brake NISSAN PULSAR 1987 Owner's Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 142 of 238
142 Automatic Transaxle
(8) Install the dipstick and start the engine and
recheck the fluid level.
NOTE; Do not overfill the transaxle or
foaming and unsatisfactory operation of the
transaxle will result.
TO DRAIN AND REFILL
This is not a normal maintenance and lubrication
procedure. It is only necessary to drain the complete
system, including the torq ue converter and the oil
cooler, when the transaxle assembly is removed for
overhaul or the renewal of transaxle components such
as bearings, clutches or as semblies. When this condi-
tion arises, the torque converter and the cooler should
be cleaned and flushed to remove any dirt or sludge.
After transaxle overhaul, install approximately 6
liters of new transaxle fluid, and top up as previously
described.
4. BRAKE BAND
Band adjustment is not a normal maintenance
procedure.
The adjustment entails removal of the valve body
and for this reason the vehicle should be taken to an
authorized dealer.
5. KICKDOWN CABLE
TO ADJUST
(1) On models with a 1.6 liter engine, remove
the air cleaner assembly. (2) With the aid of an assistant, ensure that the
throttle valve is fully open when the throttle pedal is
fully depressed. (3) Push the clip on the outer kickdown cable
and pull the cable away from the throttle linkage.
View of the kickdown cable adjustment point. 1.6 liter
engine.
(4) Slowly depress the throttle pedal to the full
throttle position.
The outer kickdown cable will automatically ad-
just and emit a clicking noise.
6. TRANSAXLE SELECTOR LINKAGE
TO ADJUST CONTROL CABLE
(1) Place the selector lever in the Park position.
(2) Loosen the control cable locknuts and ensure
that the transaxle selector lever is in the Park position.
View of the transaxle selector linkage control cable
adjustment.
(3) Hold the selector rod horizontal and adjust
the outer locknut until it touches the selector rod.
(4) Tighten the inner locknut securely.
7. NEUTRAL SAFETY SWITCH
The neutral safety switch, incorporating the re-
verse lamp switch is located on the transaxle case
View of the kickdown cable adjustment point. The
arrow indicates the direction in which the outer kick-
down cable must be pulled to initiate the automatic adjustment. 1.8 liter engine.
Page 143 of 238
Automatic Transaxle 143
facing towards the radiator support panel at the front
of the vehicle.
The neutral safety switch allows electrical current
to pass to the starter circ uit only when the selector
lever is in the Park or Neutral position. The switch is
adjustable but non-repairable.
TO TEST
(1) Disconnect the neutral safety switch wiring
connector.
(2) Connect an ohmmeter between terminals 1
and 2 at the neutral safety switch wiring connector.
Continuity should exist when the selector lever is in
the P or N positions. (3) Perform the same check with terminals 3 and
4 with the selector lever in the R position. Continuity
should exist.
NOTE: If the readings are other than that
specified, the neutral safety switch will have
to be adjusted or renewed.
Neutral safety switch connector terminal identification.
TO ADJUST
(1) Select Neutral and firmly apply the hand-
brake. (2) Loosen the neutral safety switch retaining
bolts.
(3) Align the holes in the neutral safety switch
body and the neutral safety switch arm. (4) Install a 2.5 mm diameter split pin or drill bit
into the holes to align the arm with the neutral safety
switch body. (5) Secure the retaining bolts and test the switch
as previously described.
If the test indicates a fault, renew the neutral
safety switch.
TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the selector cable split pin and wave
washer from the transaxle selector lever.
(3) Disconnect the electric al connector and re-
move the neutral safety switch retaining bolts. (4) Maneuver the neutral safety switch clear of
the transaxle selector lever and withdraw the switch
from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Clean the area around the neutral safety
switch mounting.
(2) Apply a small amount of chassis grease to the
jaws of the neutral safety switch arm. (3) Check the adjustment of the selector cable as
previously described. (4) Adjust the neutral safety switch as previ-
ously described.
