wiring MAZDA 626 1987 Repair Manual

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
STARTER (GASOLINE
ENGINE, 1.4
KW TYPE)
STARTING SYSTEM
76G05X-041
ON-VEHICLE INSPECTION
Charge the battery fully before starting the following
inspection.
1. Turn the ignition switch to the start positron.
2. Check that the starter motor operates.
3. If the starter does not operate, check the voltage
between S terminal and ground using a voltmeter.
4. If the voltage is 8V or more, the starter is mal-
function.
5. If less than 8V, the wiring harness is malfunction.
Caution
If the magnetic switch is hot, it may not func-
tion even though the voltage is standard volt-
age or more.
Note
The cranking speed is greatly affected by the
viscosity of the engine oil.
86U05X-031
5-45

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

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
Segments groove depth
If the depth of the groove is less than standard,
undercut the grooves to the standard depth.
Standard depth: 0.5—0.8 mm (0.02—0.03 in)
Minimum depth: 0.2 mm (0.008 in).
7BU05X-041
Magnetic Switch
1. Wiring damage (©terminal — ©terminal).
Check for continuity between the ©terminal and
the ©terminal using a circuit tester. Replace the
magnetic switch if there is no continuity.
67U05X-053
Wiring damage (©terminal — body)
Check for continuity between © terminal and
body using a circuit tester.
Replace the magnetic switch if there is no con-
tinuity.
67U05X-054
3. Ground of magnetic switch
Check for continuity between ©and ©terminals
using a circuit tester. Replace the magnetic switch
if there is continuity.
67U05X-055
5—50

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)
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

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
STARTER (DIESEL
ENGINE, 2.2
KW TYPE)
STARTING SYSTEM CIRCUIT
4BG05X-106
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—66

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-046
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly in the reverse order of disassembly.
4BG05X-107
1. Magnetic switch 7. Lever
2. Rear cover 8. Cover
3. Brush-holder assembly 9. Drive pinion and over-running
4. Yoke clutch assembly
5. Armature 10. Reduction gear
6. Front housing 11. Center bracket
5—67

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

5 STARTER (DIESEL ENGINE, 2.2 KW TYPE)
4BG05X-115
4BG05X-085
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
If the commutator surface is dirty, wipe it with a
cloth; if is is rough, repair it by using a lathe or fine
sandpaper.
Grind limit: 31 mm (1.22 in)
5. Segments 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
Check for continuity between the connector and
brushes by using a circuit tester. Replace the yoke
assembly if there is no continuity.
2. Ground of the field coil
Check for continuity between the connector and
yoke by using a circuit tester. 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.
4BG05X-086
5-72