drain bolt NISSAN PULSAR 1987 User Guide
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 76 of 238
Cooling and Heating Systems
7. THERMOSTAT HOUSING
Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) On 1.6 liter models, remove the air cleaner
assembly from the engine. Refer to the Fuel and
Engine Management section if necessary. (3) Drain the cooling system as previously de-
scribed. (4) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (5) Remove the bolts retaining the camshaft
drive belt rear cover to the cylinder block and remove
the rear cover.
\ COOLANT TEMPERATURE SENSOR TEMPERATURE SENDER SWITCH
View of the thermostat housing and
components.
(6) Disconnect the top radi ator hose, the heater
hose and the inlet manifold heater hose from the
thermostat housing.
(7) Disconnect the wire from the temperature
sender switch and the coolant temperature sensor. (8) Remove the bolts retaining the thermostat
housing to the cylinder head and remove the thermo-
stat housing and the O ring from the cylinder head. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure that all mounting faces are clean.
(2) Renew the O ring on installation.
NOTE; Ensure that the O ring is not
twisted. Do not use sealant.
(3) Tighten the thermostat housing retaining
bolts to the specified torque. (4) Adjust the camshaft drive belt tension as
described in the Engine section under the heading
Camshaft Drive Belt. (5) Fill the cooling system as previously de-
scribed and check for coolant leaks. 8. WATER PUMP
Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
NOTE: The water pump is non-repairable
and if faulty must be renewed as a complete
assembly.
(1)
Drain the cooling system as previously de-
scribed.
(2) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (3) Remove the water pump retaining bolts and
remove the water pump and the O ring from the
engine. Installation is a reversal of the removal procedure
with attention to the following points:
View of the water pump and components removed
from the vehicle.
(1) Ensure that all mounting faces are clean.
(2) Use a new O ring and smear it with a liberal
amount of silicone grease.
(3) Install the water pump to the engine but
do
not tighten the retaining bolts until the camshaft drive
belt has been installed and tensioned correctly as
described in the Engine section under the heading
Camshaft Drive Belt.
(4) Fill the cooling system as previously de-
scribed in this section and check for coolant leaks.
9. WELCH PLUGS
To facilitate the casting of the cylinder block and
cylinder head passages and water jackets, a number of
openings had to be ma de at manufacture.
Page 78 of 238
78 Cooling and Heating Systems
The air conditioner operates only when the engine
is running as the compressor is belt driven from the
engine.
Operating the air conditioner with the tempera-
ture control raised to a hot setting will produce
dehumidified hot air which is particularly useful for
demisting the vehicle glass.
Maximum cooling is achieved by operating the air
conditioner with the temperature control lowered
fully to the coldest setting . Operate the fan at high
speed when using the coldest temperature setting to
avoid forming ice on the evaporator.
TO REMOVE AND INSTAL HEATER UNIT
(1) Remove the dashboard as described in the
Body section. (2) Drain the cooling system as previously de-
scribed in this section. (3) Loosen the hose clamps and disconnect the
heater hoses from the heater pipes.
NOTE: If the heater hos es will not come off
the heater pipes, do not use excess force or
the heater core retaining strap will be dam-
aged. Cut the hoses from the heater pipes.
(4) Remove the steering column upper mount-
ing bolts. (5) Remove the steering column cross support
bolts and move the support towards the right hand
side of the vehicle. (6) Remove the centre support retaining bolts
and remove the centre support from the vehicle.
(7) Remove the demister duct and the right
hand side ventilator duct from the vehicle. (8) Disconnect the blower fan wiring connector
from the rear of the heater controls. (9) Remove the heater retaining bolts.
(10) On models with air conditioning, it will be
necessary to loosen the evaporator mounting bolts. (11) Working in the engine compartment, push
the heater pipe grommet through the bulkhead. (12) Maneuver the heater unit upwards slightly
and out from the bulkhead using care not to damage
the heater pipes. (13) To remove the heater core and tap assembly,
remove the screws from the retaining strap and slide
the heater core from the heater unit.
Installation is a reversal of the removal procedure
with attention to the following points:
(1 ) Before installing the heater unit to the
View of the heater unit with the dashboard, centr e support, demister duct and right hand ventilator
duct removed.
Page 80 of 238
Cooling and Heating Systems
11. BLOWER FAN
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working below the glov e compartment, dis-
connect the wiring connector to the blower fan motor.