(5) Check the operation of the neutral safety
switch and ensure that the engine will not start in any
position other than P and N. Check that the reversing
lamps operate only when R is selected.
8. TRANSAXLE ASSEMBLY
Special Equipment Required:
To Remove and Install — Suitable trolley jack to
which the transaxle can be secured
TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the left hand front wheel.
(2) Disconnect the negative battery terminal. Remove the left hand side inner mudguard
(3)
panel.
(4) Remove the left hand drive shaft as de-
scribed in the Manual Tran saxle and Drive Shafts
section. (5) Disconnect the vehicle speed sensor wiring,
selector control cable and the neutral safety switch
wiring from the transaxle. Disconnect the kickdown
cable from the throttle linkage and the support
bracket. (6) Disconnect the oil cooler hoses from the
Using a 2.5 mm drill bit to adjust the neutral safety
switch.
Page 146 of 238
146 Steering — Part 1
STEERING PULLS TO ONE SIDE
(1) Uneven tire wear or pressures: Check the
condition of the tires and inflate to the recommended
pressures.
(2) Incorrect front wheel alignment: Check and
align the front end.
(3) Dragging brakes: Check each wheel for drag-
ging brakes. Overhaul the brakes as necessary. (4) Damaged suspension or crossmember: In-
spect and renew the damaged components. (5) Faulty power steering gear assembly: Re-
move the power steering gear for overhaul.
FRONT WHEEL WOBBLE OR SHIMMY
(1) Uneven tire wear or incorrect tire pressures;
Check the condition of the tires and inflate to the
recommended pressures. (2) Tire or wheel imbalance: Check and balance
as necessary (3) Worn or badly adjusted hub bearings: Check
the condition and adjust the front hub bearings.
(4) Faulty or worn suspension, units: Check and
overhaul or renew as a pair.
NOTE: Check the steering linkage as previ-
ously described. Raise the front of the vehi-
cle and check the adjustment of the hub
bearings by moving the road wheel in and
out at the top and bottom. No movement in
the bearings should be felt. Check the sus-
pension units as outlined in the Front Sus-
pension section.
STEERING ERRATIC OR WANDERING
(1) Incorrect or uneven wheel alignment setting:
Check and adjust th e steering geometry.
(2) Smooth front tires: Check and renew the
tires as necessary.
Checking the steering gear mounting bolts for security.
(3) Steering gear assembly loose on the cross-
member: Inspect for damage and tighten the steering
gear mounting bolts.
(4) Wear in the tie rod ball housing: Renew the
worn t i e rod and ball housing. (5) Wear in the rack and pinion: Remove the
steering gear assembly for overhaul. (6) Loose or incorrectly adjusted hub bearings:
Check and adjust the front hub bearings.
FAILURE OF POWER ASSISTANCE
(1) Loose or broken pump drive belt: Renew or
adjust the pump drive belt.
(2) Low fluid level in the power steering reser-
voir: Check for leakage, repair or renew the faulty
components. Top up the fluid level. (3) Insufficient power steering pump pressure:
Check the delivery pressure, renew the pump if
defective. (4) Faulty power steering gear assembly: Re-
move the power steering gear assembly for overhaul.
