drain bolt 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 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 44 of 238
44 Engine
Rear three quarter view of the 1.8 liter engine and automatic transaxle assembly.
mountings. Lower the assembly onto the mountings
and tighten the mounting nuts and bolts.
(4) Install a new exhaust flange gasket.
(5) Fill the engine and transaxle with the correct
quantity and grade of lubricant. (6) Fill the cooling system as described in the
Cooling and Heating Systems section. (7) On models with power steering, fill the power
steering reservoir with the recommended fluid.
(8) Start and run the engine until it reaches the
normal operating temperatur e and check for fuel, oil
and coolant leaks.
4. MANIFOLDS
INLET MANIFOLD - 1.6 Liter Models
To Remove and Install
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurise the system before removing the
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.
(1) Disconnect the negative battery terminal.
(2) Remove the wingnuts retaining the air
cleaner to the throttle body, lift the air cleaner
upwards slightly and disconnect the vacuum hoses. (3) Drain the cooling system as described in the
Cooling and Heating Systems section. (4) Loosen the hose clamps and disconnect the
engine coolant hoses from the rear of the manifold.
(5) Disconnect the small branch of the engine
ventilation hose from the rear of the inlet manifold. (6) On automatic transaxle models, disconnect
the kickdown cable from the throttle lever by releasing
the wire spring clip and re moving the cable end socket
from the ball.
(7) Turn the throttle lever to the full throttle
position. Using the slack in the throttle cable, release
the throttle cable end thr ough the slot provided.
Page 49 of 238
Engine 49
Dismantled view of the camshaft housing and components.
(10) If the measurement is not within Specifica-
tions, check the retaining plate and the retaining plate
groove in the camshaft for wear or scoring after
dismantling. Renew the defective parts as necessary
on assembly. (11) Disconnect the lower radiator hose and drain
the cooling system.
NOTE: If the coolant is to be reused, drain
the coolant into a clean container.
(12) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (13) Remove the cylinder head bolts in the re-
verse order of the tighten ing sequence, backing off
each bolt a quarter of a turn then half a turn at a time
until the bolts are loose.
NOTE: Do not loosen the cylinder head
bolts while the engine is warm as distortion
of the cylinder head could result.
(14) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (15) The rocker arms, thrust pads and tappet
assemblies can now be removed from the cylinder
head. Number a rack from 1 to 8 and keep each
assembly in order so that they can be returned to their
original positions.
(16) From the distributor drive end of the cam-
shaft housing, remove the bolts securing the camshaft
retaining plate to the camshaft housing and remove
the retaining plate. (17) Withdraw the camshaft from the camshaft
housing taking care to supp ort the camshaft to avoid
scoring the inner surfaces of the camshaft bearings.
(18) With a pointed drift, tap a small hole in the
front face of the oil seal. Insert a self tapping screw in
the hole and using a pair of pliers, pull on the screw
to remove the oil seal from the housing. Discard the
oil seal.
TO CLEAN AND INSPECT
(1) Wash all parts in cleaning solvent and dry
with compressed air. Ensure that all oil ways in the
camshaft and rocker arms are free from obstruction.
(2) Check the camshaft lobes, the rocker arms. the thrust pads and the ta
ppet assemblies for pitting
and wear. The tappet assemblies are non-serviceable
and should be renewed as an assembly if wear is
apparent or internal damage is suspected.
(3) Support the camshaft at each end on Vee
blocks and using a dial gauge with its plunger bearing
on the centre journal, rotate the camshaft and check
for bend. (4) Using micrometers, measure the outside of
each camshaft journal and the inside of each camshaft
tunnel in the camshaft housing. Compare these mea-
surements to Specifications and renew defective parts
as necessary. (5) Check the retaining plate and the retaining
plate groove in the camshaft for wear and scoring.
Renew defective parts as necessary.
Dismantled view of the valve operating components.
