jump start NISSAN PULSAR 1987 Workshop Manual
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Page 11 of 238
General Information 11
Lifting Equipment
When using lifting equipment to lift heavy com-
ponents such as the engine and/or transmission, use
metal slings or chain in preference to rope. If rope
must be used, ensure that it is not placed against sharp
edges on the component.
Automotive Lubricants and Solvents
Avoid prolonged skin contact with oils, greases
and solvents as some can cause skin irritations and
dermatitis.
Exercise caution when us ing cleaning solvents as
many are inflammable. Do not smoke. Keep naked
flames and sparks clear of the work area.
Compressed Air
Never point an air hose at another person or allow
compressed air to blow onto your skin. High pressure
air forced against the skin can enter the bloodstream
and prove fatal.
Suspension and Steering Components
Damaged suspension and steering components
should not be welded. Many of these components are
fabricated from toughened metals. If welded they may
lose their strength or become brittle. Damaged com-
ponents should be renewed.
Air Conditioning
Avoid disconnecting air conditioning hoses as
escaping refrigerant can cause frostbite. The refriger-
ant is highly flammable and when burnt, a poisonous
gas is produced.
VEHICLE SAFETY
To prevent damage to the vehicle during servicing
or repair work, note the following precautions.
Brake Fluid
If spilt on the vehicle paintwork, brake fluid
should be immediately washed away with clean water
and allowed to dry naturally, not wiped with a cloth.
Catalytic Converter
The following should be observed to prevent
damage to the catalytic converter:
Do not operate the vehicle on leaded fuel.
Do not push or tow start the vehicle.
Do not allow the engine to idle for prolonged
periods.
Do not switch the ignition off while the vehicle is
in motion and the transmission is in gear.
Do not 'prime' the engine by pouring fuel into the
inlet manifold.
Do not operate the vehicle if the engine is
misfiring.
Avoid running the vehicle out of fuel.
Ensure that the engine oil is formulated to contain
low phosphorus levels.
Electronic Components
The electronic components of the ignition and
fuel injection systems can be damaged by the use of
incorrect testing equipment.
It is essential in all tests where voltage or resis-
tance is to be measured that a digital display multi-
meter with a minimum 10 megohm input impedance
be used.
Some types of tachometers, timing lights and
ignition system analyzers are not compatible with
certain engine electronic systems. It is therefore
recommended that the manufacturer of the test equip-
ment be consulted before using the equipment.
Jump starting, or being jump started by another
vehicle can cause damage to the electronic compon-
ents of the vehicle. Refer to the Roadside Trouble
shooting section for the correct jump starting proce-
dure.
3. GENERAL REPAIR PROCEDURES
SEIZED FASTENERS
Seized bolts, nuts or screws should first have a
liberal amount of penetrating oil applied. The fastener
should be left for a period of time to allow the oil to
penetrate and soften the corrosion which is causing
the binding.
Often, a sharp hammer blow to the head of the
fastener can dislodge the corrosion and permit it to be
loosened.
An impact driver, which can be fitted with a
socket or screwdriver bit, can be used to loosen a
seized fastener.
Another method is to heat the component in
which the fastener is seized. However, extreme cau-
tion should be exercised when heating aluminum
alloy components as the melting point is much lower
than that of steel.
If the above methods fail to free a seized nut,
carefully hacksaw through one side of the nut until it
can be split. Care should be taken that the threads of
the bolt or stud are not damaged.
Should a bolt or stud break below the surface of
the component, it will be necessary to use a screw
extractor to remove the remaining part. Follow the
screw extractor manuf acturers instructions.
Tap and die set and assorted screw extractors.
Page 25 of 238
25
ENGINE TUNE-UP
CAUTION: To prevent severe electrical shock, extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.
