air filter NISSAN PULSAR 1987 Workshop Manual
[x] Cancel search | Manufacturer: NISSAN, Model Year: 1987, Model line: PULSAR, Model: NISSAN PULSAR 1987Pages: 238, PDF Size: 28.91 MB
Page 8 of 238
GENERAL INFORMATION
1. TOOLS AND EQUIPMENT
To successfully perform any maintenance or re-
pair work on a motor vehicle, suitable hand tools are
essential. The use of tools for other than their intend-
ed purpose or the use of incorrectly fitting tools can
cause damage to the componen t and/or injury lo the
operator.
BASIC TOOL KIT
The following is a sugg ested list of tools and
equipment for the majority of the maintenance and
repair procedures described in this manual. Of course,
not all of the tools are required for all the jobs, so it is
wise to purchase tools on an 'as needed' basis.
Set of open ended spanners.
Set of ring spanners.
Set of socket spanners.
Spark plug spanner.
Assorted bladed screwdrivers.
Assorted Philips screwdrivers.
Assorted pliers — combination, long nose, multi-
grip, vice grip, snap ring (internal and external).
Assorted adjustable spanners.
Ball pein hammer.
Cold chisels.
Pin punches and centre punch.
Assorted files.
Scraper.
Feeler gauges.
Torque wrench.
Hydraulic jack.
Chassis stands.
Car ramps.
Grease gun.
Oil can.
Oil gun.
Oil filter removal tool.
Funnel.
Containers for draining oil and washing compon-
ents.
A comprehensive tool kit showing a wide range of general hand tools.
Page 26 of 238
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.
Page 39 of 238
Engine 39
Oil pump cover plate screws............................ 6 Nm
Oil pump mounting bolts.................................. 6 Nm
Oil pump pickup bolts
(coat with Loctite 242)..................................... 8 Nm
Sump bolts (coat with Loctite 242) .................. 5 Nm
Sump drain plug .............................................. 35 Nm
*Use new bolts
Head bolts maximum torque 135 Nm
1. ENGINE MECHANICAL TROUBLE
SHOOTING
ENGINE MISSES AT IDLING SPEED
NOTE: For other causes of engine misfire,
refer to the Fuel and Engine Management
section.
(1) Blown head gasket: Check the cylinder com-
pressions and renew the he ad gasket as necessary.
(2) Burnt valves or seats in the cylinder head:
Check the cylinder compressions and overhaul the
cylinder head as necessary. (3) Broken or worn piston rings: Check the
cylinder compressions and renew the piston rings as
necessary.
(4) Weak or broken valve springs: Remove the
camshaft housing top cover and check the condition
of the valve springs. (5) Air leak at the inlet manifold gasket; Check
for air leaks by applying oil around the manifold
joints. Renew the gasket if an air leak is evident.
NOTE: Use a compre ssion gauge and check
the compression pressure in each cylinder as
described in the Engine Tune-up section. If
a low pressure reading is indicated in one or
more cylinders, remove the cylinder head for
gasket and valve inspection. Should the
gasket and valves prove satisfactory, inspect
the cylinder bores, pistons and rings.
Check for air leaks at the inlet manifold
by applying engine oil around the manifold
joints. If the oil can be seen or heard sucking
into the manifold or excessive smoke begins
to issue from the exhaust system, there is an
air leak at the inlet manifold.
NOISY VALVE OPERATION
(1) Faulty hydraulic tappets: Renew the faulty
tappet assemblies. (2) Weak or broken valve springs: Remove the
camshaft housing top cover and check the condition
of the valve springs. (3) Worn valve guides: Overhaul the cylinder
head as described in this section. (4) Worn rocker gear: Remove (he rocker gear
and check the components for wear.
Camshaft lobe wear is also a cause of noisy valve
operation.
BIG END BEARING NOISE
(1) Inadequate oil supply: Check the oil level in
the sump and the condition of the oil pump and relief
valve. Renew the oil filter.
(2) Excessive bearing clearance: Renew the bear-
ing shells, check and regrind the big end journals if
oval or tapered. (3) Thin oil or oil diluted by petrol or water:
Change to the correct oil grade. Check and rectify the
cause of the oil dilution. Ch eck that the engine is not
operating in overheat conditions.
(4) Low oil pressure: Check the engine oil level.
