stop start NISSAN PULSAR 1987 User Guide

Fuel and Engine Management 113
(2) Disconnect the wiring connector from the
MAT sensor.

(3) Unscrew the sensor from the inlet manifold.
Installation is a reversal of the removal procedure

with attention to the following points:
(1) Apply Loctite 567 or a similar conductive
sealer to the threads of th e sensor. Tighten the sensor
to the specified torque. (2) Ensure that the wiring connector is clean and
tight.
OXYGEN SENSOR

To Test - Code 13
(1) Run the engine until the normal operating
temperature is obtained. (2) With the ignition switched Off, connect a
jumper lead between terminals A and B on the
diagnostic link connector.
(3) Start and run the engi ne at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp.
If the ECM warning lamp flashes at the rate of
twice per second, proceed to operation (5).

If the ECM warning lamp flashes at the rate of
once per second or slower, proceed as follows.

(4) Remove the jumper lead from the diagnostic
link connector and run th e engine above 2 000 rpm
for 2 minutes, noting the ECM warning lamp.

If the ECM warning lamp lights, stop the engine,
switch the ignition On and connect a jumper lead
between terminals A and B on the diagnostic link
connector. If code 13 is displayed proceed to opera-
tion (5).

If the ECM warning lamp does not light, an
intermittent fault is indicated. Proceed as follows:

(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure.
(b) Check that all earth wires are secure.
(5) Switch the ignition Off and disconnect the
oxygen sensor wiring connector. Using a jumper lead
connect the oxygen sensor wiring connector to a
suitable engine earth. (6) Start and run the engi ne at approximately
1 600-1 800 rpm and note the ECM warning lamp.
The lamp may flash for a few seconds but should then
extinguish for at least 30 seconds.
If the ECM warning lamp functions as described,
proceed to operation (7).

If the ECM warning lamp does not function as
described proceed as follows:

(a) Check the wiring harness between the oxygen
sensor wiring connector and the control unit wiring
connector D7 for open circuits. Repair or renew the
wiring harness as necessary.

{b) Check the earth circuit between the control
unit wiring connect D6 and the right rear cylinder
head bolts. Repair or renew the wiring harness as
necessary.

(c) If no fault is found in (a) and (b) renew the
control unit and retest for fault codes.

(7) Check the wiring harness earth circuit be-
tween the control unit wiring connector D6 and the
right rear cylinder head bolts. Repair or renew the
wiring harness as necessary.

If no fault is found, thoroughly check the oxygen
sensor connector. If the conne ctor is not faulty, renew
the oxygen sensor.

To Test - Code 44
(1) Run the engine until normal operating tem-
perature is attained.
(2) With the ignition switched Off, connect a
jumper lead between terminals A and B on the
diagnostic link connector. (3) Start and run the engi ne at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp. If the ECM warning lamp is off more than on or
flashes at the rate of twice per second, proceed to
operation (4).

If the ECM warning lamp flashes evenly at the
rate of once per second an intermittent fault is
indicated. Proceed as follows:

(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth wires are secure.
(4) Switch the engine Off and disconnect the
oxygen sensor wiring connector.
(5) Start and run the engine at 1 600-1 800 rpm
for at least 30 seconds and note the ECM warning
lamp. If the ECM warning lamp flashes at the rate of
twice per second procee d to operation (6).

If the ECM warning lamp extinguishes for at least
30 seconds, check the wiring harness between the
oxygen sensor wiring connector and the control unit
wiring connector terminal D7 for shorts to earth.

Repair or renew the wiring harness as necessary.
If no fault can be found in the wiring harness, renew
the control unit.

Installed view of the oxygen sensor.

Automatic Transaxle 141

(2) Incorrectly adjusted kickdown cable: Check
and adjust or renew the kickdown cable as required.

NOTE: Check and adjust the throttle cable
before adjusting the kickdown cable.

ENGINE WILL NOT START IN P OR N
RANGE OR WILL START IN ANY RANGE

(1) Neutral safety switch faulty: Adjust or renew
the neutral safety switch. (2) Incorrectly adjusted selector cable: Check
and adjust the selector cable as detailed.
2. DESCRIPTION

The automatic transaxle combines a fluid coup-
ling or torque converter with a fully automatic three
speed epicyclic gear system.

