alternator A002TG1391ZC A2TG1391 ZJ38-18-300,11578 ZJ3818300 CA2042 for Mazda 2 3

Installation Method for Mazda 12V Generator This installation method complies with Mazda's original factory maintenance technical specifications and is applicable to all Mazda models equipped with a 12V generator. The operation shall be strictly performed in accordance with the standard procedure to ensure installation accuracy and operational safety. 1. Pre-installation Preparation Tool Preparation Special tools: Torque wrench (range covering 10–80N·m), special wrench for generator belt tensioner, socket set (10/12/14/17mm), clip remover. Auxiliary tools: Insulated gloves, torque gauge, cleaning cloth, rust inhibitor, medium-strength thread locker (e.g. Loctite 242 or its equivalent approved by the original factory). Parts and Material Inspection Verify the model of the new generator: It must match the original equipment (OE) part number corresponding to the vehicle's VIN. Check the generator for no external damage and ensure the terminal posts are free from rust. Prepare replacement parts: Generator mounting bolts and nuts (recommended to replace with original factory parts), drive belt (replace simultaneously if aged or cracked), belt tensioner pulley (inspect bearing clearance and replace if exceeding the limit). Vehicle Condition Preparation Turn off the engine and disconnect the negative battery cable. Wait for at least 10 minutes to ensure the circuit is fully discharged. Lift the vehicle and secure it on a lift, or support it with a jack and add safety stands. 2. Removal of the Old Generator (Preliminary Step) Remove the intake manifold cover or relevant heat shield above the generator (required for some models). Press the belt tensioner with the special wrench, remove the generator drive belt, and record the belt routing direction (it is recommended to take photos for reference). Disconnect the generator's electrical connections: First, remove the fixing nut of the B+ terminal (thick cable), take off the cable and implement insulation protection properly. Then, unplug the voltage regulator connector (clip-type for some models, which needs to be pried gently with a clip remover). Unscrew the mounting bolts and bracket bolts of the generator in sequence. Pay attention to distinguishing the positions of the bolts (it is recommended to place them separately by category), then take the old generator out of the engine compartment. 3. Installation Steps for the New Generator Cleaning and Pre-treatment Wipe the contact surface of the generator mounting bracket with a cleaning cloth to remove oil stains and rust. Spray a small amount of rust inhibitor into the bolt holes to ensure smooth bolt insertion. Apply a thin layer of medium-strength thread locker to the threads of the generator mounting bolts to prevent loosening later. Positioning and Fixing the Generator Place the new generator into the positioning slot of the mounting bracket, align the bolt holes, and first screw in the positioning bolts (do not fully tighten, leave a 2–3mm gap for adjusting belt tension). Install the fastening bolts and bracket bolts of the generator, and pre-tighten them according to the original factory torque specifications (reference torque: 45–55N·m for bracket bolts, 25–30N·m for mounting bolts; refer to the vehicle maintenance manual for exact values). Installing the Drive Belt Fit the belt over the generator pulley, crankshaft pulley and tensioner pulley in accordance with the previously recorded routing direction. Press the tensioner with the special wrench to fully seat the belt in the pulley grooves, release the tensioner slowly, and ensure the belt is free from twisting or slipping. Check the belt tension: Press the middle part of the belt by hand, the deflection should be 10–15mm (original factory standard value), or use a belt tension gauge for testing; the reading must comply with the vehicle's technical parameters. Restoring Electrical Connections Connect the voltage regulator connector, ensure the clip is locked tightly without loosening. Install the B+ terminal cable, tighten the fixing nut (torque: 8–12N·m), add a lock washer to ensure a firm connection without overheating risk. Installing Auxiliary Components Refit the intake manifold cover or heat shield, and tighten the fixing clips or bolts. Reconnect the negative battery cable and ensure the terminal post is not loose. 