1987 NISSAN PULSAR wheel

Brakes 185
(6) Using a suitable pair of pliers, disengage the
upper and lower return springs from the leading shoe,
and then remove them from the trailing shoe. (7) Using a pair of pliers, compress the leading
shoe retainer, turn through ninety degrees and remove
the retainer, spring and pin. Remove the leading shoe
from the backing plate. (8) Using the same procedure, remove the trail-
ing shoe retainer. (9) Lift the trailing shoe from the backing plate
and disconnect the handbrake cable from the hand-
brake lever. Remove the trailing shoe assembly from
the backing plate.
(10) If the brake shoes are to be renewed, remove
the C clip from the trailing shoe and remove the
handbrake lever assembly. (11) If the wheel cylinder is to be overhauled,
proceed as follows:
(a) Disconnect the brake pipe from the rear of
the wheel cylinder and plug the pipe to prevent the
loss of fluid and the ingress of dirt. (b) Remove the bolts retaining the wheel cylin-
der to the backing plate and withdraw the wheel
cylinder from the vehicle. (c) Remove the rubber boots, pistons and spring
from the wheel cylinder bore. Remove the seals from
the pistons. Discard th e rubber boots and seals.
(d) Remove the rubber boot and bleeder valve
from the wheel cylinder.
TO CLEAN AND INSPECT

(1) Thoroughly clean all the brake components,
except the brake shoes in methylated spirits.
(2) Inspect the brake shoe linings. If the thick-
ness of the lining on one or more of the shoes is less
than 1.5 mm thick or contaminated with fluid or
grease, the brake shoes must be renewed as a set. (3) Inspect the wheel cylinder bore and piston
for pitting, wear or damage. Renew the wheel cylinder
assembly if any damage is evident. (4) Check the brake drums for cracks, scoring or
out of round. Renew or machine the brake drums as
necessary.
(5) Inspect the springs and handbrake lever for
fatigue and distortion. Renew as required. (6) Operate the handbrake lever and check for.
smooth operation of the handbrake cable. Renew as
required under the Hand brake Cable and Lever
Assembly heading. (7) Check the bleeder valve for blockage.
(8) Clean and lubricate the adjuster rod.
(9) Clean and inspect the backing plate for
cracks, damage and wear. Renew as required.
TO ASSEMBLE AND INSTAL

(1) If the wheel cylinder was overhauled, pro-
ceed as follows:

(a) Lubricate the pistons and seats with brake
fluid and install the seals on to the pistons so that the
l i p on the seals will be facing towards the centre of the
cylinder.
(b) Install the spring, pistons and rubber boots to
the wheel cylinder ensuring that the rubber boots are
securely located in the cy linder. If necessary, use a
clamp to hold the pistons in the cylinder.
(c) Position the wheel cylinder in the backing
plate and install the brake pi pe to the cylinder. Do not
fully tighten the pipe at this stage. (d) Install the wheel cylinder retaining bolts and
tighten the retaining bolts and brake pipe securely.
Install and tighten the bleeder valve. Install the
valve
boot.


Dismantled view of the right hand rear drum brake
components. Dismantled view of the rear wheel cylinder.

(2) Sparingly lubricate the brake shoe moving
contact surfaces on the backing plate and the adjuster
assembly with a high melting point grease.
(3) If necessary, position the adjusting lever
on
the handbrake lever. (4) If necessary, position the handbrake lever
assembly and washer on the trailing shoe and secure it
with the C clip.
(5) Ensure that the adjuster assembly is adjusted
to its shortest length. (6) Install the adjusting lever return spring to
the
trailing shoe.

