Testing alternator, charging system light is on?

Tiny
RAMJACCORP
  • MEMBER
  • 2002 MAZDA MILLENIA
  • 2.3L
  • TURBO
  • 2WD
  • AUTOMATIC
  • 25,000 MILES
The vehicle listed above is an S (supercharged) Battery is good, but the charging system light is on. Tested voltage at battery posts while running, and it was below 13, so it looks like battery isn't charging. I had to remove the charge air cooler to access the connector plug and post from the top. I want to test voltage from the post, before assuming the alternator is toast, but can I safely run the engine with the air cooler removed? Can't access the buried alternator with the cooler in place.
Wednesday, September 6th, 2023 AT 10:02 AM

11 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 48,363 POSTS
You should be able to but if you upload images of what you are talking about, I can tell for sure.

Here is a guide to help with the test:

https://www.2carpros.com/articles/how-to-check-a-car-alternator

Please let us know how it goes.
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Wednesday, September 6th, 2023 AT 12:57 PM
Tiny
RAMJACCORP
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Thanks for the quick response, Ken! I already watched that video - very helpful. I've attached a couple images - hope they're useful. I don't want to risk doing any damage to the supercharger or engine. I think they built the entire car from the alternator out. ;-)
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Wednesday, September 6th, 2023 AT 2:09 PM
Tiny
KEN L
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You should be okay, if the engine goes to full throttle shut it off, I would not rev the engine. Let me know what happens.
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Friday, September 8th, 2023 AT 3:28 PM
Tiny
RAMJACCORP
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  • 27 POSTS
Just realized I never followed up with you on this one. The problem just went away one day. I still think that the voltage regulator is wonky, though. Since I can't access the post to run a test on it, I'm stuck with it for now. I was able to get the wiring harness open and gave contacts a good cleaning. It needs a new serpentine belt, for sure.
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Wednesday, May 1st, 2024 AT 3:40 PM
Tiny
KEN L
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Okay, problems that go away on their own are welcome :) Thanks for letting us know, we are here to help, please use 2CarPros anytime.
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Thursday, May 2nd, 2024 AT 12:48 PM
Tiny
RAMJACCORP
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  • 27 POSTS
I have an update on the alternator issue, and a follow-up question for you. I found a post on a forum that said the Millies tend to have an issue where the alternator gets "gummed up, " and stops charging the battery. The recommended fix was spraying it down with WD-40 and giving it a few taps to shake the buildup loose. I tried that, and it worked! My question is: Is there any way to ensure that the alternator won't just crap out again while I'm driving, or is it time to replace the alternator to play it safe? Pretty pricey job, because it's a nightmare to access the thing on this car.
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Monday, December 16th, 2024 AT 10:49 AM
Tiny
KEN L
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Yes, I would replace the alternator because it sounds like the brushes are worn out, this is why the wd40 and tapping will get it to work again.
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+1
Tuesday, December 17th, 2024 AT 10:19 AM
Tiny
RAMJACCORP
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Thanks, Ken. Hard to believe the brushes could be worn out on a car with under 30K miles (yep, you read that right), but I guess maybe it's just old age and corrosion.
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Tuesday, December 17th, 2024 AT 11:21 AM
Tiny
KEN L
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If it only has 30k it might be okay, I didn't expect that low of mileage.
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Wednesday, December 18th, 2024 AT 9:38 AM
Tiny
RAMJACCORP
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  • 27 POSTS
Yeah, the car was my "weekend toy, " back when I had enough money to do that. The alternator is a crapshoot, unfortunately. It's too buried to yank out and have bench-tested, so there's no way to tell if it'll fail again while I'm driving. The guy who designed that engine compartment was a sadist!
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Wednesday, December 18th, 2024 AT 11:08 AM
Tiny
KEN L
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Lol yep it happens, I would run it until the battery light comes back on which it might not happen
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Thursday, December 19th, 2024 AT 10:37 AM

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