battery NISSAN PULSAR 1987 Repair Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 196 of 238
196 Electrical System
Check the specific gravity in each cell with a hydro-
meter.
Check the battery electrolyte level and re-
plenish as necessary. Remove the filler cap s from the battery.
Follow the battery charger manufacturers
instructions. (3) Should the battery fail to operate satisfacto-
rily after charging, it is recommended that it be taken
to a workshop with the necessary equipment to per-
form a load test. Load testing, when performed in
conjunction with the specific gravity tests described
above will give an accurate indication of the service-
ability of the battery.
7. ALTERNATOR
Special Equipment Required
To Test On Vehicle - Voltmeter, 100-0-100
amp ammeter, ohmmeter
To Dismantle — 200 watt soldering iron,
bearing
puller, press
To Assemble — 200 watt soldering iron
DESCRIPTION
Two types of alternator are installed to the range
of vehicles covered by this manual, either Hitachi or
Bosch. In the alternator, the field and pole shoe assembly
is the moving part and it is shaped to form the rotor.
Since only a low amperage current flows between the
slip rings on the rotor shaft and the brushes, wear on
the brushes and slip rings is very slight and mainte-
nance is reduced to a minimum. The output current is generated in the fixed stator
windings and is a three phase alternating current
(AC). The stator windings are wound on a laminated
soft iron former, star connected and installed between
the end brackets. As it is not possible to charge a storage battery
with alternating current, it is necessary to rectify the
output of the stator windings to direct current (DC). This is done by a bank of diodes mounted within the
alternator slip ring end bracket.
The output of the alternator is governed by the
regulator and the built in ch aracteristics of the alter-
nator.
The regulator and brush holder assembly on
Hitachi alternators is mounted within the alternator
on the slip ring end bracket side. On Bosch
alternators
the regulator and brush holder unit is mounted to the
outside of the slip ring end bracket. An electrical cut out unit is not necessary with the
alternator charging system as the diodes prevent a
reverse current flow through the alternator.
SERVICE PRECAUTIONS
Ensure that the battery is connected with the
correct polarity to earth. Refer to Specifications.
Do not short out or ground any terminals
common to the charging circuit. Always disconnect the battery before con-
necting a battery charger.
If a booster battery is used, always connect it
in a parallel circuit i.e. positive to positive ( + to + )
and negative to negative (- to -) to maintain a 12
volt supply. Never disconnect the battery or terminals in
the charging circuit while the engine is running. Regularly check that the alternator drive belt
tension is as specified. Refer to the Engine Tune-up
section.
Keep the battery terminals clean and all
electrical connections tight. Disconnect the battery and alternator when
electric welding on the vehicle.
TO TEST ON VEHICLE If the charge indicator lamp stays on after the
engine has been started and run at approximately
1 000 rpm, carry out the following tests. Stop the engine.
Check the condition and adjustment of the
alternator drive belt. Clean the battery terminals, tighten all elec-
trical connections, check the wiring for shorts to earth
and/or bridged circuits. Ensure that the battery is fully
charged. If the battery is discharged charge it or
replace it with one fully charged. Start the engine and allow it to run until
normal operating temperature is reached.
Stop the engine and disconnect the negative
battery terminal.
Remove the nut and washer from the alter-
nator output terminal (B +) and disconnect the alter-
nator output lead. Connect one lead of an ammeter to the
alternator output terminal and the other lead to the
lead removed from the output terminal. Connect the negative battery terminal and
connect a voltmeter across the battery terminals.
Page 197 of 238
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.
Page 200 of 238
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
Page 201 of 238
Electrical System 201
nosed pliers. This will safeguard the diodes
by transferring any excess heat to the jaws of
the pliers.
Using a suitable drift, install the bearing into
the drive end bracket, install the retainer plate and
screws. Tighten the screws securely. Using a suitable press and press plates, install
the bearing to the slip ring end of the rotor shaft.
