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Generators & Regulators: Diagnosis Mazda Tribute I

Charging System 5 illustrations ~3204 words

TROUBLE SHOOTING

Verify customer complaint by operating charging system. Visually inspect for obvious signs of mechanical and electrical damage. Inspect for blown fuses and damaged relays. For fuse and/or relay identification (Scheme 1)- (Scheme 4). Inspect for loose or corroded connections, damaged wiring harnesses and/or switches. Check for broken or partially broken wire inside insulation, which could cause system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found, perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM.

If problem an not be readily located, repair by symptom. See SYMPTOM INDEX table under SYSTEM TESTS.

Scheme 1

Scheme 1: TROUBLE SHOOTING
Scheme 1: TROUBLE SHOOTING

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

RETRIEVING DIAGNOSTIC TROUBLE CODES

Connect Worldwide Diagnostic System (WDS) or equivalent scan tool to the vehicle DLC-2 16-pin connector. Using WDS, perform Powertrain Control Module (PCM) self-test. If P1246: SYSTEM VOLTAGE FAILURE is displayed, see DIAGNOSTIC TROUBLE CODE DEFINITIONS (2002 models), DIAGNOSTIC TROUBLE CODE DEFINITIONS (2003 models) or DIAGNOSTIC TROUBLE CODE DEFINITIONS (2004 models) in SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If no DTCs are present, perform appropriate test under SYSTEM TESTS or ON-VEHICLE TESTS .

DTC P1246 can be set by the loss of the communication lines, GEN COM Circuit and/or GEN MON circuit. However, the generator warning indicator light will not illuminate since the generator is self-regulating and will function normally.

BATTERY LOAD TEST

  1. With the engine running, turn the A/C on, the blower motor on high speed and the headlights on high beam.
  2. Increase the engine speed to approximately 2000 RPM. The voltage should increase a minimum of 0.5 volt above the base voltage. If the voltage does not increase as specified, perform «GENERATOR LOAD TEST»(ref-154598-S20414325982003051900000) and «GENERATOR NO LOAD TEST»(ref-154598-S38326602292003051900000) . If the voltage increases as specified, the charging system is operating normally.

GENERATOR LOAD TEST

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

  1. Switch the battery tester to the ammeter function.
  2. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.
  3. Connect the current probe to the generator B+ output terminal, circuit (Yellow/White wire).
  4. With the engine running, turn the A/C on, the blower motor on high speed and the headlights on high beam.
  5. Increase the engine speed to approximately 2000 RPM. The voltage should increase a minimum of 0.5 volt above the base voltage. If the voltage does not increase as specified, perform «GENERATOR NO LOAD TEST»(ref-154598-S38326602292003051900000). If the voltage increases as specified, the charging system is operating normally.
  6. Adjust the tester load bank to determine the output of the generator. Generator output should be at least 58 amps. (Scheme 5)

Scheme 5

Scheme 5
Scheme 5

GENERATOR NO LOAD TEST

  1. Switch the battery tester to the voltmeter function.
  2. Connect the voltmeter positive lead to the generator B+ output terminal, circuit (Yellow/White wire) and the negative lead to ground.
  3. Turn all electrical accessories off.
  4. With the engine running at 2000 RPM, check the generator output voltage. The voltage should be 13.0-15.0 volts. If voltage is not 13-15 volts, diagnose by symptom. See «SYMPTOM INDEX»(ref-154598-S02197946632003051900000) table under SYSTEM TESTS.

TEST A: CHARGING SYSTEM WARNING INDICATOR IS ON WITH ENGINE RUNNING (3.0L)

  1. Using DVOM, measure voltage between generator "B" terminal X-102b (Yellow/White wire) and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair Yellow/White circuit, then retest system. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000).
  2. Disconnect generator 3-pin connector X-102a. see scheme 7 Measure voltage between generator connector terminal No. 3 (Black/Yellow wire) and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair Black/Yellow wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.
  3. Turn ignition switch to RUN position, engine off (KOEO). Measure voltage between generator connector terminal No. 1 (Light Green/Red wire) and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair Light Green/Red wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.
  4. Reconnect generator 3-pin connector X-102a. Start engine. Measure voltage drop between generator connector X-102b and battery positive (+) terminal. If voltage drop is less then.5 volt, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. If voltage drop is more than.5 volt, repair high resistance in Yellow/White wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.

