Charging Fault 1997 Protege ES 1.8l ATX
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Charging Fault 1997 Protege ES 1.8l ATX - 2/14/2007 9:47:50 AM
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mickmc
Posts: 4
Joined: 2/13/2007
Status: offline
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HELP! I am currently experiencing a horrendous charging fault which is now into its 4th week of investigation! I was driving to work and the interior lights started flickering suggesting bad battery or connection, or alternator charging fault. All the normal checks were done, ie clean connections, check battery, check alternator belt and the car ran for approximately 30 km's before the problem started again. The battery was changed and the car ran for approx 60 km's before it started again. I then checked the voltage at the battery and found it to be only 12 Volts, suggesting alternator. All connections were thoroughly checked along with belt and tension. At this point i also noticed extreme overheating on the pulley end of the alternator. The alternator was changed with a new one and the symptoms remained. After much digging around from mazda and the internet, i found out that this charging system uses a 'P-D' or 'Half-Monty' system where voltage regulation happens within the PCM and alternator. Again, after much investigation, the 'D' or driver signal should be between 1 to2 Volts at idle and i found it to be at 12Volts. Great i thought, the PCM is kicking out an incorrect Voltage to 'Drive' the base of the power transistor, i will replace that and problem solved! Not. I managed to get a PCM from an Auto Wreckers in Calgary, where i was assured it was working. I fitted it and the problems remained! I checked the harness from the PCM for various shorts, open circuits and it all checked out. After many more checks, ie replacing the main POS from the alternator output to battery and ensuring the whole engine,chassis and PCM were grounded properley, the fault still remains,ie alternator getting really hot and still not charging. Other tests i did included taking off the main POS cable from alternator output to battery, to simulate an 'unloaded condition.' Mechanically the car ran great with no overheatig of the alternator pulley and the 'unloded' alternator output got upto 17.5 Volts???? I am therfore at a stage where there looks like a major current draw 'loaded' and no major current draw 'unloaded.' Hope this makes sense to some of you out there. None of the codes match these symtoms. I am now wating for some divine inervention to help me out, thankx Mick Mc.
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RE: Charging Fault 1997 Protege ES 1.8l ATX - 2/15/2007 9:42:26 PM
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mickmc
Posts: 4
Joined: 2/13/2007
Status: offline
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Thanks for your suggestion. I will get hold of a current clamp and put it around the main POS cable from Alternator to Battery, the alternator is 70 amps rated so that will give me a major clue to see what is drawing 'loaded.' I will let you know in due course if this helps. Someome also mentioned the main battery POS Start cable, however the car starts great and doesn't sound like the second stage is sticking, although there is also the solenoid to consider. Any suggestions on this course. Note, the starter is in a real crappy position to be disconecting after the car is started and running! Thanx Mickmc
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