Check the pressure relief valve and spring and the oil
filter bypass valve. (5) Misaligned big end bearings: Align the con-
necting rods and renew the big end bearing shells.
NOTE: Big end bearing noise is indicated
by a metallic knock wh ich is usually loudest
at approximately 60 km/h with the throttle
Air leaks at the inlet manifold can be located by
applying engine oil around the suspect joints.
Page 42 of 238
42 Engine
The cylinder block is a cast iron alloy, deep skirt
design and the crankshaft is supported in the cylinder
block by five precision insert replaceable main bear-
ings. Crankshaft end float is controlled by the flanged
centre main bearing. Connecting rods are I section
forgings equipped with precision insert replaceable big
end bearings. The gudgeon pins are an interference fit
in the connecting rod and a floating fit in the piston.
The cast aluminum pistons are equipped with
two compression rings and one oil control ring.
The twin rotor, involute gear oil pump is mounted
directly to the front face of the cylinder block. The
inner rotor is internally driven by the crankshaft. The
oil pump pressure relief valve is not adjustable, and
consists of a plunger and spring mounted in the oil
pump body.
The pump draws oil through a screen in the sump
and delivers it, via a full flow replaceable oil filter, to
the oil gallery from where it is distributed to the
hydraulic tappets, camshaft and crankshaft bearings
and to the overhead rocker and valve mechanism.
3. ENGINE AND TRANSAXLE ASSEMBLY
Special Equipment Required:
To Remove and Instill — Suitable lifting tackle,
extra long chassis stands, suitable trolley
TO REMOVE
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurize the system before removing any
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
(1) Disconnect the negative battery terminal.
(2) Mark around the bonnet hinges with a soft
lead pencil Co facilitate correct installation. With the
aid of an assistant, remove the bonnet retaining bolts
and remove the bonnet from the vehicle.
(3) Drain the engine and transaxle lubricant.
(4) Open the coolant drain tap located on the
lower radiator pipe and drain the coolant. (5) Loosen the hose clips and disconnect the
heater hoses from the heater pipes at the bulkhead.
NOTE: Do not use excessive force to remove
the heater hoses from the heater pipes or the
heater core will become dislodged from the
heater unit. If necessary, cut the heater
hoses from the pipes using a sharp knife.
(6) Loosen the hose clamps and disconnect the
radiator hoses from the engine assembly. (7) Disconnect the positive lead from the bat-
tery. (8) On 1.8 liter models, disconnect the air inlet
duct.
(9) On 1.6 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary. (10) Disconnect the throttle cable from the throt-
tle body and from the camshaft housing top cover
bracket, if applicable. (11) Disconnect the fuel supply and return hoses.
Mark the hoses as an aid to installation. (12) Suitably mark and disconnect the charcoal
canister hoses. (13) Disconnect the injector wires from the injec-
tors. On 1.6 liter models, slide the wiring out from the
throttle body. (14) Disconnect the wiring fr om the throttle po-
sition sensor (TPS), idle air control (IAC) valve,
oxygen (O
2) sensor wire, coolant temperature sensor,
coolant sender and on 1.8 liter models, the manifold
air temperature (MAT) sensor. (15) Disconnect the wiring connector adjacent to
the top heater hose, the wiring from the alternator and
the two earth wires from underneath the cylinder head
bolts. (16) Lay the wiring loom over on the passenger
side of the engine compar tment, clear of the work
area.
(17) On manual transaxle models, loosen the
clutch cable adjusting nuts and remove the cable
through the slot in the lever. Remove the clutch cable
bracket from the transaxle after removing the retain-
ing bolts and place the cable to one side.
(18) Disconnect the wiring from the starter mo-
tor, speedometer sender and on manual transaxle
models, the reverse lamp switch wiring.
(19) If applicable, disconnect the power steering
lines from the pump and drain the fluid into a
container. Suitably plug the lines and the pump to
prevent the entry of dirt.
(20) On automatic transaxle models, disconnect
the selector cable and bracket from the transaxle
assembly.
Disconnect the transaxle oil cooler lines from the
transaxle. Plug the lines and fittings to prevent the
entry of dirt etc.
(21) Loosen the front wheel nuts, raise the front
of the vehicle and support it on extra long chassis
stands. Ensure that the vehicle is high enough to allow
removal of the engine from underneath. (22) Remove the front wheels and the engine
splash guards from the vehicle.