TEST B: CHARGING SYSTEM WARNING INDICATOR IS ON WITH ENGINE RUNNING (2.0L)

  1. Check The Fault Codes In PCM - Connect Worldwide Diagnostic System (WDS) tester, or equivalent and retrieve Diagnostic Trouble Codes (DTCs). See «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-154598-S33091075602004100400000) under SELF-DIAGNOSTIC SYSTEM. Diagnose and repair any DTCs as necessary. If no DTCs are present, disconnect WDS and go to next step.
  2. Check Circuit (Gray/Orange) - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Turn ignition switch to ON position, engine off (KOEO). Using DVOM, measure voltage between generator connector terminal No. 1 (Gray/Orange wire) and ground. If zero volts exists, go to next step. If more than zero volts exist, go to step 4.
  3. Check Circuit (Gray/Orange) For An Open - Turn ignition switch to OFF position. Disconnect Powertrain Control Module (PCM) harness connector, located on center of firewall. see scheme 1 Measure resistance of Gray/Orange wire between PCM harness connector terminal No. 59 and generator connector No. 1. see scheme 7and see scheme 8. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair Gray/Orange wire between PCM and generator. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.
  4. Check The Generator Output - Reconnect PCM harness connector. Perform generator load test. See «GENERATOR LOAD TEST»(ref-154598-S20414325982003051900000) under ON-VEHICLE TESTING. If generator checks out okay, go to next step. If generator is faulty, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. Retest for normal operation.
  5. Check For Correct PCM Operation - Disconnect PCM harness connector. Inspect terminals for corrosion, pushed out pin or any physical damage. Repair terminals if necessary then reconnect PCM connector. Retest system. If problem still exists, replace PCM. For PCM removal and installation, see the following: For 2002 models, see «POWERTRAIN CONTROL MODULE»(ref-134974-S01886283232002022100000) under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. For 2003 models, see «POWERTRAIN CONTROL MODULE»(ref-151901-S39392855062003010900000) under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. For 2004 models, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. If problem no longer exists, system is operating properly at this time. Problem may have been caused by a loose or corroded connector. Clear DTCs and repeat self-test.

TEST C: CHARGING SYSTEM OVERCHARGES BATTERY - BATTERY VOLTAGE IS GREATER THAN 15.5 VOLTS (3.0L)

  1. Check For Voltage Drop In A Circuit (Black/Yellow Wire) - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Turn ignition switch to ON position, engine off (KOEO). Using DVOM, measure voltage drop between generator connector terminal No. 3 (Black/Yellow wire) and battery positive (+) terminal. If voltage drop is less then.5 volt, go to next step. If voltage drop is.5 volt or more, repair high resistance in Black/Yellow wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.
  2. Check Generator & Battery Ground Connections - Turn ignition switch to OFF position. Check ground connections between voltage regulator, generator, engine and battery. Repair damaged or corroded connector as necessary. If problem still exists, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. Retest system for normal operation.

