Mazda 3 manuals

Mazda 3 Service Manual: Generator Inspection [Mzr 2.0, Mzr 2.5]

Mazda 3 Service Manual / Electrical / Starting, Charging / Generator Inspection [Mzr 2.0, Mzr 2.5]

CAUTION:

  1. Do not apply direct battery positive voltage to generator terminal D, otherwise it could cause damage to the internal parts (power transistor) of the generator.

Generator Warning Light

1. Verify that the battery is fully charged.

2. Verify that the drive belt is correct..

3. Switch the ignition to ON, verify that the generator warning light illuminates.

4. Verify that the generator warning light goes out after the engine is started.

Generator

Voltage

1. Verify that the battery is fully charged.

2. Verify that the drive belt is correct..

3. Turn off all electrical loads.

4. Start the engine.

5. Verify that the generator rotates smoothly without any noise while the engine is running.

6. Measure the voltage at each terminal using a tester.


Current

NOTE:

  1. Since the charging current decreases rapidly after starting the engine, carry out the following procedure quickly, and read the maximum current value.

1. Verify that the battery is fully charged.

2. Verify that the drive belt is correct..

3. Remove the battery cover..

4. Disconnect the negative battery cable.

5. Connect a tester, which can read 120 A or more

, between generator terminal B and the wiring harness.

6. Connect the negative battery cable..

7. Turn off all electrical loads.

8. Start the engine.

9. Increase engine speed to 2,500 rpm.

NOTE:

  1. When the electrical load on the vehicle is low, the specified current cannot be verified although the generator is normal. In this case, increase the electrical load (Leave the headlights turned on for a while, then discharge the battery, or use a similar method.) and recheck.

  2. When the generator itself or the ambient temperature are too high, the specified current also cannot be verified. In this case, cool down the generator and recheck.

10. Turn the electrical loads (headlights, blower motor, rear window defroster, brake lights, etc.) on and verify that the current reading increases more than the minimum value indicated below.

  1. If it is not as specified, go to the PCM and generator shearing inspection..

PCM and generator shearing inspection

1. Connect the M-MDS to the DLC-2.


2. Inspect as follows:

Step

Inspection

Action

1

Measure the generator terminal B voltage when the electrical loads*1 are on and off.

15 V or more

Go to Step 2.

13—15 V

Normal*2

13 V or less

Go to Step 3.

2

Monitor the ALTT V PID using the M-MDS,.

Is the value normal?

Yes

Go to Step 4.

No

Inspect the following, then repair or replace as necessary.

  • If there is no malfunction, replace the PCM.

  1. Wiring harness between PCM terminal 2AF- generator terminal P.

  2. Wiring harness between PCM terminal 2AA- generator terminal D.

  3. Generator inner parts.

3

Monitor the ALTT V PID using the M-MDS,.

Is the value normal?

Yes

Go to Step 5.

No

Inspect the following, then repair or replace as necessary.

  • If there is no malfunction, replace the PCM.

  1. Wiring harness between PCM terminal 2AF- generator terminal P.

  2. Wiring harness between PCM terminal 2AA- generator terminal D.

  3. Generator inner parts.

4

Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 2AA using an oscilloscope. Is the duty value 100%?


Yes

Replace PCM.

No

Inspect the following, then repair or replace as necessary.

  • If there is no malfunction, replace the PCM.

  1. Wiring harness between PCM terminal 2AA- generator terminal D.

  2. Generator inner parts.

5

Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 2AA using an oscilloscope. Is the duty value 0%?


Yes

Replace PCM.

No

Inspect the following, then repair or replace as necessary.

  • If there is no malfunction, replace the PCM.

  1. Wiring harness between PCM terminal 2AA- generator terminal D.

  2. Generator inner parts.


*1 Headlights, blower motor, rear window defroster, brake lights, etc.

*2 If the generator field coil duty value does not change when electrical loads (such as headlights, blower motor, rear window defroster, brake lights) are on or off, inspection with discharged battery is needed.

Generator Inner Parts

Rotor

1. Measure the resistance between the slip rings using a tester.


2. Verify that there is no continuity between the slip ring and core using a tester.


3. Inspect the slip ring surface condition.

Stator coil

1. Verify that the continuity is as indicated in the table.



2. Verify that there is no continuity between the stator coil leads and core using a tester.


Brush

1. Inspect brushes for wear.


Brush spring

1. Measure the force of the brush spring using a spring pressure gauge.

2. Read the spring pressure gauge at the brush tip projection of 2 mm {0.08 in}.


Rectifier (Using an analog circuit tester)

1. Inspect for continuity of the diodes using an analog circuit tester.


Specification


Negative

Positive

Continuity

E

P1, P2, P3, P4, P5, P6

Yes

B

No

P1, P2, P3, P4, P5, P6

E

No

B

Yes


Rectifier (Using a digital circuit tester)

1. Inspect for continuity of the diodes using a digital circuit tester.

Specification


Negative

Positive

Continuity

E

P1, P2, P3, P4, P5, P6

No

B

Yes

P1, P2, P3, P4, P5, P6

E

Yes

B

No


Bearing

1. Inspect for abnormal noise, looseness, and sticking.


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