check engine NISSAN PULSAR 1987 Manual Online
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 113 of 238
Fuel and Engine Management 113
(2) Disconnect the wiring connector from the
MAT sensor.
(3) Unscrew the sensor from the inlet manifold.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Apply Loctite 567 or a similar conductive
sealer to the threads of th e sensor. Tighten the sensor
to the specified torque. (2) Ensure that the wiring connector is clean and
tight.
OXYGEN SENSOR
To Test - Code 13
(1) Run the engine until the normal operating
temperature is obtained. (2) With the ignition switched Off, connect a
jumper lead between terminals A and B on the
diagnostic link connector.
(3) Start and run the engi ne at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp.
If the ECM warning lamp flashes at the rate of
twice per second, proceed to operation (5).
If the ECM warning lamp flashes at the rate of
once per second or slower, proceed as follows.
(4) Remove the jumper lead from the diagnostic
link connector and run th e engine above 2 000 rpm
for 2 minutes, noting the ECM warning lamp.
If the ECM warning lamp lights, stop the engine,
switch the ignition On and connect a jumper lead
between terminals A and B on the diagnostic link
connector. If code 13 is displayed proceed to opera-
tion (5).
If the ECM warning lamp does not light, an
intermittent fault is indicated. Proceed as follows:
(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure.
(b) Check that all earth wires are secure.
(5) Switch the ignition Off and disconnect the
oxygen sensor wiring connector. Using a jumper lead
connect the oxygen sensor wiring connector to a
suitable engine earth. (6) Start and run the engi ne at approximately
1 600-1 800 rpm and note the ECM warning lamp.
The lamp may flash for a few seconds but should then
extinguish for at least 30 seconds.
If the ECM warning lamp functions as described,
proceed to operation (7).
If the ECM warning lamp does not function as
described proceed as follows:
(a) Check the wiring harness between the oxygen
sensor wiring connector and the control unit wiring
connector D7 for open circuits. Repair or renew the
wiring harness as necessary.
{b) Check the earth circuit between the control
unit wiring connect D6 and the right rear cylinder
head bolts. Repair or renew the wiring harness as
necessary.
(c) If no fault is found in (a) and (b) renew the
control unit and retest for fault codes.
(7) Check the wiring harness earth circuit be-
tween the control unit wiring connector D6 and the
right rear cylinder head bolts. Repair or renew the
wiring harness as necessary.
If no fault is found, thoroughly check the oxygen
sensor connector. If the conne ctor is not faulty, renew
the oxygen sensor.
To Test - Code 44
(1) Run the engine until normal operating tem-
perature is attained.
(2) With the ignition switched Off, connect a
jumper lead between terminals A and B on the
diagnostic link connector. (3) Start and run the engi ne at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp. If the ECM warning lamp is off more than on or
flashes at the rate of twice per second, proceed to
operation (4).
If the ECM warning lamp flashes evenly at the
rate of once per second an intermittent fault is
indicated. Proceed as follows:
(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth wires are secure.
(4) Switch the engine Off and disconnect the
oxygen sensor wiring connector.
(5) Start and run the engine at 1 600-1 800 rpm
for at least 30 seconds and note the ECM warning
lamp. If the ECM warning lamp flashes at the rate of
twice per second procee d to operation (6).
If the ECM warning lamp extinguishes for at least
30 seconds, check the wiring harness between the
oxygen sensor wiring connector and the control unit
wiring connector terminal D7 for shorts to earth.
Repair or renew the wiring harness as necessary.
If no fault can be found in the wiring harness, renew
the control unit.
Installed view of the oxygen sensor.
Page 114 of 238
114 Fuel and Engine Management
(6) Check the vehicle for the following:
(a) Low fuel pressure.
(b) Contaminated fuel.
(c) Vacuum leaks at the inlet manifold, engine
vacuum hoses and engine ventilation hoses. (d) Exhaust manifold leaks before the oxygen
sensor. (e) Correct MAP sensor operation.
(f) Blocked oxygen sensor metal vent cover eg.
plugged with mud etc. (g) Fuel injectors) partially blocked. Refer to a
fuel injection specialis t or a Nissan dealer.
