check engine MAZDA 626 1987 Workshop Manual

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
Brush and Brush Holder
1. Insulation of brush holder
Check for continuity between the insulated brush
and the plate using a circuit tester. Replace the
brush holder if there is continuity.
67U05X-060
\E
Wear limit line
—r
10.0 mm
(0.39 in)
L 17.5 mm (0.69 in)
2. Brush
Replace the brushes if they are worn beyond the
wear limit, or if the wear is near the limit.
Wear limit: 10.0 mm (0.394 in)
New brush: 17.5 mm (0.689 in)
7BU05X-043
Brush holder
Check that the brush slides smoothly inside the
brush holder.
67U05X-062
4. Brush spring
(1) Measure the force of the brush spring using
a spring balance.
(2) Replace the brush spring if the force is below
specification.
Specification: 7 N (0.7 kg, 1.5 lb)
Note
a) The force is measured at the moment the
brush spring separates from the brush.
b)The force must be 18—24 N (1.8—2.4 kg,
4.0—5.3 lb) for a new brush spring.
86U05X-036
5-52

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
86U05X-037
Internal gear
Drive pinion Gear shaft
Snap ring
Stopper
7BU05X-045
Snap ring
Stopper
Overrunning
\= clutch
7BU05X-046
ASSEMBLY
Assemble in the reverse order of disassembly, refer-
ring to the assembly note.
Assembly Note
Lubricate
During assembly lubricate the following points:
1. Gear of armature shaft
2. Internal gear and planetary gears
3. Plunger circumference
4. Lever
5. Ball
6. Gear shaft spline
7. Front bracket housing
Installation of Overrunning Clutch
1. Install the washer, internal gear, drive pinion stop-
per, and the snap ring on the gear shaft.
2. Press the stopper and the snap ring into position
as shown in the figure.
Installation of lever
Check the lever faces in the correct direction.
7BU05X-047
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5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
7BU05X-048
86U05X-038
7BU05X-050
Installation of Brush Holder
Install the brush holder assembly and rear cover and
align the through bolts.
CHECKING OPERATION
Magnetic Switch
Make the following tests:
Pull-out test
1. Check that the pinion is pulled out when 12V is con-
nected to the S terminal and the body is grounded.
2. Measure the pinion gap while the pinion is pulled
out.
Specification: 0.5—2.0 mm (0.02—0.08 in)
3. Adjust the pinion gap with an adjust washer (drive
housing front cover—magnetic switch) if it is not
within specification.
Return test
1. Disconnect the motor wire from the M terminal, and
then connect the battery power to the M terminal
and ground the body.
2. Pull out the overrunning clutch with a flat-tip screw-
driver. Check that the overrunning clutch returns
to its original position when released.
86U05X-039
5-54

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Ammeter £
Battery 12V
Switch K sf
Voltmeter W Starter
86U05X-040
No-Load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use heavy gauge wires and tighten each ter-
minal fully.
2. Close switch K to run the starter.
3. Check for the following:
Voltage (V) 11.0
Current (A) 90 max.
Gear shaft speed (rpm) 3,000 min.
4. If any abnormality is noted, check for the cause
according to "Inspection".
INSTALLATION
Install in the reverse order of removal.
Note
When installing the starter, tighten the bolts
to the specified torque.
Tightening torque:
Bolts 37—52 N m
(3.8—5.3 m-kg, 27—38 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-043
5—55

STARTOR (DIESEL ENGINE, 2.0 kW TYPE) 5
Coil spring and steel ball installation
1. Install the coil spring and steel ball to the magnet-
ic switch before installing the over-running clutch
assembly.
2. Assemble the retainer and roller to the idler gear.
4BG04X-100
Brush
(
+
)

