Starting System [Skyactiv-G 2.0]: Diagnosis Mazda 3 BM

On-vehicle Inspection

1. Verify that the battery is fully charged.
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked. If the starter does not operate, inspect the following: Remove the starter, and inspect the starter unit. Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch (ATX) or starter interlock switch (MTX).

Scheme 24

1. Verify that the battery is fully charged.
2. Connect the starter, battery, and a tester as shown in the figure. (Scheme 24): Starter, Battery And Tester Setup
3. Operate the starter and verify that it rotates smoothly. If the starter does not rotate smoothly, inspect the starter unit.
4. Measure the voltage and current while the starter is operating. If not within specification, replace the starter. Starter no-load test voltage 11 V Starter no-load test current 95 A or less

Pull-out test

Note. Depending on the battery charge condition, the starter motor pinion may rotate while in an extended state. This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does not indicate an abnormality.

Scheme 25

1. Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S and the starter body is grounded. (Scheme 25): Checking Starter Motor Pinion While Applying Battery Voltage To Terminal S And Grounding Starter Body If the starter motor pinion is not extended, repair or replace the starter.

Scheme 26

1. Disconnect the motor wire from terminal M.
2. Connect battery positive voltage to terminal M and ground the starter body. (Scheme 26): Connecting Battery Voltage To Terminal M And Grounding Starter Body
3. Pull out the drive pinion with a screwdriver. Verify that it returns to its original position when released. If it does not return, repair or replace the starter.

Scheme 27

Scheme 28

1. Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded. (Scheme 27): Connecting Battery Voltage To Terminal S And Grounding Starter Body CAUTION: Applying power for more than 10 s can damage the starter. Do not apply power for more than 10 s.
2. Measure the pinion gap while the drive pinion is extended. (Scheme 28): Measuring Pinion Gap While Drive Pinion Is Extended If not as specified, adjust with an adjustment washer (between drive housing front cover and magnetic switch). Starter pinion gap 0.5-2.0 mm {0.02-0.07 in}

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

1. Verify that there is no continuity between the commutator and the core at each segment using a tester. (Scheme 29): Checking Continuity Between Commutator And Core At Each Segment If there is continuity, replace the armature.
2. Verify that there is no continuity between the commutator and the shaft using a tester. (Scheme 30): Checking Continuity Between Commutator And Shaft If there is continuity, replace the armature.
3. Place the armature on V-blocks, and measure the runout using a dial indicator. (Scheme 31): Measuring Runout Using Dial Indicator If not within specification, replace the armature. Starter armature runout 0.1 mm {0.004 in} max.
4. Measure the commutator diameter. (Scheme 32): Measuring Commutator Diameter If not within the minimum specification, replace the armature. Starter commutator diameter Standard: 29.4 mm {1.16 in} Minimum: 28.8 mm {1.13 in}
5. Measure the segment groove depth of the commutator. (Scheme 33): Measuring Segment Groove Depth Of Commutator If not within the minimum specification, undercut the grooves to the standard depth. Segment groove depth of starter commutator Standard: 0.5 mm {0.02 in} Minimum: 0.2 mm {0.008 in}

Scheme 34

Scheme 35

Scheme 36

1. Inspect for continuity between terminals S and M using a tester. (Scheme 34): Inspecting For Continuity Between Terminals S And M If there is no continuity, replace the magnetic switch.
2. Inspect for continuity between terminal S and the body using a tester. (Scheme 35): Inspecting For Continuity Between Terminal S And Body If there is no continuity, replace the magnetic switch.
3. Verify that there is no continuity between terminals M and B using a tester. (Scheme 36): Checking Continuity Between Terminals M And B If there is continuity, replace the magnetic switch.

Scheme 37

Scheme 38

Scheme 39

1. Verify that there is no continuity between each insulated brush and plate using a tester. (Scheme 37): Checking Continuity Between Each Insulated Brush And Plate If there is continuity, replace the brush holder.
2. Measure the brush length. (Scheme 38): Measuring Brush Length If any brush is worn almost to or beyond the minimum specification, replace all of the brushes. Starter brush length Standard: 12.3 mm {0.484 in} Minimum: 5.5 mm {0.22 in}
3. Measure the brush spring force using a spring balance. (Scheme 39): Measuring Brush Spring Force Using Spring Balance If not within the minimum specification, replace the brush and brush holder component. Starter brush spring force Standard: 15.1-20.4 N {1.54-2.08 kgf, 3.40-4.58 lbf} Minimum: 2.75 N {0.280 kgf, 0.618 lbf}

Scheme 40

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly. (Scheme 40): Exploded View Of Starter With Torque Specifications

STARTER INTERLOCK SWITCH INSPECTION [SKYACTIV-G 2.0]

Scheme 41

1. Remove the battery cover. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000).)
2. Disconnect the negative battery cable. (See «BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0]»(ref-579332-S32330103212013100700000).)
3. Disconnect the starter interlock switch connector.
4. Verify that the continuity is as indicated in the table using a tester. (Scheme 41): Starter Interlock Switch Terminal Continuity Chart If the continuity is not as indicated in the table, replace the starter interlock switch. (See «CLUTCH PEDAL REMOVAL/INSTALLATION [C66M-R]»(ref-579427-S34953235562013100700000).)