If the above items have been checked and no
faults have been found, a faulty oxygen sensor is
indicated. Renew the oxygen sensor, run the engine
and ensure that no fault codes are set.
To Test — Code 45
(1) Run the engine until normal operating tem-
perature is attained. (2) With the ignition switched Off, connect a
jumper lead between terminals B and A on the
diagnostic link connector. (3) Start and run the engine at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp. If the ECM warning lamp is on more than off or
flashes at the rate of twice per second, proceed to the
following operation.
If the ECM warning lamp flashes evenly at the
rate of once per second an intermittent fault is
indicated. Proceed as follows:
(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth wires are secure.
(4) Switch the engine Off and disconnect the
oxygen sensor wiring connector. (5) Using a jumper lead, connect the oxygen
sensor wiring connector to a suitable engine earth. (6) Start and run the engine at 1 600-1 800 rpm
and note the ECM warning lamp.
If the ECM warning lamp extinguishes for at least
30 seconds, proceed to operation (7).
If the ECM warning lamp flashes on more than off
or flashes at the rate of twice per second, switch the
engine Off and disconnect the control unit wiring
connectors. Using an ohmmeter, check that there is no
resistance between the co ntrol unit wiring connector
terminal D6 and earth. Repair or renew the wiring as
necessary.
If no fault can be found in the wiring harness,
renew the control unit.
NOTE: The wiring harness for terminal D6
earths through the righ t hand rear cylinder
head bolt.
(7) Check the vehicl e for the following:
(a) High fuel pressure.
(b) Leaking injector(s).
(c) Faulty ignition wiring.
(d) Charcoal canister purge system blocked or
restricted.
(e) Faulty coolant temper ature sensor circuit.
(f) Faulty MAT sensor circuit (1.8 liter engine).
(g) MAP sensor operation.
(h) Throttle position sensor operation.
If the above items have been checked and no
faults have been found, a faulty oxygen sensor is
indicated.
Renew the oxygen sensor, run the engine and
ensure that no fault codes are set.
To Remove and Install
(1) If the engine is cold, run the engine for
approximately two minutes to allow easy oxygen
sensor removal. (2) Disconnect the negative battery terminal and
the oxygen sensor connector.
View of the oxygen sensor removed from the exhaust
manifold.
(3) Remove the exhaust manifold heat shield
retaining bolts and remove the heat shield from the
engine.
(4) Remove the oxygen sensor with a short ring
spanner using care not to damage the sensor wire. Installation is a reversal of the removal procedure
with attention to the following points:
(1) When installing a sensor that has previously
been removed, coat the sen sor threads with anti-seize
compound. Nissan recommend a mixture of liquid
graphite and glass beads. (2) Install the sensor and tighten to the specified
torque. (3) Connect the electrical connector ensuring
that the wiring is secured away from the exhaust. (4) Install the heat shield and tighten the retain-
ing bolts securely. On 1.6 liter engines, ensure that the hot air inlet
tube is located correctly be tween the heat shield and
the air cleaner housing.
(5) Start the engine and check for leaks.
VEHICLE SPEED SENSOR
To Test - Code 24
(1) Check the fuel pump and meter fuses. If the
fuses are serviceable, proceed to operation (5). If a
fuse is blown, rectify the cause and renew the fuse.
Page 115 of 238
Fuel and Engine Management 115
Erase the fault codes and retest for fault codes as
follows:
(2) Start and run the engine until normal oper-
ating temperature is attained. (3) Drive the vehicle at a speed of at least 80
km/h and, with the throttle closed, allow the vehicle to
decelerate until the engine speed is below 1 500 rpm.
NOTE: After rectifying any fault it will be
necessary to retest for fault codes. To test for
Code 24 the vehicle must be driven as
previously described.
(4) Switch the engine Off and connect a jumper
lead between terminals A and B on the diagnostic link
connector. Switch the ignition On and note the fault
codes. If code 24 is displayed proceed as follows. (5) Check the operation of the speedometer and
the instrument cluster warning lamps. If the speed-
ometer only is not functioning, proceed to operation
(13).
