1987 NISSAN PULSAR stop start

Fuel and Engine Management 111


Location of the throttle position sensor. Inset shows the terminal identification.
the diagnostic link connector. Note any fault codes
displayed.

If code 21 is displayed, proceed to operation (11).
If code 22 is displayed, proceed as follows.
(10) Connect the lead of a test lamp to the
positive battery terminal and insert the probe into
terminal B on the throttle position sensor wiring
connector.

If the test lamp lights, pr oceed to operation (24).
If the test lamp does not light, check the wiring
harness between the throt tle position sensor wiring
connector terminal B and the control unit wiring
connector terminal D2 fo r continuity. Repair or
renew the wiring harness as necessary and retest for
fault codes.

(11) With the ignition switched Off, disconnect
the control unit wiring connectors. (12) With the ignition switched On, measure the
voltage at terminal C13 on the control unit wiring
connector.
If the voltage is less than 1 volt, check the wiring
harness for shorts between the throttle position sensor
wiring connector terminals C and A and the control
unit wiring connector terminals C13 and C14. Repair
or renew the wiring harness as necessary. If no fault
can be found, renew the control unit.

(13) Start and run the engine at idle speed.
(14) Connect a jumper lead across terminals A
and C on the throttle position sensor wiring connec-
tor. (15) Stop the engine, switch the ignition On and
connect a jumper lead between terminals A and B on
the diagnostic link connector . Note any fault codes
displayed. If codes 21 and 22 are displayed, proceed to
operation (24).

If code 22 only is displayed, proceed as follows.
(16) Remove the jumper lead from the throttle
position sensor wiring connector. (17) Measure the voltage across the throttle posi- tion sensor wiring connector terminals A and B.

If the voltage is below 4 volts, proceed to opera-
tion (20).

If the voltage is 4-6 volts, proceed as follows:
(18) With the ignition switched Off, disconnect
the control unit wiring connectors.
(19) Check the wiring harness between the con-
trol unit wiring connector terminal C13 and the
throttle position sensor wiring connector terminal C
for continuity and shorts. Repair or renew the wiring
harness as necessary and retest for fault codes. If no fault is found, renew the control unit and
retest for fault codes.

(20) Disconnect the wiring connector from the
MAP sensor. (21) Measure the voltage across the throttle posi-
tion sensor wiring connector terminals A and B.
If the voltage is 4 - 6 volts, renew the MAP sensor.
If the voltage is below 4 volts, proceed as follows.

(22) With the ignition switched Off, disconnect
the control unit wiring connectors. (23) Check the wiring harness between the con-
trol unit wiring connecto r terminal C14 and the
throttle position sensor wiring connector terminal A
for continuity and shorts. Repair or renew the wiring
harness as necessary and retest for fault codes. If no fault is found, renew the control unit and
retest for fault codes.

(24) With the ignition switched On, measure the
voltage at the control unit wiring connector terminal
C13.

If the voltage is 0.2-1.2 volts, proceed to opera-
tion (27).

If the voltage is 1.2-2.5 volts, proceed to opera-
tion (25).

If the voltage is over 2.5 volts, proceed as follows:
(a) Disconnect the wiring connector from the
throttle position sensor. (b) Measure the voltage at the control unit
wiring connector terminal C13. If the voltage is less than 1 volt, check the wiring
harness for continuity between the throttle position
sensor terminal B and the control unit wiring connec-
tor terminal D2. If the wiring harness is satisfactory,
renew the throttle position sensor.

(25) Check the base idle sp eed and adjust if
necessary as previously described. (26) With the ignition switched On, measure the
voltage at the control unit wiring connector terminal
C13. The voltage should be 0.2-1.2 volts. If the voltage is not as specified, renew the throttle
position sensor.

If the voltage is as specified, proceed as follows.
(27) With the ignition switched On, measure the
voltage at the control unit wiring connector terminal
C13 as the throttle is steadily opened to the wide open
throttle position. The voltage should increase steadily
with no sudden variations.

112 Fuel and Engine Management
If the voltage does not increase as specified, renew
the throttle position sensor.

If the voltage is as specified, proceed as follows.
(28) With the ignition switched On and the
throttle valve held fully open, measure the voltage at
control unit wiring connector terminal C13. The
voltage should be above 4 volts.

If the voltage is below 4 volts, renew the throttle
position sensor.

