clutch MAZDA 626 1987 Repair Manual

TROUBLESHOOTING GUIDE 5
TROUBLESHOOTING GUIDE
Problem Possible cause Remedy Page
Starter does not turn at all, or Its turning speed Is too slow to start the engine.
Battery and related parts Poor contact of battery terminals Poor grounding of negative cable Voltage drop caused by discharged battery Insufficient voltage caused by battery malfunction
Clean and tighten Clean and repair Recharge Replace
5- 8
5- 8 5- 8
Ignition switch and related parts Poor contact of ignition switch Loose ignition switch wiring or connector Broken wire between ignition switch and magnetic switch
Replace Repair Repair or replace 5-38,45,56,66
Magnetic switch and related parts Loose wiring and/or connectors Burnt magnetic switch contact plate or improper contact Broken wire in magnetic switch pull-in coil Broken wire magnetic switch holding coil
Repair Replace
Replace Replace
5-38,45,56,66 5-43,54,64,74
5-43,54,64,74 5-43,54.64,74
Starter Poor contact of brushes
Fatigued brush spring Poor grounding of field coil Poor soldering of field coil Commutator mulfunction Grounded armature Worn parts
Adjust contact or replace Replace Replace Repair Repair or Replace Replace Replace
5-43,54,64,74
Starting problem Gasoline engine Insufficient battery capacity Malfunction of spark plug (s)
Loose positive terminal Damaged distributor cap or rotor Ignition coil malfunction laniter malfunction
Recharge Clean, adjust or replace Tighten Replace Replace Renlane
5— 8 5— 9
5—16 5—10 5-16,20
Diesel engine Insufficient battery capacity QSS svstem malfunction Recharge ReDlace 5— 8 5-76
Starter turns but pinion gear does not mesh with ring gear
Starter Tip of overrunning clutch pinion is worn Weakened overrunning clutch drive spring Worn overrunning clutch Improper sliding of spline
Worn bushing Worn ring gear
Replace Replace Replace Adjust contact and repair, or replace Replace ReDlace
5-40,54,70
Starter turns continuously (does not stop) Magnetic switch Sticking contact place of magnetic switch Layer shorting coil of magnetic switch Ignition switch does not return
Replace Replace Rfinlanfi
5-43,54,64,74 5-43,54,64,74
Misfiring Dirty or damaged spark plug (s) Malfunction of wiring, or open circuit Damaged distributor cap
Clean or replace Repair or Replace Replace
5- 9 5—10 5—16
Discharging of battery Alternator Loose drive belt Grounded or broken stator coil Broken rotor coil Poor contact of brush and slip ring
Malfunction of rectifier Malfunction of IC regulator Battery and related parts Insufficient or unsuitable battery electrolyte Malfunction of battery electrode (internal short-circuit) Poor contact of battery terminal (s) Excessive electric load
Adjust Replace Replace Clean, repair or replace Replace Replace
Adjust Replace
Clean and tighten Check power consump-tion and short circuit
5-37 5-32 5-32 5-32
5-34
5— 8 5- 8
5— 8
Overcharging of battery IC regulator malfunction Operating in extremely high temperature Replace Reoair
Poor acceleration Mis-adjusted ignition timing Distributor malfunction Adjust Repair or replace 5—11 5—11
Knocking Mis-adjusted ignition timing | Distributor malfunction Adjust Repair or replace 5—11 5—11
76G05X-003
5-7

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

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
REMOVAL
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 starter bolts.
5. Draw out the starter from lower side of the vehicle.
Note
Remove the lowest starter bolt last.
76G05X-042
DISASSEMBLY
86U05X-083
1. Magnetic switch
2. Plunger and spring
3. Rear housing
4. Brush holder assembly
5. Armature
6. Ball
7. Planetary gear
8. Drive housing front cover
9. Lever
10. Drive pinion
11. Overrunning clutch
12. Internal gear
13. Yoke assembly
14. Gear shaft
Caution
Do not strike the yoke with a hammer, drop it or put it in a vise when disassembling the
starter.
5—46

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Magnetic Switch
Remove the following parts:
(1) M terminal nut
(2) Wire
(3) Switch installation screws
(4) Magnetic switch
(5) Plunger and plunger spring
86U05X-33
Rear Bracket and Brush Holder
Remove the following parts:
(1) Brush holder installation screws
(2) Through bolts
(3) Rear cover
(4) Wave washer
(5) Brush holder assembly
Note
Put an aligning mark on the yoke and rear
bracket for reassembly before removing the
rear bracket.
7BU05X-034
Yoke and Armature
Remove the armature and yoke.
Note
Put an aligning mark on the yoke and front
bracket for reassembly before removing the
front bracket.
7BU05X-035
Overrunning Clutch, Planetary Gears, and Inter-
nal Gear.
Remove the following parts:
(1) Gasket
(2) Plate
(3) Planetary gears
(4) Internal gear
(5) Drive pinion
Note
Do not lose the ball.
7BU05X-110
5—47

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
86U05X-034
Snap ring
Internal gear
Drive pinion I Gear shaft
r i
rt
n I I Washer

OC
Stopper
7BU05X-037
Overrunning Clutch Stopper
1. Remove the overrunning clutch stopper using a
pipe.
2. Disassemble the drive pinion, internal gear and
washer from the gear shaft.
Brush and Brush Holder
Remove the brush from the brush holder using a flat-
tip screwdriver.
7BU05X-038
5-48

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Overrunning Clutch
Turn the pinion shaft by hand and hold the overrun-
ning clutch.
Replace the overrunning clutch if the pinion turns in
both directions or in neither direction.
Note
Do not wash the overrunning clutch with sol-
vent; it is packed with grease and sealed.
86U05X-035
Internal Gear and Planetary Gears
1. Internal gear
Check for wear or damage. Replace if necessary.
2. Planetary gears
Check for wear or damage. Replace if necessary.
67U05X-057
Yoke
Check for damage. Replace if necessary.
67U05X-058
Bearing
Check for abnormal noise, looseness, binding.
Replace the bearing if there is any problem.
Note
Use a bearing puller to remove the bearings.
67U05X-059
5-51

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

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)
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