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Home >> Mazda >> 2002 >> B4000 Base, Standard >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Engine Mechanical - Overhaul >> Engine Disassembly/Assembly >> Assembly Note

Assembly Note

CAUTION:
  • This vehicle is equipped with a composite material fuel rail. If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.
NOTE:
  • Before engine assembly, use Metal Surface Cleaner and a suitable plastic or wooden scraper to clean the sealing surfaces. All sealing surfaces must be clean. Make sure coolant and oil passages are clear.
    NOTE:
    • The crankshaft bearings are precision selective fit. Inspect the bearing clearance.
  1. Install the crankshaft main bearings and the thrust bearing.
    1. Lubricate the crankshaft main bearings with clean engine oil.
  2. Install the crankshaft.
    Fig 1: Installing Crankshaft
    G02821216Courtesy of MAZDA MOTORS CORP.
    3. NOTE:
    • The rear main bearing cap must be installed within four minutes after applying the silicone.
    Fig 2: Applying Silicone Gasket & Sealant
    G02821217Courtesy of MAZDA MOTORS CORP.
  3. Apply silicone gasket and sealant to the rear main bearing cap to cylinder block parting line.
  4. Install the crankshaft lower main bearings in the main bearing caps.
  5. Install the main bearing caps and bolts.
    Fig 3: Installing Main Bearing Caps & Bolts
    G02821218Courtesy of MAZDA MOTORS CORP.
  6. Tighten the main bearing cap bolts.
    Fig 4: Tightening Main Bearing Cap Bolts
    G02821219Courtesy of MAZDA MOTORS CORP.
  7. Lubricate the piston rings with clean engine oil.
  8. Make sure that the piston rings are correctly spaced. Refer to PISTON AND CONNECTING ROD DISASSEMBLY/ASSEMBLY .
  9. Install rubber hose pieces on the connecting rod bolts to protect the crankshaft.
    Fig 5: Install Rubber Hose Pieces On Connecting Rod Bolts
    G02821220Courtesy of MAZDA MOTORS CORP.
    10. NOTE:
    • Position the piston with the indentation arrow toward the front of the cylinder block.
    Fig 6: Identifying Piston Ring Compressor
    G02821221Courtesy of MAZDA MOTORS CORP.
  10. Using Piston Ring Compressor SST 303-D032, install the pistons, connecting rod caps, and bolts and nuts (finger tight).
    11. NOTE:
    • The old nuts and bolts are used for checking clearances. New nuts and bolts must be used for reassembly.
  11. Check the clearance of each connecting rod bearing.
  12. Rotate the crankshaft until the piston is at the bottom of its stroke.
    13. NOTE:
    • For cylinders 1, 2, and 3, remove the connecting rod nut at the oil split hole side first. For cylinders 4, 5, and 6, remove the opposite nut first.
    Fig 7: Identifying Nut Face Approximately 2 mm (0.08 in) Over End Of Bolt
    G02821222Courtesy of MAZDA MOTORS CORP.
  13. Loosen the first nut until the face is approximately 2 mm (0.08 in) over the end of the bolt.
  14. Tap the nut until the bolt can move by hand.
    Fig 8: Taping Nut
    G02821223Courtesy of MAZDA MOTORS CORP.
  15. Repeat the previous two steps for the opposite bolt and nut.
  16. Install the new bolts making sure that the bolt head is parallel to the sideward face of the connecting rod.
    Fig 9: Installing Bolt Head Parallel To Sideward Face Of Connecting Rod
    G02821224Courtesy of MAZDA MOTORS CORP.
  17. Install the connecting rod cap in the original position.
    18. NOTE:
    • Do not exceed 20 Nm (2 kgf-m, 15 lb-ft) when tightening the connecting rod nuts.
    Fig 10: Tightening Connecting Rod Nuts Finger Tight
    G02821225Courtesy of MAZDA MOTORS CORP.
  18. Install and tighten the connecting rod nuts finger tight.
  19. Tighten the connecting rod nuts simultaneously in two stages:
    1. Stage 1: Tighten to 20 Nm (2kgf-m, 15 lb-ft).
    2. Stage 2: Tighten 90 degrees.
  20. Repeat previous four steps for remaining connecting rods.
  21. Rotate crankshaft until No. 1 piston is at top dead center.
  22. On vehicles with a balance shaft, install the balance shaft.
    1. Install the balance shaft.
    2. Install the bolts and tighten.
    Fig 11: Installing Balance Shaft
    G02821226Courtesy of MAZDA MOTORS CORP.