Ensure that pressure is ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft rear bearing stop
ring is positioned so that the protruding part of the
ring is located in the deepest part of the groove. Install the stator, diode pack and
regulator
assembly to the slip ring e nd bracket. Install the
retaining nuts and washers and tighten securely. Install the nut and insulator to the terminal
and tighten securely. Using a piece of wire, hold the brushes in a
retracted position. Hold the drive end bracket in a soft jawed
vice and install the rotor shaft assembly to the drive
end bracket. Install the pulley, retaining nut and washer to
the rotor shaft and tighten the retaining nut to the
specified torque. Apply a heated 200 watt soldering iron to the
slip ring end bracket at the bearing mounting boss for
3-4 minutes to heat the bracket and allow the
installation of the rotor shaft rear bearing. Aligning the marks made on dismantling and
ensuring that the rotor sh aft rear bearing retaining
ring protrusion is located in the deepest part of its
groove, install the rotor/stator assembly to the slip ring
end bracket.
Remove the brush retr acting wire from the
alternator, ensure that the alternator component
marks are aligned, install the retaining through bolts
and tighten them securely. Check the alternator rotor for smooth oper-
ation and install the al ternator to the vehicle
as
previously described.
Check the alternator operation on the vehicle
as previously described.
8. STARTER MOTOR
Special Equipment Required:
To Renew Brushes — Soldering iron
To Renew Armature Bearings — Bearing puller
DESCRIPTION
Two types of starter motors are installed to the
range of vehicles covere d by this manual, either
Hitachi or Bosch.
The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.
A solenoid switch is attached to the starter drive
end bracket. The solenoid plunger is connected to
the overrunning clutch and drive pinion assembly
through a lever and pivot arrangement.
When the solenoid windings are energized, the
plunger acting on the lever and pivot engages the drive
pinion with the flywheel ri ng gear and at the same
time closes the switch supplying power from the
positive lead of the battery to the starter motor field
coils and armature to operate the motor.
As the engine fires, the over-running clutch of the
drive pinion assembly prevents high speed rotation of.
and possible damage to, the starter armature if the
solenoid windings are not immediately de-energized
by releasing the ignition key.
The starter solenoid switch windings are energized
by the ignition switch.
TO TEST ON VEHICLE
Should the starter motor fail to operate when the
ignition switch is turned to the Start position, check
the following points:
Check the battery condition and state of
charge. Refer to the Battery heading for the correct
procedure.
Clean the battery terminals, taking particular
care to remove the scale from the positive ( + )
terminal post and terminal. Check the earth connection for tightness and
cleanliness.
Switch on the headlamps and turn the igni-
tion switch to Start. If the lamps dim but the starter
motor does not operate, it could indicate that a short
circuit has developed in the starting system. Check that the engine is not seized or that the
starter motor drive pinion and ring gear are not
locked as these conditions would -give the same
indications as above.
(5) If the lamps do not dim and the starter
motor does not operate, this would indicate an open
circuit such as a broken or disconnected wire or a
switch not operating.
If the vehicle is equipped with an automatic
transaxle, turn the ignition switch to Start and move
the selector lever through all the gear selection range.
If the starter motor operates in any position other
than N or P, the neutral safety switch is faulty.
(6) Check all the external wiring to ensure that
the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
starter motor, the unit will have to be removed and
tested.
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Disconnect the wiring from the starter motor
solenoid. Remove the starter motor mounting bolts,
Page 206 of 238
206 Electrical System
Install the armature and yoke to the drive end
bracket rotating the drive to align the reduction gears.
Do not use force.
Install the retaining through bolts to the
commutator end bracket and lighten the through bolts
and armature end cover retaining screws securely. Install the solenoid to the drive end bracket,
install the retaining screws and tighten them securely.
Install the brush connector strap and
install
the retaining nut and washer and tighten securely.
9 . IGNITION SYSTEM
The testing and repair procedures for the ignition
system are fully covered in the Fuel and Engine
Management section.
10. STEERING WHEEL
The removal and installation procedures for the
steering wheel and horn pad are fully covered in the
Steering section.
11. SWITCHES AND CONTROLS
IGNITION SWITCH
To Remove and Install
Disconnect the negative battery terminal.
Remove the retaining screws from the steer-
ing column cover. Unclip and separate the upper and lower
steering column covers and remove the upper cover. Release the column adjusting lever and re-
move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.
Disconnect the ignition switch wiring at the
switch. Remove the retaining screw and withdraw
the ignition switch fr om the lock assembly.
Installation is a reversal of the removal procedure.
COMBINATION SWITCH
The combination switch is mounted at the top of
the steering column and incorporates two switches.
The parking lamp, headlamp, headlamp flasher, head-
lamp dipper and turn signal lamps are operated by a
lever on the right hand side. A lever on the left hand
side operates the windscreen washer and wiper switch.