(23) On manual transaxle models, remove the
stay rod and control rod bolts and nuts and disconnect
the rods from the transaxle.
(24) Remove the lower control arm to steering
knuckle ball joint nuts and separate the ball joints
from the steering knuckle by holding a dolly or a
hammer against one side of the steering knuckle and
hitting the other side with a hammer. The taper on the
ball joint will release fr om the steering knuckle.
(25) Pull the steering knuckles outward swiftly to
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 83 of 238
Fuel and Engine Management 83
the fuel pump will not operate until the oil
pressure is sufficient to extinguish the oil
pressure warning lamp. Therefore it will be
necessary to operate the starter motor for a
longer period than usual to start the engine.
(3) Faulty EFI component wiring connections:
Check that all component wiring connections are
clean and secure.
(4) Manifold absolute pressure (MAP) sensor
vacuum hose blocked or disconnected: Clear or recon-
nect the vacuum hose. (5) Fault in the ignition system: Check the
primary and secondary ignition circuits.
(6) Engine flooded: Fully depress the throttle
pedal until the engine starts. Check the coolant
temperature sensor. Check th e injector(s) for leakage.
ENGINE STARTS THEN STALLS
(1) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(2) Air leakage at the inlet manifold: Check all
joints and hoses for air leaks. (3) Faulty EFI wiring connections: Check that
all component wiring connections are clean and
secure.
(4) Ignition timing incorrectly set: Check and
adjust the timing. (5) MAP sensor faulty or supply hose discon-
nected or blocked: Check the vacuum supply hose.
Check the operation of the MAP sensor.
ENGINE MISFIRES
(1) Faulty, dirty or incorrectly adjusted spark
plugs: Renew or clean and adjust the spark plugs.
(2) Condensation in the distributor cap: Dry and
examine the cap for cracks. (3) Faulty high tension leads: Check and renew
the high tension leads.
Testing the fuel system pressure using a pressure
gauge.
(4) Faulty ignition coil: Check and renew the
ignition coil.
(5) Fuel blockage: Check for blockage in the fuel
filter, lines and injector(s). (6) Low fuel pressure: Check the fuel pump and
fuel pressure regulator. (7) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter. (8) Loose fuel supply wiring connectors: Check
all connectors for tightness. (9) Faulty fuel injector: Check the connections
and test the condition of the fuel injectors.
ENGINE LACKS POWER
(1) Ignition timing incorrectly set: Check and
adjust the timing.
(2) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(3) Incorrectly adjusted throttle cable: Adjust the
throttle cable.
Check the distributor cap for cracks or tracking be- tween the terminals. The air filter element should be renewed at 40 000 km
intervals. 1.8 liter engine.
Page 86 of 238
86 Fuel and Engine Management
other. The fuel pressure is maintained at a constant
pressure relevant to the manifold vacuum. A dispos-
able paper element fuel filter is mounted on the engine
bulkhead.
The amount of fuel injected is relevant to the time
the injector remains open. The basic time the injector
remains open is governed by the control unit which
uses information from the various sensors to give
optimum engine efficiency for given conditions.
The idle air control (IAC) valve controls the fast
idle speed during engine warm up and maintains the
basic idle speed at a set value by compensating for
loads such as air conditioning or the selection of Drive
on automatic transaxle models.
The throttle body assembly is mounted to the
inlet manifold and controls the amount of air entering
the engine by the action of the throttle valve.
Efficient operation of the EFI system depends on
accurate signals being receiv ed by the control unit and
controlled air flow beyond the throttle valve. There-
fore it is essential that all air, fuel and electrical
connections be clean and tight.
3. SERVICE PRECAUTIONS AND
PROCEDURES
Electronic ignition systems can produce danger-
ously high voltages in both the primary and secondary
circuits. For this reason, extreme care must be taken
when working on or near the ignition system.
Do not start the engine if the battery terminals are
not clean and tight.
Do not use the fast charge or boost settings on a
battery charger to start the engine.
Do not disconnect the battery terminals while the
engine is running.
Disconnect the battery terminals before charging
the battery.
Disconnect the negative ba ttery terminal before
working on the engine management system.
Do not subject the control unit to temperatures
above 80 deg C.
Ensure that all wiring connectors are clean and
tight.
Disconnect the battery terminals and the control
unit wiring connectors before attempting any welding
operations.