  23. On vehicles with a balance shaft, install the balance shaft chain and crankshaft sprocket.
    Fig 12: Installing Balance Shaft Chain & Crankshaft Sprocket
    G02821227Courtesy of MAZDA MOTORS CORP.
    24. NOTE:
    • Due to the gear ratio between the reversal shaft and the balance shaft, up to seven complete turns of the balance shaft may be required to find the correct position.
    Fig 13: Aligning Timing Marks
    G02821228Courtesy of MAZDA MOTORS CORP.
  24. On vehicles with a balance shaft, align the timing marks.
    1. Install the 4 mm pin to hold the shaft in place.
  25. On vehicles with a balance shaft, install the balance shaft tensioner.
    1. Install the balance shaft tensioner.
    2. Install the balance shaft tensioner bolts and tighten.
    3. Position the balance shaft chain guide and install the two bolts. Tighten the bolts.
      • Remove the pin from the tensioner.
    Fig 14: Installing Balance Shaft Tensioner
    G02821229Courtesy of MAZDA MOTORS CORP.
  26. Install the oil pump and tighten the bolts.
    Fig 15: Installing Oil Pump
    G02821230Courtesy of MAZDA MOTORS CORP.
  27. Install the jackshaft.
    Fig 16: Installing Jackshaft
    G02821231Courtesy of MAZDA MOTORS CORP.
  28. Install the jackshaft thrust plate and tighten the bolts.
    Fig 17: Installing Jackshaft Thrust Plate
    G02821232Courtesy of MAZDA MOTORS CORP.
  29. Install the oil pump drive and tighten.
    Fig 18: Installing Oil Pump Drive
    G02821233Courtesy of MAZDA MOTORS CORP.
  30. Attach the rear cassette and sprocket to the bolt. Do not tighten at this time.
    Fig 19: Installing Rear Cassette & Sprocket
    G02821234Courtesy of MAZDA MOTORS CORP.
  31. Install the rear cassette and bolt with camshaft drive chains. Tighten the bolt.
    Fig 20: Installing Rear Cassette & Bolt With Camshaft Drive Chains
    G02821235Courtesy of MAZDA MOTORS CORP.
  32. Install the front cassette and bolt with camshaft drive chains. Tighten the bolt.
    Fig 21: Installing Front Cassette & Bolt With Camshaft Drive Chains
    G02821236Courtesy of MAZDA MOTORS CORP.
  33. Position the jackshaft sprocket and chain.
    Fig 22: Positioning Jackshaft Sprocket & Chain
    G02821237Courtesy of MAZDA MOTORS CORP.
  34. Install the chain guide and tighten the bolts.
    Fig 23: Installing Chain Guide
    G02821238Courtesy of MAZDA MOTORS CORP.
  35. Install the chain tensioner and tighten the bolts.
    Fig 24: Installing Chain Tensioner
    G02821239Courtesy of MAZDA MOTORS CORP.
  36. Install the front sprocket retaining bolt. Do not tighten at this time.
    Fig 25: Installing Front Sprocket Retaining Bolt
    G02821240Courtesy of MAZDA MOTORS CORP.
  37. While holding the front jackshaft sprocket bolt secure, tighten the rear bolt to 20 Nm (2 kgf-m, 15 lb-ft).
  38. Install the Rear Jackshaft Socket SST 303-634 on the rear of the jackshaft.
    Fig 26: Installing Rear Jackshaft Socket SST On Rear Of Jackshaft
    G02821241Courtesy of MAZDA MOTORS CORP.
  39. Tighten the rear bolt an additional 90 degrees.
    Fig 27: Tightening Rear Bolt
    G02821242Courtesy of MAZDA MOTORS CORP.
  40. Tighten the front bolt in two stages.
    1. Stage 1: Tighten to 45 Nm (4.5 kgf-m, 33 lb-ft).
    2. Stage 2: Tighten 90 degrees.
    Fig 28: Tightening Front Bolt
    G02821243Courtesy of MAZDA MOTORS CORP.
  41. Remove the Rear Jackshaft Socket SST 303-634 and install the rear jackshaft plug.
    Fig 29: Installing Rear Jackshaft Plug
    G02821244Courtesy of MAZDA MOTORS CORP.
