Generators & Regulators: Other — Mazda 6 GG (2002-2005)

BELT TENSION

Note. Drive belt tension is regulated by automatic tensioner. For proper belt routing on 2003 models, see DRIVE BELT ROUTING in SPECIFICATIONS & DRIVE BELT ROUTING article under COOLING SYSTEM (MECHANICAL) in ENGINES. For 2004 models, see DRIVE BELT ROUTING in SPECIFICATIONS & DRIVE BELT ROUTING article under COOLING SYSTEM (MECHANICAL) in ENGINES.

ON-VEHICLE TESTS

CAUTION

To avoid damage to the internal parts (power transistor) of the generator, do NOT apply direct battery positive voltage to the generator terminal "D".

Note. Prior to performing generator testing, turn OFF all electrical components. Place transmission in Neutral and apply parking brake.

GENERATOR VOLTAGE

Verify that the battery is fully charged.
Verify that the drive belt deflection/tension is correct.
Turn off all electrical loads.
Start the engine and verify that the generator rotates smoothly without any noise while the engine is running.
Using DVOM, measure the battery voltage at the battery and by backprobing at generator harness connector terminals "D" and "P". See «GENERATOR OUTPUT»(ref-166828-S41651349582004092900000) table. (Scheme 9)

Generator Terminal	Ignition ON - Volts	Idle - Voltage At 68°F (20°C)
B	Battery Voltage	13-15
P	About 1.0 Or Less	About 3.0-8.0
D	About Zero	(1)
(1) Turn on the following electrical loads, headlights, blower motor and rear defroster and verify voltage increases.

(1)	Turn on the following electrical loads, headlights, blower motor and rear defroster and verify voltage increases.

GENERATOR OUTPUT

Scheme 9

GENERATOR CURRENT

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

Verify that the battery is fully charged.
Verify that the drive belt deflection/tension is correct.
Disconnect the negative battery cable.
Connect a tester capable of reading 120 amps or above, between generator terminal "B" and the wiring harness connector.
Connect the negative battery cable.
Turn off all electrical loads. Start the engine. Increase engine speed to 2000-2500 RPM.
Turn headlights (high-beam), blower motor (high), rear window defroster and brake lights on and verify that the current reading increases. If generator terminal "B" current does not increase, repair or replace the generator if necessary. Standard current (reference) See «GENERATOR AMPERAGE»(ref-166828-S10288069932004093000000) table. Measuring conditions: Room temperature: 68°F (20°C). Voltage: 13.5 volts. Engine hot.

Application	Terminal "B" @ 1000 RPM - Amps (1)	Terminal "B" @ 2000 RPM - Amps (1)
2.3L	0-80	0-100
3.0L	0-90	0-105
(1) Lower limit of current must be more than zero amps.

(1)	Lower limit of current must be more than zero amps.

GENERATOR AMPERAGE

BEARING

Check bearing for abnormal noise, looseness and sticking. Replace bearing as necessary.

BRUSHES

Note. If any brush is worn almost to or beyond the limit, replace all of the brushes.

Inspect brushes for wear. Measure brush length. (Scheme 10) Replace as necessary. See GENERATOR SPECIFICATIONS.

Scheme 10

Scheme 10: BRUSHES

BRUSH SPRING

Measure the force of the brush spring using a spring pressure gauge. Read the spring pressure gauge at the brush tip projection of 0.079" (2 mm). (Scheme 11) Replace as necessary. See GENERATOR SPECIFICATIONS.

Scheme 11

Scheme 11: BRUSH SPRING

2.3L

Using DVOM, check diodes for continuity. See RECTIFIER DIODE CONTINUITY (2.3L) table. (Scheme 12) Replace rectifier if continuity is not as specified.

Tester Negative Probe	Tester Positive Probe	Continuity
E	P1, P2, P3 & P4	Yes
B	P1, P2, P3 & P4	No
P1, P2, P3 & P4	E	No
P1, P2, P3 & P4	B	Yes

RECTIFIER DIODE CONTINUITY (2.3L)

Scheme 12

3.0L

Inspect for continuity of the diodes using an analog circuit tester. (Scheme 13) See RECTIFIER DIODE CONTINUITY (3.0L). Replace rectifier if not as specified.

Tester Negative Probe	Tester Positive Probe	Continuity
E	P1, P2, P3, P4, P5 & P6	Yes
B	P1, P2, P3, P4, P5 & P6	No
P1, P2, P3, P4, P5 & P6	E	No
P1, P2, P3, P4, P5 & P6	B	Yes

RECTIFIER DIODE CONTINUITY (3.0L)

Scheme 13

ROTOR

Using DVOM, measure the resistance between the slip rings. (Scheme 14) On 2.3L models, if resistance is 1.6-2.0 ohms at 68°F (20°C), go to next step. If resistance is not 1.6-2.0 ohms at 68°F (20°C), replace rotor. On 3.0L models, if resistance is 2.4-2.9 ohms at 68°F (20°C), go to next step. If resistance is not 2.4-2.9 ohms at 68°F (20°C), replace rotor.
Using DVOM, verify there is no continuity between the slip ring and core. (Scheme 15) If continuity does not exist, go to next step. If continuity exists, replace the rotor.
Inspect the slip ring surface condition. If slip ring surface is rough, use a lathe or fine sandpaper to repair.

Scheme 14

Scheme 15

Using DVOM, check for continuity between the stator coil leads. (Scheme 16) If continuity exists, go to next step. If continuity does not exist, replace stator.
Verify that there is no continuity between the stator coil leads and the core. If continuity exists, replace the stator coil. (Scheme 17)

Scheme 16

Scheme 17

Using DVOM, check for continuity between the stator coil leads. (Scheme 18) If continuity exists, go to next step. If continuity does not exist, replace stator. Verify that there is no continuity between the stator coil leads and the core. If continuity exists, replace the stator coil. (Scheme 17)

Scheme 18

Scheme 18: 3.0L

WARNING

When the battery cables are connected, touching the vehicle body with generator terminal "B" generates sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation.

CAUTION

On 2.3L models, the generator can be damaged by the heat from the exhaust manifold. Ensure the generator duct and the generator heat insulator are installed securely.

2003

For generator specifications, see CHARGING SYSTEM in SPECIFICATIONS under SPECIFICATIONS INDEX .

2004

Application			Specification
Brush Length
Standard
2.3L			0.73" (18.5 mm)
3.0L			0.89" (22.5 mm)
Minmum (All)			0.20" (5.0 mm)
Brush Spring Force
Standard
2.3L			1.08-1.35 lb.f (4.8-6.0 N)
3.0L			0.92-1.19 lb.f (4.1-5.3 N)
Minimum
2.3L			0.49 lb.f (2.2 N)
3.0L			0.38 lb.f (1.7 N)
Generator Output
2.3L			90 Amps
3.0L			110 Amps
Rotor Resistance (Between Slip Rings)
2.3L			(1) 1.6-2.0 Ohms
3.0L			(1) 2.4-2.9 Ohms
(1) At 68°F (20°C).

(1)	At 68°F (20°C).

GENERATOR SPECIFICATIONS