Generator installation (RZ4E-TC)

1. Generator installation

1) Install the generator to the generator bracket.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2) Connect the B-terminal to the generator.

Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }

3) Connect the connector to the generator.

2. Power steering oil pump connect

1) Connect the power steering oil pump to the generator bracket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the power steering oil pump pulley to the power steering oil pump.

Note

  • Secure the M10 x 1.5 bolt with a tool, and tighten the pulley mounting bolt.

Tightening torque: 29 N・m { 3.0 kgf・m / 21 lb・ft }

3) Remove the bolt and nut from the power steering oil pump shaft.

3. Cooling fan belt installation

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt installation".

4. Radiator upper hose installation

1) Install the radiator upper hose and clamp to the water outlet pipe 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.

5. Air intake hose installation

1) Install the air intake hose to the intake air duct and 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 }

Legend

  1. Intercooler
  2. Air intake hose
  3. Intake air duct
  4. Clamp

6. Engine cover installation

1) Install the engine cover to the engine.

Legend

  1. Engine cover

7. Underguard installation

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

8. 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.

9. 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.
Copyright Mazda Motor Corporation. All rights reserved.