To Remove and Install
(1) Disconnect the negative battery terminal.
(2) On 1.6 liter engines, remove the air cleaner
assembly as previously described. (3) Disconnect the throttle position sensor wir-
ing connector. (4) Remove the throttle position sensor retain-
ing screws and remove the throttle position sensor
from the throttle body. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the throttle valve is in the fully
closed position. (2) Tighten the retaining screws securely and
install the wiring connector.

View of the throttle positi on sensor removed from the
throttle body assembly.
MANIFOLD AIR TEMPERATURE (MAT)
SENSOR - 1.8 LITRE ENGINE

To Test - Codes 23 and 25
(1) Erase the self diagnosis code memory as
previously described.
(2) Start and run the engine for 2 minutes or
until the ECM warning lamp lights. (3) Stop the engine, switch the ignition On and
connect a jumper lead between terminals A and B on
the diagnostic link connector . Note any fault codes
displayed. If codes 23 or 25 are displayed, proceed to
operation (4).

If codes 23 or 25 are not displayed but were
displayed when the self diagnosis test procedure was
originally performed, an intermittent fault is indi-
cated. Proceed as follows:

(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth wires are secure.
(4) Disconnect the wiring connector from the
MAT sensor. (5) With the ignition switched On, measure the
voltage across the terminals on the MAT sensor wiring
connector. The voltage s hould be 4-6 volts.
If the voltage is below 4 volts, proceed to opera-
tion (9).

If the voltage is as specified, proceed as follows.
(6) Remove the MAT sensor from the engine.
(7) Connect an ohmmeter to the MAT sensor
terminals. (8) Immerse the metal end of the MAT sensor in
a container of iced water at a temperature of 4 deg C.
The resistance should be 7 500 ohms. Slowly heat the water and measure the resistance
of the MAT sensor at the following temperatures.
Compare the results with the specified values:

20 deg C .................................................. 3 400 ohms
38 deg C....................................................1 800 ohms
70 degC ...................................................... 450 ohms
100 deg C.................................................... 185 ohms
If the resistances obtained are not close to the
specified figures at any of the given temperatures,
renew the MAT sensor and retest for fault codes.

(9) Disconnect the control unit wiring connec-
tors. (10) Check the wiring harness between the MAT
sensor wiring connector and the control unit wiring
connector terminals C12 and A11 for shorts and
continuity. Also check the control unit terminals for
damage. Repair or renew the wiring harness as necessary.
If no fault is found, renew the control unit and
retest for fault codes.

To Remove and Install
(1) Disconnect the negative battery terminal.
Installed view of the MAT sensor. 1.8 liter engine.

Fuel and Engine Management 113
(2) Disconnect the wiring connector from the
MAT sensor.

(3) Unscrew the sensor from the inlet manifold.
Installation is a reversal of the removal procedure

with attention to the following points:
(1) Apply Loctite 567 or a similar conductive
sealer to the threads of th e sensor. Tighten the sensor
to the specified torque. (2) Ensure that the wiring connector is clean and
tight.
OXYGEN SENSOR

To Test - Code 13
(1) Run the engine until the normal operating
temperature is obtained. (2) With the ignition switched Off, connect a
jumper lead between terminals A and B on the
diagnostic link connector.
(3) Start and run the engi ne at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp.
If the ECM warning lamp flashes at the rate of
twice per second, proceed to operation (5).

If the ECM warning lamp flashes at the rate of
once per second or slower, proceed as follows.

(4) Remove the jumper lead from the diagnostic
link connector and run th e engine above 2 000 rpm
for 2 minutes, noting the ECM warning lamp.

If the ECM warning lamp lights, stop the engine,
switch the ignition On and connect a jumper lead
between terminals A and B on the diagnostic link
connector. If code 13 is displayed proceed to opera-
tion (5).

If the ECM warning lamp does not light, an
intermittent fault is indicated. Proceed as follows:

(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure.
(b) Check that all earth wires are secure.
(5) Switch the ignition Off and disconnect the
oxygen sensor wiring connector. Using a jumper lead
connect the oxygen sensor wiring connector to a
suitable engine earth. (6) Start and run the engi ne at approximately
1 600-1 800 rpm and note the ECM warning lamp.
The lamp may flash for a few seconds but should then
extinguish for at least 30 seconds.
If the ECM warning lamp functions as described,
proceed to operation (7).

If the ECM warning lamp does not function as
described proceed as follows:

(a) Check the wiring harness between the oxygen
sensor wiring connector and the control unit wiring
connector D7 for open circuits. Repair or renew the
wiring harness as necessary.

