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Engine Mechanical - Service Information: Other Mazda 3 BK

Accessory Drive Belts 19 illustrations ~1174 words

GENERATOR DRIVE BELT

Note. Drive belt deflection/tension inspection is not necessary because of the use of the generator drive belt auto tensioner.

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Scheme 71: GENERATOR DRIVE BELT
Scheme 71: GENERATOR DRIVE BELT
  1. Verify that the drive belt auto tensioner indicator mark does not exceed the limit. If it exceeds the limit, replace the drive belt. (See «DRIVE BELT REPLACEMENT»(ref-177560-S03383094672005060200000) .)

A/C DRIVE BELT

Note. Drive belt deflection/tension inspection is not necessary because of the use of the maintenance-free type A/C drive belt. Replace the drive belt if it is found to be damaged during visual inspection, or if there is a malfunction or noise in the A/C compressor.

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Scheme 72: A/C DRIVE BELT
Scheme 72: A/C DRIVE BELT

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  1. Remove the engine under cover and splash shield (RH).
  2. Cut the A/C drive belt using scissors.
  3. Install a jig (A) to the crankshaft pulley as shown in the figure.
  4. Install a new A/C drive belt to the A/C compressor pulley, move jig (A) upward, and then install the A/C drive belt to the crankshaft pulley.
  5. Install jig (B) to the A/C compressor mount as shown in the figure.
  6. Rotate the crankshaft pulley to the right using a wrench and install the A/C drive belt.
  7. Install the under cover and splash shield (RH).

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Scheme 76: GENERATOR DRIVE BELT
Scheme 76: GENERATOR DRIVE BELT
  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION»(ref-177560-S36288006622005060200000) .)
  2. Remove the A/C drive belt.
  3. Turn the center of the auto tensioner pulley counterclockwise to release tension to the drive belt tension.
  4. Remove the generator drive belt.
  5. Install a new generator drive belt.
  6. Install the A/C drive belt.
  7. Install the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION»(ref-177560-S36288006622005060200000) .)

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Scheme 77: DRIVE BELT AUTO TENSIONER INSPECTION
Scheme 77: DRIVE BELT AUTO TENSIONER INSPECTION
  1. Remove the drive belt. (See «DRIVE BELT REPLACEMENT»(ref-177560-S03383094672005060200000) .)
  2. Verify that the generator drive belt auto tensioner moves smoothly in the operational direction. If it does not move smoothly, replace the generator drive belt auto tensioner.
  3. Turn the generator drive belt auto tensioner pulley by hand and verify that it rotates smoothly. If it does not move smoothly, replace the generator drive belt auto tensioner.
  4. Install the generator drive belt. (See «DRIVE BELT REPLACEMENT»(ref-177560-S03383094672005060200000) .)

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Scheme 78: VALVE CLEARANCE INSPECTION
Scheme 78: VALVE CLEARANCE INSPECTION
  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION»(ref-177560-S36288006622005060200000) .)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Disconnect the wiring harness.
  5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION .)
  6. Disconnect the OCV connector (L3).
  7. Remove the ventilation hose.
  8. Remove the cylinder head cover.
  9. Verify that the engine is cold.
  10. Measure the valve clearance. Turn the crankshaft clockwise so that the No. 1 piston is at TDC of the compression stroke. Measure the valve clearance at A in the figure. If the valve clearance is out of the standard value, adjust it. (See «VALVE CLEARANCE ADJUSTMENT»(ref-177560-S06113582822005060200000) .) Standard [Engine cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0107-0.0129 in} NOTE: Make sure to note down the measured values for choosing the suitable replacement tappets. Turn the crankshaft 360° clockwise so that the No.4 piston is at TDC of the compression stroke. Measure the valve clearance at B in the figure. If the valve clearance is out of the standard value, adjust it. (See «VALVE CLEARANCE ADJUSTMENT»(ref-177560-S06113582822005060200000) .) NOTE: Make sure to note down the measured values for choosing the suitable replacement tappets. Standard [Engine Cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0107-0.0129 in}
  11. Install the cylinder head cover. (See «CYLINDER HEAD COVER INSTALLATION NOTE»(ref-177560-S38014667632005060200000) .)
  12. Install the ventilation hose.
  13. Connect the OCV connector (L3).
  14. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION .)
  15. Connect the wiring harness.
  16. Connect the negative battery cable.
  17. Install the battery cover.
  18. Install the plug hole plate and bracket. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION»(ref-177560-S36288006622005060200000) .)

