Mazda Trucks 1987-1993 Repair Guide

Starter

Print

TESTING



Navajo Models

See Figures 1 and 2

Use the charts to help locate and diagnose starting system problems. Remember that the starter uses large amounts of current during operation, so use all appropriate precautions during testing.



Click image to see an enlarged view

Fig. Fig. 1: Starter system inspection chart



Click image to see an enlarged view

Fig. Fig. 2: Starter system evaluation procedure chart

Pickup and MPV Models

See Figure 3



Click image to see an enlarged view

Fig. Fig. 3: Starter motor solenoid terminal identifications

ON VEHicle test

See Figures 4



Click image to see an enlarged view

Fig. Fig. 4: Measuring the voltage between terminal S and ground, using a voltmeter

Be sure that the battery is fully charged before starting this test

  1. Turn the ignition switch to the START position.
  2.  
  3. Verify that the starter motor operates.
  4.  
  5. If the starter motor does not operate, measure the voltage between terminal S and ground, using a voltmeter.
  6.  
  7. If the voltage measures 8V or more, the starter is not working properly.
  8.  
  9. If the voltage measures less than 8V, the wiring harness is the fault.
  10.  

If the magnetic switch is hot, it may not function even though the voltage is standard or greater.

MAGNETIC SWITCH PULL OUT TEST

See Figures 5 and 6



Click image to see an enlarged view

Fig. Fig. 5: Apply battery positive voltage to terminal S and body ground



Click image to see an enlarged view

Fig. Fig. 6: Measure the pinion gap while it is pulled out-3.0L engine

  1. Apply battery positive voltage to terminal S and body ground, verify that the pinion is pulled out.
  2.  
  3. On 3.0L engines only, measure the pinion gap while the pinion is pulled out. It should measure 0.02-0.08 inch (0.5-2.0 mm).
  4.  
  5. If not within specifications, adjust with an adjustment washer (drive housing front cover-magnetic switch).
  6.  

RETURN TEST

See Figure 3

  1. Disengage the motor wire from terminal M, and then connect battery power to terminal M and ground the body.
  2.  
  3. Using a small prying tool, pull out the overrunning clutch. Verify that the overrunning clutch returns to its original position when released.
  4.  

NO-LOAD TEST

See Figures 7



Click image to see an enlarged view

Fig. Fig. 7: Schematics for connecting the battery, starter, ammeter and voltmeter

  1. Verify that the battery is fully charged.
  2.  
  3. Connect the battery, starter, ammeter and voltmeter as illustrated.
  4.  
  5. Operate the starter and verify that it turns smoothly.
  6.  
  7. Measure the voltage and current while the starter is operating.
  8.  

2.6L engine:


Voltage: 11.5V
 
Current (amps): 100 max.
 

3.0L engine:



Voltage: 11.0V
 
Current (amps): 90 max.
 

  1. If not as specified, replace the starter motor.
  2.  

REMOVAL & INSTALLATION



Except 4WD MPV Models
  1. Disconnect the negative battery cable. Raise and safely support the vehicle.
  2.  
  3. Disconnect the electrical connectors from the starter.
  4.  
  5. Remove the starter mounting bolts and remove the starter.
  6.  
  7. Place the starter in position, after cleaning the mounting flange surfaces. Install and tighten the mounting bolts. Tighten the starter mounting bolts to 24-33 ft. lbs. (32-46 Nm) on 1987-88 vehicles, 27-38 ft. lbs. (37-52 Nm) on 1989-92 vehicles except 4.0L engine or 15-20 ft. lbs. (21-27 Nm) on 4.0L engine. Connect all wiring connectors. Connect the negative battery cable.
  8.  

4WD MPV Models

See Figure 8



Click image to see an enlarged view

Fig. Fig. 8: Starter installation-4WD

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the drive belts. Remove the power steering pump pulley. Remove the alternator.
  4.  
  5. Raise and safely support the vehicle. Remove the splash shields.
  6.  
  7. Remove the power steering pump mounting bolts and position the pump aside, without disconnecting the power steering hoses.
  8.  
  9. Remove the automatic transmission cooler line brackets.
  10.  
  11. Mark the position of the driveshaft on the axle flange and remove the front driveshaft.
  12.  
  13. Remove the wiring harness bracket and the automatic transmission cooler line bracket that is next to the starter.
  14.  
  15. Disconnect the electrical connectors from the starter.
  16.  
  17. Remove the fuel and brake line shield.
  18.  
  19. Remove the starter mounting bolts and remove the starter.
  20.  
  21. Clean the mounting surface flanges. Place the starter motor into position and install the mounting bolts. Tighten the starter mounting bolts to 27-38 ft. lbs. (37-52 Nm).
  22.  
  23. Install the fuel and brake line shield. Connect the starter motor wiring. Install the wiring harness bracket.
  24.  
  25. Connect the driveshaft. Install the transmission cooler line brackets. Install the power steering pump and the splash shields.
  26.  
  27. Lower the vehicle. Install the alternator. Install the power steering pump pulley. Install and tension the drive belts. Connect the negative battery cable.
  28.  

SOLENOID REPLACEMENT



See Figures 9 and 10



Click image to see an enlarged view

Fig. Fig. 9: Gear reduction type starter components



Click image to see an enlarged view

Fig. Fig. 10: Direct drive type starter components

  1. Remove the starter from the truck.
  2.  
  3. Disconnect the field strap from the solenoid terminal.
  4.  
  5. Remove the two solenoid attaching screws.
  6.  
  7. Disengage the solenoid plunger from the shift fork and remove the solenoid.
  8.  
  9. Install the solenoid on the drive end housing, making sure that the solenoid plunger hook is engaged with the shift fork.
  10.  
  11. Apply 12v to the solenoid S terminal and measure the clearance between the starter drive and the stop-ring retainer. It should be 2.0-5.0mm (0.0787-0.1969 in.). If not, remove the solenoid and adjust the clearance by inserting an adjusting shim between the solenoid body and drive end housing.
  12.  
  13. Check the solenoid for proper operation and install the starter.
  14.  
  15. Check the operation of the starter.
  16.  

 
label.common.footer.alt.autozoneLogo