1987 NISSAN PULSAR check oil

204 Electrical System
brushes to the brush holder and position the springs
against the ends of the brushes.

Install the O ring to the yoke taking care
that
the O ring is not twisted. Install the yoke, armature and brush
holder
assembly to the drive end bracket, aligning the marks
made on dismantling. Install the end cover to the yoke. Install
and
tighten the retaining bolts securely. Connect the cable to the solenoid field coil
terminal and tighten the terminal nut securely. Install the starter motor to the vehicle
as
previously described.
BOSCH STARTER MOTOR
To Dismantle

Disconnect the brush connector strap from
the lower terminal on the solenoid switch.
Remove the screws retaining the solenoid to
the drive end bracket and remove the solenoid from
the drive end bracket.
Loosen, but do not remove the screws retain-
ing the armature end cover to the commutator end
bracket. Remove the through bolts retaining the drive
end bracket to the commutator end bracket.
Remove the yoke, armature and commutator
end bracket from the drive end bracket as an assem-
bly. Hold the rubber seal in place in the drive end
bracket to keep the engaging lever in position.
Remove the rubber seal from the drive end
bracket. Remove the cover plate from the planetary
gear set and remove the gear set, drive assembly and
engaging lever as an assembly. Remove the armature end cover and com-
mutator end bracket from the yoke. Remove the screws retaining the armature
end cover to the commutator end cover and remove
the armature end cover, C clip and shims from the
armature shaft. Remove the commutator end bracket
from the armature. Carefully remove the brush holder from the
armature. Support the gear set and drive assembly in a
vertical position with the drive assembly uppermost.
Using a suitable drift, tap the stop collar
towards the drive assembly and remove the snap ring
from the drive shaft. Remove any burrs from the drive shaft and
withdraw the drive assembly and stop ring from the
drive shaft.
Clean all parts thoroughly but do not im-
merse the armature, solenoid or drive assembly in
cleaning solvent.
To Check and Inspect

(1) With the starter motor dismantled, check the
brush holder insulation using an ohmmeter.

Connect one test lead to the brush holder positive
BRACKET

Dismantled view of the Bosch starter motor.

Electrical System 205


Dismantled view of the brush holder assembly. Bosch
starter motor.
side and the other lead to the negative side. If there is
any indication of leakage the ohmmeter will show a
reading other than infinity. Repair or renew the brush
holder if leakage is evident.

(2) Check the brushes for adequate length.
Brushes should be renewed when their length is below
Specifications. They should be a free sliding fit in the
brush holders.

NOTE: Due to the difficulty involved in
removing and installing the brushes in the
Bosch starter motor, it is recommended that
the brush holder be renewed as an assembly.

(3) Check that the commutator is free from
pitting and burning. Clean with a petrol moistened
cloth and polish with a strip of fine glass paper.

A badly worn commutator may be repaired by
mounting in a lathe, spi nning at high speed, and
taking a light cut with a very sharp tool. After turning,
undercut the insulation between the segments.

(4) Check the armature for short circuit using an
ohmmeter.

Place one of the test lead s on the armature shaft
or core and move the other lead around the circum-
ference of the commutator. If the ohmmeter shows a
reading at any point the armature is faulty and should
be renewed.

Check the drive assembly clutch pinion teeth
for wear, scoring or chipping. A clutch in good
condition should take up the drive in one direction
only. It should rotate easily and smoothly in the
non-drive direction and the assembly should move
smoothly along the armature or drive shaft helical
splines.
Check the armature shaft bushes for wear
and renew as necessary. The old bushes must be
removed and the new ones pressed into the end
brackets using a polished mandrel of the exact diam-
eter of the armature shaft. NOTE: The new bushes must not be reamed
to size, as reaming will impair the porosity
of the bushes and cause early failure. New
bushes should be allowed to stand immersed
in clean light engine oil for one hour before
installation.

To Assemble
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

Lubricate the helix of the drive shaft lightly
with graphite grease and install the drive assembly
to
the drive shaft. Install the stop collar and snap ring, slide the
stop collar over the snap ring to lock the snap ring in
position.
Lubricate the bushes in both end brackets
sparingly with engine oil. Install the engaging lever and gear set into the
drive end bracket. Install the centre rear bracket and the engag-
ing lever seal into the drive end bracket.
Slide the brush holder assembly into position
on the commutator ensuring that the brush holders
are correctly positioned in the anchor points. Install the commutator end bracket to
the
armature, install the shims and C clip. Check that the armature end float is satisfac-
tory and adjust as necessary using shims of the correct
thickness.
Align the slot in the commutator end bracket
with the cut out on the wiring seal and install the
armature end cover to the commutator end bracket.
Install the cover retaini ng screws but do not tighten.
Ensure that the permanent magnets in the
yoke have not picked up any debris and slide the yoke
over the armature ensuring that the wiring seal locates
correctly in the slot in the yoke.

