Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Starter

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Datsun/Nissan began using a reduction gear starter in the Canadian versions 200SX model. They were also available as an option on later models. The differences between the gear reduction and conventional starters are: the gear reduction starter has a set of ratio reduction gears while the conventional starter does not; the brushes on the gear reduction starter are located on a plate behind the starter drive housing, while the conventional starter's brushes are located in its rear cover. The extra gears on the gear reduction starter make the starter pinion gear turn at about half the speed of the starter, giving the starter twice the turning power of a conventional starter.

TESTING



Voltage Drop Test

The battery must be in good condition and fully charged prior to performing this test.

  1. Disable the ignition system by unplugging the coil pack. Verify that the vehicle will not start.
  2.  
  3. Connect a voltmeter between the positive terminal of the battery and the starter B+ circuit.
  4.  
  5. Turn the ignition key to the START position and note the voltage on the meter.
  6.  
  7. If voltage reads 0.5 volts or more, there is high resistance in the starter cables or the cable ground, repair as necessary. If the voltage reading is ok proceed to the next step.
  8.  
  9. Connect a voltmeter between the positive terminal of the battery and the starter M circuit.
  10.  
  11. Turn the ignition key to the START position and note the voltage on the meter.
  12.  
  13. If voltage reads 0.5 volts or more, there is high resistance in the starter. Repair or replace the starter as necessary.
  14.  

Many automotive parts stores have starter bench testers available for use by customers. A starter bench test is the most definitive way to determine the condition of your starter.

REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Disconnect the starter wiring at the starter, taking note of the positions for correct installation.
  4.  
  5. Remove the bolts attaching the starter to the engine and remove the starter from the vehicle.
  6.  

To install:
  1. Install the starter to the engine.
  2.  
  3. Tighten the attaching bolts EVENLY. Be careful not overtorque the mounting bolts as this will crack the nose of the starter case assembly.
  4.  
  5. Install the starter wiring in the correct location.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine a few times to make sure of proper operation.
  10.  

SOLENOID REPLACEMENT



The starter solenoid is also know as the magnetic switch assembly.

  1. Remove the starter from the engine as outlined above.
  2.  
  3. Place the starter in a vise or equivalent to hold the starter in place while you are working on the solenoid. DO NOT tighten the vise to tight around the case of the starter. The case will crack if you tighten the vise to much.
  4.  
  5. Loosen the lock-nut and remove the connection from the starter motor going to the M terminal of the solenoid or bottom terminal of the solenoid.
  6.  
  7. Remove the securing screws and remove the solenoid.
  8.  
  9. Install the solenoid to the starter and tighten the securing screws.
  10.  
  11. Install the connection and lock-nut at bottom terminal of the starter.
  12.  

 
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