instrument cluster NISSAN PULSAR 1987 Workshop Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 4 of 238
FRONT SUSPENSION............................ 156
Specifications......................................................... 156
Front suspension tr ouble shooting ........................ 156
Description ............................................................ 157
Steering knuckle.................................................... 157
Suspension unit..................................................... 159
Control arm ........................................................... 161
Stabiliser bar ........................................................ 162
Suspension and steering angles .......................... 163
REAR SUSPENSION................................ 164
Specifications ........................................................ 164
Rear suspension tr ouble shooting ........................ 164
Description ............................................................ 165
Rear hub ............................................................... 166
Suspension unit .................................................... 167
Control arm ........................................................... 169
Knuckle assembly.................................................. 170
Stabiliser bar ........................................................ 170
Rear wheel alignment ........................................... 171
BRAKES...................................................... 172
Specifications......................................................... 172
Brakes trouble shooting ........................................ 172
Description ............................................................ 174
Master cyli nder...................................................... 175
Brake servo unit .................................................... 177
Front brakes ......................................................... 178
Rear disc brakes................................................... 181
Rear drum brakes ................................................. 184
Handbrake cable and le ver assembly ................... 186
Brake adjustments ................................................ 187
Brake pedal ........................................................... 187
Hydraulic system................................................... 188
ELECTRICAL SYSTEM............................ 190
Specifications......................................................... 190
Battery and charging system trouble shooting ....... 190
Battery and starting system trouble shooting ........ 191
Lighting system trouble shooting ........................... 192
Turn signal lamp trouble shooting ........................ 192
Test equipment and so me applications................. 193
Battery ................................................................... 194
Alternator ............................................................... 196
Starter motor ......................................................... 201
Ignition system ...................................................... 206
Steering wheel ....................................................... 206
Switches and controls........................................... 206
Instrument cluster.................................................. 209
Blower fan .............................................................. 209
Radio/cassette...................................................... 209
lamp units ............................................................ 210
Windscreen wiper ................................................. 213
Fuses, fusible links and relays ............................. 215
Trailer wiring ......................................................... 216
Wiring diagrams ................................................... 218
BODY........................................................... 225
Windscreen and re ar glass .................................. 225
Front doors ........................................................... 225
Rear doors............................................................ 228
Engine bonnet...................................................... 231
Tailgate and lock — hatchback ............................ 231
Luggage compartment lid and lock — sedan ........ 233
Radiator grille.............................................................. 234
Centre console...................................................... 234 Dashboard ............................................................ 235
Scat belts ............................................................. 236
Seats .................................................................... 236
Vehicle cleaning ........................................................... 237
CONVERSION TABLES.......................... 238
Page 85 of 238
Fuel and Engine Management 85
View of the 1.6 liter engine showing the engine management components. Air cleaner removed for clarity.
series of tests on various components in the system
and records the results, If a fault is discovered, the
ECM warning lamp on the instrument cluster will
illuminate while the engine is running. When the self
diagnosis mode is activated, the ECM warning lamp
will flash codes indicating the area in which the fault
has occurred.
This function is very useful in locating system
faults, particularly intermittent problems. However,
the self diagnosis mode does not provide comprehen-
sive testing of the EFI system, and therefore should
always be used in conjunction with the other test
procedures described later in this section in order to
accurately locate system faults.
The high energy electronic ignition system con-
sists of a distributor and an ignition coil.
The distributor has two functions. The first is to
produce and distribute secondary high tension voltage
to the spark plugs.
The second function is to provide the control unit
with information on engine speed and crankshaft
position.
The ignition timing is constantly adjusted by the
control unit to suit varying engine and vehicle oper-
ating conditions.
In the fuel injection system, a metered amount of
fuel is sprayed into the air stream. The air/fuel
mixture then enters the combustion chamber via the
inlet valves.
On 1.6 liter engines, the fuel is injected by a single
injector, located above the throttle valve within the
throttle body assembly. The injector fires twice per
engine revolution under most operating conditions.
On 1.8 liter engines, four injectors are used. The
fuel is distributed to the injectors via the fuel rail. All
injectors fire simultaneous ly once per engine revolu-
tion under most operating conditions.
Under conditions of high load the control unit
may signal the injector(s) to fire more often. However,
if the engine speed exceeds 6 700 rpm the control unit
will cease firing the injectors until the engine speed is
below 6 200 rpm.
Fuel is supplied under pressu re by an electric fuel
pump mounted in the fuel tank and the pressure is
regulated by a pressure regulator.