  42. Position the front cover gasket and install the front cover. Tighten the bolts.
    Fig 30: Installing Front Cover
    G02821245Courtesy of MAZDA MOTORS CORP.
  43. Apply sealant to the front cover in four places.
    Fig 31: Applying Sealant To Front Cover
    G02821246Courtesy of MAZDA MOTORS CORP.
  44. Apply silicone gasket and sealant to the rear main bearing cap as shown.
    1. Position the ladder frame gasket.
    Fig 32: Applying Silicone Gasket & Sealant To Rear Main Bearing Cap
    G02821247Courtesy of MAZDA MOTORS CORP.
    45. CAUTION:
    • The ladder frame inserts must be loosened completely or damage to the ladder frame and/or oil leaks may result.
    Fig 33: Loosening Ladder Frame Inserts
    G02821248Courtesy of MAZDA MOTORS CORP.
  45. Loosen the ladder frame inserts.
  46. Position the ladder frame and gasket assembly.
    Fig 34: Positioning Ladder Frame & Gasket Assembly
    G02821249Courtesy of MAZDA MOTORS CORP.
  47. Install and hand tighten the 15 bolts and 2 nuts.
    Fig 35: Installing & Hand Tightening Bolts & Nuts
    G02821250Courtesy of MAZDA MOTORS CORP.
  48. Install and hand tighten the ladder frame bolts.
    Fig 36: Installing & Hand Tightening Ladder Frame Bolts
    G02821251Courtesy of MAZDA MOTORS CORP.
    49. NOTE:
    • The ladder frame to cylinder block alignment must be within a maximum mismatch of 0.25 mm (0.01 in) ladder frame under flush or 0.05 mm (0.00196 in) ladder frame protrusion.
    Fig 37: Aligning Transmission Face Of Ladder Frame With Rear Of Cylinder Block
    G02821252Courtesy of MAZDA MOTORS CORP.
  49. Using a straight edge, align the transmission face of the ladder frame with the rear of the cylinder block.
  50. Tighten the 15 bolts and 2 nuts.
    Fig 38: Tightening Ladder Frame Bolts & Nuts
    G02821253Courtesy of MAZDA MOTORS CORP.
  51. Tighten the ladder frame bolts.
    Fig 39: Tightening Ladder Frame Bolts
    G02821254Courtesy of MAZDA MOTORS CORP.
  52. Tighten the inserts.
    Fig 40: Tightening Inserts
    G02821255Courtesy of MAZDA MOTORS CORP.
  53. Install new seals on the two silver bolts and position them in the ladder frame.
    Fig 41: Installing New Seals On Two Silver Bolts
    G02821256Courtesy of MAZDA MOTORS CORP.
  54. Position the six remaining bolts.
    Fig 42: Positioning Six Remaining Bolts
    G02821257Courtesy of MAZDA MOTORS CORP.
  55. Tighten the ladder frame bolts in two stages.
    1. Stage 1: Tighten to 15 Nm (1.5 kgf-m, 11 lb-ft).
    2. Stage 2: Tighten to 33 Nm (3.3 kgf-m, 24 lb-ft).
    Fig 43: Tightening Ladder Frame Bolts
    G02821258Courtesy of MAZDA MOTORS CORP.
    56. NOTE:
    • Assemblies that measure out of specification must have the entire assembly procedure repeated.
    Fig 44: Identifying Step Between Rear Face Of Cylinder Block And Transmission Face Of Ladder Frame
    G02821259Courtesy of MAZDA MOTORS CORP.
  56. Measure the step between the rear face of the cylinder block and the transmission face of the ladder frame.
  57. Repair all assemblies that exceed under-flush specification by installing shims on one or both sides of the ladder frame.
    Fig 45: Installing Shims On Sides Of Ladder Frame
    G02821260Courtesy of MAZDA MOTORS CORP.
  58. Install the oil pump screen cover and tube.
    Fig 46: Installing Oil Pump Screen Cover & Tube
    G02821261Courtesy of MAZDA MOTORS CORP.
  59. Install the gasket, and the oil pan. Tighten the bolts.
    Fig 47: Installing Oil Pan
    G02821262Courtesy of MAZDA MOTORS CORP.
  60. Install the oil filter adapter and tighten.
    Fig 48: Installing Oil Filter Adapter
    G02821263Courtesy of MAZDA MOTORS CORP.
  61. Install the oil filter and tighten.
    Fig 49: Installing Oil Filter
    G02821264Courtesy of MAZDA MOTORS CORP.
