1987 NISSAN PULSAR bulb

Fuel and Engine Management 89
The procedure for fabricating an LED test lamp is
fully described in the El ectrical System section.

If a conventional test lamp with a filament type
bulb is to be used, ensure that the current draw of the
test lamp does not exceed 0.3 amp to avoid damage to
the electronic components.

To check the current draw connect an accurate
ammeter, such as the multimeter described previ-
ously, in series with the test lamp and a battery.

If the ammeter reads less than 0.3 amp the test
lamp is suitable.

Tachometer
(1) Disconnect the resistor from the tachometer
pick-up wiring connector which is located on the
ignition coil wiring harness, and connect the positive
lead of an accurate tachometer to the brown wire
terminal in the wiring connector. (2) Connect the negative lead to a good earthing
point.

View showing the location of the tachometer pickup
wiring connector with the resistor installed.
Timing Light
(1) Connect the timing light to the engine fol-
lowing the instrument manufacturers instructions.

NOTE: Do not connect or disconnect the
timing light with the engine running as
voltage surges could damage the alternator
or control unit. Do not allow the high
tension leads to open circuit with the engine
running as damage to the engine manage-
ment system could result.

(2) Do not connect the timing light positive lead
to the alternator output terminal. Where possible,
connect the power leads of the timing light to an
external power source to prevent possible transient
voltages damaging the alternator or control unit.

4. SYSTEM DIAGNOSIS AND ADJUSTMENTS
NOTE: Due to the use of complex electronic
components in the engine management sys-

tem, the diagnosis and testing procedures
described in this section should not be
carried out by persons lacking an under-
standing of electronics and the precautions
associated with the servicing of electronic
components. It is rec ommended that should
a fault arise in the system, the vehicle be
referred to an authorized workshop.

The control unit can be damaged by
component faults not indicated by the self
diagnosis codes and the renewal of the
control unit without lo cating the cause of
the failure will result in the failure of the
replacement unit. It is for this reason that
the practice of substituting components to
isolate faults is not recommended.

Prior to performing any of the follow-
ing operations, refer to the Service Pre-
cautions and Procedures heading.

PRELIMINARY CHECKS
Prior to performing the Self Diagnosis Test Pro-
cedures, perform the following preliminary checks and
rectify any problems as necessary.

(1) Check for an adequate supply of fuel in the
fuel tank. (2) Check the wiring connectors and earth points
of all engine management components for clean,
secure connections. To prevent damage to the control
unit, disconnect the negative battery terminal before
disconnecting any engine ma nagement wiring connec-
tors. (3) Check the condition of the battery. Refer to
the Electrical System sectio n for checking procedures.
Rectify any faults as necessary. (4) Check the air cleaner element for restriction.
(5) Check for air leaks at the throttle body, inlet
manifold and all related hoses. (6) Check the fuel pump pr essure as described
later in this section. (7) Ensure that the engine is in a satisfactory
mechanical condition and is in tune. Refer to the
Engine and Engine Tune-up sections as necessary.
SELF DIAGNOSIS

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 engine management system, and
therefore should always be used in conjunction with
the other test procedures described later, in order to
accurately locate system faults.

To Interpret Self Diagnosis Codes
Once the self diagnosis mode is activated, various
fault codes will be displayed as a series of flashes by
the ECM warning lamp on the instrument cluster.

90 Fuel and Engine Management
To identify the code number, count the number of
times the ECM warning lamp flashes. Each fault code
comprises two groups of flashes separated by a 1.2
second pause. The first group represents tens and the
second group represents single units. For example 1
flash followed by a 1.2 second pause followed by 4
flashes would be code number 14. Similarly 4 flashes
followed by a 1.2 second pause followed by 2 flashes
would be code number 42.

The code will be displayed three times. If more
than one fault code is present, the self diagnosis
system will indicate each one in numerical order, with
a 3.2 second pause between each code, and then
repeat the sequence.

The fault codes can be identified as follows:
CODE NUMBER FAULT AREA
12 Satisfactory operation
13 Oxygen sensor open circuit
14 Coolant temperature sensor circuit (voltage low)
15 Coolant temperature sensor circuit (voltage high)
21 Throttle position sensor circuit (voltage high)
22Throttle position sensor circuit (voltage low)
23MAT sensor circuit (voltage' high) 1.8 liter engine
only
24 Vehicle speed sensor circuit
25 MAT sensor circuit

(voltage low) 1.8 liter engine
only
33 MAP sensor circuit

(voltage high)
34MAP sensor circuit (voltage low)
42 Electronic spark timing circuit
44
Oxygen sensor circuit

(lean exhaust)
45Oxygen sensor circuit (rich exhaust)
51 Mem-Cal
55 Control unit input circuits
Test Procedure
(1) Perform the following checks:

(a) Ensure that the battery voltage is above 11
volts. (b) Ensure that the throttle valve is fully closed.
(c) Place the transaxle in neutral.
(d) Ensure that the air conditioner, fan, tights
and all other accessories are switched off.
(2) Turn the ignition On and confirm that the
ECM warning lamp on the instrument cluster is
illuminated but not flashing.

If code 55 is displayed, refer to the Control Unit
heading, perform the circuit test procedure and rectify
the cause of the code before proceeding.

If the ECM warning lamp flashes codes other than
code 55, check the wiring harness between the diag-
nostic link connector terminal B and the control unit
wiring connector terminal A9 for shorts. Repair or
renew the wiring harness as necessary.

If no fault can be found, renew the control unit.
If the ECM warning lamp does not illuminate,
proceed as follows:

(a) Check the METER fuse located in the fuse
panel adjacent to the steering column and the fusible
links located in the fusible link connecting block at the
rear of the battery. Renew the fuse or fusible links as
necessary. (b) Check the wiring harness to the instrument
cluster. Repair or renew the harness. (c) Check the Check Engine lamp bulb. Renew if
necessary. (d) Check the EGI relay. Renew as necessary.
(3) Connect a jumper lead across terminals A
and B on the diagnostic link connector located under
the front passengers seat above the control unit.
(4) Note the codes indicated by the flashing
ECM warning lamp.
If code 12 is displayed, the system is operating
correctly.

If codes other than code 12 are displayed, refer to
the component or circuit test procedure under the
appropriate heading as indicated by the code number.

If more than one code is being displayed, test each
indicated fault working in the order of display of the
code numbers.

(5) After completing the self diagnosis test pro-
cedure, remove the jumper lead from the diagnostic
link connector. (6) After repairing or renewing the necessary

View showing the location of the diagnostic link
connector. Passengers seat removed for clarity.
Inset shows the diagnostic link connector terminal identification.

Electrical System 191
This is usually accompanied by discoloura-
tion of the electrolyte.

CHARGE INDICATOR LAMP REMAINS ON
• Loose or broken alternator drive belt: Adjust
or renew the drive belt.
• Faulty regulator unit: Check and renew the
regulator unit. • Faulty alternator: Check and overhaul the
alternator. • Short to earth in the warning lamp circuit:
Check and repair the circuit.

Checking the alternator drive belt for deterioration.
CHARGE INDICATOR LAMP DOES NOT
OPERATE

• Lamp bulb blown: Check and renew the
faulty bulb. • Open circuit in the wi ring or bulb socket:
Check and rectify the open circuit. • Faulty alternator diode: Overhaul the alter-
nator.
NOISE IN DRIVE BELT OR ALTERNATOR

(1) Drive belt frayed or out of alignment with
the pulleys: Renew the drive bell or align the pulleys.

• Loose alternator moun ting bolts or worn
bearings: Tighten the mounting bolts or renew the
bearings. • Loose alternator pulley: Tighten the pulley
retaining nut.
• Faulty alternator: Overhaul or renew the
alternator. • Faulty diodes in the alternator: Overhaul the
alternator, install a new heat sink.
NOTE: To check if the noise is in the
alternator or drive belt, loosen the alternator
and remove the drive belt. If the noise is
gone when the engine is run for a short time
check the serviceability of the belt and
alternator components.

2. BATTERY AND STARTING SYSTEM TROUBLE SHOOTING

STARTER LACKS POWER TO CRANK ENGINE
(1) Battery undercharged: Check the charging
system and rectify as necessary.


Cleaning the battery terminals using a battery post
cleaner.
• Battery faulty, will not hold charge: Check
and renew the battery. • Battery leads or terminals loose or corroded:
Clean and tighten the leads or terminals.
• Faulty starter motor: Check and overhaul the
starter motor. • Faulty starter solenoid switch or contacts:
Check and renew the solenoid as necessary.
STARTER WILL NOT ATTEMPT TO CRANK
ENGINE

(1 ) Open circuit in the starting system : Check
for dirty or loose leads or terminals, dirty commuta-
tor, faulty solenoid or faulty switch. On automatic
Spin the alternator pulley over by hand to check the
bearings for noise.

