1987 NISSAN PULSAR engine

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 79


Front view of the heater unit showing the heater controls.
vehicle adjust the heater water tap control rod as
follows:

(a) Disconnect the control rod from the air mix
door lever.
(b) Pull the control rod un til there is a clearance
of approximately 2 mm between the end of the
control rod, which is inside the spring and the top
lever. Hold the rod in this position.
(c) Turn the air mix door lever fully anti-
clockwise and while holding the lever install the
control rod to the air mix door lever. (d) Ensure that the heater water tap is operating
correctly and shutting off correctly by blowing through
the heater pipes.
NOTE: No access to the heater water tap
control rod is possible once the heater unit is
installed in the vehicle.

(2) When maneuvering the heater unit into
position use care not to damage the heater pipes. (3) Wet the heater pipe grommets with soapy
water and install onto the heater pipes. (4) Check the heater controls for correct opera-
tion before installing the dashboard and adjust the
controls if necessary using the procedure that follows. (5) Operate the heater unit with the engine
running and ensure that the operation is satisfactory
and no leaks are present. clockwise and install the lower rod then the upper
rod
in that order.

(5)
Hold the side link fully clockwise and the
demist door lever fully anti-clockwise and install the
demist door rod. (6) Holding the side link fully clockwise, set the
air control lever on the dashboard to the face vent
position and install the air control cable to the side
link. (7) With the fan running on the high speed
setting, operate the air cont rol lever through all ranges
and ensure that the operation is correct.

Right hand side view of the heater unit.
To Adjust Temperature Control Rod and Cable
If the temperature control rod requires adjust-
ment it will be necessary to remove the heater unit
from the vehicle. Follow the procedure described
under the heading To Remove and Install Heater Unit.

(1) Working in the passenger footwell disconnect
the temperature control cable from the clip on the side
of the heater unit. (2) Set the heater controls to the maximum heat
position. (3) Hold the air mix door lever clockwise while
lightly pulling on the outer control cable to remove
slack, then install the control cable into the retaining
clip.
(4) With the engine at operating temperature
check the operation of the temperature control lever.

TO ADJUST HEATER CONTROLS
To Adjust Air Control Door Rods and Cable
(1) Disconnect the air control cable from the
side link. (2) Working on the right hand side of the heater
unit disconnect the upper and lower door lever and
demist door lever rods from the retaining clips.
(3) Hold the side link fully anti-clockwise.
(4) Hold the upper and lower door levers fully To Adjust Air Control Cable

(1)
Working in the passeng er footwell, discon-
nect the intake air control cable from the clip on the
intake unit. (2) Set the air intake lever to the recirculate
position. (3) Hold the intake lever to wards the front of the
vehicle and install the control cable into the
retaining
clip.
(4) Check the operation of the air intake control.

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.

Cooling and Heating Systems 81
continuous stream of bubbles indicates that the refriger-
ant charge is low.

A large number of bubbles or foam indicates that
the refrigerant charge is very low.

No bubbles or the presen ce of oil streaks in the
sight glass indicate that the system is completely
empty.

NOTE: If the outside air temperature is
high, a certain number of bubbles may be
observed in the sight gl ass, even though the
system is fully charged.

If the system requires recharging, the vehicle
should be taken to an authorized dealer for evacu-
ation, leak testing and recharging.

Do not operate the system if it is known that the
refrigerant charge is low as damage may result.

MAINTENANCE
The air conditioning system requires l i t t l e main-
tenance other than the following. Where applicable,
refer to the Lubrication an d Maintenance section for
the recommended service intervals.

(1) Check the refrigerant charge level in the
receiver/dryer sight glass. Recharge the system as
necessary. It is considered normal for the system to
require periodic recharging. (2) Inspect the air conditioner pipes and hoses
for leaks, deterioration and alignment. Evidence of oil
leakage is an indication of refrigerant leakage. Repair
or renew as necessary.
(3) Inspect the evaporator drain tube and the
condenser cooling fins for blockage. Clean as neces-
sary.
(4) Check the drive belt for deterioration and for
correct tension. Refer to the Engine Tune-up section
for the correct procedure.
(5) Operate the system at least once a week for
approximately 15 minutes to keep the compressor
seals lubricated.

