Starting System: Diagnosis Mazda CX-5 I

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 2

1. Verify that the battery is fully charged.
2. Connect the starter, battery, and a tester as shown in the figure.
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 (Scheme 2): Measuring Starter Voltage And Current

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 3

1. Verify that the starter motor pinion is extended while battery positive voltage is connected to terminal S and the starter body is grounded. If the starter motor pinion is not extended, repair or replace the starter. (Scheme 3): Connecting Battery Positive Voltage To Terminal S

Scheme 4

1. Disconnect the motor wire from terminal M.
2. Connect battery positive voltage to terminal M and ground the 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 4): Connecting Battery Positive Voltage To Terminal M

Scheme 5

Scheme 6

1. Pull out the drive pinion with the battery positive voltage connected to terminal S and the starter body grounded. CAUTION: Applying power for more than 10 s can damage the starter. Do not apply power for more than 10 s. (Scheme 5): Connecting Battery Positive Voltage To Terminal S
2. Measure the pinion gap while the 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 6): Identifying Starter Pinion Gap

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Verify that there is no continuity between the commutator and the core at each segment using a tester. If there is continuity, replace the armature. (Scheme 7): Checking Continuity Between Commutator And Core At Each Segment Using Tester
2. Verify that there is no continuity between the commutator and the shaft using a tester. If there is continuity, replace the armature. (Scheme 8): Checking Continuity Between Commutator And Shaft Using Tester
3. Place the armature on V-blocks, and measure the runout using a dial indicator. If not within specification, replace the armature. Starter armature runout 0.1 mm {0.004 in} max. (Scheme 9): Measuring Starter Armature Runout Using Dial Indicator
4. Measure the 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} (Scheme 10): Measuring Starter Commutator Diameter
5. Measure the segment groove depth of the 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 11): Measuring Segment Groove Depth Of Commutator

Scheme 12

Scheme 13

Scheme 14

1. Inspect for continuity between terminals S and M using a tester. If there is no continuity, replace the magnetic switch. (Scheme 12): Checking Continuity Between Terminals S And M Using Tester
2. Inspect for continuity between terminal S and the body using a tester. If there is no continuity, replace the magnetic switch. (Scheme 13): Checking Continuity Between Terminal S And Body Using Tester
3. Verify that there is no continuity between terminals M and B using a tester. If there is continuity, replace the magnetic switch. (Scheme 14): Checking Continuity Between Terminals M And B Using Tester

Scheme 15

Scheme 16

Scheme 17

1. Verify that there is no continuity between each insulated brush and plate using a tester. If there is continuity, replace the brush holder. (Scheme 15): Checking Continuity Between Insulated Brush And Plate Using Tester
2. Measure the 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} (Scheme 16): Identifying Standard And Minimum Brush Length
3. Measure the brush spring force using a 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 17): Measuring Brush Spring Force Using Spring Balance

Scheme 18

1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly. (Scheme 18): Disassembled View Of Starter With Torque Specifications

STARTER INTERLOCK SWITCH INSPECTION [SKYACTIV-G 2.0]

Scheme 19

Scheme 20

1. Disconnect the negative battery cable. (See «NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 2.0]»(ref-615412-S04991947062014051000000) ).
2. Disconnect the starter interlock switch connector.
3. Verify that the continuity is as indicated in the table using a tester. (Scheme 19): Identifying Starter Interlock Switch Connector If the continuity is not as indicated in the table, replace the starter interlock switch. (See «CLUTCH PEDAL REMOVAL/INSTALLATION [C66M-R]»(ref-615414-S18664173562014051000000) ). (Scheme 20): Identifying Starter Interlock Switch Connector Terminal Continuity