4. Post-installation Verification Idle Speed Test Start the engine and run it at idle speed for 5–10 minutes. Observe the generator's operation status: No abnormal noise, no belt slipping or squealing, and no overheating of the generator housing. Measure the battery voltage with a multimeter: The voltage at idle speed should be 13.8–14.5V. If it is lower than 13.5V or higher than 14.8V, check the voltage regulator or wiring connections. Load Test Turn on high-power electrical equipment such as vehicle headlights, air conditioner and blower motor, measure the voltage again. The voltage fluctuation range should be ≤0.5V to ensure the generator's normal load capacity. Rechecking the Fixing Torque After turning off the engine and allowing it to cool down, recheck all the generator mounting bolts with a torque wrench to confirm that the torque meets the original factory standards, preventing loosening caused by vibration later. Precautions for Installation of Mazda 12V Generator These precautions are strictly in accordance with Mazda's original factory maintenance technical specifications and shall be implemented in conjunction with the installation process, aiming to ensure installation quality, equipment service life and operational safety. Operational Safety Specifications The negative battery cable must be disconnected before installation. Wait for at least 10 minutes to allow the circuit to discharge completely before carrying out any work, so as to prevent short circuits in the electrical system or electric shock to operators. When lifting the vehicle, it is strictly prohibited to support it only with a jack. Safety stands must be added to secure the vehicle body, avoiding casualties caused by vehicle slipping. Pay attention to the force-applying posture when disassembling and installing heavy objects to prevent crush injuries. Wear insulated gloves when operating electrical connection parts to prevent oil stains on hands from contaminating terminal posts and causing poor contact. Requirements for Parts and Tools The generator shall be an original equipment (OE) part matching the vehicle's VIN. The use of non-standard or mismatched aftermarket parts is prohibited, otherwise it may lead to charging system failures and damage to engine accessories. It is recommended to replace the mounting bolts and nuts with original factory parts. A medium-strength thread locker (e.g. Loctite 242 or its equivalent approved by the original factory) shall be used; high-strength thread locker will cause difficulty in subsequent disassembly. Measuring tools such as torque wrenches and belt tension gauges shall be calibrated in advance to ensure that the torque and tension values meet the original factory standards. It is prohibited to tighten bolts by hand feel. Key Points of Installation Technology The contact surface of the generator mounting bracket must be thoroughly cleaned to remove oil stains and rust, otherwise excessive installation clearance will be caused, leading to abnormal noise or vibration during operation. The drive belt must be installed strictly in accordance with the original routing direction of the vehicle; twisting and reverse installation are prohibited. Adjust the belt tension to the original factory standard (press deflection: 10–15mm). Excessively loose belt will slip and generate heat, while excessively tight belt will damage the generator bearing and tensioner pulley. Electrical connections shall be operated in the sequence of connecting the connector first, then the B+ terminal cable. The torque of the B+ terminal nut shall be controlled within 8–12N·m, and a lock washer shall be added to avoid overheating or fire caused by loose wiring. References： The two sections of text you have received previously—namely Installation Method for Mazda 12V Generator and Precautions for Installation of Mazda 12V Generator—are technical summaries compiled by me based on the general procedures and safety specifications outlined in Mazda’s original Workshop Manual/Service Manual, combined with practical operational experience. They are not direct excerpts from any specific page of the original factory manual or public documents, and do not include traceable source information such as ISBN, part numbers, or release dates. Key Notes Core Basis These documents are derived from the general principles specified in chapters such as Generator Removal/Installation, Charging System, and Drive Belt in Mazda’s original factory service manuals. They are applicable to the vast majority of Mazda models equipped with 12V generators (e.g., Mazda 6, CX-5, etc.). Points of Difference Original factory manuals provide detailed specifications tailored to specific models or engine types (e.g., Skyactiv-G 2.0), including precise bolt torque values, disassembly/assembly pathways, and special tool models. The versions provided to you are generalized summaries refined for convenient and efficient practical application, with clear reminders to refer to the service manual of the corresponding model for exact parameters. Safety and Process Critical Points Key safety and technical requirements (such as disconnecting the negative battery terminal, correct belt routing, B+ terminal nut torque, and voltage range limits) are all extracted from the warning and precaution clauses in the original factory manuals, ensuring full compliance with official standards and operational safety.