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REMOVAL AND INSTALLATION

Fig. 1: Alternator removal and installation -- 1993-94 323 and MX3, 1.6L (B6E) and Protege 1.8L (BPE, BPD) engines shown

1993-94 323 and MX3, 1.6L (B6E), 1993-95 Protege 1.8L (BPE, BPD), 1995 MX3 1.6L (B6-ZE) and 1995-97 Protege 1.5L (Z5D) and 1.8L (BPD) Engines
  1. Disconnect the negative battery cable.
  2. On 323/Protege, disconnect the vacuum hose and remove the solenoid bracket, if equipped.
  3. On 1995-97 1.8L engines, remove the pressure pipe bracket and the EGR solenoid valve bracket.
  4. Remove the alternator drive belt.
  5. Label and disconnect the electrical connectors from the alternator.
  6. On the 1995-97 1.8L engines, remove the alternator bracket.
  7. Remove the alternator pivot and adjusting bar bolts and remove the alternator.

    To install:

  8. Install the alternator with the through-bolt.
  9. On the 1995-97 1.8L engines, install the alternator bracket.
  10. Connect the alternator electrical connectors.
  11. Install the drive belt and upper mounting bolt. Adjust the belt tension. Tighten the lower through-bolt to 27-38 ft. lbs. (37-52 Nm) and the upper mounting bolt to 12-19 ft. lbs. (16-26 Nm).
  12. On the 1995-97 1.8L engines, install the pressure pipe bracket and the EGR solenoid valve bracket.
  13. Connect the negative battery cable.
1993-95 MX3 1.8L (K8) and 1993-97 626 and MX6 2.5L (KL) Engines
  1. Disconnect the negative battery cable.
  2. Remove the fresh air duct and radiator upper bracket.
  3. If equipped, remove the condenser fan.
  4. Disconnect the electrical connectors from the alternator.
  5. Loosen the belt tensioner locknut and tension adjusting bolt. Remove the alternator upper mounting bolt.
  6. Raise and safely support the vehicle.
  7. Remove the right splash shield.
  8. Remove the drive belt from the alternator pulley.
  9. If necessary, remove the A/C compressor mounting bolts and and support the compressor aside, leaving the refrigerant lines connected.
  10. Remove the alternator through-bolt and the alternator.

    To install:

  11. Position the alternator and install the through-bolt. Tighten the alternator through-bolt to 24-33 ft. lbs. (32-46 Nm) on the 1.8L, and to 38 ft. lbs. (51 Nm) on the 2.5L engine.
  12. If removed, install the mounting bolts and tighten the A/C compressor mounting bolts to 26 ft. lbs. (35 Nm).
  13. Install the right splash shield, and lower the vehicle.
  14. Install the drive belt and adjust the tension.
  15. Install the alternator upper mounting bolt and tighten to 18 ft. lbs. (25 Nm).
  16. Tighten the belt tensioner locknut and tension adjusting bolt.
  17. Connect the electrical connectors from the alternator.
  18. If removed, install the condenser fan.
  19. Install the radiator upper bracket and fresh air duct.
  20. Connect the negative battery cable.
626 and MX6 2.0L (FS) Engines
  1. Disconnect the negative battery cable.
  2. Remove the alternator upper mounting bolt.
  3. Loosen the alternator adjusting bolt and remove the drive belt from the alternator pulley.
  4. Raise and safely support the vehicle.
  5. Remove the 6 bolts and remove the transverse member.
  6. Disconnect the electrical connectors from the alternator.
  7. Remove the front exhaust pipe as follows:
    1. Support the exhaust system at the catalytic converter with a jack.
    2. Disconnect the oxygen sensor electrical connector and remove the sensor using a sensor wrench.
    3. Remove the 3 exhaust manifold flange nuts and remove the clamp from the hold-down bracket.
    4. Remove the exhaust pipe-to-converter nuts and pry the rubber hangers from the mounting hooks. Remove the pipe.
  8. Remove the alternator lower through-bolt and remove the alternator.

    To install:

  9. Install the alternator with the through-bolt.
  10. Install the exhaust pipe, using new gaskets. Tighten the pipe-to-converter nuts to 28-38 ft. lbs. (38-51 Nm) and the exhaust manifold flange nuts to 28-38 ft. lbs. (38-51 Nm). Tighten the exhaust clamp nuts to 14-18 ft. lbs. (19-25 Nm).
  11. Install the oxygen sensor, using a sensor wrench, and tighten to 36 ft. lbs. (49 Nm). Connect the oxygen sensor electrical connector.
  12. Connect the alternator electrical connectors.
  13. Install the transverse member and tighten the bolts to 68-96 ft. lbs. (94-131 Nm). Lower the vehicle.
  14. Install the drive belt and upper mounting bolt. Adjust the belt tension. Tighten the lower through-bolt to 24-33 ft. lbs. (32-46 Nm) and the upper mounting bolt to 12-16 ft. lbs. (16-22 Nm).
  15. Connect the negative battery cable.
1993-95 929 3.0L (JE-ZE) Engines
  1. Disconnect the negative battery cable. Disconnect the positive battery cable and remove the battery and battery tray.
  2. Remove the B terminal wire from the alternator.
  3. Disconnect the electrical connector from the alternator.
  4. Remove the alternator drive belt.
  5. Remove the alternator through and adjusting bar bolts, and remove the alternator.