{b) Check the earth circuit between the control
unit wiring connect D6 and the right rear cylinder
head bolts. Repair or renew the wiring harness as
necessary.

(c) If no fault is found in (a) and (b) renew the
control unit and retest for fault codes.

(7) Check the wiring harness earth circuit be-
tween the control unit wiring connector D6 and the
right rear cylinder head bolts. Repair or renew the
wiring harness as necessary.

If no fault is found, thoroughly check the oxygen
sensor connector. If the conne ctor is not faulty, renew
the oxygen sensor.

To Test - Code 44
(1) Run the engine until normal operating tem-
perature is attained.
(2) With the ignition switched Off, connect a
jumper lead between terminals A and B on the
diagnostic link connector. (3) Start and run the engi ne at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp. If the ECM warning lamp is off more than on or
flashes at the rate of twice per second, proceed to
operation (4).

If the ECM warning lamp flashes evenly at the
rate of once per second an intermittent fault is
indicated. Proceed as follows:

(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth wires are secure.
(4) Switch the engine Off and disconnect the
oxygen sensor wiring connector.
(5) Start and run the engine at 1 600-1 800 rpm
for at least 30 seconds and note the ECM warning
lamp. If the ECM warning lamp flashes at the rate of
twice per second procee d to operation (6).

If the ECM warning lamp extinguishes for at least
30 seconds, check the wiring harness between the
oxygen sensor wiring connector and the control unit
wiring connector terminal D7 for shorts to earth.

Repair or renew the wiring harness as necessary.
If no fault can be found in the wiring harness, renew
the control unit.

Installed view of the oxygen sensor.

Automatic Transaxle 141

(2) Incorrectly adjusted kickdown cable: Check
and adjust or renew the kickdown cable as required.

NOTE: Check and adjust the throttle cable
before adjusting the kickdown cable.

ENGINE WILL NOT START IN P OR N
RANGE OR WILL START IN ANY RANGE

(1) Neutral safety switch faulty: Adjust or renew
the neutral safety switch. (2) Incorrectly adjusted selector cable: Check
and adjust the selector cable as detailed.
2. DESCRIPTION

The automatic transaxle combines a fluid coup-
ling or torque converter with a fully automatic three
speed epicyclic gear system.

The transaxle provides th ree forward ratios and
one reverse. The hydraulic system consists of a single
pump and valv e arrangement.

The final drive or differential and the transaxle
use a common lubricant. The transaxle oil pan and
final drive drain plug will have to be removed to drain
the transaxle completely. Topping up or refilling is
done through the dipstick tube.

The gear selector lever is floor mounted and
connected to the transaxle by an adjustable cable. The
selector quadrant adjacent to the base of the lever is
marked P, R, N, D, 2, 1.

It is necessary for the selector lever to be in P or
N before the engine can be started. When testing or
tuning the engine, the handbrake must be firmly
applied and the selector lever placed in the P position,
otherwise the vehicle could move forward or back-
wards as the engine speed is increased.

For long distance towing the vehicle should be
towed with the front end raised.

It is not possible to start the engine by either
towing or pushing the vehicle.

The transaxle can be removed from the vehicle
without engine removal.

NOTE: As extensive knowledge and equip-
ment is required to overhaul the automatic
transaxle assembly, it is therefore not a
worthwhile repair proposition for the aver-
age person. However if the transaxle must
be overhauled by a specialist or be replaced
with a reconditioned unit, the removal and
installation procedure is fully described at
the end of this section.

3. TRANSAXLE FLUID
Only use the recommended transaxle fluid speci-
fied by the manufacturer when topping up or changing
the fluid in the system.

TO CHECK AND TOP UP
NOTE: The fluid level should be checked
after approximately 5 minutes driving on
the road when the engine has achieved its
normal operating temperature of approxi-
mately 65 deg C.

(1) Place the vehicle on a level floor and open
the engine bonnet.

NOTE: When working on the automatic
transaxle cleanliness is very important. Do
not reuse transaxle fluid and do not allow
foreign matter to enter the filler opening.

(2) Clean around the top of the dipstick to
ensure that no dirt or foreign matter can enter the
dipstick tube.
(3) Place the selector in the P position and
firmly apply the handbrake. (4) Move the selector thro ugh each gear return-
ing it to the P position.
(5) Check the fluid level with the engine running
at idle. Install the dipstick fully into the dipstick tube.
NOTE: If the vehicle has been driven at high
speed, or has been towing a load, or driven
through heavy city traffic in hot weather, a
period of about 30 minutes should be
allowed to permit the transaxle to cool
before checking the fluid level.