1. TUNE-UP SPECIFICATIONS
Firing orde r................................................... 1 -3-4-2
Spark plugs:
Type .............................................NGK BPR 6ES
Gap ........................................................... 1.1 mm
Tightening torque...................................... 20 Nm
Ignition timing with diagnostic link
connector jumped........................... 10 deg BTDC
Idle speed (ECU controlled):
Manual transaxle 1.8 liter ............ 850 ± 50 rpm
Manual transaxle 1.6 liter............800 ± 50 rpm
Automatic transaxle
(Park or Neutral).......................... 825 ± 50 rpm
Drive belt deflection:
Alternator ........................................... 14-16 mm
Power steering pump ......................... 14-16 mm
Air conditioner compressor .................. 9-11 mm
NOTE: When performing an engine tune-
up, a/ways compare the above Specifications
with the emission control information label
inside the engine compartment.
2. TUNE-UP OPERATIONS
Special Equipment Required:
To Test Compression — Compression gauge
TO SERVICE AIR CLEANER
The air cleaner is equipped with a paper element.
The element should be regu larly inspected but should
not be cleaned in service.
The element should be renewed every 40 000 km.
This distance is only a guide for normal operating
conditions and should be reduced accordingly if the
vehicle is operating under ex tremely dusty conditions.
NOTE: Paper air cleaner elements should
not be washed in petrol or any other type of
cleaning solvent. If the element has been
washed in solvent or has become oil soaked,
it should be discarded and a new element
installed.
1.8 Liter Engine
(1) Release the clamp securing the air intake
hose to the throttle body and disconnect the throttle
cable from the support bracket. (2) Release the clips reta ining the upper air
cleaner housing to the lowe r air cleaner housing and
raise the upper housing while disconnecting the air
intake hose from the throttle body. Remove the air
cleaner element.
The air cleaner element should be renewed at 40 000
km intervals. 1.8 liter engine.
(3) Clean the inside of the air cleaner housing
using a damp rag to remove all traces of dust and
check the upper housing and air inlet hose for cracks
and air leaks. Renew if necessary. (4) Install a new air cleaner element to the lower
housing ensuring that the element is correctly seated
around the edges. (5) Install the upper housing and lock the clips,
securing it to the lower housing. Connect the air
intake hose to the throttle body and the throttle cable
to the support bracket. Tighten the hose clamp
securely. (6) Start the engine and check the air cleaner
assembly for air leaks.
Page 30 of 238
30 Engine Tune-up
(1) With the distributor cap and leads removed
as an assembly, test one lead at a time, connecting the
meter probes at the spark plug end of the lead and at
the corresponding terminal in side the cap. Resistance
should be less than 15 000 ohms.
(2) If the resistance is more than 15 000 ohms
remove the lead from the distributor cap and check
(he resistance in the lead only. The lead should be
renewed if the resistance is still more than 15 000
ohms. (3) High distributor cap resistance may be due
to corrosion deposits on the cap terminals. These
deposits should be removed with a small scraper or
emery cloth. Check the distributor cap for cracks or tracking
between the high tension terminals on both the inside
and outside of the cap. Renew the cap if cracks or
tracking are evident.
Check the carbon brush in the centre of the
distributor cap for evidence of arcing and renew as
necessary.
Check the condition of the rotor and renew if
arced excessively or cracked.
HOW TO CONNECT ELECTRICAL TEST
EQUIPMENT
NOTE: Some types of tachometers, timing
lights and ignition system analysers are not
compatible with this type of electronic igni-
tion system and may result in incorrect
readings. It is therefore recommended that
the manufacturer of the test equipment be
consulted before using the equipment.
Do not allow the tachometer lead connec-
tor to short to earth as damage to the test
equipment or ignition system may result.
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.
Do not allow the high tension leads to open
circuit as damage to the ignition system
could result.
(2) Where necessary, connect the power leads of
the timing light to an external power source to prevent
possible transient voltages in the timing light damag-
ing the vehicle alternator.
Tachometer
(1) Ensure that the tachometer is compatible
with the vehicle ignition system. (2) Disconnect the resistor from the tachometer
View showing the location of the tachometer pickup
wiring connector with the resistor installed
.
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.
(3) Connect the negative lead to a good earthing
point.
TO CHECK AND ADJUST IGNITION TIMING
( 1 ) Connect an accurate tachometer and timing
light to the engine as previously described.
View showing the location of the diagnostic link
connector. Passengers seat removed for clarity.
Inset shows the diagnostic link connector terminal
identification.
(2) Start the engine and allow it to reach normal
operating temperature. (3) Connect a jumper lead between terminals A
and B on the diagnostic link connector. (4) With the engine idling at the specified speed,
check the ignition timing with the timing light.
Correct timing exists when the marks on the
crankshaft pulley are aligned with the pointer on the
inner timing cover.
Page 32 of 238
![NISSAN PULSAR 1987 Workshop Manual
32
ROADSIDE TROUBLE SHOOTING
CAUTION: To prevent severe electrical shock extreme care must be taken w\
hen
working on or near the electronic ignition system as dangerous high tension voltages
are](/img/5/57382/w960_57382-31.png "NISSAN PULSAR 1987 Workshop Manual
32
ROADSIDE TROUBLE SHOOTING
CAUTION: To prevent severe electrical shock extreme care must be taken w\
hen
working on or near the electronic ignition system as dangerous high tension voltages
are")
32
ROADSIDE TROUBLE SHOOTING
CAUTION: To prevent severe electrical shock extreme care must be taken w\
hen
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.
This section deals with the common causes of
engine failure to start, as inevitably there will come a
time when every driver will experience this problem
and will therefore need to call upon his own resources
to rectify the trouble. Roadside breakdowns other
than engine failure can be identified by reference to
the Trouble Shooting section on the particular com-
ponent affected.
1. TROUBLE SHOOTING
Trouble shooting is only a process of elimination
and provided the procedure is carried out correctly
and systematically an accur ate diagnosis of the trouble
can be made in the minimum amount of time.
For an internal combustion engine to run there
are three basic requirements, these are ignition, fuel
and compression. There are other factors of course
but as a rule an engine's failure to start can be
attributed to a fault in one of these three systems.
Reports from field engineers of motoring organi-
sations prove that the bigg est percentage of engine
breakdowns are in the order of ignition or electrical
failure first, followed by fuel, with mechanical or
compression failure the least common.
Should the engine fail to start, first check that
there is adequate fuel in the tank and if so. carry out
the following checking procedures in the order de-
scribed.
TO JUMP START A VEHICLE
NOTE: Jump starting a vehicle can be
dangerous if the procedure described below
is not performed correctly. If any doubt
exists, it is recommended that the services of
a competent mechanic be obtained.
The vehicles covered by this manual are
equipped with complex electronic circuitry
which can be damaged by voltage surges.
These voltage surges can be generated when
jump starting, or being jump started by
another vehicle. If av ailable use jumper
leads equipped with a surge protection de-
vice and follow the lead manufacturers in-
structions carefully, particularly regarding
the connection and disconnection of the
leads.
(1) Ensure that the booster battery is 12 volts
and the negative terminal is earthed.
(2) Ensure that the vehicles are not touching and
that the ignition and all accessories on both vehicles
are switched Off. (3) Ensure that the transmissions on both vehi-
cles are in Park or Neutral and the handbrakes are
firmly applied. (4) Remove the vent caps from the battery and
check the electrolyte level. Replenish with distilled
water as necessary.
View showing the correct jumper lead connections for
jump starting a vehicle. The leads shown are equipped
with a surge protection device.
Page 33 of 238
Roadside Trouble Shooting
(5) Place the vent caps loosely over the cell
apertures.
(6) Connect one end of the red jumper lead to
the positive ( + ) battery terminal of the booster
battery and the other end of the red lead to the
positive (+) battery terminal of the discharged bat-
tery.
NOTE: The battery emits hydrogen gas
which is explosive. Do not expose the battery
to naked /lames or sparks.
Do not lean over the battery when con-
necting the jumper leads.
Do not allow the ends of the jumper leads
to touch one another or any part of the
engine.
(7) Connect one end of the black juniper lead to
the negative (-) battery terminal of the booster
battery and the other end of the black lead to a good
earthing point on the engine of the vehicle with the
discharged battery.
