tow NISSAN PULSAR 1987 Owner's Guide

204 Electrical System
brushes to the brush holder and position the springs
against the ends of the brushes.

Install the O ring to the yoke taking care
that
the O ring is not twisted. Install the yoke, armature and brush
holder
assembly to the drive end bracket, aligning the marks
made on dismantling. Install the end cover to the yoke. Install
and
tighten the retaining bolts securely. Connect the cable to the solenoid field coil
terminal and tighten the terminal nut securely. Install the starter motor to the vehicle
as
previously described.
BOSCH STARTER MOTOR
To Dismantle

Disconnect the brush connector strap from
the lower terminal on the solenoid switch.
Remove the screws retaining the solenoid to
the drive end bracket and remove the solenoid from
the drive end bracket.
Loosen, but do not remove the screws retain-
ing the armature end cover to the commutator end
bracket. Remove the through bolts retaining the drive
end bracket to the commutator end bracket.
Remove the yoke, armature and commutator
end bracket from the drive end bracket as an assem-
bly. Hold the rubber seal in place in the drive end
bracket to keep the engaging lever in position.
Remove the rubber seal from the drive end
bracket. Remove the cover plate from the planetary
gear set and remove the gear set, drive assembly and
engaging lever as an assembly. Remove the armature end cover and com-
mutator end bracket from the yoke. Remove the screws retaining the armature
end cover to the commutator end cover and remove
the armature end cover, C clip and shims from the
armature shaft. Remove the commutator end bracket
from the armature. Carefully remove the brush holder from the
armature. Support the gear set and drive assembly in a
vertical position with the drive assembly uppermost.
Using a suitable drift, tap the stop collar
towards the drive assembly and remove the snap ring
from the drive shaft. Remove any burrs from the drive shaft and
withdraw the drive assembly and stop ring from the
drive shaft.
Clean all parts thoroughly but do not im-
merse the armature, solenoid or drive assembly in
cleaning solvent.
To Check and Inspect

(1) With the starter motor dismantled, check the
brush holder insulation using an ohmmeter.

Connect one test lead to the brush holder positive
BRACKET

Dismantled view of the Bosch starter motor.

Electrical System 213


Renewing the high mounted stop lamp bulb.
Remove the bulb holder from the lamp by
twisting it anti-clockwise and removing it from the
lamp body.
Push the bulb inwards, turn it anti-clockwise
and remove it from the holder. Installation is a reversal of the removal procedure.

LUGGAGE COMPARTMENT LAMP
To Renew Bulb

Working inside the luggage compartment,
carefully prise the lens from the luggage compartment
lamp.
Remove the lamp bulb by gripping it firmly
and pulling it from the lamp socket. Installation is a reversal of the removal procedure.


Renewing the luggage compartment lamp bulb.
16. WINDSCREEN WIPER
WIPER BLADE
To Remove and Install
Pull the wiper arm away from the wind-
screen until it locks in the vertical position.
Push the pin retaining the wiper blade to the
Removing the wiper blade.
arm and slide the wiper blade along the arm towards
the pivot to allow the blade to be maneuvered from
the arm.

Installation is a reversal of the removal procedure
ensuring that the blade snaps into place as it is
installed to the wiper arm.

WIPER RUBBER
To Renew

(1) Remove the wiper blade from the vehicle as
previously described.


Renewing the wiper rubber.
Squeeze the sides of the clip retaining the
wiper rubber and spine ass embly to the wiper blade
and slide the rubber and spine assembly from the
blade. Slide the new rubber and spine assembly into
the wiper blade ensuring that the spine is engaged with
all the lugs in the blade. Install the wiper blade to the wiper arm.
WIPER ARM

To Remove and Install
(1) Remove the nut retaining the wiper arm to
the drive spindle.

216 Electrical System

NOTE: While checking the operation of the
fusible link, loosely connect the battery-
terminal only, to safeguard against damage
to the wiring harness.

(5) If the circuit is still inoperative or the fusible
link burns out again, refer the problem to an auto-
motive electrician.

RELAY LOCATIONS
The various relays employed in the vehicle elec-
trical system are located behind the fusible links
adjacent to the washer bottle in the engine compart-
ment, on the engine compartment bulkhead, under
the windscreen wiper motor and in the fuse box at the
lower right hand side of the dashboard.

The engine compartment relays power the radia-
tor fan, horn, condenser fan, bulb check, automatic
transaxle neutral safety switch, air conditioner and
condenser motor.


Installed view of the fuse box relays.
The fuse box relays power the fuel pump, ignition,
some accessories and the el ectronic control module.

18. TRAILER WIRING
There are several brands of trailer wiring connec-
tors available with a variet y of pin configurations. The
most common is the seven pin type which provides
for two auxiliary circuits, usually used for reverse
lamps and electric trailer brakes.


Installed view of the engine compartment relays.
Installed view of the engine compartment relays.


Useful connections which can be used if the trailer to
be towed is fitted with different type plug to the towing
vehicle socket
Brylite seven pin trailer plug and socket.

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

Body 229
trol assembly escutcheon to the door and remove the
escutcheon.

(4) On models with manual windows, lever back
the regulator handle escutcheon and using a suitable
wire hook, withdraw the handle retaining clip and
remove the handle and escutcheon.

