1987 MAZDA 626 Workshop Manual

STARTER (DIESEL ENGINE, 2.0 KW TYPE) 5
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: 17 mm (0.669 in)
Wear limit: 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
5-63

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
Suitable _
steel plate
Armature
4BG05X-104
4BG05X-092
4BG05X-093
Bearing
Check for abnormal noise, looseness, insufficient
lubrication, etc. Replace the bearing if there is any
abnormality.
Take out the bearing, as shown in the figure, by us-
ing the suitable tools.
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.
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.
4BG05X-094
5—64

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
(S) terminal Switch (K)
(B) terminal
Amp. meter
Voltmeter
4BG05X-105
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.
If
the voltmeter
and ammeter show the following values while the
starter is running, it is normal.
Battery voltage: 11.5 volts
Current: 120 amperes or less
Gear shaft speed: at 4,000 or more
3. If any abnormality is noted, check it according to
"INSPECTION"
5—65

5 STARTER (DIESEL ENGINE, 2.0 KW TYPE)
STARTER (DIESEL
ENGINE, 2.2
KW TYPE)
STARTING SYSTEM CIRCUIT
4BG05X-106
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—66

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-046
DISASSEMBLY AND ASSEMBLY
1. Disassemble in the numbered order shown in the figure.
2. Assembly in the reverse order of disassembly.
4BG05X-107
1. Magnetic switch 7. Lever
2. Rear cover 8. Cover
3. Brush-holder assembly 9. Drive pinion and over-running
4. Yoke clutch assembly
5. Armature 10. Reduction gear
6. Front housing 11. Center bracket
5—67

5 STARTER (DIESEL ENGINE, 2.2 KW TYPE)
Disassembly
1. Remove the magnetic switch.
4BG05X-108
2. Remove the rear housing.
4EG05X-069
3. Using radio pliers or a similar tool, raise the posi-
tive (+) side brush spring, and remove the brush.
36G05X-032
4. Remove the brush holder assembly and the ar-
mature.
36G05X-033
5—68

STARTER (DIESEL ENGINE, 2.2 KW TYPE) 5
36G05X-034
36G05X-035
36G05X-036
5. Remove the front cover, and remove the lever and
springs (two).
6. Separate the yoke and center bracket.
7. Remove the cover and pull out the snap ring and
washer.
8. Remove the pinion, over-running clutch assembly
and reduction gear from the center bracket.
36G05X-037
5-69

5 STARTER (DIESEL ENGINE, 2.2 KW TYPE)
Reduction gear
Adjusting washer
-Pinion shaft
-Thrust gap
-Snap ring
-Washer
Washer bracket
4BG05X-109
4BG05X-110
4BG05X-111
Assembly (main point)
Pinion shaft play
1. Measure the thrust gap by moving the pinion shaft
axial direction.
Standard play: Less than 0.5 mm (0.02 in)
2. Adjust the play with the adjusting washer.
Lever installation
Install the lever as shown in figure.
Rear bracket installation
Align the matching marks when assembling the rear
bracket.
Greasing
When disassembling or assembling the starter,
grease each sliding part, gear and bearing.
(1) Armature shaft gear
(2) Reduction gear
(3) Ball bearings (both ends of armature)
(4) Bearing box of rear bracket
(5) Snap ring of pinion shaft
(6) Sleeve bearing, pinion lever sliding part, others
4BG05X-112
5—70