NOTE: Do not connect the jumper lead
directly to the negative (-) battery terminal
of the discharged battery.
(8) Start the engine on the vehicle with the
booster battery and run the engine at a moderate
speed. (9) Start the engine on the vehicle with the
discharged battery.
(10) If possible, leave the engines of both vehi-
cles running for 10 minutes.
(11) Disconnect the jumper leads in the reverse
order of the sequence in which they were connected.
2. TO CHECK IGNITION AND ELECTRICAL SYSTEM
(1) Switch on the ignition and check for warning
lamp illumination on the dashboard. (2) Operate the starter and check that the starter
rotates the engine at a steady speed.
(3) Switch on the headlamps and check for good
light intensity. Should the lamps not illum inate or the starter
motor not turn the engine, carry out the following
steps:
(a) Remove the battery terminals and clean both
terminals and posts. Connect the terminals and where
applicable tighten firmly but not excessively.
(b) Check that the earth lead from the battery to
the engine or body frame is not broken and that the
connections are clean and secure. . (c) Check that the lead from the battery to the
starter motor or starter solenoid is intact and has a
clean and secure connection.
Ensure that the battery posts and terminals are clean.
(d) Where necessary carry out repairs to (b) and
(c).
Repeat the check procedur e. Should the starter
motor still not operate, or the lamps not illuminate,
one or more of the following faults may be the cause:
No starter motor operation or lamps: Battery flat
or defective.
Lamps illuminate but no starter operation: Starter
motor drive jammed in mesh with flywheel ring gear.
Starter motor or solenoid defective. Ignition/starter
switch faulty. On automatic transaxle models, faulty
neutral safety switch.
Lamps dim and starter operation sluggish: Dis-
charged battery or fault in starter motor. Battery flat
due to broken fan belt or de fective alternator. Faulty
battery due to cell breakdown.
NOTE: Electronic ignition systems can pro-
duce dangerously high voltages in both the
primary and secondary circuits. For this
reason, extreme care must be taken when
performing these checks. When disconnect-
Securely earth the body of a test spark plug to check
for sparks at the spark plug leads.
Page 34 of 238
Roadside Trouble Shooting
ing the wiring from any component, ensure
that the ignition switch is off and the
negative battery terminal is disconnected to
prevent damage to the solid state circuitry.
(4) Open the electrode gap of a serviceable spark
plug to 6 mm. Securely earth the plug using a jumper
lead or by tying the plug to an earthed engine
component.
(5) Disconnect the high tension lead from a
spark plug and connect it to the test spark plug.
(6) Have an assistant operate the starter motor.
(7) Check that a spark, if any, jumps the gap on
the test spark plug. If the spark is satisfactory, proceed to operation
(8).
If there is no spark, proceed as follows:
(a) Check the high tension leads to ensure that
they are dry and that the insulation is not cracked or
perished. Check the ends of the leads for burning. Using an ohmmeter, measure the resistance in
each high tension lead. The resistance should be no
more than 15 000 ohms per lead.
(b) Check the distributor cap to ensure that it is
dry and clean. Examine both the inside and outside of
the cap for cracks or tracki ng, particularly between the
high tension lead segments.
Check that the carbon brush in the centre of the
distributor cap interior fa ce is clean and dry and
ensure that the brush moves freely in and out of its
locating hole.
(c) Check the rotor arm for cracks, deposits and
burning on the metal arm. (d) Ensure that the high tension leads have dry.
clean and secure connections on the distributor cap. (8) If the above checks r esult in a good spark at
the spark plug high tension leads but the engine is still
not operating satisfac torily, remove all the spark plugs
and check the condition and electrode gap as de-
scribed in the Engine Tune-up section under the
appropriate heading.
3. TO CHECK FUEL SYSTEM
Due to the complex nature of the EFI system, it is
recommended that should the following checks prove
satisfactory but the engine fail to start, reference be
made to the Fuel and Engine Management section of
this manual or a Nissan workshop be consulted.
