MAZDA 323 1989 Factory Repair Manual

IGNITION SYSTEM G
Removal I Installation
1. Remove in the order shown in the figure.
2. Install in the reverse order of removal.
RP I’lClHC
FIRING ORDER AND POSITION
19-25 (1.9-2.6,
14-19)
N-m (m-kg, R-lb
03UOGX-053
(1.9-2.6, 14-19)
FIRING ORDER AND POSITION
1. Air hose 4. Distributor
2. High-tension lead Disassembly / Assembly. . . . . . . . . . . . . page G-22
Inspection ,..*....,.........,..,............. page G-l 7 Inspection.. . ,.....,,.,..,........,,.,....... page G-22
3. Connector
G-21

\jl IGNITION SYSTEM
1.6-3.0 N.m
(16-30 cm-Fg,
14-26 in-lb)
Disassembly / Assembly
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
1 BUOGX-00.
1. Cap
3. Cover
Inspection . . . . . . . . . . . . . . . . . . . . . . . ..*..................
below 4. Crank angle sensor
2. Rotor
5. O-ring
Inspection .,..........................................
below
CAP
G-22
I
ROTOR
I 03UOGX.051 ?
REPLACE
Inspection
Cap and rotor
1. Check for corrosion, damage, and cracks.
2. Replace if necessary.

IGNITION SYSTEM G
03UOGX-05
03UOGX-05t 3
03UOGX-059
03UOGX-06
VOLTMETER 0
03UOGX-06
IGNITER
Inspection
1. Disconnect the igniter connector.
2. Connect the
SST between the igniter and the wire harness.
3. Connect the connector (4-pin) of the Igniter Checker to the
adapter harness.
4. Connect the power leads of the
SST (Igniter Checker) to
the battery.
Spark test
1. Turn the ignition switch ON.
2. Disconnect the high-tension coil lead from the distributor
and hold it
5--10mm (0.20-0.39in) from a ground.
Caution
l Hold the SW2 ON for no longer than one second.
3. Flip the SW2 ON and OFF, and verify that strong blue sparks
are discharged from the high-tension lead.
Voltage test
1. Turn the ignition switch ON.
2. Connect a voltmeter to the terminal of the black wire of the
adapter harness.
Caution
l Hold the SW2 ON for no longer than one second.
3. Flip the SW2 ON and OFF, and verify that the voltmeter
pointer fluctuates.
G-23

G STARTING SYSTEM
STARTING SYSTEM
PREPARATION
SST
49 E301 144
Removing plate
I I 03UOGX-062
CIRCUIT DIAGRAM
I --II /l--f--I1 I It------t--r/
INHIBITER SWITCH-ATX 1 It---f-l/
SWITCH STARTER IF
SWFCH-MTX
II
BATTERY V 0
FIELD COIL
BRUSH
S TERMIN
M TERMINAL
““““.“I “1 Note
l BP ATX vehicles use a coaxial reduction starter.
G-24

STARTING SYSTEM G
STARTER
Removal / Installation
1. Remove in the order shown in the figure.
2. Inspect all parts and repair or replace as necessary.
3. Install in the reverse order of removal.
37-52 (3.8-5.3, 27-38)
I 9.8-12 N-m (100-120 cm-kg, 87-104 in-lb)
9 I
1 1 ~ /;’ (1.9-2.6, 14-19)
I
9.8-12 N.m /
(100-120 cm-ka. 87-104 In-lb) (3.8-5.3, 27-38)
L-
\\ 37-52 ,d-5.3. 27-38
REMOVE THE STARTER
AS SHOWN IN THE FIGURE
N-m Im-ka. ft.lb 1
I
031JOGX.06
1. Battery 5. Starter
2. intake manifold bracket Disassembly I Assembly.. . . . . . . . . . . . page G-26
3. S terminal wire Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
page G-28
4. B terminal wire 6. Starter bracket
G-25

G
Disassembly / Assembly STARTING SYSTEM
1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Inspect all parts and repair or replace as necessary.
3. Assemble in the reverse order of disassembly, referring to
Assembly Note.
BP ATX
1, Magnetic switch 6. Planetary gear
Inspection.. . . . . . . . . . . ..I.........I..I..I... page G-28 7. Front cover
2. Rear cover 8. Lever
3. Brush holder assembly 9. Drive pinion
Inspection.. . . . . . . . . . . . page G-28 10. Internal gear
-_/I
4. Armature 11, Gear shaft
Inspection ..,..,..,..,..,......,..,.., ,...... page G-29 12. Bearing
5. Yoke assembly Inspection .,........,..,..,.................. page G-30
2.4-4.4 N.m (24-45 cm-kg, 21-39 In-lb)
in-lb)
4.1-1.5 N-m (42-77 cm-kg, 36-67 in-lb)
G-26