(6) Withdraw the dipstick and check the fluid
level reading. The fluid should be at the H mark on
the dipstick. If the fluid is low, stop the engine and
remove the dipstick from the vehicle. Using a funnel,
top up the transaxle with the recommended type of
transaxle fluid through the dipstick tube. (7) If the level is reading too high allow the
engine to cool down for about 30 minutes and recheck
the level as described. If the level is still too high, a
small amount of transaxle fluid may be drained from
the transaxle.

Checking the fluid level on the automatic transaxle
dipstick.

Steering — Part 3 153

TO CHECK FLUID LEVEL
Check the fluid level in the power steering reser-
voir when the fluid is cold.

If it is necessary to top up the fluid, fill to between
the arrow marks on the dipstick using the recom-
mended fluid.

NOTE: Do not overfill the reservoir.
Checking the power steering fluid level using the
dipstick incorporated in the cap.
TO CHECK FOR FLUID LEAKS
Using a suitable solvent, clean around all power
steering assemblies and hose fittings where fluid
leakage might occur and start the engine. Turn the
steering wheel from one steering lock to the other
several times and stop the engine. Check for leakage.
Where leakage is found at ho se fittings, tighten and
recheck.

If the leak remains, renew the hoses or fittings as
required.

Where leakage is found in the steering gear
assembly or pump assembly, specialist attention is
necessary.

TO CHECK STEERING WHEEL FREE PLAY
With the engine running and the steering wheel in
the straight ahead positi on, measure the free move-
ment of the steering wheel before the front wheels
move. This is specified as steering wheel free play and
if it exceeds Specifications, check for free play in the
steering linkages and the universal coupling joints. If
these components are satisfactory, it will be necessary
to remove the steering gear from the vehicle for
renewal or overhaul.

PUMP BELT TENSION
The procedure for adjusting the power steering
pump bell tension is describe d in the Engine Tune-up
section

TO PURGE THE POWER STEERING SYSTEM
OF AIR

(1) Check that the pump reservoir is filled to the
correct mark on the dipstick. (2) Raise the front of the vehicle and support it
on chassis stands. (3) Turn the steering wheel quickly from lock to
lock several times, recheck the fluid level within the
pump reservoir and top up if required. (4) Start the engine, allow it to idle and slowly
turn the steering wheel from lock to lock several times.
Do not hold the steering at full lock for more than 15
seconds. (5) Check the fluid level in the pump reservoir,
top up if necessary. (6) If the fluid is aerated within the pump
reservoir or if pump noise persists, repeat operations
(3) to (6).
3. STEERING WHEEL

The procedure for removing and installing the
steering wheel is fully covered in the Manual Steering
section under the above heading.

4. STEERING COLUMN
The procedure for removing, dismantling and
assembling the steering column is fully covered in the
Manual Steering section under the above heading.

5. POWER STEERING PUMP
TO REMOVE AND INSTAL
( 1 ) Disconnect the negative battery terminal.

View of the power steering pump removed from the
vehicle.

Brakes 177
installed. Install the second back up ring, large
diam-
eter first.