Do not direct a steam cleaning or pressure
washing nozzle at engine management components
when cleaning the engine.
Ensure that the ignition is Off prior to disconnect-
ing the battery terminals, fusible links or the control
unit wiring connectors.
TO CONNECT ELECTRICAL TEST
EQUIPMENT
NOTE: Some types of tachometers, timing
lights and ignition system analysers are not
compatible with this engine management
system and may result in incorrect readings.
It is therefore recommended that the man-
ufacturer of the lest equipment be consulted
before proceeding to use the equipment.
If a test procedure requires the use of a
test lamp or voltmeter, ensure that only the
specified instrument is used to prevent mis-
leading diagnosis.
MULTIMETER
It is essential that in all tests where voltage or
resistance is to be measur ed, a digital display multi-
meter with a minimum 10 megohms impedance be
used.
The correct method of backprobing the wiring connec-
tors. The meter test probe should be modified with a piece of thin wire as shown.
All meter readings are to be performed with the
component wiring connectors installed unless other-
wise instructed. This can be done by inserting the
meter test probes from the wiring harness side of the
connector or backprobing. If the test probes are not
thin, they should be modified by attaching a thin piece
of wire to the end, giving a fine point that will not
damage the connector. Ensure that the wire is making
good contact with the probe.
If sealing plugs or boots are removed from wiring
connectors to facilitate bac kprobing, ensure that they
are correctly installed at the conclusion of the test
procedure.
To identify wiring connector terminals refer to the
wiring circuit diagrams.
Test Lamp
To avoid damage to the electronic components
when testing, the use of an LED (light emitting diode)
test lamp is recommended.
Page 96 of 238
96 Fuel and Engine Management
terminal D16 on 1.6 liter engines, or D15 and D16
on
1.8 liter engines.
The test lamp should light.
If the test lamp does not light check the wiring
harness for continuity between the injector wiring
connector(s) and the control unit wiring connector
terminals.
Repair or renew the wiring harness as necessary.
To Remove and Install Injectors and Fuel Rail — 1.8
Liter Engine.
(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal.
(3) Thoroughly clean around the injectors and
View of the fuel rail, injectors and pressure regulator
removed from the engine.
the fuel rail to prevent foreign material entering the
engine.
(4) Suitably mark the fuel hoses, loosen the hose
clamps and disconnect the fuel hoses from the fuel
rail. (5) Disconnect the vacuum hose from the fuel
pressure regulator. (6) Loosen the hose clamp and disconnect the
engine ventilation hose from the throttle body. (7) Remove the bolts securing the fuel rail and
injectors to the inlet manifold. (8) Carefully raise the fuel rail and injectors
from the inlet manifold until the injector nozzles are
clear of the manifold. (9) Disconnect each injector wiring connector by
pushing in the wire retaining clip.
(10) Using a small screwdriver, remove the injec-
tor retaining clip and withdraw the injectors from the
fuel rail.
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Check the condition of the injector O ring
seals and renew if necessary. (2) Install the injectors to the fuel rail and secure
with the retaining clips. (3) Connect the wiring connectors to each injec-
tor ensuring that the wire clip is locked in position. (4) Install the injectors to the inlet manifold,
carefully guiding the injectors into place ensuring that
the O ring seals are not damaged.
(5) Install the fuel rail retaining bolts and tighten
to the specified torque. (6) Install the fuel hoses to the fuel rail
and
tighten the hose clamps securely.
(7) Check for fuel leaks as previously described.
To Remove and Install Injector — 1.6 Liter Engine
(1) Depressurize the fuel system as previously
described. (2) Disconnect the negative battery terminal.
(3) Remove the air cleaner assembly. If neces-
sary refer to the heading Air Cleaner Assembly in this
section.
(4) Remove the injector retaining plate screw
and remove the injector retaining plate from the
throttle body assembly. (5) Insert the blade of a screwdriver from the
front of the throttle body assembly under the rim of
the injector in which the retaining plate locates.
Support the screwdriver on a suitable object to act as
a fulcrum. (6) Carefully lever the screwdriver until the
injector can be withdrawn from the throttle body
assembly.
(7) Remove and discard the upper and lower O
ring seals from the injector . If necessary remove the
lower filter screen from the injector.
NOTE: As the injector contains electrical
View of the fuel injector removed from the throttle body assembly. 1.6 liter engine.
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.