AutoZone 1986 Mazda 323 1.6L MFI SOHC 4cyl | Repair Guides | Engine Electrical | Starting System | Starter | AutoZone.com

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    1986 Mazda 323 1.6L MFI SOHC 4cyl

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    Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

    Starter

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    Removal & Installation



    2.0L Engine
    Automatic Transaxle
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    4.  
    5. Remove or disconnect the following:

      Air cleaner resonator
       
      Transmission Control Module (TCM) mounting screws.
       

    6.  
    7. Move TCM to provide access to top starter mounting bolt.
      NOTE
      Do not disconnect TCM wiring.

    8.  
    9. Remove top bolt attaching starter to transmission housing.
    10.  
    11. Raise vehicle.
    12.  
    13. Remove battery positive cable nut from starter and remove cable.
    14.  
    15. Disconnect push on solenoid connector. Unlock the red locking tab and compress lock to release the connector.
    16.  
    17. Remove the bottom bolt attaching starter to transmission housing
    18.  
    19. Remove starter from vehicle

      Click image to see an enlarged view

      Fig. View of the starter motor-2.0L (DOHC) engine and 2.5L (SOHC) engine



      Click image to see an enlarged view

      Fig. Location of starter motor-2.0L engine

    20.  

    To install:

    1. With vehicle is raised, set starter face into transmission housing.
    2.  
    3. Lower vehicle.
    4.  
    5. Install top starter mounting bolt but do not tighten.
    6.  
    7. Raise vehicle.
    8.  
    9. Install bottom starter mounting bolt and torque to 40 ft. lbs. (54 Nm)
    10.  
    11. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid.
    12.  
    13. Connect battery positive cable to solenoid post
    14.  
    15. Connect the push-on solenoid connector.
    16.  
    17. Lower vehicle.
    18.  

    Install:



    Top starter bolt and torque to 40 ft. lbs. (54 Nm)
     
    TCM and the mounting screws.
     
    Air cleaner resonator.
     

    1. Connect battery remote cable to the remote terminal.
    2.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:
      NOTE
      Do not disconnect the TCM electrical connector(s).



      Negative battery cable from the shock tower
       
      Air cleaner resonator
       
      Transmission Control Module (TCM) and move it aside
       



      Upper starter-to-transaxle bolt
       
      Battery cable from the starter
       
      Solenoid connector by unlocking the red tab and compressing it
       
      Lower starter-to-transaxle bolt
       
      Starter
       

    4.  

    To install:

    1. Install or connect the following:

      Starter
       
      Lower starter-to-transaxle bolt and torque the bolt to 40 ft. lbs. (54 Nm)
       
      Electrical connectors to the starter
       
      Upper starter-to-transaxle bolt and torque the bolt to 40 ft. lbs. (54 Nm)
       
      TCM
       
      Air cleaner resonator
       
      Negative battery cable to the shock tower

      Click image to see an enlarged view

      Fig. Exploded view of the starter and related components-2.0L engine with an automatic transaxle

       

    2.  

    Manual Transaxle
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    4.  
    5. Remove or disconnect the following:

      Air cleaner resonator.
       
      Battery positive cable nut from starter.
       
      Battery positive cable and generator output wire from starter.
       

    6.  
    7. Disconnect push-on solenoid connector. Unlock the red locking tab and compress lock to release the connector.
    8.  
    9. Remove two bolts attaching starter to transmission housing and remove starter from vehicle.

      Click image to see an enlarged view

      Fig. View of the starter motor-2.0L (DOHC) engine and 2.5L (SOHC) engine

    10.  

    To install:

    Installation is reverse of removal. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid.

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable from the shock tower
       
      Air cleaner resonator
       
      Electrical connectors from the starter
       
      Starter-to-transaxle bolts
       
      Starter

      Click image to see an enlarged view

      Fig. Exploded view of the starter and related components-2.0L engine with manual transaxle

       

    4.  

    To install:

    1. Install or connect the following:

      Starter and torque the bolts to 40 ft. lbs. (54 Nm)
       
      Electrical connectors to the starter
       
      Air cleaner resonator
       
      Negative battery cable to the shock tower
       

    2.  

    2.5L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    4.  
    5. Raise vehicle.
    6.  
    7. Remove or disconnect the following:

      Oil filter.
       
      Battery positive cable nut from starter and remove cable.
       
      Push-on solenoid connector.
       

    8.  
    9. Remove three bolts attaching starter to transmission housing and remove starter from vehicle.

      Click image to see an enlarged view

      Fig. Exploded view of the front exhaust pipe and related components-2.5L engine



      Click image to see an enlarged view

      Fig. View of the starter motor-2.0L (DOHC) engine and 2.5L (SOHC) engine



      Click image to see an enlarged view

      Fig. Location of starter motor-2.5L engine

    10.  

    To install:

    Installation is the reverse of removal. Clean corrosion/dirt from wire terminals before installing wiring to the solenoid.