(6) Install the second garter spring. Insert
a
machined drift into the bore and lightly push the
garter spring into its locating groove.
(7) Smear the secondary piston with clean brake
fluid. Ease the seal over the piston body into the
groove adjacent to the spring, ensuring that the seal lip
faces the spring and that the nylon spacer is against
the back of the seal. (8) Install the guide onto the secondary
piston,
large internal diameter first, followed by the main seal
with the lip facing away from the spring. (9) Lubricate the secondary piston assembly
with clean brake fluid and install the secondary spring
and retainer to the piston. Install the complete assem-
bly into the master cylinder bore. (10) Smear the primary piston with clean brake
fluid. Install the guide, large internal diameter first,
followed by the main seal with the lip facing towards
the small end of the piston.
(11) Install the retainer to the spigot on the front
end of the primary piston ensuring that the legs of the
retainer engage with the groove on the piston. (12) Lubricate the primary piston assembly with
clean brake fluid and install the assembly into the
master cylinder bore. With a blunt rod, push the
assembly down the bore sufficiently to preload the
pistons. While holding the preload, install the stop pin
and valve assemblies into
the master cylinder body and tighten securely. (13) Install a new O ring to the groove on the boss
of the mounting flange of the master cylinder.
(14) Install new O rings to th e pressure differential
pistons, smear them with cl ean brake fluid and install
them into the master cylinder body. (15) Install a new O ring to the pressure differen-
tial end plug, install the plug to the master
cylinder
body and tighten to the specified torque. (16) Using a blunt probe entered through the
sensing switch location hole, separate the pressure
differential pistons and install the switch actuating
lever between them. (17) Screw the sensing switch into its locating
hole until the detents on the switch body just contact
the locating hole facing (w ith the radial grooves).
Screw the switch assembly in a further half to one full
turn ensuring that the dete nts locate in the grooves.
(18) Install new valve seal s to the proportioning
valve plungers, with the serrations of the seals facing
away from the hexagons of the plungers.
(19) Install the new O rings to the
proportioning
valve plugs. (20) Install the valve springs over the stems of the
proportioning valves, insert the install the valve
plugs.
Tighten the plugs to the specified torque.
(21) Install a new O ring to the base of the fast fill
valve assembly. Install a new valve washer to the base
of the valve.
(22) Install the fast fill valve assembly in
the
primary reservoir port (nearest to the mounting flange
of the master cylinder) and install the snap ring
to
retain the assembly. Ensure that the snap ring is
correctly seated in the groove. (23) Smear the new reservoir retainers with clean
brake fluid and install them into the reservoir ports.
Carefully press the brake fluid reservoir into position,
ensuring that the outlet extensions are fully inserted in
the reservoir retainers. (24) Install the reservoir cap insert to the dia-
phragm and press the cap assembly onto the reservoir.
TO INSTAL

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

(1) Pour a small amount of clean brake fluid into
the reservoir and pump the master cylinder pistons
with a blunt rod until fluid begins to emerge from the
outlets. (2) Install the master cylinder to the brake servo
unit and loosely install the master cylinder retaining
nuts. (3) Connect the brake pipes to the master cylin-
der outlets, but do not tighten at this stage. (4) Securely tighten the nuts retaining the master
cylinder to the brake servo unit.
(5) Securely tighten the brake pipes and connect
the wiring to the pressure sensing switch.

(6) Fill the master cylinder reservoir with clean
brake fluid and bleed the brakes as described under
the Hydraulic System heading. (7) Check and if necessary adjust the brake
pedal height and free play as described under the
Brake Pedal heading.
4. BRAKE SERVO UNIT

TO CHECK OPERATION
(1) With the engine switched off, apply the
footbrake several times to exhaust all vacuum from
the system.
(2) Apply the footbrake and hold the brake pedal
fully depressed.
(3) Start the engine. If the servo unit is function-
ing satisfactorily a distinct downward movement of
the
brake pedal should be noticed. Should the pedal fail to move downward when the
engine has been started, the vacuum system can be
considered inoperative.

NOTE: If the pedal continues to fall away
there is a fault in the hydraulic system.

(4) Ensure that the brake pedal is fully released,
start the engine and run it at medium speed. Stop the
engine.

190
ELECTRICAL SYSTEM
CAUTION: To prevent severe electrical shock extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

SPECIFICATIONS
BATTERY
Type ..................................................12 volt lead acid
Polarity to earth .................................... Negative ( - )
Specific gravity:
Fully charged ................................... A bove 1.250
Fully discharged ................................Below 1.130
ALTERNATOR
Make .................................................Bosch or Hitachi
Maximum output .......................................... 70 amps
Polarity to earth .................................... Negative ( - )
Stator windings ......................................... Star wound
Regulator type ................................................ Integral
Brush length minimum:
Bosch ........................................................ 5.0 mm
Hitachi ............................. 6.0 mm or limit mark
STARTER MOTOR
Make .................................................Hitach i or Bosch
Type ............................ 4 pole 4 brush reduction gear
Operation control.................................. Solenoid and
overrunning clutch
Undercut of commutator (maximum):
Hitachi ...................................................... 0.8 mm
Brush length (minimum):
Bosch ........................................................ 8.0 mm
Hitachi ........................................................11 mm
Brush spring tension;
Hitachi ............................................... 15.7-19.6 N
Hitachi:
Drive pinion stopper clearance ........ 0.3-1.5 mm
Selective fit adjuster plates ........ 0.5 and 0.8 mm
IGNITION SYSTEM
The ignition system is an integral part of the
engine management system. The Specifications, testing
and overhaul procedures are fully covered in the Fuel
and Engine Management section.