  62. Install the water pump and tighten the bolts.
    Fig 50: Installing Water Pump
    G02821265Courtesy of MAZDA MOTORS CORP.
    63. NOTE:
    • LH shown, RH similar.
    Fig 51: Installing Cylinder Head Gasket
    G02821266Courtesy of MAZDA MOTORS CORP.
  63. Install the cylinder head gasket.
    64. NOTE:
    • LH shown, RH similar.
    Fig 52: Cylinder Head Bolt Tightening Sequence
    G02821267Courtesy of MAZDA MOTORS CORP.
  64. Install the cylinder head and tighten the bolts in the sequence shown.
    65. NOTE:
    • LH shown, RH similar.
    Fig 53: Installing Two 8 mm Bolts
    G02821268Courtesy of MAZDA MOTORS CORP.
  65. Install the two 8 mm bolts and tighten.
    66. NOTE:
    • LH shown, RH similar.
    Fig 54: Cylinder Head Bolt Tightening Sequence
    G02821269Courtesy of MAZDA MOTORS CORP.
  66. Tighten the cylinder head bolts in the sequence shown in two stages.
    1. Stage 1: Rotate 80 degrees.
    2. Stage 2: Rotate an additional 80 degrees.
  67. Using the Crankshaft Damper Replacer SST 303-102 (or 49UN-01-0020), install the crankshaft pulley.
    Fig 55: Installing Crankshaft Pulley
    G02821270Courtesy of MAZDA MOTORS CORP.
    68. CAUTION:
    • A new bolt must be used each time it is removed.
    Fig 56: Tightening Crankshaft Pulley Bolt
    G02821271Courtesy of MAZDA MOTORS CORP.
  68. Tighten the bolt in two stages.
    1. Stage 1: Tighten to 50 N.m (5.0 kgf-m, 37 lb-ft).
    2. Stage 2: Rotate an additional 90 degrees.
    69. CAUTION:
    • The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 57: Installing RH Camshaft Sprocket Bolt
    G02821272Courtesy of MAZDA MOTORS CORP.
  69. Install the RH camshaft bolt.
  70. Install the bolt and tighten.
    Fig 58: Tightening RH Camshaft Sprocket Bolt
    G02821273Courtesy of MAZDA MOTORS CORP.
    71. CAUTION:
    • The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
    Fig 59: Installing LH Front Camshaft Sprocket Bolt
    G02821274Courtesy of MAZDA MOTORS CORP.
  71. Install the LH front camshaft bolt.
  72. Install the bolt and tighten.
    Fig 60: Tightening LH Front Camshaft Sprocket Bolt
    G02821275Courtesy of MAZDA MOTORS CORP.
  73. Turn the crankshaft one revolution clockwise.
    74. NOTE:
    • The crankshaft holding tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC).
    Fig 61: Installing Crankshaft Holding Tool
    G02821276Courtesy of MAZDA MOTORS CORP.
  74. Install the Crankshaft Holding Tool SST 303-573.
    75. NOTE:
    • Camshaft timing slots are off-center.
    NOTE:
    • Position the camshaft tinning slots below centerline of the camshaft to correctly fit the special tools.
    Fig 62: Installing Camshaft Holding Tool & Adapter
    G02821277Courtesy of MAZDA MOTORS CORP.
  75. Install the Camshaft Holding Tool SST 303-577 and Camshaft Holding Tool Adapter SST 303-576 on the front of the RH cylinder head.
    76. NOTE:
    • Leave the top two special tool clamp bolts loose.
    NOTE:
    • If cam is not in the correct position, the top of SST  303-576 will not sit flush with the top of SST  303-577. Rotate the cam 180° to set correctly.
  76. Install the RH camshaft chain tensioner, but do not tighten.
  77. Tighten the camshaft bolt to 85 Nm (8.5 kgfm, 63lb-ft).
  78. Tighten RH camshaft tensioner.
    Fig 63: Tightening RH Camshaft Tensioner
    G02821278Courtesy of MAZDA MOTORS CORP.
  79. Remove the special tools from the RH cylinder head.
    80. NOTE:
    • Camshaft timing slots are off-center.
    NOTE:
    • Position the camshaft timing slots below centerline of the camshaft to correctly fit the special tools.
    Fig 64: Install the Camshaft Holding Tool & Adapter
    G02821279Courtesy of MAZDA MOTORS CORP.