On 1.6 liter engines, the regulator consists of a
spring tensioned diaphragm which is mounted to the
side of the throttle body assembly. The fuel pressure is
regulated by the tension of the spring against the
diaphragm, opening and closing the fuel return port.
On 1.8 liter engines, the pressure regulator is
mounted adjacent to the fuel rail and consists of a
diaphragm with fuel pressu re acting on one side and
spring tension and manifold vacuum acting on the
Page 89 of 238
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.
Page 90 of 238
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.
Page 108 of 238
108 Fuel and Engine Management
Installed view of the control unit with the passengers seat removed.
(2) Secure the Mem-Cal unit retaining clips.
Ensure that the clips locate into the Mem-Cal unit. (3) When installing a new control unit, transfer
the identification and bar code label to the new
control unit. (4) Ensure that the control unit wiring connec-
tors are securely installed to the control unit. (5) Activate the self diagnosis codes. If code 51
is displayed or the Check Engine warning lamp is
constantly illuminated, the Mem-Cal unit is not fully
installed. If the Mem-Cal uni t is installed correctly, a
fault in the Mem-Cal unit is indicated. Renew the
Mem-Cal unit as previously described.
To Check Power Supply and Earth Circuit
(1) Disconnect the control unit wiring connec-
tors and check for voltage at terminals B1 and C16.
If there is no voltage check the fusible link which
is located third from the front in the fusible link
connecting block. If the fu sible link is serviceable,
repair the open circuit in the wiring harness.
(2) Check for continuity to earth on terminals
A12, D1, D6 and also D3 and D10 on 1.8 liter
engines.
If there is no continuity check the earth connec-
tions at the right hand rear cylinder head bolts. If the
connections are clean and secure, repair the open
circuit in the wiring harness.
MEM-CAL UNIT
To Test - Code 51
If code 51 is displayed during the self diagnosis
test procedure, pr oceed as follows:
(1) Check that the Mem-Cal unit is fully inserted
in the control unit. (2) Erase the fault code memory and retest for
fault codes. (3) If code 51 is still displayed, renew the
Mem-Cal unit.
(4) Erase the fault code memory and retest for
fault codes. (5) If code 51 is still displayed, renew the control
unit.
To Remove and Install
The Mem-Cal unit is incorporated within the
control unit. Refer to the previous heading for the
removal and installation procedure.
FUEL PUMP AND EGI RELAYS
To Remove and Install
(1) Disconnect the negative battery terminals.
(2) Remove the fuse panel cover which is lo-
cated adjacent to the steering column under the
instrument cluster. (3) Remove the spare fuse holder from the fuse
panel and remove the releva nt relay from the connec-
tor. Installation is a reversal of the removal procedure.
View showing the location of the EGI and fuel pump
relays.
To Test Relays
NOTE: When testing the fuel pump relay
circuit ensure that th e EGI relay is service-
able and installed to the relay connector
(1) Remove the relevant relay as previously
described. (2) Using an ohmmeter, check for continuity
between terminals 1 and 2, and 3 and 5. Continuity should exist be tween terminals 1 and 2
but should not exist between terminals 3 and 5.
(3) Using suitable jumper leads, apply 12 volts
to terminal 1 and connect terminal 2 to a good earth
point. (4) Connect the ohmmeter between terminals 3
and 5. Continuity should exist. If continuity does not
exist, renew the relay.
Page 115 of 238
Fuel and Engine Management 115
Erase the fault codes and retest for fault codes as
follows:
(2) Start and run the engine until normal oper-
ating temperature is attained. (3) Drive the vehicle at a speed of at least 80
km/h and, with the throttle closed, allow the vehicle to
decelerate until the engine speed is below 1 500 rpm.
NOTE: After rectifying any fault it will be
necessary to retest for fault codes. To test for
Code 24 the vehicle must be driven as
previously described.
(4) Switch the engine Off and connect a jumper
lead between terminals A and B on the diagnostic link
connector. Switch the ignition On and note the fault
codes. If code 24 is displayed proceed as follows. (5) Check the operation of the speedometer and
the instrument cluster warning lamps. If the speed-
ometer only is not functioning, proceed to operation
(13).
If the speedometer and the instrument cluster
warning lamps are not functioning, a fault in the
instrument cluster wiring harness is indicated. Refer
the fault to an auto electrical workshop or a Nissan
dealer.
If the speedometer is functioning, proceed as
follows:
(6) Raise the front of the vehicle and support it
on chassis stands. (7) Place the transaxle in Neutral and switch the
ignition On. (8) With the aid of assistants, slowly spin the
front wheels by hand while backprobing the control
unit wiring connector terminal A10 with a digital
voltmeter to earth. The voltage should alternate from under 1 volt to
over 10 volts.