These switches can be re newed without removing
the combination switch.
To Remove and Install Switches
Remove the retaining screws from the steer-
ing column cover.
Unclip and separate the upper and lower
steering column covers and remove the upper cover.
View of the combination switch removed from the
vehicle.
Release the column adjusting lever and re-
move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover. Disconnect the wiring connectors from the
applicable switch. Remove the retaining screws located at the
top and bottom of the applicable switch and remove
the switch. Installation is a reversal of the removal procedure.
To Remove and Install Combination Switch Base
Disconnect the negative battery terminal.
Remove the steering wheel as described in
the Steering section Remove the retaining screws from the steer-
ing column cover. Unclip and separate the upper and lower
steering column covers and remove the upper cover.
Release the column adjusting lever and re-
move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.
Dismantled view of the steering lock and ignition
switch assembly
Page 207 of 238
Electrical System 207
Disconnect the wiring connectors from the
rear of the combination switch.
Loosen the clamping screw located at the left
hand side of the combination switch. Push, turn and slide the combination switch
from the steering column. Installation is a reversal of the removal procedure.
REAR WINDOW DEMISTER
SWITCH/HAZARD WARNING LAMP SWITCH
To Remove and Install
Disconnect the negative battery terminal.
Using two small flat bladed screwdrivers,
carefully lever the edges of the switch forward to
release it from the instrument cluster surround.
Withdraw the switch from the surround and
disconnect the switch wiri ng at the connectors.
Installation is a reversal of the removal procedure.
View of the hazard warning switch removed from the
instrument cluster surround.
DOOR LOCKS AND POWER WINDOW
SWITCHES
To Remove and Install
Disconnect the negative battery terminal.
Loosen the retaining screws securing the
armrest to the door. Using a small flat bladed screwdriver, care-
fully lever the front edge of the switch panel up and
maneuver the switch forward and away from the
armrest. Disconnect the wiring connector and remove
the switch from the armrest. Installation is a reversal of the removal procedure.
POWER MIRRORS AND INSTRUMENT
ILLUMINATION SWITCHES
To Remove and Install
Disconnect the negative battery terminal.
Using two small flat bladed screwdrivers,
View of the power mirror switch removed from the
vehicle.
carefully lever the edges of the switch forward to
release it from the fascia lo cated directly above the
fuse box.
(3) Withdraw the switch from the fascia and
disconnect the wiring.
Installation is a reversal of the removal procedure.
REAR WINDOW WIPER/WASHER SWITCH
To Remove and Install
Disconnect the negative battery terminal.
Using two small flat bladed screwdrivers,
carefully lever the edges of the switch forward to
release it from the instrument cluster surround. Withdraw the switch from the surround and
disconnect the wiring.
Installation is a reversal of the removal procedure.
View of the rear window wiper/washer switch re-
moved from the vehicle.
Page 209 of 238
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.
Page 210 of 238
210 Electrical System
Using the radio/cassette removal tools during removal of the unit.
Construct the special tools as illustrated,
insert both tools into the release holes on the radio/
cassette and carefully withdraw the radio/cassette
from the mounting bracket.
Disconnect the wiring harness terminal plug
and remove the radio/cassette.
Installation is a reversal of the removal procedure
with attention to the following points:
Remove the special tools from the radio/
cassette, connect the wiring harness terminal and push
the radio/cassette into the mounting bracket. Install the release hole covers on each side
of
the radio/cassette.
15. LAMP UNITS
HEADLAMPS
To Remove and Install
Disconnect the negative battery terminal.
If removing the drivers side headlamp on 1.8
liter engines, remove the bo lt securing the air cleaner
intake duct and remove the air cleaner intake duct.
Dismantled view of the headlamp assembly.
Remove the radiator grille as described in
the Body section. Remove the bolt and nut from the front and
rear of the inner headlamp. Remove the side indicator lamp assembly
and remove the bolts from the side of the headlamp.
Maneuver the headlamp inner side out first
and remove the headlamp from the vehicle. Installation is a reversal of the removal procedure.
To Adjust Headlamp Aim
Ensure that the tires are inflated to the
correct pressure and that the vehicle is positioned on
level ground.
The vehicle should be unladen, with a full
fuel tank and the driver sitting in the vehicle. When using a headlamp aiming machine,
refer to the manufacturers instructions for equipment
being used.