186 Brakes
(7) Using a pair of pliers, compress the hand-
brake cable spring and install the cable to the hand-
brake lever.
(8) Position the trailing shoe on the backing
plate with the upper end located on the wheel cylinder
piston and the lower end on the anchor plate. (9) Install the adjuster assembly to the
trailing
shoe ensuring that the adjuster fork is correctly
located on the upper end of the shoe. (10) Install the pin, spring and retainer to the
trailing shoe, turn the reta iner through 90 degrees and
secure the brake shoe to the backing plate. (11) Connect the upper and lower return springs
to the trailing shoe as noted on removal. (12) Position the leading shoe on the backing
plate with the upper end located on the wheel cylinder
piston and the lower end on the anchor plate. Ensure
that the adjuster assembly is correctly located on the
upper end of the shoe. (13) Install the pin, spring and retainer to the
leading shoe, turn the retainer through 90 degrees and
secure the shoe to the backing plate. (14) Connect the upper and lower return springs
to the leading shoe.
(15) By alternatively adjust ing the automatic ad-
juster manually and sliding the brake drum on and off
the brake shoe assembly, adjust the brakes until the
brake drum will just slide over the brake shoes. Ensure
that the adjuster lever contacts the adjuster star wheel.
Install the brake drum and operate the handbrake
several times to adjust the brake shoes. (16) Install the rear wheels and rotate each wheel
to ensure that the brake shoe linings are not dragging.
(17) Bleed the hydraulic system as described
under the Hydraulic System heading. (18) Adjust the handbrake as described under the
Brake Adjustments heading.
8. HANDBRAKE CABLE AND LEVER
ASSEMBLY

HANDBRAKE LEVER AND FRONT CABLE
ASSEMBLY

To Remove and Install
(1) Raise the vehicle and support it on chassis
stands. Release the handbrake.

(2) Working beneath the vehicle, remove the
exhaust pipe centre heat shield retaining bolts and
maneuver the shield from the vehicle. (3) Remove the rear handbrake cable front
clamp retaining nuts and disconnect the rear hand-
brake cable from the equalizer. (4) Working within the vehicle, remove the
carpet square from the rear of the console. Remove
the retaining screw from the front and rear of the rear
console section and maneuver the rear console from
the vehicle.

Dismantled view of the handbrake lever components.
(5) Disconnect the handbrake warning lamp
switch wiring. (6) Remove the handbrake lever assembly re-
taining bolts and remove the handbrake lever and
front cable assembly. (7) If necessary slide the boot and cover towards
the equalizer, straighten the tang on the lower edge of
the lever and remove the adjuster nut and washer.
(8) Withdraw the front cable from the lever and
remove the boot and cover. Inspect the cable for
chafing or broken strands. Renew the cable if damage
is evident. (9) Check the handbrake lever ratchet and pawl
for wear and renew as necessary. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Apply lubricant to all the working parts prior
to installation. (2) Ensure that the handbrake cable clamp is
correctly installed. (3) Adjust the handbrake cable as described
under the Brake Adjustments heading.
REAR HANDBRAKE CABLES
TO Remove and Install
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove th e rear wheels and release
the handbrake.

(2) Working beneath the vehicle, remove the
exhaust pipe centre and rear heat shield retaining
bolts and maneuver the heat shields from the
vehicle.
(3) Remove the bolts and nuts retaining the
handbrake cable clamps to the underbody and discon-
nect the rear handbrake cable from the equalizer.
(4) On disc brake models, remove the handbrake
cable to bracket retaining clip on the rear of the
caliper and disconnect the handbrake cable from the
cam lever. Remove the cable from the vehicle.
(5) On drum brake models , proceed as follows:
(a) Remove and dismantle the rear brakes as

previously described.

Brakes 187
(b) Disengage the handbrake cable return spring
from the backing plate.

handbrake cable flange from the rear of the backing
plate and remove the cable from the vehicle.

(6) Inspect the rear handbrake cables for chafing
or broken strands. Renew the cables if damage is
evident.

Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the handbrake cable clamps are
correctly installed. (2) On drum brake models, install the
handbrake
cable to the backing plate by carefully tapping the
flange on the handbrake cable. Ensure that the cable is
not damaged. (3) Adjust the handbrake cable as described
under the Brake Adjustments heading.
9. BRAKE ADJUSTMENTS

FRONT AND REAR DISC BRAKES
The disc brakes are self adjusting and no manual
adjustment is required or provided.

