Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 23

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 above 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, disconnect 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 considered 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 begins 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 injectors are indicated. Remove
the injectors as described later in this section to locate
the leaking injectors.

If the pressure remains steady 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.

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Fuel and Engine Management

FUEL FILTER

To Remove and Install

Refer to the Engine Tune-up section for the

procedure to remove and install the fuel filter.

FUEL PUMP

To Test Electrical Circuit

Refer to the EGI and Fuel Pump Relays heading

later in this section for the test procedures.

To Remove and Install

(1) Depressurize the fuel system as previously

described.

(2) Disconnect the negative battery terminal.
(3) Remove the rear seat backrest as described

under the Seats heading in the Body section.

(4) Remove the bolts securing the fuel pump

cover plate to the floor panel, remove the rubber
grommet and slide the cover plate from the wiring
harness.

(5) Mark the fuel hoses to ensure correct install-

lation and disconnect the hoses from the fuel pump.

(6) Remove the fuel pump retaining screws and

carefully remove the fuel pump from the fuel tank.

View of the fuel pump cover plate removed, showing

the fuel pump installed.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Ensure that a new fuel pump O ring seal is

installed.

(2) Tighten the fuel pump retaining screws and

the fuel hose clamps securely.

(3) Ensure that the rubber grommet is seated

correctly in the fuel pump cover plate.

(4) Install the fuel pump cover plate ensuring

that the arrow on the plate is facing the front of the
vehicle.

(5) Connect the negative battery terminal, start

the engine and test for leaks as previously described.
Rectify as necessary.

FUEL PRESSURE REGULATOR

To Remove and Install — 1.8 Liter Engine

(1) Depressurize the fuel system as previously

described.

(2) Disconnect the negative battery terminal.

View of the fuel pump assembly removed from the fuel

tank.

Installed view of the fuel pressure regulator. 1.8 liter

engine

.

Fuel and Engine Management

95

(3) Disconnect the vacuum hose from the pres-

sure regulator.

(4) Release the fuel hose clamps, disconnect the

hoses from the pressure regulator and remove the
pressure regulator.

Installation is a reversal of the removal procedure

ensuring that the fuel hose clamps are tightened
securely.

To Remove and Install — 1.6 Liter Engine

(1) Depressurize the fuel system as previously

described.

(2) Disconnect the negative battery terminal.
(3) Remove the air cleaner assembly. If neces-

sary, refer to the Air Cleaner Assembly heading in this
section.

(4) Remove the screws securing the pressure

regulator cover to the throttle body assembly.

When removing the final screw hold the cover

firmly as it is under spring tension.

(5) Remove the cover, spring seat, spring and

diaphragm from the throttle body assembly. Discard
the diaphragm.

View of the pressure regulator components removed

from the throttle body assembly. 1.6 liter engine.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Install a new diaphragm ensuring that

the
diaphragm is correctly seated in the groove in the
throttle body assembly.

(2) Apply Loctite 262 to the threads of the

retaining screws.

(3) Place the spring seat and the spring in the

cover and install the cover to the throttle body
assembly, ensuring that the cover is positioned on the
locating dowels.

(4) While holding the cover in position install

the
retaining screws and tighten securely.

NOTE: When installing the pressure regu-
lator cover ensure that the diaphragm is not
disturbed, to prevent the possibility of a fuel
leak.

INJECTORS

To Test Injector Circuit and Injectors

(1) Disconnect the injector wiring connectors.
(2) Connect a test lamp between the injector

wiring connector terminals, ensuring that the test
lamp probes do not contact each other.

(3) With the ignition switched On the test lamp

should not light. On 1.8 liter engines, check each of
the other connectors.

If the test lamp lights check the wiring harness for

a short to earth between the injector wiring connec-
tor(s) and the control unit wiring connector termi-
nal - D15 and D16 on 1.8 liter engines, or D16 on
1.6 liter engines.

(4) With the aid of an assistant, operate the

starter motor. The test lamp should flash. On 1.8 liter
engines, check each of the other connectors.

If the test lamp does not flash when connected to

the injector wiring connector(s), proceed to operation
(6).

If the test lamp lights as described, proceed as

follows.

