Mazda Car 2002-04

Starter

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Removal & Installation



  1. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner
     
    Intake manifold support bracket bolts
     
    Starter electrical connectors
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter and loosely tighten the lower starter mounting bolt
     
    Starter electrical connectors
     
    Intake manifold support bracket. Torque the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    Starter bolts. Torque the bolts 28-38 ft. lbs. (38-51 Nm). The upper mounting bolts must be tightened first.
     
    Air cleaner
     
    Negative battery cable
     

  2.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Dipstick tube
     
    Intake manifold bracket
     
    Wiring at the starter
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter. Torque the bolts to 33 ft. lbs. (46 Nm).
     
    Wiring at the starter
     
    Intake manifold bracket. Torque the bolts to 38 ft. lbs. (51 Nm).
     
    Dipstick tube
     
    Air cleaner assembly
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery cover and disconnect the negative battery cable.
  4.  
  5. Remove the under cover.
  6.  
  7. If equipped with a manual transaxle, remove the clutch release cylinder with the line still attached.
  8.  
  9. Remove the starter electrical connections and wiring harness bracket.
  10.  
  11. Remove the starter bolts and the starter.
  12.  

To install:

  1. Installation is the reverse of removal. Tighten the wiring harness bracket retainers to 70-104 inch lbs. (8-11 Nm) and the starter bolts to 28-38 ft. lbs. (38-51 Nm).
  2.  

2.0L (Fs) Engine
  1. Remove or disconnect the following:

    Battery
     
    Air cleaner assembly
     
    Transverse member
     
    Intake manifold bracket
     
    Wiring at the starter
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter. Torque the bolts to 38 ft. lbs. (51 Nm).
     
    Wiring at the starter
     
    Intake manifold bracket
     
    Transverse member
     
    Air cleaner assembly
     
    Battery
     

  2.  

2.3L (Kj) Engine
  1. Remove or disconnect the following:

    Negative battery cable
     
    Charge air cooler duct
     
    Battery clamp, box and battery
     
    Battery tray
     
    Rear charge air cooler
     
    Pipe bracket
     
    Starter electrical connectors
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter. Torque the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    B-terminal wire
     
    S-terminal wire
     
    Pipe bracket. Torque the bolt to 14-18 ft. lbs. (19-25 Nm).
     
    Rear charge air cooler using new O-rings. Torque the nuts to 14-18 ft. lbs. (19-25 Nm).
     
    Battery tray
     
    Battery, box and clamp
     
    Charge air cooler duct
     
    Negative battery cable
     

  2.  

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery cover and disconnect the negative battery cable.
  4.  
  5. Remove the under cover.
  6.  
  7. If equipped with a manual transaxle, remove the clutch release cylinder with the line still attached.
  8.  
  9. Remove the starter electrical connection.
  10.  
  11. Remove the starter bolts and the starter.
  12.  

To install:

  1. Installation is the reverse of removal. Tighten the starter bolts to 29-37 ft. lbs. (38-51 Nm).
  2.  

2.5L (Kl) Engine
  1. Remove or disconnect the following:

    Battery
     
    Air cleaner assembly
     
    Transverse member
     
    Fuel filter with the hose still attached and set aside
     
    Oil filler pipe
     
    Transaxle selector cable from the automatic transaxle and remove the cable bracket
     
    Wiring at the starter
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter. Torque the bolts to 38 ft. lbs. (51 Nm).
     
    Wiring at the starter
     
    Cable bracket and connect the transaxle selector cable to the transaxle
     
    Oil filler pipe
     
    Fuel filter
     
    Transverse member
     
    Air cleaner assembly
     
    Battery
     

  2.  

  1. Remove or disconnect the following:

    Negative battery cable
     
    Battery clamp, box and battery
     
    Battery tray
     
    Shift cable from the selector lever
     
    Cable from the bracket by squeeze the lock tabs
     
    Electrical connectors from the starter solenoid
     
    2 selector cable bracket bolts and the bracket
     
    2 nuts and the bolt from the starter bracket and the bracket
     
    Starter electrical connectors
     
    Starter
     

  2.  

To install:

  1. Install or connect the following:

    Starter. Torque the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    B-terminal wire.
     
    S-terminal wire to the solenoid
     
    Starter bracket
     
    Selector cable bracket. Torque the bolts to 5-7 ft. lbs. (7-9 Nm).
     
    Starter solenoid electrical connectors
     
    Shift cable into the cable bracket and into the selector lever
     
    Battery tray
     
    Battery, box and clamp
     
    Negative battery cable
     

  2.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery and tray.
  4.  
  5. Disconnect the selector cable and bracket.
  6.  
  7. Remove the starter electrical connection.
  8.  
  9. Remove the starter bolts and the starter.
  10.  

To install:

  1. Installation is the reverse of removal. Tighten the starter bolts to 28-38 ft. lbs. (38-51 Nm).
  2.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the battery and tray.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Remove the under cover.
  8.  
  9. Remove the oil filter and cooler component with the water hoses attached and set the assembly aside.
  10.  
  11. Remove the harness bracket.
  12.  
  13. Remove the heater pipe with the hoses attached and position aside.
  14.  
  15. Remove the starter electrical connection.
  16.  
  17. Remove the starter bolts and the starter.
  18.  

To install:

  1. Installation is the reverse of removal. Tighten the starter bolts to 29-37 ft. lbs. (38-51 Nm).
  2.  

Testing & Troubleshooting



  1. Verify that the battery is fully charged.
  2.  
  3. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
  4.  
  5. If the starter does not operate, inspect the following:
    1. Remove the starter, and inspect the starter unit.
    2.  
    3. Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch).
    4.  

  6.  
  7. Verify that the battery is fully charged.
  8.  
  9. Connect the starter, battery, and a tester as shown in the illustration.
  10.  
  11. Operate the starter and verify that it rotates smoothly.
  12.  
  13. If the starter does not rotate smoothly, inspect the starter unit.
  14.  
  15. Measure the voltage which should be 11 volts or current which should be 90 Amps while the starter is operating.If not within the specification, replace the starter.

    Click image to see an enlarged view

    Fig. Connect the starter, battery, and a tester as shown

  16.  

  1. Verify that the battery is fully charged.
  2.  
  3. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
  4.  
  5. If the starter does not operate, inspect the following:
    1. Remove the starter, and inspect the starter unit.
    2.  
    3. Inspect the related wiring harnesses, the ignition switch, and the transaxle range switch).
    4.  

  6.  
  7. Verify that the battery is fully charged.
  8.  
  9. Connect the starter, battery, and a tester as shown in the illustration.
  10.  
  11. Operate the starter and verify that it rotates smoothly.
  12.  
  13. If the starter does not rotate smoothly, inspect the starter unit.
  14.  
  15. Measure the voltage which should be 11 volts or current which should be 90 Amps while the starter is operating. If not within the specification, replace the starter.

    Click image to see an enlarged view

    Fig. Connect the starter, battery, and a tester as shown

  16.  

 
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