REAR DRUM BRAKES
Depress the handbrake lever button, apply and
release the handbrake lever several times to adjust the
rear brake shoes.

HANDBRAKE
(1) Raise the rear of the vehicle and support it
on chassis stands. (2) Remove the carpet square from the rear of
the console. Remove the retaining screws from the
front and rear of the rear console section and manoeu-
vre the rear console from the vehicle. (3) Tighten the adjusting nut until the hand-
brake lever pull is between 7-11 notches. (4) Check that the rear wheels are not binding. If
the rear wheels do not rotate freely refer to the Brakes
Trouble Shooting for possible causes.
(5) With the ignition switched On, check that
the handbrake warning lamp is extinguished when the
lever is fully released. (6) Lower the vehicle to the ground and test the
handbrake on an incline.
10. BRAKE PEDAL

TO REMOVE AND INSTAL
(1) Working inside the vehicle remove the re-
taining clip from the clevis pin and remove the clevis
pin connecting the brake pedal to the pushrod.

Dismantled view of the brake pedal components.
(2) Remove the nut from the pivot bolt and
withdraw the brake pedal pivot bolt.
(3) Maneuver the brake pedal from the mount-
ing bracket. (4) Remove the spring from the brake pedal.
(5) Inspect the return spring for breakage or
fatigue. Renew as required.
(6) Inspect the pedal pivot bolt for damage or
wear. Renew as required. (7) Inspect the brake pedal for wear, cracks or
fatigue. Renew as required. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Sparingly lubricate the pedal pivot bolt and
clevis pin with a suitable grease. (2) Ensure that the brake pedal pivot bolt is
correctly located in the pedal bracket. (3) Ensure that the clevis pin is inserted fully
through the clevis and the retaining clip is correctly
installed. (4) Check and if necessary adjust the brake
pedal height and stop lamp switch as described below.
TO ADJUST PEDAL HEIGHT

The dimension for the pedal height is measured at
right angles from the floor, with the carpet pulled
back, to the centre of the pedal pad.

(1) Working inside the ve hicle, disconnect the
wiring from the stop lamp switch.
(2) Loosen the stop lamp switch locknut and
position the switch away from the brake pedal. (3) Loosen the locknut on the brake pedal push-
rod and adjust the pushrod to achieve a pedal height
of 155-165 mm on manual transaxle models or
164-174 mm on automatic transaxle models. Tighten
the locknut. (4) Adjust the stop lamp switch as described
under the following heading.

188 Brakes

Illustration showing the brake pedal adjustments. Di-
mension H = brake pedal height, Dimension C = stop
lamp switch clearance, Dimension F - brake pedal free
play.
TO ADJUST STOP LAMP SWITCH
(1) Loosen the stop lamp switch locknut and
disconnect the wiring from the switch.
(2) Adjust the stop lamp switch to achieve a
clearance of 0.3-1.0 mm between the pedal stop and
the threaded end of the switch. (3) Tighten the locknut and connect the wiring
to the switch. Ensure that the stop lamps are off when
the pedal is released.
(4) Ensure that the pedal free play is 1.0-3.00
mm after adjustments have been completed.
11. HYDRAULIC SYSTEM

TO BLEED
Bleeding the hydraulic system should only be
necessary when some portion of the hydraulic system
has been disconnected or fluid has been drained,
allowing air to enter the system.

The brake fluid in the hydraulic system should be
changed every 30 000 km or 18 months. The proce-
dure for changing the brake fluid and bleeding the
hydraulic system are simila r with attention to the
notes in the text.

There are four points in the system where bleeder
valves are installed, one on each front caliper and one
on each rear wheel cylinder or rear caliper.

