2008 Mazda CX-9 Grand Touring

2008 ENGINE Charging System (MZI-3.7) - Mazda CX-9

2008 ENGINE

Charging System (MZI-3.7) - Mazda CX-9

CHARGING SYSTEM LOCATION INDEX [MZI-3.7]

Fig. 1: Identifying Battery & Generator Location

Courtesy of MAZDA MOTORS CORP.

BATTERY REMOVAL/INSTALLATION [MZI-3.7]

1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.

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Fig. 2: Identifying Battery Components & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

BATTERY BOX INSTALLATION NOTE

1. Install the battery box so that the side with the notch points toward the front fender (LH).

Fig. 3: Identifying Battery Box

Courtesy of MAZDA MOTORS CORP.

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BATTERY INSPECTION [MZI-3.7]

WARNING:  Since battery acid is toxic, be careful when handling the battery.
 Since battery acid is highly corrosive, be careful not to allow it to
contact clothing or the vehicle.
 In case battery acid contacts skin, eyes, or clothing, flush it
immediately with running water. Especially if the acid gets in the
eyes, flush with water for more than 15 min and get prompt medical
attention.

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 [MZI-
3.7].)

Battery electrolyte specific gravity [20 C {68 °F}]

1.22-1.29

BATTERY VOLTAGE

1. Inspect the battery as follows:

VOLTAGE SPECIFICATION
Step Inspection Action
12.4 V or
Go to Step 3.
more
1 Measure the battery positive voltage.
Less than Go to the
12.4 V next step.
12.4 V or Go to the
more next step.
2 Quick charge for 30 min and recheck voltage.
Less than Replace the
12.4 V battery.
Yes Normal
Using the battery load tester, apply load current (see ) and record battery
3 Replace the
voltage after 15 s. Is voltage more than the specification? No
battery.

Battery load test current

80D26L(55): 195 A

Standard specification

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VOLTAGE SPECIFICATION
Battery temp. (°C {°F}) Minimum voltage (V)
4 {39} 9.3
10 {50} 9.4
16 {61} 9.5
21 {70} 9.6

BACK-UP CURRENT

1. Verify that the ignition switch is off (key has been removed) and that all doors are closed.
2. Disconnect the negative battery cable.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 30 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 30 min , the tester will indicate
a high value (approx. 300 mA) .
 If the key or any electrical accessory is operated within approx. 30
min after the tester is connected, the battery must be left undisturbed
for approx. 30 min from that point.

CAUTION:  Operating electrical loads while the back-up current is being

measured can damage the tester.

NOTE:  For vehicles with the immobilizer system, the system periodically
shifts synchronization of the security light flashing. Therefore, 60 mA
(0.1 s) current is supplied when the security light is illuminated, and
50 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 55 mA .

Battery back-up current (When the ignition switch is off, the ignition key is removed, and all doors
are closed.)

Vehicles with immobilizer system: 50-60 mA

Vehicles without immobilizer system: 55 mA or less

4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.

BATTERY RECHARGING [MZI-3.7]

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WARNING:  Keep all flames away from the battery, otherwise evaporated gas
from the battery fluid may catch fire, and cause serious injury.
 Remove the battery filler caps when recharging to prevent battery
deformation or damage.

CAUTION:  Do not quick charge for more than 30 min. It will damage the battery.

1. Remove the battery and then place it in a 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

80D26L (55): 5.5-6.5 A

Battery quick charge current [30 min]

80D26L (55): 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 the specification, replace the battery.

Standard voltage

12.4 V or more

Fig. 4: Identifying Battery & Battery Charger

Courtesy of MAZDA MOTORS CORP.

GENERATOR REMOVAL/INSTALLATION [MZI-3.7]

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WARNING:  Remove and install all parts when the engine is cold, otherwise they
can cause severe burns or serious injury.
 When the battery cables are connected, touching the vehicle body
with generator terminal B will generate sparks. This can cause
personal injury, fire, and damage to the electrical components.
Always disconnect the negative battery cable before performing the
following operation.

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7] .)
3. Remove the air cleaner and fresh air duct component. (See INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION [MZI-3.7] .)
4. Remove the cooling fan component. (See COOLING FAN COMPONENT
REMOVAL/INSTALLATION [MZI-3.7] .)
5. Remove the front splash shield (RH).
6. Remove the generator and A/C drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-
3.7] .)
7. Remove in the order indicated in the table.
8. Install in the reverse order of removal.
9. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7] .)
10. Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [MZI-
3.7] .)

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Fig. 5: Identifying Generator, Generator Connector, Lower Bolt & Torque Specifications
Courtesy of MAZDA MOTORS CORP.

GENERATOR LOWER BOLT REMOVAL NOTE

NOTE:  The generator lower bolt cannot be fully removed from the engine because
it contacts the body frame. However, the generator can be
removed/installed without fully removing the lower bolt because there is a
notch at the lower bolt installation part of the generator.

