Charging System [Skyactiv-G 2.0]: Other Mazda 3 BM

Using GR8-1291

1. Remove the battery filler caps and check the water level. If necessary, add water to the appropriate level. Reinstall the caps.
2. Attach the small red clamp to the positive battery terminal and the small black clamp to the negative terminal.
3. Select the Battery Test icon in the Main Menu, then press the NEXT key.
4. Test the battery by following the on-screen instructions to enter the appropriate information. Refer to the Mazda GR8-1291 Instruction Manual for more information.
5. After the test, the Control Module displays a battery decision with an analysis in a series of screens. The analysis includes the battery state of health (SOH) and state of charge (SOC). Before the Battery Test results are displayed, use the keypad on the Control Module to enter the last 5 digits of the vehicle's VIN and press NEXT to continue.
6. The Mazda GR8-1291 will print out the test results and display one of the eight possible results listed below. Review the results and follow the Action Step for the displayed result. Battery Tester Display Action Step GOOD BATTERY Return the battery to service. GOOD - RECHARGE Fully charge the battery and return it to service. CHARGE & RETEST Fully charge the battery and retest. Failure to fully charge the battery before retesting may cause false readings. If CHARGE & RETEST appears again after you fully charge the battery, replace the battery. REPLACE BATTERY A REPLACE BATTERY result may also mean a poor connection between the battery and the vehicle. If you tested the battery using the System test, disconnect the battery cables and retest using the Battery Test before replacing it. BAD CELL - REPLACE Replace the battery. WARNING: Do not charge the battery. Charging a battery with one or more bad cells could cause an explosion and serious harm to the user. SIDE POST TEST Test data was inconclusive using the side post. Retest using side post adapters. JUMP START POST Data was inconclusive using the jump start post. Retest at the battery terminals. 24 VOLT BATTERY 24-volt battery detected. You are attempting to test both in-vehicle batteries in a 24-volt system. Disconnect the batteries and test them individually.

Using Electrolyte Specific Gravity Method

1. Remove the battery filler caps and check the water level. If necessary, add water to the appropriate level.
2. Measure the electrolyte specific gravity using a hydrometer. If it is less than the specification, recharge the battery. (See «BATTERY RECHARGING [SKYACTIV-G 2.0]»(ref-579332-S03427359012013100700000) .) Battery electrolyte specific gravity [20 °C {68 °F}] 1.22-1.29

Using Battery Voltage Method

1. Inspect the battery as follows after removing the battery filler caps, checking the water level, and adding water to the appropriate level if needed: STEP INSPECTION Action 1 Measure the battery positive voltage. 12.4 V or more Go to Step 3. Less than 12.4 V Go to the next step. 2 Quick charge for 30 min and recheck voltage. 12.4 V or more Go to the next step. Less than 12.4 V Replace the battery. 3 Using the battery load tester, apply load current (see battery load test current) and record battery voltage after 15 s Is voltage more than the specification? Yes Normal No Replace the battery. Battery load test current
2. 55D23L (48): 180 A
3. 75D23L (52): 195 A Standard specification Battery temp. (°C {°F}) Minimum voltage (V) 4 {39} 9.3 10 {50} 9.4 16 {61} 9.5 21 {70} 9.6

1. Remove the battery filler caps and check the water level. If necessary, add water to the appropriate level. Reinstall the caps.
2. Attach the large red clamp to the positive battery terminal and the large black clamp to the negative terminal.
3. Select the diagnostic icon in the Main Menu, then press the NEXT key.
4. Follow the on-screen instructions to input the appropriate information. Refer to the Mazda GR8-1291 Instruction Manual for more information.
5. The GR8-1291 will test and charge the battery. Before the diagnostic charging results are displayed, use the keypad on the Control Module to input the last 5 digits of the vehicle's VIN and press NEXT to continue.
6. After the charging is completed, the Mazda GR8-1291 will print out the diagnostic charging results and display one of the following results listed below. Review the results and follow the action step for the displayed result. Battery Tester Display Action Step GOOD BATTERY Return the battery to service. REPLACE BATTERY Replace the battery. BAD CELL - REPLACE Replace the battery. WARNING: Do not charge the battery. Charging a battery with one or more bad cells could cause an explosion and serious harm to the user. SIDE POST TEST Test data was inconclusive using the side post. Retest using side post adapters. JUMP START POST Data was inconclusive using the jump start post. Retest at the battery terminals.

Without Using GR8-1291

Scheme 71

1. Remove the battery and then place it in a pan of water. (Scheme 71): Placing Battery In Pan Of Water
2. Remove the battery filler caps.
3. Connect a battery charger to the battery and adjust the charging current as follows. Battery slow charge current 55D23L (48): 4.5-5.5 A 75D23L (52): 5.0-6.0 A Battery quick charge current [30 min] 55D23L (48): 30 A 75D23L (52): 35 A
4. After the battery is recharged, verify that the voltage is within the specification and remains at the same value for 1 h or more after the recharging has been completed. If not within specification, replace the battery. Standard voltage 12.4 V or more

Generator Warning Light

1. Verify that the battery is fully charged.
2. Verify that the drive belt is correct. (See «DRIVE BELT INSPECTION [SKYACTIV-G 2.0]»(ref-579373-S24398540832013100700000) .)
3. Switch the ignition to ON, verify that the generator warning light illuminates. If it does not illuminate, inspect the generator warning light and the wiring harness. If the generator warning light and the wiring harness are normal, inspect the PCM.
4. Verify that the generator warning light goes out after the engine is started. If the generator warning light does not go out, perform the DTC inspection, then perform troubleshooting according to the corresponding diagnostic procedure. (See «ON-BOARD DIAGNOSTIC TEST [SKYACTIV-G 2.0]»(ref-579395-S07770122602013100700000) .) (See «DTC TABLE [SKYACTIV-G 2.0]»(ref-579395-S20964230882013100700000) .)