If the voltmeter readi ng is not as specified,
proceed to operation (9).
If the voltmeter reading is as specified, the vehicle
speed sensor is operating satisfactorily, indicating an
intermittent fault was the cause of the fault code.
Proceed as follows:
(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth c onnections are secure.
(9) Remove the instrument cluster as described
in the Electrical System section. (10) With the ignition switched On, backprobe
the control unit wiring connector terminal A10 with a
voltmeter to earth. The voltage should be over 10
volts. If the voltage is less than specified, check the
wiring harness for shorts to earth between the black
and yellow wire terminal on the instrument cluster
wiring connector and the control unit connector
terminal A10. Repair or renew the wiring harness as
necessary. If no fault can be found, renew the control
unit.
(11) With the ignition switched On, backprobe
the black and yellow wire terminal on the instrument
cluster wiring connector with a voltmeter to earth.
The voltage should be over 10 volts.
If the voltage is less than specified, locate the open
circuit between the instrument cluster black and
yellow wire terminal and the control unit wiring
connector terminal A10. Repair or renew the wiring
harness as necessary.
(12) With a test lamp connected to 12 volts,
backprobe the black wire terminals on the instrument
cluster wiring connectors. The test lamp should light.
If the test lamp does not light locate the open
circuit between the black wire terminals and earth.
Repair or renew the wiring harness as necessary.
If the test lamp does light, renew the signal
divider circuit board which is located in the instru-
ment cluster.
(13) With the ignition switched On and the
engine not running, disconnect the vehicle speed
sensor wiring connector from the harness connector.
(14) With a test lamp connected to earth, probe
the yellow wire terminal on the harness wiring con-
nector. The test lamp should light. If the test lamp does not light, locate the open
circuit between the yellow wi re terminal and the Fuel
Pump fuse. Repair or renew the wiring harness as
necessary.
(15) With a test lamp connected to 12 volts,
probe the black wire terminal on the harness wiring
connector. The test lamp should light.
If the test lamp does not light, locate the open
circuit between the black wire terminal and earth.
Repair or renew the wiring harness as necessary.
(16) Using a voltmeter measure the voltage at the
red wire terminal on the harness wiring connector.
If the voltage is 5-9 volts proceed to operation
(19).
If the voltage is over 9 vol ts proceed to operation
(18).
Installed view of the vehicle speed sensor.
Page 116 of 238
116 Fuel and Engine Management
Rear view of the instrument cluster showing the flexible printed circuit.
If the voltage is under 5 volts proceed as follows.
(17) Check the wiring harness for continuity or
shorts to earth between th e red wire terminal on the
speed sensor harness connector and the green and
black wire terminal on th e instrument cluster wiring
connector.
If no fault can be found check the instrument
cluster printed circuit for continuity or shorts. If no
fault can be found, renew the speedometer and the
signal divider circuit board.
(18) Remove the instrument cluster as described
in the Electrical System se ction and repeat operation
(16).
If the voltage is under 1 volt, check the flexible
printed circuit on the rear of the instrument cluster for
continuity or shorts and re new as necessary. If no fault
can be found, renew the speedometer and the signal
divider circuit board.
(19) Connect the harness connector to the vehicle
speed sensor wiring connector. (20) Raise the front of the vehicle and support it on chassis stands. Place the transaxle in Neutral.
(21) With the aid of assistants, slowly spin the
front wheels by hand while backprobing the brown
wire terminal on the vehicle speed sensor wiring
connector with a voltmeter to earth.
The voltage should alternate between approxi-
mately 1 and 7 volts.
If the voltage is as specif ied, check the flexible
printed circuit on the rear of the instrument cluster for
continuity or shorts. If no fault can be found, renew
the speedometer and the signal divider circuit board.
If the voltage is not as specified, proceed as
follows.
(22) Disconnect the vehicle speed sensor wiring
connector and unscrew the sensor from the speedom-
eter drive housing. (23) Rotate both front wheels in the same direc-
tion and check that the speedometer drive shaft is
turning and does not slip. If the drive shaft does not operate as described,
renew the drive assembly as described in the Manual
or Automatic Transaxle section.
If the drive shaft operates satisfactorily, renew the
vehicle speed sensor.
To Remove and Install
(1) Disconnect the negative battery terminal.
(2) Disconnect the vehicle speed sensor wiring
connector. (3) Unscrew the vehicle speed sensor from the
speedometer drive housing.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Align the cut-out in the speedometer drive
shaft with the notch in the vehicle speed sensor shaft.
(2) Tighten the vehicle speed sensor securely.
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.