If the speedometer and the instrument cluster
warning lamps are not functioning, a fault in the
instrument cluster wiring harness is indicated. Refer
the fault to an auto electrical workshop or a Nissan
dealer.
If the speedometer is functioning, proceed as
follows:
(6) Raise the front of the vehicle and support it
on chassis stands. (7) Place the transaxle in Neutral and switch the
ignition On. (8) With the aid of assistants, slowly spin the
front wheels by hand while backprobing the control
unit wiring connector terminal A10 with a digital
voltmeter to earth. The voltage should alternate from under 1 volt to
over 10 volts.
If the voltmeter readi ng is not as specified,
proceed to operation (9).
If the voltmeter reading is as specified, the vehicle
speed sensor is operating satisfactorily, indicating an
intermittent fault was the cause of the fault code.
Proceed as follows:
(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth c onnections are secure.
(9) Remove the instrument cluster as described
in the Electrical System section. (10) With the ignition switched On, backprobe
the control unit wiring connector terminal A10 with a
voltmeter to earth. The voltage should be over 10
volts. If the voltage is less than specified, check the
wiring harness for shorts to earth between the black
and yellow wire terminal on the instrument cluster
wiring connector and the control unit connector
terminal A10. Repair or renew the wiring harness as
necessary. If no fault can be found, renew the control
unit.
(11) With the ignition switched On, backprobe
the black and yellow wire terminal on the instrument
cluster wiring connector with a voltmeter to earth.
The voltage should be over 10 volts.
If the voltage is less than specified, locate the open
circuit between the instrument cluster black and
yellow wire terminal and the control unit wiring
connector terminal A10. Repair or renew the wiring
harness as necessary.
(12) With a test lamp connected to 12 volts,
backprobe the black wire terminals on the instrument
cluster wiring connectors. The test lamp should light.
If the test lamp does not light locate the open
circuit between the black wire terminals and earth.
Repair or renew the wiring harness as necessary.
If the test lamp does light, renew the signal
divider circuit board which is located in the instru-
ment cluster.
(13) With the ignition switched On and the
engine not running, disconnect the vehicle speed
sensor wiring connector from the harness connector.
(14) With a test lamp connected to earth, probe
the yellow wire terminal on the harness wiring con-
nector. The test lamp should light. If the test lamp does not light, locate the open
circuit between the yellow wi re terminal and the Fuel
Pump fuse. Repair or renew the wiring harness as
necessary.
(15) With a test lamp connected to 12 volts,
probe the black wire terminal on the harness wiring
connector. The test lamp should light.
If the test lamp does not light, locate the open
circuit between the black wire terminal and earth.
Repair or renew the wiring harness as necessary.
(16) Using a voltmeter measure the voltage at the
red wire terminal on the harness wiring connector.
If the voltage is 5-9 volts proceed to operation
(19).
If the voltage is over 9 vol ts proceed to operation
(18).
Installed view of the vehicle speed sensor.
Page 116 of 238
116 Fuel and Engine Management
Rear view of the instrument cluster showing the flexible printed circuit.
If the voltage is under 5 volts proceed as follows.
(17) Check the wiring harness for continuity or
shorts to earth between th e red wire terminal on the
speed sensor harness connector and the green and
black wire terminal on th e instrument cluster wiring
connector.
If no fault can be found check the instrument
cluster printed circuit for continuity or shorts. If no
fault can be found, renew the speedometer and the
signal divider circuit board.
(18) Remove the instrument cluster as described
in the Electrical System se ction and repeat operation
(16).
If the voltage is under 1 volt, check the flexible
printed circuit on the rear of the instrument cluster for
continuity or shorts and re new as necessary. If no fault
can be found, renew the speedometer and the signal
divider circuit board.
(19) Connect the harness connector to the vehicle
speed sensor wiring connector. (20) Raise the front of the vehicle and support it on chassis stands. Place the transaxle in Neutral.
(21) With the aid of assistants, slowly spin the
front wheels by hand while backprobing the brown
wire terminal on the vehicle speed sensor wiring
connector with a voltmeter to earth.
The voltage should alternate between approxi-
mately 1 and 7 volts.
