Starter - Nippondenso Ford Festiva I

DESCRIPTION

The Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive housing. When starter is energized, starter solenoid causes the starter pinion to engage with the flywheel ring gear. The overrunning clutch pinion drive is mounted directly on the drive end of armature shaft.

PINION DEPTH ADJUSTMENT

1. Disconnect field strap. Field strap must be disconnected from "M" terminal during this test to prevent starter from turning. Connect a 12-volt battery by connecting a lead from positive battery terminal to "S" terminal of solenoid. Connect another lead from negative battery terminal to "M" terminal of solenoid. (Scheme 1)
2. When battery is connected, the solenoid should activate and kick out pinion gear. With pinion extended, measure gap between pinion gear and collar. This is the pinion depth adjustment and gap should be.020-.080 " (.5-2.0 mm). (Scheme 1) NOTE: DO NOT engage solenoid for more than 20 seconds at a time. If this test must be repeated, wait at least 3 minutes between attempts to allow solenoid to cool.
3. Add or subtract shims between solenoid and drive end housing as necessary to achieve proper pinion gap. Install field strap to "M" terminal of solenoid. Install nut and tighten to 70-110 INCH lbs. (8-12 mm). (Scheme 1)

Scheme 1

NO LOAD TEST

Place starter on bench. Connect a fully-charged 12-volt battery to starter. (Scheme 2) Starter should rotate smoothly. Ensure starter draw is less maximum specification with starter turning at 5000 RPM minimum.

Scheme 2

NO LOAD TEST SPECIFICATIONS

CRANKING TEST

1. Connect voltmeter and ammeter to battery. (Scheme 3) Connect tachometer to engine. Disconnect ignition coil secondary wire from distributor and ground it. Turn ignition switch to "START" position.
2. Check cranking voltage and current draw. Voltage should be no less than specification and current draw should be less specification.

Scheme 3

CRANKING TEST SPECIFICATIONS

SOLENOID PULL-IN TEST

Note. Test must be performed with starter assembled with field lead disconnected at solenoid from starter.

Connect test leads to starter. (Scheme 4) Connect negative leads to starter housing and "M" terminal. Battery positive lead is connected to terminal "S". If starter pinion gear does not move out, replace solenoid.

SOLENOID HOLD-IN TEST

Note. Test must be performed with starter assembled with field lead disconnected at solenoid from starter.

Connect test leads to starter. (Scheme 4) Disconnect "M" terminal. Starter pinion gear should stay out. If not, replace solenoid.

PINION GEAR RETURN TEST

Note. Test must be performed with starter assembled with field lead disconnected at solenoid from starter.

Connect test leads to starter. (Scheme 4) Disconnect negative lead from starter housing. Starter pinion should retract.

Scheme 4

ARMATURE

1. Place armature in growler. Turn on growler and hold a piece of hacksaw blade over armature. Slowly rotate armature. If hacksaw blade is attracted to core or if it vibrates, replace armature.
2. Remove armature from growler. Using an ohmmeter, check continuity between commutator and core. If continuity exists, replace armature. Check continuity between commutator and shaft. If continuity exists, replace armature.
3. Check continuity between each commutator segment. If an open exists between any 2 segments, replace armature.

COMMUTATOR

1. Clean surface and polish with No. 400 sandpaper if required. If surface is scored, out of round or pitted, turn commutator in a lathe.
2. Maximum commutator runout and minimum diameter of commutator must not exceed specification after turning. COMMUTATOR SPECIFICATIONS Application Maximum Runout Minimum Thickness Festiva & Tracer .016 (.40) 1.22 (31.0)
3. Commutator mica undercut depth on all models should be .016-.031" (.40-.80 mm). Minimum mica undercut depth is .008" (.20 mm). If not within specification, undercut with a hacksaw blade to standard depth.

BRUSHES & SPRINGS

1. Connect ohmmeter lead to positive brush holder and other lead to negative brush holder. If test needle moves, brush holder assembly is shorted and must be replaced.
2. Check brush length. If less than specification, replace brushes. Check spring tension. Spring tension should be 37-48 ozs. (1050-1350 g). Brushes must move freely in holders.

MINIMUM BRUSH LENGTH

FIELD COILS

1. Connect one ohmmeter lead to field coil. Connect other lead to soldered portion of brush lead. If meter does not register, repair or replace field coil.
2. Check field coil for shorts to ground by connecting a test lead to field coil lead. Connect other lead to starter housing. If meter registers, repair or replace field coil.

REMOVAL

1. Disconnect battery negative cable. Disconnect wire at starter solenoid "S" terminal and "M" terminals. Remove mounting bracket bolt attaching starter motor to vehicle. Remove bolts securing starter motor to transaxle clutch housing. Remove starter motor.
2. Remove support bracket-to-mounting bracket bolt and remove the mounting bracket. Remove support bracket-to-starter motor attaching nuts and remove support bracket.

INSTALLATION

1. Position starter motor on clutch housing and install attaching bolts. Tighten attaching bolts to 23-34 ft. lbs. (31-46 N.m). Install support bracket attaching bolts and tighten to 23-34 ft. lbs. (31-46 N.m).
2. Install mounting bracket attaching bolts and tighten to 23-34 ft. lbs. (31-46 N.m). Reverse removal procedures to complete installation.

OVERHAUL

For disassembly & reassembly (Scheme 5)for an exploded view of the Nippondenso starter motor.

Scheme 5