View showing the planetary gear set. Bosch starter
motor.

220 Electrical System


Wiring diagram (WD2) for the instruments, hazard and turning signal systems.
COLOUR CODE
The first letter of the code
represents the main wire color,
the other letters represent the
trace colors.

B - BLACK
L - BLUE
G - GREEN
R - RED
Y - YELLOW
W- WHITE
N - BROWN
O - OHANGE
K - PINK
S - GREY V -VIOLET
P - PURPLE X - LIGHT GREEN Z - LIGHT BLUE M - DARK GREEN T - DARK BLUE A - LIGHT BROWN E - SLATE D - TAN
KEY 1. Fuse 11 Ignition
2. Speedometer
3. Vehicle speed sensor
4. To No. 21 WD1
5. To ECU A10
6. To No. 13 WD1
7. Tachometer
8. Voltage regulator
9. Resistor
10. Temperature gauge
11. Fuel gauge
12. Temperature sender
13. Fuel sender
14. To ECM lamp
15. Oil lamp
16. Park brake lamp
17. Low fuel lamp
18. To ECU A5
19. To No. 20 WD1
20. Park brake switch
21. Low fuel switch
22. Brake switch
23. Brake fail lamp
24. Bulb check relay
25. Charge lamp
26. Door ajar lamp
27. To No. 6 VWD1
28. To No. 8 WD4
29. To No. 18 WD6
30. To No. 17 WD6 31. Hazard switch

32. Flasher unit
33. Turn signal switch
34. L H front combination
lamp
35. L H side indicator lamp
36. L H rear combination lamp
37. L H instrument warning
lamp
38. R H instrument warning lamp
39. R H rear combination lamp
40. R H side indicator lamp
41. R H front combination lamp
42. Divider circuit

236 Body

top of the dashboard rearwards and maneuver the
dashboard through the front door opening.

Installation is a reversal of the removal procedure
with attention to the following points:

With the aid of an assistant, ensure that the
outer edges of the dashboard engage properly with the
door pillar brackets.
Hold the dashboard in position and loosely
install all retaining bolts. Align the dashboard
and
tighten all screws and bolts securely.
10. SEAT BELTS

The front and outer rear seats are equipped with
lap/sash inertia reel seat belts, which are designed to
lock with any sudden change in vehicle motion.

The centre rear seat is equipped with a manually
adjustable lap seat belt.

Child restraint anchorages are located on the
parcel shelf behind the rear seat on Sedan models and
at the rear of the lugg age compartment floor on
Hatchback models. These anchorages must be used if
a child's seat or capsule is installed to the vehicle. The
anchorages should not be used for adult scat bells or
harnesses.

The seat belts should be periodically inspected as
described below. Any seat belt assembly that is worn
or damaged, or has been subjected to abnormal
loadings in a collision, should be renewed as a
complete assembly.

Only mild soap and water should be used to clean
the webbing. Contamination wi th polish, oil, bleaches
and other chemicals should be avoided.

TO INSPECT
(1) Check the seat belt webbing for fraying, cuts,
burns or other damage. On inertia reel belts, slowly
pull the belt from the reel to allow the entire length to
be examined. If the webbing is damaged or worn,
renew the seat belt assembly.


Check the seat belt webbing for fraying, cuts, burns or
other damage.
Ensure that the belts are not twisted.
Check all retaining nuts and bolts for secu-
rity.
Inspect the belt buckles for correct and
secure engagement. If the buckles are damaged or do
not function correctly, renew the seat belt assembly. On inertia reel seat belts, check the retractor
mechanism as follows:
Pull the belt slowly from the reel and check
for smooth operation. Release the belt and ensure that
it retracts fully.
Pull the belt rapidly from the reel. The reel
should lock.
Drive the vehicle at walking pace and at-
tempt to withdraw the belt slowly while braking
sharply. The reel should lock. If the retractor mechanism does not function
correctly, renew the seat belt assembly.

11. SEATS
FRONT SEAT
To Remove and Install
Adjust the seat to the most forward position.
Remove the mounting bolts from the rear of
the seat.
Adjust the seat to allow access to the mount-
ing bolts at the front of the seat. Remove the mounting bolts and withdraw
the seat from the vehicle.
Installed view of the fron t seat belt with the door pillar
trim removed showing the mounting points.