If the voltage is as specif ied, check the flexible
printed circuit on the rear of the instrument cluster for
continuity or shorts. If no fault can be found, renew
the speedometer and the signal divider circuit board.
If the voltage is not as specified, proceed as
follows.
(22) Disconnect the vehicle speed sensor wiring
connector and unscrew the sensor from the speedom-
eter drive housing. (23) Rotate both front wheels in the same direc-
tion and check that the speedometer drive shaft is
turning and does not slip. If the drive shaft does not operate as described,
renew the drive assembly as described in the Manual
or Automatic Transaxle section.
If the drive shaft operates satisfactorily, renew the
vehicle speed sensor.
To Remove and Install
(1) Disconnect the negative battery terminal.
(2) Disconnect the vehicle speed sensor wiring
connector. (3) Unscrew the vehicle speed sensor from the
speedometer drive housing.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Align the cut-out in the speedometer drive
shaft with the notch in the vehicle speed sensor shaft.
(2) Tighten the vehicle speed sensor securely.
Page 117 of 238
117
EMISSION CONTROL
INTRODUCTION
To reduce the output level of the three primary
automotive emissions, carbon monoxide (CO), hydro-
carbons (HC) and oxides of nitrogen (NOx), and thus
comply with legislation on the maintenance of clean
air, several different emissi on control systems are used
in the Pulsar range of vehicles covered by this manual.
The systems will be discussed under the headings
( 1 ) Crankcase Ventilation System, (2) Evaporative
Control System, (3) Air Preheat System — 1.6 Liter
Engine and (4) Exhaust Control System.
1. CRANKCASE VENTILATION SYSTEM
DESCRIPTION
The crankcase ventilation system is of the closed
type and is designed to prevent crankcase vapors
being emitted into the atmosphere. Crankcase
vapors are caused by gases escaping past the piston
rings into the crankcase during the combustion pro-
cess.
The crankcase vapors are collected in the cam-
shaft housing from the cra nkcase via the various oil
drain passages and the pipe from the side of the
crankcase.
The crankcase vapors are then drawn into the
engine via a branched hose connected to the camshaft
housing oil baffle and the throttle body (1.8 liter
engines) or inlet manifold (1.6 liter engines).
At idle speed, vapors are drawn through the
small branch of the hose and into the engine.
As the engine speed increases, vapors are also
drawn into the engine via the main hose.
TO SERVICE THE SYSTEM
(1) At intervals of 40 000 km, disconnect the
small engine ventilation hose from the throttle body
or inlet manifold and check that the metering orifice
is not blocked.
If necessary, clean the orifice using compressed air
and solvent.
(2) Disconnect all the engine ventilation hoses
and check for blocking, collapsing and deterioration.
Renew the hoses as necessary.
2. EVAPORATIVE CONTROL SYSTEM
Special Equipment Required:
To Test Purge Valve — Hand vacuum pump
DESCRIPTION
The evaporative control system reduces the
amount of hydrocarbons emitted to the atmosphere
through fuel evaporation.
The vehicles covered by this manual use an
absorption regeneration system to reduce vapor loss.
The system utilizes a canister of activated charcoal to
trap and hold the fuel vapors until they can be fed
into the induction system for burning in the combus-
tion chambers.
The basic components of the evaporative control
system are a fuel tank with a sealed filler cap, a
charcoal canister with a pur ge control valve, a fuel
check valve and pipes a nd hoses to connect the
various components.
NOTE: The fuel tank filler cap is not vented
to the atmosphere but is equipped with a one
way relief valve to prevent a vacuum form-
ing in the fuel tank.
View of the engine ventilation hoses and pipe. 1.8 liter
engine.
Page 118 of 238
118 Emission Control
Installed view of the charcoal canister.
When the engine is at rest, fuel vapor through
evaporation gradually fills the air space in the fuel
tank. The sealed filler cap pr events the escape of this
vapor and pressure builds up within the system,
forcing the vapor to flow into the charcoal canister
which is located in the engine compartment beneath
the windscreen wiper motor.