Page 156 of 238
156
FRONT SUSPENSION
SPECIFICATIONS
Type.................. Independent MacPherson strut with
coil springs and control arms
Shock absorber .................. Hydraulic, non-repairable
Hub bearing end float (maximum) ............. 0.05 mm
Ball joint axial play (maximum) ....................0.7 mm
Ball joint turning torque (used)...............0.5-4.9 Nm
Wheel alignment:
Toe in ..................................................... 0-2 mm
Camber ........................................- 0 ° 1 0 ' ± 4 5 '
Caster ..............................................1 ° 1 0 ' ± 4 5 '
King pin inclination..................... 1 3 ° 5 5 ' ± 4 5 '
TORQUE WRENCH SETTINGS
Hub bearing nut..................................... 196-235 Nm
Suspension unit to steering knuckle nut ...... 118 Nm
Suspension unit to body nuts ......................... 29 Nm
Piston rod nut .................................................. 72 Nm
Brake caliper to steering knuckle bolts ........... 52 Nm
Ball joint to steering knuckle bolt ................... 86 Nm
Control arm bracket bolts ............................... 98 Nm
Control arm pivot bolt ................................ 118 Nm
Stabiliser bar link nuts..................................... 44 Nm
Stabiliser bar bracket bolts .............................. 21 Nm
1. FRONT SUSPENSION TROUBLE
SHOOTING
FRONT END NOISE
(1) Loose upper suspension mounting or piston
rod: Tighten the mounting or piston rod nuts. (2) Loose or worn suspension unit lower ball
joint: Tighten or renew the lower ball joint.
(3) Noise in the suspension unit: Renew the
faulty suspension unit, preferably in pairs.
(4) Worn or loose steering gear: Overhaul the
steering gear assembly. (5) Worn front hub bearings: Renew the hub
bearings:
(6) Loose or defective stab ilizer bar, control arm
or mountings: Check, tighten or renew the mounting
rubbers.
Check the ball joints for wear and deterioration.
(7) Worn stabilizer bar link ball joints: Renew
the stabilizer bar links.
(8) Drive shafts worn or insufficiently lubri-
cated: Check the lubricant and the dust boots and
renew as necessary. (9) Drive shaft splines in the hub or the
differential worn or dama ged: Check and renew as
necessary.
NOTE: To check the front suspension com-
ponents for wear, raise the front of the
vehicle, support it on chassis stands and
allow both front wheel to hang free. With an
assistant pushing and pulling the front
wheels in and out at the top and then at the
bottom, check for excessive looseness at the
front hub bearings and lower control arm
inner pivot bushes. Noise or vibration in the
front end can also be caused by excessive
tire or wheel unbalance. Drive shaft joint
noise is usually more pronounced when
moving slowly with the steering on full lock.
POOR OR ERRATIC ROAD HOLDING
ABILITY
(1) Low or uneven tire pressures: Inflate the
tires to the recommended pressures.
(2) Defective suspension unit: Renew the faulty
unit, preferably in pairs.
Page 158 of 238
158 Front Suspension
Installed view of the front suspension. When using a floor jack locate the head of the jack on the crossmember.
(2) Remove the cap, split pin, castellated re-
tainer and with the aid of an assistant applying the
brakes, loosen and remove the hub nut.
(3) Remove the split pin and the castellated nut
retaining the tie rod end to the steering knuckle. (4) Disconnect the tie rod end from the steering
knuckle using a suitable puller. Alternatively place a
suitable dolly or hammer against one side of the
steering knuckle eye and strike the opposite side with
a hammer.
(5) Remove the brake caliper anchor plate bolts,
withdraw the caliper from the disc and support it with
a piece of wire inside the inner mudguard. Ensure that
the brake hose is not twisted.
(6) Withdraw the brake disc from the hub.
(7) Loosely install the hub nut and tap on the nut
with a soft faced hammer to separate the drive shaft
from the hub. (8) Place a mark on the suspension unit to
steering knuckle cam head bolt to ensure correct wheel
alignment on assembly. (9) Remove the steering knuckle to suspension
unit nuts and bolts. (10) Remove the split pin and the castellated nut
retaining the lower ball joint stud to the steering
knuckle. (11) Disconnect the ball joint stud from the steering knuckle using a suitable puller or alternatively
place a suitable dolly or hammer against one side of
the steering knuckle eye and strike the opposite side
with a hammer.
(12)
Withdraw the steering knuckle from the
vehicle taking care not to drop the drive shaft or
damage its boot. (13) Clean and check the steering knuckle for
wear, cracks and damage. (14) If necessary, dismantle the hub and check
the bearing assembly using the dismantling procedure
described later in this section. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Install the steering knuckle and hub assembly
over the drive shaft and loosely install the ball joint
stud nut and the suspension unit to knuckle bolts and
nuts.