Partially removed view of the headlamp assembly. Diagram showing the correct light patterns using an
aiming board. Dimension A = 5 meters.
Page 214 of 238
214 Electrical System
Removing the wiper arm.
(2) Using a suitable lever, carefully prise the
wiper arm from the drive spindle, taking care not to
damage the paintwork.
Installation is a reversal of the removal procedure
with attention to the following point:
Ensure that the wiper arms are installed so that
the wiper blades sweep within 10-20 mm of the
windscreen lower moulding.
WIPER LINKAGE
To Remove and Install
Remove both windscreen wiper arms as
previously described.
Carefully prise the wiper arm drive linkage
from the ball stud on the wiper motor driving crank. Remove the retaining nuts and metal spacers
from the wiper arm dr ive spindle housings.
Maneuver both drive spindle housings into
the plenum chamber taking care not to damage the
paintwork. Ensure that th e water seals on the spindle
housings arc not lost during the removal procedure.
Remove the assembly from the vehicle. Installation is a reversal of the removal procedure.
WINDSCREEN WIPER MOTOR
To Remove and Install
(1) Disconnect the negative battery terminal.
Carefully prise the wiper arm drive linkage
from the ball stud on the wiper motor driving crank.
Disconnect the wiring from the wiper motor
at the connector socket. Remove the wiper motor retaining screws
and remove the wiper motor from the vehicle. Installation is a reversal of the removal procedure.
REAR WIPER MOTOR
To Remove and Install
Remove the wiper arm and blade assembly
from the pivot as previously described. Remove the nut retaining the pivot to the
rear window. Using a flat bladed screwdriver, prise out the
clips retaining the trim pane! to the interior of the
tailgate and carefully wit hdraw the trim panel from
the vehicle. Depress the lock tab and disconnect the
wiring connector. Remove the bolts retaining the wiper motor
mounting bracket to the tailgate and withdraw the
wiper motor and mounting bracket from the vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:
Installed view of the windscreen wiper motor.
Installed view of the rear wiper motor.
Removing the rear wiper arm.
Page 215 of 238
Electrical System 215
Ensure that the wiper motor is in the Park
position before installing the wiper arm. If in doubt,
turn the wiper switch to the Off position and turn the
ignition switch to the On position until the wiper
motor stops.
Install the wiper arm to the pivot so that the
wiper blade is horizontal to the lower edge of the edge
of the rear window when in the Park position.
17. FUSES, FUSIBLE LINKS AND RELAYS
TO CHECK AND RENEW FUSE
NOTE: If a fuse is found to be faulty or
burnt out, use a replacement fuse of the
specified amperage only. The specified amp-
erage is marked on the fuse.
The use of a higher amperage fuse than
that specified could cause damage to the
vehicle wiring harness.
The fuses are mounted in a fuse box
located in the lower right hand corner of the
dashboard.
Remove the cover from the lower right hand
corner of the dashboard and using the information
marked on the fuse box, locate the fuse protecting the
circuit at fault. Pull the fuse out of the fuse box and inspect
it for serviceability.
Should the fuse appear to be in a serviceable
condition, test its continuity with an ohmmeter or test
lamp. Should the fuse be faulty or burnt out,
install
a new fuse of the same amperage. If the circuit is still inoperative or the fuse
burns out again, test the circuit as previously de-
scribed in this section or refer the problem to an
automotive electrician.
TO CHECK AND RENEW FUSIBLE LINK
NOTE: If a fusible link is found to be faulty
or burnt out, use a genuine replacement
fusible link of the specified amperage only.
The use of a higher amperage fusible link
than that specified could cause damage to
the vehicle wiring harness.
A new fusible link should never be in-
stalled until the fault which caused the
original link to fail has been repaired.
The fusible links installed to protect the
vehicles wiring system are located adjacent
to the washer bottle on the right hand inner
mudguard.
Disconnect the negative battery terminal
Check the fusible link visually for service-
ability.
Should the fusible link appear to be in a
serviceable condition, test its continuity using
an
ohmmeter or a test lamp. If the fusible link proves to be faulty, install
a
new fusible link and have an assistant temporarily
connect the battery while the circuit is checked for
operation.
View of the fuse box cover showing the fuse identifi-
cation label. Installed view of the fusible links.
View of the fuse box.