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Generator Removal/Installation: Notes

WARNING:
  • Remove and install all parts when the engine is cold, otherwise they can cause severe burns or serious injury.
  • When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the negative battery cable before performing the following operation.
  1. Disconnect the negative battery cable. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. Set the resonance duct and air intake hoses No. 1 and 2 aside as a single unit using the following procedure. (With resonance chamber No. 2)
    1. Remove the bolt shown in the illustration.
      Fig 1: Resonance Duct Bolt With Torque Specification
      G14588404Courtesy of MAZDA MOTORS CORP.
    2. Disconnect the air intake hose No. 1 from the joint pipe.
      G14588405Courtesy of MAZDA MOTORS CORP.
    3. Set the resonance duct and air intake hoses No. 1 and 2 aside as a single unit in the direction of the arrow shown in the illustration.
      G14588406Courtesy of MAZDA MOTORS CORP.
  3. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION .)
  4. Remove the air cleaner, air hose and resonance chamber No. 1 as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  5. Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  6. Remove the drive belt auto tensioner. (See DRIVE BELT AUTO TENSIONER REMOVAL/INSTALLATION .)
  7. Detach the clip and set the wiring harness aside.
    G14588407Courtesy of MAZDA MOTORS CORP.
  8. Remove the bolt and nuts shown in the illustration.
    Fig 2: PCM Component, Bolt And Nuts With Torque Specification
    G14588408Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The PCM component can be moved freely with the PCM connector connected by removing the nuts and bolt.

    Example of PCM component movement 

    G14588409Courtesy of MAZDA MOTORS CORP.
  9. Remove the nut shown in the illustration.
    Fig 3: Wiring Harness Protector Nuts With Torque Specification
    G13488399Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • If the nut is removed, the wiring harness protector can be slightly moved.
  10. Remove in the order indicated in the table.
  11. Install in the reverse order of removal.
    Fig 4: Generator Components With Torque Specification
    G14588411Courtesy of MAZDA MOTORS CORP.
    PART DESCRIPTION

    Component no. Refer to
    1 Terminal B cable
    2 Generator connector
    3 Generator
    (See GENERATOR REMOVAL NOTE .)
    (See GENERATOR INSTALLATION NOTE .)
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