The transaxle provides th ree forward ratios and
one reverse. The hydraulic system consists of a single
pump and valv e arrangement.

The final drive or differential and the transaxle
use a common lubricant. The transaxle oil pan and
final drive drain plug will have to be removed to drain
the transaxle completely. Topping up or refilling is
done through the dipstick tube.

The gear selector lever is floor mounted and
connected to the transaxle by an adjustable cable. The
selector quadrant adjacent to the base of the lever is
marked P, R, N, D, 2, 1.

It is necessary for the selector lever to be in P or
N before the engine can be started. When testing or
tuning the engine, the handbrake must be firmly
applied and the selector lever placed in the P position,
otherwise the vehicle could move forward or back-
wards as the engine speed is increased.

For long distance towing the vehicle should be
towed with the front end raised.

It is not possible to start the engine by either
towing or pushing the vehicle.

The transaxle can be removed from the vehicle
without engine removal.

NOTE: As extensive knowledge and equip-
ment is required to overhaul the automatic
transaxle assembly, it is therefore not a
worthwhile repair proposition for the aver-
age person. However if the transaxle must
be overhauled by a specialist or be replaced
with a reconditioned unit, the removal and
installation procedure is fully described at
the end of this section.

3. TRANSAXLE FLUID
Only use the recommended transaxle fluid speci-
fied by the manufacturer when topping up or changing
the fluid in the system.

TO CHECK AND TOP UP
NOTE: The fluid level should be checked
after approximately 5 minutes driving on
the road when the engine has achieved its
normal operating temperature of approxi-
mately 65 deg C.

(1) Place the vehicle on a level floor and open
the engine bonnet.

NOTE: When working on the automatic
transaxle cleanliness is very important. Do
not reuse transaxle fluid and do not allow
foreign matter to enter the filler opening.

(2) Clean around the top of the dipstick to
ensure that no dirt or foreign matter can enter the
dipstick tube.
(3) Place the selector in the P position and
firmly apply the handbrake. (4) Move the selector thro ugh each gear return-
ing it to the P position.
(5) Check the fluid level with the engine running
at idle. Install the dipstick fully into the dipstick tube.
NOTE: If the vehicle has been driven at high
speed, or has been towing a load, or driven
through heavy city traffic in hot weather, a
period of about 30 minutes should be
allowed to permit the transaxle to cool
before checking the fluid level.

(6) Withdraw the dipstick and check the fluid
level reading. The fluid should be at the H mark on
the dipstick. If the fluid is low, stop the engine and
remove the dipstick from the vehicle. Using a funnel,
top up the transaxle with the recommended type of
transaxle fluid through the dipstick tube. (7) If the level is reading too high allow the
engine to cool down for about 30 minutes and recheck
the level as described. If the level is still too high, a
small amount of transaxle fluid may be drained from
the transaxle.

Checking the fluid level on the automatic transaxle
dipstick.

Steering — Part 3 153

TO CHECK FLUID LEVEL
Check the fluid level in the power steering reser-
voir when the fluid is cold.

If it is necessary to top up the fluid, fill to between
the arrow marks on the dipstick using the recom-
mended fluid.

NOTE: Do not overfill the reservoir.
Checking the power steering fluid level using the
dipstick incorporated in the cap.
TO CHECK FOR FLUID LEAKS
Using a suitable solvent, clean around all power
steering assemblies and hose fittings where fluid
leakage might occur and start the engine. Turn the
steering wheel from one steering lock to the other
several times and stop the engine. Check for leakage.
Where leakage is found at ho se fittings, tighten and
recheck.

If the leak remains, renew the hoses or fittings as
required.

Where leakage is found in the steering gear
assembly or pump assembly, specialist attention is
necessary.

