Crankshaft pulley installation (4JJ3 with DPD)

1. Component views

Crankshaft pulley

Part name

  1. Bolt
  2. Washer
  3. Crankshaft pulley

Tightening torque

1-1: 30 N・m { 3.1 kgf・m / 22 lb・ft }

1-2: 180 °

1-3: 60 °

2. Crankshaft pulley installation

1) Apply engine oil to the threaded portions and seating surfaces of the bolts.

2) Install the crankshaft pulley to the crankshaft in the order shown in the diagram.

Note

  • Install the crankshaft pulley aligned with the knock pin of the crankshaft.

Caution

  • Do not reuse the crankshaft pulley bolt and washer.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft } 1st time

3) Retighten the bolts in the order shown in the diagram using the special tool.


SST: 5-8840-0266-0 - angle gauge

Tightening Angle : 180 ° 2nd time

4) Retighten the bolts in the order shown in the diagram using the special tool.


SST: 5-8840-0266-0 - angle gauge

Tightening Angle : 60 ° 3rd time

5) Remove the special tool from the starter installation section of the rear plate.

3. Cooling fan installation

1) Install the fan pulley to the water pump.

2) Install the cooling fan and cooling fan clutch as a set to the water pump.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

4. Cooling fan belt installation

1) Install the cooling fan belt to the following parts.

  • Fan pulley
  • Generator
  • Crankshaft pulley

MT models

Legend

  1. Adjust bolt
  2. Cooling fan belt
  3. Lock nut

AT models

Legend

  1. Adjust bolt
  2. Cooling fan belt
  3. Lock nut

5. A/C compressor drive belt installation

1. M/T models (Euro 5 or above)

1) Install the A/C compressor drive belt to the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley
  • Idle pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. Idle pulley
  4. A/C compressor drive belt
  5. Idle pulley

2. Except M/T models (Euro 5 or above)

1) Install the A/C compressor drive belt to the following parts.

  • Tension pulley
  • A/C compressor
  • Crankshaft pulley

Legend

  1. Lock nut
  2. Adjust bolt
  3. A/C compressor drive belt

6. Fan guide installation

1) Install the fan guide to the radiator.

Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2) Install the fan shroud to the fan guide.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

7. Radiator upper hose installation

1) Install the radiator upper hose and clamp to the thermostat and radiator.

Note

  • Align the painted arrow on the upper hose with the pipe boss section to install.
  • Insert the upper hose until it makes full contact with the pipe.
  • Soapy water can be applied when installing the upper hose.

Legend

  1. Radiator upper hose
  2. Boss section
  3. Clamp
  4. Arrow mark

Note

  • Align the clamp with the upper hose arrow mark end to install.

Legend

  1. Clamp
  2. Arrow mark

Note

  • Install the clamp in the direction shown in the following diagram.
  • The diagram about the clamp direction shows the state viewed from the vehicle front.

8. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note

  • Wash with clean water, and drain the water.

2) Assemble the reserve tank hose to the radiator reserve tank.

Legend

  1. Radiator reserve tank
  2. Reserve tank hose

3) Install the radiator reserve tank to the fan guide.

Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

4) Connect the radiator reserve tank hose to the radiator.

Caution

  • Assemble the reserve tank hose to the dent to fit the radiator reserve tank shape.

9. Intake air duct installation

1) Install the intake duct to the intake throttle valve.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in } Clamp (Intake throttle valve side)

2) Connect the air intake hose to the intercooler.

Caution

  • Align the marks on the pipe side and hose side.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp (Intercooler side)

3) Connect the connector to charge air cooler temperature sensor 2.

10. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

2) Connect the connector to the MAF and IAT sensor.

Legend

  1. Air cleaner
  2. MAF and IAT sensor

11. Air duct installation

1) Align the air duct with the air cleaner and turbocharger.

Legend

  1. Air duct

2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

Legend

  1. Alignment mark

3) Install the PCV hose to the cylinder head cover and air duct.

Caution

  • Align the marks on the pipe side and hose side.

Legend

  1. PCV hose
  2. Clamp

4) Install the intake air duct to the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

12. Engine cover installation

1) Install the engine cover to the engine.

