Nissan PULSAR N13 Series / ASTRA LD Series. Manual - part 50

Electrical System

 

201

 

 

nosed pliers. This will safeguard the diodes 
by transferring any excess heat to the jaws of 
the pliers.

 

 

Using a suitable drift, install the bearing into 

the drive end bracket, install the retainer plate and 
screws. Tighten the screws securely. 

 

Using a suitable press and press plates, install 

the bearing to the slip ring end of the rotor shaft. 
Ensure that pressure is exerted only on the inner race 
and that the stop ring groove is nearest to the slip 
rings. 

 

Ensure that the rotor shaft rear bearing stop 

ring is positioned so that the protruding part of the 
ring is located in the deepest part of the groove. 

 

Install the stator, diode pack and 

regulator 
assembly to the slip ring end  bracket.   Install the 
retaining nuts and washers and tighten securely. 

 

Install the nut and insulator to the terminal 

and tighten securely. 

 

Using a piece of wire, hold the brushes in a 

retracted position. 

 

Hold the drive end bracket in a soft jawed 

vice and install the rotor shaft assembly to the drive 
end bracket. 

 

Install the pulley, retaining nut and washer to 

the rotor shaft and tighten the retaining nut to the 
specified torque. 

 

Apply a heated 200 watt soldering iron to the 

slip ring end bracket at the bearing mounting boss for 
3-4   minutes  to  heat   the  bracket  and  allow the 
installation of the rotor shaft rear bearing. 

 

Aligning the marks made on dismantling and 

ensuring that the rotor shaft rear bearing retaining 
ring protrusion is located in the deepest part of its 
groove, install the rotor/stator assembly to the slip ring 
end bracket. 

 

Remove the brush retracting wire from the 

alternator,   ensure   that   the   alternator  component 
marks are aligned, install the retaining through bolts 
and tighten them securely. 

 

Check the alternator rotor for smooth oper- 

ation and  install the alternator to the vehicle 
as 
previously described. 

 

Check the alternator operation on the vehicle 

as previously described. 

8.    STARTER MOTOR 

Special Equipment Required: 

To Renew Brushes — Soldering iron 
To Renew Armature Bearings — Bearing puller 

DESCRIPTION 

Two types of starter motors  are installed to the 

range of vehicles covered by this manual, either 
Hitachi or Bosch.

 

The starter motor is the induced pole type with 

four brushes and four pole shoes with field coils.

 

A solenoid switch is attached to the starter drive 

end bracket. The solenoid plunger is connected to 
the overrunning clutch and drive pinion assembly 
through a lever and pivot arrangement.

 

When the solenoid windings are energized, the 

plunger acting on the lever and pivot engages the drive 
pinion with the flywheel ring gear and at the same 
time closes the switch supplying power from the 
positive lead of the battery to the starter motor field 
coils and armature to operate the motor.

 

As the engine fires, the over-running clutch of the 

drive pinion assembly prevents high speed rotation of. 
and possible damage to, the starter armature if the 
solenoid windings are not immediately de-energized 
by releasing the ignition key.

 

The starter solenoid switch windings are energized 

by the ignition switch.

 

TO TEST ON VEHICLE

 

Should the starter motor fail to operate when the 

ignition switch is turned to the Start position, check 
the following points:

 

 

Check  the  battery condition  and  state of 

charge. Refer to the Battery heading for the correct 
procedure. 

 

Clean the battery terminals, taking particular 

care  to remove the scale from  the  positive ( + ) 
terminal post and terminal. 

 

Check the earth connection for tightness and 

cleanliness. 

 

Switch on the headlamps and turn the igni- 

tion switch to Start. If the lamps dim but the starter 
motor does not operate, it could indicate that a short 
circuit has developed in the starting system. 

Check that the engine is not seized or that the 

starter motor drive pinion and ring gear are not 
locked as these conditions would -give the same 
indications as above.

 

(5)  If the lamps do not dim and the starter 

motor does not operate, this would indicate an open 
circuit such as a broken or disconnected wire or a 
switch not operating.

 

If the vehicle is equipped with an automatic 

transaxle, turn the ignition switch to Start and move 
the selector lever through all the gear selection range. 
If the starter motor operates in any position other 
than N or P, the neutral safety switch is faulty.

 

(6)  Check all the external wiring to ensure that 

the fault is not external. If the external circuit proves 
satisfactory, indicating that the problem is in the 
starter motor, the unit will have to be removed and 
tested.

 

TO REMOVE AND INSTAL

 

 

Disconnect the negative battery terminal. 

 

Disconnect the wiring from the starter motor 

solenoid. 