192 Electrical System
transaxle models, check for a faulty or incorrectly
adjusted neutral safety switch.

1. Discharged battery: Check for a fault or short
circuit in the system. 2. Battery fully charged but will not crank
engine. Check for a locked drive and ring gear,
internal starter faul t or seized engine.
3. Fusible link blown: Check and repair the
cause and renew as necessary.
NOTE: Rotate the engine by hand to ensure
that the starter drive is not locked with the
flywheel ring gear and t hat the engine is not
seized. Ensure that the ignition key is
turned off before rotating the engine.

3. LIGHTING SYSTEM TROUBLE SHOOTING
LAMP OR LAMPS FAIL TO LIGHT
1. Faulty bulb(s): Check and renew the faulty
bulb(s). 2. Open circuit in the wiring or connections:
Check the lamp circuits and rectify as necessary.

1. Faulty lamp switch: Check and if necessary
renew the lamp switch. 2. Faulty fuse or fuse connection: Repair the
fuse connection or renew the fuse. 3. Lamp relay faulty: Check and renew as
necessary.
NOTE: Switch on the lamps concerned and
using a test lamp, check that the lamp
circuits are operating. This is best done by
starting at the lamp wiring connector or
bulb holder and work ing back to the power
source.

LAMP OR LAMPS INCORRECTLY
ILLUMINATED

1. Lamp or lamps incorrectly earthed: Check
the lamp earth for loosene ss or clean the contact,
either at the lamp body or wire.
2. Incorrect bulbs installe d: Check the bulb
wattage and voltage and renew with the correct type if
necessary. 3. Dirty or damaged lamp reflector: Clean or
renew the lamp reflector. 4. Faulty bulb: Check with a known serviceable
bulb and renew if necessary. 5. Dirty lamp lens: Clean or renew the lamp
lens. 6. High resistance or faulty connections be-
tween the alternator and battery: Check the circuit
and rectify th e condition.
7. Poor earth connection between the battery
and the engine or alternat or: Check the battery earth
lead and the strap between the engine and the body. 8. Voltage regulator faulty: Check and renew
the voltage regulator.
NOTE: The most common cause for this
condition is dirty t erminals on the earth
leads. Check all earth leads at their earthing
points.

4. TURN SIGNAL LAMP TROUBLE SHOOTING
TURN SIGNAL LAMP DOES NOT LIGHT AND
NO AUDIBLE NOISE FROM FLASHER UNIT

(1) Fuse blown: Rectify the fault and renew the
fuse.

(2) The Flasher unit is faulty: Renew the unit
(3) Turn signal switch faulty: Renew the switch
(4) Fault in the wiring circuit: Check and repair
the fault.

TURN SIGNAL WARNING LAMP DOES NOT
FLASH BUT AUDIBLE CLICKING FROM
FLASHER UNIT

(1) Warning lamp bulb blown: Check and renew
the bulb.

Checking the rear combination lamp circuit using a test
lamp.
Checking the headlamp circuit using a test lamp.

Electrical System 193


Installed view of the stop lamp switch and the flasher
unit.
(2) Fault in the warning lamp wiring: Check and
repair the fault.

NOTE: When renewing bulbs ensure that a
new bulb of the correct wattage is used.

TURN SIGNAL LAMPS FLASH WEAKLY AND
AT GREATER THAN NORMAL SPEED

1. Faulty flasher unit: Check and renew the
flasher unit.
2. Front or rear bulb blown on the turn side:
Check and renew the bulb.
NOTE: If the flasher unit is to be renewed,
always try to obtain a genuine replacement
part.

HAZARD WARNING LAMPS DO NOT
OPERATE

Fuse blown: Rectify the fault and renew as
necessary.
Flasher unit faulty: Re new the flasher unit.
Hazard warning switch faulty: Renew the
switch.
Fault in the wiring circuit: Check and repair
the fault.
5. TEST EQUIPMENT AND SOME APPLICATIONS

Special Equipment Required:
To Make Test Lamp or Jumper Lead — Soldering
iron

When working on the electrical system, a test
lamp and jumper leads can be very useful to check
circuits.