  80. Install the Camshaft Holding Tool SST 303-577 and Camshaft Holding Tool Adapter SST 303-576 on the rear of the LH cylinder head.
    81. NOTE:
    • Leave the top two special tool clamp bolts loose.
    NOTE:
    • If cam is not in the correct position, the top of SST 303-576 will not sit flush with the top of SST 303-577. Rotate the cam 180° to set correctly.
  81. Install the LH camshaft chain tensioner, but do not tighten.
  82. Tighten the camshaft bolt to 85 Nm (8.5 kgf-m, 63 lb-ft).
    83. NOTE:
    • When using a new washer, the camshaft tensioner must be tightened to 44 N.m (4.4 kgf-m, 32 lb-ft).
    Fig 65: Tightening LH Camshaft Tensioner
    G02821280Courtesy of MAZDA MOTORS CORP.
  83. Tighten the LH camshaft tensioner.
  84. Remove the special tools from the LH cylinder head.
  85. Remove the crankshaft holding tool.
    Fig 66: Removing Crankshaft Holding Tool
    G02821281Courtesy of MAZDA MOTORS CORP.
    86. NOTE:
    • Lubricate the parts with clean engine oil prior to installing.
    Fig 67: Installing Roller Followers
    G02821282Courtesy of MAZDA MOTORS CORP.
  86. Using the Valve Spring Compressor SST 303-581, install the roller followers in their original position.
  87. Install the gasket and the RH exhaust manifold. Tighten the bolts.
    Fig 68: Installing RH Exhaust Manifold
    G02821283Courtesy of MAZDA MOTORS CORP.
  88. Install the gasket and the LH exhaust manifold. Tighten the bolts.
    Fig 69: Installing LH Exhaust Manifold
    G02821284Courtesy of MAZDA MOTORS CORP.
    89. NOTE:
    • Prior to installation, use Metal Surface Cleaner to clean mating surfaces.
    Fig 70: Installing Knock Sensor
    G02821285Courtesy of MAZDA MOTORS CORP.
  89. Install the knock sensor and tighten the bolt.
  90. Install the oil level indicator tube.
    Fig 71: Installing Oil Level Indicator Tube
    G02821286Courtesy of MAZDA MOTORS CORP.
    91. NOTE:
    • If the oil level indicator tube is not installed flush with the cylinder block, false readings of the oil level may occur.
    Fig 72: Identifying Oil Level Indicator Tube Flush With Cylinder Block
    G02821287Courtesy of MAZDA MOTORS CORP.
  91. Make sure the oil level indicator tube is flush with the cylinder block.
  92. Install the thermostat housing.
    1. Install the housing into the bypass hose.
    2. Install the bolts and tighten.
    3. Position the bypass hose clamp.
    Fig 73: Installing Thermostat Housing
    G02821288Courtesy of MAZDA MOTORS CORP.
  93. Install the fuel injectors.
    1. Lubricate the fuel injector O-ring seals with engine oil.
    Fig 74: Installing Fuel Injectors
    G02821289Courtesy of MAZDA MOTORS CORP.
  94. Install the gasket and the RH valve cover and tighten the bolts.
    Fig 75: Installing RH Valve Cover
    G02821290Courtesy of MAZDA MOTORS CORP.
  95. Install the gasket and the LH valve cover and tighten the bolts.
    Fig 76: Installing LH Valve Cover
    G02821291Courtesy of MAZDA MOTORS CORP.
  96. Install the fuel rail and tighten the bolts.
    Fig 77: Installing Fuel Rail
    G02821292Courtesy of MAZDA MOTORS CORP.
  97. Install the lower fuel line bracket and tighten the bolt.
    Fig 78: Installing Lower Fuel Line Bracket
    G02821293Courtesy of MAZDA MOTORS CORP.
  98. Connect the EGR valve-to-the exhaust manifold tube to the exhaust manifold and tighten.
    Fig 79: Connecting EGR Valve Exhaust Manifold Tube
    G02821294Courtesy of MAZDA MOTORS CORP.
  99. Connect the EGR valve-to-exhaust manifold tube to the EGR valve and tighten to 34 N.m {3.4 kgf-m, 25 lb-ft}.
  100. Install the fuel charging wiring.
    Fig 80: Installing Fuel Charging Wiring
    G02821295Courtesy of MAZDA MOTORS CORP.
    101. NOTE:
    • LH shown, RH similar.
    Fig 81: Connecting Fuel Injector Electrical Connectors
    G02821296Courtesy of MAZDA MOTORS CORP.
