How to properly remove the starter on a Nissan Sunny FB15: instructions with photos and tips

Removing the starter Nissan Sunny FB15 - a task that sooner or later faces every owner of this reliable, but no longer young car. The starter in this model, produced between 1990 and 1995, has problems typical for age: wear of the brushes, burnt contacts or failure of the solenoid relay. However, its replacement or repair is often postponed due to fear of damaging adjacent components or lack of knowledge of the sequence of actions.

Unlike modern cars, where access to the starter can be blocked by plastic panels and electronics, FB15 provides relatively easy access to the unit. But even here there are pitfalls: for example, the inconvenient location of the lower mounting bolt or the risk of damaging the wiring during careless dismantling. This article will help you understand all the nuances of the process - from preparing tools to the final performance check.

Preparing for work: tools and safety precautions

Before you begin dismantling, make sure you have everything you need. The absence of even one key can stop the process halfway, and the wrong approach to security can lead to short circuits or injuries.

Basic set of tools for working with Nissan Sunny FB15:

• 🔧 A set of open-end and spanner wrenches (required availability key 12 And 14 mm)
• 🔨 Extension for keys with universal joint (for access to the bottom bolt)
• 🔋 Multimeter to check terminal voltage
• 🧲 Magnetic holder or telescopic grip (so as not to drop the bolts into the engine compartment)
• 🔦 Flashlight with bracket (lighting in the engine compartment of the FB15 leaves much to be desired)
• 🧴 Penetrating type lubrication WD-40 (useful for rusty fasteners)

Pay special attention to the following precautions:

• ⚡ Disconnect the negative battery terminal before touching the starter. Even with the ignition off, residual current in the circuit can cause a short circuit.
• 🔥 Do not smoke or use open fire near the battery - the release of hydrogen during charging/discharging is explosive.
• 🧤 Wear gloves: dirt and oil deposits often accumulate on the starter housing and near it.

⚠️ Attention: If your Sunny FB15 is equipped with gas cylinder equipment, before work, be sure to turn off the gas supply and release the residual pressure in the system. A spark from an accidental short circuit can ignite gas vapors.

Localization of the starter in the engine compartment FB15

On Nissan Sunny FB15 The starter is located at the bottom of the engine, on the gearbox side. Its exact position depends on the engine type:

• 🔍 For motors GA14DE And GA16DE (1.4 and 1.6 l, respectively), the starter is attached to the cylinder block on the right (in the direction of travel) under the intake manifold.
• 🔍 On diesel versions CD17 Access to the starter is more difficult due to the presence of a turbine and additional pipelines.

Visually, the starter is a cylindrical body with a diameter of about 10 cm with a thick positive wire connected (from the battery) and a thinner control wire (from the ignition switch). At its end you can see the Bendix gear, which meshes with the flywheel when starting.

Engine type	Number of mounting bolts	Difficulty of access	Additional nuances
GA14DE (1.4 l)	2 bolts	Average	The lower bolt is hidden behind the engine mount bracket
GA16DE (1.6 l)	2 bolts	High	Requires removal of the air duct and part of the intake manifold
CD17 (diesel)	3 bolts	Very high	It is necessary to dismantle the turbocharger or its piping

To make access easier, it is recommended:

1. Remove the air filter and the pipe leading to the throttle valve.
2. Disconnect the crankshaft position sensor connector (if it interferes).
3. Raise the car on a jack or drive it into an inspection hole - this will give a better view of the lower mount.

Step-by-step dismantling of the starter: from theory to practice

Now we move on to the most important stage - removing the starter. Follow the instructions strictly step by step to avoid damage to the wiring or the unit itself.

Step 1: Disconnect electrical connections

• 🔌 Remove first plastic protective cap from the positive terminal of the starter (if there is one).
• 🔧 Unscrew the nut securing the power wire (12 mm wrench) and disconnect the wire. Do not pull on the wire - pull on the tip to avoid damaging the insulation.
• 🔌 Unclip the latch and remove the control wire (thin, usually black) from the retractor relay.