TO INSTAL
Installation is a reversal of the removal procedure
with attention to the following points:
(1) Lubricate the lip of a new oil seal with engine
oil and position the seal squarely in the camshaft
housing. Ensure that the li p of the seal faces towards
the inside of the camshaft housing. Tap around the
edge of the seal with a soft faced hammer until the seal
is fully seated in the recess in the camshaft housing. (2) Apply clean engine oil to the camshaft bear-
ings and camshaft journals. Insert the camshaft into
position taking care not to damage the bearings with
the edges of the cam lobes or journals. (3) Apply engine oil to the camshaft retaining
plate and position it in the groove in the camshaft.
Install the retaining bolts and tension the bolts to the
specified torque.
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50 Engine
(4) Ensure that the tappet assemblies are full of
clean engine oil and insert the tappets in their
respective bores in the cylinde r head. Install the thrust
pads to the top of each valve assembly ensuring that
they are returned to their original location.
(5) Coat the contact surfaces of the rocker arms
with molybdenum disulphide grease and install the
rocker arms to their origin al locations on the cylinder
head. (6) Clean the mating surfaces of the camshaft
housing and cylinder head. Apply a bead of Loctite
515 to the cylinder head and camshaft housing mating
surfaces. Take care that no sea lant is forced into the
oil passages and install the camshaft housing to the
cylinder head.
(7) Install new cylinder head bolts and lubricate
the bolts and washers with oil.
(8) Apply an initial torque to the cylinder head
bolts of 25 Nm in the corr ect sequence as shown in
the illustration under the Cylinder Head heading.
Further tighten the head bolts in the correct sequence,
in three separate 60 degree stages. Refer to Specifica-
tions. (9) Install the bolts securing the camshaft
drive
belt inner cover to the camshaft housing. (10) Install the camshaft timing gear to the cam-
shaft ensuring that it is correctly located. Tighten the
camshaft timing gear retain ing boll to the specified
torque. (11) Install and adjust the camshaft drive belt as
described under the previous heading. (12) Install the distributor. Refer to the Fuel and
Engine Management section.
(13) Connect the lower radiat or hose and fill the
cooling system with the required coolant. Refer to the
Cooling and Heating Systems section if necessary. (14) Start and run the engine until normal oper-
ating temperature is attained and tighten the cylinder
head bolts another 30-50 degrees in the correct
sequence, ensuring that the tension does not exceed
135 Nm.
TO RENEW CAMSHAFT OIL SEAL,
CAMSHAFT INSTALLED
(1) Remove the camshaft drive belt from the
camshaft timing gear as described under the previous
heading.
(2) Remove the camshaft housing top cover
retaining bolts, remove the cover and discard the
gasket.
(3) Use an open end spanner to hold the cam-
shaft between the inlet and exhaust lobes of number
four cylinder and remove the camshaft timing gear
retaining bolt and the camshaft timing gear. (4) With a pointed drift, tap a small hole in the
front face of the oil seal. Insert a self tapping screw in
the hole and using a pair of pliers, pull on the screw
to remove the oil seal from the housing.
(5) Clean the seal recess and the camshaft sea!
running surface. (6) Lubricate the lip of a new oil seal with engine
oil and slide the seal over the camshaft. Ensure that
the lip of the seal faces to wards the inside of the
camshaft housing. Tap evenly around the edges of the
seal until it is fully seated in the camshaft housing.
(7) Install the camshaft timing gear to the cam-
shaft, ensuring that it is co rrectly located. Tighten the
camshaft timing gear retain ing bolt to the specified
torque. Do not allow the camshaft to rotate while
tightening the bolt. (8) Install and adjust the drive belt as described
under the previous heading. Ensure that the timing
marks are aligned. (9) Install the camshaft hou sing top cover using a
new gasket. Tighten the retaining bolts to the specified
torque.
7. CYLINDER HEAD
Special Equipment Required:
To Dismantle and Assemble — Valve spring com-
pressor
To Inspect — Dial gauge and straight edge
To Install — Drive belt adjusting tool
TO REMOVE AND INSTAL
NOTE: Due to the high residua! 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.