TEST D: CHARGING SYSTEM OVERCHARGES BATTERY - BATTERY VOLTAGE GREATER THAN 15.5 VOLTS (2.0L)

  1. Check For Fault Codes In PCM - Connect Worldwide Diagnostic System (WDS) tester and retrieve Diagnostic Trouble Codes (DTCs). See «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-154598-S33091075602004100400000) under SELF-DIAGNOSTIC SYSTEM. Diagnose and repair any DTCs as necessary. If no DTCs exist, disconnect WDS tester and go to next step.
  2. Check Battery Voltage - Start engine. Turn all accessories off. Using DVOM, measure voltage at battery while varying engine RPM. If voltage is not greater than 15 volts, system is okay at this time. If voltage is greater than 15 volts, go to next step.
  3. Check Generator Output - Turn ignition switch to OFF position. Disconnect generator connector X-102a. see scheme 7 Start engine. Perform generator load test. See «GENERATOR LOAD TEST»(ref-154598-S20414325982003051900000) under ON-VEHICLE TESTING. If generator is okay, go to next step. If generator output is not within specification, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION.
  4. Check Circuit (Black/Yellow Wire) - Measure voltage between generator connector X-102a terminal No. 3 (Black/Yellow wire) and ground. If voltage drop is less then.5 volt, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. If measured voltage drop is.5 volt or more, repair high resistance in Black/Yellow wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.

TEST E: CHARGING SYSTEM WARNING INDICATOR IS ON WITH ENGINE RUNNING & THE BATTERY INCREASES VOLTAGE (3.0L)

  1. Check "I" Circuit (Light Green/Red) For A Short To Ground - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Turn ignition switch to ON position, engine off (KOEO). Observe charging system warning indicator light. If charging system warning indicator illuminates, repair short to ground in Light Green/Red wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation. If charging system warning indicator does not illuminate, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. Retest system for normal operation.

TEST F: CHARGING SYSTEM WARNING INDICATOR IS ON WITH ENGINE RUNNING & THE SYSTEM INCREASES VOLTAGE (2.0L)

  1. Check For Fault Codes In PCM - Connect Worldwide Diagnostic System (WDS) tester and retrieve Diagnostic Trouble Codes (DTCs). See «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-154598-S33091075602004100400000) under SELF-DIAGNOSTIC SYSTEM. Diagnose/repair any DTCs as necessary. If no DTCs exist, disconnect WDS tester and go to next step.
  2. Check System For Overcharging - Start engine. With engine running and all accessories off, measure voltage at battery terminals while varying engine RPM. If measured voltage is greater than 15 volts, go to «TEST D: CHARGING SYSTEM OVERCHARGES BATTERY - BATTERY VOLTAGE GREATER THAN 15.5 VOLTS (2.0L)»(ref-154598-S02719237632003051900000). If measured voltage is less than 15 volts, go to next step.
  3. Check Circuit (Black/Yellow Wire) - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Turn ignition switch to ON position, engine off (KOEO). Using DVOM, measure voltage between generator connector terminal No. 3 (Black/Yellow wire) and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair Black/Yellow wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation.
  4. Check Charging System Warning Indicator Operation - Turn ignition off. Disconnect Powertrain Control Module (PCM) harness connector, located at center of firewall. Turn ignition switch to ON position, engine off (KOEO) while observing the charging system warning indicator. If indicator illuminates, repair short to ground in Gray/Orange wire. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000). Retest system for normal operation. If indicator does not illuminate, reconnect PCM connector and go to next step.
  5. Check Generator Output - Perform generator load test. See «GENERATOR LOAD TEST»(ref-154598-S20414325982003051900000) under ON-VEHICLE TESTING. If generator output is okay, go to next step. If generator output is not within specification, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. Retest system for normal operation.
  6. Check For Correct Module Operation - Disconnect PCM harness connector and inspect terminals for corrosion, pushed out terminals or damaged terminals. Repair connectors as necessary. Retest system. If system is still faulty, replace PCM. For removal and installation of PCM, see the following: For 2002 models, see «POWERTRAIN CONTROL MODULE»(ref-134974-S01886283232002022100000) under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. For 2003 models, see «POWERTRAIN CONTROL MODULE»(ref-151901-S39392855062003010900000) under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. For 2004 models, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE.

