engine NISSAN PULSAR 1987 User Guide

WHEELS AND TYRES
SPECIFICATIONS
TYRES PRESSURES
Front:
Normal load ............................................ 200 kPa
Heavy load or high speed ......................230 kPa
Rear:
Normal load............................................ 180 kPa
Heavy load or high speed ...................... 210 kPa
NOTE: The above pressures are measured
cold and are meant as a guide only. Always
refer to the tire placard positioned on the
inside of the glove compartment lid and the
tire manufacturers recommendations first.

TORQUE WRENCH SETTINGS
Wheel nut torque .............................................98 Nm
1. HOW TO CHANGE A ROAD WHEEL
(1) Ensure that the vehicle is on level firm
ground and clear of any passing traffic. (2) If necessary, switch on the hazard
flashers.
(3) Switch off the engine a nd place the transaxle
in the (P) Park position on automatic transaxle
models or in reverse gear on manual transaxle models.

(4) Apply the handbrake firmly and chock the
front and rear of the wheel diagonally opposite the
wheel being changed.
(5) Remove the spare wheel, tool kit and jack
located in the luggage compartment. (6) On vehicles equipped with full wheel covers,
remove the trim from the wheel. (7) Using the wheel spanner, loosen the wheel
nuts progressively in a diagonal sequence half a turn.
(8) Position the jack und er the jacking point
closest to the wheel being removed and raise the jack
until the head of the jack contacts the jacking point.
(9) Raise the vehicle slightly and check that the
jack is stable and vertical.

Underbody view showing the jacking and supporting
points. O indicates the jacking points and X indicates
the supporting points.
Chock the front and rear of the wheel diagonally
opposite the wheel being changed. View of the jack correctly installed to the rear jacking
point.

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.

26 Engine Tune-up

1.6 Liter Engine
(1) Remove the nuts and washers securing the
upper air cleaner housing to the lower air cleaner
housing and release the retaining clips. (2) Remove the air cleaner element.
(3) Clean the inside of the air cleaner housing
using a damp rag to remo ve all traces of dust.
(4) Install a new air cleaner element ensuring that
the element is correctly seated around the edges.
(5) Install the upper housing and secure the
retaining clips. Tighten th e retaining nuts securely.
TO RENEW FUEL FILTER

filter should
The fuel
40 000 km.

(1) Depressurize the fuel system using the fol-
lowing procedure:

(a) Lift the front edge of the rear seat cushion
and remove the cushion from the vehicle.


When depressurizing the fuel system, remove the rear
seat cushion and disconnect the fuel pump wiring
connector.

(b) Disconnect the fuel pump wiring connector.
(c) Start and run the engine until it stalls.
Operate the starter motor for 10 seconds to ensure
that the fuel pressure has dissipated.
(2) Disconnect the negative battery terminal.
(3) Release the hose clamps and disconnect the
fuel hoses from the filter. Remove the filter from the
retaining clamp noting the direction of the arrow on
the filter body. On some models it will be necessary to remove the
screw from the side of the clamp to allow the filler to
be removed.

Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the fuel filter with the arrow facing the
direction noted on removal, that is, in the direction of
fuel flow.
(2) Ensure that the hose clamps are tightened
securely.
(3) Connect the fuel pump wiring connector and
install the rear seat cushion. (4) Start the engine and check for fuel leaks.
Rectify as necessary.
TO ADJUST DRIVE BELTS

It is essential that all drive belts are adjusted to
the correct tension to prevent slippage or premature
wear of the bearings in the alternator and, if equipped,
the power steering pump and air conditioner compres-
sor.

(1) Push down on the drive belt with a 10 kg
force midway between the pulleys of the drive belt
concerned.

On models with air conditioning, push down on
the upper section of the drive belt between the
compressor and crankshaft pulleys.

If the drive belt deflection is not within Specifi-
cations it will require adjustment as follows.

(2) Loosen the alternator and, if equipped, the
power steering pump pivot and adjusting bolts and

ALTERNATOR
POWER STEERING PUMP


be renewed every
Installed view of the fuel filter. Note the direction of the arrow on the filter prior to removal. Illustration of the alternator, power steering pump and

air conditioner compressor drive belts. The arrows
indicate the deflection measuring points.

Engine Tune-up 27

move the alternator or power steering pump as
required until the drive belt concerned has the
specified deflection.

On models with air conditioning, loosen the nut
in the centre of the idler pulley and turn the adjusting
bolt until the drive belt has the specified deflection.

(3) Tighten the alternator or power steering
pump bolts securely and check the belt tension.

On models with air conditioning, tighten the idler
pulley nut securely.

TO SERVICE SPARK PLUGS
The spark plugs should be renewed at intervals of
40 000 km.

Before removing the spark plugs ensure that the
area around each plug is cl ean to prevent foreign
matter entering the cylinder when the plugs are
removed.

Spark plugs removed from an engine in good
mechanical condition should have a light powdery
deposit ranging from light brown to grayish tan in
color. After considerable service the electrodes will
show signs of wear or no rmal burning. Spark plugs
showing a thick black oily deposit indicate an engine
in poor mechanical condition or possibly, that a plug
with too low a heat range has been installed.

Spark plugs showing a white or yellowish deposit
indicate sustained high speed driving or possibly that
plugs with too high a heat range have been installed,
particularly when these deposits are accompanied by
blistering of the porcelain and burning of the elec-
trodes.

