Starter - Gear Reduction Mazda Protege BG

DESCRIPTION

The Nippondenso gear reduction starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing. The overrunning clutch pinion drive is mounted directly on the drive end of armature shaft (except on B2600i and MPV 6-cylinder).

Gear reduction is performed by an armature mounted coaxial planetary gear set (except on B2600i and MPV 6-cylinder). Gear reduction on B2600i and MPV 6-cylinder is performed by an offset gear and shaft assembly which drives the overrunning clutch pinion drive.

Note. For information on B2200, Miata, Protege and 323 models with manual transmissions, see STARTERS - DIRECT DRIVE article.

Scheme 7

CIRCUIT TEST

1. Ensure battery is fully charged. Turn ignition switch to START position. Starter should operate. If starter does not operate, use voltmeter to check voltage between starter solenoid "S" terminal and ground. (Scheme 8)
2. If voltage is less than 8 volts, check ignition switch, relays and/or wiring circuit for fault. See appropriate chassis wiring in WIRING DIAGRAMS. If voltage is greater than 8 volts and starter is inoperative, there is an internal starter fault. Remove starter and proceed to BENCH TESTING in this article.

Scheme 8

INHIBITOR SWITCH (A/T)

RX7 (Without Theft Deterrent Control)

1) Switch harness connector is located near starter. Ensure transmission gear selector is in Park position and ignition switch is in START position. Using test light, backprobe Black/Yellow wire terminal at inhibitor switch harness connector.

2) If test light does not illuminate, check fuse No. 8 of fuse block and/or repair open in Black/Yellow wiring circuit between inhibitor switch and fuse block fuse No. 8. At fuse No. 8 Black/Yellow wire color changes to Black/Red to continue wiring circuit to ignition switch.

3) If test light does illuminate, backprobe Black/Red wire terminal at inhibitor switch harness connector. If test light does not illuminate now, adjust or replace switch.

Except RX7 (Without Theft Deterrent Control)

1) Switch is located on transmission manual shift shaft. Disconnect starter solenoid wire at "S" terminal. Ensure transmission gear selector is in Park position and ignition switch is in START position. Using test light, backprobe Black/Yellow wire (Green wire on MPV) terminal at inhibitor switch harness connector.

2) If test light does not illuminate, repair open in Black/Yellow wiring (Green wiring on MPV) circuit between ignition switch and inhibitor switch harness connector. If test light does illuminate, backprobe Black/Red wire terminal at inhibitor switch harness connector. If test light does not illuminate now, adjust or replace switch.

STARTER CUT RELAY

Models With Theft Deterrent Control

See appropriate chassis wiring diagram in WIRING DIAGRAMS.

STARTER INTERLOCK SWITCH (CLUTCH START SWITCH)

Switch is mounted on bracket near top front of clutch pedal. Disconnect switch harness connector. Using ohmmeter, ensure continuity exists between switch connector terminals when clutch pedal is depressed. If continuity does not exist, adjust or replace switch.

NO-LOAD TEST

Connect a fully-charged 12-volt battery to starter. Connect voltmeter and ammeter to starter circuit. (Scheme 8) Using remote starter or jumper, engage starter. Starter should spin smoothly. Note meter readings and check no load specification. See NO-LOAD TEST SPECIFICATIONS table. If not within specifications, disassemble and inspect starter components.

NO-LOAD TEST SPECIFICATIONS

SOLENOID TESTS

Note. Solenoid tests must be performed with starter assembled and field wire from starter disconnected at solenoid terminal "M".

Solenoid Pull-In Test

Connect positive battery lead to solenoid "S" terminal and negative battery lead to solenoid case. Starter pinion drive gear should extend quickly and maintain this position. If starter pinion drive gear does not extend, replace solenoid. (Scheme 8)

Solenoid Return Test

Connect positive battery lead to solenoid "M" terminal and ground negative battery lead to starter body. Using screwdriver, pry overrunning clutch pinion drive outward. Release screwdriver and ensure overrunning clutch pinion drive returns to original position. (Scheme 8)

Solenoid

1. Disconnect all wires to solenoid. Using ohmmeter, ensure continuity between "S" and "M" terminals, and between "S" terminal and solenoid body. (Scheme 7) If continuity does not exist between these terminals, solenoid must be replaced.
2. Ensure continuity does not exist between "M" and "B" terminals. If continuity exists between these terminals, solenoid is shorted and must be replaced.

