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2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup DESCRIPTION & OPERATION Starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing. ADJUSTMENTS PINION GAP MVP & MX-5 Miata 1. Disconnect field lead ("M" terminal wire) at solenoid. See Fig. 2 . Connect positive battery lead to solenoid "S” terminal and negative battery lead to starter body. Starter pinion drive gear should extend outward and stop. 2. Quickly measure pinion gap between end of pinion drive and circlip retainer. See Fig. 1. DO NOT operate starter solenoid for more than 10 seconds. On MX-5 Miata, pinion gap should be .02-.08" (0,5-2.0 mm). On MPV, pinion gap should be 0” (0 mm) 3. If pinion gap is not within specification, adjust by increasing or decreasing thickness of solenoid shims located between solenoid and drive housing 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup Pinion \ Gap ——~—> | |+$———— CHECKING PINION GAP Solenoid Qe, Shims Solenoid ADJUSTING PINION GAP G97E11001 Fig. 1: Checking & Adjusting Pinion Gap (Typical) Courtesy of MAZDA MOTORS CORP. 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup TROUBLE SHOOTING NOTE: See TROUBLE SHOOTING article in GENERAL INFORMATION. ON-VEHICLE TESTING NOTE: On models with anti-theft system, obtain code number and deactivate audio anti-theft system before disconnecting battery. CIRCUIT TEST Ensure battery is fully charged, battery cables and terminals are clean and tight, and engine grounds are okay. If starter does not operate, measure voltage at starter "S" terminal (Black/Red wire) with ignition switch in START position (ensure clutch is depressed on MIT or gear selector in Park on A/T). If voltage is greater than 8 volts and vehicle does not crank, repair or replace starter as required. If voltage is 8 volts or less, check ignition switch, park/neutral switch (A/T), starter interlock (clutch start) switch (M/T) and wiring, STARTER INTERLOCK SWITCH (M/T) Starter interlock (clutch start) switch is mounted on bracket near top front of clutch pedal Disconnect interlock switch wiring connector. Using ohmmeter, ensure continuity exists between interlock switch connector terminals when clutch pedal is depressed and no continuity exists when clutch pedal is released. If continuity is not as described, adjust or replace interlock switch NO-LOAD TEST Remove starter, Connect fully-charged 12-volt battery, voltmeter and ammeter to starter. See 2, Using remote starter wires or jumper, engage solenoid. Starter should spin smoothly Compare readings with specifications. See NO-LOAD TEST SPECIFICATIONS table. If. voltage is less than specified or amperage is more than specified, repair or replace starter as necessary. NO-LOAD TEST SPECIFICATIONS, Application Specification Millenia, MVP, MX-5 Miata, Protege & 626 Voltage (Minimum) u ‘Amperage (Maximum) 90] 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup Inductive Remote Starter Pick-Up Switch Terminal "B" ‘Terminal "M" oe Terminal "S' Starter” Volt/Amp Voltmeter Meter Leads @gsi12524 2: Checking Starter Current Draw Courtesy of MAZDA MOTORS CORP. BENCH TESTING NOTE: Testing information for all models is not available from manufacturer. ARMATURE TEST MVP & MX-5 Miata 1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature. 2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, replace armature. 3. Check continuity between commutator and shaft. If continuity exists, replace armature. Check continuity between each commutator segment. If an open exists between any two segments, replace armature. COMMUTATOR TEST 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup MVP & MX-5 Miata 1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning on lathe. 2. Standard commutator mica undercut depth is .020" (.50 mm). Minimum mica undercut depth is .008" (.20 mm). If undercut is not within specification, undercut to standard depth, BRUSH TEST MVP & MX-5 Miata 1. Connect one ohmmeter lead to positive brush holder and other lead to negative brush holder. If continuity exists, replace brush holder assembly. 2. Check brush length. Minimum brush length is .28" (7.0 mm). If brush length is less than specified, replace brushes. OVERRUNNING CLUTCH ION DRIVE Hold overrunning clutch housing and turn pinion gear by hand. If pinion turns in both directions or does not turn at all, clutch is faulty. Replace clutch. REMOVAL & INSTALLATION NOTE: On models with anti-theft system, obtain code number and deactivate audio anti-theft system before disconnecting battery. STARTER Removal & Installation (Millenia) 1, Disconnect battery cables. Remove battery, battery tray and cable bracket. On Millenia S, remove air cleaner assembly, intake air ducting and charge air cooler. See Fig. 3. On all models, remove shift selector cable, if necessary. Disconnect wiring from starter. Remove starter mounting bolts and starter. 2. To install, reverse removal procedure. