Starter - Gear Reduction Mazda MPV V

DESCRIPTION

The gear reduction starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing. When starter is energized, starter solenoid causes the starter pinion to engage with the flywheel ring gear. The overrunning clutch pinion drive is mounted directly on the drive end of armature shaft. Gear reduction is by an armature mounted coaxial planetary gear set (except B2600i and MPV 6-cylinder). Gear reduction on B2600i and MPV 6-cylinder is by an offset gear, mounted in the starter housing, which drives the pinion.

Note. B2200 models equipped with manual transmissions use a direct drive type starter. See STARTERS - DIRECT DRIVE article in this section.

Voltage Supply Test

Ensure battery is fully charged. Turn ignition switch to "START" position and ensure starter operates. If starter does not operate, use a voltmeter to check the voltage between "S" terminal and ground. If voltage is less than 8 volts, wiring harness is faulty. If voltage is greater than 8 volts and starter is inoperative, there is an internal starter fault.

No-Load Test

With starter on bench, connect a fully-charged 12-volt battery to starter. Connect a voltmeter and ammeter to starter circuit. (Scheme 1) Check no load specification. See NO-LOAD TEST SPECIFICATIONS table. If not within specifications, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

Scheme 1

Note. Tests must be performed with starter assembled and field lead ("M") from starter disconnected at the solenoid.

Solenoid Pull-Out Test

Connect battery negative to solenoid case and battery positive to terminal "S". Starter pinion gear should move outward and maintain this position. If starter pinion gear does not move out, replace solenoid.

Solenoid Return Test

Disconnect starter motor wire from "M" terminal. Connect battery voltage to "M" terminal at solenoid and ground starter body. Using a screwdriver, pull overrunning clutch outward. Ensure overrunning clutch returns to original position when screwdriver is released.

Pinion Gap Adjustment

Disconnect solenoid-to-starter connection (terminal "M"). When battery is connected between terminal "S" and starter case, pinion will move outward and stop. Measure clearance (pinion gap) between pinion teeth and circlip retainer. DO NOT operate starter for more than 20 seconds. Pinion gap should be.020-.080" (0.5-2.0 mm). If pinion gap is not within specifications, adjust by increasing or decreasing the thickness of the shims located between the solenoid and drive housing. (Scheme 4)thru (Scheme 8).

Armature

1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, the armature is shorted and must be replaced. Check continuity between commutator and shaft. If continuity exists, replace armature.
3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

Commutator

1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.
2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. COMMUTATOR SPECIFICATIONS Application Maximum Runout Minimum Diameter B2200 (1.4kW, A/T) .004 (.10) 1.13 (28.8) B2600i .002 (.05) 1.08 (27.4) MPV V6 Engine (1.7 kW) .004 (.10) 1.13 (28.8) 4-Cylinder Engine Standard Starter (1.2 kW) .004 (.10) 1.08 (27.4) Heavy Duty (1.4 kW: A/T) .004 (.10) 1.24 (31.4) MX-6 & 626 .004 (.10) 1.13 (28.8) RX7 .004 (.10) 1.12 (28.4) 929 .004 (.10) 1.13 (28.8)
3. Commutator mica undercut depth should be .02-.03" (.5-.8 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut to standard depth.

Brushes & Springs

1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If test needle moves, brush holder assembly is shorted and must be replaced.
2. Check brush length. Brush should not be worn beyond limit line. If less than specification, replace brushes. See BRUSH WEAR SPECIFICATIONS table. Use a brush spring scale to check spring tension. Spring tension is measured at point where spring separates from brush. Tension should be greater than 1.5 lbs. (0.7 kg.). Tension specification for a new spring is 4.0-5.3 lbs. (1.8-2.4 kg.). Brushes must move freely in holders. (Scheme 4)thru (Scheme 8).

BRUSH WEAR SPECIFICATIONS

Field Coils

1. Connect one ohmmeter lead to field coil lead from starter solenoid. Connect other lead to soldered portion of brush lead. If there is no continuity, repair or replace field coil.
2. Check field coil for shorts to ground by connecting a test lead to field coil lead. Connect other lead to starter housing. If continuity exists, repair or replace field coil.

Overrunning Clutch

Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions, clutch is faulty and must be replaced. DO NOT wash overrunning clutch with solvent, it is packed with grease and sealed by manufacturer.

Solenoid

Check continuity between terminals "S" and "M". (Scheme 1) Check continuity between terminal "S" and solenoid body. There must be continuity between these terminals or solenoid must be replaced. Check continuity between terminals "M" and "B". If continuity exists between these terminals, solenoid is shorted and solenoid must be replaced.

REMOVAL & INSTALLATION

Disconnect negative battery terminal. Disconnect wiring from starter. Remove differential lock assembly (4WD models). Remove brace from intake manifold (MX-6 and 626 models). Remove 2 mounting bolts and remove starter from lower side of vehicle. To install starter, reverse removal procedure. Tighten mounting bolts to specifications.

Planetary Gear Type

1. Remove solenoid housing, plunger and spring from starter. Remove rear housing. Mark components for reassembly reference. Remove brush holder. Remove armature. Ensure ball (thrust) located on end of armature does not get misplaced.
2. Remove planetary gears from gear shaft. Remove front drive housing and yoke lever. Remove circlip, stopper and drive pinion from gear shaft. Remove overrunning clutch, thrust shim and internal gear plate from gear shaft.
3. To assemble, reverse removal procedures. Lubricate the following components during reassembly: Armature shaft gear teeth, internal and planetary gears, solenoid plunger, yoke lever and armature thrust ball, bushings.
4. Assemble the thrust shim, internal gear plate, and overrunning clutch on the gear shaft. Use a press to hold the overrunning clutch depressed on the gear shaft and install the stopper and circlip. Ensure brush holder and rear cover are aligned when installing through bolts.

Offset Gear Type

1. Remove rear cover. Remove through bolts and rear cover. Remove brush plate, armature and field coil. Remove solenoid from front cover housing. Remove center support plate and yoke from front cover housing.
2. Remove shaft retainer circlip and cover. Remove reduction gear assembly. To assemble, reverse removal procedures. Lubricate all bushing and thrust surfaces.

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS