1987 NISSAN PULSAR radiator

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.

Cooling and Heating Systems 75
(4) Remove the bolts retaining the fan shroud
assembly to the radiator and carefully move the
shroud assembly upwards and towards the engine to
release it from the lower mountings.

NOTE: On models with air conditioning, it
will be necessary to hold the air conditioning
compressor hoses toward s the engine to
allow clearance for removal of the shroud
assembly.

(5) If necessary, remove the fan from the fan
motor by removing the retaining bolts or on some
models the nut and washers.
(6) If necessary, remove the fan motor from the
shroud assembly by removing the retaining bolts or
nuts. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure all the fan motor and fan retaining
nuts and bolts are tightened securely. (2) Ensure that all the rubber mountings are in
good condition. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all sealing surfaces are clean.
(2) Renew the O ring on installation.
(3) Tighten the thermostat cover retaining bolts
securely.
(4) Fill the cooling system as previously de-
scribed ensuring that the heater control lever is in the
maximum heat position. Check for coolant leaks.
TO CHECK

NOTE: A visual examination of the thermo-
stat will often determine its serviceability
and make further testing unnecessary. For
instance, a thermostat with its valve fully-
open when removed from a cold engine is
obviously faulty and should be renewed.

Remove the thermostat from the thermostat
6. THERMOSTAT
Special Equipment Required:
To Check — Thermometer

TO REMOVE AND INSTAL
(1) Drain the cooling system as previously de-
scribed under the Radiator heading.
(2) On 1.6 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary. (3) Disconnect the top radiator hose from the
thermostat cover.
(4) Remove the bolts retaining the thermostat
cover to the thermostat housing. (5) Remove the thermostat cover, thermostat
and O ring from the thermostat housing.
NOTE: The thermostat and cover are ser-
viced as a unit and cannot be renewed
separately.


View of the thermostat removed from the vehicle and dismantled for testing. Line drawing showing the correct method to test the
thermostat.

(4) Progressively heat the mixture noting the
temperature reading on the thermometer as the ther-
mostat valve commences to open and when it is fully
open.

See the Specifications for opening and fully open
temperatures.

A thermostat which is not opening or is not open
at the specified temperatures should be renewed.

Cooling and Heating Systems 77
These openings are plugged with welch plugs. The
plugs may have to be renewed when cleaning the
engine water jackets or when defective due to corro-
sion.

TO RENEW
NOTE: If a welch plug is found to be
corroded it is good policy to renew all the
welch plugs.

(1) Drain the radiator and cylinder block.
(2) Remove the necessary engine components or
accessories to gain ampl e working space around the
welch plug. (3) Using a punch and hammer, tap the welch
plug on its outer circumference into its opening. (4) Grasp the edge of the welch plug with a pair
of multi-grip pliers and using the shoulder of the pliers
as a fulcrum, lever the plug out of its opening. (5) Thoroughly clean and dry the welch plug
opening.
(6) Lightly smear the edge of a new welch plug
and the opening with Loctite 675. (7) Place the welch plug onto the opening and
using a tube or socket fitting the rim of the plug, drive
the plug squarely into its opening.
NOTE; The welch plug must be driven into
the opening straight and squarely or leaks
may occur.

(8) Install the components which were removed
to gain access to the plug. (9) Fill the cooling system as previously de-
scribed. With the reserve tank pressure cap installed,
run the engine until it reaches normal operating
temperature and check for coolant leaks.
10. HEATER UNIT, WATER VALVE AND
CONTROLS
DESCRIPTION
The heater controls use four adjustments to direct
air through the vehicle.

The air intake control selects fresh air from
outside the vehicle or recirculates air from inside the
vehicle. The recirculate position is used in dusty
conditions or to rapidly heat or cool the vehicle
interior. The fresh air positi on is the best to deodorize
the vehicle interior or demist the windscreen.

The air control lever is used to direct air to the
face outlets, the floor outle ts and the windscreen
outlets. This control also has two bi-level positions
where air may be directed to the face and floor outlets
or the windscreen and floor outlets.

The temperature control opens or shuts the heater
water valve to control the flow of engine coolant
through the heater core, which raises or lowers the
temperature of the air passing through the core.
Maximum heating is only available when the engine is
at the normal operating temperature.

The fan speed control switches the fan on and off
and is used to select the desired fan speed.

Air conditioned models use identical controls
with the addition of an air conditioner on/off button.
The centre of the button is illuminated when the air
conditioner is switched on.

Tap the welch plug on its ou ter circumference into the
cylinder block.
Using a correct fitting tube or socket, drive the welch
plug into its opening. View of the heater controls.

Automatic Transaxle 143
facing towards the radiator support panel at the front
of the vehicle.