  101. Connect the six fuel injector electrical connectors.
  102. Connect the water temperature sender unit and the Engine Coolant Temperature (ECT) sensor electrical connectors.
    Fig 82: Connecting Water Temperature Sender Unit & ECT Sensor Electrical Connectors
    G02821297Courtesy of MAZDA MOTORS CORP.
  103. Connect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 83: Connecting CKP Sensor Electrical Connector
    G02821298Courtesy of MAZDA MOTORS CORP.
  104. Connect the differential pressure feedback EGR transducer.
    Fig 84: Connecting Differential Pressure Feedback EGR Transducer
    G02821299Courtesy of MAZDA MOTORS CORP.
  105. Connect the Camshaft Position (CMP) sensor electrical connector.
    Fig 85: Connecting CMP Sensor Electrical Connector
    G02821300Courtesy of MAZDA MOTORS CORP.
  106. Attach the wiring harness retainer and install the heater tube bracket assembly.
    Fig 86: Attaching Wiring Harness Retainer
    G02821301Courtesy of MAZDA MOTORS CORP.
  107. Install the bolts and tighten.
    Fig 87: Installing Bracket Bolts
    G02821302Courtesy of MAZDA MOTORS CORP.
  108. Position the intake manifold close to the installed position.
  109. Install the heated PCV fitting.
    Fig 88: Installing Heated PCV Fitting
    G02821303Courtesy of MAZDA MOTORS CORP.
  110. Install the intake manifold and tighten the bolts.
    Fig 89: Installing Intake Manifold
    G02821304Courtesy of MAZDA MOTORS CORP.
  111. Connect and attach the electrical connector.
    Fig 90: Connecting Electrical Connector
    G02821305Courtesy of MAZDA MOTORS CORP.
  112. Connect the vacuum hoses.
    Fig 91: Connecting Vacuum Hoses
    G02821306Courtesy of MAZDA MOTORS CORP.
  113. Install the coil and ignition wire. Install the bolt and tighten.
    Fig 92: Installing Coil & Ignition Wire
    G02821307Courtesy of MAZDA MOTORS CORP.
  114. Install the bolts and tighten.
    Fig 93: Installing Bracket Bolts
    G02821308Courtesy of MAZDA MOTORS CORP.
    115. CAUTION:
    • Make sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifolds. Wire contact can send voltage spikes to other electronic modules.
    NOTE:
    • Apply dielectric compound to the inside of the spark plug boots.
  115. Connect the spark plug wires to the spark plugs.
  116. Connect the Exhaust Gas Recirculation (EGR) vacuum regulator electrical connector.
    Fig 94: Connecting EGR Vacuum Regulator Electrical Connector
    G02821309Courtesy of MAZDA MOTORS CORP.
  117. Connect the radio ignition interference capacitor electrical connector.
    Fig 95: Connecting Radio Ignition Interference Capacitor Electrical Connector
    G02821310Courtesy of MAZDA MOTORS CORP.
  118. Connect the ignition coil electrical connector.
    Fig 96: Connecting Ignition Coil Electrical Connector
    G02821311Courtesy of MAZDA MOTORS CORP.
  119. Connect the EGR valve-to-exhaust manifold tube to the EGR valve.
    Fig 97: Connecting EGR Valve-To-Exhaust Manifold Tube
    G02821312Courtesy of MAZDA MOTORS CORP.
  120. Connect the Idle Air Control (IAC) valve electrical connector and connect the EGR valve vacuum hose.
    Fig 98: Connecting IAC Valve Electrical Connector
    G02821313Courtesy of MAZDA MOTORS CORP.
  121. Connect the Throttle Position (TP) sensor electrical connector.
    Fig 99: Connecting TP Sensor Electrical Connector
    G02821314Courtesy of MAZDA MOTORS CORP.
  122. Install the generator mounting bracket and tighten the bolts.
    1. Install the generator mounting bracket bolts.
    2. Install the drive belt tensioner bolt and tighten.
    Fig 100: Installing Generator Mounting Bracket
    G02821316Courtesy of MAZDA MOTORS CORP.
  123. Install the accessory bracket and tighten the bolts.
  124. Rotate the drive belt tensioner counterclockwise and install the drive belt.
    Fig 101: Rotating Drive Belt Tensioner Counterclockwise
    G02821317Courtesy of MAZDA MOTORS CORP.
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