If the spark plugs are to be cleaned, use a
sandblasting machine and blow clean with com-
pressed air. Ensure that all traces of abrasive grit are
removed from the spark plug threads and from the
well in the plug body. Carefully open the electrode gap
a little, by bending the side electrode, and lightly file
the electrodes flat with a points file.


Black damp deposits can be caused by excessive oil
consumption or incorrect plug type. Spark plugs in this
condition are usually not firing.
Cutaway view of spark plug showing a crack in the
insulator nose which can be caused by exerting pres-
sure against the centre electrode when adjusting the
gap. The other crack shown on the insulator is caused
by tilting the plug spanner.

When plug electrodes are eroded to this degree the
spark can be considered worn out and should be
renewed using a plug of the recommended heat range
.
CRACK

Engine Tune-up
Spark plug with burnt electrodes and white blistered
appearance, possibly due to incorrect plug type, loose
plug or motor running too hot.
NOTE: Never attempt to alter the electrode
gap by bending the centre electrode as
damage to the porcelain insulator will
result.

Before installing any spark plugs measure the gap
between the electrodes, pref erably with clean wire
gauges. If wire gauges are una vailable, use clean feeler
gauges. Move the side electrode towards or away from
the centre electrode to obtain the correct gap-

Screw the plugs into the cylinder head ringer tight,
then use a torque wrench to tighten the plugs lo the
specified torque.



Checking the spark plug electrode gap with a wire
gauge.
NOTE: If a torque wrench is unavailable,
extreme care must be taken when tightening
the spark plugs as over tightening may lead
to stripping of the thread from the cylinder
head. If the plugs are tightened with the
fingers and then taken up an additional 1/4
of a turn with a spark plug wrench, they will
be tight enough.

TO TEST COMPRESSION
(1) With the engine at operating temperature.
disconnect the high tension leads from the spark
plugs.
(2) Ensure that the area around each spark plug
is clean to prevent foreign matter entering the cylin-
ders and remove the spark plugs. (3) Remove the fusible link that is positioned
third from the front of th e fusible link connecting
block, located at the rear of the battery. Disconnect
the coil high tension lead from the coil.
NOTE: Failure to remove the fusible link
can result in an explosion.

(4) Install a compression gauge to number one
spark hole according to the gauge manufacturers
instructions. (5) Have an assistant fully open the throttle and
operate the starter switch to rotate the engine. Ob-
serve the compression gauge and stop the engine when
the gauge has reached the highest reading, usually
after 3 or 4 compression strokes.
(6) Record the reading a nd check the compres-
sion of the remaining cylinders in the same manner.
(7) Compare all the readings taken. Variation
between the highest and lowest reading cylinders
should not exceed 100 kPa. (8) If a low reading is recorded on one or more
cylinders the trouble may be isolated as follows :

Lightly file the plug electrodes flat with a points file

Engine Tune-up 29


Check the cylinder compressions using a compression gauge.
(a) Inject a small amount of engine oil into the
spark plug hole of the cylinder concerned ensuring
that the oil is evenly distributed within the cylinder by
rotating the engine.
(b) Repeat the compression test on the cylinder
concerned.
A substantial increase of compression pressure
indicates faulty or worn piston rings, pistons or
cylinder.

No increase of compression pressure indicates
burnt, obstructed or sticking valves, or a leaking or
blown cylinder head gasket.

(9) Install the fusible li nk and connect the high
tension lead to the coil.

TO SERVICE THE DISTRIBUTOR
The electronic ignition system requires virtually
no maintenance except for checking of the distributor
cap. rotor and high tension leads as described below.

Refer to the Fuel and Engine Management section
for Specifications and Trouble Shooting.

NOTE: When working on or near electronic
ignition systems, care should be taken as
dangerous high voltages are present in both
the primary and secondary circuits.

The ignition switch should be turned off
before removing or inst alling any electrical
connections otherwise damage to the igni-
tion system as well as severe electrical shock
could result.

TO SERVICE HIGH TENSION LEADS
Check the leads for perishing or cracking and
renew as required. Never a ttempt to repair defective
carbon impregnated core leads.

The lead may be carefully cleaned, using cloth
moistened with kerosene a nd then wiped completely
dry.

If an ohmmeter is available the electrical resis-
tance of the leads may be checked as follows:

View showing the location of the fusible links.
Check the spark plug high tension leads for cracks and
burnt or corroded terminals.
Check the distributor cap for cracks or tracking
between the terminals
.

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.

Engine Tune-up

View of the engine timing marks showing the 10 deg
BTDC crankshaft notch aligned with the pointer on the
front of the engine.
(5) If adjustment is necessary, loosen the distrib-
utor body retaining nuts and turn the distributor body
until the correct setting is obtained.
(6) Tighten the distributor body retaining nuts
and ensure that the timing is still correct.
(7) Remove the jumper lead from the diagnostic
link connector.
(8) Disconnect the timing light from the engine.
TO ADJUST IDLE SPEED AND MIXTURE

The idle speed and mixt ure are not adjusted as
normal service procedure. However, should the per-
formace of the vehicle indicate that the mixture is
incorrect, refer to the Fuel and Engine Management
section for the procedures to test for faulty compo-
nents in the engine management system.

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.

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.