14. Fill the fluid reservoir with clean hydraulic
brake fluid and maintain at least one third full
throughout the entire operation. 15. Attach a transparent hose to the bleeder
valve on the left rear cali per and immerse the other
Bleeding the right hand rear brake caliper.
end of the hose in a small amount of clean brake fluid
contained in a clean glass jar held higher than the
bleeder valve.

14. Unscrew the bleeder valve one
complete turn.
15. Have an assistant depress the brake
pedal slowly to the full extent of its travel. Close
the bleeder valve and allow the brake pedal to
r e t u r n w i t h o u t assistance. 16. Repeat operations (3) and (4) until
a con stant stream of fluid, without any air
bubbles, is being discharged into the gl ass jar,
hold the brake pedal down and tighten the
bleeder valve.
Bleeding the right hand front brake caliper.

192 Electrical System
transaxle models, check for a faulty or incorrectly
adjusted neutral safety switch.

1. Discharged battery: Check for a fault or short
circuit in the system. 2. Battery fully charged but will not crank
engine. Check for a locked drive and ring gear,
internal starter faul t or seized engine.
3. Fusible link blown: Check and repair the
cause and renew as necessary.
NOTE: Rotate the engine by hand to ensure
that the starter drive is not locked with the
flywheel ring gear and t hat the engine is not
seized. Ensure that the ignition key is
turned off before rotating the engine.

3. LIGHTING SYSTEM TROUBLE SHOOTING
LAMP OR LAMPS FAIL TO LIGHT
1. Faulty bulb(s): Check and renew the faulty
bulb(s). 2. Open circuit in the wiring or connections:
Check the lamp circuits and rectify as necessary.

1. Faulty lamp switch: Check and if necessary
renew the lamp switch. 2. Faulty fuse or fuse connection: Repair the
fuse connection or renew the fuse. 3. Lamp relay faulty: Check and renew as
necessary.
NOTE: Switch on the lamps concerned and
using a test lamp, check that the lamp
circuits are operating. This is best done by
starting at the lamp wiring connector or
bulb holder and work ing back to the power
source.

LAMP OR LAMPS INCORRECTLY
ILLUMINATED

1. Lamp or lamps incorrectly earthed: Check
the lamp earth for loosene ss or clean the contact,
either at the lamp body or wire.
2. Incorrect bulbs installe d: Check the bulb
wattage and voltage and renew with the correct type if
necessary. 3. Dirty or damaged lamp reflector: Clean or
renew the lamp reflector. 4. Faulty bulb: Check with a known serviceable
bulb and renew if necessary. 5. Dirty lamp lens: Clean or renew the lamp
lens. 6. High resistance or faulty connections be-
tween the alternator and battery: Check the circuit
and rectify th e condition.
7. Poor earth connection between the battery
and the engine or alternat or: Check the battery earth
lead and the strap between the engine and the body. 8. Voltage regulator faulty: Check and renew
the voltage regulator.
NOTE: The most common cause for this
condition is dirty t erminals on the earth
leads. Check all earth leads at their earthing
points.

4. TURN SIGNAL LAMP TROUBLE SHOOTING
TURN SIGNAL LAMP DOES NOT LIGHT AND
NO AUDIBLE NOISE FROM FLASHER UNIT

(1) Fuse blown: Rectify the fault and renew the
fuse.

(2) The Flasher unit is faulty: Renew the unit
(3) Turn signal switch faulty: Renew the switch
(4) Fault in the wiring circuit: Check and repair
the fault.

TURN SIGNAL WARNING LAMP DOES NOT
FLASH BUT AUDIBLE CLICKING FROM
FLASHER UNIT

(1) Warning lamp bulb blown: Check and renew
the bulb.

Checking the rear combination lamp circuit using a test
lamp.
Checking the headlamp circuit using a test lamp.

Electrical System 201
nosed pliers. This will safeguard the diodes
by transferring any excess heat to the jaws of
the pliers.

