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.