engine MAZDA 626 1987 Workshop Manual

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
5—53

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

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
STARTER (DIESEL
ENGINE, 2.0
KW TYPE)
STARTING SYSTEM CIRCUIT
4BG05X-096
76G05X-060
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—56

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
REMOVAL AND INSTALLATION
Removal is as follows:
1. Disconnect the negative battery cable.
2. Disconnect the wiring from the starter.
3. Remove the starter.
Install in the reverse order of removal.
Tightening torque:
Bolts 64—89 N-m
(6.5—9.1 m-kg, 47—66 ft-lb)
B terminal 9.8—11.8 N-m
(1.0—1.2 m-kg, 87—104 in-lb)
76G05X-044
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
4BG05X-047
1. Yoke assembly 7. Over-running clutch assembly
2. Brush holder 8. Pinion gear
3. Armature 9. Steel ball
4. Magnetic switch assembly 10. Coil spring
5. Idler gear 11. Housing
6. Retainer and rollers
5—57

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
Disassembly
1. Remove the lead wire connected to the magnetic
switch.
4BG05X-098
2. Remove the two through-bolts.
4EG05X-041
3. Remove the yoke from the magnetic switch.
4EG05X-042
f /"Spring
Brush holder f 0rf# )
N
Itfc
Sr IP Brush
4. Using radio pliers or a similar tool, raise the + side
brush spring and remove the brush.
Caution
Be careful not to scratch the brush or com-
mutator.
4EG05X-043
5—58

STARTER (DIESEL ENGINE, 2.0 KW TYPE) 5
5. Remove the armature from the yoke.
Caution
Be careful not to drop the armature.
4EG05X-044
6. Remove the two screws which hold the housing
and the magnetic switch.
4EG05X-045
7. Remove the housing from the magnetic switch.
4EG05X-046
8. Remove the idle gear, retainer and roller.
Caution
Be careful not to lose the roller.
4EG05X-047
5-59

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
9. Remove the over-running clutch assembly from the
housing.
4EG05X-048
10. Remove the steel ball from the over-running clutch
assembly.
Caution
Be careful not to lose the steel ball.
4EG05X-049
y
/

~7| j j-jy
Coil spring Magnet switch
11. Remove the coil spring from the magnetic switch.
4EG05X-050
Assembly (main point)
Greasing
Apply grease (lithium base, NLGI No. 2) to the places
shown in the figure.
4BG05X-099
5—60

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
5-62