check engine 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 3 of 238
CONTENTS
INTRODUCTION........................................ 5
VEHICLE IDENTIFICATION AND
GENERAL SPECIFICATIONS................. 7
GENERAL INFORMATION...................... 8
Tools and equipment ............................................. 8 Safety .................................................................... 10
General repair procedures..................................... 11
LUBRICATION AND MAINTENANCE... 14
Specifications......................................................... 14
How to grease and oil change .............................. 14
Service schedule ................................................... 17
WHEELS AND TYRES............................. 21
Specifications......................................................... 21
How to change a road wheel ................................ 21
Tire wear troubl e shooting ..................................... 22
Care and main tenance ......................................... 23
ENGINE TUNE-UP.................................... 25
Tune-up specifications ........................................... 25
Tune-up operat ions............................................... 25
ROADSIDE TROUBLE SHOOTING....... 32
Trouble shoot ing.................................................... 32
To check ignition and el ectrical system ................ 33
To check fuel system ............................................ 34
To check mechani cal system ................................ 35
ENGINE....................................................... 37
Specifications ........................................................ 37
Engine mechanical tr ouble shooting ...................... 39
Description ............................................................ 41
Engine and transaxle assembly ........................... 42
Manifolds ............................................................... 44 Camshaft, rocker arms and tappets..................... 48
Cylinder head........................................................ 50
Engine sump and oil pum p pickup pipe................ 54
Oil pump ............................................................... 55
Pistons, connecting rods and cylinder bores ........ 57
Crankshaft and bearings ...................................... 60
Flywheel /drive plate............................................... 63
Engine mountings.................................................. 64
Exhaust system .................................................... 66
COOLING AND HEATING SYSTEMS.... 68
Specifications ........................................................ 68 Cooling system trouble shooting ........................... 68
Heater and air conditioner trouble shooting ......... 69 Description ............................................................ 70
Radiator ................................................................ 70
Cooling fan ............................................................ 73
Thermost at............................................................ 75
Thermostat housing .............................................. 76
Water pump .......................................................... 76
Welch plugs .......................................................... 76
Heater unit, water valv e and controls ................... 77
Blower fan ............................................................. 80
Air condition ing ..................................................... 80
FUEL AND ENGINE MANAGEMENT ... 82
Specifications ........................................................ 82 Fuel and engine management trouble shooting ... 82
Description ............................................................ 84
Service precautions and procedures
..................... 86
System diagnosis and adjustments ...................... 89
Fuel supply components ....................................... 92
Air flow components .............................................. 98
Electronic components .......................................... 104
EMISSION CONTROL............................. 117
Introduction ........................................................... 117
Crankcase ventilati on system............................... 117
Evaporate control system..................................... 117
Air preheat system — 1.6 liter engines ................ 119
Exhaust control system ........................................ 120
CLUTCH...................................................... 121
Specifications........................................................ 121
Clutch trouble shooting......................................... 121
Description ............................................................ 122
Clutch unit and release mechanism..................... 123
Clutch pedal ......................................................... 124
Clutch c able.......................................................... 124
Clutch adjustments ............................................... 125
MANUAL TRANSAXLE AND
DRIVE SHAFTS......................................... 126
Specifications ........................................................ 126
Manual transaxle and drive shaft trouble shooting 126
Description............................................................ 128
Transaxle assembly.............................................. 129
Differential and final drive assembly ..................... 135
Gear lever assembly ............................................ 136
Drive shafts .......................................................... 137
AUTOMATIC TRANSAXLE....................... 140
Specifications........................................................ 140
Automatic transaxle trouble shooting.................... 140
Description............................................................ 141
Transaxle fluid ...................................................... 141
Brake band........................................................... 142
Kickdown cable .................................................... 142
Transaxle select or linkage ................................... 142
Neutral safety switch ............................................ 142
Transaxle assembly .............................................. 143
STEERING................................................. 145
PART 1. STEERING TROUBLE SHOOTING....145
Faults, causes and remedies................................ 145
PART 2. MANUA L STEERING......................... 147
Specifications ........................................................ 147
Description............................................................ 147
Steering wheel ...................................................... 147
Steering column.................................................... 148
Steering gear assembly ....................................... 149
PART 3. POWE R STEERING .......................... 152
Specifications........................................................ 152
Description............................................................ 152
In car adjustments, checks and minor repairs ..... 152
Steering wheel ...................................................... 153
Steering column.................................................... 153 Power steering pump ........................................... 153
Power steering gear assembly............................. 154
Page 10 of 238
10 General Information
If tools are to be stored for any length of time, it is
good policy to wipe them with an oily cloth.
