1987 MAZDA 626 Workshop Manual

ALTERNATOR 5
10. Replace the brushes
Remove the solder from the pigtail, and then re-
move the brush.
86U05X-088
Wear limit line
JL
mark
2-3 mm 7 T > (0.079 ~ 0.118 in) Brush holder
end line
11. When soldering the brush, solder the pigtail so that
the wear limit line of the brush projects 2—3 mm
(0.079—0.118 in) out from the end of the brush
holder.
86U05X-089
5—31

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

ALTERNATOR 5
T Minimum
_L
Standard
A
-Wear limit line
76G05X-034
86U05X-090
Brush

If
the brushes are worn almost to or beyond the limit,
replace them.
Standard: 16.5 mm (0.650 in)
21.5 mm (0.846 in)—RF-CX
Minimum: 8 mm (0.315 in)
Brush Spring
1. Measure the force of the brush spring using a
spring pressure gauge.
2. Replace the spring if necessary.
Standard force: 3.0—4.2 N
(310—430 g, 10.9—15.2 oz)
Minimum: 1.7—2.5 N
(170—250 g, 6.0—8.8 oz)
Note
Read the spring pressure gauge at the brush
tip projection of 2 mm (0.079 in).
Bearing
1. Check for abnormal noise, looseness, or insufficient
lubrication.
2. Replace the bearing(s)
if
there is any abnormality.
86U05X-023
5-33

5 ALTERNATOR
p,
—**—' — w—
> .J
—*—
n -B
L
Rectifier
1. Check for continuity of the diodes using an
ohmmeter.
Negative (Black) Positive (Red) Continuity
E Yes
B Pi, P2, Pa No
L No
E No
Pi, P2, Pa B Yes
L Yes
86U05X-024
2. Replace the rectifier.
86U05X-025
5—34

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