Using a suitable drift, install the bearing into
the drive end bracket, install the retainer plate and
screws. Tighten the screws securely. Using a suitable press and press plates, install
the bearing to the slip ring end of the rotor shaft.
Ensure that pressure is ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft rear bearing stop
ring is positioned so that the protruding part of the
ring is located in the deepest part of the groove. Install the stator, diode pack and
regulator
assembly to the slip ring e nd bracket. Install the
retaining nuts and washers and tighten securely. Install the nut and insulator to the terminal
and tighten securely. Using a piece of wire, hold the brushes in a
retracted position. Hold the drive end bracket in a soft jawed
vice and install the rotor shaft assembly to the drive
end bracket. Install the pulley, retaining nut and washer to
the rotor shaft and tighten the retaining nut to the
specified torque. Apply a heated 200 watt soldering iron to the
slip ring end bracket at the bearing mounting boss for
3-4 minutes to heat the bracket and allow the
installation of the rotor shaft rear bearing. Aligning the marks made on dismantling and
ensuring that the rotor sh aft rear bearing retaining
ring protrusion is located in the deepest part of its
groove, install the rotor/stator assembly to the slip ring
end bracket.
Remove the brush retr acting wire from the
alternator, ensure that the alternator component
marks are aligned, install the retaining through bolts
and tighten them securely. Check the alternator rotor for smooth oper-
ation and install the al ternator to the vehicle
as
previously described.
Check the alternator operation on the vehicle
as previously described.
8. STARTER MOTOR
Special Equipment Required:
To Renew Brushes — Soldering iron
To Renew Armature Bearings — Bearing puller
DESCRIPTION
Two types of starter motors are installed to the
range of vehicles covere d by this manual, either
Hitachi or Bosch.

The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.

A solenoid switch is attached to the starter drive
end bracket. The solenoid plunger is connected to
the overrunning clutch and drive pinion assembly
through a lever and pivot arrangement.

When the solenoid windings are energized, the
plunger acting on the lever and pivot engages the drive
pinion with the flywheel ri ng gear and at the same
time closes the switch supplying power from the
positive lead of the battery to the starter motor field
coils and armature to operate the motor.

As the engine fires, the over-running clutch of the
drive pinion assembly prevents high speed rotation of.
and possible damage to, the starter armature if the
solenoid windings are not immediately de-energized
by releasing the ignition key.

The starter solenoid switch windings are energized
by the ignition switch.

TO TEST ON VEHICLE
Should the starter motor fail to operate when the
ignition switch is turned to the Start position, check
the following points:

Check the battery condition and state of
charge. Refer to the Battery heading for the correct
procedure.
Clean the battery terminals, taking particular
care to remove the scale from the positive ( + )
terminal post and terminal. Check the earth connection for tightness and
cleanliness.
Switch on the headlamps and turn the igni-
tion switch to Start. If the lamps dim but the starter
motor does not operate, it could indicate that a short
circuit has developed in the starting system. Check that the engine is not seized or that the
starter motor drive pinion and ring gear are not
locked as these conditions would -give the same
indications as above.

(5) If the lamps do not dim and the starter
motor does not operate, this would indicate an open
circuit such as a broken or disconnected wire or a
switch not operating.

If the vehicle is equipped with an automatic
transaxle, turn the ignition switch to Start and move
the selector lever through all the gear selection range.
If the starter motor operates in any position other
than N or P, the neutral safety switch is faulty.

(6) Check all the external wiring to ensure that
the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
starter motor, the unit will have to be removed and
tested.

TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Disconnect the wiring from the starter motor
solenoid. Remove the starter motor mounting bolts,

206 Electrical System
Install the armature and yoke to the drive end
bracket rotating the drive to align the reduction gears.
Do not use force.
Install the retaining through bolts to the
commutator end bracket and lighten the through bolts
and armature end cover retaining screws securely. Install the solenoid to the drive end bracket,
install the retaining screws and tighten them securely.
Install the brush connector strap and
install
the retaining nut and washer and tighten securely.
9 . IGNITION SYSTEM

The testing and repair procedures for the ignition
system are fully covered in the Fuel and Engine
Management section.