(1) Check that the fuel tank contains a reason-
able amount of fuel. (2) Have an assistant switch the ignition on and
off while squeezing the fuel supply hose with the
fingers. If the fuel pump is operating it should be
possible to feel the fuel pr essure increase for approx-
imately two seconds.
NOTE: When conducting the above test it
should be possible to hear the fuel pump and
ignition relays clicking when the ignition is
switched on and off
If the fuel pump relay fails, power will be
supplied to the fuel pump via the oil pressure
Check the distributor cap for cracks or tracking between the terminals. Squeeze the fuel supply hose while the ignition is
switched On. An increase in pressure should be felt.
Check the spark plug high tension leads for cracks and
burnt or corroded terminals.
Page 74 of 238
74 Cooling and Heating Systems
NOTE: Refer to the Fuel and Engine Man-
agement section for the correct procedure for
backprobing the control unit.
(3) In operation (1) if the cooling fan is station-
ary proceed as follows:
(a) Connect a jumper lead between the terminals
A and B of the diagnostic link connector. (b) if the fan runs, the fan circuit is satisfactory.
If the engine is overheating check the coolant temper-
ature sensor as described in the Fuel and Engine
Management section under the appropriate codes. (c) If the fan does not run, check the fuse (6) and
the fusible link (4) show n on the illustration.
(d) Backprobe terminal C1 at the electronic
control unit using an LED t est lamp connected to the
positive battery terminal. If no circuit exists, renew
the electronic control unit. (e) If the fuse and fusible links are serviceable,
ensure that power is available at the white and pink
wires from the fuse and fusible link of the cooling fan
relay. Repair any faults in the wiring to that point if
necessary. (f) Switch the ignition Off. disconnect the
cooling fan wiring connector at the radiator and
connect power to the fan. Renew the fan if it does not
run.
(4) On air conditioned models, remove the
jumper lead from the ALDL connector if still in-
stalled, start the engine and allow it to idle. Switch the
air conditioning on and ensu re that the cooling fan
runs.
If the cooling fan is opera ting as described above
but cooling system problems still exist, refer to the
Trouble Shooting heading at the start of this section.
TO REMOVE AND INSTAL COOLING FAN
(1) Disconnect the negative battery terminal.
(2) Disconnect the cooling fa n and, if applicable,
the air conditioning fan wiring connectors at the
upper edge of the radiator. (3) On models with air conditioning, remove the
compressor hose bracket bolt from the centre of the
radiator support panel.
Dismantled view of the fans and the shroud assembly. Air conditioned model.
Page 91 of 238
Fuel and Engine Management 91
components, erase the self diagnosis memory as
described under the following heading.
(7) Repeat the self diagnosis test procedure and
ensure that code 12 is displayed.
To Erase Memory
(1) With the ignition Off, remove the fusible link
that is positioned third from the front of the fusible
link connecting block located at the rear of the
battery. (2) Install the fusible link after 10 seconds.
View showing the location of the fusible links.
TO CHECK AND ADJUST IGNITION TIMING
(1) Connect a timing light to the engine as
previously described under the Service Precautions
and Procedures heading.
(2) Start the engine and allow it to reach normal
operating temperature. (3) Connect a jumper lead between terminals A
and B on the diagnostic link connector. (4) With the engine idling at the specified speed,
check the ignition timing with the timing light.
The timing mark on the crankshaft pulley should
be aligned with the pointer on the inner liming belt
cover.
(5) If necessary, loosen the distributor body
retaining nuts and turn the distributor until the timing
marks are aligned. (6) Tighten the distributor body retaining nuts
and check that the timing is correct. (7) Remove the jumper lead from the diagnostic
link connector and disconnect the timing light from
the engine.
TO ADJUST BASE IDLE SPEED
NOTE: The idle speed is controlled by the
idle air control (IAC) valve and is not
adjustable. The throttle stop screw controls
the base idle speed a nd is factory set. The
following base idle speed adjustment should
only be performed if the throttle body has
been renewed, or if comprehensive testing of
related components indicates that adjust-
ment is required.