TO CHECK STEERING WHEEL FREE PLAY
With the engine running and the steering wheel in
the straight ahead positi on, measure the free move-
ment of the steering wheel before the front wheels
move. This is specified as steering wheel free play and
if it exceeds Specifications, check for free play in the
steering linkages and the universal coupling joints. If
these components are satisfactory, it will be necessary
to remove the steering gear from the vehicle for
renewal or overhaul.

PUMP BELT TENSION
The procedure for adjusting the power steering
pump bell tension is describe d in the Engine Tune-up
section

TO PURGE THE POWER STEERING SYSTEM
OF AIR

(1) Check that the pump reservoir is filled to the
correct mark on the dipstick. (2) Raise the front of the vehicle and support it
on chassis stands. (3) Turn the steering wheel quickly from lock to
lock several times, recheck the fluid level within the
pump reservoir and top up if required. (4) Start the engine, allow it to idle and slowly
turn the steering wheel from lock to lock several times.
Do not hold the steering at full lock for more than 15
seconds. (5) Check the fluid level in the pump reservoir,
top up if necessary. (6) If the fluid is aerated within the pump
reservoir or if pump noise persists, repeat operations
(3) to (6).
3. STEERING WHEEL

The procedure for removing and installing the
steering wheel is fully covered in the Manual Steering
section under the above heading.

4. STEERING COLUMN
The procedure for removing, dismantling and
assembling the steering column is fully covered in the
Manual Steering section under the above heading.

5. POWER STEERING PUMP
TO REMOVE AND INSTAL
( 1 ) Disconnect the negative battery terminal.

View of the power steering pump removed from the
vehicle.

Brakes 177
installed. Install the second back up ring, large
diam-
eter first.

(6) Install the second garter spring. Insert
a
machined drift into the bore and lightly push the
garter spring into its locating groove.
(7) Smear the secondary piston with clean brake
fluid. Ease the seal over the piston body into the
groove adjacent to the spring, ensuring that the seal lip
faces the spring and that the nylon spacer is against
the back of the seal. (8) Install the guide onto the secondary
piston,
large internal diameter first, followed by the main seal
with the lip facing away from the spring. (9) Lubricate the secondary piston assembly
with clean brake fluid and install the secondary spring
and retainer to the piston. Install the complete assem-
bly into the master cylinder bore. (10) Smear the primary piston with clean brake
fluid. Install the guide, large internal diameter first,
followed by the main seal with the lip facing towards
the small end of the piston.
(11) Install the retainer to the spigot on the front
end of the primary piston ensuring that the legs of the
retainer engage with the groove on the piston. (12) Lubricate the primary piston assembly with
clean brake fluid and install the assembly into the
master cylinder bore. With a blunt rod, push the
assembly down the bore sufficiently to preload the
pistons. While holding the preload, install the stop pin
and valve assemblies into
the master cylinder body and tighten securely. (13) Install a new O ring to the groove on the boss
of the mounting flange of the master cylinder.
(14) Install new O rings to th e pressure differential
pistons, smear them with cl ean brake fluid and install
them into the master cylinder body. (15) Install a new O ring to the pressure differen-
tial end plug, install the plug to the master
cylinder
body and tighten to the specified torque. (16) Using a blunt probe entered through the
sensing switch location hole, separate the pressure
differential pistons and install the switch actuating
lever between them. (17) Screw the sensing switch into its locating
hole until the detents on the switch body just contact
the locating hole facing (w ith the radial grooves).
Screw the switch assembly in a further half to one full
turn ensuring that the dete nts locate in the grooves.
(18) Install new valve seal s to the proportioning
valve plungers, with the serrations of the seals facing
away from the hexagons of the plungers.
(19) Install the new O rings to the
proportioning
valve plugs. (20) Install the valve springs over the stems of the
proportioning valves, insert the install the valve
plugs.
Tighten the plugs to the specified torque.
(21) Install a new O ring to the base of the fast fill
valve assembly. Install a new valve washer to the base
of the valve.
(22) Install the fast fill valve assembly in
the
primary reservoir port (nearest to the mounting flange
of the master cylinder) and install the snap ring
to
retain the assembly. Ensure that the snap ring is
correctly seated in the groove. (23) Smear the new reservoir retainers with clean
brake fluid and install them into the reservoir ports.
Carefully press the brake fluid reservoir into position,
ensuring that the outlet extensions are fully inserted in
the reservoir retainers. (24) Install the reservoir cap insert to the dia-
phragm and press the cap assembly onto the reservoir.
TO INSTAL

