1987 NISSAN PULSAR wiring

Engine 51

coolant temperature sensor and temperature sender
switch located in the thermostat housing.

(8) Remove the bolt securing the wiring clamp
to the rear of the manifold and maneuver the wiring
away from the cylinder head and the inlet manifold.
(9) Disconnect the throttle cable and on auto-
matic transaxle models, the kickdown cable from the
throttle body linkage. (10) Remove the bolls securing the throttle cable
bracket to the inlet manifold and place the bracket
and cable(s) to one side.
(11) Mark the fuel supply and return hoses to
ensure correct installation and disconnect the hoses
from the fuel rail or throttle body. Plug the hoses to
prevent the loss of fuel or the entry of dirt. (12) Mark the vacuum hoses connected to the
inlet manifold and throttle body to ensure correct
installation and disconnect the hoses. (13) Remove the nuts securing the engine pipe to
the exhaust manifold and separate the pipe from the
manifold. (14) Remove the oxygen sensor from the exhaust
manifold. Refer to the Fuel and Engine Management
section if necessary. (15) Remove the distributor and coil as described
in the Fuel and Engine Management section. (16) Disconnect the engine breather hoses from
the camshaft housing and cams haft housing top cover.
(17) Remove the bolts retaining the top cover to
the camshaft housing and remove the top cover. (18) Using an open end spanner, hold the cam-
shaft between the inlet and exhaust lobes of number
four cylinder and remove the camshaft timing gear
retaining bolt and the camshaft timing gear.
(19) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (20) Loosen the cylinder head bolts in the reverse
order of the tightening sequence, backing off each bolt
a quarter turn then half a turn at a time until the bolts
are loose.
NOTE: Do not loosen the head bolts while
the engine is warm as distortion of the
cylinder head could result.

(21) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (22) Remove the cylinder head and gasket from
the cylinder block. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Thoroughly clean the gasket surfaces of the
cylinder head, cylinder block and camshaft housing
and check all mating surfaces with a straight edge.
Ensure that all the oilways are clean and free of any
foreign material and lightly oil all operating parts with
engine oil.
(2) Install new gaskets throughout during
assem-
bly.

View of the cylinder head showing the bolt tightening
sequence.
(3) Ensure that the cylinde r head and gasket are
located correctly on the dowels on the cylinder block
face. The head gasket is marked TOP to aid in correct
installation. (4) With the cylinder head and gasket in posi-
tion on the cylinder block, apply an even smear of
Loctite 515 to the cylinder head and camshaft housing
mating surfaces. Take care that no sealant is forced
into the oil passages. (5) Install new cylinder head bolts and lubricate
the bolts and washers with engine oil,
(6) Apply an initial torque to the cylinder head
bolts of 25 Nm in the sequence shown in the
illustration. Further tighten the head bolts in the same
sequence in three separate 60 degree stages. Refer to
Specifications. (7) Install the bolts secur ing the camshaft drive
belt inner cover to the camshaft housing. Install the
camshaft timing gear and tighten the retaining bolt to
the specified torque. (8) Install and adjust the camshaft drive belt as
previously described. (9) Install the distributor, coil and oxygen sensor
as described in the Fuel and Engine Management
section.
(10) Using a new gasket, connect the engine pipe
to the exhaust manifold flange, coat the nuts with an
anti-seize compound and install and tighten the nuts
to
the specified torque. (11) Connect all hoses and electrical wiring dis-
connected during the removal of the cylinder head.
Ensure that all the hoses are returned to their original
locations. (12) Connect the throttle cable and where appli-
cable, the kickdown cable. Adjust the cables as
described in the Fuel and Engine Management section
and the Automatic Transaxle section. (13) Check the engine oil fo r correct level on the
dipstick and for dilution. Change the engine oil and
filter if necessary. (14) Fill the cooling system as described in the
Cooling and Heating Systems section. (15) Start the engine and check for oil or water

Engine 65
(4) Hold the nut and remove the mounting
through bolt. (5) Remove the bolts retaining the mounting to
the transaxle and maneuver the mounting from the
engine compartment. (6) If necessary remove the bolts retaining the
support bracket to the inner mudguard and withdraw
the support bracket. Installation is a reversal of the removal procedure
ensuring that the weight of the engine is bearing on
the engine mounting before tightening the through
bolt securely.

TO RENEW RIGHT HAND SIDE MOUNTING
(1) Disconnect the negative battery terminal.
(2) On 1.8 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary. (3) Support the engine under the sump using a
jack. Interpose a block of wood between the head of
the jack and the sump to prevent damage.
(4) Hold the nut and remove the mounting
through bolt and rubber. (5) Remove the bolts retain ing the mounting to
the inner mudguard and maneuver the mounting
from the engine compartment. (6) If necessary, remove the nuts and bolts
retaining the support brackets to the engine assembly
and withdraw the support brackets.