The neutral safety switch allows electrical current
to pass to the starter circ uit only when the selector
lever is in the Park or Neutral position. The switch is
adjustable but non-repairable.

TO TEST
(1) Disconnect the neutral safety switch wiring
connector.
(2) Connect an ohmmeter between terminals 1
and 2 at the neutral safety switch wiring connector.
Continuity should exist when the selector lever is in
the P or N positions. (3) Perform the same check with terminals 3 and
4 with the selector lever in the R position. Continuity
should exist.
NOTE: If the readings are other than that
specified, the neutral safety switch will have
to be adjusted or renewed.


Neutral safety switch connector terminal identification.
TO ADJUST
(1) Select Neutral and firmly apply the hand-
brake. (2) Loosen the neutral safety switch retaining
bolts.
(3) Align the holes in the neutral safety switch
body and the neutral safety switch arm. (4) Install a 2.5 mm diameter split pin or drill bit
into the holes to align the arm with the neutral safety
switch body. (5) Secure the retaining bolts and test the switch
as previously described.

If the test indicates a fault, renew the neutral
safety switch.

TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the selector cable split pin and wave
washer from the transaxle selector lever.
(3) Disconnect the electric al connector and re-
move the neutral safety switch retaining bolts. (4) Maneuver the neutral safety switch clear of
the transaxle selector lever and withdraw the switch
from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Clean the area around the neutral safety
switch mounting.
(2) Apply a small amount of chassis grease to the
jaws of the neutral safety switch arm. (3) Check the adjustment of the selector cable as
previously described. (4) Adjust the neutral safety switch as previ-
ously described.

(5) Check the operation of the neutral safety
switch and ensure that the engine will not start in any
position other than P and N. Check that the reversing
lamps operate only when R is selected.

8. TRANSAXLE ASSEMBLY
Special Equipment Required:
To Remove and Install — Suitable trolley jack to
which the transaxle can be secured

TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the left hand front wheel.

(2) Disconnect the negative battery terminal. Remove the left hand side inner mudguard

(3)
panel.

(4) Remove the left hand drive shaft as de-
scribed in the Manual Tran saxle and Drive Shafts
section. (5) Disconnect the vehicle speed sensor wiring,
selector control cable and the neutral safety switch
wiring from the transaxle. Disconnect the kickdown
cable from the throttle linkage and the support
bracket. (6) Disconnect the oil cooler hoses from the
Using a 2.5 mm drill bit to adjust the neutral safety
switch.

Electrical System 197
Switch on all lamps and allow them to
illuminate for approximately five minutes to reduce
the charge of the battery and to apply a load to the
circuit.
Start the engine and gradually increase the
speed to approximately 2 500 rpm. The reading on
the ammeter should be approximately 75% of the
rated output of the altern ator. See Specifications.
Switch off all the lamps and run the engine at
1 500-2 000 rpm until the indicated charge is below
10 amps. The voltmeter should now read in excess of
13.6 volts.
NOTE: Should the alternator fail to reach
the specific output, the unit will have to be
removed and overhauled or a replacement
unit installed.

Should the voltage reading be above or
below Specifications, the regulator will have
to be renewed.

TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
On 1.8 liter engines, remove the bolt secur-
ing the air cleaner intake duct and remove the air
cleaner intake duct. Drain the radiator by releasing the radiator
drain plug, located at the bottom of the radiator and
allow the coolant level to fall below the thermostat
housing level. NOTE: Refer to the Cooling and Heating
Systems section when refilling the radiator
coolant to its correct l
evel, failure to do so
could result in severe damage to engine
components.

Remove the retaining bolts securing the
thermostat housing, disconnect the hose from the
radiator and remove the thermostat housing and
radiator hose from the vehicle. Using a socket and extension bar, remove the
bolt securing the alternator to the drive belt tensioning
bar located under the alternator. On vehicles not equipped with air condition-
ing, remove the front splash guard from under the
front of the vehicle and remove the bolt securing the
alternator to the drive belt tensioning bar. Loosen the upper mounting bolts, slacken
the alternator drive belt and remove it from the
alternator pulley.
While supporting the alternator, remove the
upper mounting bolts and remove the alternator from
the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

Do not over tension the drive belt. Refer
to
the Engine Tune-up section for the correct belt
adjusting procedure. Ensure that the wiring and connectors are
securely located on the alternator.

Dismantled view of the Bosch alternator.

198 Electrical System
(3) Replenish the coolant in the radiator. Refer
to the Cooling and Heating Systems section for the
correct procedure.