1. Fully loosen the generator lower bolt.

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Fig. 6: Identifying Notch

Courtesy of MAZDA MOTORS CORP.

GENERATOR REMOVAL NOTE

1. Remove the generator from above the engine compartment.

GENERATOR INSTALLATION NOTE

1. Tighten the upper and lower bolts temporarily.

2. Tighten the upper bolt to the specified tightening torque.
3. Tighten the lower bolt to the specified tightening torque.

GENERATOR INSPECTION [MZI-3.7]

GENERATOR WARNING LIGHT

1. Verify that the battery is fully charged.

2. Verify that the generator and A/C drive belt deflection/tension is correct. (See DRIVE BELT
INSPECTION [MZI-3.7] .)
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 out after the engine is started.
 If it does not go out, inspect if any DTCs are displayed.

 If any DTCs are displayed, carry out troubleshooting according to the corresponding DTC
inspection.

GENERATOR

Voltage

1. Verify that the battery is fully charged.

2. Verify that the generator and A/C drive belt deflection/tension is correct. (See DRIVE BELT
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INSPECTION [MZI-3.7] .)
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.

 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 A: B+

Terminal RC: Approx. 1 V or less

Terminal LI: Approx. 1 V

Generator standard voltage [Idle, 20°C {68 °F}]

Terminal B: 12-16 V

Terminal A: 12-16 V

Terminal RC: 0-16 V

Terminal LI: 1-16 V

Fig. 7: Identifying Connector Terminal

Courtesy of MAZDA MOTORS CORP.

Current

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

1. Verify that the battery is fully charged.

2. Verify that the generator and A/C drive belt deflection/tension is correct. (See DRIVE BELT
INSPECTION [MZI-3.7] .)
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 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.

9. Turn the following electrical loads on and verify that the current reading increases more than the
minimum value indicated below.
 Headlights (high-beam)

 Blower motor (HI)

 Rear window defroster

 Brake lights

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]

GENERATOR INNER PARTS

Rotor

1. Measure the resistance between the slip rings using a tester.

 If not within the specification, replace the rotor.

Generator rotor resistance (between slip rings) [20 °C {68 °F}]

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1.8-2.2 ohm

Fig. 8: Measuring Resistance Between Slip Rings With Tester

Courtesy of MAZDA MOTORS CORP.

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 smooth it.

Fig. 9: Measuring Continuity Between Slip Ring & Core With Tester
Courtesy of MAZDA MOTORS CORP.

Stator coil

1. Verify that the continuity is as indicated in the table.

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Fig. 10: Continuity Reference Chart

Courtesy of MAZDA MOTORS CORP.

Fig. 11: Identifying Stator Coil Terminal

Courtesy of MAZDA MOTORS CORP.

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.
 If there is continuity, replace the stator coil.

Fig. 12: Measuring Continuity Between Stator Coil Leads

Courtesy of MAZDA MOTORS CORP.

Brush

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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: 22.5 mm {0.89 in}

Minimum: 5.0 mm {0.20 in}

Fig. 13: Identifying Brush Length

Courtesy of MAZDA MOTORS CORP.

Brush spring

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: 4.1-5.3 N {0.42-0.54 kgf, 0.92-1.19 lbf}

Minimum: 1.7 N {0.17 kgf, 0.38 lbf}

Fig. 14: Measuring Force Of Brush Spring With Spring Pressure Gauge

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Courtesy of MAZDA MOTORS CORP.

Rectifier (Using an analog circuit tester)

1. Inspect for continuity of the diodes using an analog circuit tester.

 If not as specified, replace the rectifier.

Specification

CONTINUITY SPECIFICATION
Negative Positive Continuity
E Yes
P1, P2, P3, P4, P5, P6
B No
E No
P1, P2, P3, P4, P5, P6
B Yes

Fig. 15: Identifying Rectifier

Courtesy of MAZDA MOTORS CORP.

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

CONTINUITY SPECIFICATION
Negative Positive Continuity
E No
P1, P2, P3, P4, P5, P6
B Yes
E Yes
P1, P2, P3, P4, P5, P6
B No

Bearing

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1. Inspect for abnormal noise, looseness, and sticking.

 Replace the bearing if necessary.

Fig. 16: Inspecting Bearing Looseness, & Sticking

Courtesy of MAZDA MOTORS CORP.

GENERATOR DISASSEMBLY/ASSEMBLY [MZI-3.7]

CAUTION:  Melt the solder quickly, otherwise the diodes (rectifier) and regulator
will be damaged by excessive heat.

1. Disassemble in the order indicated in the table.

2. Assemble in the reverse order of disassembly.

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Fig. 17: Identifying Generator Components & Torque Specifications

Courtesy of MAZDA MOTORS CORP.

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