Starter - Reduction Gear Mazda Navajo I

DESCRIPTION

The permanent magnet, gear reduction type starter has an externally mounted, solenoid actuated drive. The starting system consists of a starter, (ignition) switch, relay, neutral start switch (A/T) or clutch switch (M/T), battery and circuit wiring.

The hold-in coil keeps the drive pinion gear engaged with the flywheel until the ignition switch is released from the START position. An overrunning clutch in the drive assembly protects the starter from excessive speeds (engine RPM), after the engine starts and before the operator releases the ignition switch from the START position.

ON-VEHICLE TESTING

SYSTEM FUNCTION TEST

1. If engine cannot be started, turn heater blower motor on and turn off all other accessories. Use cables to jump-start vehicle.
2. If engine starts, check charging system. If engine does not start, clean and tighten connections at battery posts, starter relay, and battery ground at engine. Check for positive short to ground. If no faults are found, test solenoid, starter relay or service starter.

Scheme 1

1. Attach cables to jump-start vehicle (if necessary). Disconnect terminal "S" of starter relay. (Scheme 1) Connect remote starter switch between terminal "S" and positive battery terminal. Ensure transmission is in Park (A/T) models or Neutral (M/T) models.
2. Crank engine with remote starter. If engine cranks, relay is okay. Check ignition switch, neutral switch or clutch switch and circuitry for open or loose connections. If engine does not crank, replace relay.

SOLENOID TEST

1. If engine does not start, ensure battery is fully charged and in good condition. Ensure all cable connections are clean and tight. Attach cables to jump-start vehicle (if necessary).
2. Connect remote starter switch between starter solenoid terminals "B" and "M". (Scheme 1)and (Scheme 2). Ensure transmission is in Park (A/T) or Neutral (M/T) models. Crank engine with remote starter switch. If engine cranks, replace solenoid. If engine does not crank, replace starter.

LOAD TEST

1. Connect starter load tester and voltmeter to battery terminals. Ensure no current is flowing through ammeter and carbon pile of tester. Disconnect terminal "S" of starter relay.
2. Connect remote starter switch between terminal "S" and positive battery terminal. Ensure transmission is in Park (A/T) or Neutral (M/T) models prior to testing starter.
3. Crank engine with ignition off and note voltmeter reading. Stop cranking engine. Turn carbon pile tester rheostat knob to match voltage obtained while cranking. Note ammeter reading. Replace or repair starter if current exceeds specification. See STARTER SPECIFICATIONS table at end of article.

Scheme 2

1. Connect voltmeter to battery terminals. Connect battery, jumper cables and starter load tester to starter. (Scheme 2) Starter will operate without a load. Ensure no current is flowing through ammeter and carbon pile of tester.
2. Note voltmeter reading. Disconnect battery from starter. Turn carbon pile to achieve voltage obtained while starter was operating. Note ammeter reading. Replace or repair starter if current exceeds specification. See STARTER SPECIFICATIONS table at end of article.

ARMATURE OPEN CIRCUIT TEST

An open armature circuit can be detected by inspecting commutator for evidence of burning. If burning is present, replace armature assembly. Check for damage to other related components.

ARMATURE GROUNDED CIRCUIT TEST

Connect ohmmeter leads to armature and commutator. (Scheme 3) Ohmmeter should read infinity. If ohmmeter shows any other value, replace starter.

Scheme 3

Removal

Disconnect negative battery cable. Raise vehicle. Disconnect positive battery cable from starter and ground cable (if equipped). Remove starter solenoid wiring. Remove starter mounting bolts or nuts. Remove starter from vehicle.

Installation

1. Position starter assembly to flywheel housing and start bolts. Hold starter against mounting surface, fully inserted into pilot hole. Tighten bolts or nuts to specification.
2. Connect positive battery cable and solenoid wiring to starter. Tighten to specification. Lower vehicle. Connect negative battery cable. Check starter operation.

Scheme 4

1. Remove connector from "M" terminal. Remove solenoid retaining screws and solenoid. Remove starter housing through bolts, and separate housing from frame. (Scheme 4)
2. Remove drive assembly and drive lever. Remove stop ring and retainer from shaft assembly. Push "E" ring off shaft, and remove gear assembly from shaft. Remove brush end plate and brush assembly. Pull armature out of frame.

Inspection

Check armature winding for separated or burned insulation. Check for open or shorted circuits. Check armature shaft and bearings for scoring or excessive wear. Check commutator for excessive runout. Machine commutator if runout exceeds .005" (.12 mm).

Reassembly

1. Reverse disassembly procedure. Lubricate armature shaft and splines with low temperature grease. Fill drive end housing bearing bore about 1/4 full with grease.
2. Tighten through bolts to 55-75 INCH lbs. (6.2-8.5 N.m). Position solenoid so solenoid plunger is attached to drive lever. Perform NO-LOAD TEST to ensure current draw is within specification.

STARTER SPECIFICATIONS

STARTER SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS