1987 MAZDA 626 oil

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

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)
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
5-61