1987 NISSAN PULSAR torque

Cooling and Heating Systems
7. THERMOSTAT HOUSING
Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) On 1.6 liter models, remove the air cleaner
assembly from the engine. Refer to the Fuel and
Engine Management section if necessary. (3) Drain the cooling system as previously de-
scribed. (4) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (5) Remove the bolts retaining the camshaft
drive belt rear cover to the cylinder block and remove
the rear cover.
\ COOLANT TEMPERATURE SENSOR TEMPERATURE SENDER SWITCH
View of the thermostat housing and
components.
(6) Disconnect the top radi ator hose, the heater
hose and the inlet manifold heater hose from the
thermostat housing.
(7) Disconnect the wire from the temperature
sender switch and the coolant temperature sensor. (8) Remove the bolts retaining the thermostat
housing to the cylinder head and remove the thermo-
stat housing and the O ring from the cylinder head. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all mounting faces are clean.
(2) Renew the O ring on installation.
NOTE; Ensure that the O ring is not
twisted. Do not use sealant.

(3) Tighten the thermostat housing retaining
bolts to the specified torque. (4) Adjust the camshaft drive belt tension as
described in the Engine section under the heading
Camshaft Drive Belt. (5) Fill the cooling system as previously de-
scribed and check for coolant leaks. 8. WATER PUMP

Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
NOTE: The water pump is non-repairable
and if faulty must be renewed as a complete
assembly.

(1)
Drain the cooling system as previously de-
scribed.
(2) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (3) Remove the water pump retaining bolts and
remove the water pump and the O ring from the
engine. Installation is a reversal of the removal procedure
with attention to the following points:


View of the water pump and components removed
from the vehicle.
(1) Ensure that all mounting faces are clean.
(2) Use a new O ring and smear it with a liberal
amount of silicone grease.
(3) Install the water pump to the engine but
do
not tighten the retaining bolts until the camshaft drive
belt has been installed and tensioned correctly as
described in the Engine section under the heading
Camshaft Drive Belt.
(4) Fill the cooling system as previously de-
scribed in this section and check for coolant leaks.
9. WELCH PLUGS

To facilitate the casting of the cylinder block and
cylinder head passages and water jackets, a number of
openings had to be ma de at manufacture.

82
FUEL AND ENGINE MANAGEMENT
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
FUEL INJECTION
Type:
1.6 liter engine .................................. Single point
1.8 liter engine................................... Multi point
FUEL PUMP
Type ................................................................ Electric
Pressure at idle:
1.6 liter engine ..................................... 62-90 kPa
1.8 liter engine ................................ 190-230 kPa
FUEL FILTER
Type ................................................ Inline, disposable
AIR FILTER
Type ................................... Disposable paper element
DISTRIBUTOR
Make ........................................................ Delco Remy
Advance contro l .......................................... Electronic
Rotation of rotor .................................. Anti-clockwise
Firing order....................................................1 -3-4-2
ADJUSTMENTS
Base idle speed ..................................... 550-650 rpm
Ignition timing.......................................... 10° BTDC
TORQUE WRENCH SETTINGS
Throttle body nuts.......................................... 10 Nm
*Throttle body bolts ........................................ 12 Nm
*Fuel hose fittings............................................ 35 Nm
Fuel rail bolts ....................................................8 Nm
Fuel tank drain plug ........................................ 24 Nm
Coolant temperature sensor ............................ 12 Nm
Oxygen sensor .................................................. 40 Nm
MAT sensor..................................................... 14 Nm
*1.6 liter engine
l . 8 liter engine

1. FUEL AND ENGINE MANAGEMENT
TROUBLE SHOOTING

NOTE: The following Trouble Shooting pro-
cedures are basic checks only. If these pro-
cedures fail to locate the fault, refer to the
System Diagnosis and Adjustments heading
for more thorough testing.

Prior to performing any of the following
operations, refer to the Service Precautions
and Procedures heading.

ENGINE WILL NOT START OR HARD TO
START
(1) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(2) Fault in the power supply: Check the battery,
fusible links and fuses. Check for clean, secure con-
nections, particularly the earth connections. Check the
EG1 and fuel pump relays.
NOTE: If the fuel pump relay fails, power
will be supplied to the fuel pump via the oil
pressure switch. When starting the engine,


Check that the MAP sensor hose is not blocked or split
and ensure that all electrical connections are clean and
secure.

96 Fuel and Engine Management

terminal D16 on 1.6 liter engines, or D15 and D16
on
1.8 liter engines.

The test lamp should light.
If the test lamp does not light check the wiring
harness for continuity between the injector wiring
connector(s) and the control unit wiring connector
terminals.

Repair or renew the wiring harness as necessary.
To Remove and Install Injectors and Fuel Rail — 1.8
Liter Engine.

(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal.
(3) Thoroughly clean around the injectors and

View of the fuel rail, injectors and pressure regulator
removed from the engine.
the fuel rail to prevent foreign material entering the
engine.

(4) Suitably mark the fuel hoses, loosen the hose
clamps and disconnect the fuel hoses from the fuel
rail. (5) Disconnect the vacuum hose from the fuel
pressure regulator. (6) Loosen the hose clamp and disconnect the
engine ventilation hose from the throttle body. (7) Remove the bolts securing the fuel rail and
injectors to the inlet manifold. (8) Carefully raise the fuel rail and injectors
from the inlet manifold until the injector nozzles are
clear of the manifold. (9) Disconnect each injector wiring connector by
pushing in the wire retaining clip.
(10) Using a small screwdriver, remove the injec-
tor retaining clip and withdraw the injectors from the
fuel rail.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Check the condition of the injector O ring
seals and renew if necessary. (2) Install the injectors to the fuel rail and secure
with the retaining clips. (3) Connect the wiring connectors to each injec-
tor ensuring that the wire clip is locked in position. (4) Install the injectors to the inlet manifold,
carefully guiding the injectors into place ensuring that
the O ring seals are not damaged.
(5) Install the fuel rail retaining bolts and tighten
to the specified torque. (6) Install the fuel hoses to the fuel rail
and
tighten the hose clamps securely.
(7) Check for fuel leaks as previously described.
To Remove and Install Injector — 1.6 Liter Engine

(1) Depressurize the fuel system as previously
described. (2) Disconnect the negative battery terminal.
(3) Remove the air cleaner assembly. If neces-
sary refer to the heading Air Cleaner Assembly in this
section.
(4) Remove the injector retaining plate screw
and remove the injector retaining plate from the
throttle body assembly. (5) Insert the blade of a screwdriver from the
front of the throttle body assembly under the rim of
the injector in which the retaining plate locates.
Support the screwdriver on a suitable object to act as
a fulcrum. (6) Carefully lever the screwdriver until the
injector can be withdrawn from the throttle body
assembly.
(7) Remove and discard the upper and lower O
ring seals from the injector . If necessary remove the
lower filter screen from the injector.
NOTE: As the injector contains electrical

View of the fuel injector removed from the throttle body assembly. 1.6 liter engine.

Fuel and Engine Management 97
circuitry do not immerse it in cleaning
solvent as this may result in irreparable
damage.

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

(1) Lubricate the new O ring seals with auto-
matic transmission fluid prior to installing them to the
injector. If removed, ensure that the lower filter screen
is installed. (2) Firmly push the injector into the throttle
body assembly until it is fully seated, ensuring that the
injector connection terminals face towards the rear of
the vehicle.
(3) Apply Loctite 262 to the injector retaining
plate screw and tighten securely.
(4) Start the engine and check for fuel leaks as
previously described.
(5) Install the air cleaner and tighten the retain-
ing nuts securely.
FUEL METER ASSEMBLY - 1.6 LITRE
ENGINE

To Remove and Install
(1) Remove the injector as previously described.
(2) Mark the fuel supp ly and return hoses,
release the clamps and disconnect the hoses from the
fuel meter assembly.
(3) Remove the air cleaner assembly base gasket
from the fuel meter assembly. (4) Remove the bolts and screws securing the
fuel meter assembly to the throttle body and remove the fuel meter assembly. Remove and discard the
gasket.

(5) If necessary, remove the fuel pressure regu-
lator as previously described.

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

(1) If removed, install the fuel pressure
regulator
as previously described.
(2) Place a new gasket on the throttle body,
aligning the holes in the gasket with those in the
throttle body, ensuring that the idle air passage is not
blocked. (3) Coat the fuel meter assembly retaining
screws with Loctite 26 2 and tighten securely.
(4) Install the fuel meter assembly retaining bolts
and tighten to the specified torque.
(5) Connect the fuel supply and return hoses and
tighten the clamps securely. (6) Install the injector as previously described.
(7) Start the engine and check for fuel leaks.
Rectify as necessary. (8) Install the air cleaner assembly.
FUEL TANK

To Remove and Install
(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal.
(3) Remove the fuel pump cover plate retaining
screws, disconnect the wi ring harness rubber grommet
from the cover plate and remove the cover plate from
the wiring harness. (4) Raise the rear of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary. (5) Remove the fuel tank drain plug and drain
the fuel into a petroleum resistant container. (6) Mark the fuel hoses and disconnect the hoses
from the fuel pump.
(7) Disconnect the hoses from the fuel filler neck
pipe, the fuel check valve and the fuel tank breather
pipe.
View of the fuel meter assembly removed from the
throttle body. HANDBRAKE CABLE MOUNTING
Installed view of the fuel tank.

Fuel and Engine Management
(8) Remove the bolts retaining the intermediate
exhaust pipe to the rear of the catalytic converter,
remove the bolt securing the exhaust mounting to the
underbody and slightly lower the intermediate exhaust
pipe. Support the intermediate pipe to prevent the
tailpipe fouling the lower bumper panel.
(9) Remove the bolts retaining the stabilizer bar
mounting brackets to the underbody and allow the
stabilizer bar to drop.
(10) Remove the bolts retaining the exhaust heat
shield to the underbody, located at the front of the
fuel tank. (11) Remove the handbrake cable mounting
bracket retaining nuts and remove the mounting
brackets from the mounting studs. (12) Remove the fuel tank retaining bolts and
maneuver the fuel tank from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) When installing the fuel tank, ensure that the
fuel pump wiring harness is directed through the
aperture in the floor. (2) Install the stabilizer bar mounting
bracket
bolts and tighten to the specified torque. Refer to the
Rear Suspension section.
(3) Using a new gasket, install the intermediate
exhaust pipe to the catalyti c converter ensuring that
the earth wire terminal is installed and tighten the
bolts securely. (4) Connect the fuel filler neck hose, the fuel
check valve hose and the breat her hose ensuring that
they are secured firmly. (5) Tighten the fuel tank drain plug to the
specified torque. (6) Connect the fuel hoses to the fuel pump,
using the marks made during removal to ensure
correct installation. (7) Install the fuel pump wiring harness and the
rubber grommet to the fuel pump cover plate. Install
the cover plate and tighten the retaining bolts se-
curely.
(8) Connect the fuel pump wiring connector
securely. (9) Check for fuel leaks as previously described.
6. AIR FLOW COMPONENTS
NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.

AIR CLEANER ASSEMBLY
To Renew Element
The procedure for renewing the air cleaner ele-
ment is covered in the Engine Tune-up section.

To Remove and Install — 1.8 Liter Engine
(1) Disconnect the negative battery terminal.
(2) Release the air intake hose retaining clamps,
disconnect the hose from the air cleaner upper
housing and the throttle body and remove the hose. (3) Remove the screw securing the air cleaner
intake duct to the front panel mounting bracket. (4) Remove the hexagon head screws retaining
the air cleaner mounting bracket to the right hand
inner mudguard and remove the air cleaner from the
engine compartment. (5) Release the upper housing retaining clips,
separate the upper housing from the lower housing
and remove the element. (6) Remove the air cleaner intake duct retaining
screw and disconnect the duct from the lower air
cleaner housing. (7) If necessary, remove the bolts securing the
mounting bracket to the ai r cleaner lower housing and
separate the mounting bracket from the housing. (8) Thoroughly clean the upper and lower hous-
ings in cleaning solvent and check for cracks, splits or
damage that would allow unfiltered air to enter the
engine. Renew any components as necessary.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the r ubber insulators are in-
Dismantled view of the ai r cleaner assembly. 1.8 liter
engine.

100 Fuel and Engine Management
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all throttle body passages are
clean. Blow out with compressed air if necessary. (2) Install the throttle body to the inlet
manifold
using a new gasket and tighten the retaining nuts to
the specified torque. (3) Connect the vacuum hoses to the throttle
body in the positions previously marked. (4) Clip the actuating rod to the throttle body
lever. Check the dimensions shown in the illustration
and adjust the rod length if necessary.
(5) Check the adjustment of the throttle cable as
described later in this section.
(6) Connect the air intake hose and tighten the
hose clamps securely.
To Remove and Install — 1.6 Liter Engine

(1) Depressurize the fuel system as previously
described. (2) Disconnect the negative battery terminal.
(3) Remove the air cleane r assembly and base
gasket as previously described. (4) Mark the fuel supply and return hoses,
release the clamps and disconnect the hoses from the
throttle body assembly. (5) Disconnect the injector, throttle position
sensor and the IAC valve wiring connectors. Remove
the injector wiring harness from the throttle body
assembly and place it to one side.
(6) Mark and disconnect the vacuum hoses from
the throttle body assembly. (7) On automatic transaxle models, disconnect
the kickdown actuating rod from the throttle linkage.
(8) Slide the outer throttle cable from the
mounting bracket, rotate the throttle linkage and disconnect the inner throttle cable from the throttle
linkage.

(9)
Remove the bolts retaining the throttle body
assembly to the inlet manifold and remove the
assembly and the gasket from the engine. (10) If necessary remove the retaining screws and
remove the fuel meter assembly, the IAC valve and
the throttle position sensor from the throttle body
assembly. Installation is a reversal of the removal procedure
with attention to the following points:

(1) If removed, install the fuel meter assembly,
the throttle position sensor and the IAC valve as
described under the relevant headings. (2) Install the throttle body assembly to the inlet
manifold using a new gasket and tighten the retaining
bolts to the specified torque. (3) Connect the vacuum ho ses to the throttle
body using the marks made on removal to ensure
correct installation. (4) On automatic transaxle models, connect the
kickdown actuating rod to the throttle linkage.
(5) Install the throttle cable and check the adjust-
ment as described later in this section.
INLET MANIFOLD

To Remove and Install
To remove and install the inlet manifold, refer to
the relevant heading in the Engine section.

IDLE AIR CONTROL (IAC) VALVE
To Test

(1) Connect an accurate tachometer to the en-
gine. (2) With the engine at normal operating temper-
ature and all accessories switched Off, note the idle
speed.
(3) With the ignition switched Off, disconnect
the IAC valve wiring connector. (4) Start the engine and check the idle speed.
If the idle speed is the same as that noted in

operation (2) proceed to operation (7).
If the idle speed is higher than noted in operation
(2) proceed as follows.

(5) With the ignition switched Off, connect the
IAC valve wiring connector.

(6) Start the engine and check the idle speed.
If the idle speed is not the same as that noted in

operation (2) proceed to operation (7).
If the idle speed is the same as noted in operation
(2) the IAC valve is operating correctly. However, if
the engine is not idling correctly carry out the
following checks.

(a) Check the air inlet system for vacuum leaks.
NOTE: Any vacuum leak will cause a fast
idle.

View of the throttle body assembly showing the loca-
tion of the base idle adjusting screw. 1.8 literengine.

110 Fuel and Engine Management
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
coolant temperature sensor. (5) With the ignition switched On, measure the
voltage across the terminals on the coolant tempera-
ture sensor wiring connector. The voltage should 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 coolant temperature sensor
from the vehicle. (7) Connect an ohmmeter to the coolant temper-
ature sensor terminals. (8) Immerse the meta1 end of the coolant
tem-
perature sensor in a 50/50 mixture of glycol and iced
water at a temperature of 0 deg C. The resistance
should be 6 000 ohms. Slowly heat the mixture and measure the resis-
tance of the coolant temperature sensor at the follow-
ing temperatures. Compare the results with the spec-
ified values:

0 d e g C ................................................. 6 000 ohms
20 deg C .................................................. 2 500 ohms
30 deg C .................................................. 1 800 ohms
40 deg C.................................................. 1 200 ohms
70 deg C .......................................................450 ohms
90 degC .......................................................250 ohms
100 deg C.....................................................190 ohms
110 deg C.....................................................110 ohms
If the resistances obtained are not as specified at
any of the given temperatures, renew the coolant
temperature sensor and retest for fault codes.

(9) Disconnect the control unit wiring connec-
tors.
(10) Check the wiring harness for shorts and
continuity between the coolant temperature sensor
wiring connector terminals and the control unit wiring
connector terminals C10 and D2. Repair or renew the
wiring harness as necessary.
Also check the control unit terminals for damage.
If no fault is found, renew the control unit and
retest for fault codes.

To Remove and Install
(1) Disconnect the negative battery terminal.
(2) Disconnect the wiring connector from the
coolant temperature sensor.
(3) Drain the coolant as described in the Cooling
and Heating Systems section to a level below the
sensor.
(4) Unscrew the sensor from the thermostat
housing. Installation is a reversal of the removal procedure
with attention to the following points;

(1) Apply Loctite 675 or a similar conductive
sealer to the threads of th e sensor. Tighten the sensor
to the specified torque.
(2) Fill the cooling system with the correct
mixture of water and inhibitor as described in the
Cooling and Heating Systems section. (3) Ensure that the wiring connector is clean and
secure.
THROTTLE POSITION SENSOR
To Test - Codes 21 and 22

NOTE: The following test procedure as-
sumes that fault codes 21 or 22 have been
displayed during the se lf diagnosis test pro-
cedure. If no codes have been displayed but
the operation of the throttle position sensor
is suspect, begin the test procedure at oper-
ation (24).

(1) Erase the self diagnosis code memory as
previously described.
(2) Start and run the engine at idle speed for 60
seconds or until the ECM warning lamp lights. If the engine will not start, disconnect the throttle
position sensor wiring co nnector and proceed to
operation (8). .

(3) With the engine id ling, quickly increase the
engine speed to 3 000 rpm and return to idle.

If the ECM warning lamp remains illuminated,
proceed to operation (4).

If the ECM warning lamp extinguishes, an inter-
mittent 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) Stop the engine, switch the ignition On and
connect a jumper lead between terminals A and B on
the diagnostic link connect or. Note any fault codes
displayed.

If codes 21 or 22 are displayed, proceed as
follows.

(5) Remove the jumper lead from the diagnostic
link connector. (6) Erase the self diagnosis codes as previously
described. (7) Disconnect the wiring connector from the
throttle position sensor. If code 22 was displayed in operation (4), proceed
to operation (13).

If code 21 was displayed in operation (4), proceed
as follows.

(8) Start and run the engine at idle speed for 2
minutes or until the ECM warning lamp lights. If the
engine will not start, pr oceed to operation (11).
(9) Stop the engine, switch the ignition On and
connect a jumper lead between terminals A and B on

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.