Legend

  1. Engine cover

13. Starter motor installation

Refer to "1.Engine 1J.Electrical(4JJ3 with DPD) starter motor installation".

14. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

15. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

16. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution

  • Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.

Note

  • Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant lowers.

Caution

  • Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

Legend

  1. Radiator reserve tank
  2. MAX line
  3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution

  • Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note

  • If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note

  • Touch the radiator upper hose, and confirm that it has become warm.
  • If it has not become warm, go back to Step 11.

Caution

  • Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution

  • If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.

17. Cooling fan belt adjustment

When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the cooling fan belt, readjust the cooling fan belt tension.

1) Loosen the tension pulley lock nut using a wrench.

2) Adjust the cooling fan belt tension by turning the adjust bolt.

Note

  • The standard amount of deflection shown is the value obtained when the standard pressure is applied to the midpoint of the fan pulley and generator.

Standard: 98 N { 10.0 kg / 22 lb }

Caution

  • Accurately adjust the tension as there is a possibility the service life of the belt may be shortened or belt squeal may be generated if the tension is not within the appropriate range.
  • Use a sonic tension meter to verify accurate tension adjustment.
Cooling fan belt tension standard value
Adjustment conditions
 Deflection
 Vibration frequency
When new
 5.0 to 6.0 mm { 0.20 to 0.24 in }
 207 to 231 Hz
Reused
 7.0 to 7.8 mm { 0.28 to 0.31 in }
 176 to 190 Hz

Legend

  1. Tension pulley adjust bolt
  2. Measurement point
  3. Cooling fan belt

3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

18. A/C compressor drive belt adjustment

1. M/T models (Euro 5 or above)

When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the A/C compressor drive belt, adjust the tension of the A/C compressor drive belt again.

1) Loosen the tension pulley lock nut.

2) Turn the tension pulley adjust bolt to adjust the tension.

Note

  • The standard deflection shown is the value obtained when the specified load is applied to the measurement point of the A/C compressor drive belt.

98 N { 10.0 kg / 22 lb } Load

Caution

  • Accurately adjust the tension as there is a possibility the service life of the belt may be shortened or belt squeal may be generated if the tension is not within the appropriate range.
  • Use a sonic tension meter to verify accurate tension adjustment.
Measurement point 1
Adjustment conditions
 Deflection
 Vibration frequency
When new
 10.2 to 11.2 mm { 0.40 to 0.44 in }
 163 to 179 Hz
Reused
 12.1 to 13.3 mm { 0.48 to 0.52 in }
 131 to 147 Hz
Measurement point 4
Adjustment conditions
 Deflection
 Vibration frequency
When new
 6.8 to 7.4 mm { 0.27 to 0.29 in }
 249 to 273 Hz
Reused
 7.9 to 8.7 mm { 0.31 to 0.34 in }
 201 to 225 Hz

Legend

  1. Measurement point 1
  2. Lock nut
  3. Adjust bolt
  4. Measurement point 4
  5. A/C compressor drive belt

3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

2. Except M/T models (Euro 5 or above)

When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the A/C compressor drive belt, adjust the tension of the A/C compressor drive belt again.

1) Loosen the tension pulley lock nut.

2) Turn the tension pulley adjust bolt to adjust the tension.

Note

  • The standard deflection shown is the value obtained when the specified load is applied to the measurement point of the A/C compressor drive belt.

98 N { 10.0 kg / 22 lb } Load

Caution

  • Accurately adjust the tension as there is a possibility the service life of the belt may be shortened or belt squeal may be generated if the tension is not within the appropriate range.
  • Use a sonic tension meter to verify accurate tension adjustment.
Adjustment conditions
 Deflection
 Vibration frequency
When new
 12.5 to 16.5 mm { 0.49 to 0.65 in }
 92 to 112 Hz
Reused
 16.5 to 19.1 mm { 0.65 to 0.75 in }
 79 to 91 Hz

Legend

  1. Lock nut
  2. Adjust bolt
  3. Measurement point
  4. A/C compressor drive belt

3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

Copyright Mazda Motor Corporation. All rights reserved.