The fuel check valve prevents liquid fuel entering
the charcoal canister when the fuel tank is full or the
vehicle is parked on a steep incline. When the engine
is running, the vapor is drawn via a hose from the
charcoal canister to the throttle body and burnt in the
combustion chambers.
TO RENEW CHARCOAL CANISTER
(1) Suitably mark and disconnect the hoses from
the canister. (2) Release the retaining spring and remove the
canister from the engine compartment. Installation is a reversal of the removal procedure.
TO RENEW FUEL CHECK VALVE
(1) Disconnect the negative battery terminal.
(2) Raise the rear of the vehicle and support it
on chassis stands. Remove the left hand rear wheel. (3) Drain the fuel from the fuel tank using a
hand pump or a suitable siphon. Do not siphon fuel
using the mouth.
(4) Remove the hoses from the check valve.
(5) Squeeze the retaining clip and remove the
check valve from the mounting bracket. Installation is a reversal of the removal procedure.
TO SERVICE THE SYSTEM
(1) Inspect the vacuum lines and connectors for
signs of leakage, cracks and deterioration and renew
as necessary. (2) Remove the fuel tank cap and check that a
slight resistance is felt, when vacuum is applied to the
one-way relief valve in the centre of the cap. Renew the fuel tank cap if no resistance is felt or
if the valve is blocked.
(3) Inspect the fuel tank cap seal for deteriora-
tion. Renew as necessary.
Installed view of the fuel check valve as seen with the
left hand rear wheel removed.
Check the fuel filler cap seal for damage.
23Q/LDZ GAUGE
Line drawing showing a hand vacuum pump.
Page 119 of 238
Emission Control 119
(4) Remove the charcoal canister as previously
described under the heading To Renew Charcoal
Canister. (5) Shake the canister, there should no audible
carbon movement. If there is, renew the canister. (6) Check the purge valve by applying 20-35
kPa of vacuum with a hand pump to the control port. Using a piece of hose, blow through the purge
hose connection. If this is not possible, renew the
canister.
Remove the vacuum source and blow air through
the purge hose connection. If this is possible, renew
the canister.
(7) Apply 20-35 kPa air pressure into the fuel
tank connector. Air should flow freely from all the
other connectors.
If poor air flow through the drain tube exists,
block off the fuel tank tube and blow compressed air
at approximately 300 kPa through the purge port.
Check the air flow and if st ill poor, renew the canister.
(8) Apply 20-35 kPa air pressure to any one of
the canister ports except th e purge valve control port
and with the other ports blocked, ensure that there are
no leaks from the canister. If leaks exist, renew the
canister. (9) Remove the fuel check valve as previously
described under the heading To Renew Fuel Check
Valve. (10) Blow through the check valve from the side
that is connected to the fu el tank hose. Considerable
resistance should be felt with only a small amount of
air passing through the valve. If no resistance is felt or
if the valve is blocked renew the fuel check valve.
(11) Blow air through the fuel check valve from
the opposite end. There should be a smooth flow of air
through the valve. If the valve is blocked, renew the
fuel check valve.
3. AIR PREHEAT SYSTEM — 1.6 LITRE
ENGINE
DESCRIPTION
To reduce emissions and improve drivability
when the engine is cold, hot air is drawn into the air
cleaner from a heat shield which partially surrounds
the exhaust manifold.
When the ambient temperature is below 30°C, the
thermal vacuum valve, which is located inside the air
cleaner housing, allows vacuum to operate a servo
actuated flap in the air cleaner intake duct. When the
flap closes, hot air is dr awn from the exhaust heat
shield, through the hot air inlet tube into the air
cleaner intake duct.
When the ambient temperature is above 30°C,
the flap in the air cleaner intake duct opens allowing
cool air to enter the air cleaner.
View of the air preheat system components. 1.6 liter
engine.
TO CHECK OPERATION
(1) When the engine is cold, use a mirror to
check that the passage from the hot air inlet tube is
closed by the flap.
(2) Start and run the engi ne at approximately
1 200 rpm. The hot air inlet passage should now be
open, allowing hot air from the exhaust heat shield to
be drawn into the air cleaner. (3) Allow the engine to idle for fifteen minutes
and inspect the position of th e air cleaner intake flap.
