2008 Mazda MX-5 Miata Grand Touring
2008 ENGINE Starting System - MX-5 Miata
2008 ENGINE
Starting System - MX-5 Miata
STARTING SYSTEM LOCATION INDEX [LF]
Fig. 1: Identifying Location Of Starting System Components
Courtesy of MAZDA MOTORS CORP.
STARTER REMOVAL/INSTALLATION [LF]
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. Remove the battery cover.
2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Remove the side cover. (LH)
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2008 ENGINE Starting System - MX-5 Miata
4. Remove the under cover. (MT) (See TRANSVERSE MEMBER REMOVAL/INSTALLATION .)
5. Remove the clutch release cylinder with the pipes still connected. Position the clutch release cylinder so
that it is out of the way. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [M15M-D] .)
(See TRANSMISSION REMOVAL/INSTALLATION [P66M-D] .)
6. Remove in the order indicated in Fig. 2 .
7. Install in the reverse order of removal.
Fig. 2: View Of Starter Removal Order & Components (With Torque Specifications)
Courtesy of MAZDA MOTORS CORP.
STARTER INSTALLATION NOTE
NOTE: If there is peeling on or damage to the insulator, attach a new insulator
using the following procedure:
1. Peel off the insulator from the starter completely using a scraper.
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2008 ENGINE Starting System - MX-5 Miata
Fig. 3: Identifying Starter Insulator
2. Degrease the insulator attachment area.
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Fig. 4: Identifying Insulator Attachment Area
3. Attach a new insulator to the starter.
Fig. 5: Identifying New Starter Insulator
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2008 ENGINE Starting System - MX-5 Miata
STARTER INSPECTION [LF]
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 transmission range switch
(AT).
NO-LOAD TEST
1. Verify that the battery is fully charged.
2. Connect the starter, battery and a tester as shown in Fig. 6 .
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 the specification, replace the starter.
Starter no load test voltage
11 V
Starter no load test current
90 A or less
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2008 ENGINE Starting System - MX-5 Miata
Fig. 6: No - Load Test - Circuit Diagram
Courtesy of MAZDA MOTORS CORP.
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.
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2008 ENGINE Starting System - MX-5 Miata
Fig. 7: Energizing Starter S Terminal
Courtesy of MAZDA MOTORS CORP.
Return test
1. Disconnect the motor wire from terminal M.
2. Connect battery positive voltage to terminal M and ground the starter body.
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2008 ENGINE Starting System - MX-5 Miata
Fig. 8: Connecting Battery Positive Voltage To Terminal M & Ground Starter Body
Courtesy of MAZDA MOTORS CORP.
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 10s.
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Fig. 9: Energizing Starter S Terminal
Courtesy of MAZDA MOTORS CORP.
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}
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Fig. 10: Measuring Pinion Gap While Drive Pinion Is Extended
Courtesy of MAZDA MOTORS CORP.
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.
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Fig. 11: Inspecting Continuity Between Commutator & Core
Courtesy of MAZDA MOTORS CORP.
2. Verify that there is no continuity between the commutator and the shaft using a tester.
If there is continuity, replace the armature.
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Fig. 12: Inspecting Continuity Between Commutator & Shaft
Courtesy of MAZDA MOTORS CORP.
3. Place the armature on V-blocks, and measure the runout using a dial indicator.
Starter armature runout
0.1 mm {0.004 in} max.
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Fig. 13: Measuring Armature Runout Using Dial Indicator
Courtesy of MAZDA MOTORS CORP.
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}
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Fig. 14: Measuring Commutator Diameter
Courtesy of MAZDA MOTORS CORP.
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}
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2008 ENGINE Starting System - MX-5 Miata
Fig. 15: Measuring Segment Groove Depth Of Commutator
Courtesy of MAZDA MOTORS CORP.
Magnetic Switch
1. Inspect for continuity between terminals S and M using a tester.
If there is no continuity, replace the magnetic switch.
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Fig. 16: Verifying If There Is Continuity Between Terminals S & M
Courtesy of MAZDA MOTORS CORP.
2. Inspect for continuity between terminal S and the body using a tester.
If there is no continuity, replace the magnetic switch.
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Fig. 17: Verifying If There Is Continuity Between Terminal S & Body
Courtesy of MAZDA MOTORS CORP.
3. Verify that there is no continuity between terminals M and B using a tester.
If there is continuity, replace the magnetic switch.
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Fig. 18: Verifying If There Is No Continuity Between Terminals M & B
Courtesy of MAZDA MOTORS CORP.
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.
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Fig. 19: Verifying If There Is No Continuity Between Insulated Brush & Plate
Courtesy of MAZDA MOTORS CORP.
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 {0.48 in}
Minimum: 5.5 mm {0.22 in}
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Fig. 20: Measuring Brush Length
Courtesy of MAZDA MOTORS CORP.
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 {0.28 kgf, 0.62 lbf}
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Fig. 21: Measuring Brush Spring Force Using Spring Balance
Courtesy of MAZDA MOTORS CORP.
STARTER DISASSEMBLY/ASSEMBLY [LF]
1. Disassemble in the order indicated in Fig. 22 .
2. Assemble in the reverse order of disassembly.
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Fig. 22: Identifying Disassemble Order Of Starter & Components (With Torque Specifications)
Courtesy of MAZDA MOTORS CORP.
STARTER INTERLOCK SWITCH INSPECTION [MT]
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. Remove the battery cover.
2. Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [LF] .)
3. Disconnect the starter interlock switch connector.
4. Verify that the continuity is as indicated in Fig. 23 using a tester.
If the continuity is not as indicated in Fig. 23 , replace the starter interlock switch.
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2008 ENGINE Starting System - MX-5 Miata
Fig. 23: Starter Interlock Switch Continuity Check Table
Courtesy of MAZDA MOTORS CORP.
Fig. 24: Identifying Starter Interlock Switch Connector Terminals
Courtesy of MAZDA MOTORS CORP.
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