensioner pulley center locknut to 27-38 ft. lbs. (37-52 Nm).
  6.  
  7. Install and tension the alternator belt, if necessary, and the power steering pump belt.
  8.  
  9. Run the engine for 5 minutes and then recheck the belt deflection.
  10.  

Serpentine (Navajo and B Series Pick-up)

See Figures 18, 19, 20, 21 and 22

All Navajo and B Series Pick-up engines utilize one wide-ribbed V-belt to drive the engine accessories such as the water pump, alternator, air conditioner compressor, air pump, etc. Because this belt uses a spring loaded tensioner for adjustment, belt replacement tends to be somewhat easier than on engines where accessories are pivoted and bolted in place for tension adjustment, such as the MPV. Basically, all belt replacement involves is to pivot the tensioner to loosen the belt, then slide the belt off of the pulleys. The two most important points are to pay CLOSE attention to the proper belt routing (since serpentine belts tend to be "snaked" all different ways through the pulleys) and to make sure the V-ribs are properly seated in all the pulleys.



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Fig. Fig. 18: Belt routing diagram-2.3L/2.5L engines



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Fig. Fig. 19: Belt routing diagram-3.0L engines



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Fig. Fig. 20: Belt routing diagram-4.0L engines

Although belt routing diagrams have been included in this section, the first places you should check for proper belt routing are the labels in your engine compartment. These should include a belt routing diagram which may reflect changes made during a production run.



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Fig. Fig. 21: A belt routing label can usually be found under the hood

  1. Disconnect the negative battery cable for safety. This will help assure that no one mistakenly cranks the engine over with your hands between the pulleys.
  2.  

Take a good look at the installed belt and make a note of the routing. Before removing the belt, make sure the routing matches that of the belt routing label or one of the diagrams in this guide. If for some reason a diagram does not match (you may not have the original engine or it may have been modified,) carefully note the changes on a piece of paper.

  1. For tensioners equipped with a 1 / 2 inch square hole, insert the drive end of a large breaker bar into the hole. Use the breaker bar to pivot the tensioner away from the drive belt. For tensioners not equipped with this hole, use the proper-sized socket and breaker bar (or a large handled wrench) on the tensioner idler pulley center bolt to pivot the tensioner away from the belt. This will loosen the belt sufficiently that it can be pulled off of one or more of the pulleys. It is usually easiest to carefully pull the belt out from underneath the tensioner pulley itself.
  2.  



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Fig. Fig. 22: Once the tension is relieved, slip the belt off the pulley then slowly release the tensioner

  1. Once the belt is off one of the pulleys, gently pivot the tensioner back into position. DO NOT allow the tensioner to snap back, as this could damage the tensioners internal parts.
  2.  
  3. Now finish removing the belt from the other pulleys and remove it from the engine.
  4.  

To install:
  1. While referring to the proper routing diagram (which you identified earlier), begin to route the belt over the pulleys, leaving whichever pulley you first released it from for last.
  2.  
  3. Once the belt is mostly in place, carefully pivot the tensioner and position the belt over the final pulley. As you begin to allow the tensioner back into contact with the belt, run your hand around the pulleys and make sure the belt is properly seated in the ribs. If not, release the tension and seat the belt.
  4.  
  5. Once the belt is installed, take another look at all the pulleys to double check your installation.
  6.  
  7. Connect the negative battery cable, then start and run the engine to check belt operation.
  8.  
  9. Once the engine has reached normal operating temperature, turn the ignition OFF and check that the belt tensioner arrow is within the proper adjustment range.
  10.  

 
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