Mazda 2: Starting System
STARTING SYSTEM LOCATION INDEX

- Starter interlock switch (MTX)
- (See STARTER INTERLOCK SWITCH INSPECTION)
- Starter
- (See STARTER REMOVAL/INSTALLATION)
- (See STARTER INSPECTION)
- (See STARTER DISASSEMBLY/ASSEMBLY)
STARTER REMOVAL/INSTALLATION
WARNING:
- Remove and install all parts when the engine is cold, otherwise they can
cause severe burns or serious injury.
- When the battery cables are connected, touching the vehicle body with
starter terminal B will generate sparks. This can cause
personal injury, fire, and damage to the electrical components. Always
disconnect the negative battery cable before performing
the following operation.
1. Disconnect the negative battery cable.
2. Perform the following procedure. (ATX)
CAUTION:
- Removing the fresh-air duct from the air cleaner case may damage the
fresh-air duct. Remove the fresh-air duct
and the air cleaner case as a single unit except when the fresh-air duct is
to be replaced with a new one.
- Remove the fresh-air duct and air cleaner as a single unit. (See
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.

- Terminal B cable
- Terminal S connector
- Starter
Starter Removal Note
ATX
1. Remove the starter upper bolt from above the engine compartment.
2. Remove the starter lower bolt and starter from below the engine compartment.
MTX
1. Remove the starter bolts (upper, lower) and starter from below the engine
compartment.
Starter Installation Note (ATX)
CAUTION:
- Do not overlap the starter with the end plate (area A shown in figure)
when installing. If the starter is not correctly installed,
the nut installed to the drive plate may contact the end plate causing
abnormal noise.

STARTER INSPECTION
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. The starter is normal if it rotates smoothly and without any noise when the
engine is
cranked.
- If the starter does not operate, inspect the following:
- Remove the starter, and inspect the starter unit.
- Inspect the related wiring harnesses, the ignition switch,
and the transaxle range switch (ATX) or starter interlock
switch (MTX).
No-load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, and a tester as shown in the figure.

3. Operate the starter and verify that it rotates smoothly.
- If the starter does not rotate smoothly, inspect the starter unit.
4. Measure the voltage and current while the starter is operating.
- If not within specification, replace the starter.
Starter no-load test voltage
Starter no-load test current
- MTX: 95 A or less
- ATX: 90 A or less
Magnetic Switch Operation Inspection
Pull-out test
NOTE:
- Depending on the battery charge condition, the starter motor pinion may
rotate while
in an extended state. This is due to current flowing to the starter motor
through the
pull-in coil to turn the starter motor, and does not indicate an
abnormality.
1. Verify that the starter motor pinion is extended while battery positive
voltage is connected
to terminal S and the starter body is grounded.

- If the starter motor pinion is not extended, repair or replace the
starter.
Return test
1. Disconnect the motor wire from terminal M.
2. Connect battery positive voltage to terminal M and ground the starter body.

3. Pull out the drive pinion with a screwdriver. Verify that it returns to
its original position
when released.
- If it does not return, repair or replace the starter.
Pinion Gap Inspection
1. Pull out the drive pinion with the battery positive voltage connected to
terminal S and the
starter body grounded.

CAUTION:
- Applying power for more than 10 s can damage the starter. Do not apply
power for more than 10 s.
2. Measure the pinion gap while the drive pinion is extended.

- If not as specified, adjust with an adjustment washer (between drive
housing front cover and magnetic switch).
Starter pinion gap
- 0.5-2.0 mm {0.02-0.07 in}
Starter Inner Parts Inspection
Armature
1. Verify that there is no continuity between the commutator and the core at
each segment
using a tester.

- If there is continuity, replace the armature.
2. Verify that there is no continuity between the commutator and the shaft
using a tester.

- If there is continuity, replace the armature.
3. Place the armature on V-blocks, and measure the runout using a dial
indicator.

- If it exceeds the maximum specification, replace the armature.
Starter armature runout
4. Measure the commutator diameter.

- If not within the minimum specification, replace the armature.
Starter commutator diameter
- Standard: 29.4 mm {1.16 in}
- Minimum: 28.8 mm {1.13 in}
5. Measure the segment groove depth of the commutator.

