Many owners Nissan Almera are faced with a situation when the car’s starting system begins to work unstably, or wear parts need to be replaced. Often the problem lies not in the starter itself, but in its drive mechanism - the so-called kickstarter or retractor relay with bendix. Disassembling this unit allows you to identify gear wear, burnt contacts or armature jamming without the need to completely replace the unit.
The process of dismantling and subsequent disassembly requires accuracy and understanding of the structure of the electromechanical unit. Incorrect actions can lead to damage to the case or loss of small parts, which ultimately increases the cost of repairs. In this article we will look in detail at how to safely remove the device, dismantle it into its components and carry out troubleshooting.
It is important to understand that kickstarter in the context of modern cars, it is often an integral part of the starter, responsible for extending the bendix. On Nissan Almera (especially generations G15 and previous) this unit has a specific fastening and design features that must be taken into account when working. Ignoring the nuances may result in you simply not being able to put the mechanism back into working order.
Preparation of the workplace and necessary tools
Before you begin any physical impact on the car, you need to prepare everything you need. Working with an electric starter Nissan Almera often requires access to hard-to-reach areas of the engine compartment or even removal of the unit from the engine. The absence of the necessary tool at the most crucial moment can delay the repair for hours.
You will need a set of standard wrenches, as well as sockets with extensions. Pay special attention to the selection of tightening torque, since the bolts securing the starter and retractor relay covers often have a specific thread. To disassemble the kickstarter mechanism itself, you need thin screwdrivers and pliers to remove the circlips.
- 🔧 Set of socket heads for 8, 10, 13 and 14 mm
- 🔩 Screwdrivers with flat and Phillips blades (different sizes)
- 🔨 Hammer with a rubber striker for accurately knocking down parts
- 🧼 Carburetor cleaner and degreasing rags
- 🛢️ Lubricant for gears and bearings (litol or specialized)
Be sure to disconnect the battery before starting work. This is critical for safety since you will be working with high current components. Remove the negative terminal and set it aside to prevent accidental shorting.
Free up space under your car or in your garage. If the starter is difficult to access, you may have to remove the air filter or other accessories. In some cases on Nissan Almera It’s easier to remove the entire starter and then completely disassemble it on a workbench.
Removing the unit from the car
The process of removing the starter begins with disconnecting the electrical connectors. On the body of the retractor relay there is a main power wire, which is secured with a 13 nut. You also need to disconnect the control wire, which supplies the start signal. Be careful not to damage the wire insulation when disconnecting.
Next, you need to unscrew the bolts securing the starter housing to the cylinder block or gearbox. Usually there are two or three. If the bolts are stuck, use penetrating lubricant (WD-40) and give it time to work. Do not use excessive force to avoid stripping the threads in the aluminum motor housing.
After unscrewing the fastener, carefully remove the starter. This can be inconvenient due to limited space and the weight of the unit. Place your hand under it or use a safety rope to prevent it from falling to the floor and damaging the engine pan or yourself.
- 🚫 Do not leave open connectors in a humid environment
- ✅ Mark the position of the wires before disconnecting (take photos)
- ⚙️ Check the condition of the clamp on the fuel hose next to the starter
If you plan to disassemble the kickstarter directly on the car, make sure that you have easy access to the retractor relay mounting bolts. However, experienced craftsmen recommend carrying out complete disassembly on a table, where all parts are visible and there is no risk of losing small screws or springs.
Diagnostics and external examination
After removing the assembly, perform a thorough visual inspection. Pay attention to the body Nissan Almera starter: are there any cracks, signs of overheating or corrosion. Pay special attention to the condition of the armature shaft and bendix. If there is play or signs of wear, this is a clear sign of the need for replacement or repair.
Check the condition of the brushes and commutator. Wear of the brushes to the minimum size or their jamming in the holders is often the reason that the starter does not turn or works intermittently. Also inspect the solenoid relay for mechanical damage and integrity of the windings.