Step 2. Removing the mounting bolts

• 🔧 The upper bolt securing the starter to the cylinder block can be unscrewed with a 14 mm wrench without any problems.
• 🔧 The bottom bolt is the most difficult place. Use an extension cord with a universal joint to reach it from the side of the inspection hole. Pre-treat the thread WD-40if the bolt does not budge.

Step 3. Removing the starter

• 🔄 After unscrewing the bolts, gently rock the starter left and right to separate it from the seat.
• 🖐️ Pull the unit down, at an angle of about 30 degrees, so as not to catch the bendix on the flywheel.

Negative battery terminal disconnected |

All connectors and wires were photographed|

Have a bolt magnet handy|

Checked for lower bolt extension|

Access to the starter is freed (interfering parts have been removed) -->

⚠️ Attention: On some copies FB15 A paronite gasket can be installed between the starter and the cylinder block. When reassembling it, it must be replaced with a new one, otherwise air or oil leaks may occur.

Starter diagnostics: what can you fix yourself?

Before running to the store for a new starter, inspect the removed unit. In most cases, it can be repaired, saving up to 70% of the cost of a new one.

Typical starter faults Nissan Sunny FB15:

• 🔋 Brush wear — checked visually after disassembly. The minimum length of brushes must be at least 7 mm.
• 🔄 Burning of the solenoid relay contacts - cleaned with fine sandpaper or replacing the contact group.
• 🛠️ Flywheel crown wear — if the bendix clings, but the flywheel rotates, the problem may be in the flywheel teeth (requires removal of the gearbox).
• 🔊 Armature shaft play — checked by rocking the shaft in the radial direction. Allowable play is no more than 0.5 mm.

To disassemble the starter you will need:

• 🔧 10 mm socket wrench (for retractor relay).
• 🔨 Screwdriver with a flat blade (for removing retaining rings).
• 🧲 Torque wrench (for proper tightening during assembly).

If you are not confident in your abilities, pay attention to solenoid relay - it can be replaced separately without disassembling the entire starter. Cost of a new relay for FB15 is about 1500–2000 rubles, which is much cheaper than a complete replacement.

How to check the starter winding for an interturn short circuit?

To check the armature or stator winding, use a multimeter in resistance measurement mode (200 Ohms). Connect the probes to the adjacent commutator lamellas. The resistance between all pairs of lamellas should be the same (usually 0.1–0.3 Ohm). If on any pair the resistance tends to zero, this is a sign of an interturn short circuit, and the armature must be replaced.

Starter installation and performance check

Assembly is carried out in the reverse order, but there are some nuances here. Main rule: All connections must be clean and securely tightened.

Installation procedure:

1. Clean the starter seat on the cylinder block from dirt and oil. If necessary, remove any remaining old gasket.
2. Install a new paronite gasket (if there was one).
3. Carefully insert the starter into place, aligning the holes for the bolts and the Bendix gear with the flywheel ring.
4. Tighten the fastening bolts to a torque of 25–30 Nm (do not overtighten so as not to strip the threads in the aluminum block!).
5. Connect the control wire to the solenoid relay, then the power cable (tighten the nut to 10 Nm).

After installation, perform a test run:

1. Connect the battery and turn the ignition key to the "ON" position (without starting the engine). You should hear a click from the solenoid relay.
2. Try starting the engine. The starter should spin the flywheel confidently without any extraneous noise.
3. Check the voltage at the starter terminals during starting (must be at least 10.5 V).

⚠️ Attention: If after installation the starter “sticks” or makes a grinding noise, stop trying to start immediately! This is a sign of improper alignment of the bendix relative to the flywheel. Check if the drive fork is bent or if the starter bushings are worn.

Common mistakes and how to avoid them

Even experienced craftsmen sometimes make mistakes when working with a starter. Nissan Sunny FB15. Here are the most common ones and how to prevent them:

Error	Consequences	How to avoid
Re-tightening of fastening bolts	Thread breakage in cylinder block	Use a torque wrench (torque 25–30 Nm)
Installation without gasket	Air leaks, oil getting into the starter	Always check for gasket presence before installation
Incorrect wire connection	Short circuit, failure of the solenoid relay	Take a photo of the connection diagram before removing
Ignoring armature shaft play	Rapid wear of brushes and bearings	Check play before installation (maximum 0.5 mm)

Another common problem is forget to check bendix after installation. If it does not disengage from the flywheel, the starter will rotate with the engine after starting, which will lead to instant destruction. To check the bendix:

1. Start the engine.
2. After starting, listen: if you hear a characteristic “howl” from the starter, the bendix does not come off.
3. Stop the engine immediately and check the drive fork or solenoid spring.

