heating NISSAN PULSAR 1987 Owner's Manual

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.

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.

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.

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

Brakes 181

chor plate to the steering knuckle and slide the caliper
off the brake disc. Suspend the caliper clear of the
work area using wire or cord.

(3) Suitably mark the location of the disc in
relation to the hub.

(4) Slide the disc off the hub. If the disc is
difficult to remove, install two M8 x 1.25 mm bolts in
the disc and by alternatively tightening the bolts,
remove the disc.

Do not use a hammer to remove the disc.
Installation is a reversal of the removal procedure
ensuring that the mating face s of the disc and hub are
clean and free from burrs and that the marks made on
removal are aligned.

To Inspect
(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating. (2) Using a micrometer, measure the thickness
of the disc at several positi ons around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

Inspect the brake discs for scoring and wear.
(3) If the disc thickness is satisfactory but the
disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.

NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

6. REAR DISC BRAKES
Special Equipment Required:
To Check Disc Runout — Dial gauge
To Check Disc Thickness — Micrometer
TO CHECK AND RENEW BRAKE PADS
( 1 ) Raise the rear of the vehicle and place it on
chassis stands. Remove the rear wheels.


Renew the rear brake pads if the friction material is less
than 2 mm thick.
(2) Inspect the brake pads on both sides of the
vehicle. If the friction material on one or more of the
pads is less than 2 mm thick or contaminated with
fluid or grease, renew the brake pad as a set as follows.

NOTE: If the brake pads are contaminated
trace and rectify the cause prior to installing
the new set of pads.

(3) Drain approximately two thirds of the brake
fluid from the master cylinder reservoir. This can be
done by loosening the bleeder valve on the caliper and
allowing the fluid to drai n into a container. Discard
this fluid.

NOTE: Do not drain all the fluid from the
reservoir otherwise it will be necessary to
bleed the hydraulic system. The fluid is
drained from the reservoir to prevent over-
flow when the caliper piston is pushed back
into the caliper bore to facilitate pad re-
newal.

(4) Remove the guide bolts and lift the caliper
body clear of the disc.

NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Noting the installed positions, remove the
brake pads, shims and spring clips from the anchor
plate.
(6) Using a pair of long nosed pliers with the
nose located in the recesses of the piston, rotate the
piston clockwise to retract it into the cylinder body.
Align the recesses between the brake pad retaining
lugs on the caliper body. Refer to the illustration. (7) If necessary, check the disc runout and
thickness as described under the Brake Disc heading.
(8) Ensure that the guide bolts move freely in the
caliper body and that the dust boots are in good
condition.

184 Brakes
than 0.05 mm. If the wheel hub end float exceeds
Specifications, the bearing must be renewed as de-
scribed in the Rear Suspension section.

(3) Position the dial gauge plunger against the
centre of the brake disc contact area. Rotate the hub
and measure the runout. Ma ximum allowable runout
is 0.07 mm. (4) If the runout exceeds the specified amount,
machine or renew the brake disc. (5) Install the rear wheel and lower the vehicle to
the ground. (6) Road test the vehicle and check for correct
brake operation.
To Remove and Install

(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the relevant rear wheel.
(2) Remove the clip securing the brake hose to
the suspension unit and disengage the hose. (3) Remove the bolts retaining the caliper an-
chor plate. (4) Slide the caliper from the brake disc and
suspend the caliper clear of the work area using wire
or cord.
NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Remove the grease cap from the rear hub.
(6) Remove the split pin, nut retainer, hub nut
and washer from the stub axle. (7) Remove the hub assembly from the stud
axle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the rear hub to the specified torque.
(2) Install the brake caliper and tighten all the
bolts to the specified torque. (3) Rotate the hub and check for roughness. If
the hub does not rotate smoothly, renew the hub
bearing as described in the Rear Suspension section. (4) Install the rear wheel and lower the vehicle to
the ground.
(5) Road test the vehicle and check for correct
brake operation.
To Inspect

(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating. (2) Using a micrometer, measure the thickness
of the disc at several posit ions around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

(3) If the disc thickness is satisfactory but the
disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.


Inspect the machined faces of the disc for scores,
cracks, wear and signs of overheating.
NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

7. REAR DRUM BRAKES
TO REMOVE AND DISMANTLE
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove th e rear wheels and release
the handbrake.
(2) Remove the grease cap from the rear hub.
(3) Remove the split pin, nut retainer, hub nut
and washer from the stub axle. Remove the brake
drum and hub assembly.

(4) Mark each brake shoe and spring to ensure
correct assembly. (5) Rotate the star wheel until the adjuster
assembly is at its shortest length.
Installed view of the left hand side rear drum brake
components.

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.