Allow the engine to cool prior to the
removal of the cylinder head to prevent
possible distortion of the cylinder head.
(1) Disconnect the negative battery terminal and
remove the nuts securing the earth wires to the
cylinder head bolts.
(2) Remove the camshaft drive belt as previ-
ously described.
(3) Disconnect the lower radiator hose and drain
the cooling system. Refer to the Cooling and Heating
Systems section if necessary. (4) Remove the alternator adjusting bracket
mounting bolt and insulating washers from the inlet
manifold. Loosen the adjusting bolt at the alternator
and slide the bracket away from the cylinder head. (5) Disconnect the upper radiator hose, coolant
by-pass hose and the heater hose from the thermostat
housing and on 1.6 liter m odels, the coolant hoses
from the inlet manifold. (6) Disconnect the electrica l connectors from the
throttle body, fuel injectors, coil, distributor and on
1.8 liter models, the MAT sensor. (7) Disconnect the oxygen sensor wiring connec-
tor and remove the wiring connectors from the
Page 54 of 238
54 Engine
in the valve stem groove before releasing the spring
compressor. A sharp tap to the top of the valve stem
with a soft faced hammer will ensure that the collets
are correctly seated.
(7) Install the inlet and exhaust manifolds using
new gaskets and tighten the mounting nuts to the
specified torque as previously described. (8) Install a new sealing ring to the
thermostat
housing, install the housing to the cylinder head and
tighten the mounting bolts to the specified torque.
(9) Ensure that the lappet assemblies are filled
with clean engine oil and install the tappets in
their
respective bores in the cylinder head. (10) Install the thrust pads to the top of each
valve
assembly, ensuring that they are returned to their
original locations. (11) Coat the contact surfaces of the rocker arms
with molybdenum disulphide grease and install the
rocker arms to their origin al locations on the cylinder
head. (12) Install the cylinder head to the engine as
previously described.
8. ENGINE SUMP AND OIL PUMP PICKUP . PIPE
TO REMOVE
(1) Disconnect the negative battery terminal.
(2) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section for the correct procedure.
(3) Remove the sump plug and drain the engine
oil into a container. Install and tighten the plug
after the oil has been drained.
(4)
Remove the engine pipe as described at the
end of this section.
(5) Remove the nuts and bolts retaining the
engine crossmember to the vehicle underbody and
withdraw the crossmember from the vehicle. On
automatic transaxle models, it will be necessary to
release the selector cable from the crossmember
bracket.
(6) Remove the sump retaining bolts and wash-
ers and if necessary firmly bump the sump with the
palm of the hand and remove it from the engine. (7) Remove the bolts retaining the oil pump
pickup pipe to the oil pump and disconnect the
pickup pipe from the support bracket. Remove the
pickup pipe and discard the O ring seal. (8) Remove the scraper and gasket from the
engine. (9) Clean the gasket material from the sump,
engine block and the scraper.
NOTE: If the scraper assembly is damaged
it should be renewed.
TO INSTAL
(1) Wash the inside of the sump to remove
carbon and sludge deposits. Check for any metal
deposits which may indicate an imminent component
failure. (2) Inspect the sump for dents and cracks.
Ensure that the gasket sea ling face is not distorted or
damaged. (3) Clean the pickup pipe screen with solvent
and a brush. (4) Using a new O ring seal, install the pickup
pipe. Coat the pipe retain ing bolts with Loctite 242
and tighten to the specified torque. (5) Apply a bead of KP510-00150 sealer or
equivalent to the oil pump to cylinder block mating
joint area. (6) Ensure that the sump gasket is correctly
located on the scraper and install the sump to
the
engine. Apply Loctite 242 to the threads of the sump
bolts and tighten the bolts to the specified torque.