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable from the shock tower
       
      Oil filter
       
      Electrical connectors from the starter
       
      Starter-to-transaxle bolts
       
      Starter

      Click image to see an enlarged view

      Fig. Exploded view of the starter and related components-2.5L engine

       

    4.  

    To install:

    1. Install or connect the following:

      Starter and torque the bolt to 40 ft. lbs. (54 Nm)
       
      Electrical connectors to the starter
       
      Oil filter
       
      Negative battery cable
       

    2.  

    2.7L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Oxygen Sensor (O 2 S) electrical connector
       
      Front engine mount through bolt
       
      Starter electrical connectors
       
      Starter
       

    4.  

    To install:

    1. Install or connect the following:

      Starter and hand tighten the lower bolt
       
      Starter electrical connectors and torque the starter bolts to 40 ft. lbs. (54 Nm)
       
      Engine mount through bolt and torque it to 45 ft. lbs. (61 Nm)
       
      O 2 sensor and torque it to 20 ft. lbs. (27 Nm)
       
      Negative battery cable
       

    2.  

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      The negative battery cable
       
      The Oxygen Sensor (O 2 S) electrical connector
       
      The front engine mount through bolt
       
      The starter electrical connectors
       
      The starter
       

    4.  

    To install:

    1. Install or connect the following:

      The starter and hand tighten the lower bolt
       
      The starter electrical connectors and torque the starter bolts to 40 ft. lbs. (54 Nm)
       
      The engine mount through bolt and torque it to 45 ft. lbs. (61 Nm)
       
      The O 2 sensor and torque it to 20 ft. lbs. (27 Nm)
       
      The negative battery cable
       

    2.  

    3.0L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
    4.  
    5. Remove or disconnect the following:

      Air cleaner resonator
       
      Starter motor cover
       
      Starter electrical connectors
       
      Starter assembly

      Click image to see an enlarged view

      Fig. Location of starter motor-2.4L and 3.0L engines

       

    6.  

    To install:

    1. Install or connect the following:

      Starter assembly. Torque the starter bolt to 23 ft. lbs. (30 Nm). If vehicle is equipped with a rear starter bracket, torque it to 8 inch lbs. (1 Nm).
       
      Electrical connectors to the starter
       
      Starter cover and torque the bolt to 15 inch lbs. (6 Nm)
       
      Air cleaner resonator
       
      Negative battery cable to the shock tower
       

    2.  

    Solenoid or Relay



    The relay is located in the Power Distribution Center (PDC). Refer to the cover of the PDC for relay location.

    The starter relay is located in the Power Distribution Center (PDC). Refer to the cover of the PDC for relay location.

    Testing & Troubleshooting




    CAUTION
    Battery posts, terminals and related accessories contain lead and lead compounds. WASH HANDS AFTER HANDLING.

    If the starter does not work, check the following:



    Battery voltage
     
    Starter condition
     
    Poor contact at the battery terminals and starter
     
    Transmission range switch <A/T>
     
    Starter relay <M/T>
     
    Clutch interlock switch <M/T>
     
    Cable between the battery positive and starter motor "S" terminal
     


    NOTE
    If the starter cranks when 12 volts is applied to the "S" terminal, check the ignition switch.



    Excessive rotational resistance of the engine.
     

    If the starter does not stop:



    Replace the starter.
     

    The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch, connection wires and the battery cables. When the ignition key is turned to the start position, current flows and energizes the starter motor solenoid coil. The solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear. The contacts close and the starter motor cranks the engine. In order to prevent damage caused by excessive rotation of the starter armature when the engine starts, the clutch pinion gear overruns.

    1. Inspect for aftermarket devices which could affect the operation of the starting and charging systems. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause a fault symptom.
    2.  
    3. The starter should crank the engine smoothly and steadily. If the starter engages, but cranks the engine erratically, remove it, and inspect the starter drive gear and torque converter ring gear for damage. Check the drive gear overrunning clutch for binding or slipping when the armature is rotated with the drive gear held in place. If damaged, replace the starter drive.
    4.  
    5. If the starter is not turning over the engine, check that the wire connections are fastened securely to the starter solenoid and that battery voltage (12 volts) is supplied to the starter.
    6.  

    The Powertrain Control Module (PCM) controls engine cranking based on a power mode input and the status of the clutch start switch (manual transaxle) or the Park/Neutral Position (PNP) switch (automatic transaxle). With the transaxle in Park/Neutral or the clutch depressed, voltage at the PCM PNP/clutch start switch signal circuit is high. This indicates to the PCM that conditions are acceptable for cranking. When a power mode crank request is seen, the PCM grounds the starter relay coil control circuit. This energizes the coil side of the relay, which pulls the switch side of the relay closed, applying voltage to the starter S-terminal and engaging the starter solenoid.

    1. A misadjusted PNP switch or clutch start switch may result in a starter solenoid that will not engage or click.
    2.  

     
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