Installation is a reversal of the removal procedure
ensuring that the weight of the engine is bearing on
the engine mounting before tightening the through
bolt securely.

TO RENEW FRONT TORQUE DAMPER
(1) Raise the front of the vehicle, remove the
splash guard fasteners and remove the splash guard(s)
from the front of the vehicle.
(2) Remove the through bolts and nuts from the
torque damper.
NOTE: It may be necessary to unclip the
wiring harness from the lower radiator sup-
port panel to gain access to the front through
bolt.


Dismantled view of the front torque damper. The arrow of the engine bracket must face upwards.
(3) Withdraw the torque damper from the
engine.
(4) If necessary the support brackets can be
removed. Installation is a reversal of the removal procedure
ensuring that the arrow on the engine bracket faces
upwards.

TO RENEW REAR ENGINE MOUNTING AND
TORQUE DAMPER

Automatic and manual transaxle models both use
a similar rear engine moun ting with different support
brackets. Manual transaxle models use a rear torque
damper.

(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the stabilizer bar mounting bracket
bolts and allow the rear of the stabilizer bar to hang
down slightly. (3) Remove the nuts and bolts retaining the
engine crossmember to the vehicle underbody and
withdraw the crossmember from the vehicle.
Dismantled view of the right hand side engine mount-
ing assembly.

66 Engine

View of the rear engine mounting. Automatic transaxle models.
(4) Remove the bolt retaining the exhaust
mounting to the engine mounting bracket. (5) Remove the engine mounting through bolt.
(6) Remove the bolts and nuts retaining the
engine mounting to the floor panel and remove the
mounting from the vehicle.
(7) On manual transaxle models, the torque
damper can be removed after removal of the through
bolts and nuts. (8) If necessary, remove the bolts retaining the
support bracket to the engine and withdraw the
support bracket.
Installation is a reversal of the removal procedure.

14. EXHAUST SYSTEM
TO REMOVE AND INSTAL

Engine Pipe
(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the nuts retaining the engine pipe to
the exhaust manifold flange.

NOTE: It is advisable to soak all exhaust
system nuts and bolts wi th penetrating oil to
prevent breakage when removing.

(3) Remove the bolts from the flexible joint and
withdraw the engine pipe from the vehicle. Discard
the gasket.

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

(1) Clean any carbon build up from the exhaust
flange and pipe joints. (2) Inspect the condition of the flexible joint
spring. Renew the engine pipe assembly if necessary. (3) Use a new exhaust manifold flange gasket
and coat the manifold studs with anti-seize com-
pound. (4) Ensure that all nuts and bolts are tightened
securely.
Rear System

(1) Raise the front and rear of the vehicle and
support it on chassis stands. (2) Loosen the clamp securing the tailpipe and
muffler assembly to the rear pipe. (3) Remove the mounting bolts and slide the
tailpipe and muffler assembly from the rear pipe.
NOTE; Should difficulty be experienced
when separating the exhaust pipes, they
may be cut with a hacksaw or pipe cutter if
a replacement system is to be installed.

If heat is used to loosen frozen joints take
extreme care near floor panels, fuel and
brake lines or electrical wiring.

(4) Remove the bolts from the intermediate pipe
and rear pipe mountings and lower the exhaust
system. Use care not to drop the catalytic converter.
(5) If necessary the cataly tic converter can be
removed from the intermediate pipe and the rear pipe
assembly by removing the retaining bolts.

Underbody view of the exhaust system. Underbody view of the tailpipe and muffler.

Cooling and Heating Systems 73
(1) Renew all hoses that show signs of cracking
or perishing.
(2) Before finally tightening the hose clips, en-
sure that the hoses are push ed fully onto the radiator
and are not kinked. (3) On automatic transaxle models, ensure that
the oil cooler hoses are correctly installed to the
radiator and show no signs of leakage. Check and top
up the automatic transaxle fluid as necessary.
5. COOLING FAN
The radiator cooling fan is controlled by the
electronic control unit, and on vehicles with air
conditioning, the condenser fan relay. On vehicles
with air conditioning there are two cooling fans, one
is larger than the other. The large fan is for the
radiator and the smaller fan provides extra cooling
when the air conditioning is activated. Each fan is
controlled by a separate system.

TO TEST COOLING FAN AND SYSTEM
(1) With the cooling system cold and the air
conditioning, if applicable, switched off, switch the
ignition On and confirm that the cooling fan is
stationary.

NOTE: Leave the ignition On for all tests
unless otherwise stated.