STARTING SYSTEM G
BP MTX AND B6
3.6-7.1 N.m
(39-72 cm-kg, 34-62 in-lb)
4.1-7.5 N.m
(42-77 cm-kg, 36-67 in-lb)
@
0
2.4-4.4 N.m
(24-45 cm-kg, 21-39 in-lb)
1. Magnetic switch 5. Front cover
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-28
6. Lever
2. Rear cover 7. Drive pinion
3. Brush holder assembly 8. Armature
Inspection.. .,..,........................... page G-28 Inspection .,,..,...............,.,........... page G-29
4. Field coil 9. Bearing (if equipped)
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page G-29 Inspection.. ,....,......................,... page G-30
--_I__-
03UOGX-06
03UOGX-06
Disassembly Note
Drive pinion
1. Remove the stopper for the overrunning clutch with a pipe
as shown in the figure.
Assembly Note
Drive pinion
1. Set the drive pinion onto the armature (66, BP SOHC) or
gear shaft (BP DOHC), and install the ring.
2. Install the stopper with the
SST and an arbor press as shown
in the figure.
G-27

G STARTING SYSTEM
t
03UOGX.0%
03UOGX.07(
03UOGX.07
03UOGX-072
03UOGX-07:
G-28
BRUSH SPRING
Inspection
Magnetic switch
1. Continuity (S terminal:M terminal)
Check for continuity between S and M terminals with ohm-
meter. Replace the magnetic switch it there is no continuity.
2. Continuity (S terminal-Body)
Check for continuity between the S terminal and the body
with ohmmeter. Replace the magnetic switch if there is no
continuity.
3. Grounding
Check continuity between M and B terminals with an ohm-
meter. Replace the magnetic switch if there is continuity.
.-.’
Brush and .brush holder
1. Insulation
Check continuity between each insulated brush and the
plate with an ohmmeter. Replace the brush holder if there
is continuity.
2. Measure the force of the brush spring with a spring balance.
3. Replace the spring if necessary.

STARTING SYSTEM G
WEAR LIMIT
/ -- _._- .------
03UOGX-07L i
-----.
i
03UOGX 076
03UOGX-07
Brush
If a brush is worn almost to or beyond the wear limit, replace
all of the brushes.
Type
--pFeE?~Ix _~~_ -.~+~~zE~~:
Standard - mm (In) 1
--.-
Minimum mm (In) 11.5 (0.453) 10.0 (0.39)
Field coil
1. Check for continuity between the M terminal wire and brush-
es with an ohmmeter. Replace the yoke assembly if there
is no continuity.
2. Check continuity between the M terminal wire and yoke with
an ohmmeter. Replace the yoke assembly if there is con-
tinuity.
3. Check if the field coil is loose. Replace the yoke assembly
if necessary.
Armature
1. Check continuity between the commutator and the core with
an ohmmeter. Replace the armature it there is continuity.
2. Check continuity between the commutator and the shaft with
an ohmmeter. Replace the armature if there is continuity.
G-29

G STARTING SYSTEM
1 03lJOGX.079
23LJOGX-011
I I OBUOGX-081
3. Place the armature on V-blocks, and measure the runout
with a dial indicator.
If the runout is not within specification, repair it with a lathe
or replace the armature.
Runout: 0.05mm (0.002 in)
Maximum: O.lmm (0.004 in)
4. Replace the armature if the outer diameter of the commu-
tator is almost at or less than the grind limit.
5. If the commutator surface is dirty, wipe it with a cloth; if it
is rough, repair it with a lathe or fine sandpaper.
Engine
Grind limit mm (in) 1 B6 1 BP (MTX) 1 BP (ATX)
31.4 (1.24) 1 28.8 (1.13)
6. Segment groove depth
If the depth of the mold between segments is almost at or
less than the minimum, undercut the grooves to the stan-
dard depth.
Depth: OS-0.8mm (0.02-0.03 in)
Minimum: 0.2mm (0.008 in)
Bearing (if equipped)
1. Check for abnormal noise, looseness, or sticking.
2. Replace the bearing(s) if necessary.
I
03UOGX-082
G-30