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
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FRONT SUSPENSION............................ 156
Specifications......................................................... 156
Front suspension tr ouble shooting ........................ 156
Description ............................................................ 157
Steering knuckle.................................................... 157
Suspension unit..................................................... 159
Control arm ........................................................... 161
Stabiliser bar ........................................................ 162
Suspension and steering angles .......................... 163
REAR SUSPENSION................................ 164
Specifications ........................................................ 164
Rear suspension tr ouble shooting ........................ 164
Description ............................................................ 165
Rear hub ............................................................... 166
Suspension unit .................................................... 167
Control arm ........................................................... 169
Knuckle assembly.................................................. 170
Stabiliser bar ........................................................ 170
Rear wheel alignment ........................................... 171
BRAKES...................................................... 172
Specifications......................................................... 172
Brakes trouble shooting ........................................ 172
Description ............................................................ 174
Master cyli nder...................................................... 175
Brake servo unit .................................................... 177
Front brakes ......................................................... 178
Rear disc brakes................................................... 181
Rear drum brakes ................................................. 184
Handbrake cable and le ver assembly ................... 186
Brake adjustments ................................................ 187
Brake pedal ........................................................... 187
Hydraulic system................................................... 188
ELECTRICAL SYSTEM............................ 190
Specifications......................................................... 190
Battery and charging system trouble shooting ....... 190
Battery and starting system trouble shooting ........ 191
Lighting system trouble shooting ........................... 192
Turn signal lamp trouble shooting ........................ 192
Test equipment and so me applications................. 193
Battery ................................................................... 194
Alternator ............................................................... 196
Starter motor ......................................................... 201
Ignition system ...................................................... 206
Steering wheel ....................................................... 206
Switches and controls........................................... 206
Instrument cluster.................................................. 209
Blower fan .............................................................. 209
Radio/cassette...................................................... 209
lamp units ............................................................ 210
Windscreen wiper ................................................. 213
Fuses, fusible links and relays ............................. 215
Trailer wiring ......................................................... 216
Wiring diagrams ................................................... 218
BODY........................................................... 225
Windscreen and re ar glass .................................. 225
Front doors ........................................................... 225
Rear doors............................................................ 228
Engine bonnet...................................................... 231
Tailgate and lock — hatchback ............................ 231
Luggage compartment lid and lock — sedan ........ 233
Radiator grille.............................................................. 234
Centre console...................................................... 234 Dashboard ............................................................ 235
Scat belts ............................................................. 236
Seats .................................................................... 236
Vehicle cleaning ........................................................... 237
CONVERSION TABLES.......................... 238
Page 5 of 238
INTRODUCTION
This Service and Repair Manual
covers the Australian manufac-
tured Nissan Pulsar (hatchback) and Vector (sedan) N13 Series 1
(J87 - 91 and
the Holden Astra LD Series 1987 - 89.
Two engines were available: a 1.8 l i t e r engine with multi-point fuel injec-
tion, and a 1.6 liter throttle body injected engine. The engines are similar
having single overhead camshafts and computer controlled fuel injection and
ignition control. There was a choice of three speed automatic or five speed
manual transaxles.
A viscous coupling limited s l i p differential was introduced from July 1989
to the five speed manual transaxle models of the Pulsar Q and Vector SSS.
Disc brakes are fitted at the front of a l l models, while the rear brakes are
either discs or drums.
All models are equipped with independent coil spring suspension. Steering
can be by either manual or power assisted rack and pinion.
This manual includes information on trouble shooting, lubrication and
maintenance, specifications and the rem oval, installation and overhaul of com-
ponents which are considered to be with in the scope of the average, well
equipped home mechanic.
Certain repair jobs covered in this manual require the use of special
equipment not normally found in a home tool kit. When such equipment is
required, the equipment and i t s functi on is brought to the users attention
underneath the heading for that component. Some jobs, such as automatic
transmission overhaul, should he left to an authorized dealer or a specialist
who has the extensive knowledge and equi pment required. In these cases, the
removal and installation procedures are fully covered, enabling the unit to be
removed for repair or a reconditioned unit to be installed.
Reference in the manual to the left an d right hand sides of the vehicle are
from the point of view of someone sta nding at the back of the vehicle and
looking forward.
Inexperienced operators should not a ttempt a service or repair operation
before completely reading the appropriat e section (or other sections which may
be referred to) in the manual.
Page 7 of 238
VEHICLE IDENTIFICATION AND GENERAL SPECIFICATIONS
1. VEHICLE IDENTIFICATION
When purchasing spare parts or when
registering
or insuring a vehicle, it may be necessary to quote
various vehicle identification codes. The location of
these codes are as follows: The Engine Number is stamped on the front
face
of the engine block below No. 4 spark plug. The Chassis Number is stamped on the bulkhead
above and to the right of the brake booster. The Vehicle Identification Plate is located on the
bulkhead to the left of the MAP sensor and contains
codings relating to body style, engine capacity,
model,
transaxle type, engine number, paint, trim and build
date. The Compliance Plate contains information on
the vehicle make, model, month and year of manu-
facture, chassis number, seating, capacity and the
Australian Design Rules (ADR) with which the vehi-
cle complies. This plate is affixed to the bulkhead
above and to the left of the brake booster. The Tire Placard, which is located on the inside
of the glove compartment, contains information
on
the tire size, rim size, tire pressure and load ratings.
