1987 MAZDA 626 Workshop Manual

ALTERNATOR 5
TROUBLESHOOTING
Preliminary Check
1. Turn the ignition switch ON, and check that
the alternator warning light illuminates.
2. Start the engine, and check that the alternator warning light goes off.
76G05X-024
1. Alternator warning light always not illuminate
76G05X-025
2. Alternator warning light illuminates when engine running
76G05X-026
5-23

5 ALTERNATOR
3. Alternator warning light operates properly, but battery discharged
OK
NG OK
1
a) Poor connection between B terminal and positive battery cable
b) Poor connection of negative battery cable c) Poor connection between alternator connector (2-pin) and positive battery terminal d) Stator coil or diodes malfunction (Refer to page 5—32 or 5—34.)
Perform TEST 2. (Refer to page 5--25.)
NG
Perform TEST 3. (Refer to Dage 5--26.)
I OK
Perfrom TEST 4. (Refer to page 5--26.)
NG
Perform TEST 5 (F Refer to page 5—26)
OK
Alternator normal.
Check other electrical components.
NG
Alternator normal.
Check other electrical components.
Perform TEST 5. (Refer to page 5—26.)
OK
Stator coil, diode, main fuse, or wiring har-ness between B ternimal and battery mal-function.
(Refer to page 5—32 or 5—34.)
IC regulator, bush, or rotor coil malfunction. (Refer to page 5—32 or 5—33)
NG
76G05X-027
4. Battery overcharged
Less than 14.1V
(At 20°C, 68°F)
More than 14.7V
(At 20oC,68°F)
IC regulator malfunction,
Perform TES T 6. (Refer to page 5—27.)
NG OK
Wiring harness malfunction.
76G05X-028
5—24

ALTERNATOR 5
Warning
Disconnect the nagative battery terminal when disconnect or reconnect B terminal.
TEST 1
1. Disconnect the alternator connector (2-pin).
2. Connect the SST.
4. Connect the red clip of the adapter harness to the battery
(
+
),
and check that the red
lamp and green lamp illuminate.
5. Start the engine and check that both lamps go off.
86U05X-010
TEST 2
1. Connect an ammeter (75A min.) between the wire and the B terminal.
2. Turn all headlights and accessories on, and depress the brake pedal.
3. Start the engine and check that output current is 70A (RF-CX: 75A) or more at
2,500—3,000 rpm of the engine speed.
Caution
Do not ground the B terminal.
76G05X-029
B terminal
5-25

5 ALTERNATOR
TEST 3
1. Turn all electric loads off and release the brake pedal.
2. Check that output current is 5A or more at 2,500—3,000 rpm of the engine speed.
B • , \ B terminal
.w/^y
w
86U05X-013
TEST 4
1. Turn all electric loads off and release the brake pedal.
2. Check that output voltage between S terminal and ground is within specification at
2,500—3,000 rpm of the engin speed.
Voltage: 14.1—14.7V
S terminal
86U05X-072
TEST 5
1. Turn the ignition switch ON.
2. Check that L terminal voltage is within specification.
Voltage: 1—5 V
- L terminal
86U05X-073
5—26

ALTERNATOR 5
TEST 6
1. Turn the ignition switch ON.
2. Turn all electric loads off and release
the brake pedal.
3. Check that voltage between S terminal
and ground is battery voltage.
S terminal
76G05X-057
76G05X-030
86U05X-074
REMOVAL (GASOLINE)
Remove in the sequence shown in the figure.
1. Disconnect the negative battery terminal.
2. Disconnect the wire and connector from the al-
ternator.
3. Remove the bolts.
4. Remove the V-belt.
-5. Remove the alternator to upper side (LHD) or lower
side (RHD).
REMOVAL (DIESEL)
1. Disconnect the negative battery terminal.
2. Remove the right hand driveshaft (Refer to Sec-
tion 9).
3. Disconnect the wire and connector from the al-
ternator.
4. Loosen the idle pulley nuts and remove the drive
belts.
5. Remove the bolts and remove the alternator from
under the vehicle.
76G05X-031
5-27

5 ALTERNATOR
DISASSEMBLY
Disassemble in the sequence shown in the figure.
76G05X-033
6. Pulley
7. Rear bracket
8. Stator
9. Brush holder assembly
10. Rectifier
5—28
1. Lock nut (RF-CX)
2. Pulley (RF-CX)
3. Bolt
4. Front bracket and rotor
5. Lock nut

ALTERNATOR 5
86U05X-020
63U05X-999
1. Place a soldering iron (200W) on the bearing box
for 3 or 4 minutes to heat it to about 50—60°C
(122—140°F).
Pull out the three bolts, and then insert a screw-
driver between the stator and front bracket and
separate them.
Note
a) If the bearing box is not heated, the bear-
ing cannot be pulled out because the rear
bearing and rear bracket fit together very
tightly.
b) Be careful not to force the screwdriver in
too far. The stator may become scratched.
2. Separate the rear and front sections.
Note
Be careful not to lose the stopper spring that
fits around the circumference of the rear
bearing.
5BU05X-057
Front bracket
Pulley
Locknut
Rotor
3. Place the rotor in a vise and loosen the pulley nut,
then disassemble the pulley, rotor, and front
bracket.
86U05X-021
5-29

ALTERNATOR
Bearing
Suitable socket
4. Replace the front bearing
Using a socket which exactly fits on the outer race
of the bearing, carefully press in the bearing. Use
a hand press or a vise.
86U05X-076
5. Replace the rear bearing
The bearing can be pulled off by using a bearing
puller.
When it is pressed on, press
it
on so
that the
groove
at the bearing circumference is at the slip ring side.
86U05X-086
6. Remove the nut of the B terminal and the insula-
tion bushing.
7. Remove the rectifier holding screws and the brush
holder holding screw.
8. Separate the rear bracket and the stator.
86U05X-077
9. Use a soldering iron to remove the solder from the
rectifier and the stator leads, and then remove the
IC regulator.
Caution
Disconnect quickly, use the soldering iron no
more than about 5 seconds because the rec-
tifier may be damaged if it is overheated.
86U05X-087
5—30