Bladed screwdrivers should be checked for dam-
age to the tip. If necessary, the tip can be returned to
its original profile by careful grinding. Do not grind
screwdriver tips to a sharp point.
Hammer heads should be secure on their handles
and should be regularly checked for cracking or other
damage.
Chisels and punches should be checked for dam-
age or 'mushrooming' of the head. Any faults should
be rectified by grinding.
Hydraulic jacks should be regularly checked for
fluid leaks. Chassis stands and car ramps should be
checked for damage and cracks. Any equipment that
is suspect should not be used.
STORES
For routine maintenance, stores of automotive
oils, greases and additives should be kept on hand.
The following is a suggested list.
Engine oil.
Brake fluid.
Manual transmission or automatic transmission
oil — automatic transmission oil is also used in
the power steering system.
Rear axle oil.
Cooling system corrosion inhibitor/antifreeze.
Chassis grease.
High melting point grease, for hub bearings etc.
Penetrating oil or spray.
Kerosene or similar cleaning solvent.
Methylated spirits.
Oils and greases are available in handy pack size for
do-it-yourself lube jobs.
2. SAFETY
PERSONAL SAFETY
Safety when working on a motor vehicle is basical-
ly a matter of commonsense. Some safety precautions
to prevent personal in juries are as follows.
Raising a Vehicle
Always jack a vehicle on firm, level ground and at
the specified jacking points . Ensure that the wheels
remaining on the ground are fully chocked.
After raising the vehicle, place chassis stands
underneath and allow the weight of the vehicle to rest
on them. Do not use bricks, blocks of wood or similar
material.
NOTE: Never work under a vehicle which is
only supported by a jack.
Electrical System
Always disconnect the negative battery terminal
when working on any electrical components. Avoid
wearing metal watches, rings and chains which may
short across live terminals.
As battery gases are explosive, keep naked flames
and sparks clear of the work area. When connecting
and disconnecting jumper leads, use extreme caution
to avoid sparking.
Electronic Ignition Systems
Electronic ignition systems produce dangerous
high tension voltages in bo th the primary and second-
ary circuits which can be fatal. Exercise extreme
caution when working on or near any ignition system
components. Do not disconnect high tension leads
while the engine is running.
Work Area
Do not run the engine in a confined space. Ensure
that the work area is adequately ventilated.
Spilt oil or water should be cleaned immediately
to avoid the possibility of slipping.
Fuel System
Always disconnect the negative battery terminal
when working on any fuel components. Do not smoke.
Keep naked flames and sparks clear of the work area.
Do not siphon fuel using the mouth. Use a hand
pump or suitable siphon.
Do not attempt to repair a fuel tank by welding it.
This is an extremely hazardous procedure and should
be entrusted to a specialist.
Cooling System
To avoid scalding, use caution when releasing the
radiator cap on an engine wh ich is at normal operating
temperature. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to release.
When the pressure is released, remove the cap from
the radiator.
Brakes
As asbestos is used in some brake lining material,
avoid inhaling brake dust. Do not use compressed air
to remove the dust. Gentle brushing with a small
brush or using a vacuum cleaner with a hose attach-
ment are the safest methods of cleaning the brakes.
The above precautions also apply to the clutch plate
lining material.
Page 13 of 238
General Information 13
A simple bush removing tool using a bolt, nut, suitable spacer and large and small washers.
Bushes in blind holes can also be removed using
hydraulic force. With the hole packed with grease,
insert a neat fitting drift and tap the drift into the hole.
The pressure of the grease on the rear of the bush
should force it from the hole.
ROTATING THE CRANKSHAFT
There are many occasions when it is necessary to
rotate the crankshaft to a certain position. These
include timing and valve adjustment and checking
valve timing.
To make the engine easier to rotate, remove the
spark plugs. This will re lieve compression pressure.