Installation is a reversal of the removal procedure
with attention to the following points:

(1) Pour a small amount of clean brake fluid into
the reservoir and pump the master cylinder pistons
with a blunt rod until fluid begins to emerge from the
outlets. (2) Install the master cylinder to the brake servo
unit and loosely install the master cylinder retaining
nuts. (3) Connect the brake pipes to the master cylin-
der outlets, but do not tighten at this stage. (4) Securely tighten the nuts retaining the master
cylinder to the brake servo unit.
(5) Securely tighten the brake pipes and connect
the wiring to the pressure sensing switch.

(6) Fill the master cylinder reservoir with clean
brake fluid and bleed the brakes as described under
the Hydraulic System heading. (7) Check and if necessary adjust the brake
pedal height and free play as described under the
Brake Pedal heading.
4. BRAKE SERVO UNIT

TO CHECK OPERATION
(1) With the engine switched off, apply the
footbrake several times to exhaust all vacuum from
the system.
(2) Apply the footbrake and hold the brake pedal
fully depressed.
(3) Start the engine. If the servo unit is function-
ing satisfactorily a distinct downward movement of
the
brake pedal should be noticed. Should the pedal fail to move downward when the
engine has been started, the vacuum system can be
considered inoperative.

NOTE: If the pedal continues to fall away
there is a fault in the hydraulic system.

(4) Ensure that the brake pedal is fully released,
start the engine and run it at medium speed. Stop the
engine.

190
ELECTRICAL SYSTEM
CAUTION: To prevent severe electrical shock extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

SPECIFICATIONS
BATTERY
Type ..................................................12 volt lead acid
Polarity to earth .................................... Negative ( - )
Specific gravity:
Fully charged ................................... A bove 1.250
Fully discharged ................................Below 1.130
ALTERNATOR
Make .................................................Bosch or Hitachi
Maximum output .......................................... 70 amps
Polarity to earth .................................... Negative ( - )
Stator windings ......................................... Star wound
Regulator type ................................................ Integral
Brush length minimum:
Bosch ........................................................ 5.0 mm
Hitachi ............................. 6.0 mm or limit mark
STARTER MOTOR
Make .................................................Hitach i or Bosch
Type ............................ 4 pole 4 brush reduction gear
Operation control.................................. Solenoid and
overrunning clutch
Undercut of commutator (maximum):
Hitachi ...................................................... 0.8 mm
Brush length (minimum):
Bosch ........................................................ 8.0 mm
Hitachi ........................................................11 mm
Brush spring tension;
Hitachi ............................................... 15.7-19.6 N
Hitachi:
Drive pinion stopper clearance ........ 0.3-1.5 mm
Selective fit adjuster plates ........ 0.5 and 0.8 mm
IGNITION SYSTEM
The ignition system is an integral part of the
engine management system. The Specifications, testing
and overhaul procedures are fully covered in the Fuel
and Engine Management section.

TORQUE WRENCH SETTINGS
Alternator pulley retaining nut:
Bosch ......................................................... 50 Nm
Hitachi ....................................................... 59 Nm
1. BATTERY AND CHARGING SYSTEM
TROUBLE SHOOTING

BATTERY UNDERCHARGED
3. Loose or broken drive belt: Adjust or renew
the drive belt. 4. Faulty alternator regulator; Renew the regu-
lator unit.
5. Faulty battery: Install a new battery of
the
recommended type and capacity. 6. Faulty alternator: Overhaul or renew the
alternator. 7. Fault in the charging circuit wiring: Check
and repair or renew the wiring harness. 8. Faulty connections in the charging circuit:
Check and repair the connections. 9. Fusible link blown; Rectify the fault and
renew as necessary.
NOTE: Check the state of charge (specific
gravity) of the battery- as described under
the
Battery heading in this section. If the battery
is undercharged, check the possible causes in
the order given.