TO MAKE A JUMPER LEAD
The minimum materials required to make a
jumper lead are one length of 4 mm wire and two
small alligator clips.

Grouping of materials to construct jumper leads of
various sizes.
Bare both ends of a suitable length of 4 mm
wire. Connect a small alligato r clip to each end of
the wire. Solder and tape the connections. Test the jumper lead for continuity by re-
moving one battery cable and connecting the lead
between the cable and the battery terminal. Turn the
ignition On and the dashboard warning lamps should
operate indicating a completed circuit through the
jumper lead. Remove the jumper lead from the circuit and
reconnect the battery.
NOTE: Make a few jumper leads of various
lengths using different sizes and types of
alligator and battery clips.

TO MAKE A TEST LAMP
Due to the extensive use of electronic components
in the electrical system, an LED (light emitting diode)
test lamp can be made from a suitable length of 3 mm
wire, an alligator clip, an LED, a 1/4 watt 560 ohm
resistor, a suitable case such as an old ball point pen
case and a length of rod or wire sharpened to form a
probe.

(1) Solder the length of wire to the K (cathode)

194 Electrical System


Schematic of LED test lamp. Ensure that the connec-
tions to the K (cathode) lead and A (anode) lead of the LED are as illustrated.
lead of the LED. The K lead is the shorter of the two
leads and is adjacent to the flat on the LED.

Solder the 560 ohm resister to the A (anode)
lead of the LED. Solder a short length of wire to the other lead
of the resistor and to the probe. Drill a hole in the side of the case to accept
the wire attached to the K lead of the LED. Mount the probe in the case. If using a pen
case, push the probe through the lower end of the pen
after removing the refill. Push the lead attached to the K lead of the
LED through the hole made in the side of the case and
solder the alligator clip to the lead.
Mount the LED to the case. If using a pen
case, the LED may be mounted in the plug at the top
of the pen after drilling the plug to accept the LED. Suitably attach the probe to the case using
adhesive or tape.
TO TEST SWITCHES

Disconnect the wires from the switch.
Using a test lamp, test each wire to locate the
power wire. It may be nec essary to turn the ignition
On as the switch may be wired through the ignition
circuit. Disconnect the test lamp and connect a jumper lead between the power wire and the wire
from the other side of the switch.

If the circuit functions, the switch can be consid-
ered faulty and should be renewed. Refer to the
heading Switches and Controls.

TO TEST BULBS
Remove the bulb from the bulb holder.
Connect a jumper lead between the positive
terminal of a battery a nd the base of the bulb.
Connect another jumper lead between the
negative battery terminal and the contact on the base
of the bulb. The bulb should illuminate. If the bulb has two filaments, connect the jumper
lead to the second contact on the base of the bulb. The
second filament should illuminate.

If the bulb fails to illuminate, it should be
renewed with a bulb of the correct voltage and
wattage.

TO TEST CIRCUITS
Turn the circuit switch On.
Using a test lamp, check for power at one of
the circuit connections. A fuse is a good starting point.
If power is available, reconnect the connector and
continue checking towards the motor or bulb end of
the circuit.

If power is not available, continue checking
towards the battery or switch end of the circuit.

6. BATTERY
Special Equipment Required: To Test — Hydrometer
To Charge — Battery charger

TO REMOVE AND INSTAL
(1) Disconnect the negative and positive battery
terminals.

Installed view of the battery.

200 Electrical System


Using an ohmmeter to test for bridging or internal shorting of the rotor fields.

internally, while a high reading indicates an open
circuit or high resistance in the windings. In both
cases a new rotor assembly will have to be installed.

Stator Windings
The stator test is carried out using a test lamp.
The stator leads must be detached from the
diode pack.
Connect a jumper lead from the negative
terminal of a charged 12 volt battery to the stator
winding frame. Connect one en d of a test lamp to the
battery positive terminal, the other end of the test
lamp to the stator lead, one at a time. Should the test lamp illuminate, however
dimly, a short circuit is indicated and the stator
assembly must be renewed.
Diodes
On some models the diod es may be tested after
disconnection. Testing can be done by using a 12 volt
battery and a 1.5 watt bulb in series with a jumper
lead.