(1) Before adjusting the base idle speed perform
the following tests;
(a) Check the spark plug gaps, the high tension
leads and the ignition timin g as described previously
in the Engine Tune-up section.
(b) Check the air inlet syst em for leaks between
the throttle body and inlet manifold and the inlet
manifold and cylinder head.
NOTE; Any vacuum leaks will make the
engine idle faster than it should.
(c) Check that all wiring connectors and vacuum
hoses are securely connected. (d) Ensure that the transaxle is in Park or
Neutral. (e) Ensure that the air cleaner element is service-
able.
(2) On 1.6 liter engines, remove the air cleaner
assembly, disconnect the vacuum hose from the
throttle body and seal the vacuum hose fitting.
(3) Ensure that the throttle valve moves freely
and returns to the fully closed position when slowly
released. (4) Connect an accurate tachometer to the en-
gine as previously descri bed under the Service Pre-
cautions and Procedures heading.
(5) Start the engine and allow the engine to
warm up and the idle rpm to stabilize. Check that all
electrical accessories and the air conditioning, if
equipped, are turned off. (6) With the engine idling in Park or Neutral,
slowly disconnect the brake servo unit vacuum supply
hose from the inlet manifold. Allow the engine to run
for one minute.
Location of the base idle adjusting screw. 1.8 liter
engine.
Page 92 of 238
92 Fuel and Engine Management
Installed view of the throttle body assembly showing
the location of the base idle adjusting screw. 1.6 liter
engine.
(7) Disconnect the IAC valve wiring connector
and slowly connect the vacuum supply hose to the
inlet manifold. Allow five seconds to elapse and note
the engine speed.
(8) If the engine speed is not to Specifications,
remove the plug from the throttle body housing on 1.6
liter engines, or the cap from the base idle adjusting
screw on 1.8 liter engines, and adjust the idle screw
until the engine speed is 625 rpm. (9) Stop the engine and connect the IAC valve
wiring connector. (10) On 1.8 liter engines, install a new cap to
the
base idle adjusting screw.
On 1.6 liter engines, seal the throttle stop screw
with silicone sealant and install the air cleaner assem-
bly.
(11) Erase the memory codes as previously de-
scribed.
(12) Start the engine and increase the speed to
3 000 rpm for 10 seconds to allow the idle air control
valve to reset.
5. FUEL SUPPLY COMPONENTS
Special Equipment Required:
To Check Fuel Pressure — 0-500 kPa pressure
gauge
NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.
TO DEPRESSURISE FUEL SYSTEM
(1) Lift the front edge of the rear seat cushion on
each side, slide the cushion forward and remove it
from the vehicle. (2) Disconnect the fuel pump wiring harness
connector.
When depressurizing the fuel system, remove the rear
seat cushion and disconnect the fuel pump wiring
connector.
(3) Start and run the engine until it stalls.
Operate the starter motor for 10 seconds to ensure
that the pressure has dissipated.
(4) Connect the fuel pump wiring connector and
install the rear seat cushion.
NOTE: Failure to depressurize the fuel sys-
tem when instructed may result in a fuel
spray and possible fire.
TO TEST FOR EXTERNAL LEAKS
(1) Connect a jumper lead between terminals G
and H on the diagnostic link connector.
(2) Switch the ignition On.
(3) Check for leaks at all hose connections and
joints between the fuel pump and the engine. (4) Switch the ignition Off and remove the
jumper lead from the diagnostic link connector.
(5) If renewal of a component is necessary,
depressurize the fuel system as previously described. (6) Use only hoses and clamps as specified by
the manufacturer.
TO CHECK FUEL PRESSURE
(1) Depressurize the fuel system as previously
described. (2) On 1.6 liter engines, remove the air cleaner
as described in this section under the Air Cleaner
Assembly heading. (3) On 1.8 liter engines, release the hose clamp
securing the fuel supply hos e to the fuel rail and
disconnect the hose. On 1.6 liter engines, release the hose clamp
securing the fuel supply hose to the rear throttle body
hose fitting and disconnect the hose.