Scheme 72

1. Verify that the battery is fully charged.
2. Verify that the drive belt is correct. (See «DRIVE BELT INSPECTION [SKYACTIV-G 2.0]»(ref-579373-S24398540832013100700000).)
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. If there is any noise, find the cause and repair or replace the generator.
6. Measure the voltage at each terminal using a tester. (Scheme 72): Identifying Generator Connector Terminals If it is not as specified, find the cause and repair or replace the applicable part. Generator standard voltage [IG-ON] Terminal B: B+ Terminal P: Approx. 1 V or less Terminal D: Approx. 0 V Generator standard voltage [Idle, 20 °C {68 °F}] Terminal B: 13-15 V Terminal P: Approx. 3-8 V Terminal D: Turn the electrical loads (headlights, blower motor, rear window defroster, brake lights, etc.) on and verify that the voltage reading increases.

Current

Note. 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. (See «DRIVE BELT INSPECTION [SKYACTIV-G 2.0]»(ref-579373-S24398540832013100700000) .)
3. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000) .)
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. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000) .)
7. Turn off all electrical loads.
8. Start the engine.
9. Increase engine speed to 2,500 rpm. NOTE: 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. 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. If it is not as specified, go to the PCM and generator shearing inspection. (See «PCM AND GENERATOR SHEARING INSPECTION»(ref-579332-S04040153392013100700000) .) Generator generated current minimum value 70% of the nominal output current (nominal output current: 110 A) [Ambient temp. 20 °C {68 °F}, voltage 13.0-15.0 V, both engine and generator are hot]

Scheme 73

Scheme 74

Scheme 75

1. Connect the M-MDS to the DLC-2. (Scheme 73): Locating 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, (See «ON-BOARD DIAGNOSTIC TEST [SKYACTIV-G 2.0]»(ref-579395-S07770122602013100700000).) or measure the PCM 1AF terminal waveform using an oscilloscope. (See «PCM INSPECTION [SKYACTIV-G 2.0]»(ref-579396-S14636467412013100700000).) 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. Wiring harness between PCM terminal 1AF- generator terminal P. Wiring harness between PCM terminal 1BE- generator terminal D. Generator inner parts. 3 Monitor the ALTT V PID using the M-MDS, (See «ON-BOARD DIAGNOSTIC TEST [SKYACTIV-G 2.0]»(ref-579395-S07770122602013100700000).) or measure the PCM 1AF terminal waveform using an oscilloscope. (See «PCM INSPECTION [SKYACTIV-G 2.0]»(ref-579396-S14636467412013100700000).) 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. Wiring harness between PCM terminal 1AF- generator terminal P. Wiring harness between PCM terminal 1BE- generator terminal D. Generator inner parts. 4 Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 1BE 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. Wiring harness between PCM terminal 1BE - generator terminal D. Generator inner parts. 5 Monitor the ALTF PID using the M-MDS, or calculate the duty value of the PCM terminal 1BE 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. Wiring harness between PCM terminal 1BE- generator terminal D. 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.

Scheme 76

Scheme 77

1. Measure the resistance between the slip rings using a tester. (Scheme 74): Measuring Resistance Between Slip Rings If not within specification, replace the rotor. Generator rotor resistance (between slip rings) [20 °C {68 °F}] 1.9-2.2 ohms
2. Verify that there is no continuity between the slip ring and core using a tester. (Scheme 75): Checking Continuity Between Slip Ring And Core If there is continuity, replace the rotor.
3. Inspect the slip ring surface condition. If the slip ring surface is rough, use a lathe or fine sandpaper to make it smooth.

Scheme 78

Scheme 79

Scheme 80

1. Verify that the continuity is as indicated in the table. (Scheme 76): Identifying Stator Coil Terminals (Scheme 77): Stator Coil Terminals Continuity Chart If there is any malfunction, replace the stator.
2. Verify that there is no continuity between the stator coil leads and core using a tester. (Scheme 78): Checking Continuity Between Stator Coil Leads And Core If there is continuity, replace the stator coil.

Scheme 81

1. Inspect brushes for wear. (Scheme 79): Inspecting Brushes For Wear If any brush is worn almost to or beyond the limit, replace all of the brushes. Generator brush length Standard: 22.5 mm {0.886 in} Minimum: 5.0 mm {0.20 in}

Scheme 82

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}. (Scheme 80): Reading Brush Spring Pressure If not within specification, replace the brush spring. Generator brush spring force Standard: 4.1-5.3 N {0.42-0.54 kgf, 1.0-1.1 lbf} Minimum: 1.7 N {0.17 kgf, 0.38 lbf}

Scheme 83

1. Inspect for continuity of the diodes using an analog circuit tester. (Scheme 81): Inspecting Continuity Of Diodes If not as specified, replace the rectifier. 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. If not as specified, replace the rectifier. SPECIFICATION Negative Positive Continuity E P1, P2, P3, P4, P5, P6 No B Yes P1, P2, P3, P4, P5, P6 E Yes B No

Scheme 84

1. Inspect for abnormal noise, looseness, and sticking. (Scheme 82): Inspecting Bearing For Abnormal Noise, Looseness, And Sticking Replace the bearing if necessary.