Scheme 9

1. Ensure field wire is disconnected from solenoid "M" terminal. Connect positive battery lead to "S" terminal and negative battery lead to starter case. Starter pinion drive gear will extend outward and stop.
2. Quickly measure pinion gap clearance between end of pinion drive and circlip retainer. (Scheme 9) DO NOT operate starter solenoid for more than 10 seconds. Pinion gap clearance should be.02-.08" (0.5-2.0 mm).
3. If pinion gap clearance is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing. (Scheme 9)

ARMATURE TESTING

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 TESTING

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. See COMMUTATOR SPECIFICATIONS table. COMMUTATOR SPECIFICATIONS Application Maximum Runout In. (mm) Minimum Diameter In. (mm) B2200 (A/T), MX-3 V6, MX-6, Protege (A/T), RX7, 626 & 929 .004 (.10) 1.13 (28.8) B2600i (M/T) .002 (.05) 1.08 (27.4) B2600i (A/T) .002 (.05) 1.24 (31.4) MPV 4-Cylinder Engine Standard (M/T & A/T) .004 (.10) 1.08 (27.4) Heavy Duty (A/T) .004 (.10) 1.24 (31.4) V6 Engine .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.

BRUSH TESTS

1. Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, brush holder assembly is shorted and must be replaced.
2. Check brush length. See BRUSH LENGTH SPECIFICATIONS table. If less than specification, replace brushes. Use 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.

BRUSH LENGTH SPECIFICATIONS

FIELD COIL TESTING

1. Connect one ohmmeter lead to field coil lead ("M" terminal lead). Connect other lead to soldered portion of brush lead. If continuity does not exist, repair or replace field coil.
2. Check field coil for shorts to ground by connecting ohmmeter lead to field coil lead. Connect other lead to field coil housing. If continuity exists, repair or replace field coil.

OVERRUNNING CLUTCH PINION DRIVE

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 clean overrunning clutch with solvent, as it is packed with grease and sealed by manufacturer.

MPV 4WD

1. Disconnect negative battery cable. Remove alternator and power steering (P/S) belts. Remove P/S pulley. Remove alternator harness connector and battery cable. Remove alternator. Remove 2 engine undercovers. DO NOT disconnect P/S pump hoses, but remove P/S pump from brackets to enable removal of A/T oil cooler line brackets behind pump. Remove front driveshaft.
2. Remove wiring harness bracket bolts, heat shield and A/T oil cooler line bracket bolt from rear of engine, near starter. Disconnect starter wires. Remove fuel and brake line cover on frame rail. Remove starter. Remove lower starter mounting bolt last. To install, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS table at end of this article.

Except MPV 4WD

1. Disconnect negative battery cable. Raise vehicle on hoist. Remove undercover. Disconnect wiring from starter. Remove differential lock assembly on 4WD models. On MX-6, Protege (A/T), and 626 models, remove support brace from under intake manifold. Remove starter mounting bolts. Remove lowest mounting bolt last. Remove starter from under side of vehicle.
2. To install starter, reverse removal procedure. Tighten mounting bolts to specification. See TORQUE SPECIFICATIONS table at end of this article.

Coaxial Planetary Gear Type

1. Remove solenoid housing, plunger and spring from starter. (Scheme 11) Remove rear cover. Mark components for reassembly reference. Remove brush plate. Remove armature. Ensure thrust ball located inside gear shaft or on end of armature DOES NOT get misplaced.
2. Remove planetary gears from gear shaft. Remove front drive housing and yoke lever. Use arbor press to remove circlip, stopper and drive pinion from gear shaft. (Scheme 10) Remove overrunning clutch, thrust shim and internal gear plate from gear shaft.
3. To assemble, reverse disassembly procedures. Lubricate following components during reassembly: armature shaft gear teeth, internal and planetary gears, solenoid plunger, yoke lever and armature thrust ball, and bushings.
4. Assemble internal gear plate, thrust shim and overrunning clutch on the gear shaft. Use arbor press and overrunning clutch to install stopper and circlip on armature shaft. (Scheme 10) Ensure brush plate, rear cover and internal gear plate are aligned when installing through bolts.

Scheme 10

Offset Gear Type

1. Remove through bolts and rear cover. (Scheme 12) Remove brush plate, armature and field coil housing. Remove solenoid and shims from front housing. Remove center support plate and yoke lever from front housing.
2. Remove pinion drive circlip cover and retainer circlip. Remove pinion drive/reduction gear assembly. To assemble, reverse removal procedures. Lubricate all bushing and thrust surfaces.

Scheme 11

Scheme 12

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS