1987 NISSAN PULSAR length

Electrical System 205


Dismantled view of the brush holder assembly. Bosch
starter motor.
side and the other lead to the negative side. If there is
any indication of leakage the ohmmeter will show a
reading other than infinity. Repair or renew the brush
holder if leakage is evident.

(2) Check the brushes for adequate length.
Brushes should be renewed when their length is below
Specifications. They should be a free sliding fit in the
brush holders.

NOTE: Due to the difficulty involved in
removing and installing the brushes in the
Bosch starter motor, it is recommended that
the brush holder be renewed as an assembly.

(3) Check that the commutator is free from
pitting and burning. Clean with a petrol moistened
cloth and polish with a strip of fine glass paper.

A badly worn commutator may be repaired by
mounting in a lathe, spi nning at high speed, and
taking a light cut with a very sharp tool. After turning,
undercut the insulation between the segments.

(4) Check the armature for short circuit using an
ohmmeter.

Place one of the test lead s on the armature shaft
or core and move the other lead around the circum-
ference of the commutator. If the ohmmeter shows a
reading at any point the armature is faulty and should
be renewed.

Check the drive assembly clutch pinion teeth
for wear, scoring or chipping. A clutch in good
condition should take up the drive in one direction
only. It should rotate easily and smoothly in the
non-drive direction and the assembly should move
smoothly along the armature or drive shaft helical
splines.
Check the armature shaft bushes for wear
and renew as necessary. The old bushes must be
removed and the new ones pressed into the end
brackets using a polished mandrel of the exact diam-
eter of the armature shaft. NOTE: The new bushes must not be reamed
to size, as reaming will impair the porosity
of the bushes and cause early failure. New
bushes should be allowed to stand immersed
in clean light engine oil for one hour before
installation.

To Assemble
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

Lubricate the helix of the drive shaft lightly
with graphite grease and install the drive assembly
to
the drive shaft. Install the stop collar and snap ring, slide the
stop collar over the snap ring to lock the snap ring in
position.
Lubricate the bushes in both end brackets
sparingly with engine oil. Install the engaging lever and gear set into the
drive end bracket. Install the centre rear bracket and the engag-
ing lever seal into the drive end bracket.
Slide the brush holder assembly into position
on the commutator ensuring that the brush holders
are correctly positioned in the anchor points. Install the commutator end bracket to
the
armature, install the shims and C clip. Check that the armature end float is satisfac-
tory and adjust as necessary using shims of the correct
thickness.
Align the slot in the commutator end bracket
with the cut out on the wiring seal and install the
armature end cover to the commutator end bracket.
Install the cover retaini ng screws but do not tighten.
Ensure that the permanent magnets in the
yoke have not picked up any debris and slide the yoke
over the armature ensuring that the wiring seal locates
correctly in the slot in the yoke.

View showing the planetary gear set. Bosch starter
motor.

Electrical System 217
When installing a trailer socket, it may be neces-
sary to replace the original vehicle flasher unit with a
heavy duty unit to maintain the flash rate in accor-
dance with local regulations. Local regulations may
also require the installation of a dashboard mounted
repeater lamp.

Should the trailer socket and plug not be matched,
adaptors can be made or obtained to facilitate con-
nection.

TO INSTAL TRAILER SOCKET.
The minimum materials required are a trailer
socket, mounting bracket, seven core flex, insulated
wiring connectors and a rubber grommet.

(1) Disconnect the negative battery terminal.
(2)Locate the wiring harness for the lamps at
the rear of the vehicle.

For five pin sockets and plugs, use the following
standard trailer wiring code:

Terminal No.CircuitColor2 Left turn signal lampYellow
3Earth White
5 Ri
ght turn signal lampGreen
6Stop lamp Red
7 Tail lam
p Brown

Minimum material needed for wiring up a trailer.
Utilux trailer socket and plug shown.
(3) Identify the wires for the right turn signal
lamp, left turn signal lamp, tail lamp, stop lamp,
reverse lamp and earth. Use the vehicle wiring
diagram in this section to determine the wire color
for each lamp circuit.
(4)Connect the seven core flex to the various
lamp wires using insulated connectors.
For seven pin sockets and plugs, use the following
standard trailer wiring code:

Terminal No.CircuitColor1 Left turn signal lamp Yellow
2 Reversing lamp Black
3EarthWhite
4 Right turn signal Green
lamp
5Electric brakesBlue
6 Stop lampRed
7
Tail lampBrown
For six pin sockets and pl ugs, use the following
standard trailer wiring code:
Terminal No.CircuitColor1 Tail LampBrown
2 Left Turn Signal Lamp Yellow
3Right Turn Signal LampGreen
4 Stop LampRed
5AuxilaryBlue
6 Earth White

(5) Drill a suitably si
zed hole through the vehicle
floor and install a rubber grommet to the hole.