BATTERY OVERCHARGED
• Faulty alternator regulator unit:
Renew the
regulator unit.
• Faulty alternator: Overhaul or
renew the
alternator. • Faulty charging circuit wiring or
connec-
tions: Check and renew or repair the faulty
compo-
nents.
NOTE: An overcharged battery is indicated
by continual loss of water through boiling.

196 Electrical System



Check the specific gravity in each cell with a hydro-
meter.
Check the battery electrolyte level and re-
plenish as necessary. Remove the filler cap s from the battery.
Follow the battery charger manufacturers
instructions. (3) Should the battery fail to operate satisfacto-
rily after charging, it is recommended that it be taken
to a workshop with the necessary equipment to per-
form a load test. Load testing, when performed in
conjunction with the specific gravity tests described
above will give an accurate indication of the service-
ability of the battery.
7. ALTERNATOR
Special Equipment Required
To Test On Vehicle - Voltmeter, 100-0-100
amp ammeter, ohmmeter
To Dismantle — 200 watt soldering iron,
bearing
puller, press
To Assemble — 200 watt soldering iron
DESCRIPTION
Two types of alternator are installed to the range
of vehicles covered by this manual, either Hitachi or
Bosch. In the alternator, the field and pole shoe assembly
is the moving part and it is shaped to form the rotor.
Since only a low amperage current flows between the
slip rings on the rotor shaft and the brushes, wear on
the brushes and slip rings is very slight and mainte-
nance is reduced to a minimum. The output current is generated in the fixed stator
windings and is a three phase alternating current
(AC). The stator windings are wound on a laminated
soft iron former, star connected and installed between
the end brackets. As it is not possible to charge a storage battery
with alternating current, it is necessary to rectify the
output of the stator windings to direct current (DC). This is done by a bank of diodes mounted within the
alternator slip ring end bracket.
The output of the alternator is governed by the
regulator and the built in ch aracteristics of the alter-
nator.
The regulator and brush holder assembly on
Hitachi alternators is mounted within the alternator
on the slip ring end bracket side. On Bosch
alternators
the regulator and brush holder unit is mounted to the
outside of the slip ring end bracket. An electrical cut out unit is not necessary with the
alternator charging system as the diodes prevent a
reverse current flow through the alternator.
SERVICE PRECAUTIONS
Ensure that the battery is connected with the
correct polarity to earth. Refer to Specifications.
Do not short out or ground any terminals
common to the charging circuit. Always disconnect the battery before con-
necting a battery charger.
If a booster battery is used, always connect it
in a parallel circuit i.e. positive to positive ( + to + )
and negative to negative (- to -) to maintain a 12
volt supply. Never disconnect the battery or terminals in
the charging circuit while the engine is running. Regularly check that the alternator drive belt
tension is as specified. Refer to the Engine Tune-up
section.
Keep the battery terminals clean and all
electrical connections tight. Disconnect the battery and alternator when
electric welding on the vehicle.
TO TEST ON VEHICLE If the charge indicator lamp stays on after the
engine has been started and run at approximately
1 000 rpm, carry out the following tests. Stop the engine.
Check the condition and adjustment of the
alternator drive belt. Clean the battery terminals, tighten all elec-
trical connections, check the wiring for shorts to earth
and/or bridged circuits. Ensure that the battery is fully
charged. If the battery is discharged charge it or
replace it with one fully charged. Start the engine and allow it to run until
normal operating temperature is reached.
Stop the engine and disconnect the negative
battery terminal.
Remove the nut and washer from the alter-
nator output terminal (B +) and disconnect the alter-
nator output lead. Connect one lead of an ammeter to the
alternator output terminal and the other lead to the
lead removed from the output terminal. Connect the negative battery terminal and
connect a voltmeter across the battery terminals.

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 ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft 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 e nd 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 sh aft 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 retr acting 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 al ternator 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 covere d 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 ri ng 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,

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 smoothl y 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, th e 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 subt ract 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.

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, spi nning 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 lead s 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 retaini ng 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.