1987 MAZDA 626 engine

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

5 STARTER (GASOLINE ENGINE, 1.4 KW TYPE)
Brush and Brush Holder
1. Insulation of brush holder
Check for continuity between the insulated brush
and the plate using a circuit tester. Replace the
brush holder if there is continuity.
67U05X-060
\E
Wear limit line
—r
10.0 mm
(0.39 in)
L 17.5 mm (0.69 in)
2. Brush
Replace the brushes if they are worn beyond the
wear limit, or if the wear is near the limit.
Wear limit: 10.0 mm (0.394 in)
New brush: 17.5 mm (0.689 in)
7BU05X-043
Brush holder
Check that the brush slides smoothly inside the
brush holder.
67U05X-062
4. Brush spring
(1) Measure the force of the brush spring using
a spring balance.
(2) Replace the brush spring if the force is below
specification.
Specification: 7 N (0.7 kg, 1.5 lb)
Note
a) The force is measured at the moment the
brush spring separates from the brush.
b)The force must be 18—24 N (1.8—2.4 kg,
4.0—5.3 lb) for a new brush spring.
86U05X-036
5-52

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.
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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

STARTER (GASOLINE ENGINE, 1.4 KW TYPE) 5
Ammeter £
Battery 12V
Switch K sf
Voltmeter W Starter
86U05X-040
No-Load Test
1. After adjusting the pinion gap, form a test circuit
with a voltmeter and an ammeter.
Note
Use heavy gauge wires and tighten each ter-
minal fully.
2. Close switch K to run the starter.
3. Check for the following:
Voltage (V) 11.0
Current (A) 90 max.
Gear shaft speed (rpm) 3,000 min.
4. If any abnormality is noted, check for the cause
according to "Inspection".
INSTALLATION
Install in the reverse order of removal.
Note
When installing the starter, tighten the bolts
to the specified torque.
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)
76G05X-043
5—55

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)
Disassembly
1. Remove the lead wire connected to the magnetic
switch.
4BG05X-098
2. Remove the two through-bolts.
4EG05X-041
3. Remove the yoke from the magnetic switch.
4EG05X-042
f /"Spring
Brush holder f 0rf# )
N
Itfc
Sr IP Brush
4. Using radio pliers or a similar tool, raise the + side
brush spring and remove the brush.
Caution
Be careful not to scratch the brush or com-
mutator.
4EG05X-043
5—58