The starter is a four-pole, four-brushless DC electric motor with excitation from permanent magnets, combined with a planetary gearbox and an electromagnetic two-winding traction relay. The covers and the stator housing are tightened with two bolts

Permanent magnets are fixed in the stator housing. Rotation from the armature shaft of the electric motor is transmitted to the drive shaft through a planetary gearbox. A freewheel roller clutch is mounted on the drive shaft.

Starter circuit connection diagram

When turning the key in the ignition switch (lock) to the "START" position, the battery voltage is applied to the retracting and holding windings of the traction relay, as a result, the drive lever moves, and the starter gear engages with the gear ring of the engine flywheel.

At the same time, the anchor of the traction relay closes the power contacts (at this moment the retracting winding turns off), the starter motor is supplied with voltage from the battery

The starter armature turns the crankshaft of the engine through the planetary gearbox.

After starting the engine, when the gear speed exceeds the speed of the starter shaft, the freewheel clutch will unlock and begin to slip, thereby protecting the starter from high speed and damage.

Mazda 6 Vehicle starter design and malfunctions

Possible starter malfunctions and remedies

When the starter is turned on, the anchor does not rotate, the traction relay does not work

- the battery is defective or discharged

Charge or replace the battery

- battery terminals are strongly oxidized and the tips are loosely tightened

Clean the terminals and wire tips and lubricate with vaseline

- inter-turn closure in the retracting winding of the traction relay, its closure to the ground or breakage

Replace the traction relay

- breakage in the power supply circuit of the traction starter relay

Check the wires and their connections in the circuit between the "50" plugs of the starter and the ignition switch

- the contact part of the ignition switch is faulty

Replace the contact part of the ignition switch

- jamming of the anchor of the traction relay

Remove the traction relay, check the ease of moving the armature

- burning of the collector, hanging of brushes or their wear

Clean the collector, replace the brushes

When the starter is turned on, the anchor does not rotate or rotates too slowly, the traction relay is triggered

- the battery is defective or discharged

Charge or replace the battery

- battery terminals are strongly oxidized and the tips are loosely tightened

Clean the terminals and wire tips and lubricate with vaseline

- the attachment of the tips of the wire connecting the power unit to the body is loosened

Tighten the wire tip fasteners

- the contact bolts of the traction relay are oxidized or the nuts of fixing the wire tips on the contact bolts are loosened

Clean the contact bolts, tighten the wire nuts

- burning of the collector, hanging of brushes or their wear

Replace the collector, replace the brushes

- open or short circuit in the rotor winding

Replace the rotor

When the starter is turned on, the traction relay repeatedly triggers and turns off

- the battery is discharged

Charge the battery

- breakage or short circuit in the holding winding of the traction relay

Replace the traction relay

- significant voltage drop in the traction relay supply circuit due to strong oxidation of the wire tips

Check the wires and their connections in the circuit from the battery to the "50" plug of the starter

When the starter is turned on, the armature rotates, the flywheel does not rotate

- slip of the freewheel clutch

Replace the coupling

- the drive gear does not engage with the gear ring of the flywheel (noise is heard, wear of the flywheel teeth has appeared)

Replace the drive or flywheel

Starter noise during armature rotation

- excessive wear of bearings (armature shaft bushings)

Replace the bearings or starter covers

- the starter mount is loose or its cover on the drive side is broken

Tighten the mounting nuts or replace the starter cover on the drive side

- the teeth of the drive gear or the crown of the flywheel are damaged

Replace the drive or flywheel

The gear does not disengage from the flywheel

- clutch jamming on the drive shaft slots

Clean the slots and lubricate them with engine oil

- jamming of the anchor of the traction relay

Replace the traction relay or eliminate jamming

Removing and installing the starter

The starter is mounted on the cylinder block on the rear side of the power unit

We prepare the car and install it on a lift or an observation ditch

Removing the protection of the engine crankcase

Disconnect the negative battery terminal

Removing and installing the Mazda 6 starterRemoving and installing the Mazda 6 starter

Disconnect the block of the control wire of the traction relay

We open the plastic cap

Removing and installing the Mazda 6 starterRemoving and installing the Mazda 6 starter

Unscrew the nut of the power wire attachment and remove the wire from the contact bolt of the traction relay

Removing and installing the Mazda 6 starterRemoving and installing the Mazda 6 starter

Loosen the tightening of the starter mounting bolts

Removing the starter

We remove the starter from the cylinder block and lower it down

Removing the seal

Installing the starter and all the parts in reverse order