The flap should now be in the open position allowing
cool air to be drawn into the air cleaner and shutting
oft' air from the exhaust manifold heat shield.
TO CHECK COMPONENTS
(1) Disconnect the vacuum hose from the servo
unit and connect a vacuum pump to the unit.
When the vacuum is applied to the servo unit, the
flap in the air cleaner intake duct should close.
When the vacuum is removed, the flap should
open.
View of the air cleaner raised showing the engine
ventilation hose and the thermal vacuum valve supply
hose connection. 1.6 liter engine.
Page 120 of 238
120 Emission Control
If the flap does not operate as described, renew
the air cleaner housing.
(2) Disconnect the vacuum hose from the servo
unit and connect it to a vacuum gauge.
(3) Start and run the engine at approximately
1 200 rpm. If the engine is cold there should be
vacuum. (4) As the engine temperature increases the
vacuum should decrease to zero. If the vacuum gauge does not read as described,
check that the vacuum supply hose is connected to the
thermal vacuum valve and the throttle body.
If no fault is found, renew the thermal vacuum
valve.
4. EXHAUST CONTROL SYSTEM
DESCRIPTION
The exhaust system is the greatest source of
pollutant emission from the internal combustion
engine.
On the Pulsar range of vehicles covered by this
manual, the exhaust control system consists of a
catalytic converter and the engine management sys-
tem. The engine management system constantly mon-
itors the exhaust gases via an oxygen sensor located in
the exhaust system. Fuel injection is then adjusted
accordingly to give the minimum amount of exhaust
emissions. Refer to the Fuel and Engine Management
section for further information.
CATALYTIC CONVERTER
The catalytic converter, which is located in the
exhaust system, converts hydrocarbons, oxides of
nitrogen and carbon monoxide present in the exhaust
gases into carbon dioxide, nitrogen, water and heat.
The catalytic converter does not require periodic
maintenance or replacement under normal circum-
stances. However, it can be damaged or poisoned by
excessively high exhaust gas temperatures, raw fuel
and the use of leaded fuel.
Installed view of the catalytic converter.
To prevent the use of leaded fuel, a small diam-
eter fuel filler neck with a spring loaded trap door is
used.
To prevent damage to the catalytic converter, the
following precautions sh ould be observed.
(1) Do not operate the vehicle on leaded fuel.
(2) Do not push or tow start the vehicle.
(3) Do not allow the engine to idle for prolonged
periods. (4) Do not operate the vehicle if the engine is
misfiring.
(5) Avoid running the vehicle out of fuel.
(6) Ensure that the engine oil is formulated to
contain low phosphorous levels.
To Inspect Catalytic Converter
(1) Inspect the converter for dents and damage.
If the converter is damaged, it should be renewed. (2) Inspect the converter heat shield for damage
and ensure that it is positioned correctly. Renew the
converter heat shield if necessary.
To Remove and Install
To remove and install the catalytic converter,
refer
to the Exhaust System heading in the Engine section.
Page 121 of 238
121
CLUTCH
SPECIFICATIONS
Type................................................... Single dry plate
Operation................................................... Mechanical
Pressure plate type .................................... Diaphragm
Release bearing type .......................Prelubri cated ball
Driven plate:
Outside diameter .................................... 215 mm
Rivet depth limit ....................................0.3 mm
Runout limit .........................................0.5 mm
Maximum spline backlash ...................0.7 mm
Pressure plate:
Diaphragm spring height
(installed) ...................................... 30.5-32.5 mm
Spring finger vari ation limit.....................0.5 mm
Clutch pedal:
Height .............................................. 175-185 mm
Free play ....................................... 12.5-17.5 mm
Release lever free play............................ 2.5-3.5 mm
Flywheel machining limit ...............................0.3 mm
TORQUE WRENCH SETTINGS
Pressure plate bolts.......................................... 29 Nm
Pedal pivot pin nut ......................................... 22 Nm
Cable loc knut.................................................... 4 Nm
Lower clutch housing to engine bolts.............. 21 Nm
Centre and upper clutch housing
to engine bolts .................................................. 49 Nm
1. CLUTCH TROUBLE SHOOTING
CLUTCH SLIPPING
(!) Worn driven plate facing: Check and renew
the clutch driven plate.
