GENERATOR INSPECTION [MZR 1.6]

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Caution
•  Do not apply direct battery positive voltage to generator terminal 2B, otherwise it could cause damage to the internal parts (power transistor) of the generator.

Charging System Warning Light

1.  Verify that the battery is fully charged. (See BATTERY INSPECTION [MZR 1.6].)

2.  Verify that the drive belt is correct. (See DRIVE BELT INSPECTION [MZR 1.6].)

3.  Switch the ignition to ON, verify that the charging system warning light illuminates.

•  If it does not illuminate, inspect the charging system warning light and the wiring harness.
―  If the charging system warning light and the wiring harness are normal, inspect the PCM.

4.  Verify that the charging system warning light goes out after the engine is started.

•  If the charging system warning light does not go out, perform the DTC inspection, then perform troubleshooting according to the corresponding diagnostic procedure. (See ON-BOARD DIAGNOSTIC TEST [MZR 1.6].) (See DTC TABLE [MZR 1.6].)


Generator


Generator voltage inspection

1.  Verify that the battery is fully charged. (See BATTERY INSPECTION [MZR 1.6].)

2.  Verify that the drive belt is correct. (See DRIVE BELT INSPECTION [MZR 1.6].)

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.

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•  If it is not as specified, find the cause and repair or replace the applicable part.
Generator standard voltage [IG-ON]
Terminal 1A: B+
Terminal 2A: Approx. 1 V or less
Terminal 2B: Approx. 0 V
Generator standard voltage [Idle, 20 °C {68 °F}]
Terminal 1A: 13—15 V
Terminal 2A: Approx. 3—8 V
Terminal 2B: Turn the electrical loads (headlights, blower motor, rear window defroster, brake light, etc.) on and verify that the voltage reading increases.


Generator current inspection

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. (See BATTERY INSPECTION [MZR 1.6].)

2.  Verify that the drive belt is correct. (See DRIVE BELT INSPECTION [MZR 1.6].)

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. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

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 electrical loads (headlights, blower motor, rear window defroster, brake lights, etc.) on and verify that the current reading increases more than the minimum value indicated below.

―  If it is not as specified, replace the PCM. (See GENERATOR REMOVAL/INSTALLATION [MZR 1.6].)
Generator generated current minimum value
70% of the nominal output current (nominal output current: 90 A)
[Ambient temp. 20 °C {68 °F}, voltage 13.0—15.0 V, both engine and generator are hot]


Generator Internal Parts


Rotor

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

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•  If not within specification, replace the rotor.
Generator rotor resistance (between slip rings) [20 °C {68 °F}]
2.1—2.5 ohms

2.  Verify that there is no continuity between the slip ring and core using a ohmmeter.

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•  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.


Stator coil

1.  Inspect for continuity between the stator coil leads using a ohmmeter.

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2.  Verify that there is no continuity between the stator coil leads and core using a ohmmeter.

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•  If there is continuity, replace the stator coil.


Brush

1.  Inspect brushes for wear.

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•  If any brush is worn almost to or beyond the limit, replace all of the brushes.
Generator brush length
Standard: 18.5 mm {0.728 in}
Minimum: 5.0 mm {0.20 in}


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 {0.008 in}.

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•  Replace the brush spring if necessary.
Generator brush spring force
Standard: 4.8—6.0 N {0.49—0.61 kgf, 1.1—1.3 lbf}
Minimum: 2.16 N {0.220 kgf, 0.486 lbf}


Rectifier

1.  Inspect for continuity of the diodes using a ohmmeter.

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•  If not as specified, replace the rectifier.

Specification

Negative

Positive

Continuity
E
P1, P2, P3, P4
Yes
B
No
P1, P2, P3, P4
E
No
B
Yes


Bearing

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

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•  Replace the bearing if necessary.