(3) Remove the bolts retaining the blower fan
motor and carefully lower the motor while disconnect-
ing the drain hose.
Installation is a reversal of the removal procedure
with attention to the following points:
( t ) Tighten all bolts securely.
(2) Check that the blow er fan operates correctly.
Dismantled view of the blower fan and associated
components.
12. AIR CONDITIONING
DESCRIPTION
The air conditioning system, when used in con-
junction with the heater, enables any reasonable tem-
perature to be achieved inside the vehicle. It can also
reduce the humidity of the incoming air, aiding
demisting even when cooling is not required.
The basic components of the air conditioning sys-
tem are an evaporator, co ndenser, compressor, re-
ceiver/dryer, expansion valve and pipes and hoses
carrying the refrigerant through the system. Various
subsidiary controls and sensors are also utilized to
protect the system against low or high pressure and
excessive temperature.
The refrigerant will boil at a very low tempera-
ture (-33 deg C) and therefore must be contained
under pressure. Escaping refrigerant can cause frost-
bite and eye damage and will produce a poisonous gas
when burnt. Also, if the system suffers a rapid loss of
refrigerant, oil from the compressor may be carried
out with the refrigerant. It is recommended that any
work requiring disconnection of the components be
referred to an au thorized dealer.
In the event of major repair s to the vehicle such as
engine removal, the compress or hoses are of sufficient
Schematic diagram of a typical air conditioning
system.
length to allow the compressor to be removed as the
engine is lowered from the engine compartment with-
out disturbing any refrigerant line connections.
If the operation of the air conditioning system is
in doubt, it is recommended that the vehicle be taken
to an authorized dealer for testing and repair.
TO CHECK REFRIGERANT CHARGE
(1) Start the engine and operate the air condi-
tioner on maximum cooling for a few minutes.
(2) Observe the flow of refrigerant through the
sight glass located at the top of the receiver/dryer. On
some models it may be necessary to use a mirror to
see the sight glass. (3) If the system is operating correctly, the sight
glass will be clear during the operation of the com-
pressor. Occasional bubbles may be seen when the
compressor cycles on and off during operation, but a
NUT j-
Bubbles in the sight glass when the air conditioner is
operating indicates a low refrigerant charge.
Page 82 of 238
82
FUEL AND ENGINE MANAGEMENT
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.
SPECIFICATIONS
FUEL INJECTION
Type:
1.6 liter engine .................................. Single point
1.8 liter engine................................... Multi point
FUEL PUMP
Type ................................................................ Electric
Pressure at idle:
1.6 liter engine ..................................... 62-90 kPa
1.8 liter engine ................................ 190-230 kPa
FUEL FILTER
Type ................................................ Inline, disposable
AIR FILTER
Type ................................... Disposable paper element
DISTRIBUTOR
Make ........................................................ Delco Remy
Advance contro l .......................................... Electronic
Rotation of rotor .................................. Anti-clockwise
Firing order....................................................1 -3-4-2
ADJUSTMENTS
Base idle speed ..................................... 550-650 rpm
Ignition timing.......................................... 10° BTDC
TORQUE WRENCH SETTINGS
Throttle body nuts.......................................... 10 Nm
*Throttle body bolts ........................................ 12 Nm
*Fuel hose fittings............................................ 35 Nm
Fuel rail bolts ....................................................8 Nm
Fuel tank drain plug ........................................ 24 Nm
Coolant temperature sensor ............................ 12 Nm
Oxygen sensor .................................................. 40 Nm
MAT sensor..................................................... 14 Nm
*1.6 liter engine
l . 8 liter engine
1. FUEL AND ENGINE MANAGEMENT
TROUBLE SHOOTING
NOTE: The following Trouble Shooting pro-
cedures are basic checks only. If these pro-
cedures fail to locate the fault, refer to the
System Diagnosis and Adjustments heading
for more thorough testing.
Prior to performing any of the following
operations, refer to the Service Precautions
and Procedures heading.
ENGINE WILL NOT START OR HARD TO
START
(1) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(2) Fault in the power supply: Check the battery,
fusible links and fuses. Check for clean, secure con-
nections, particularly the earth connections. Check the
EG1 and fuel pump relays.
NOTE: If the fuel pump relay fails, power
will be supplied to the fuel pump via the oil
pressure switch. When starting the engine,
Check that the MAP sensor hose is not blocked or split
and ensure that all electrical connections are clean and
secure.