⚠️ Attention: If you see traces of melted plastic or insulation, do not try to simply clean the contacts. This is a sign of severe overheating that could damage the internal windings or the relay housing.
Use a multimeter to check the integrity of the solenoid relay coils. Test the circuit from the control terminal to ground. If the resistance is infinitely high or, conversely, equal to zero (short circuit), the relay requires replacement or rewinding.
It is important to assess the condition of the Bendix. The gear should rotate freely in one direction and be locked in the other. If it turns in both directions or sticks, the drive mechanism is faulty. This is a common problem that owners face Nissan Almera after 100 thousand mileage.
The process of disassembling the mechanism
Disassembly begins with removing the solenoid relay. Remove the two mounting bolts that connect the relay to the starter housing. Carefully remove the relay without tearing the wires. If the wires are soldered, unsolder them or bite them off so you can solder new ones later if necessary.
Next, you need to remove the retaining ring from the armature shaft. This is the most crucial moment, since the ring is under spring tension. Use a thin screwdriver and pliers to carefully pry apart the ring and remove it. Be prepared for the ring to fly out with force.
- 🛑 Use safety glasses when removing circlips
- 📸 Take a photo of each stage of disassembly for proper assembly
- 🧩 Lay out the parts in the order of dismantling on a clean surface
After removing the ring, you can separate the front cover and the anchor itself. Remove the armature from the stator housing. Pay attention to the location of the bushings and bearings. If they show signs of wear or scoring, they must be replaced. On Nissan Almera The rear bushing often wears out, which leads to armature misalignment.
Remove the bendix from the armature shaft. To do this, you need to unscrew the restrictive ring or lock nut (depending on the modification). The Bendix is removed with force, sometimes requiring a light blow with a hammer through a wooden spacer. Do not hit the gear directly to avoid damaging the teeth.
Troubleshooting and replacement of parts
Now you have all the parts on the table. Carry out their detailed troubleshooting. Inspect the armature commutator: if it is covered with a thick layer of graphite dust or has deep grooves, it needs to be cleaned with fine sandpaper or turned on a lathe.
Check the condition of the brush assembly. The length of the brushes should not be less than half of their original height. If they are worn, replace the entire brush holder or the brushes themselves. Also check that they move freely in their grooves without jamming.
Pay special attention to the bendix teeth and flywheel ring. If the Bendix teeth are chipped or ground down, replacement is required. Also check the flywheel crown to which the bendix is attached. If it is damaged, the engine will not be able to start even after the starter has been repaired.
| Detail | Wear criterion | Action |
|---|---|---|
| Brushes | Length less than 10 mm | Replacing the kit |
| Bushings | Shaft play, scuffing | Replacing bushings |
| Bendix | Scroll both ways | Replacement or repair |
| Collector | Deep grooves, carbon deposits | Stripping or grooving |
| Winding | Open circuit, short circuit | Rewind or replace |
- up to 50,000 km
- 50,000 - 100,000 km
- 100,000 - 150,000 km
- more than 150,000 km
Assembly and lubrication of components
Assembly is carried out in reverse order. Before installing parts, they must be thoroughly cleaned of old grease and dirt. Use carburetor cleaner and a rag. Pay special attention to the inner surface of the body and the grooves of the brushes.
Apply special lubricant to the armature shaft, bushings and bendix gear. Do not use lithol in large quantities, as it may thicken in the cold. It is better to use synthetic lubricants for starters, which retain their properties at low temperatures.
☑️ Starter assembly procedure
When installing the retaining ring, make sure it is securely seated in the groove. This ring keeps the bendix and armature from falling out. If it comes off after starting the engine, the starter could fly out of its mount and cause serious damage to the vehicle.
Assemble the solenoid relay and secure it to the housing. Make sure the relay rod moves freely and is not stuck. Check the tightness of the contacts. If the contacts are burnt, they can be cleaned with a file, but it is better to replace the entire relay, as this is more reliable.