(7) Install the front exhaust pipe using a
new
gasket and coat the threads of the flange nuts with an
anti-seize compound before tightening the nuts to the
specified torque. (8) Install the engine crossmember and
tighten
the nuts and bolts securely. If applicable, connect the
automatic transaxle selector cable to the crossmember
bracket. (9) Ensure that the sump drain plug is secure
and lower the vehicle to the ground. (10) Fill the engine with the specified amount and
grade of engine oil. Refer to the Lubrication and
Maintenance section if necessary. (11) Start and run the engine and check for oil
leaks.
View of the sump, oil pump pickup, gasket and scraper
removed from the engine.
Page 55 of 238
Engine 55
9. OIL PUMP
TO REMOVE AND DISMANTLE
(1) Disconnect the negative battery terminal.
(2) Disconnect the lower radiator hose and drain
the cooling system. (3) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary. (4) Remove the right hand front wheel.
(5) Remove the fasteners securing the engine
splash guard to the right hand front inner mudguard
and remove the splash guard. (6) Remove the engine sump and oil pump
pickup pipe as previously described. Remove the oil
filter.
(7) Remove the camshaft timing belt as de-
scribed previously. (8) Disconnect the oil pressure sender electrical
connector. (9) Using a socket and bar, remove the bolt and
spacer retaining the crankshaft timing gear to the
crankshaft. Discard the bolt.
NOTE: It may be necessary to lock the
crankshaft when removing the crankshaft
timing gear retaining bolt. If necessary,
insert a piece of timber between the crank-
case and the crankshaft to prevent the
crankshaft turning.
(10) Remove the crankshaft timing gear from the
crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft. (11) Remove the camshaft housing top cover.
(12) Using an open ended spanner, hold the
camshaft between the inlet and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.
(13) Remove the bolts securing the water pump
to the cylinder block and remove the water pump. If
necessary- refer to the Cooling and Heating Systems
section. (14) Remove the camshaft drive belt inner cover
retaining bolts and remove the inner cover. (15) Remove the bolts securing the oil pump to
Dismantled view of the oil pump assembly.
the cylinder block and remove the oil pump from the
engine. Discard the gasket.
(16) Remove the screws retaining the oil pump
cover plate and lift the cover plate from the rear of the
oil pump. (17) Lift the inner and outer rotors from the oil
pump housing. Note that the outer rotor may be
stamped with a mark which must face the cover plate
on assembly. (18) Unscrew the oil pressure relief valve plug
and remove the relief spring and plunger from the oil
pump housing. Discard the sealing washer from the
relief valve plug. (19) If necessary, remove the oil pressure gauge
sender unit.
(20) Remove the crankshaft oil seal from the
pump housing.
TO CHECK AND INSPECT
(1) Wash all the pump components thoroughly
in cleaning solvent and allow to dry.
(2) Inspect the inner and outer rotors and the
cover plate for scoring or wear. Renew the rotors
and/or the cover plate if these faults are evident. (3) Temporarily install the rotors into the oil
pump housing. Check the b acklash between the teeth
of the inner and outer rotors at the point where the
rotor teeth are most closely meshed. If the clearance at
this point exceeds the Specif ications, check the rotors
and housing for wear and renew as necessary. (4) Check the rotor end float by placing a
straight edge across the oil pump housing and measure
the clearance between the straight edge and the rotors
View of the oil pump and associated components.
Page 63 of 238
Engine
edge of the bearing cap to cylinder block joint. Install
the bearing cap bolts and tighten to the specified
torque.
(17) Lubricate the l i p of the new oil seal with
lithium grease and carefully install the seal into
position over the crankshaft . Insert the seal as far as
possible using finger pressure and then fully install the
sea! using a tubular drift. Ensure that the seal is not
damaged during installation and that the seal is
mounted square to the block face.
(18) Install the remainder of the engine
compo-
nents by referring to the relevant headings in
this
section.
TO RENEW CRANKSHAFT OIL SEALS
Front
(1) Remove the camshaft drive belt as previ-
ously described.