Page 97 of 238
Fuel and Engine Management 97
circuitry do not immerse it in cleaning
solvent as this may result in irreparable
damage.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Lubricate the new O ring seals with auto-
matic transmission fluid prior to installing them to the
injector. If removed, ensure that the lower filter screen
is installed. (2) Firmly push the injector into the throttle
body assembly until it is fully seated, ensuring that the
injector connection terminals face towards the rear of
the vehicle.
(3) Apply Loctite 262 to the injector retaining
plate screw and tighten securely.
(4) Start the engine and check for fuel leaks as
previously described.
(5) Install the air cleaner and tighten the retain-
ing nuts securely.
FUEL METER ASSEMBLY - 1.6 LITRE
ENGINE
To Remove and Install
(1) Remove the injector as previously described.
(2) Mark the fuel supp ly and return hoses,
release the clamps and disconnect the hoses from the
fuel meter assembly.
(3) Remove the air cleaner assembly base gasket
from the fuel meter assembly. (4) Remove the bolts and screws securing the
fuel meter assembly to the throttle body and remove the fuel meter assembly. Remove and discard the
gasket.
(5) If necessary, remove the fuel pressure regu-
lator as previously described.
Installation is a reversal to the removal procedure
with attention to the following points;
(1) If removed, install the fuel pressure
regulator
as previously described.
(2) Place a new gasket on the throttle body,
aligning the holes in the gasket with those in the
throttle body, ensuring that the idle air passage is not
blocked. (3) Coat the fuel meter assembly retaining
screws with Loctite 26 2 and tighten securely.
(4) Install the fuel meter assembly retaining bolts
and tighten to the specified torque.
(5) Connect the fuel supply and return hoses and
tighten the clamps securely. (6) Install the injector as previously described.
(7) Start the engine and check for fuel leaks.
Rectify as necessary. (8) Install the air cleaner assembly.
FUEL TANK
To Remove and Install
(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal.
(3) Remove the fuel pump cover plate retaining
screws, disconnect the wi ring harness rubber grommet
from the cover plate and remove the cover plate from
the wiring harness. (4) Raise the rear of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary. (5) Remove the fuel tank drain plug and drain
the fuel into a petroleum resistant container. (6) Mark the fuel hoses and disconnect the hoses
from the fuel pump.
(7) Disconnect the hoses from the fuel filler neck
pipe, the fuel check valve and the fuel tank breather
pipe.
View of the fuel meter assembly removed from the
throttle body. HANDBRAKE CABLE MOUNTING
Installed view of the fuel tank.
Page 98 of 238
Fuel and Engine Management
(8) Remove the bolts retaining the intermediate
exhaust pipe to the rear of the catalytic converter,
remove the bolt securing the exhaust mounting to the
underbody and slightly lower the intermediate exhaust
pipe. Support the intermediate pipe to prevent the
tailpipe fouling the lower bumper panel.
(9) Remove the bolts retaining the stabilizer bar
mounting brackets to the underbody and allow the
stabilizer bar to drop.
(10) Remove the bolts retaining the exhaust heat
shield to the underbody, located at the front of the
fuel tank. (11) Remove the handbrake cable mounting
bracket retaining nuts and remove the mounting
brackets from the mounting studs. (12) Remove the fuel tank retaining bolts and
maneuver the fuel tank from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:
(1) When installing the fuel tank, ensure that the
fuel pump wiring harness is directed through the
aperture in the floor. (2) Install the stabilizer bar mounting
bracket
bolts and tighten to the specified torque. Refer to the
Rear Suspension section.
(3) Using a new gasket, install the intermediate
exhaust pipe to the catalyti c converter ensuring that
the earth wire terminal is installed and tighten the
bolts securely. (4) Connect the fuel filler neck hose, the fuel
check valve hose and the breat her hose ensuring that
they are secured firmly. (5) Tighten the fuel tank drain plug to the
specified torque. (6) Connect the fuel hoses to the fuel pump,
using the marks made during removal to ensure
correct installation. (7) Install the fuel pump wiring harness and the
rubber grommet to the fuel pump cover plate. Install
the cover plate and tighten the retaining bolts se-
curely.
(8) Connect the fuel pump wiring connector
securely. (9) Check for fuel leaks as previously described.
6. AIR FLOW COMPONENTS
NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.
AIR CLEANER ASSEMBLY
To Renew Element
The procedure for renewing the air cleaner ele-
ment is covered in the Engine Tune-up section.