- If not within the minimum specification, undercut the grooves to the
standard depth.
Segment groove depth of starter commutator
- Standard: 0.5 mm {0.02 in}
- Minimum: 0.2 mm {0.008 in}
Magnetic switch
1. Inspect for continuity between terminals S and M using a tester.

- If there is no continuity, replace the magnetic switch.
2. Inspect for continuity between terminal S and the body using a tester.

- If there is no continuity, replace the magnetic switch.
3. Verify that there is no continuity between terminals M and B using a
tester.

- If there is continuity, replace the magnetic switch.
Brush and brush holder
1. Verify that there is no continuity between each insulated brush and plate
using a tester.

- If there is continuity, replace the brush holder.
2. Measure the brush length.

- If any brush is worn almost to or beyond the minimum specification,
replace
all of the brushes.
Starter brush length
- Standard: 12.3 mm {0.484 in}
- Minimum: 5.5 mm {0.22 in}
3. Measure the brush spring force using a spring balance.

- If not within the minimum specification, replace the brush and brush
holder
component.
Starter brush spring force
- Standard: 15.0-20.4 N {1.53-2.08 kgf, 3.38-4.58 lbf}
- Minimum: 2.75 N {0.280 kgf, 0.618 lbf}
STARTER DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.

- Magnetic switch
- Adjustment washer
- Rear housing
- Brush and brush holder
- Armature
- Yoke
- Planetary gear
- Front cover
- Lever
- Drive pinion
- Internal gear
- Gear shaft
STARTER INTERLOCK SWITCH INSPECTION
CAUTION:
- Do not reuse the starter interlock switch if it is removed from the
vehicle even once.
Replace with a new starter interlock switch when installing.
1. Disconnect the negative battery cable.
2. Disconnect the starter interlock switch connector.
3. Verify that the continuity is as indicated in the table using a tester.


CRUISE CONTROL SWITCH INSPECTION
1. Switch the ignition to off.
2. Disconnect the negative battery cable and wait for 1 min or more.
3. Remove the driver-side air bag module. (See DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION).
4. Disconnect the clock spring connector (part wiring harness-side).
5. Inspect for resistance and continuity between clock spring terminals B and D
(part wiring harness-side) using
a tester.

- If not as specified, replace the audio control switch. (See AUDIO
CONTROL SWITCH
REMOVAL/INSTALLATION).


6. Apply battery positive voltage to clock spring terminal G (part wiring
harness-side) and terminal E (part
wiring harness-side) to ground.

7. Verify that the LED illuminates.
- If the LED does not illuminate, replace the audio control switch. (See
AUDIO CONTROL SWITCH
REMOVAL/INSTALLATION).
READ NEXT:
CONTROL SYSTEM LOCATION INDEX
PCM (BARO sensor, PCM temperature sensor)
(See PCM REMOVAL/INSTALLATION)
(See PCM INSPECTION)
(See PCM CONFIGURATION)
(See BAROMETRIC PRESSURE (BARO) SENSOR
PCM REMOVAL/INSTALLATION
CAUTION:
The PCM is built into the air cleaner cover. Applying excessive pressure
to the cover
could damage the PCM. Be careful not to put your hands on the PCM during th
NEUTRAL SWITCH INSPECTION
1. Disconnect the negative battery cable.
2. Remove the neutral switch. (See NEUTRAL SWITCH REMOVAL/INSTALLATION).
3. Inspect for continuity between the neutral switch term
SEE MORE:
Spare tyre and tools are stored in the locations illustrated in the diagram.
*1 The jack point attachment can be used by vehicle repair shops and road
assistance services.
Consult an Authorised Mazda Repairer for details.
Hatchback
Without spare tyre
Jack *
NOTE
Your vehicle may
VALVE CLEARANCE INSPECTION
1. Disconnect the negative battery cable.
2. Remove the splash shield (RH). (See DRIVE BELT REMOVAL/INSTALLATION).
3. Remove the fresh-air duct and the air cleaner as a single unit. (See
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION).
4. Remove the ignition coils. (See IGNITI
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