(2) Disconnect the lower radiator hose and drain
the cooling system. (3) Select fifth gear on manual transaxle models
and firmly apply the handbrake. (4) On automatic transaxle models, remove the
torque converter inspection cover to allow access to
the ring gear. Have an assi stant hold the ring gear
using a suitable lever. (5) Remove the crankshaft timing gear retaining
bolt and discard. (6) Remove the crankshaft timing gear from the
crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft. (7) Using a centre punch, tap a small hole in the
front face of the oil seal. (8) Insert a self tapping screw into the hole.
(9) Remove the seal from the oil pump by
gripping and pulling the end of the screw with a pair
of pliers. (10) Coat the l i p of a new seal with multi-purpose
grease. (11) Install the oil seal to the oil pump using a
tubular drift. Ensure that the lip of the oil seal faces
the inside of the housing.
(12) Install the remaining components in the re-
verse order of removal, usi ng a new crankshaft timing
gear retaining bolt and referring to the relevant
headings in this section as necessary.
Rear
(1) Remove the automatic transaxle or manual
transaxle as described in the appropriate section. (2) Remove the flywheel/drive plate as described
under the following heading. (3) Lever the oil seal from the rear of the
crankcase being careful not to damage the crankshaft.
(4) Coat the lip of a new seal with Lithium
grease.
(5) Install the oil seal over the crankshaft. Ensure
that the li p of the oil sea l faces towards the engine.
(6) Insert the seal as far as possible using finger
pressure, and then fully seat the seal using a tubular
drift. (7) Install the remaining components in the
re-
verse order of removal, referring to the relevant
headings in this section as necessary.
12. FLYWHEEL/DRIVE PLATE
Special Equipment Required:
To Renew Ring Gear — Suitable heat source
TO REMOVE
(1) Remove the transaxle from the vehicle as
described in the Manual or Automatic Transaxle
sections, whichever is applicable. (2) On manual transaxle models, mark the fly-
wheel and the clutch pressure plate cover to ensure
correct assembly.
View of the drive plate and retaining bolts.
Progressively loosen and remove the pressure
plate retaining bolts.
Using a dial gauge, check the runout of the clutch
face contacting surface of the flywheel. If the runout
exceeds 0.3 mm have the flywheel face surfaced by a
clutch specialist or authorized dealer.
(3) Suitably mark the flywheel or drive plate so
that the unit can be installed in the original position
on the crankshaft. Remove the retaining bolts. (4) Lift the flywheel or drive plate from the
engine.
TO CHECK AND INSPECT
Inspect the clutch face contacting surface of the
flywheel for cracks or excessive scoring.
(2) Inspect the ring gear teeth for damage, cracks
or wear. The ring gear on manual transaxle models
can be renewed separately from the flywheel, but on
Page 72 of 238
72 Cooling and Heating Systems
(16) After the vehicle has been driven several
kilometers check the coolant level in the reserve tank
and top up if necessary.
TO REMOVE
(1) Drain the cooling system as previously de-
scribed.
(2) Loosen the hose clamps and disconnect the
hoses from the radiator. (3) If applicable disconnect the automatic trans-
axle oil cooler hoses from the left hand side radiator
tank. Plug the hoses and fitt ings to prevent the entry
of dirt and the loss of fluid.
(4) Disconnect the hose from the reserve tank at
the top of the radiator. (5) On models with air conditioning, remove the
hoses and support bracket bolts and move the bracket
and hoses away from the top of the radiator. (6) Remove the radiator support bracket bolts
from the radiator support pa nel and lift the radiator
from the lower mountings and out of the vehicle.
NOTE: A radiator that has been in use for
some time should not be allowed to stand
empty for any length of time. The radiator
should be immersed in a tank of coolant or
otherwise kept full. If applicable, ensure that
no coolant is allowed to enter the automatic
transaxle oil cooler in the left hand side tank
of the radiator.
Failure to observe this precaution may
result in overheating when the engine is put
back into service. This is caused by internal
deposits in the radiator drying and flaking
and so obstructing the circulation of the
coolant in the system.