⚠️ Attention: Do not overtighten the retractor relay mounting bolts. The relay housing is often made of silumin, which easily cracks under excessive force.
What to do if the bendix does not come off?
Sometimes the bendix gets stuck to the armature shaft. In this case, you can carefully heat the joint with a hair dryer or use a puller. Do not try to knock it down with a hammer, as this may damage the shaft threads or crack the gear.
After complete assembly, check the mechanism manually. The rotation of the shaft should be smooth, without jamming. The Bendix should move freely along the shaft splines. Make sure the bendix return spring is working correctly and returning the gear to its original position.
High-quality lubrication and correct installation of retaining rings are the key to long service life of a rebuilt starter.
Installation and performance check
Reinstall the assembled starter. Tighten the fastening bolts with a torque that meets the technical requirements. Connect the power and control wires. Make sure that the wires do not touch moving parts and are not pinched.
Connect the battery. Before starting for the first time, check that there are no tools or parts left near the starter. Turn on the ignition and try to start the engine. The starter should operate smoothly, without any extraneous noise or vibration.
If the starter engages but the engine does not start, check the bendix and flywheel ring. If a characteristic cracking sound is heard, the bendix may not engage the flywheel. In this case, you will have to remove the starter again and check the gap.
- 🔊 Listen to the sound of the starter: it should be smooth
- 🔥 Do not allow the starter to rotate for a long time (more than 5 seconds)
- 📉 Monitor the battery voltage during startup
After starting successfully, run the engine for a few minutes and check for a burning smell or smoke. Inspect the location where the starter is installed for sparking or heating. If everything is ok, the installation is completed successfully.
Before installing the starter, apply a thin layer of graphite grease to the armature shaft splines - this will ensure easy movement of the bendix and prevent it from jamming in the future.
Common mistakes during repairs
One of the most common mistakes is ignoring the condition of the bushings. Many craftsmen change only brushes and bendix, forgetting that wear on the bushings leads to misalignment of the armature and rapid failure of even new parts.
Another mistake is using the wrong lubricant. Thick lubricants, such as grease, freeze in the cold and block the movement of the bendix. This results in the starter turning but not engaging the flywheel, or not turning at all.
⚠️ Warning: Never use WD-40 as a lubricant for moving starter parts. This is a cleaner that flushes out remaining oil and promotes rapid wear.
Another common problem is the incorrect installation of the retaining ring. If it does not sit completely in the groove, at the first start it may jump off and the bendix will fly out. Always check that the ring is securely attached visually and tactilely.
Do not forget to check the condition of the solenoid relay contacts. Even with good windings, poor contact inside the relay can result in the starter not working or operating intermittently. Cleaning the contacts often solves the problem without replacing the entire assembly.
FAQ: Questions and answers
Is it possible to disassemble the kickstarter without removing the starter from the car?
Theoretically, this is possible if there is convenient access to the relay mounting bolts and covers. However, on Nissan Almera The engine compartment space is often limited, and it is more convenient to carry out complete disassembly and troubleshooting of parts on a workbench after removing the unit.
How to check the serviceability of the solenoid relay before disassembly?
You can apply 12 volts directly to the relay control terminal and to ground. If the relay rod comes out with a characteristic click and closes the power contacts, the relay is working properly. If there is no click or the rod does not move, the relay is faulty.
Why does the starter turn, but the engine does not start?
Most often this is due to wear on the bendix (it slips) or damage to the flywheel crown. The cause may also be poor contact in the power circuit or insufficient battery charge.
What is the best lubricant to use for Bendix?
It is recommended to use special synthetic-based lubricants for starters and generators. They are resistant to high temperatures and do not thicken in the cold. Avoid graphite lubricants inside the mechanism as they can clog the clearances.
How long does it take to completely disassemble and reassemble?
If you have experience and tools, the process takes from 1 to 2 hours. If you are doing this for the first time, spend more time studying the design and carefully disassembling small parts.