The simplest method is to use a socket or ring
spanner on the crankshaft pulley nut and turn the
engine in the normal direction of rotation.
On vehicles with manual transmission, the engine
can be turned by selecting top gear and rolling the
vehicle forward. A variation of this method is to raise
one of the driving wheels and, with top gear selected,
rotate the driving wheel in a forward direction to turn
the engine.
Alternatively, the engine can be brought to the
desired position by briefly actuating the starter motor.
Page 14 of 238
14
LUBRICATION AND MAINTENANCE
SPECIFICATIONS
CAPACITY AND GRADE
Engine:
Lubricant........................................... 15W-50 SF
Sump capacity including filter ........... 3.3 liters
Cooling system capacity............................ 6.0 liters
Manual transaxle:
Lubricant....................................... 80W-90 GL-4
Capacity ............................................... 2.7 liters
Automatic transaxle:
Lubricant.............................................. Dexron II
Capacity ............................................... 6.0 liters
Power steering:
Lubricant.............................................. Dexron II
Capacity ............................................... 1.0 liters
Manual steering lubricant ........ Castrol EPLl grease
Brake fluid type ................................................ Dot 4
1. HOW TO GREASE AND OIL CHANGE
(1) Run the front of the vehicle onto car ramps
and stop the engine. Chock the front wheels. (2) Raise the rear of the vehicle and place
chassis stands under the rear jacking points.
NOTE: It is best if the vehicle is kept as level
as possible to avoi d false readings when
checking the lubricant levels.
(3) Clean around the engine sump drain plug.
(4) Place a drain tin under the engine sump,
remove the engine sump drain plug and allow the
engine sump to completely drain.
NOTE: It is best to drain the engine sump
with the oil at operating temperature. How-
ever, if the oil is hot take care to avoid
scalding.
(5) Check that the sealing gasket on the sump
plug is in a serviceable condition. (6) When the engine sump has completely
drained, install and firmly tighten the sump drain plug.
Wipe around the plug after installation. (7) Place the drain tin under the oil filler,
remove the oil filter using a filter removal tool and
allow the residual engine oil to drain. Smear the
scaling ring of the new filter with engine oil and
lighten the filter by hand as per the instructions
supplied with the new filter.
NOTE: Before installing the new filter, en-
sure that the sealing gasket from the old
filter has not adhered to the filter sealing
surface on the engine.
(8) Remove the level checking plug from the
Location of the engine sump drain plug.
Removing the engine oil filter using a filter removal tool.
Page 15 of 238
Lubrication and Maintenance 15
Location of the manual transaxle level plug.
manual transaxle. Using a finger, check that the oil is
level with the bottom of the plug hole. Overfilled units
should be drained to the correct level.
If the oil level is low, use an oil gun to fill the
transaxle to the correct level.
When satisfied that the oil level is correct, install
the plug and tighten firmly. Wipe around the plug
after installation.
NOTE: On automatic transaxle vehicles,
refer to the Automatic Transaxle section for
the checking and topping up procedure.
Location of the manual transaxle drain plug.
(9) Using a funnel, fill the engine with the
specified amount and grade of engine oil. start the
engine and run it for a few minutes. Ensure that the
oil light goes out. Stop the engine, wait for a few
minutes and check the engine oil on the dipstick. If
necessary add oil to bring the level to the full mark on
the dipstick.
NOTE: To prevent overfilling the engine
initially, it is good policy not to pour all the
Underbonnet view of the 1.8 liter engine. Automatic transaxle model.
AUTOMATIC TRANSAXLE DIPSTICK
r
Page 16 of 238
16 Lubrication and Maintenance
Underbonnet view of the 1.6 liter engine. Manual transaxle model.
oil into the engine in one go as sometimes
the amounts specified are only approximate.
If is best to hold back at least half a liter and
top up the level after the engine has been run
for a few minutes.
(10) Check thoroughly for oil leaks at the engine
sump drain plug and oil filter if a new filter was
installed.
(11) Referring to the service schedule, lubricate
and check all other items which coincide with the
grease and oil change intervals.
(12) Lower the vehicle to the ground.
Page 21 of 238
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.
Page 25 of 238
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.
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 27 of 238
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