    To install:

  6. Position the alternator and install the through-bolt. Tighten the alternator through-bolt to 28-38 ft. lbs. (38-51 Nm).
  7. Install the adjusting bar, and tighten the mounting bolt to 14-18 ft. lbs. (19-25 Nm).
  8. Install the drive belt. Adjust the belt tension.
  9. Connect the electrical connector to the alternator.
  10. Install the B terminal wire from the alternator.
  11. Install the battery tray and the battery. Connect the positive and negative battery cables.
Millenia
  1. Disconnect the negative battery cable.
  2. On some models it may be necessary to remove the front charge air cooler, radiator upper seal board and the condenser fan assembly.
  3. Disconnect the electrical connectors from the alternator.
  4. Raise and safely support the vehicle.
  5. Remove the right splash shield.
  6. Remove the drive belt from the alternator pulley.
  7. Remove the A/C compressor mounting bolts and and support the compressor aside, leaving the refrigerant lines connected.
  8. Remove the upper and lower alternator mounting bolts and the alternator.

    To install:

  9. Position the alternator and install the through-bolt. Tighten the alternator lower bolt to 24-33 ft. lbs. (32-46 Nm). Install the alternator upper mounting bolt and tighten to 12-16 ft. lbs. (16-22 Nm).
  10. Install the mounting bolts and tighten the A/C compressor mounting bolts to 12-16 ft. lbs. (16-22 Nm).
  11. Install the right splash shield, and lower the vehicle.
  12. Install the drive belt.
  13. Connect the electrical connectors to the alternator.
  14. Install the condenser fan assembly.
  15. Install the radiator upper seal board.
  16. Install the front charge air cooler using new O-rings. Tighten the mounting bolts to 12-16 ft. lbs. (16-22 Nm).
  17. Connect the negative battery cable.
1993 Miata 1.6L (B6-ZE) Engines

NOTE: Voltage regulator is of the internal type.

  1. Disconnect the negative battery cable.
  2. Disconnect the vacuum hose and remove the solenoid bracket, if equipped.
  3. Remove the alternator drive belt.
  4. Label and disconnect the electrical connectors from the alternator.
  5. Remove the alternator pivot and adjusting bar bolts and remove the alternator.
  6. Installation is the reverse of the removal procedure. Adjust the belt tension.
1994-97 Miata 1.8L (BPD) Engines

NOTE: The voltage regulator is of the internal type.

  1. Disconnect the negative battery cable.
  2. Label and disengage the power steering pressure switch, water thermoswitch and idle air control valve electrical connectors.
  3. Remove the intake air pipe.
  4. Disconnect the electrical connectors from the alternator.
  5. Remove the alternator upper mounting bolt.
  6. Loosen the alternator adjusting bolt and remove the drive belt from the alternator pulley.
  7. Remove the alternator lower through-bolt, and remove the alternator.

    To install:

  8. Install the alternator with the through-bolt.
  9. Connect the alternator electrical connectors.
  10. Install the drive belt and upper mounting bolt. Adjust the belt tension. Tighten the lower through-bolt to 28-38 ft. lbs. (38-51 Nm) and the upper mounting bolt to 14-18 ft. lbs. (19-25 Nm).
  11. Install the intake air pipe.
  12. Engage the power steering pressure switch, water thermoswitch and idle air control valve electrical connectors.
  13. Connect the negative battery cable.
1993-95 RX7 1.3L (13B) Engines
  1. Disconnect the negative battery cable.
  2. Partially drain the cooling system.
  3. Remove the air intake hose and air relief hose.
  4. Disconnect the accelerator cable.
  5. Disconnect the vacuum hoses and remove the pressure chamber.
  6. Remove the turbocharger-to-intercooler pipe and bracket.
  7. Label and disconnect the electrical connectors from the alternator.
  8. Disconnect the air pump hoses, and remove the air pump.
  9. Loosen the tension and remove the alternator drive belt.
  10. Remove the coolant hose at the rear of the water pump.
  11. Remove the alternator mounting bolt and nut, and remove the alternator.

    To install:

  12. Position the alternator, and install the mounting bolt and nut. Tighten the mounting bolt to 28-38 ft. lbs. (38-51 Nm), and the mounting nut to 14-18 ft. lbs. (19-25 Nm).
  13. Install the coolant hose at the rear of the water pump.
  14. Install the drive belt. Adjust the belt tension.
  15. Install the air pump and connect the hoses.
  16. Connect the electrical connectors to the alternator.
  17. Install the turbocharger-to-intercooler bracket and pipe.
  18. Install the pressure chamber and connect the vacuum hoses.
  19. Connect and adjust the accelerator cable.
  20. Install the air relief and intake hoses.
  21. Fill and bleed the cooling system.
  22. Connect the negative battery cable.
 
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