 

Remove the starter motor mounting bolts, 

202

 

Electrical System

 

 

 

View of the Bosch starter motor removed from the 

vehicle. 

noting the position of the earth cable, and maneuver 
the starter motor out of the engine compartment.

 

Installation is a reversal of the removal procedure 

with attention to the following points:

 

 

Replace the earth cable to the position noted 

on removal. 

 

Tighten the starter motor mounting bolts 

securely. 

HITACHI STARTER MOTOR

 

To Dismantle

 

 

Remove the starter motor from the vehicle 

as previously described. 

 

Mount the starter motor upright in a soft 

jawed vice gripping the drive end bracket. 

 

Loosen the solenoid field coil terminal nut 

and disconnect the cable from the solenoid. 

 

 

Scribe a line across the drive end bracket, 

yoke and end cover to facilitate correct alignment 
during assembly. 

 

Remove the bolts retaining the end cover 

and yoke to the drive end bracket and remove the end 
cover from the yoke. 

 

Remove   the   yoke,   armature   and   brush 

holder as an assembly from the drive end bracket. 
Note the position of the O ring sealing the yoke. 

 

Release the brush springs and separate the 

brushes from the brush holder. 

 

Remove the brush holder from the yoke. 

 

Separate the armature from the yoke. 

 

Scribe a line across the solenoid and the 

drive   end   bracket   to   facilitate   correct   alignment 
during assembly. 

 

Remove the solenoid retaining bolts and lift 

the solenoid, spring, lever and rubber seal out of the 
drive end bracket. Note the installed position of the 
components. 

 

Mount the drive end bracket in the vice with 

the pinion uppermost and Remove the screws retaining 
the pinion housing to the drive end bracket. 

 

Remove the pinion housing from the drive 

end bracket, 

 

Remove the pinion assembly from the drive 

end bracket, 

 

Mount the pinion in the vice, hold the collar 

down and remove the snap ring from the end of the 
pinion. 

 

Remove  the  collar  and   spring   from   the 

pinion and slide the pinion out of the clutch assembly. 

 

If necessary, prise the bearings off the clutch 

assembly using two screwdrivers. Note the location of 
the larger bearing. 

 

If necessary, remove the bearings from the 

armature using a bearing puller. 

To Check and Inspect

 

 

Clean all the starter motor components thor- 

oughly but do not immerse the yoke, armature or 
clutch assembly in cleaning solvent. 

 

Check the brush holder insulation using an 

ohmmeter. 

Connect one test probe to the brush holder 

positive side and the other test probe to the negative 
side. If continuity exists, renew the brush holder.

 

 

Check the brushes for adequate length. Re- 

new the brushes if they are worn to less than the 
length listed in Specifications. The brushes should be 
a free sliding fit in the brush holders. Check the brush 
springs for adequate tension. 

 

Check the  field coil  continuity  using an 

ohmmeter. Connect one test probe to the positive 
brush and the other test probe to the solenoid cable 
terminal. If continuity does not exist, renew the field 
coils. 

View of the Hitachi starter motor removed from the 

vehicle

. 

Electrical System 

203

 

BRUSH HOLDER

 

Dismantled view of the Hitachi starter motor. 

 

Check  the  field   coil  insulation   using an 

ohmmeter. Connect one test probe to the solenoid 
cable terminal and the other test probe to the body of 
the yoke. If continuity exists, renew the field coils. 

 

Check  that  the  commutator  is  free  from 

pitting and burning. Clean the commutator with a 
petrol moistened cloth and polish with a strip of fine 
glass paper. 

A badly worn commutator may be repaired by 

mounting in a lathe and taking a light cut using a very 
sharp tool with the lathe rotating at high speed. After 
machining, undercut the insulation between the seg- 
ments to Specifications. Do not machine the commu- 
tator to below 29 mm diameter. Check the armature 
gear teeth for wear and damage.

 

 

Check the armature for short circuit using an 

ohmmeter.   Place  one of the  test  probes  on  the 
armature shaft or core and move the other test probe 
around the periphery of the commutator. If continuity 
exists at any point, the armature is faulty and should 
be renewed. 

 

Check the pinion for wear and damage. The 

pinion should move smoothly along the clutch assem- 
bly helical splines. Check the spring, collar and snap 
ring for serviceability. 

 

Check that the clutch assembly locks in one 

direction and rotates smoothly in the opposite direc- 
tion. Check for wear and damage to the reduction gear 
teeth on the outside of the clutch assembly. 

