Mazda MPV 1999-06

Starter

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Removal & Installation



2.5L & 3.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery and tray
     
    Air intake assembly
     
    Gear select cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10-12 Nm).
     
    Gear select cable
     
    Air intake assembly
     
    Battery and tray
     

  2.  

2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Battery and tray
     
    Air intake assembly
     
    Gear select cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10-12 Nm).
     
    Gear select cable
     
    Air intake assembly
     
    Battery and tray
     

  2.  

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

    Battery and tray
     
    Air intake assembly
     
    Gear select cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10-12 Nm).
     
    Gear select cable
     
    Air intake assembly
     
    Battery and tray
     

  2.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Battery and tray
     
    Air intake assembly
     
    Gear select cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10-12 Nm).
     
    Gear select cable
     
    Air intake assembly
     
    Battery and tray
     

  2.  

2 Wheel Drive
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Starter harness connectors
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 24-33 ft. lbs. (32-46 Nm).
     
    Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10-12 Nm).
     
    Negative battery cable
     

  2.  

4 Wheel Drive
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Alternator
     
    Engine under covers
     
    Power steering pump
     
    Front driveshaft
     
    Wiring harness bracket
     
    Transmission oil cooler pipe brackets
     
    Starter harness connectors
     
    Fuel and brake pipe cover
     
    Starter motor
     

  4.  

To install:

  1. Install or connect the following:

    Starter motor. Tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
     
    Fuel and brake pipe cover
     
    Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10-12 Nm).
     
    Transmission oil cooler pipe brackets
     
    Wiring harness bracket
     
    Front driveshaft
     
    Power steering pump
     
    Engine under covers
     
    Alternator
     
    Negative battery cable
     

  2.  

Testing & Troubleshooting



Feed Circuit Test

NOTE
Make all multimeter connections at the component terminal rather than the cable or wiring terminal.

  1. Make sure the battery is fully charged.
  2.  
  3. Disconnect the ignition coil connector.
  4.  
  5. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive post.
  6.  
  7. Connect the positive lead of digital multimeter to the battery positive post. Connect the negative lead of the multimeter to the starter solenoid M-terminal.
  8.  
  9. Engage the remote starter switch. Read and record the voltage. The multimeter reading should be 0.5 volt or less.
  10.  
  11. If the voltage reading is 0.5 volt or less, go to the Ground Circuit Component Test
  12.  
  13. If the voltage reading is greater than 0.5 volt, this is an indication of excessive resistance in the connections, the positive battery cable or in the starter solenoid. Move the digital multimeter negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading at the B-terminal is lower than 0.5 volt, the concern is either in the connections at the starter solenoid or in the solenoid contacts.
  14.  
  15. Remove the cables at the starter solenoid B-, S-, and M-terminals. Clean the connections and install the cables. Repeat Steps 3 through 6 above. If the reading is still higher than 0.5 volt at the M-terminal and 0.5 volt or lower at the B-terminal, the concern is the solenoid contacts. Install a new starter motor.
  16.  
  17. If the voltage measured in Step 5 is greater than 0.5 volt, the concern is either the positive battery cable connection or the positive battery cable itself. Clean the positive battery cable connection. If this does not solve the problem, install a new positive battery cable.
  18.  

Ground Circuit Test
  1. Disconnect the ignition coil connector.
  2.  
  3. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+) terminal.
  4.  
  5. Connect the positive lead of digital multimeter to the starter motor housing. The connection must be clean and free of rust or grease. Connect the negative lead to the negative battery terminal.
  6.  
  7. Engage the remote starter switch and read the voltage. The reading should be 0.2 volt or less.
  8.  
  9. If the voltage drop is greater than 0.2 volt, clean the negative battery cable connections at the battery, the body ground connections, and the starter ground connections. Retest.
  10.  
  11. If the voltage is still more than 0.2 volt, install a new cable. If the reading is less than 0.2 volt and the engine still cranks slowly, install a new starter motor.
  12.  

 
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