engine MAZDA 626 1987 Workshop Manual

5 DISTRIBUTOR
INSTALLATION
Note
After installing the distributor, adjust the ig-
nition timing (Refer to 5—11).
1. Apply engine oil to the O-ring and driven gear.
76G05X-056
Note
Gear driven type, check that the No.1 cylin-
der is at top dead center and aline the distrib-
utor matching marks.
76G05X-016
2. Install the distributor and connect the high-tension
leads and distributor connector.
3. Tighten lock bolt to the specified torque.
Torque specification:
19—25 Nm (1.9—2.6 m-kg, 14—18 ft-lb)
86U05X-064
5—18

5 ALTERNATOR
CHARGING SYSTEM
76G05X-023
86U05X-008
Caution
a) Be sure the battery connections are not
reversed, because this will damage the rec-
tifier.
b) Do not use high-voltage testers such as a
megger, because they will damage the rec-
tifier.
c) Remember that battery voltage is always
applied to the alternator B terminal.
d) Do not ground the L terminal while the en-
gine is running.
e) Do not start the engine while the connec-
tor is disconnected from the L and S ter-
minals.
5—22

ALTERNATOR 5
TROUBLESHOOTING
Preliminary Check
1. Turn the ignition switch ON, and check that
the alternator warning light illuminates.
2. Start the engine, and check that the alternator warning light goes off.
76G05X-024
1. Alternator warning light always not illuminate
76G05X-025
2. Alternator warning light illuminates when engine running
76G05X-026
5-23

ALTERNATOR 5
Warning
Disconnect the nagative battery terminal when disconnect or reconnect B terminal.
TEST 1
1. Disconnect the alternator connector (2-pin).
2. Connect the SST.
4. Connect the red clip of the adapter harness to the battery
(
+
),
and check that the red
lamp and green lamp illuminate.
5. Start the engine and check that both lamps go off.
86U05X-010
TEST 2
1. Connect an ammeter (75A min.) between the wire and the B terminal.
2. Turn all headlights and accessories on, and depress the brake pedal.
3. Start the engine and check that output current is 70A (RF-CX: 75A) or more at
2,500—3,000 rpm of the engine speed.
Caution
Do not ground the B terminal.
76G05X-029
B terminal
5-25

5 ALTERNATOR
TEST 3
1. Turn all electric loads off and release the brake pedal.
2. Check that output current is 5A or more at 2,500—3,000 rpm of the engine speed.
B • , \ B terminal
.w/^y
w
86U05X-013
TEST 4
1. Turn all electric loads off and release the brake pedal.
2. Check that output voltage between S terminal and ground is within specification at
2,500—3,000 rpm of the engin speed.
Voltage: 14.1—14.7V
S terminal
86U05X-072
TEST 5
1. Turn the ignition switch ON.
2. Check that L terminal voltage is within specification.
Voltage: 1—5 V
- L terminal
86U05X-073
5—26

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
STARTER (GASOLINE
ENGINE, 0.85, 0.95
KW TYPE)
STARTING SYSTEM CIRCUIT
76G05X-039
START
i Turn ON
(S) terminal
0
t* t
Voltmeter
4BG05X-074
ON-VEHICLE INSPECTION
Charge the battery fully before starting the following
inspections.
A. If the magnetic switch dose not function dur-
ing starting.
1. Turn the ignition switch to the start position.
2. Measure the voltage between the S terminal and
ground.
3. If the measured value is standard voltage or more,
there is starter malfunction.
4. If it is less than standard voltage, there is a mal-
function in the wiring.
Standard voltage: 8 V
Caution
If the magnetic switch is hot, it may not func-
tion even though the voltage is standard volt-
age or more.
B.lf the starter won't crank, or if the cranking
speed is slow.
The problem may be a malfunction of the starter
or in the wiring.
Note
The cranking speed is greatly affected by the
viscosity of the engine oil.
5-38

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
76G05X-040
REMOVAL AND INSTALLATION
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Raise the front of the vehicle and support it with
safety stands.
4. Remove the intake manifold bracket. (Fuel Injec-
tion Engine)
5. Remove the starter bolts.
6. Draw out the starter from lower side of the vehicle.
Installation in the revers order of removal.
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)
Intake manifold bracket bolt
37—52 N-m (3.8—5.3 m-kg, 27—38 ft-lb)
Nut
19—25 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly is the reverse order of disassembly. 4BG05X-049
4BG05X-075
1. Magnetic switch
2. Bolt
3. Rear cover
4. Brush-holder assembly
5. Yoke
6. Lever
7. Drive housing
(front cover)
8. Drive pinion
9. Armature
5-39

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
4BG05X-078
4BG05X-079
4BG05X-080
Drive Pinion
Remove the stopper for the overrunning clutch by us-
ing a pipe as shown in the figure.
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.
Pinion gap: 0.5—2.0 mm (0.020—0.079 in)
Caution
Do not let electricity flow continuously for
more than 10 seconds.
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
(0.079 in) in all.
more than 2 mm
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
5—40

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
4BG05X-082
4BG05X-083
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: 31 mm (1.22 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
5—41

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
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:
Wear limit:
17 mm (0.669 in)
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—42