TO FLUSH AND CLEAN
(1) Remove the radiator as previously described.
(2) Apply a water hose to the radiator outlet and
reverse flush the radiator until the water flowing from
it is clean.
Cleaning the radiator core from the rear to the front
using a garden hose.
(3) Stand the radiator upright and apply a
stream of water or compressed air to the radiator core
from the rear to [he front. Maintain this procedure
until all dirt and foreign matter is removed from the
radiator core.
(4) With the aid of a light, make a visual check
of the core tubes through the radiator inlet or outlet
fittings. If it is apparent that the tubes are severely
impregnated with flakes of rust it will be necessary to
renew the radiator assembly.
TO REPAIR
The repair procedure described below is only
suitable for holes occurring in the radiator core tubes
that are not bigger than approximately 1 mm.
(1) Suitably mark the area of the leak using a
piece of chalk or similar. (2) Remove the radiator from the vehicle as
previously described, clean it thoroughly and dry the
damaged area with a hair dryer. (3) If necessary, carefully cut away or bend the
fins from the tubes to expose the affected area.
NOTE: Do not remove more than 25 mm
total finning from the radiator or cooling
performance will be affected.
(4) Clean the damaged area carefully using a
scraper and wipe clean using a cloth moistened with
petrol.
(5) Apply well mixed Nissan or Holden adhe-
sive part number 21411-J7025, or equivalent, spar-
ingly to the damaged area using a wooden spatula.
(6) Allow the repair to dry in ambient condi-
tions for a minimum of 3 hours before installing the
radiator to the vehicle and testing for leaks. Do not
use heat to promote drying.
TO INSTAL
Installation is a reversal of the removal procedure
with attention to the following points:
Reverse flushing the radiator using water pressure.
Page 75 of 238
Cooling and Heating Systems 75
(4) Remove the bolts retaining the fan shroud
assembly to the radiator and carefully move the
shroud assembly upwards and towards the engine to
release it from the lower mountings.
NOTE: On models with air conditioning, it
will be necessary to hold the air conditioning
compressor hoses toward s the engine to
allow clearance for removal of the shroud
assembly.
(5) If necessary, remove the fan from the fan
motor by removing the retaining bolts or on some
models the nut and washers.
(6) If necessary, remove the fan motor from the
shroud assembly by removing the retaining bolts or
nuts. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure all the fan motor and fan retaining
nuts and bolts are tightened securely. (2) Ensure that all the rubber mountings are in
good condition. Installation is a reversal of the removal procedure
with attention to the following points:
(1) Ensure that all sealing surfaces are clean.
(2) Renew the O ring on installation.
(3) Tighten the thermostat cover retaining bolts
securely.
(4) Fill the cooling system as previously de-
scribed ensuring that the heater control lever is in the
maximum heat position. Check for coolant leaks.
TO CHECK
NOTE: A visual examination of the thermo-
stat will often determine its serviceability
and make further testing unnecessary. For
instance, a thermostat with its valve fully-
open when removed from a cold engine is
obviously faulty and should be renewed.
Remove the thermostat from the thermostat
6. THERMOSTAT
Special Equipment Required:
To Check — Thermometer
TO REMOVE AND INSTAL
(1) Drain the cooling system as previously de-
scribed under the Radiator heading.
(2) On 1.6 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary. (3) Disconnect the top radiator hose from the
thermostat cover.
(4) Remove the bolts retaining the thermostat
cover to the thermostat housing. (5) Remove the thermostat cover, thermostat
and O ring from the thermostat housing.
NOTE: The thermostat and cover are ser-
viced as a unit and cannot be renewed
separately.
View of the thermostat removed from the vehicle and dismantled for testing. Line drawing showing the correct method to test the
thermostat.
(4) Progressively heat the mixture noting the
temperature reading on the thermometer as the ther-
mostat valve commences to open and when it is fully
open.
See the Specifications for opening and fully open
temperatures.
A thermostat which is not opening or is not open
at the specified temperatures should be renewed.