(2) Ensure that the suspension unit to steering
knuckle cam head bolt mark s are aligned and tighten
the retaining nuts to the specified torque.
NOTE: If the cam head bolt is not installed
in its original position, a wheel alignment
should be performed.
(3) Tighten the ball joint to steering knuckle stud
bolt to the specified torque.
Page 159 of 238
Front Suspension 159
(4) Install the tie rod end to the steering knuckle
and tighten the castellated nut securely. Install a
new
split pin.
(5) Install the brake disc to the hub.
(6) Install the brake caliper to the steering
knuckle and tighten the retaining bolts to the specified
torque. (7) Install the hub nut and washer to the
drive
shaft and with the aid of an assistant applying the
brakes, tighten the hub nut to the specified torque. (8) Install the hub nut retainer and a new
split
pin to the drive shaft. (9) Check the hub end float as described later in
this section. (10) Install the fron t wheel and lower the vehicle
to the ground.
TO DISMANTLE
NOTE: The front wheel bearing assembly is
non-serviceable. If the wheel bearing is dis-
mantled for any reason it should be re-
newed.
(1) Remove the steering knuckle from the vehi-
cle as previously described. (2) Hold the steering knuckle assembly in a vice
with soft jaw guards. (3) Using a hammer and a suitable pipe or tube
that pushes on the inside of the hub, drive out the
wheel hub and outside inner race from the steering
knuckle assembly. (4) Using snap ring pliers, remove the snap ring
that retains the outer bearing race from the wheel side
of the steering knuckle. (5) Using a suitable press and press plates,
support the steering knuckle with the outside face
downwards. To aid in dismantling, position the inside
inner race in the bearing and press the assembly from
the steering knuckle. Discard the bearing assembly. (6) Using a bearing puller and a press, remove
the inner race from the hub assembly. If the inner race cannot be removed from the hub
in this manner, it may be necessary to grind the race
using an angle grinder and split the race using a cold
chisel.
(7) Thoroughly clean and dry the steering
knuckle and hub in a suitable solvent. (8) Inspect all the components for wear, damage
and cracks and renew if necessary.
TO ASSEMBLE
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:
(1) Apply grease to the oil seal lips of the new
bearing assembly.
NOTE: Ensure that (he inside of the outer
race of the bearing is precoated with wheel
bearing grease. If necessary, pack the outer
race of the wheel bearing with wheel bearing
grease after it is installed to the steering
knuckle.
(2) Using the press and press plates, support the
steering knuckle with the outside face uppermost.
Using a suitable diameter steel tube that contacts on
the outer race only, press the outer race full into the
steering knuckle.
(3) Install the snap ring to the groove in the
steering knuckle.
(4) Install the inner races to the steering
knuckle
and support the inner race on the press using a
suitable tube or mandrel. (5) Using the press and a suitable tube press the
hub assembly into the steerin g knuckle. When using
the press ensure that the pressing force does not
exceed 29 kN. (6) With the press exerting a force of 44.1 kN
rotate the steering knuckle from side to side several
turns to ensure that the wh eel bearings are operating
smoothly.
(7) Install the steering knuckle to the vehicle
as
previously described.
TO CHECK HUB END FLOAT
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheel.
(2) Mount the dial gauge on the steering knuckle
so that the dial gauge plunger is against the wheel hub.
(3) Zero the dial gauge and attempt to move the
hub in and out. Total hub e nd float should not exceed
0.05 mm. (4) Renew the wheel bearing as previously de-
scribed if necessary.
4. SUSPENSION UNIT
Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheels.
Dismantled view of the steering knuckle and hub
components.
Page 160 of 238
160 Front Suspension
(2) Disconnect the flexible brake hoses from the
suspension unit bracket.
(3) Using quick drying paint, place mating
marks on the camber adjustin g cam head bolt and the
suspension unit lower mounti ng as an aid to installa-
tion. (4) Remove the bolts and nuts retaining the
suspension unit lower mounting to the steering
knuckle. (5) Open the bonnet and remove the nuts
retaining the suspension unit upper mounting to the
inner mudguard panel and remove the suspension
unit assembly from the vehicle. Use care when
removing not to damage the drive shaft boot.
(6) Remove the dust cover and loosen the piston
rod nut but do not remove it at this stage. (7) Install a spring compressor to the
suspension
unit assembly. Compress the coil spring and remove
the piston rod nut. (8) Remove the washer, upper mounting assem-
bly, the thrust washer, spring seat, insulator, coil
spring, bump rubber and dust cover from the suspen-
sion unit. (9) Check the operation of the suspension unit.
With the suspension unit in a vertical position, move
the piston rod up and down a number of times. A
Dismantled view of the front suspension unit.
uniform resistance should be felt with no abnormal
slack spots or noise evident. If the suspension unit is
defective, it should be renewed.
NOTE: It is recommended that the suspen-
sion unit on the opposite side be renewed at
the same time.
(10) Check the upper mounting assembly for
damage and fatigue. Check the thrust washer for wear.
Check all rubber components, the spring seat and
insulator for wear, damage and deterioration. Renew
worn or damaged components. (11) Check the coil spring for fatigue by compar-
ison with a new spring. Al so check the spring for
cracks and damage. If the coil spring is defective, it is
recommended that the springs on both sides be
renewed.
TO ASSEMBLE AND INSTAL
Assembly and installation is a reversal of the
removal and dismantling procedure with attention to
the following points:
View of the front suspension unit with the spring
compressor installed.
Page 161 of 238
Front Suspension 161
View of the suspension unit and knuckle assembly removed as a unit to show the cam head bolt.
(1) With the piston rod fully extended, install the
coil springs. Ensure that the spring compressor is
tightened sufficiently.
NOTE: The flat coiled end of the spring
should face the top and the lower end of the
spring should be located correctly.
(2) Install the dust cover, bump rubber, insulator,
spring seat, thrust washer and mounting assembly
ensuring that the arrow on the spring seat will face the
outside of the vehicle when the suspension unit
assembly is installed.
(3) Install the piston rod nut and tighten the nut
securely.
(4) Remove the coil spring compressor from the
suspension unit assembly and tighten the piston rod
nut to the specified torque. (5) Install the suspension unit assembly to the
vehicle, holding it in position by loosely installing the
upper mounting retaining nuts. (6) Install the suspension unit assembly lower
mounting to the steering knuckle, align the mating
marks on the cam head bolt and tighten the nuts and
bolts to the specified torque.
NOTE: If the cam head bolt is not installed
in its original position, a wheel alignment
must be performed.
(7) Tighten the upper retaining nuts to the
specified torque.
(8) Install the brake hoses to the suspension unit.
Lower the vehicle to the ground.
(9) Check the front wheel alignment and adjust
as necessary. Refer to the Suspension and Steering
Angles heading in this section.
5. CONTROL ARM
Special Equipment Required:
To Renew Ball Joint and Control Arm Bushes —
Press, suitable t ubes and mandrels
To Test Ball Joint — Small torque wrench or
preload gauge, spring scale
TO REMOVE AND INSTAL
(1) Loosen the front wheel nuts, raise the front
of the vehicle and support it on chassis stands.
Remove the front wheel.
(2) Remove the split pin from the ball joint
retaining nut and remove the nut.
(3) Disconnect the ball joint from the control
arm using a suitable puller, or alternatively place a
suitable dolly against one si de of the control arm eye
and strike the opposite side with a hammer until the
ball joint stud is free from the control arm eye. (4) Remove the nut retaining the stabilizer link
to the control arm.