Brush installation
1. Assemble the brush holder to the yoke.
2. Assemble the two brushes on the yoke side to the
brush holder.
4BG05X-101
Magnetic switch installation
Align the cut out part with the projection of the mag-
netic switch.
4BG05X-102
INSPECTION
Armature Coil
1. Ground of the armature coil
(1) Check for continuity between the commutator
and the core by using a circuit tester.
(2) Replace the armature if there is continuity.
4BG05X-081
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5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
4BG05X-082
4BG05X-103
Faulty repair
Bad Good
Mica
Undercut
Segments
4BG05X-084
2. Vibration of the commutator
(1) Place the armature on V blocks, and measure
the vibration by using a dial gauge.
(2) If the vibration is Limit or more, repair so that
it becomes standard by using a lathe, or re-
place the armature.
Standard vibration: 0.05 mm (0.002 in)
Limit: 0.4 mm (0.018 in)
Note
Before checking, be sure that there is no play
in the bearings.
3. Outer diameter of the commutator
Replace the armature if the outer diameter of the
commutator is grind limit or less.
4. Roughness of the commutator surface
(1) If the commutator surface is dirty, wipe it with
a cloth.
(2) If it is rough, repair it by using a lathe or fine
sandpaper.
Grind limit: 34 mm (1.34 in)
5. Segment groove depth
If the depth of the mold between segments is limit
depth or less, undercut the grooves by standard
depth.
Standard depth:
0.5—0.8 mm (0.020—0.031 in)
Limit depth: 0.2 mm (0.008 in)
Field Coil
1. Wiring damage
(1) Check for continuity between the connector
and brushes by using a circuit tester.
(2) Replace the yoke assembly if there is no con-
tinuity.
4BG05X-085
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STARTER (DIESEL ENGINE, 2.0 KW TYPE) 5
4BG05X-086
4BG05X-087
4BG05X-088
2. Ground of the field coil
(1) Check for continuity between the connector
and yoke by using a circuit tester.
(2) Repair, or replace the yoke assembly if there
is continuity.
3. Installation of the field coil
Replace the yoke assembly
if
the field coil is loose.
Brush and Brush Holder
1. Brush
If the brushes are worn beyond the wear limit, or
if the wear is near the limit, replace the brushes.
Standard: 17 mm (0.669 in)
Wear limit: 11 mm (0.433 in)
2. Brush spring
(1) Measure the force of the brush spring by us-
ing a spring balance.
(2) Replace the brush spring if the force is limit or
less.
Limit: 9 N (900 g, 31.75 oz)
3. Brush holder
(1) Check for continuity between the insulated
brush and the plate by using a circuit tester.
(2) Repair or replace if there is continuity.
(3) Also check to be sure that the brush slides
smoothly inside the brush holder.
4BG05X-089
5-63

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
Suitable _
steel plate
Armature
4BG05X-104
4BG05X-092
4BG05X-093
Bearing
Check for abnormal noise, looseness, insufficient
lubrication, etc. Replace the bearing if there is any
abnormality.
Take out the bearing, as shown in the figure, by us-
ing the suitable tools.
PERFORMANCE INSPECTION
Magnetic Switch
Disconnect the terminal M wire, and make the fol-
lowing tests.
Pull-in Test
The switch is normal
if
the pinion ejects outward when
the battery is connected as shown in the figure.
Caution
Do not supply power continuously for more
than 10 seconds.
Hold-in Test
1. After completing the pull-in test, disconnect the wire
from terminal M (with the pinion left ejected).
2. The hold-in coil is functioning properly if the pin-
ion does not return.
Return Test
1. Connect the battery between terminal M of the
magnetic switch and the body, as shown in the
figure.
2. Pull the pinion out manually to the pinion stopper
position.
3. The pinion should immediately return to its origi-
nal position when it is released.
4BG05X-094
5—64

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
(S) terminal Switch (K)
(B) terminal
Amp. meter
Voltmeter
4BG05X-105
No-load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use wires as thick as possible and tighten
each terminal fully.
2. Close switch "K" to run the starter.
If
the voltmeter
and ammeter show the following values while the
starter is running, it is normal.
Battery voltage: 11.5 volts
Current: 120 amperes or less
Gear shaft speed: at 4,000 or more
3. If any abnormality is noted, check it according to
"INSPECTION"
5—65

STARTER (DIESEL ENGINE, 2.2 KW TYPE) 5
4BG05X-113
4BG05X-080
Adjustment of pinion gap
1. Disconnect the wiring from terminal (M).
2. Apply battery power to the terminal (S) and ground
the starter motor body, the pinion will eject outward
and then stop.
3. Measure the clearance (pinion gap) between the
pinion and the stopper.
Note
Be careful not to let electricity flow continu-
ously for more than 10 seconds.
Pinion gap: 0.5—2.0 mm (0.020—0.079 in)
4. If the pinion gap is not within the specified range,
make the adjustment by increasing or decreasing
the number of washers used between the magnetic
switch and the drive housing. The gap will become
smaller if the number of washers is increased.
Caution
Do not use the washers more than plates.
INSPECTION
Armature Coil
1. Ground of the armature coil
Check for continuity between the commutator and
the core by using a circuit tester. Replace the ar-
mature if there is continuity.
4BG05-081
2. Vibration of the commutator
Plate the armature on V blocks, and measure the
vibration by using a dial gauge. If the vibration is
Limit or more, repair so that is standard by using
a lathe, or replace the armature.
Standard vibration: 0.05 mm (0.002 in)
Limit: 0.4 mm (0.018 in)
Note
Before checking, be sure than there is no play
in the bearings.
4BG05X-Q82
5-71