To Remove and Install — 1.8 Liter Engine
(1) Disconnect the negative battery terminal.
(2) Release the air intake hose retaining clamps,
disconnect the hose from the air cleaner upper
housing and the throttle body and remove the hose. (3) Remove the screw securing the air cleaner
intake duct to the front panel mounting bracket. (4) Remove the hexagon head screws retaining
the air cleaner mounting bracket to the right hand
inner mudguard and remove the air cleaner from the
engine compartment. (5) Release the upper housing retaining clips,
separate the upper housing from the lower housing
and remove the element. (6) Remove the air cleaner intake duct retaining
screw and disconnect the duct from the lower air
cleaner housing. (7) If necessary, remove the bolts securing the
mounting bracket to the ai r cleaner lower housing and
separate the mounting bracket from the housing. (8) Thoroughly clean the upper and lower hous-
ings in cleaning solvent and check for cracks, splits or
damage that would allow unfiltered air to enter the
engine. Renew any components as necessary.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure that the r ubber insulators are in-
Dismantled view of the ai r cleaner assembly. 1.8 liter
engine.
Page 126 of 238
126
MANUAL TRANSAXLE AND DRIVE SHAFTS
SPECIFICATIONS
TRANSAXLE
Type .....................................Five speed, synchromesh
on all forward gears
Model .......................................................... RS5F31A
Gear ratios: 1.6 liter -
First .......................................................... 3.333:1
Second...................................................... 1.955:1
Third......................................................... 1.286:1
Fourth....................................................... 0.975:1
Fifth.......................................................... 0.810:1
Reverse .................................................... 3.417:1
1.8 liter -
First .......................................................... 3.063:1
Second...................................................... 1.826:1
Third......................................................... 1.286:1
Fourth ....................................................... 0.975:1
Fifth.......................................................... 0.810:1
Reverse .................................................... 3.417:1
Gear end float:
Fifth...............................................0.18-0.41 mm
Second, third and fourth................0.20-0.40 mm
First ...............................................0.18-0.31 mm
Synchro ring to gear clearance:
Standard ............................................ 1.0-1.3 mm
Minimum ................................................. 0.7 mm
Turning torque (new bearings):
Differential assembly ........................ 3.9-7.8 Nm
Total differential and mainshaft __ 5.9-13.7 Nm
Differential and final drive:
Type ........................ Helical ring gear and pinion
Ratio......................................................... 4.167:1
Lubricant:
Grade ............................................. 80W-90 GL-4
Capacity ..................................................2.7 liters
DRIVE SHAFTS
C.V. joint lubrication:
Lubricant ........ Valvoline Special Moly EP grease
Amount ................................................. 40 grams
TORQUE WRENCH SETTINGS
Transaxle case retaining bolts ........
Cover plate to transaxle case .......................... 8.3 Nm
Input shaft bearing retainer bolts ..................... 21 Nm
Control bracket bolts ...................................... 8.3 Nm
Reverse check plug.......................................... 25 Nm
Ring gear to differential case........................... 88 Nm
Filler and drain plugs....................................... 34 Nm
Reverse lamps switch ...................................... 29 Nm
Upper and centre clutch housing to engine…...49 Nm
Lower clutch housing to engine ...................... 21 Nm
1. MANUAL TRANSAXLE AND DRIVE
SHAFT
TROUBLE SHOOTING
DIFFICULT GEAR CHANGE
(1) Faulty clutch or clutch release mechanism:
Check and adjust or overhaul the clutch or the clutch
release mechanism. (2) Loose control bracket retaining bolts: Dis-
mantle the transaxle and tighten the control bracket
retaining bolts. Apply Loctite or an equivalent to the
bolt threads to prevent a repeat of the problem.
(3) Faulty gear lever assembly: Check and
renew
or repair the gear lever assembly. (4) Bent or worn gear lever control rod: Repair
or renew the faulty components. (5) Worn transaxle selector mechanism: Over-
haul the transaxle assembly. Renew components as
necessary.
.21 NmCheck the synchronizing teeth on the gears and synchro
rings for chipping or wear.