2. GENERAL VEHICLE SPECIFICATIONS
Length:
Pulsar ................................................... 4 030 mm
Astra hatchback .................................. 4 035 mm
Vector ..................................................4215 mm
Astra sedan.......................................... 4 255 mm
Width:
Nissan.................................................. 1 640 mm
Holden ................................................. 1 655 mm
Height ........................................................ 1 380 mm
Wheelbase .................................................. 2 430 mm
Wheel track:
Front .................................................... 1 435 mm
Rear ..................................................... I 430 mm
View of the engine compartment showing the location
of various vehicle identification information.
Minimum ground clearance:
Nissan.................................................... 128 mm
Holden ................................................... 110 mm
Turning circle kerb to kerb .......................... 10.8 m
Fuel tank capacity:
Nissan.................................................... 47 liters
Holden ................................................... 50 liters
Towing capacity:
Without trailer brakes............................ 400 kg
With trailer brakes ................................. 900 kg
*Fuel consumption:
L/100km L/100km
(City) (Highway)
Manual transaxle 8.5 6.6
Automatic transaxle 9.0 7.2
*The fuel consumption information is based on
tests made according to Australian Standard 2877.
The actual fuel consumption will depend on many
factors including driving habits, vehicle condition
and equipment and the prevailing conditions.
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 11 of 238
General Information 11
Lifting Equipment
When using lifting equipment to lift heavy com-
ponents such as the engine and/or transmission, use
metal slings or chain in preference to rope. If rope
must be used, ensure that it is not placed against sharp
edges on the component.
Automotive Lubricants and Solvents
Avoid prolonged skin contact with oils, greases
and solvents as some can cause skin irritations and
dermatitis.
Exercise caution when us ing cleaning solvents as
many are inflammable. Do not smoke. Keep naked
flames and sparks clear of the work area.
Compressed Air
Never point an air hose at another person or allow
compressed air to blow onto your skin. High pressure
air forced against the skin can enter the bloodstream
and prove fatal.
Suspension and Steering Components
Damaged suspension and steering components
should not be welded. Many of these components are
fabricated from toughened metals. If welded they may
lose their strength or become brittle. Damaged com-
ponents should be renewed.
Air Conditioning
Avoid disconnecting air conditioning hoses as
escaping refrigerant can cause frostbite. The refriger-
ant is highly flammable and when burnt, a poisonous
gas is produced.
VEHICLE SAFETY
To prevent damage to the vehicle during servicing
or repair work, note the following precautions.
Brake Fluid
If spilt on the vehicle paintwork, brake fluid
should be immediately washed away with clean water
and allowed to dry naturally, not wiped with a cloth.
Catalytic Converter
The following should be observed to prevent
damage to the catalytic converter:
Do not operate the vehicle on leaded fuel.
Do not push or tow start the vehicle.
Do not allow the engine to idle for prolonged
periods.
Do not switch the ignition off while the vehicle is
in motion and the transmission is in gear.
Do not 'prime' the engine by pouring fuel into the
inlet manifold.
Do not operate the vehicle if the engine is
misfiring.
Avoid running the vehicle out of fuel.
Ensure that the engine oil is formulated to contain
low phosphorus levels.
Electronic Components
The electronic components of the ignition and
fuel injection systems can be damaged by the use of
incorrect testing equipment.
It is essential in all tests where voltage or resis-
tance is to be measured that a digital display multi-
meter with a minimum 10 megohm input impedance
be used.
Some types of tachometers, timing lights and
ignition system analyzers are not compatible with
certain engine electronic systems. It is therefore
recommended that the manufacturer of the test equip-
ment be consulted before using the equipment.
Jump starting, or being jump started by another
vehicle can cause damage to the electronic compon-
ents of the vehicle. Refer to the Roadside Trouble
shooting section for the correct jump starting proce-
dure.
3. GENERAL REPAIR PROCEDURES
SEIZED FASTENERS
Seized bolts, nuts or screws should first have a
liberal amount of penetrating oil applied. The fastener
should be left for a period of time to allow the oil to
penetrate and soften the corrosion which is causing
the binding.
Often, a sharp hammer blow to the head of the
fastener can dislodge the corrosion and permit it to be
loosened.
An impact driver, which can be fitted with a
socket or screwdriver bit, can be used to loosen a
seized fastener.
Another method is to heat the component in
which the fastener is seized. However, extreme cau-
tion should be exercised when heating aluminum
alloy components as the melting point is much lower
than that of steel.
If the above methods fail to free a seized nut,
carefully hacksaw through one side of the nut until it
can be split. Care should be taken that the threads of
the bolt or stud are not damaged.
Should a bolt or stud break below the surface of
the component, it will be necessary to use a screw
extractor to remove the remaining part. Follow the
screw extractor manuf acturers instructions.
Tap and die set and assorted screw extractors.
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.