1987 MAZDA 626 check oil

5 ALTERNATOR
3. Alternator warning light operates properly, but battery discharged
OK
NG OK
1
a) Poor connection between B terminal and positive battery cable
b) Poor connection of negative battery cable c) Poor connection between alternator connector (2-pin) and positive battery terminal d) Stator coil or diodes malfunction (Refer to page 5—32 or 5—34.)
Perform TEST 2. (Refer to page 5--25.)
NG
Perform TEST 3. (Refer to Dage 5--26.)
I OK
Perfrom TEST 4. (Refer to page 5--26.)
NG
Perform TEST 5 (F Refer to page 5—26)
OK
Alternator normal.
Check other electrical components.
NG
Alternator normal.
Check other electrical components.
Perform TEST 5. (Refer to page 5—26.)
OK
Stator coil, diode, main fuse, or wiring har-ness between B ternimal and battery mal-function.
(Refer to page 5—32 or 5—34.)
IC regulator, bush, or rotor coil malfunction. (Refer to page 5—32 or 5—33)
NG
76G05X-027
4. Battery overcharged
Less than 14.1V
(At 20°C, 68°F)
More than 14.7V
(At 20oC,68°F)
IC regulator malfunction,
Perform TES T 6. (Refer to page 5—27.)
NG OK
Wiring harness malfunction.
76G05X-028
5—24

5 ALTERNATOR
86U05X-078
86U05X-080
86U05X-081
INSPECTION
Rotor
1. Wiring damage
(1) Check the resistance between the slip rings us-
ing an ohmmeter.
Specification: 2—6 U
(2) If it is not within specification, replace the rotor
2. Ground of the field coil
(1) Check for continuity between the slip ring and
the core using an ohmmeter.
(2) Replace the rotor if there is continuity.
3. Slip ring surface
If the slip ring surface is rough, use a lathe or fine
sandpaper to repair it.
Stator
1. Wiring damage
(1) Check for continuity between the stator coil
leads using an ohmmeter.
(2) Replace the stator if there is no continuity.
2. Ground of the stator coil
(1) Check for continuity between the stator coil
leads and the core using a circuit tester.
(2) Replace the stator if there is continuity.
86U05X-082
5—32

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

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

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
INSPECTION
Armature
1. Ground of armature coil
Check for continuity between the commutator and
the core using a circuit tester. Replace the arma-
ture if there is continuity.
67U05X-048
2. Insulation of armature coil
Check for continuity between the commutator and
the shaft using a circuit tester. Replace the arma-
ture if there is continuity.
67U05X-049
Runout of commutator
(1) Place the armature on V blocks, and measure
the runout using a dial gauge.
(2)
If
the runout is excessive, replace the armature.
Runout: 0.05 mm (0.002 in)
Maximum: 0.1 mm (0.004 in)
7BU05X-039
Outer diameter of commutator
Replace the armature if the outer diameter of the
commutator is less than the grind limit.
Roughness of commutator surface
Repair using a lathe or fine sandpaper if it is rough;
wipe it with a rag if it is dirty.
Grind limit: 28.8 mm (1.13 in)
7BU05X-040
5-49