Nissan Pick-ups and Pathfinder 1989-1995

Starter

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Disconnect the negative battery cable at the battery, then disconnect the positive battery cable at the starter.
  2.  



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Fig. Fig. 1: Starter removal on 4WD-6-cylinder engine



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Fig. Fig. 2: Starter removal on 2WD-6-cylinder engine

  1. On 4wd models with the 6-cylinder engine:
    1. Remove the front gravel shield.
    2.  
    3. Detach the oil pressure switch connector.
    4.  
    5. Drain the engine oil and remove the oil filter.
    6.  

  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. On 2wd models with the 6-cylinder engine:
    1. Remove the front right wheel.
    2.  
    3. Remove the front gravel shield.
    4.  
    5. Remove the exhaust manifold heat insulator.
    6.  
    7. Remove the exhaust manifold.
    8.  
    9. Detach the oil pressure switch connector.
    10.  

  2.  
  3. Unfasten the remaining electrical connections at the starter solenoid.
  4.  
  5. Remove the two nuts holding the starter to the bell housing, then pull the starter toward the front of the vehicle and out.
  6.  

To install:
  1. Insert the starter into the bell housing, being sure that the starter drive is not jammed against the flywheel.
  2.  
  3. Tighten the attaching nuts and secure all electrical connections to the starter assembly.
  4.  
  5. Install all remaining components in reverse order of removal.
  6.  
  7. Reconnect the battery cables. If applicable, refill and check the oil level. Check the starter assembly for proper operation.
  8.  

OVERHAUL



See Figures 3 through 10

Solenoid Replacement
  1. Remove the starter.
  2.  
  3. Unscrew the two solenoid switch (magnetic switch) retaining screws.
  4.  
  5. Remove the solenoid. In order to unhook the solenoid from the starter drive lever, lift it up at the same time that you are pulling it out of the starter housing.
  6.  
  7. Installation is in the reverse order of removal. Make sure that the solenoid switch is properly engaged with the drive lever before tightening the mounting screws.
  8.  



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Fig. Fig. 3: Exploded view of S114-516 type starter-1989-91 models



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Fig. Fig. 4: Exploded view of S114-605, 606B, 607 and 608SA type starters-1989-95 models



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Fig. Fig. 5: Exploded view of M3T38482 type starter-1989-95 models



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Fig. Fig. 6: Exploded view of S114-453 and 454 type starters-1989-91 models



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Fig. Fig. 7: Exploded view of S114-527A type starter-1989-95 models



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Fig. Fig. 8: Exploded view of M1T60281 type starter-1989-95 models



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Fig. Fig. 9: Exploded view of S114-703A type starter-1989-95 models

Brush Replacement
NON-REDUCTION GEAR TYPE
  1. Remove the starter.
  2.  
  3. Remove the solenoid (magnetic switch).
  4.  
  5. Unfasten the two end frame cap mounting bolts and remove the end frame cap.
  6.  
  7. Remove the O-ring and lock plate from the armature shaft groove, then slide the shims off the shaft.
  8.  
  9. Unfasten the two long housing screws (at the front of the starter) and carefully pull off the end plate.
  10.  
  11. Using a screwdriver, separate the brushes from the brush holder.
  12.  
  13. Slide the brush holder off of the armature shaft.
  14.  
  15. Crush the old brushes off of the copper braid and file away any remaining solder.
  16.  
  17. Fit the new brushes to the braid and spread the braid slightly.
  18.  

Use a soldering iron of at least 250 watts.

  1. Using a light-grade solder, solder the brush to the braid. Grip the copper braid with flat pliers to prevent the solder from flowing down its length.
  2.  
  3. File off any extra solder and then repeat the procedure for the remaining three brushes.
  4.  
  5. Installation is in the reverse order of removal.
  6.  

When installing the brush holder, make sure that the brushes line up properly.

REDUCTION GEAR TYPE
  1. Remove the starter and the solenoid.
  2.  
  3. Remove the through-bolts and the rear cover. The rear cover can be pried off with a small prytool, but be careful not to damage the O-ring.
  4.  
  5. Separate the starter housing, armature, and brush holder from the center housing. They can be removed as an assembly.
  6.  
  7. Remove the positive side brush from its holder. The positive brush is insulated from the brush holder, and its lead wire is connected to the field coil.
  8.  
  9. Carefully lift the negative brush from the commutator and remove it from the holder.
  10.  
  11. Installation is in the reverse order of removal.
  12.  

Starter Drive Replacement
NON-REDUCTION GEAR TYPE
  1. With the starter motor removed from the vehicle, separate the solenoid from the starter.
  2.  
  3. Remove the two through-bolts and separate the gear case from the yoke housing.
  4.  
  5. Remove the pinion stopper clip and the pinion stopper.
  6.  
  7. Slide the starter drive off the armature shaft.
  8.  
  9. Install the starter drive and reassemble the starter in the reverse order of removal.
  10.  

REDUCTION GEAR TYPE
  1. Remove the starter.
  2.  
  3. Unfasten the solenoid and the shift lever.
  4.  
  5. Remove the bolts securing the center housing to the front cover and separate the parts.
  6.  
  7. Remove the gears and starter drive.
  8.  
  9. Installation is in the reverse order of removal.
  10.  



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Fig. Fig. 10:

 
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