Page 140 of 238
140
AUTOMATIC TRANSAXLE
SPECIFICATIONS
Make .............................................. JATCO RL3F01A
Type .....................3 speed and reverse epicyclic gear
train with lock up torque converter
Operation .................................... Automatic hydraulic
Lubricant:
Type....................................................... Dexron IT
Capacity................................................. 6.3 liters
TORQUE WRENCH SETTINGS
Drive plate to crankshaft bolls ........................60 Nm
Drive plate to torque converter bolts ..............49 Nm
Convener housing to engine ...........................22 Nm
Converter housing to transaxle ........................23 Nm
Transaxle sump to transaxle ............................. 7 Nm
Oil cooler pipe to transaxle .............................49 Nm
Selector shaft locknut .......................................42 Nm
Transaxle filter bolts.........................................12 Nm
1. AUTOMATIC TRANSAXLE TROUBLE SHOOTING
NO DRIVE IN D RANGE
{1) Low fluid level in transaxle: Check the fluid
level in the transaxle and top up if required.
(2) Incorrectly adjusted selector cable: Check
and adjust the selector cable as detailed. (3) Incorrect or contaminated transaxle fluid:
Drain and refill with the recommend type and quan-
tity of transaxle fluid.
NOTE: Check the possible causes in the
order given.
NO REVERSE IN R RANGE
(1) Low fluid level in transaxle: Check the fluid
level and top up if required. (2) Incorrectly adjusted selector linkage: Check
the condition of the selector cable, selector quadrant
and selector arm for wear and damage. Adjust as
required.
Check the drive shaft oil seals as a likely leak source.
SLIPPING OR ROUGH UPSHIFT
(1) Incorrectly adjusted selector linkage: Check
and adjust the selector linkage. (2) Low fluid level in transaxle: Check the fluid
level and top up if required.
NO TRANSAXLE KICKDOWN
(1) Incorrectly adjusted throttle cable: Check
and adjust the cable as detailed in the Fuel and Engine
Management section.
Check the oil cooler hose connections for leaks if the
fluid level is low.
Page 154 of 238
154 Steering —
(2) Remove the air inlet duct from the air
cleaner and throttle body. (3) Position a container or a piece of cloth
beneath the steering pump reservoir and disconnect
the fluid return and power steering pump supply hose
from the reservoir.
(4) Loosen the steering pump drive belt as
described in the Engi ne Tune-up section.
(5) Loosen the return hose clamp and the supply
union and disconnect the hoses from the power
steering pump. Plug the hoses to prevent the loss of
fluid.
(6) Loosen the retaining bolts and withdraw the
pump. (7) Thoroughly clean the exterior of the steering
pump and inspect it for cracks, damage and signs of
leakage.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the pump and retaining bolts.
(2) Install the drive belt and adjust it as de-
scribed in the Engine Tune-up section. (3) Install the hoses to the power steering pump
and tighten securely. (4) Top up the pump reservoir and purge the
power steering system of air as previously described.
TO OVERHAUL
As specialist knowledge and equipment arc re-
quired to overhaul the power steering pump, it is
recommended that this operation be performed by an
authorized dealer or steering specialist.
6. POWER STEERING GEAR ASSEMBLY
Special Equipment Required:
To Renew Tie Rod Ball Housings — Large Still-
sons
TO REMOVE AND INSTAL
The procedures for removing and installing the
power steering gear are similar to those carried out in
the Manual Steering section under the Steering Gear
Assembly heading except fo r the following differences.
(1) Place a container under the pressure and
return pipes that are conn ected to the steering gear
valve housing. Remove the pipes and allow the fluid
to drain into the container. (2) Suitably seal the pipes and the steering gear
to prevent the entry of di rt whilst the pipes are
removed.
(3) Upon removal of the power steering gear,
thoroughly clean the steering gear except the tie rod
ends in a suitable solvent. Be careful not to allow the
solvent to enter the apertu res where the pressure and
return pipes were removed. (4) Check the pipes and co nnections for cracks,
damage or obstructions and renew as necessary.
Installed view of the power steering gear with the
engine removed.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the pressure and return pipes to the
steering gear valve housing and tighten securely. (2) Fill the power steering reservoir to the cor-
rect level and bleed the system as described previously
under the heading In Car Adjustments. Checks and
Minor Repairs. (3) Check all power steering pipe connections
for leaks and repair as necessary. (4) Check, and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. After adjustment ensure that the rubber boots
are not distorted or twisted and the rubber boot
clamps and clips are facing downward.
TO OVERHAUL
As specialist knowledge and equipment are re-
quired to overhaul the power steering gear, it is rec-
ommended that this opera tion be performed by an
authorized dealer or steering specialist.