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup 11 go 10 1. Dynamic Chamber Cover 8. Resonator 2. Charge Air Cooler 9. Charge Air Cooler (Rear) 3. Air Cleaner Assembly 10. Charge Air Cooler (Front) 4. Air Duct 11. Coupler 5. Fresh Air Assembly 12. Accelerator Cable 8. Mass Airflow Sensor 13. EGR Valve 7. Air Intake Hose G98E01879 Fig. 3: Exploded View Of Intake Air System Components (Millenia S) Courtesy of MAZDA MOTORS CORP. Removal & Installation (MVP) Disconnect negative battery cable. Remove air cleaner assembly and associated ducting. Disconnect wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten starter mounting bolts to specification. See TORQUE 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup SPECIFICATIONS Removal & Installation (MX-5 Miata) Disconnect negative battery cable. Remove intake manifold bracket. On models with A/T, remove transmission oil filler pipe. Disconnect wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS . Removal & Installation (Protege) Disconnect negative battery cable. Remove air cleaner assembly and associated ducting Remove intake manifold bracket. Remove 3-way catalyst if necessary. Disconnect wiring from starter. Remove starter mounting bolts and starter. To install, reverse removal procedure. Tighten starter mounting bolts to specification. See TORQUE SPECIFICATIONS . Removal & Installation (626 - 2.0L & 2.5L MIT) 1. Disconnect negative battery cable. Remove intake air duct and air cleaner housing, Remove transverse member. On 2.0L models, remove intake manifold bracket. On all models, disconnect wiring from starter. Remove starter mounting bolts and starter. 2. To install, reverse removal procedure. Tighten starter mounting bolts to specification See TORQUE SPECIFICATIONS Removal & Installation (626 - 2.5L A/T) 1, Release fuel pressure from fuel system, Drain coolant. Disconnect negative battery cable, Remove intake air duct and air cleaner housing. If necessary, disconnect accelerator cable from throttle body and remove throttle body. N Disconnect A/T cooler line. Disconnect fuel line with filter attached and position aside. Disconnect shift cable from transaxle. Remove shift cable bracket. Remove starter bracket. Disconnect wiring from starter. Remove starter mounting bolts and starter. 3. To install, reverse removal procedure. Tighten starter mounting bolts to specification, See TORQUE SPECIFICATIONS OVERHAUL See Fig. 4 for starter overhaul 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup 1. Solenoid 7. Front Cover 2. Rear Housing 8. Lever 3. Brush & Brush Holder 9. Drive Pinion 4. Armature 10. Internal Gear 5. Yoke. 11. Drive Shaft 6. Planetary Gear Geepos6es Courtesy of MAZDA MOTORS CORP. 4: Exploded View Of Gear Reduction Type Starter (MX-5 Miata; MPV Is Simil: TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS ‘Application Ft. Lbs. (N.m) Air Cleaner Housing Bolt (626) 12-16 (16-22) Starter Mounting Bolts 28-38 (38-51) INCH Lbs. (N.m) Battery Cable Nut (Solenoid Terminal "B") 80-115 (9-13) Battery Cable Nut (Solenoid Terminal "B" - MVP) 87-104 (9.8 - 11.7) Charge Air Cooler Duct Bolt (Millenia) 70-95 (7-10) Intake Air Duct Nut (626) 71-97 (8-11) WIRING DIAGRAMS r) 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup om == =F --=jaxenon \ Sauron ' Cn oh eer | 1 cewma p> V(GNER ee mSgs[ | Bene emer Steoronie wT, _ 158 188 1 om L_---8¥7_-_ Js LTGRNBLK suewar F BLWORG 1 . oan, 6 suower_| ean ' a {Srey J srsiow [ruse suksuu RSE’) Fuse | tock { roe | Qe STARTER RELAY | ey Gurr rovr pera ler wen SENDER NED |} 1208 | PANEL) BLKMWHT_| ue Trae. suey CRUSE CONTROL Eee Sonos a . naine couraots, t suns ‘CLUSTER q eK ‘SYSTEM BLKRED _| ‘ioe or bast) sranrer peu ovWAn i fosescon BATTERY ! wood | $9 aces i 2 | _ gucrt| | | upreR t | excaror! | | Renee TRANSAXLE RANGE swiTcH FNGINE? ! erie Noa (2.3L: CENTER REAR coe hon * + Seewene cower Gus 25 Ta weer rect ona 10 or enaine Coney Fig. 5: Starting System Wiring Diagram (Millenia) 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup Reo Buk Bk RELAY (eFrsive OF ENGINE Sour Yel =} exon SWC puuvet CRUSE LUveL conrRo: ¢ SEE SYSTEM ENGINE | pLuveL conTrats ¢ Eg sere - eee coe f Sarno | Tag ot [eter f he n OFENGINE) Le er ONT | 5 srsien | sox FUSE | (@EHIND Irv” | Terrie Le PANEL) ve ig, 6: Starting System Wiring Diagram (MPV) 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup wares ETT “1 cnition swe grant, war A POWER = upwra 9 WHTIBLA _» pysTRIBUTION (TSIG FUSE) warieLk warren i ofF List I BLOCK WHTIBLK Bln st I (OF ENGINE 7 piciTaL, STARTER I | (LEFT SIDE OF LEFT SIDE (ee a isemamas, | —Pigrsse 14002 Fig. 7: Starting System Wiring Diagram (MX-5 Miata) 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup BLT Go == 1ewmon i | Suen | ore START | ' aa 1 woo” Gu || eels wr crust | aca ome: tg 5 wemmuen eNoNe © aucauu i Guster contmens qt g , f | 1 i Se — HAs 1 eansaue ener Sige | ‘as SE | Bet baze |BBK | Sarr saree \ ‘oe imo | iGeexone 2 Corrie | San (her | iene oro 2 Suse a f 1 008 ul A aucve, wr uc uve. Hi ig, 8: Starting System Wiring Diagram (Protege) 2001 Mazda MX-5 Miata 2001 STARTING & CHARGING SYSTEMS Starters - Except Pickup Bux 7 1enmon swe gTarT_ J caw orn run an at cs fe ial on = MAIN | STARTER a PEDAL) auweLu _~-_ onn] t ewe { ~ TRANSAMLE RANGE MODELS eLW/eLU swirch ONLY) (RIGHT SIDE OF BuweLY TTRANAXLE) STARTER PULLIN HoLo 12107 Fig. 9: Starting System Wiring Diagram (626)

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