1987 NISSAN PULSAR check engine

Electrical System 201
nosed pliers. This will safeguard the diodes
by transferring any excess heat to the jaws of
the pliers.

Using a suitable drift, install the bearing into
the drive end bracket, install the retainer plate and
screws. Tighten the screws securely. Using a suitable press and press plates, install
the bearing to the slip ring end of the rotor shaft.
Ensure that pressure is ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft rear bearing stop
ring is positioned so that the protruding part of the
ring is located in the deepest part of the groove. Install the stator, diode pack and
regulator
assembly to the slip ring e nd bracket. Install the
retaining nuts and washers and tighten securely. Install the nut and insulator to the terminal
and tighten securely. Using a piece of wire, hold the brushes in a
retracted position. Hold the drive end bracket in a soft jawed
vice and install the rotor shaft assembly to the drive
end bracket. Install the pulley, retaining nut and washer to
the rotor shaft and tighten the retaining nut to the
specified torque. Apply a heated 200 watt soldering iron to the
slip ring end bracket at the bearing mounting boss for
3-4 minutes to heat the bracket and allow the
installation of the rotor shaft rear bearing. Aligning the marks made on dismantling and
ensuring that the rotor sh aft rear bearing retaining
ring protrusion is located in the deepest part of its
groove, install the rotor/stator assembly to the slip ring
end bracket.
Remove the brush retr acting wire from the
alternator, ensure that the alternator component
marks are aligned, install the retaining through bolts
and tighten them securely. Check the alternator rotor for smooth oper-
ation and install the al ternator to the vehicle
as
previously described.
Check the alternator operation on the vehicle
as previously described.
8. STARTER MOTOR
Special Equipment Required:
To Renew Brushes — Soldering iron
To Renew Armature Bearings — Bearing puller
DESCRIPTION
Two types of starter motors are installed to the
range of vehicles covere d by this manual, either
Hitachi or Bosch.

The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.

A solenoid switch is attached to the starter drive
end bracket. The solenoid plunger is connected to
the overrunning clutch and drive pinion assembly
through a lever and pivot arrangement.

When the solenoid windings are energized, the
plunger acting on the lever and pivot engages the drive
pinion with the flywheel ri ng gear and at the same
time closes the switch supplying power from the
positive lead of the battery to the starter motor field
coils and armature to operate the motor.

As the engine fires, the over-running clutch of the
drive pinion assembly prevents high speed rotation of.
and possible damage to, the starter armature if the
solenoid windings are not immediately de-energized
by releasing the ignition key.

The starter solenoid switch windings are energized
by the ignition switch.

TO TEST ON VEHICLE
Should the starter motor fail to operate when the
ignition switch is turned to the Start position, check
the following points:

Check the battery condition and state of
charge. Refer to the Battery heading for the correct
procedure.
Clean the battery terminals, taking particular
care to remove the scale from the positive ( + )
terminal post and terminal. Check the earth connection for tightness and
cleanliness.
Switch on the headlamps and turn the igni-
tion switch to Start. If the lamps dim but the starter
motor does not operate, it could indicate that a short
circuit has developed in the starting system. Check that the engine is not seized or that the
starter motor drive pinion and ring gear are not
locked as these conditions would -give the same
indications as above.

(5) If the lamps do not dim and the starter
motor does not operate, this would indicate an open
circuit such as a broken or disconnected wire or a
switch not operating.

If the vehicle is equipped with an automatic
transaxle, turn the ignition switch to Start and move
the selector lever through all the gear selection range.
If the starter motor operates in any position other
than N or P, the neutral safety switch is faulty.

(6) Check all the external wiring to ensure that
the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
starter motor, the unit will have to be removed and
tested.

TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Disconnect the wiring from the starter motor
solenoid. Remove the starter motor mounting bolts,

202 Electrical System


View of the Bosch starter motor removed from the
vehicle.
noting the position of the earth cable, and maneuver
the starter motor out of the engine compartment.

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

Replace the earth cable to the position noted
on removal.
Tighten the starter motor mounting bolts
securely.
HITACHI STARTER MOTOR

To Dismantle
Remove the starter motor from the vehicle
as previously described. Mount the starter motor upright in a soft
jawed vice gripping the drive end bracket. Loosen the solenoid field coil terminal nut
and disconnect the cable from the solenoid.
Scribe a line across the drive end bracket,
yoke and end cover to facilitate correct alignment
during assembly. Remove the bolts retaining the end cover
and yoke to the drive end bracket and remove the end
cover from the yoke. Remove the yoke, armature and brush
holder as an assembly from the drive end bracket.
Note the position of the O ring sealing the yoke. Release the brush spri ngs and separate the
brushes from the brush holder. Remove the brush holder from the yoke.
Separate the armature from the yoke.
Scribe a line across the solenoid and the
drive end bracket to facilitate correct alignment
during assembly. Remove the solenoid retaining bolts and lift
the solenoid, spring, lever an d rubber seal out of the
drive end bracket. Note the installed position of the
components. Mount the drive end bracket in the vice with
the pinion uppermost and Remove the screws retaining
the pinion housing to the drive end bracket. Remove the pinion housing from the drive
end bracket,
Remove the pinion assembly from the drive
end bracket, Mount the pinion in the vice, hold the collar
down and remove the snap ring from the end of the
pinion. Remove the collar and spring from the
pinion and slide the pinion out of the clutch assembly. If necessary, prise the bearings off the clutch
assembly using two screwdri vers. Note the location of
the larger bearing. If necessary, remove the bearings from the
armature using a bearing puller.
To Check and Inspect