TO RENEW TIE ROD BALL HOUSINGS
TRW Steering Gear
The renewal of the tie rod ball housings is the
same as for the manual steering gear. Refer to Part 2.
Manual Steering section.
PR24SA Steering Gear
(1) Remove the power steering gear assembly
from the vehicle as previously described.
(2) Carefully mount the power steering gear in a
vice equipped with soft jaws. Loosen the tie rod end
locknuts without disturbing the location of the tie rod
ends and unscrew the tie rod ends, taking note of the
number of turns required to remove them. Unscrew
and remove the locknuts from the tie rod. (3) Remove the clamps from the rubber boots
and remove the boots.
Page 175 of 238
Brakes 175
A pressure proportioning valve is incorporated in
each circuit to prevent premature locking of the rear
wheels during severe braking.
The four wheel hydraulically operated brakes
utilize disc brakes on each front wheel and disc brakes
or leading and trailing drum brake shoes on each rear
wheel.
The front disc brakes comprise a disc attached to
the hub assembly and a caliper bolted to the steering
knuckle.
The rear disc brakes comprise a disc and hub
assembly attached to the rear stub axle and a caliper
and anchor plate bolted to the backing plate.
The front and rear calipers are of the sliding type.
As pad wear takes place, the caliper piston is allowed
to slide outwards through the seal to take up a new
position in the caliper bore. Elastic deformation of the
seal takes place when the brakes are applied, which
returns the piston slightly when the brakes are re-
leased. Thus a constant clearance is maintained
between the pads and the disc when the brakes are in
the off position.
The disc brakes do not require periodical adjust-
ment in service to compensate for pad wear as they
are self adjusting.
The leading and trailing shoe drum brakes on the
rear wheels use a double ended wheel cylinder to
operate both brake shoes at the top. The lower end of
each brake shoe abuts a fixed anchor point. The brake
shoes are automatically adju sted when the brakes are
operated.
The handbrake operates the rear brakes via a
cable arrangement.
3. MASTER CYLINDER
Special Equipment Required:
To Install New Seals — Suitable machined drift
TO REMOVE
(1) Depress the brake pedal several times to
deplete the vacuum from the system.
(2) Raise the bonnet and install covers to
both
the front mudguards. Cover the areas of paintwork
beneath the master cylinder with absorbent cloth.
(3) Disconnect the wiring from the pressure
sensing switch. (4) Disconnect the brake pipes from the master
cylinder and plug the outlets and pipes to prevent the
loss of fluid and the ingress of dirt.
(5) Remove the nuts retaining the master cylin-
der to the brake servo unit and remove the master
cylinder from the vehicle.
TO DISMANTLE
(1) Remove the master cylinder as previously
described. (2) Remove the reservoir cap and diaphragm,
drain and discard the brake fluid from the reservoir. (3) Carefully remove the reservoir from the
master cylinder by pulling it from the reservoir
retainers by hand. Remove and discard the retainers
from the master cylinder. (4) Using internal snap ring pliers, remove the
snap ring from the primary reservoir port. (5) Remove the fast fill valve assembly and the
O ring from the port. Remove and discard the valve
washer from the fast fill valve.
(6) Remove the proportioning valve plugs and
the O rings. Discard the O rings. Withdraw the springs
and valve plungers from the master cylinder. Remove
and discard the seals from the valve plungers. (7) Remove the pressure sensing switch and
lever assembly from the master cylinder. {8) Remove the cylinder end plug from the
master cylinder. Remove and discard the O ring from
the plug.
(9) Carefully tap the front of the master cylinder
vertically on a block of wo od and remove the pressure
differential pistons from the master cylinder. Remove
and discard the O rings from the pistons. (10) Push the primary piston forward in the
cylinder with a blunt rod and while holding the
pressure, remove the stop pin from the master cylin-
der.
(11) The primary piston may now be withdrawn
from the cylinder bore. The secondary piston, retainer
and spring can also be withdrawn by carefully tapping
the master cylinder on a block of wood. (12) Prise the legs of the seal retainer upwards
and remove it from the primary piston. Remove the
seal and guide. Discard the seal and retainer.
NOTE: The secondary piston must no! be
dismantled by removing the screw. This
assembly has a factory p reset length and the
screw must not be altered in service.
(13) Remove the main seal and the guide from
the front of the secondary piston. Stretch the rear seal
from the groove and remove it from the piston. Take
Installed view of the master cylinder and servo unit. Air
duct removed for clarity. 1.8 liter model.