Charging System (L3): Other Mazda 5 I

Electrolyte specific gravity

1. Measure the electrolyte specific gravity using a hydrometer. If it is less than the specification, recharge the battery. (See «BATTERY RECHARGING [L3]»(ref-244326-S04281732302006092100000) ). Battery electrolyte specific gravity [20 C {68 °F}] 1.22-1.29

Battery voltage

1. Inspect the battery as follows: BATTERY VOLTAGE COMPONENT CHART 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 specification? Yes Normal No Replace the battery. Battery load test current 50D20L (40): 150 A 80D26L (55): 195 A Standard specification

STANDARD SPECIFICATION

Back-up current

1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
2. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [L3]»(ref-244326-S41790335602006092100000) ).
3. Disconnect the negative battery cable.
4. Connect the tester between the negative battery terminal and negative battery cable, leave the battery undisturbed for 15 min. , and then measure the back-up current. If not within the specification, measure the back-up current while removing the fuses one by one from the inside of the main fuse block and the inside of the fuse block. NOTE: If the battery is not left undisturbed for 15 min. , the tester will indicate a high value (approx. 300 mA) . If the key or any electrical accessory is operated within approx. 15 min. after the tester is connected, the battery must be left undisturbed for approx. 15 min. from that point. CAUTION: Operating electrical loads while the back-up current is being measured can damage the tester. NOTE: For the vehicles with the immobilizer system, periodically shifts synchronization of the security light flashing. Therefore, 45 mA (0.1 s) current is supplied when the security light is illuminated, and 25 mA (2 s) current is supplied when the security light is not illuminated. In addition, the measuring instrument, which shows the average value, indicates around 30 Ma . Battery back-up current Vehicles with immobilizer system: 25-45 mA Vehicles without immobilizer system: 30 mA or less
5. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.

BATTERY RECHARGING [L3]

Scheme 14

1. Remove the battery and then place it in a pan of water.
2. Connect a battery charger to the battery and adjust the charging current as follows. Battery slow charge current 50D20L (40): 4.0-5.0 A 80D26L (55): 5.5-6.5 A Battery quick charge current [30 min.] 50D20L (40): 25 A 80D26L (55): 35 A
3. 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 was completed. If not within the 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 deflection/tension is correct. (See «DRIVE BELT INSPECTION [L3]»(ref-244325-S03146936522006092100000) ).
3. With the ignition switch turned to the ON position, 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 off after the engine is started. If it does not go out, inspect if any one of the following DTCs in the on-board diagnostic system are displayed: P0112, P0113, P2502, P2503, P2504. (See «DTC TABLE [L3]»(ref-244323-S35277163902006092100000) ).

Scheme 15

1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct. (See «DRIVE BELT INSPECTION [L3]»(ref-244325-S03146936522006092100000) ).
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. 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) 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 deflection/tension is correct. (See «DRIVE BELT INSPECTION [L3]»(ref-244325-S03146936522006092100000) ).
3. Disconnect the negative battery cable.
4. Connect a tester, which can read 120 A or more , between generator terminal B and the wiring harness.
5. Connect the negative battery cable.
6. Turn off all electrical loads.
7. Start the engine.
8. Increase engine speed to 2,500 RPM . NOTE: When the electrical load of the vehicle is low, specified current will not be verified although the generator is normal. In this case, increase the electrical load (by turning on the headlight and leave it for a while, then discharge the battery or by similar methods) and recheck. When the generator itself or the ambient temperature are too high, specified current will also not be verified. In this case, cool down the generator and recheck.
9. Turn the following electrical loads on and verify that the current reading increases more than the minimum value indicated below. If it is not as specified, go to PCM and generator shearing inspection. (See «PCM AND GENERATOR SHEARING INSPECTION»(ref-244326-S06133739392006092100000) ). Headlights (high-beam) Blower motor (HI) Rear window defroster Brake light Generator generated current minimum value 70% of the nominal output current (nominal output current: 90 A) [ambient temp. 20 °C {68 °F}, voltage 13.0-15.0 V, both engine and generator are hot]

Scheme 16

1. Connect the WDS or equivalent to the DLC-2.
2. Inspect as follows

DIAGNOSTICS PROCEDURE 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 WDS or equivalent, or measure the voltage of PCM terminal 2AM using a tester. Is the voltage between 13 and 15 V? Yes Go to Step 4. No PCM input error. 3 Monitor the ALTT V PID using WDS or equivalent, or measure the voltage of PCM terminal 2AM using a tester. Is the voltage between 13 and 15 V? Yes Go to Step 5. No PCM input error. 4 Monitor the ALTF PID using WDS or equivalent, or calculate the duty value of the PCM terminal 2AQ using oscilloscope. Is the duty value 100 % ? Yes PCM input error. No PCM, generator, or both are not normal. 5 Monitor the ALTF PID using WDS or equivalent, or calculate the duty value of the PCM terminal 2AQ using oscilloscope. Is the duty value 0 % ? Yes PCM input error. No PCM, generator, or both are not normal. (1) Headlights, blower motor, rear window defroster, and brake light. (2) If the generator field coil duty value does not change when electrical loads (such as headlights, blower motor, rear window defroster, brake light) are on or off, inspection with discharged battery is needed

Scheme 17

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Scheme 20

1. Measure the resistance between the slip rings using a tester. If not as specified, replace the rotor. Generator rotor resistance (between slip rings) [20 C {68 F}] 1.7-2.1 ohms
2. Verify that there is no continuity between the slip ring and core using a tester. 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 repair it.

Scheme 21

Scheme 22

1. Inspect for continuity between the stator coil leads using a tester. If there is no continuity, replace the stator.
2. Verify that there is no continuity between the stator coil leads and the core using a tester. If there is continuity, replace the stator coil.

Scheme 23

1. Inspect brushes for wear. If any brush is worn almost to or beyond the limit, replace all of the brushes. Generator brush length Standard: 18.5 mm {0.73 in} Minimum: 5.0 mm {0.2 in}

Scheme 24

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 {0.079 in} . Replace the brush spring if necessary. Generator brush spring force Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.08-1.34 lbf} Minimum: 2.16 N {0.22 kgf, 0.49 lbf}

Scheme 25

Scheme 26

1. Inspect for continuity of the diodes using a tester. If not as specified, replace the rectifier. Specification CONTINUITY CHART Tester Continuity Negative Positive E P1, P2, P3, P4 Yes B No P1, P2, P3, P4 E No B Yes

Scheme 27

1. Inspect for abnormal noise, looseness, and sticking. Replace the bearing if necessary.