TORQUE WRENCH SETTINGS
Alternator pulley retaining nut:
Bosch ......................................................... 50 Nm
Hitachi ....................................................... 59 Nm
1. BATTERY AND CHARGING SYSTEM
TROUBLE SHOOTING

BATTERY UNDERCHARGED
3. Loose or broken drive belt: Adjust or renew
the drive belt. 4. Faulty alternator regulator; Renew the regu-
lator unit.
5. Faulty battery: Install a new battery of
the
recommended type and capacity. 6. Faulty alternator: Overhaul or renew the
alternator. 7. Fault in the charging circuit wiring: Check
and repair or renew the wiring harness. 8. Faulty connections in the charging circuit:
Check and repair the connections. 9. Fusible link blown; Rectify the fault and
renew as necessary.
NOTE: Check the state of charge (specific
gravity) of the battery- as described under
the
Battery heading in this section. If the battery
is undercharged, check the possible causes in
the order given.

BATTERY OVERCHARGED
• Faulty alternator regulator unit:
Renew the
regulator unit.
• Faulty alternator: Overhaul or
renew the
alternator. • Faulty charging circuit wiring or
connec-
tions: Check and renew or repair the faulty
compo-
nents.
NOTE: An overcharged battery is indicated
by continual loss of water through boiling.

196 Electrical System



Check the specific gravity in each cell with a hydro-
meter.
Check the battery electrolyte level and re-
plenish as necessary. Remove the filler cap s from the battery.
Follow the battery charger manufacturers
instructions. (3) Should the battery fail to operate satisfacto-
rily after charging, it is recommended that it be taken
to a workshop with the necessary equipment to per-
form a load test. Load testing, when performed in
conjunction with the specific gravity tests described
above will give an accurate indication of the service-
ability of the battery.
7. ALTERNATOR
Special Equipment Required
To Test On Vehicle - Voltmeter, 100-0-100
amp ammeter, ohmmeter
To Dismantle — 200 watt soldering iron,
bearing
puller, press
To Assemble — 200 watt soldering iron
DESCRIPTION
Two types of alternator are installed to the range
of vehicles covered by this manual, either Hitachi or
Bosch. In the alternator, the field and pole shoe assembly
is the moving part and it is shaped to form the rotor.
Since only a low amperage current flows between the
slip rings on the rotor shaft and the brushes, wear on
the brushes and slip rings is very slight and mainte-
nance is reduced to a minimum. The output current is generated in the fixed stator
windings and is a three phase alternating current
(AC). The stator windings are wound on a laminated
soft iron former, star connected and installed between
the end brackets. As it is not possible to charge a storage battery
with alternating current, it is necessary to rectify the
output of the stator windings to direct current (DC). This is done by a bank of diodes mounted within the
alternator slip ring end bracket.
The output of the alternator is governed by the
regulator and the built in ch aracteristics of the alter-
nator.
The regulator and brush holder assembly on
Hitachi alternators is mounted within the alternator
on the slip ring end bracket side. On Bosch
alternators
the regulator and brush holder unit is mounted to the
outside of the slip ring end bracket. An electrical cut out unit is not necessary with the
alternator charging system as the diodes prevent a
reverse current flow through the alternator.
SERVICE PRECAUTIONS
Ensure that the battery is connected with the
correct polarity to earth. Refer to Specifications.
Do not short out or ground any terminals
common to the charging circuit. Always disconnect the battery before con-
necting a battery charger.
If a booster battery is used, always connect it
in a parallel circuit i.e. positive to positive ( + to + )
and negative to negative (- to -) to maintain a 12
volt supply. Never disconnect the battery or terminals in
the charging circuit while the engine is running. Regularly check that the alternator drive belt
tension is as specified. Refer to the Engine Tune-up
section.
Keep the battery terminals clean and all
electrical connections tight. Disconnect the battery and alternator when
electric welding on the vehicle.
TO TEST ON VEHICLE If the charge indicator lamp stays on after the
engine has been started and run at approximately
1 000 rpm, carry out the following tests. Stop the engine.
Check the condition and adjustment of the
alternator drive belt. Clean the battery terminals, tighten all elec-
trical connections, check the wiring for shorts to earth
and/or bridged circuits. Ensure that the battery is fully
charged. If the battery is discharged charge it or
replace it with one fully charged. Start the engine and allow it to run until
normal operating temperature is reached.
Stop the engine and disconnect the negative
battery terminal.
Remove the nut and washer from the alter-
nator output terminal (B +) and disconnect the alter-
nator output lead. Connect one lead of an ammeter to the
alternator output terminal and the other lead to the
lead removed from the output terminal. Connect the negative battery terminal and
connect a voltmeter across the battery terminals.