Clean all the starter motor components thor-
oughly but do not immerse the yoke, armature or
clutch assembly in cleaning solvent.
Check the brush holder insulation using an
ohmmeter. Connect one test probe to the brush holder
positive side and the other test probe to the negative
side. If continuity exists , renew the brush holder.

Check the brushes for adequate length. Re-
new the brushes if they are worn to less than the
length listed in Specifications. The brushes should be
a free sliding fit in the brush holders. Check the brush
springs for adequate tension.
Check the field coil continuity using an
ohmmeter. Connect one test probe to the positive
brush and the other test probe to the solenoid cable
terminal. If continuity does not exist, renew the field
coils.
View of the Hitachi starter motor removed from the
vehicle
.

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.

216 Electrical System

NOTE: While checking the operation of the
fusible link, loosely connect the battery-
terminal only, to safeguard against damage
to the wiring harness.

(5) If the circuit is still inoperative or the fusible
link burns out again, refer the problem to an auto-
motive electrician.

RELAY LOCATIONS
The various relays employed in the vehicle elec-
trical system are located behind the fusible links
adjacent to the washer bottle in the engine compart-
ment, on the engine compartment bulkhead, under
the windscreen wiper motor and in the fuse box at the
lower right hand side of the dashboard.

The engine compartment relays power the radia-
tor fan, horn, condenser fan, bulb check, automatic
transaxle neutral safety switch, air conditioner and
condenser motor.


Installed view of the fuse box relays.
The fuse box relays power the fuel pump, ignition,
some accessories and the el ectronic control module.

18. TRAILER WIRING
There are several brands of trailer wiring connec-
tors available with a variet y of pin configurations. The
most common is the seven pin type which provides
for two auxiliary circuits, usually used for reverse
lamps and electric trailer brakes.


Installed view of the engine compartment relays.
Installed view of the engine compartment relays.


Useful connections which can be used if the trailer to
be towed is fitted with different type plug to the towing
vehicle socket
Brylite seven pin trailer plug and socket.

Body 231

4. ENGINE BONNET
TO REMOVE, INSTAL AND ADJUST
Raise the engine bonnet and place covers on
both front mudguards. Mark the hinge mountings on
the bonnet with a soft lead pencil to aid assembly.
Place a quantity of soft rag folded several
times under each rear corner of the bonnet on the
scuttle panel. Disconnect the windscreen washer hose from
the bonnet at the tee piece. With the aid of an assistant supporting the
bonnet, remove the retaining bolts and lift the bonnet
from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

Holding the bonnet in the position previ-
ously marked, install the bonnet hinge bolts
and
tighten to just over finger tight.
Close the bonnet and by pushing with the
hand, position the bonnet evenly in its opening.

Open the bonnet carefully and tighten the
mounting bolts. Check for correct positioning and adjust
again if necessary. Check the adjustment of the bonnet catch.
When the bonnet is closed the bonnet should align
with the front panels. When the catch is released the
bonnet should pop up sufficiently to enable the safety
catch to be released. If adjustment is necessary, mark the base
position with a pencil, loosen the retaining bolts and
move the catch in the desired direction. Tighten the
bolts and recheck.
NOTE: When adjusting the bonnet catch
ensure that the bonnet striker plate is enter-
ing centrally into the catch. Adjust the catch
or the bonnet lunges if necessary.

(7) When adjustment is complete, adjust the
bump rubbers on the radiator support panel up or
down by turning them to support the outer edges of
the bonnet.


View of the bonnet hinge showing the retaining/adjust-
ing bolts.

5. TAILGATE AND LOCK - HATCHBACK
TAILGATE
To Remove
Raise the tailgate and place protective covers
over the surrounding paintwork.

Using a soft lead pencil, mark around the
tailgate hinges to aid assembly. Remove the sealing grommets from the tail-
gate and disconnect the rear window washer hose. Prise out the tailgate trim panel retaining
clips and maneuver the tailgate interior trim panel
from the tailgate.
Disconnect the wiring connectors) inside the
tailgate and tie a piece of st ring to the connector(s).
Pull the tailgate wiring from the tailgate,

Installed view of the bonnet catch. View showing the right hand side tailgate components.