(2) In the above test, if the cooling fan rotates,
proceed as follows:

(a) Disconnect the cooling fan relay from the
rear of the engine compartment relay box.
(b) If the fan stops, backprobe terminal C1 at
the electronic control unit using an LED test lamp
connected to the positive battery terminal. If no
circuit exists, renew the cooling fan relay.

View showing the location of the diagnostic link
connector. Passengers seat removed for clarity.
If a circuit exists, check the wiring harness
between the electronic control unit and the relay for
short circuits to earth and repair if necessary. If no
short circuit is present renew the electronic control
unit.


Schematic layout of the cooling fan, coolant temper-
ature sensor and related electrical components.

Installed view of the engine compartment relays. KEY

1. To Battery
2. Fusible link
COLOUR CODE
3. Fusible link
B-Black
4. Fusible linkL- Blue
5. I
gnition relayY- Yellow
6. Fuse 20 am
pW-White
7. Coolin
g fan relayO-Orange
8. Coolin
g fan
9. Coolant tem
perature
sensor
10. To air conditionin
g
fan rela
y
11. To throttle
position
sensor
12. Control unit

74 Cooling and Heating Systems
NOTE: Refer to the Fuel and Engine Man-
agement section for the correct procedure for
backprobing the control unit.

(3) In operation (1) if the cooling fan is station-
ary proceed as follows:

(a) Connect a jumper lead between the terminals
A and B of the diagnostic link connector. (b) if the fan runs, the fan circuit is satisfactory.
If the engine is overheating check the coolant temper-
ature sensor as described in the Fuel and Engine
Management section under the appropriate codes. (c) If the fan does not run, check the fuse (6) and
the fusible link (4) show n on the illustration.
(d) Backprobe terminal C1 at the electronic
control unit using an LED t est lamp connected to the
positive battery terminal. If no circuit exists, renew
the electronic control unit. (e) If the fuse and fusible links are serviceable,
ensure that power is available at the white and pink
wires from the fuse and fusible link of the cooling fan
relay. Repair any faults in the wiring to that point if
necessary. (f) Switch the ignition Off. disconnect the
cooling fan wiring connector at the radiator and
connect power to the fan. Renew the fan if it does not
run.

(4) On air conditioned models, remove the
jumper lead from the ALDL connector if still in-
stalled, start the engine and allow it to idle. Switch the
air conditioning on and ensu re that the cooling fan
runs.

If the cooling fan is opera ting as described above
but cooling system problems still exist, refer to the
Trouble Shooting heading at the start of this section.

TO REMOVE AND INSTAL COOLING FAN
(1) Disconnect the negative battery terminal.
(2) Disconnect the cooling fa n and, if applicable,
the air conditioning fan wiring connectors at the
upper edge of the radiator. (3) On models with air conditioning, remove the
compressor hose bracket bolt from the centre of the
radiator support panel.

Dismantled view of the fans and the shroud assembly. Air conditioned model.

78 Cooling and Heating Systems
The air conditioner operates only when the engine
is running as the compressor is belt driven from the
engine.

Operating the air conditioner with the tempera-
ture control raised to a hot setting will produce
dehumidified hot air which is particularly useful for
demisting the vehicle glass.

Maximum cooling is achieved by operating the air
conditioner with the temperature control lowered
fully to the coldest setting . Operate the fan at high
speed when using the coldest temperature setting to
avoid forming ice on the evaporator.

TO REMOVE AND INSTAL HEATER UNIT
(1) Remove the dashboard as described in the
Body section. (2) Drain the cooling system as previously de-
scribed in this section. (3) Loosen the hose clamps and disconnect the
heater hoses from the heater pipes.
NOTE: If the heater hos es will not come off
the heater pipes, do not use excess force or
the heater core retaining strap will be dam-
aged. Cut the hoses from the heater pipes.

(4) Remove the steering column upper mount-
ing bolts. (5) Remove the steering column cross support
bolts and move the support towards the right hand
side of the vehicle. (6) Remove the centre support retaining bolts
and remove the centre support from the vehicle.
(7) Remove the demister duct and the right
hand side ventilator duct from the vehicle. (8) Disconnect the blower fan wiring connector
from the rear of the heater controls. (9) Remove the heater retaining bolts.
(10) On models with air conditioning, it will be
necessary to loosen the evaporator mounting bolts. (11) Working in the engine compartment, push
the heater pipe grommet through the bulkhead. (12) Maneuver the heater unit upwards slightly
and out from the bulkhead using care not to damage
the heater pipes. (13) To remove the heater core and tap assembly,
remove the screws from the retaining strap and slide
the heater core from the heater unit.
Installation is a reversal of the removal procedure
with attention to the following points:

(1 ) Before installing the heater unit to the

View of the heater unit with the dashboard, centr e support, demister duct and right hand ventilator
duct removed.