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Scheme 79: VALVE CLEARANCE ADJUSTMENT
Scheme 79: VALVE CLEARANCE ADJUSTMENT

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  1. Remove the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION»(ref-177560-S36288006622005060200000) .)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Disconnect the wiring harness.
  5. Disconnect the OCV connector (L3).
  6. Remove the following parts: Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .) Engine under cover and splash shield (RH). Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION .) Ventilation hose. Cylinder head cover. Engine front cover lower blind plug. Engine front cover upper blind plug. Cylinder block lower blind plug.
  7. Install the SST as shown in the figure.
  8. Turn the crankshaft clockwise the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is attached to the SST) .
  9. Loosen the timing chain. Unlock the chain tensioner ratchet using a suitable screwdriver or equivalent tool. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain. Placing the suitable bolt (M6 X 1.0 length 25mm-35mm {0.99-1.37in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
  10. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
  11. Remove the exhaust camshaft sprocket.
  12. Loosen the camshaft cap bolts in 2-3 passes in the order shown in the figure.
  13. Remove the camshaft.
  14. Remove the tappet.
  15. Select proper adjustment shim. New Adjustment Shim=Removed Shim Thickness + Measured Valve Clearance - Standard Valve Clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in}) Standard [Engine Cold] IN: 0.22-0.28 mm {0.0087-0.0110 in} EX: 0.27-0.33 mm {0.0107-0.0129 in}
  16. Install the camshaft with No. 1 cylinder aligned with the TDC position.
  17. Tighten the camshaft cap bolt with the following 2 steps. Tightening Torque 5.0-8.0 N.m {51.0-81.5 kgf.cm, 44.3-70.8 in.lbf} 14-17 N.m {1.43-1.73 kgf.m, 10.4-12.5 ft.lbf}
  18. Install the exhaust camshaft sprocket.
  19. Install the SST to the camshaft as shown in the figure.
  20. Remove the (M6 X 1.0 length 25mm-35mm {0.99-1.37in}) bolt from the engine front cover to apply tension to the timing chain.
  21. Turn the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is attached to the SST) .
  22. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
  23. Tighten the exhaust camshaft sprocket lock bolt. Tightening Torque 69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
  24. Remove the SST from the camshaft.
  25. Remove the SST from the block lower blind plug.
  26. Rotate the crankshaft clockwise two turns until the TDC position. If not aligned, loosen the crankshaft pulley lock bolt and repeat from step 14 .
  27. Apply silicone sealant to the engine front cover upper blind plug.
  28. Install the following parts: Engine front cover upper blind plug. Tightening Torque 8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf} Cylinder block lower blind plug. Tightening Torque 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf} New engine front cover lower blind plug. Tightening Torque 10-14 N.m {1.1-1.4 kgf.m, 7.4-10.3 ft.lbf} Cylinder head cover. (See «CYLINDER HEAD COVER INSTALLATION NOTE»(ref-177560-S38014667632005060200000) .) Ventilation hose. Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION .) Engine under cover and splash shield (RH). Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION) .)
  29. Connect the OCV connector (L3).
  30. Connect the wiring harness.
  31. Connect the negative battery cable.
  32. Install the battery cover.
  33. Install the plug hole plate. (See «PLUG HOLE PLATE REMOVAL/INSTALLATION»(ref-177560-S36288006622005060200000) .)

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