TEST G: CHARGING SYSTEM WARNING INDICATOR IS OFF WITH IGNITION SWITCH IN RUN POSITION WITH ENGINE OFF (3.0L)

Check Charging System Warning Indicator Lamp - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Connect fused (15-amp) jumper wire between generator connector terminal No. 1 (Light Green/Red wire) and ground. Turn ignition switch to ON position, engine off (KOEO). If charging system warning indicator illuminates, replace generator. See GENERATOR under REMOVAL & INSTALLATION. If charging system warning indicator does not illuminate, inspect instrument cluster for possible fault. For 2002 models, see INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. For 2003-04 models, see appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.

TEST H: CHARGING SYSTEM WARNING INDICATOR IS OFF WITH IGNITION SWITCH IN RUN POSITION WITH ENGINE OFF (2.0L)

  1. Check For Fault Codes In PCM - Connect Worldwide Diagnostic System (WDS) tester, or equivalent, and retrieve Diagnostic Trouble Codes (DTCs). See «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-154598-S33091075602004100400000) under SELF-DIAGNOSTIC SYSTEM. Diagnose/repair any DTCs as necessary. If no DTCs are present, disconnect WDS tester and go to next step.
  2. Check Charging System Warning Indicator Operation - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Connect fused (15-amp) jumper wire between generator connector terminal No 1. (Grey/Orange wire) and ground. Turn ignition switch to ON position, engine off (KOEO), while observing charging system warning indicator. If charging system warning indicator illuminates, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. If charging system warning indicator does not illuminate, go to next step.
  3. Check For Correct PCM Operation - Disconnect Powertrain Control Module (PCM) harness connectors, located on engine firewall. Inspect terminals for corrosion, pushed out terminals or damage. Repair connectors if necessary. Reconnect PCM and generator connectors and retest system. If problem still exists, replace PCM.

TEST I: CHARGING SYSTEM WARNING INDICATOR FLICKERS (3.0L)

  1. Check For Loose Connections - Inspect generator, battery and power distribution connectors for looseness, corrosion or damaged terminals. Repair as necessary then retest system for proper operation. If problem persists, go to next step.
  2. Check Fuses - Start engine. Check battery junction box fuse No. 11 (15-amp) for looseness by wiggling fuse. Observe charging system warning indicator. If indicator flickers, repair loose fuse connectors, then retest system for normal operation. If indicator does not flicker, go to next step.
  3. Check A Circuit (Black/Yellow Wire) Connections - Turn ignition switch to OFF position. Connect fused (15-amp) jumper wire between generator connector terminal No. 3 (Black/Yellow wire) and battery positive (+) terminal. Leave generator connector connected to generator. Start engine while observing charging system warning indicator. If indicator flickers, load test generator. See «GENERATOR LOAD TEST»(ref-154598-S20414325982003051900000) under ON-VEHICLE TESTING. Replace generator if faulty. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. If indicator does not flicker, repair loose connectors in circuits. See «WIRING DIAGRAMS»(ref-154598-S41210994422003051900000) . Retest system for normal operation.

TEST J: CHARGING SYSTEM WARNING INDICATOR FLICKERS (2.0L)