NOTE: Before drilling the hole, check
whether there is an existing hole which may-
be used. Ensure that a rubber grommet is
installed to prevent chafing of the wires.

Pass the seven core flex through the rubber
grommet. Cut the seven core flex to the required length
and slide the dust cover onto the flex. Remove approximately 15 mm of insulation
from each wire in the flex.
Connect the wires of the seven core flex to
the terminals of the socket, using the standard wiring
code and following the socket manufacturers connec-
tion procedure. Assemble the socket and install the dust cover
to the rear of the socket. Install the mounting bracket as close as
possible to the tow bar ball and high enough to
maintain vehicle ground clearance. Install the socket to the mounting bracket.
Connect a trailer plug to the socket and test
for correct lamp operation.
TO INSTAL TRAILER PLUG

The minimum materials required are a trailer
plug, seven core flex and insulated wiring connectors.

The installation procedure for the trailer plug is
similar to that for the socket with attention to the
following points:

Connect the trailer wiring to the plug accord-
ing to the standard wiring color code and the plug
manufacturers instructions. Use a suitable length of
seven core flex and insulated connectors should the
trailer wiring not be long enough.
If the trailer wiring does not conform to the
standard color code, identify each circuit as follows: (a) Locate the trailer earth wire.

PLUG

236 Body

top of the dashboard rearwards and maneuver the
dashboard through the front door opening.

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

With the aid of an assistant, ensure that the
outer edges of the dashboard engage properly with the
door pillar brackets.
Hold the dashboard in position and loosely
install all retaining bolts. Align the dashboard
and
tighten all screws and bolts securely.
10. SEAT BELTS

The front and outer rear seats are equipped with
lap/sash inertia reel seat belts, which are designed to
lock with any sudden change in vehicle motion.

The centre rear seat is equipped with a manually
adjustable lap seat belt.

Child restraint anchorages are located on the
parcel shelf behind the rear seat on Sedan models and
at the rear of the lugg age compartment floor on
Hatchback models. These anchorages must be used if
a child's seat or capsule is installed to the vehicle. The
anchorages should not be used for adult scat bells or
harnesses.

The seat belts should be periodically inspected as
described below. Any seat belt assembly that is worn
or damaged, or has been subjected to abnormal
loadings in a collision, should be renewed as a
complete assembly.

Only mild soap and water should be used to clean
the webbing. Contamination wi th polish, oil, bleaches
and other chemicals should be avoided.

TO INSPECT
(1) Check the seat belt webbing for fraying, cuts,
burns or other damage. On inertia reel belts, slowly
pull the belt from the reel to allow the entire length to
be examined. If the webbing is damaged or worn,
renew the seat belt assembly.


Check the seat belt webbing for fraying, cuts, burns or
other damage.
Ensure that the belts are not twisted.
Check all retaining nuts and bolts for secu-
rity.
Inspect the belt buckles for correct and
secure engagement. If the buckles are damaged or do
not function correctly, renew the seat belt assembly. On inertia reel seat belts, check the retractor
mechanism as follows:
Pull the belt slowly from the reel and check
for smooth operation. Release the belt and ensure that
it retracts fully.
Pull the belt rapidly from the reel. The reel
should lock.
Drive the vehicle at walking pace and at-
tempt to withdraw the belt slowly while braking
sharply. The reel should lock. If the retractor mechanism does not function
correctly, renew the seat belt assembly.

11. SEATS
FRONT SEAT
To Remove and Install
Adjust the seat to the most forward position.
Remove the mounting bolts from the rear of
the seat.
Adjust the seat to allow access to the mount-
ing bolts at the front of the seat. Remove the mounting bolts and withdraw
the seat from the vehicle.
Installed view of the fron t seat belt with the door pillar
trim removed showing the mounting points.