If the test lamp lights but fails to flash, a faulty

control unit is indicated. Prior to renewing the control
unit, check the condition of the injectors as follows.

(5) Connect an ohmmeter between the terminals

of the injectors).

The resistance should be more than 1.2 ohms on

1.6 liter engines or more than 12 ohms on 1.8 liter
engines.

If the injector resistance is as specified, the

injector circuit can be considered serviceable.

If the injector resistance is not as specified, renew

the faulty injector(s).

(6) With the ignition switched On, probe the

injector wiring connector terminals with a test lamp to
earth.

If the test lamp lights when the probe contacts the

pink wire terminal on 1.6 liter engines, or the white
wire terminal on 1.8 liter engines, check the wiring
harness for a short to voltage between the injector
wiring connector(s) and the control unit wiring con-
nector terminal(s) D16 on 1.6 liter engines, or D15
and D16 on 1.8 liter engines.

If the test lamp does not light when the probe

contacts the blue wire terminal on 1.6 liter engines, or
the black and red wire terminal on 1.8 liter engines,
check the EGI relay and circuit as described under the
EG! and Fuel Pump Relays heading in this section.

If the test lamp lights when the probe contacts the

blue wire terminal on 1.6 liter engines, or the blue and
red wire terminal on 1.8 liter engines, proceed as
follows.

(7) Switch the ignition Off and connect the

injector wiring connectors).

(8) Switch the ignition On and, using a test lamp

to earth, backprobe the control unit wiring connector

96

Fuel and Engine Management

terminal D16 on 1.6 liter engines, or D15 and D16
on
1.8 liter engines.

The test lamp should light.

If the test lamp does not light check the wiring

harness for continuity between the injector wiring
connector(s) and the control unit wiring connector
terminals.

Repair or renew the wiring harness as necessary.

To Remove and Install Injectors and Fuel Rail — 1.8
Liter Engine.

(1) Depressurize the fuel system as previously

described.

(2) Disconnect the negative battery terminal.
(3) Thoroughly clean around the injectors and

View of the fuel rail, injectors and pressure regulator

removed from the engine.

the fuel rail to prevent foreign material entering the
engine.

(4) Suitably mark the fuel hoses, loosen the hose

clamps and disconnect the fuel hoses from the fuel
rail.

(5) Disconnect the vacuum hose from the fuel

pressure regulator.

(6) Loosen the hose clamp and disconnect the

engine ventilation hose from the throttle body.

(7) Remove the bolts securing the fuel rail and

injectors to the inlet manifold.

(8) Carefully raise the fuel rail and injectors

from the inlet manifold until the injector nozzles are
clear of the manifold.

(9) Disconnect each injector wiring connector by

pushing in the wire retaining clip.

(10) Using a small screwdriver, remove the injec-

tor retaining clip and withdraw the injectors from the
fuel rail.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Check the condition of the injector O ring

seals and renew if necessary.

(2) Install the injectors to the fuel rail and secure

with the retaining clips.

(3) Connect the wiring connectors to each injec-

tor ensuring that the wire clip is locked in position.

(4) Install the injectors to the inlet manifold,

carefully guiding the injectors into place ensuring that
the O ring seals are not damaged.

(5) Install the fuel rail retaining bolts and tighten

to the specified torque.

(6) Install the fuel hoses to the fuel rail

and
tighten the hose clamps securely.

(7) Check for fuel leaks as previously described.

To Remove and Install Injector — 1.6 Liter Engine

(1) Depressurize the fuel system as previously

described.

(2) Disconnect the negative battery terminal.
(3) Remove the air cleaner assembly. If neces-

sary refer to the heading Air Cleaner Assembly in this
section.

(4) Remove the injector retaining plate screw

and remove the injector retaining plate from the
throttle body assembly.

(5) Insert the blade of a screwdriver from the

front of the throttle body assembly under the rim of
the injector in which the retaining plate locates.
Support the screwdriver on a suitable object to act as
a fulcrum.

(6) Carefully lever the screwdriver until the

injector can be withdrawn from the throttle body
assembly.

(7) Remove and discard the upper and lower O

ring seals from the injector. If necessary remove the
lower filter screen from the injector.

NOTE: As the injector contains electrical

View of the fuel injector removed from the throttle

body assembly. 1.6 liter engine.