Generators & Regulators: Other Mazda MPV II рестайлинг

BELT TENSION

Note. Drive belt tension is regulated by automatic tensioner. For proper belt routing, see the following: On 2002 models, see BELT ROUTING in SPECIFICATIONS & DRIVE BELT ROUTING article under COOLING SYSTEM (MECHANICAL) in ENGINES. On 2003 models, see DRIVE BELT ROUTING in SPECIFICATIONS & DRIVE BELT ROUTING article under COOLING SYSTEM (MECHANICAL) in ENGINES. On 2004 models, see DRIVE BELT ROUTING in SPECIFICATIONS & DRIVE BELT ROUTING article under COOLING SYSTEM (MECHANICAL) in ENGINES.

ON-VEHICLE TESTS

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

BACK-UP CURRENT

1. Verify that the ignition switch is off and that the ignition key has been removed.
2. Disconnect the negative battery cable.
3. Measure the back-up current between the negative battery terminal and the negative battery cable. If the current exceeds 20 mA, remove the fuse in the main fuse block and the fuse block one by one while measuring the back-up current. see scheme 2and see scheme 3. Inspect and repair harnesses and connectors of the fuse at which the current reduces.

BATTERY CONDITION

1. Measure battery voltage. If 12.4 volts or more exists, go to step 3 . If less than 12.4 volts exist, go to next step.
2. Quick charge for 30 minutes and recheck voltage. If 12.4 volts or more exists, go to next step. If less than 12.4 volts exists, replace battery.
3. Apply load test to battery using a battery load tester and record battery voltage after 15 seconds. See «BATTERY LOAD TEST SPECIFICATIONS»(ref-167358-S37902043772004101300000) table. See «LOAD TEST MINIMUM VOLTAGE»(ref-167358-S16205834632004101300000) . If voltage is within specification, battery is okay at this time. If voltage is not within specification, replace battery.

BATTERY LOAD TEST SPECIFICATIONS

LOAD TEST MINIMUM VOLTAGE

BATTERY CHARGING

1. Place a battery in a pan of water to prevent it from overheating. The water level should come up about halfway on the battery. Keep water off the top of the battery.
2. Connect a battery charger to the battery.
3. Adjust the charging current as specified. See «BATTERY CHARGING SPECIFICATIONS»(ref-167358-S11595079382004101300000) table.
4. After the battery has been recharged, measure the battery positive voltage and verify that the battery voltage is more than 12.4 volts for more than one hour. If not as specified, replace the battery.

BATTERY CHARGING SPECIFICATIONS

GENERATOR VOLTAGE

1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct. See «BELT TENSION»(ref-167358-S17976314802004101300000) under ADJUSTMENTS.
3. Turn off all electrical loads.
4. Start the engine and verify that the generator rotates smoothly without any noise while the engine is running.
5. Using DVOM, measure the battery voltage at the battery and by backprobing at generator harness connector terminals "D" and "P". See «GENERATOR OUTPUT»(ref-167358-S06059145922004101300000) table. (Scheme 8)

GENERATOR OUTPUT

Scheme 8

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.

1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is correct.
3. Disconnect the negative battery cable.
4. Connect a tester capable of reading 120 amps or above, between generator terminal "B" and the wiring harness connector.
5. Connect the negative battery cable.
6. Turn off all electrical loads. Start the engine. Increase engine speed to 2000-2500 RPM.
7. 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-167358-S02160009002004101300000) table. Measuring conditions: Room temperature: 68°F (20°C). Voltage: 13.5 volts. Engine hot.

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 9) Replace as necessary. See GENERATOR SPECIFICATIONS.

Scheme 9

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 10) Replace as necessary. See GENERATOR SPECIFICATIONS.

Scheme 10

RECTIFIER

Inspect for continuity of the diodes using an analog circuit tester. (Scheme 11) See RECTIFIER DIODE CONTINUITY. Replace rectifier if not as specified.

RECTIFIER CONTINUITY

Scheme 11

ROTOR

1. Using DVOM, measure the resistance between the slip rings. (Scheme 12) If resistance is 2.5-2.9 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.
2. Using DVOM, verify there is no continuity between the slip ring and core. (Scheme 13) If continuity does not exist, go to next step. If continuity exists, replace the rotor.
3. Inspect the slip ring surface condition. If slip ring surface is rough, use a lathe or fine sandpaper to repair.

Scheme 12

Scheme 13

STATOR COIL

Using DVOM, check for continuity between the stator coil leads. (Scheme 14) 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 14)

Scheme 14

2002

For charging system wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.

2003

For charging system wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.

2004

For charging system wiring diagram, see STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article.