Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 51

Electrical System

205

Dismantled view of the brush holder assembly. Bosch

starter motor.

side and the other lead to the negative side. If there is
any indication of leakage the ohmmeter will show a
reading other than infinity. Repair or renew the brush
holder if leakage is evident.

(2) Check the brushes for adequate length.

Brushes should be renewed when their length is below
Specifications. They should be a free sliding fit in the
brush holders.

NOTE: Due to the difficulty involved in
removing and installing the brushes in the
Bosch starter motor, it is recommended that
the brush holder be renewed as an assembly.

(3) Check that the commutator is free from

pitting and burning. Clean 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, spinning at high speed, and
taking a light cut with a very sharp tool. After turning,
undercut the insulation between the segments.

(4) Check the armature for short circuit using an

ohmmeter.

Place one of the test leads on the armature shaft

or core and move the other lead around the circum-
ference of the commutator. If the ohmmeter shows a
reading at any point the armature is faulty and should
be renewed.

Check the drive assembly clutch pinion teeth

for wear, scoring or chipping. A clutch in good
condition should take up the drive in one direction
only. It should rotate easily and smoothly in the
non-drive direction and the assembly should move
smoothly along the armature or drive shaft helical
splines.

Check the armature shaft bushes for wear

and renew as necessary. The old bushes must be
removed and the new ones pressed into the end
brackets using a polished mandrel of the exact diam-
eter of the armature shaft.

NOTE: The new bushes must not be reamed
to size, as reaming will impair the porosity
of the bushes and cause early failure. New
bushes should be allowed to stand immersed
in clean light engine oil for one hour before
installation.

To Assemble

Assembly is a reversal of the dismantling proce-

dure with attention to the following points:

Lubricate the helix of the drive shaft lightly

with graphite grease and install the drive assembly
to
the drive shaft.

Install the stop collar and snap ring, slide the

stop collar over the snap ring to lock the snap ring in
position.

Lubricate the bushes in both end brackets

sparingly with engine oil.

Install the engaging lever and gear set into the

drive end bracket.

Install the centre rear bracket and the engag-

ing lever seal into the drive end bracket.

Slide the brush holder assembly into position

on the commutator ensuring that the brush holders
are correctly positioned in the anchor points.

Install the commutator end bracket to

the
armature, install the shims and C clip.

Check that the armature end float is satisfac-

tory and adjust as necessary using shims of the correct
thickness.

Align the slot in the commutator end bracket

with the cut out on the wiring seal and install the
armature end cover to the commutator end bracket.
Install the cover retaining screws but do not tighten.

Ensure that the permanent magnets in the

yoke have not picked up any debris and slide the yoke
over the armature ensuring that the wiring seal locates
correctly in the slot in the yoke.

View showing the planetary gear set. Bosch starter

motor.

206

Electrical System

Install the armature and yoke to the drive end

bracket rotating the drive to align the reduction gears.
Do not use force.

Install the retaining through bolts to the

commutator end bracket and lighten the through bolts
and armature end cover retaining screws securely.

Install the solenoid to the drive end bracket,

install the retaining screws and tighten them securely.

Install the brush connector strap and

install
the retaining nut and washer and tighten securely.

9. IGNITION

SYSTEM

The testing and repair procedures for the ignition

system are fully covered in the Fuel and Engine
Management section.

10. STEERING

WHEEL

The removal and installation procedures for the

steering wheel and horn pad are fully covered in the
Steering section.

11. SWITCHES AND CONTROLS

IGNITION SWITCH

To Remove and Install

Disconnect the negative battery terminal.

Remove the retaining screws from the steer-

ing column cover.

Unclip and separate the upper and lower

steering column covers and remove the upper cover.

Release the column adjusting lever and re-

move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.

Disconnect the ignition switch wiring at the

switch.

Remove the retaining screw and withdraw

the ignition switch from the lock assembly.

Installation is a reversal of the removal procedure.

COMBINATION SWITCH

The combination switch is mounted at the top of

the steering column and incorporates two switches.
The parking lamp, headlamp, headlamp flasher, head-
lamp dipper and turn signal lamps are operated by a
lever on the right hand side. A lever on the left hand
side operates the windscreen washer and wiper switch.

These switches can be renewed without removing

the combination switch.

To Remove and Install Switches

Remove the retaining screws from the steer-

ing column cover.

Unclip and separate the upper and lower

steering column covers and remove the upper cover.

View of the combination switch removed from the

vehicle.

Release the column adjusting lever and re-

move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.