10. STEERING WHEEL
The removal and installation procedures for the
steering wheel and horn pad are fully covered in the
Steering section.

11. SWITCHES AND CONTROLS
IGNITION SWITCH
To Remove and Install
Disconnect the negative battery terminal.
Remove the retaining screws from the steer-
ing column cover. Unclip and separate the upper and lower
steering column covers and remove the upper cover. Release the column adjusting lever and re-
move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.

Disconnect the ignition switch wiring at the
switch. Remove the retaining screw and withdraw
the ignition switch fr om the lock assembly.
Installation is a reversal of the removal procedure.

COMBINATION SWITCH
The combination switch is mounted at the top of
the steering column and incorporates two switches.
The parking lamp, headlamp, headlamp flasher, head-
lamp dipper and turn signal lamps are operated by a
lever on the right hand side. A lever on the left hand
side operates the windscreen washer and wiper switch.

These switches can be re newed without removing
the combination switch.

To Remove and Install Switches
Remove the retaining screws from the steer-
ing column cover.
Unclip and separate the upper and lower
steering column covers and remove the upper cover.

View of the combination switch removed from the
vehicle.
Release the column adjusting lever and re-
move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover. Disconnect the wiring connectors from the
applicable switch. Remove the retaining screws located at the
top and bottom of the applicable switch and remove
the switch. Installation is a reversal of the removal procedure.

To Remove and Install Combination Switch Base
Disconnect the negative battery terminal.
Remove the steering wheel as described in
the Steering section Remove the retaining screws from the steer-
ing column cover. Unclip and separate the upper and lower
steering column covers and remove the upper cover.
Release the column adjusting lever and re-
move the lower cover by guiding the column adjusting
lever through the hole in the upper end of the cover.
Dismantled view of the steering lock and ignition
switch assembly

Body 235
lever and remove the screws underneath. Withdraw
the rear console.

On manual transaxle models, unscrew the
gear lever knob and prise out the gear lever rubber
boot. On automatic transaxle models, prise out the
panel around the selector lever and maneuver the
panel over the lever. Remove the screws retaining the front of the
console to the floor panel and withdraw the console
from the vehicle. Installation is a reversal of the removal procedure.

9, DASHBOARD
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Remove the centre console as previously
described in this section. Remove the steering wheel as described in
the Steering section. Remove the upper and lower steering col-
umn shrouds and remove the combination switch.
Refer to the Electrical System section if necessary. Remove the retaining screws and withdraw
the lower trim panel from underneath the steering
column. Remove the screws from underneath the
bonnet lock handle and slide the bonnet lock handle
downwards out of the dashboard. Remove the screws retaining the centre fas-
cia panel, two upper and two lower, withdraw the
fascia panel slightly and disconnect the wiring to the
cigarette lighter.

Dismantled view of the centre console assembly. Au-
tomatic transaxle model.
Remove the radio/cassette bracket retaining
screws. Disconnect the aerial and the wiring and
withdraw the radio/cassette from the centre bracket. Remove the heater control knobs and re-
move the heater fascia panel screws. Carefully remove
the heater fascia panel leaving the heater controls in
place.
Loosen the bolt retaining the large wiring
connector at the lower right hand side of the dash-
board. As the bolt is loosened it will force the
connector apart. Using a screwdriver, carefully prise out the
demister ducts from th e top of the dashboard.
Using a suitable socket, remove the bolts
from underneath the demister ducts. Remove the bolts from the outer lower edges
and the lower part of th e centre bracket assembly.
NOTE: Refer to the illustration for the
location of the dashboard retaining bolts.

(14) With the aid of an assistant lift the dash-
board straight up at the door pillar brackets. Tilt the


View of the dashboard removed from the vehicle. The arrows indicate the location of the retaining bolts.