TO DISMANTLE
Bosch Alternator
Remove the alternator from the vehicle as
previously described.
Scribe a mark across the drive end bracket,
stator and slip ring end bracket to facilitate correct
alignment during assembly. Remove the screws and washers securing the
regulator and brush holder assembly. Withdraw the
regulator and brush holder assembly from the alter-
nator. Remove the long screws securing the drive
end bracket to the slip ring end bracket and withdraw
the drive end bracket, rotor and pulley assembly.
NOTE: Ensure that the wave washer behind
the rotor shaft rear bearing in the slip ring
end bracket is not mislaid.

Holding the rotor in a soft jawed vice,
remove the split drive pulley retaining nut, washer
and spacer from the rotor shaft. Remove the split driv e pulley, spacer, plate
washer and fan from the rotor shaft. Using a suitable pres s and press plates,
support the drive end bracket with the pulley end of
the rotor shaft uppermost a nd carefully press the rotor
shaft from the spacer, bearing and the drive end
bracket.
Remove the spacer and the bearing retainer
plate screws from the drive end bracket. Remove the bearing retainer plate and the
bearing from the drive end bracket. If necessary, using a bearing puller, remove
the rear bearing from the rotor shaft. Remove the nut, spring washer and output
terminal components from the {B + ) terminal on the
outside of the slip ring end bracket.

(12) Working inside the slip ring end bracket,
remove the screws securing the diode pack to the
bracket and withdraw the stator and diode pack as an
assembly. Remove the insulating spacer and washer
from the (B +) terminal.

NOTE: The diode pack is supplied as an
assembly and in the event of a component
'failure, must be renewed as a complete unit.

Mark all wiring connections prior to removal
to aid assembly. Where necessary, unsolder the stator leads
from the connector terminals to separate the diode
pack.
NOTE: When soldering or unsoldering the
stator leads from the diodes, grip the leads
with a pair of long nosed pliers. This will
safeguard the diodes by transferring any
excess heat to the jaws of the pliers.

Hitachi Alternator
Remove the alternator from the vehicle as
previously described.

Scribe a mark across the drive end bracket,
stator and slip ring end bracket to facilitate correct
alignment during assembly. Remove the through bolts retaining the drive
end bracket to the slip ring end bracket. 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 removal
of the slip ring end bearing. Carefully prise the slip ring end bracket and
stator assembly from the drive end bracket and rotor
assembly using suitable levers. Do not insert the levers
too far or damage to the stator will occur.
Hold the rotor and driv e end bracket assem-
bly in a soft jawed vice and remove the nut retaining
the drive pulley to the rotor. Remove the washer, pulley and spacer
washer from the rotor shaft.
Using a soft faced hammer, drive the rotor
shaft assembly from the drive end bracket and remove
the inner spacer washer from the rotor shaft.
Remove the bearing retainer plate screws
and remove the plate. Using a suitable drift, drive the
bearing from the bracket. Remove the retaining nut and insulator
washer from the alternator terminal. Remove the slip ring end bracket retaining
nuts and separate the diode pack, stator and regulator
assembly.
If necessary, file the ends of the brush
assembly retaining rivets, caref ully unsolder the ter-
minal plate and remove the brush assembly and
terminal plate from the diode pack. If necessary, remove the fan guide retaining
View of the Bosch alternator stator assembly and the
slip ring end bracket.

210 Electrical System


Using the radio/cassette removal tools during removal of the unit.
Construct the special tools as illustrated,
insert both tools into the release holes on the radio/
cassette and carefully withdraw the radio/cassette
from the mounting bracket.
Disconnect the wiring harness terminal plug
and remove the radio/cassette.
Installation is a reversal of the removal procedure
with attention to the following points:

Remove the special tools from the radio/
cassette, connect the wiring harness terminal and push
the radio/cassette into the mounting bracket. Install the release hole covers on each side
of
the radio/cassette.
15. LAMP UNITS

HEADLAMPS
To Remove and Install
Disconnect the negative battery terminal.
If removing the drivers side headlamp on 1.8
liter engines, remove the bo lt securing the air cleaner
intake duct and remove the air cleaner intake duct.

Dismantled view of the headlamp assembly.
Remove the radiator grille as described in
the Body section. Remove the bolt and nut from the front and
rear of the inner headlamp. Remove the side indicator lamp assembly
and remove the bolts from the side of the headlamp.
Maneuver the headlamp inner side out first
and remove the headlamp from the vehicle. Installation is a reversal of the removal procedure.

To Adjust Headlamp Aim
Ensure that the tires are inflated to the
correct pressure and that the vehicle is positioned on
level ground.
The vehicle should be unladen, with a full
fuel tank and the driver sitting in the vehicle. When using a headlamp aiming machine,
refer to the manufacturers instructions for equipment
being used.

Partially removed view of the headlamp assembly. Diagram showing the correct light patterns using an
aiming board. Dimension A = 5 meters.

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.