Cooling and Heating Systems
11. BLOWER FAN
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working below the glov e compartment, dis-
connect the wiring connector to the blower fan motor.
(3) Remove the bolts retaining the blower fan
motor and carefully lower the motor while disconnect-
ing the drain hose.

Installation is a reversal of the removal procedure
with attention to the following points:
( t ) Tighten all bolts securely.
(2) Check that the blow er fan operates correctly.

Dismantled view of the blower fan and associated
components.
12. AIR CONDITIONING
DESCRIPTION
The air conditioning system, when used in con-
junction with the heater, enables any reasonable tem-
perature to be achieved inside the vehicle. It can also
reduce the humidity of the incoming air, aiding
demisting even when cooling is not required.

The basic components of the air conditioning sys-
tem are an evaporator, co ndenser, compressor, re-
ceiver/dryer, expansion valve and pipes and hoses
carrying the refrigerant through the system. Various
subsidiary controls and sensors are also utilized to
protect the system against low or high pressure and
excessive temperature.

The refrigerant will boil at a very low tempera-
ture (-33 deg C) and therefore must be contained
under pressure. Escaping refrigerant can cause frost-
bite and eye damage and will produce a poisonous gas
when burnt. Also, if the system suffers a rapid loss of
refrigerant, oil from the compressor may be carried
out with the refrigerant. It is recommended that any
work requiring disconnection of the components be
referred to an au thorized dealer.

In the event of major repair s to the vehicle such as
engine removal, the compress or hoses are of sufficient


Schematic diagram of a typical air conditioning
system.
length to allow the compressor to be removed as the
engine is lowered from the engine compartment with-
out disturbing any refrigerant line connections.

If the operation of the air conditioning system is
in doubt, it is recommended that the vehicle be taken
to an authorized dealer for testing and repair.

TO CHECK REFRIGERANT CHARGE
(1) Start the engine and operate the air condi-
tioner on maximum cooling for a few minutes.
(2) Observe the flow of refrigerant through the
sight glass located at the top of the receiver/dryer. On
some models it may be necessary to use a mirror to
see the sight glass. (3) If the system is operating correctly, the sight
glass will be clear during the operation of the com-
pressor. Occasional bubbles may be seen when the
compressor cycles on and off during operation, but a
NUT j-
Bubbles in the sight glass when the air conditioner is
operating indicates a low refrigerant charge.

Fuel and Engine Management 83
the fuel pump will not operate until the oil
pressure is sufficient to extinguish the oil
pressure warning lamp. Therefore it will be
necessary to operate the starter motor for a
longer period than usual to start the engine.

(3) Faulty EFI component wiring connections:
Check that all component wiring connections are
clean and secure.
(4) Manifold absolute pressure (MAP) sensor
vacuum hose blocked or disconnected: Clear or recon-
nect the vacuum hose. (5) Fault in the ignition system: Check the
primary and secondary ignition circuits.
(6) Engine flooded: Fully depress the throttle
pedal until the engine starts. Check the coolant
temperature sensor. Check th e injector(s) for leakage.
ENGINE STARTS THEN STALLS

(1) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(2) Air leakage at the inlet manifold: Check all
joints and hoses for air leaks. (3) Faulty EFI wiring connections: Check that
all component wiring connections are clean and
secure.
(4) Ignition timing incorrectly set: Check and
adjust the timing. (5) MAP sensor faulty or supply hose discon-
nected or blocked: Check the vacuum supply hose.
Check the operation of the MAP sensor.
ENGINE MISFIRES

(1) Faulty, dirty or incorrectly adjusted spark
plugs: Renew or clean and adjust the spark plugs.
(2) Condensation in the distributor cap: Dry and
examine the cap for cracks. (3) Faulty high tension leads: Check and renew
the high tension leads.

Testing the fuel system pressure using a pressure
gauge.
(4) Faulty ignition coil: Check and renew the
ignition coil.
(5) Fuel blockage: Check for blockage in the fuel
filter, lines and injector(s). (6) Low fuel pressure: Check the fuel pump and
fuel pressure regulator. (7) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter. (8) Loose fuel supply wiring connectors: Check
all connectors for tightness. (9) Faulty fuel injector: Check the connections
and test the condition of the fuel injectors.
ENGINE LACKS POWER

(1) Ignition timing incorrectly set: Check and
adjust the timing.
(2) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(3) Incorrectly adjusted throttle cable: Adjust the
throttle cable.



Check the distributor cap for cracks or tracking be- tween the terminals. The air filter element should be renewed at 40 000 km
intervals. 1.8 liter engine.