(2) Insufficient clutch pedal free play: Check and
adjust the clutch pedal free play. Ensure that the
release lever free play is correct.
(3) Weak or broken pressure plate diaphragm
spring: Check and renew the pressure plate assembly. (4) Worn or scored flywh eel: Machine or renew
the flywheel. Worn or scored pressure plate face: Renew the
pressure plate assembly.
Renew the clutch driven plate if the friction material is
worn down to, or is within 0.3 mm of the rivets.
NOTE: In most cases clutch slippage is first
evident by a marked increase in engine revs,
for no apparent reason, when pulling up a
steep hill. The clutch condition can be
positively diagnosed as follows: With the
handbrake firmly applied, and the rear
wheels chocked, select top gear and release
the clutch with the engine running at ap-
proximately 2 000 rpm. Clutch slippage is
evident if the engine does not stall. Make the
test as quickly as possible to prevent any
further clutch damage.
CLUTCH SHUDDER
(1) Oil on the driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Scored pressure plate or flywheel face: Re-
new the pressure plate assembly or machine the
flywheel. (3) Loose or damaged driven plate hub: Check
and renew the clutch driven plate. (4) Loose driven plate facings: Renew the clutch
driven plate. (5) Cracked pressure plate face: Renew the pres-
sure plate assembly.
Page 122 of 238
122 Clutch
Check the engine mountings for damage and deterio- ration.
NOTE: Clutch shudder is usually most
evident when reversing up an incline. As
loose or damaged engine mountings are a
cause for clutch shudder, thoroughly check
the engine mounting rubbers and mounting
hardware for damage or looseness before
removing the clutch for inspection.
CLUTCH GRAB
(1) Oil soaked driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Cracked pressure plate face: Renew the pres-
sure plate assembly. (3) Loose or broken engine mountings: Check
and renew the engine mountings as necessary.
(4) Binding release mechanism: Check the oper-
ation of the release mechanism.
NOTE: Visually check the operation of the
cable actuated release mechanism. Check
the inner cable for fraying and jamming in
the outer cable.
INSUFFICIENT CLUTCH RELEASE
(1) Stretched, frayed or broken clutch cable:
Check and renew the clutch cable. (2) Worn or damaged release mechanism: Check
and renew components as necessary. (3) Insufficient pedal height: Check and adjust
the pedal height.
(4) Warped clutch driven plate: Renew the
clutch driven plate. (5) Excessive clutch release lever free play:
Check and adjust the release lever free play to
Specifications.
NOTE: Visually check that the clutch cable
operates the release lever before removing
the clutch for inspection.
RELEASE BEARING NOISE
(1) Dry or worn release bearing: Check and
renew the release bearing.
(2) Damaged pressure plate diaphragm spring;
Check and renew the pressure plate assembly.
NOTE: Lightly depress the clutch pedal with
the engine running to check for release
bearing noise. If the release bearing is faulty
and has to be renewed, always check the
other clutch components.
Check the diaphragm spring fingers for scoring and damage.
2. DESCRIPTION
The clutch consists of a single, dry, driven plate
assembly, splined to slide on the transaxle input shaft.
A diaphragm spring type pr essure plate assembly is
bolted to the engine flywheel.
The driven plate is sandwiched between the
pressure plate and the flywheel and transmits the
drive from the engine to the transaxle.
Cushion rubbers are interposed between the hub
of the driven plate assembly and the plate friction
surfaces in order to cushion the drive.
The release mechanism is actuated by the clutch
pedal through a cable to the release lever and bearing.
Operation of the clutch pedal moves the release
lever which pushes the release bearing into contact
with the diaphragm spring fingers, forcing the dia-
phragm centre towards the flywheel. When the outer
edge of the diaphragm deflects, the clutch is caused to
disengage.
Clutch pedal free play is adjusted at the release
lever end of the clutch cable.
Clutch pedal height is adjusted at the pedal stop
on the pedal mounting bracket located under the
dashboard.