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.

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.

Fuel and Engine Management
(4) MAP sensor faulty or supply hose discon-
nected or blocked: Check the vacuum supply hose.
Check the operation of the MAP sensor.

EXCESSIVE FUEL CONSUMPTION
(1) Blocked air cleaner element: Check the ele-
ment and clean or renew as necessary.
(2) Incorrect fuel pressure: Check the fuel pump
and fuel pressure regulator. (3) Faulty coolant temperature sensor: Check
the connections and operation.
(4) Leaks in the fuel supply system: Check the
connections and components for leakage. (5) Leaking fuel injector(s): Clean or renew the
faulty injector(s). (6) Engine operating temperature too low:
Check the thermostat and electric cooling fan as
described in the Cooling an d Heating Systems section.
2. DESCRIPTION
The engine management system on the range of
vehicles covered by this manual controls the opera-
tion of the ignition system and the fuel system.

The central component of the engine management
system is the electronic control unit (ECU). The con-
trol unit is a micro-computer which controls the igni-
tion timing and the amount of fuel injected according
to signals received from various sensors. As changes
are detected in engine load and speed, coolant tem-
perature, barometric pressure, air temperature (1.8
liter engine), throttle position and vehicle speed, the
control unit alters the ignition timing and the fuel
injection amount to achieve optimum engine effi-
ciency.

The control unit incorporates a self diagnosis
mode which stores and displays codes relating to
certain system malfunctions. Whenever power is sup-
plied to the control unit, the control unit performs a


View of the 1.8 liter engine showing the engine management components.
Ensure that all fuel connections are securely tightened.

Fuel and Engine Management 85


View of the 1.6 liter engine showing the engine management components. Air cleaner removed for clarity.
series of tests on various components in the system
and records the results, If a fault is discovered, the
ECM warning lamp on the instrument cluster will
illuminate while the engine is running. When the self
diagnosis mode is activated, the ECM warning lamp
will flash codes indicating the area in which the fault
has occurred.

This function is very useful in locating system
faults, particularly intermittent problems. However,
the self diagnosis mode does not provide comprehen-
sive testing of the EFI system, and therefore should
always be used in conjunction with the other test
procedures described later in this section in order to
accurately locate system faults.

The high energy electronic ignition system con-
sists of a distributor and an ignition coil.

The distributor has two functions. The first is to
produce and distribute secondary high tension voltage
to the spark plugs.

The second function is to provide the control unit
with information on engine speed and crankshaft
position.

The ignition timing is constantly adjusted by the
control unit to suit varying engine and vehicle oper-
ating conditions.

In the fuel injection system, a metered amount of
fuel is sprayed into the air stream. The air/fuel

mixture then enters the combustion chamber via the
inlet valves.

On 1.6 liter engines, the fuel is injected by a single
injector, located above the throttle valve within the
throttle body assembly. The injector fires twice per
engine revolution under most operating conditions.

On 1.8 liter engines, four injectors are used. The
fuel is distributed to the injectors via the fuel rail. All
injectors fire simultaneous ly once per engine revolu-
tion under most operating conditions.

Under conditions of high load the control unit
may signal the injector(s) to fire more often. However,
if the engine speed exceeds 6 700 rpm the control unit
will cease firing the injectors until the engine speed is
below 6 200 rpm.

Fuel is supplied under pressu re by an electric fuel
pump mounted in the fuel tank and the pressure is
regulated by a pressure regulator.

On 1.6 liter engines, the regulator consists of a
spring tensioned diaphragm which is mounted to the
side of the throttle body assembly. The fuel pressure is
regulated by the tension of the spring against the
diaphragm, opening and closing the fuel return port.

On 1.8 liter engines, the pressure regulator is
mounted adjacent to the fuel rail and consists of a
diaphragm with fuel pressu re acting on one side and
spring tension and manifold vacuum acting on the