  1. Check For Fault Codes In PCM - Connect Worldwide Diagnostic System (WDS) tester, or equivalent, and retrieve Diagnostic Trouble Codes (DTCs). See «RETRIEVING DIAGNOSTIC TROUBLE CODES»(ref-154598-S33091075602004100400000) under SELF-DIAGNOSTIC SYSTEM. Diagnose/repair any DTCs as necessary. If no DTCs are present, disconnect WDS tester and go to next step.
  2. Check For Loose Connections - Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Check all generator, battery, and power distribution connections for looseness, corrosion or damaged terminals. Reconnect generator connector X-102a. Retest system for normal operation. If charging system warning indicator still flickers, go to next step.
  3. Check Fuse Connection - Start engine. Check battery junction box fuse No. 11 (15-amp) for tightness by wiggling fuse and noting charging system warning indicator. If indicator flickers, repair loose fuse connector, then retest system for normal operation. If indicator does not flicker, go to next step.
  4. Check Battery Voltage - With engine running and all accessories turned off, measure battery voltage. If battery voltage is greater than 15 volts, go to «TEST D: CHARGING SYSTEM OVERCHARGES BATTERY - BATTERY VOLTAGE GREATER THAN 15.5 VOLTS (2.0L)»(ref-154598-S02719237632003051900000). If voltage is 15 volts or less, go to next step.
  5. Check Warning System Indicator Operation - Turn ignition switch to OFF position. Disconnected generator 3-pin connector. Turn ignition switch to ON position, engine off (KOEO). Connect a fused jumper wire between generator connector terminals No. 3 (Black/Yellow wire) and ground. If charging system warning indicator illuminates, go to next step. If indicator does not illuminate, repair Black/Yellow wire as necessary. Retest system for normal operation.
  6. Check PCM Operation - Turn ignition switch to OFF position. Connect generator 3-pin connector. Turn ignition switch to ON position, engine off (KOEO). Monitor the charging system warning indicator operation. If the charging system warning indicator illuminates, the PCM is operating correctly. Recheck generator and related circuits for intermittent shorts or opens. Repair as necessary. Retest system for normal operation. If charging system warning indicator is not illuminated, go to next step.
  7. Check For Correct PCM Operation - Disconnect Powertrain Control Module (PCM) harness connector, located on engine firewall. Inspect harness connector for corroded, pushed out terminals or damaged terminals. Repair connector as necessary. Reconnect PCM harness connector. Retest system for normal operation. If fault still exists, replace PCM. For removal and installation of PCM, see the following: For 2002 models, see «POWERTRAIN CONTROL MODULE»(ref-134974-S01886283232002022100000) under COMPUTERIZED ENGINE CONTROLS in REMOVAL, OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. For 2003 models, see «POWERTRAIN CONTROL MODULE»(ref-151901-S39392855062003010900000) under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. For 2004 models, see POWERTRAIN CONTROL MODULE under COMPUTERIZED ENGINE CONTROLS in REMOVAL & INSTALLATION article in ENGINE PERFORMANCE. If fault no longer exists, system is okay at this time. Concern may have been caused by a loose or corroded connector. Clear DTCs and repeat self-test.

TEST K: GENERATOR IS NOISY

  1. Check For Accessory Drive Noise - Check accessory drive belt for damage and correct installation. Check accessory mounting brackets and generator pulley for looseness or misalignment. Repair as necessary. Retest system for normal operation. If accessory drive belts are okay, and noise persists, go to next step.
  2. Check Generator Mounting - Check generator mounting for loose bolts or misalignment. Repair or adjust as necessary, then retest system for normal operation. If generator mounting is okay, go to next step.
  3. Check Generator For Electrical Noise - Disconnect generator 3-pin connector X-102a. see scheme 7 Start engine. With the engine running, use a stethoscope or equivalent listening device, if necessary. If noise is still present, go to next step. If noise is not present, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. Retest system for normal operation.
  4. Check Generator For Mechanical Noise - Turn ignition switch to OFF position. Start engine. Turn all accessories off. Using stethoscope, check generator for unusual mechanical noise. If generator is noise source, replace. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. If generator is not noise source, replace generator. See «GENERATOR»(ref-154598-S29244319502003051900000) under REMOVAL & INSTALLATION. Retest system for normal operation. If generator is not the noise source, check engine for noise.

TEST L: RADIO INTERFERENCE

Verify Generator Is Source Of Radio Interference - Start engine. Tune radio to station where interference is present. Turn ignition switch to OFF position. Disconnect generator 3-pin connector X-102a. see scheme 7 Start engine. Listen for interference with radio. If interference is still present, problem lies with audio system. Investigate and repair as necessary. If interference is not present, replace generator. See GENERATOR under REMOVAL & INSTALLATION. Retest system for normal operation.

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