Connect a jumper lead from the negative
terminal of a charged battery to the carrier/bracket
holding the diode to be tested. Connect one end of a test lamp to the battery
positive terminal and the other end of the lamp to the
diode lead. Note whether the lamp is illuminated and
then reverse the connections on the battery. If the lamp was illuminated in both direc-
tions or was not illuminated at all, the diode is faulty
and the diode pack/heat sink must be renewed.
Brush Springs and Brushes
Check the brush spring s for overheating and
distortion, check for binding in the brush holder.

Check the brush length and renew as neces-
sary. Refer to Specifications for the correct dimen-
sions. TO ASSEMBLE

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

Using a hot soldering iron and a pair of long
nosed pliers as a heat sink, solder the stator leads to
their respective terminals on the diode pack. Install the insulating washer and spacer to the
(B +) terminal post and position the diode pack and
stator assembly onto the slip ring end bracket. Install
the diode pack retaining screws and tighten securely. Working on the exterior of the slip ring end
bracket, install the output terminal components to
the
(B + ) terminal and secure the retaining nut.
Position the bearing retainer, bearing and
spacer on the rotor shaft. Using a suitable press and press plates,
support the rotor sh aft on the front face of the spacer
and carefully press the rotor shaft fully into the
bearing and spacer. Position the rotor shaft assembly into the
rear of the drive end bracket and install and tighten the
bearing retainer plate screws. Install the fan, plate, spacer and split
drive
pulley to the rotor shaft and secure them with the
retaining washer and nut. If necessary, using a suitable press and press
plates, support the rotor shaft rear bearing and
carefully press the rotor shaft fully into the bearing.
NOTE: Ensure that pressure is applied only
to the inner race of the bearing.

Ensure that the rotor shaft bearing wave
washer is located in the slip ring end bracket and
insert the rotor in the stator and slip ring end bracket
assembly. Align the marks made on dismantling and
install and tighten the long securing screws.
Position the regulator and brush holder as-
sembly to the slip ring end bracket and install
and
tighten the retaining screws. Install the alternator to the vehicle and
test
the operation as prev iously described.
Hitachi Alternator
If necessary, position the new brush termi-
nals in the brush assembly and install the
brush
assembly and terminal plate to the diode pack.
Carefully solder the terminal plate to the diode pack
and secure the brush assembly by installing and
staking new rivets.

If necessary, solder the diode pack and
regulator to the stator and install the fan guide
and
retaining nuts. Tighten the retaining nuts securely.
NOTE: When soldering or unsoldering the
stator leads or bridges from the diodes or
regulator, grip the leads with a pair of long

Electrical System 209
12. INSTRUMENT CLUSTER
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Remove the retaining screws from the instru-
ment cluster surround. Carefully withdraw the instrument cluster
surround from the instrument panel sufficiently to
enable the wiring to be disconnected. Remove the
surround from the vehicle.
.
FLEXIBLE PRINTED
CIRCUIT

Rear view of the instrument cluster removed from the
vehicle.

(4) Remove the instrument cluster assembly
retaining screws and gently ease the assembly from the
instrument panel sufficiently to enable the wiring to be
disconnected.

If necessary, remove the instruments as follows:
Carefully depress the retaining clips on the
front lens and remove the front lens. On models equipped with a tachometer, slide
the plastic rib from between the speedometer and the
tachometer. Remove the screws retaining the speedome-
ter and the tachometer or fuel/temperature gauges
from the rear of the instrument cluster.
CLUSTER ASSEMBLY

(d) Withdraw both instruments from the front of
the instrument cluster being careful as these instru-
ments are held by protruding pin terminals.

NOTE: Do not touch the faces of the instru-
ment dials as they mark easily.

(e) On models equipped with a tachometer,
remove the retaining nuts and remove the tempera-
ture and/or the fuel gauge from the cluster assembly.

Installation is a reversal of the removal procedure
ensuring that all electrical connectors are correctly
installed.

13. BLOWER FAN
The removal and installation procedure for the
blower fan is described in the Cooling and Heating
Systems section.

14. RADIO/CASSETTE
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Remove the release hole covers on each side
of the radio/cassette.

Dismantled view of the instrument cluster.
Illustration of the radio/cass ette removal tool showing
the required dimensions.
BULB HOLDERS
BULB HOLDERS
Removing the release hole covers from the radio/cas-
sette.