Disconnect the wiring connectors from the

applicable switch.

Remove the retaining screws located at the

top and bottom of the applicable switch and remove
the switch.

Installation is a reversal of the removal procedure.

To Remove and Install Combination Switch Base

Disconnect the negative battery terminal.

Remove the steering wheel as described in

the Steering section

Remove the retaining screws from the steer-

ing column cover.

Unclip and separate the upper and lower

steering column covers and remove the upper cover.

Release the column adjusting lever and re-

move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.

Dismantled view of the steering lock and ignition

switch assembly

Electrical System

207

Disconnect the wiring connectors from the

rear of the combination switch.

Loosen the clamping screw located at the left

hand side of the combination switch.

Push, turn and slide the combination switch

from the steering column.

Installation is a reversal of the removal procedure.

REAR WINDOW DEMISTER
SWITCH/HAZARD WARNING LAMP SWITCH

To Remove and Install

Disconnect the negative battery terminal.

Using two small flat bladed screwdrivers,

carefully lever the edges of the switch forward to
release it from the instrument cluster surround.

Withdraw the switch from the surround and

disconnect the switch wiring at the connectors.

Installation is a reversal of the removal procedure.

View of the hazard warning switch removed from the

instrument cluster surround.

DOOR LOCKS AND POWER WINDOW
SWITCHES

To Remove and Install

Disconnect the negative battery terminal.

Loosen the retaining screws securing the

armrest to the door.

Using a small flat bladed screwdriver, care-

fully lever the front edge of the switch panel up and
maneuver the switch forward and away from the
armrest.

Disconnect the wiring connector and remove

the switch from the armrest.

Installation is a reversal of the removal procedure.

POWER MIRRORS AND INSTRUMENT
ILLUMINATION SWITCHES

To Remove and Install

Disconnect the negative battery terminal.

Using two small flat bladed screwdrivers,

View of the power mirror switch removed from the

vehicle.

carefully lever the edges of the switch forward to
release it from the fascia located directly above the
fuse box.

(3) Withdraw the switch from the fascia and

disconnect the wiring.

Installation is a reversal of the removal procedure.

REAR WINDOW WIPER/WASHER SWITCH

To Remove and Install

Disconnect the negative battery terminal.

Using two small flat bladed screwdrivers,

carefully lever the edges of the switch forward to
release it from the instrument cluster surround.

Withdraw the switch from the surround and

disconnect the wiring.

Installation is a reversal of the removal procedure.

View of the rear window wiper/washer switch re-

moved from the vehicle.

208

Electrical System

STOP LAMP SWITCH

To Remove and Install

Disconnect the switch wiring at the connec-

tors.

Loosen the switch locknut and unscrew the

switch from the pedal bracket.

Installation is a reversal of the removal procedure

with attention to the following points:

The stop lamp switch is also the return stop for

the brake pedal. Adjust the pedal free play as de-
scribed in the Brakes section.

Installed view of the stop lamp switch and the flasher

unit.

HANDBRAKE WARNING LAMP SWITCH

To Remove and Install

Lift the small plastic cover directly under the

handbrake and remove the screws.

Remove the carpet at the rear of the centre

console and remove the screws.

Carefully remove the console from the hand-

brake assembly.

Remove the retaining screw and withdraw

the switch from the handbrake lever.

To Test

Remove the handbrake console as described

in the previous text.

Disconnect the switch wiring at the con-

nector.

Connect an ohmmeter between the switch

terminal and a suitable earth.

Pull the handbrake lever up.

If no reading is displayed on the ohmmeter,

the switch is faulty and should be renewed using the
procedure previously described.

Installation is a reversal of the removal procedure.

COURTESY LAMP DOOR SWITCH

To Remove and Install

With the door fully open, remove the retain-

ing screw from within the rubber cover of the switch.

Withdraw the switch from the centre door

pillar.

Disconnect the wiring from the switch and

remove the switch from the vehicle.

Installation is a reversal of the removal procedure.

View of the courtesy lamp door switch removed from

the vehicle.

REVERSE LAMP SWITCH

On automatic transaxle models, a combined neu-

tral safety switch and reverse lamp switch is installed
on the side of the transaxle. The test and renewal
procedures are described in the Automatic Transaxle
section.

To Remove and Install

Disconnect the wiring connector terminals at

the reverse lamp switch.

Remove the reverse lamp switch from the

transaxle housing.

Installation is a reversal of the removal procedure.

Installed view of the handbrake warning lamp switch.