Also, don't skimp on lubrication. After repairing the starter, apply a thin layer of high temperature grease (such as Molykote BR2 Plus) onto the armature shaft and bendix gear. This will extend the service life of the unit by 20–30%.

Choosing a new starter: original vs analogues

If repair is impossible or impractical, you will have to buy a new starter. For Nissan Sunny FB15 there are several options:

Original starters:

• 🔹 23300-4M000 - for engines GA14DE/GA16DE (1.4/1.6 l).
• 🔹 23300-5M000 - for diesel CD17.

Pros: perfect compatibility, resource 150–200 thousand km. Cons: price (from 8,000 to 12,000 rubles), long delivery.

High-quality analogues:

• 🔹 Denso (article 280-0001) — reliability at the level of the original, price ~6500 rubles.
• 🔹 Bosch (article 0 001 108 005) - a good option for gasoline versions, price ~7000 rubles.
• 🔹 Valeo (article 438086) - optimal for diesel FB15, price ~7500 rubles.

When choosing an analogue, pay attention to:

• 🔧 Rated power (for FB15 - 0.8–1.2 kW).
• 🔄 Direction of rotation (must match the original, usually clockwise).
• 📏 Dimensions (body length, flange diameter).

⚠️ Attention: There are many fake starters on the market under the brands Denso or Bosch. Original parts always have a logo engraved on the case and are supplied in original packaging with a hologram. Buy only from authorized dealers or trusted suppliers.

FAQ: Frequently asked questions about the Nissan Sunny FB15 starter

The starter turns, but the engine does not start. What's the problem?

There may be several reasons:

• 🔋 Battery is discharged (voltage below 11.5 V at startup).
• 🔌 The starter terminals or the engine mass wire are oxidized.
• 🛢️ Bendix is faulty (gear slipping).
• 🔥 The flywheel crown is worn out (requires flywheel replacement or restoration).

First check the voltage at the starter terminals with a multimeter during starting. If it drops below 10V, there is a problem with the battery or cables.

Is it possible to start the FB15 from the pushrod if the starter does not work?

Yes, but with reservations:

• ✅ Allowed for petrol versions (GA14DE/GA16DE).
• ❌ Prohibited for diesel (CD17) - this can damage the timing belt.
• ⚠️ On cars with automatic transmission, starting from a pusher is impossible without the risk of breaking the box.

If you decide to push start, engage 2nd gear, accelerate the car to 10–15 km/h, then sharply release the clutch and add gas.

How often does the starter on FB15 need to be serviced?

Recommended service interval:

• 🔧 Every 50,000 km: cleaning terminals, checking fastenings.
• 🔄 Every 100,000 km: checking the brushes and bushings (if necessary, replacing the lubricant).
• 🛠️ Every 150,000 km: complete revision with replacement of worn parts.

If the car is operated in conditions of high humidity or frequent short trips, the intervals should be reduced by 20–30%.

What should I do if, after replacing the starter, it works intermittently?

Probable reasons:

1. Insufficient tightening of the mounting bolts (check torque 25–30 Nm).
2. Poor contact on the solenoid relay control wire.
3. Incompatibility of the new starter with the flywheel (different number of teeth on the ring).
4. Worn starter bushings (shaft play more than 0.5 mm).

Remove the starter and test it on a bench. If the problem persists, compare the number of the original starter with the installed analogue.

Is it possible to repair the FB15 starter yourself?

Yes, but it requires experience and tools. You can replace it yourself:

• 🔧 Brushes and brush holder.
• 🔄 Retractor relay (sold separately).
• 🛠️ Bendix (when the gear is worn out).
• 🔊 Bearings (bushings) of the armature shaft.

The situation is more complicated with rewinding an armature or stator - this requires special equipment. If the winding is burned out, it is cheaper to buy a new starter.