 

Check that continuity exists between the 

solenoid spade terminal and the solenoid body and 
between the solenoid spade terminal and the solenoid 
field coil terminal. Renew the solenoid if continuity 
does not exist. 

 

Renew   all   the   components   found   to  be 

unserviceable in the above checks. 

To Assemble

 

Assembly is a reversal of the dismantling proce- 

dure with attention to the following points:

 

(1)    If removed, install new bearings to the clutch

 

assembly and the armature. Lubricate the armature 
bearings with high temperature grease.

 

The sealed bearings on the clutch assembly are 

lubricated during manufacture and further lubrication 
is unnecessary.

 

 

Apply high temperature grease to the yoke 

end cover bearing recess, the drive end bracket and 
pinion housing bearing recesses, the clutch assembly 
reduction gear teeth, the armature gear teeth, the 
pinion helical splines, the solenoid plunger and the 
spring and lever. 

 

Install the pinion to the clutch assembly and 

install the spring and collar to the pinion. 

 

Hold the collar down and install the snap ring 

to the end of the pinion. 

 

Position the collar over the snap ring. If 

necessary, squeeze the snap ring into the groove using 
multigrip pliers to enable the collar to be clipped over 
the snap ring. 

 

Install the pinion and clutch assembly to the 

drive end bracket. 

 

Install the pinion housing to the drive end 

bracket.  Install and tighten the retaining screws 
se- 
curely. Check that the pinion rotates freely. 

 

Assemble the lever and spring to the solenoid 

in the position noted on dismantling. 

 

Install the solenoid assembly and rubber seal 

to the drive end bracket. 

 

Install   and   tighten   the   solenoid   retaining 

bolts securely. 

 

Connect 12 volts between the solenoid spade 

terminal  and  the  solenoid  field  coil  terminal  and 
measure  the  distance  that  the  end  of the  pinion 
protrudes from the pinion housing. 

Pull the pinion by hand until it contacts the stop 

and measure the pinion end protrusion.

 

If necessary, add or subtract shims between the 

solenoid mounting face and the drive end bracket 
until the difference between the above measurements 
is 0.3-1.5 mm.

 

 

Install the armature to the yoke. 

 

Install the brush holder to the yoke. Install 

the 

PLUNGER

 

O RING

204

 

Electrical System

 

 

brushes to the brush holder and position the springs 
against the ends of the brushes.

 

 

Install the O ring to the yoke taking care 

that 
the O ring is not twisted. 

 

Install the yoke, armature and brush 

holder 
assembly to the drive end bracket, aligning the marks 
made on dismantling. 

 

Install the end cover to the yoke. Install 

and 
tighten the retaining bolts securely. 

 

Connect the cable to the solenoid field coil 

terminal and tighten the terminal nut securely. 

 

Install the starter motor to the vehicle 

as 
previously described. 

BOSCH STARTER MOTOR 
To Dismantle

 

 

Disconnect the brush connector strap from 

the lower terminal on the solenoid switch. 

 

Remove the screws retaining the solenoid to 

the drive end bracket and remove the solenoid from 
the drive end bracket. 

 

Loosen, but do not remove the screws retain- 

ing the armature end cover to the commutator end 
bracket. 

 

Remove the through bolts retaining the drive 

end bracket to the commutator end bracket. 

 

Remove the yoke, armature and commutator 

end bracket from the drive end bracket as an assem- 
bly. Hold the rubber seal in place in the drive end 
bracket to keep the engaging lever in position. 

 

 

Remove the rubber seal from the drive end 

bracket. 

 

Remove the cover plate from the planetary 

gear set and remove the gear set, drive assembly and 
engaging lever as an assembly. 

 

Remove the armature end cover and com- 

mutator end bracket from the yoke. 

 

Remove the screws retaining the armature 

end cover to the commutator end cover and remove 
the armature end cover, C clip and shims from the 
armature shaft. Remove the commutator end bracket 
from the armature. 

 

Carefully remove the brush holder from the 

armature. 

 

Support the gear set and drive assembly in a 

vertical position with the drive assembly uppermost. 

 

Using a suitable drift, tap the stop collar 

towards the drive assembly and remove the snap ring 
from the drive shaft. 

 

Remove any burrs from the drive shaft and 

withdraw the drive assembly and stop ring from the 
drive shaft. 

 

Clean all parts thoroughly but do not im- 

merse the armature, solenoid or drive assembly in 
cleaning solvent. 

To Check and Inspect

 

(1)   With the starter motor dismantled, check the 

brush holder insulation using an ohmmeter.

 

Connect one test lead to the brush holder positive

 

BRACKET

 

 

Dismantled view of the Bosch starter motor.