(4) Using a suitable gauge, tee piece, short piece
of fuel hose and clamps, install the pressure
gauge
between the fuel supply ho se and the fuel rail on 1.8
Page 93 of 238
Fuel and Engine Management 93
liter engines, or the throttle body hose fitting on 1.6
liter engines.
(5) Tighten all connectors securely. Check for
external leaks as previously described. (6) Start the engine and note the pressure while
the engine is idling.
(7) Switch the engine Off and check that the
residual pressure does not decrease.
If the fuel pressure is within Specifications and
does not decrease, the fuel system is in a serviceable
condition. Depressurize the fuel system and discon-
nect the pressure gauge.
If the fuel pressure is a bove Specifications proceed
to operation (9).
If the fuel pressure is below Specifications proceed
to the following operation.
If the fuel pressure decreases, an internal leak is
indicated. Proceed to the following heading and carry
out the test procedure.
Testing the fuel system pressure using a pressure
gauge. 1.8 liter engine.
NOTE: There may be a small initial de-
crease in pressure when the engine is
switched Off This is acceptable and does not
indicate a fault in the system.
(8) If the fuel pressure is below Specifications
proceed as follows:
(a) Check the fuel lines for blockages and kinks
or a blocked fuel filter or fuel pump pickup strainer. (b) If no fault can be found in the previous
checks, on 1.8 liter engines clamp the fuel return hose
at the fuel rail. On 1.6 liter engines, clamp the hose that is
connected to the front throttle body hose fitting.
(c) Connect a jumper lead between terminals G
and H on the diagnostic link connector and switch the
ignition On.
NOTE: Do not operate the fuel pump for
longer than is necessary to obtain a pressure
reading.
If the fuel pressure is less than 270 kPa on 1.8 liter
engines or 90 kPa on 1.6 liter engines, renew the fuel
pump.
If the fuel pressure is more than previously
specified, renew the pressure regulator assembly on
1.8 liter engines or the pressure regulator diaphragm
on 1.6 liter engines.
(9) If the fuel pressure in operation (6) is above
Specifications, proceed as follows:
(a) On 1.8 liter engines, disconnect the fuel
return hose from the pressure regulator outlet.
On 1.6 liter engines, disc onnect the fuel return
hose from the front throttle body hose fitting.
(b) Connect a suitable length of fuel hose to the
pressure regulator or the front throttle body hose
filling and place the opposite end of the hose into a
petroleum resistant container. (c) Connect a jumper lead between terminals G
and H on the diagnostic link connector and switch the
ignition On. If the fuel pressure is 230-270 kPa on 1.8 liter
engines or 62-90 kPa on 1.6 liter engines, locate and
remove the restriction in the fuel return hose or pipe.
If the fuel pressure is more than previously
specified, renew the pressure regulator assembly on
1.8 liter engines or the pressure regulator diaphragm
on 1.6 liter engines.
TO TEST FOR INTERNAL FUEL LEAKAGE
Check the residual fuel pressure as previously
described.
If the pressure has decreased it is an indication of
an internal leak. With the pressure gauge still at-
tached, proceed as follows:
(1) Switch the ignition On to pressurize the fuel
system.
(2) As the pressure begins to decrease clamp the
fuel supply hose shut. If the pressure remains steady
the fuel pump may be consid ered faulty and should be
renewed as described later in this section. (3) If the pressure continues to decrease switch
the ignition On after it has been Off at least 10
seconds. As the pressure begi ns to decrease clamp the
fuel return hose shut. If the pressure remain steady on 1.8 liter engines,
renew the pressure regulator. If the pressure continues
to decrease, leaking inject ors are indicated. Remove
the injectors as described later in this section to locate
the leaking injectors.
If the pressure remains stea dy on 1.6 liter engines,
renew the pressure regulator diaphragm as described
later in this section. If the pressure continues to
decrease remove the injector and renew the O ring
seals as described later in this section. If this fails to
rectify the fault remove the injector and clean or
renew the injector as necessary.