(5) Remove the nut and through bolt from the
front control arm bush. (6) Remove the bolts from the rear control arm
bush bracket and withdraw the control arm from the
vehicle. (7) Inspect the control arm for cracks, damage
and distortion and renew if necessary. (8) Inspect the ball joint and bushes for damage,
deterioration and excessive wear. If necessary renew
BALLJOINT
View of the control arm and associated components.
Page 165 of 238
Rear Suspension 165
Checking the rear control arm outer pivot bolt for security.
(5) Loose or worn control arm bushes or pivot
bolts: Check and tighten or renew the worn compo-
nents.
NOTE: Check the service ability of the sus-
pension units, control arm bushes and pivot
bolts as previously described.
If incorrect rear wheel alignment is sus-
pected, it is recommended that the vehicle be
taken to a wheel alignment specialist or a
Nissan dealer to be checked and if necessary
adjusted.
Visually inspect the stabilizer bar for
damage.
2. DESCRIPTION
The independent type rear suspension consists of
a suspension unit, a knuckle assembly which incorpo-
rates the stub axle, inboard control arms and a
stabilizer bar.
The suspension unit consists of a sealed, oil filled
shock absorber, enclosed at the upper end by a coil
spring on which an upper mounting assembly is
located and attached to the body.
The shock absorber piston rod is attached to the
centre of the suspension unit upper mounting assem-
bly.
The lower end of the suspension unit is attached
to the knuckle assembly to which the brake caliper
and/or the brake backing plate is mounted.
The control arms are attached to the knuckle
assembly at the outer end, and the crossmember at the
inner end.
The stabilizer bar is attached to the knuckle
assembly and mounted to the underbody. As well as
reducing body roll when cornering it also secures the
knuckle assembly, preventing fore and aft movement.
Adjustment of the toe out is provided by a
graduated cam mounted on the rear control arm inner
pivot bolt. Each graduation on the cam is equivalent
to 2 mm adjustment.
Camber is set in production and cannot be
adjusted. If the camber is not within Specifications,
inspect the suspension components and renew the
damaged or worn components as necessary.
Installed view of the rear suspension.
Page 166 of 238
166 Rear Suspension
3. REAR HUB
Special Equipment Required
To Check Hub Bearing End Float — Dial gauge
To Renew Bearing — Press and suitable drift
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the rear wheel and release
the handbrake.
(2) On models with rear drum brakes, proceed
to operation (6).
(3) Remove the clip securing the brake hose to
the suspension unit and disengage the hose.
(4) Remove the bolts securing the brake caliper
to the knuckle assembly. (5) Slide the caliper from the disc and support it
away from the working area, ensuring that no excess
strain is placed on the brake hose. (6) Rotate the hub and check that it rotates
smoothly. If it does not rotate smoothly, renew the
hub bearing. (7) Mount a dial gauge with the plunger posi-
tioned against the outer face of the hub. Move the hub
back and forth in line with the stub axle and note the
reading on the dial gauge. If the end float exceeds
Specifications, renew the hub bearing.
(8) Remove the hub grease cap from the rear
hub. (9) Remove the split pin from the stub axle and
remove the nut retainer, the hub retaining nut and
washer. Remove the hub assembly from the stub axle. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Tighten the hub retaining nut to the specified
torque. (2) Check the hub bearing end float as previ-
ously described.
(3) On models with disc brakes, install the brake
caliper and tighten the retaining bolts to the torque
specified in the Brakes section. Install the brake hose to
the suspension unit and secure with the retaining clip.
TO RENEW BEARING
(1) Remove the rear hub as previously de-
scribed. (2) Remove the snap ring from the rear of the
hub assembly. (3) Support the rear of the hub around the
bearing housing, ensuring that the bearing will not be
obstructed when being pressed out. (4) Using a suitable drift, press the bearing out
of the hub.
Dismantled view of the rear hub assembly. Drum brake
model.
Tightening the hub retaining nut with a torque wrench. Dismantled view of the rear hub assembly. Disc brake
model.