MAZDA 626 1987 Workshop Manual

ALTERNATOR 5
Stopper spring
Rear bearing
86U05X-026
86U05X-027
86U05X-028
.
',
; i
(S) -^jJSTjT^/
ASSEMBLY
Assemble in the reverse order of disassembly, refer-
ring to assembly note.
Assembly Note
Stopper spring installation
1. Fit the stopper spring into the eccentric groove of
the rear bearing circumference.
2. Check that the protruding part of the spring is fitted
into the deepest part of the groove.
Front bracket and rotor
When assembling the front bracket and rotor, tight-
en the locknut to the specified torque.
Tightening torque:
49—88 N-m (5—9 m-kg, 36—65 ft-lb)
Brush lifting
1. Before assembly, use a finger to hold the brushes
into the brush holder; then pass a wire
(2
mm,
40—50 mm, 00.08 in, 1.6—2.0 in) through the
hole shown in the figure.
2. Secure the brushes in position.
Note
Be sure to remove wire after assembly is com-
pleted.
Rear bearing installation
1. Heat the rear bracket.
2. Press the rear bearing into the rear bracket.
3. Check that the rotor turns easily.
4BG05X-054
5-35

5 ALTERNATOR
INSTALLATION
Note
When installing the alternator, tighten the
bolts to the specified torque.
Install in the reverse order of removal.
Tightening torque:
Bolt (1) 37.3—52 N-m
(3.8—5.3 m-kg, 27.5—38.3 ft-lb)
Bolt (2) 18.6—25.5 Nm
(1.9—2.6 m-kg, 13.7—18.8 ft-lb)
69G05X-018
Nut 37—52 N-m
(3.8—5.3 m-kg, 27.5—38.3 ft-lb)
76G05X-036
5—36

ALTERNATOR 5
Adjusting bar bolt
Mounting bolt
Alternator
drive pulley
Mounting bolt
Drive pulley
76G05X-037
-Adjusting bolt
tidier pulley
v v Ml/v — Locknut
/
Alternator x
V-BELT TENSION (GASOLINE)
Adjustment
1. Loosen the alternator mounting bolt and adjusting
bar bolt.
2. Adjust the alternator belt deflection while pushing
the V-belt with a force of 98 N (10 kg, 22 ft-lb).
Deflection:
New: 6—8 mm (0.24—0.31 in)
Used: 7—9 mm (0.27—0.35 in)
3. Tighten the bolts and recheck the tension.
V-BELT TENSION (DIESEL)
Adjustment
1. Looson the alternator idler pulley locknut.
2. Adjust the alternator belt deflection while pushing
the V-belt with a force of 98 N (10 kg, 22 ft-lb).
Deflection:
Alternator
New: 8—10 mm (0.31—0.39 in)
Used: 9—11 mm (0.35—0.43 in)
76G05X-038
—" , ^Comprex pulley
/ Locknut
/ ^"Wvl If Adjusting bolt^
Idler pulley
Alternator pulley—-V-
(rear) >
Comprex
New: 4.0—5.0 mm (0.16—0.20 in)
Used: 4.5—5.5 mm (0.18—0.21 in)
3. Tighten the bolts and nuts and recheck the tension.
76G05X-058
5—37

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

STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE) 5
4BG05X-090
4BG05X-091
4BG05X-092
Drive Pinion and Housing
1. Pinion gear
(1) Check for wear or damage of the pinion gear.
(2) Replace if necessary.
(3) If the pinion gear is seriously damaged, also
check the flywheel ring gear.
2. Bushing
(1) Check for wear or damage.
(2) Replace if necessary.
3. Switch coil
(1) Check for continuity between the M terminal
and the body by using a circuit tester.
(2) Replace the switch if there is no continuity.
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.
4BG05X-093
5-43

5 STARTER (GASOLINE ENGINE, 0.85, 0.95 KW TYPE)
(TM (TM /AgLjM) terminal
xtsfif
4BG05X-094
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.
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.
3. If the voltmeter and ammeter show the following
values while the starter is running, it is normal.
0.85 kW
type
0.95 kW
type
Battery voltage (volt) 11.5
Current
(ampere) 60 or less
Gear shaft speed (rpm) 6,500 or more
6,600
or more
4. If any abnormality is noted, check it according to
"INSPECTION"
5—44