Alternatively, a piece of sturdy cloth can be used
to remove the regulator handle by sliding the cloth
behind the handle and pulling on each end of the cloth
in a see-saw action to release the retaining clip.

On models with a step lamp located in the
door trim panel, remove the screws, withdraw the
lamp and disconnect the wiring connector. Using a broad bladed screwdriver, carefully
lever the trim panel outwa rds and disengage all the
retaining clips. When all the clips have been disen-
gaged maneuver the trim panel from the door. Carefully remove the plastic sealing sheet
from the inner door panel. Installation is a reversal of the removal procedure
with attention to the following points:

Ensure that the plastic sealing sheet is cor-
rectly installed and not torn or damaged. Check the trim panel retaining clips and
renew any damaged clips as necessary. On models with manual windows, wind the
door glass to the closed position, install the
retaining
clip to the regulator handle and install the regulator
handle to correspond with the regulator handle on the
opposite door.
DOOR GLASS, REGULATOR AND QUARTER
GLASS

To Remove and Install
Remove the interior handles, the trim panel
and the plastic scaling sheet as previously described. Lower the door glass to align the lift channel
with the lower aperture.
Support the door glass and remove the
retaining screws from the lift channel.
Remove the screws retaining the rear run
channel to the door.
NOTE: To gain a ccess to the upper screw
carefully ease a small section of the door
rubber from the upper door flange.

Maneuver the run channel from the door
using care not to chip the d oor paintwork or the glass.
Withdraw the door glass through the door
glass aperture. Slide the quarter glass and seal assembly
towards the front top corner of the door and withdraw
the quarter glass from the vehicle. Remove the regulator retaining bolts and
withdraw the regulator from the door through the
lower aperture. Installation is a reversal of the removal procedure
with attention to the following points:


Dismantled view of the manually operated rear window
regulator and glass components.
Ensure that the regulator sliding surfaces are
adequately lubricated with a zinc oxide grease. Ensure that the door glass slides freely in the
run channels. The rear channe l lower bolts and the lift
channel screw are adjustable in slotted holes to
achieve this. Install the plastic sealing sheet, the trim panel
and the interior handles as previously described.
REMOTE CONTROL AND DOOR LOCK
To Remove and Install

Remove the interior handles, the trim panel
and the plastic sealing sheet as previously described. Remove the retaining screws from the re-
mote control assembly.
Remove the retaining screws from the door
lock assembly. On models with central door locking, discon-
nect the lock actuator li nk from the lock assembly by
releasing the snap clip. Withdraw the door lock assembly from the
door at the same time turning the snipper button
pivot holder to release the pivot from the door. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the exterior handle link enters
the door lock stepped adjuster when maneuvering the
door lock into position.

Body 233
Remove the lock assembly retaining bolts
and withdraw the lock assembly, insulator and link
from the tailgate.
Using a suitable screwdriver, remove the
lock cylinder retaining clip and withdraw the lock
cylinder from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

Ensure that the positioning of the lock is
correct in relation to the striker plate.
Ensure that the interior lamp switch wiring
connector is connected.
6. LUGGAGE COMPARTMENT LID
AND LOCK — SEDAN
LUGGAGE COMPARTMENT LID
To Remove
Raise the luggage compartment lid and place
protective covers over the surrounding paintwork.
Using a soft lead pencil, mark around the
luggage compartment lid hi nges to aid assembly.
With the aid of an assistant supporting the
lid, remove the hinge retaining bolts and withdraw the
luggage compartment lid from the vehicle.
To Install and Adjust

With the aid of an assistant, install the
luggage compartment lid in position on the hinges
according to the marks made on removal. Install the
retaining bolts. Close the lid and check the vertical and
lateral alignment of the l i d in relation to the body.
If adjustment is necessary, loosen the l i d
hinge retaining bolts on one hinge at a time and adjust
the lid as required.
If vertical adjustment is required, loosen the
lid hinge retaining bolts and increase or decrease the
number of washers under the bolts. If required, adjust the striker plate using the
procedure that follows.
STRIKER PLATE

To Remove, Install and Adjust
Fold back the trim material from inside the
luggage compartment.
Using a soft lead pencil, scribe a line around
the outside of each striker plate retaining bolt washer. Remove the striker plate bolts and washers
and the screw retaining the remote release cable
bracket.

Installed view of the luggage compartment lid striker
with the trim material folded back.
(4) Slide the striker assembly towards the right
hand side of the vehicle and disconnect the remote
release cable. Withdraw the striker plate from the
vehicle.

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

(1) Install the remote release cable to the striker
plate and install the striker plate retaining bolts and
washers to the lines made on dismantling.

Tighten the retaining bolts to just over finger
tight.

Close the lid ensuring that the striker has
actuated the locking mechanism. Check the alignment of the luggage compart-
ment lid in its opening an d adjust the locking action
by moving the striker plate. Tighten the retaining
bolts securely.
When the striker plate is adjusted correctly
pull the remote release ca ble towards the right hand
side of the vehicle until the cable end has 0.5-1.5 mm
clearance and tighten the re taining screws. Check the
operation of the remote release cable and readjust if
necessary.
Installed view of the luggage compartment lid hinge.