1987 NISSAN PULSAR engine

118 Emission Control


Installed view of the charcoal canister.
When the engine is at rest, fuel vapor through
evaporation gradually fills the air space in the fuel
tank. The sealed filler cap pr events the escape of this
vapor and pressure builds up within the system,
forcing the vapor to flow into the charcoal canister
which is located in the engine compartment beneath
the windscreen wiper motor.

The fuel check valve prevents liquid fuel entering
the charcoal canister when the fuel tank is full or the
vehicle is parked on a steep incline. When the engine
is running, the vapor is drawn via a hose from the
charcoal canister to the throttle body and burnt in the
combustion chambers.

TO RENEW CHARCOAL CANISTER
(1) Suitably mark and disconnect the hoses from
the canister. (2) Release the retaining spring and remove the
canister from the engine compartment. Installation is a reversal of the removal procedure.

TO RENEW FUEL CHECK VALVE
(1) Disconnect the negative battery terminal.
(2) Raise the rear of the vehicle and support it
on chassis stands. Remove the left hand rear wheel. (3) Drain the fuel from the fuel tank using a
hand pump or a suitable siphon. Do not siphon fuel
using the mouth.
(4) Remove the hoses from the check valve.
(5) Squeeze the retaining clip and remove the
check valve from the mounting bracket. Installation is a reversal of the removal procedure.

TO SERVICE THE SYSTEM
(1) Inspect the vacuum lines and connectors for
signs of leakage, cracks and deterioration and renew
as necessary. (2) Remove the fuel tank cap and check that a
slight resistance is felt, when vacuum is applied to the
one-way relief valve in the centre of the cap. Renew the fuel tank cap if no resistance is felt or
if the valve is blocked.

(3) Inspect the fuel tank cap seal for deteriora-
tion. Renew as necessary.

Installed view of the fuel check valve as seen with the
left hand rear wheel removed.
Check the fuel filler cap seal for damage.
23Q/LDZ GAUGE
Line drawing showing a hand vacuum pump.

Emission Control 119

(4) Remove the charcoal canister as previously
described under the heading To Renew Charcoal
Canister. (5) Shake the canister, there should no audible
carbon movement. If there is, renew the canister. (6) Check the purge valve by applying 20-35
kPa of vacuum with a hand pump to the control port. Using a piece of hose, blow through the purge
hose connection. If this is not possible, renew the
canister.

Remove the vacuum source and blow air through
the purge hose connection. If this is possible, renew
the canister.

(7) Apply 20-35 kPa air pressure into the fuel
tank connector. Air should flow freely from all the
other connectors.

If poor air flow through the drain tube exists,
block off the fuel tank tube and blow compressed air
at approximately 300 kPa through the purge port.
Check the air flow and if st ill poor, renew the canister.

(8) Apply 20-35 kPa air pressure to any one of
the canister ports except th e purge valve control port
and with the other ports blocked, ensure that there are
no leaks from the canister. If leaks exist, renew the
canister. (9) Remove the fuel check valve as previously
described under the heading To Renew Fuel Check
Valve. (10) Blow through the check valve from the side
that is connected to the fu el tank hose. Considerable
resistance should be felt with only a small amount of
air passing through the valve. If no resistance is felt or
if the valve is blocked renew the fuel check valve.
(11) Blow air through the fuel check valve from
the opposite end. There should be a smooth flow of air
through the valve. If the valve is blocked, renew the
fuel check valve.
3. AIR PREHEAT SYSTEM — 1.6 LITRE
ENGINE
DESCRIPTION
To reduce emissions and improve drivability
when the engine is cold, hot air is drawn into the air
cleaner from a heat shield which partially surrounds
the exhaust manifold.

When the ambient temperature is below 30°C, the
thermal vacuum valve, which is located inside the air
cleaner housing, allows vacuum to operate a servo
actuated flap in the air cleaner intake duct. When the
flap closes, hot air is dr awn from the exhaust heat
shield, through the hot air inlet tube into the air
cleaner intake duct.

When the ambient temperature is above 30°C,
the flap in the air cleaner intake duct opens allowing
cool air to enter the air cleaner.


View of the air preheat system components. 1.6 liter
engine.
TO CHECK OPERATION
(1) When the engine is cold, use a mirror to
check that the passage from the hot air inlet tube is
closed by the flap.
(2) Start and run the engi ne at approximately
1 200 rpm. The hot air inlet passage should now be
open, allowing hot air from the exhaust heat shield to
be drawn into the air cleaner. (3) Allow the engine to idle for fifteen minutes
and inspect the position of th e air cleaner intake flap.
The flap should now be in the open position allowing
cool air to be drawn into the air cleaner and shutting
oft' air from the exhaust manifold heat shield.
TO CHECK COMPONENTS

(1) Disconnect the vacuum hose from the servo
unit and connect a vacuum pump to the unit.

When the vacuum is applied to the servo unit, the
flap in the air cleaner intake duct should close.

When the vacuum is removed, the flap should
open.


View of the air cleaner raised showing the engine
ventilation hose and the thermal vacuum valve supply
hose connection. 1.6 liter engine.

120 Emission Control
If the flap does not operate as described, renew
the air cleaner housing.

(2) Disconnect the vacuum hose from the servo
unit and connect it to a vacuum gauge.
(3) Start and run the engine at approximately
1 200 rpm. If the engine is cold there should be
vacuum. (4) As the engine temperature increases the
vacuum should decrease to zero. If the vacuum gauge does not read as described,
check that the vacuum supply hose is connected to the
thermal vacuum valve and the throttle body.

If no fault is found, renew the thermal vacuum
valve.

4. EXHAUST CONTROL SYSTEM
DESCRIPTION
The exhaust system is the greatest source of
pollutant emission from the internal combustion
engine.

On the Pulsar range of vehicles covered by this
manual, the exhaust control system consists of a
catalytic converter and the engine management sys-
tem. The engine management system constantly mon-
itors the exhaust gases via an oxygen sensor located in
the exhaust system. Fuel injection is then adjusted
accordingly to give the minimum amount of exhaust
emissions. Refer to the Fuel and Engine Management
section for further information.

CATALYTIC CONVERTER
The catalytic converter, which is located in the
exhaust system, converts hydrocarbons, oxides of
nitrogen and carbon monoxide present in the exhaust
gases into carbon dioxide, nitrogen, water and heat.

The catalytic converter does not require periodic
maintenance or replacement under normal circum-
stances. However, it can be damaged or poisoned by
excessively high exhaust gas temperatures, raw fuel
and the use of leaded fuel.

Installed view of the catalytic converter.
To prevent the use of leaded fuel, a small diam-
eter fuel filler neck with a spring loaded trap door is
used.

To prevent damage to the catalytic converter, the
following precautions sh ould be observed.

(1) Do not operate the vehicle on leaded fuel.
(2) Do not push or tow start the vehicle.
(3) Do not allow the engine to idle for prolonged
periods. (4) Do not operate the vehicle if the engine is
misfiring.
(5) Avoid running the vehicle out of fuel.
(6) Ensure that the engine oil is formulated to
contain low phosphorous levels.
To Inspect Catalytic Converter

(1) Inspect the converter for dents and damage.
If the converter is damaged, it should be renewed. (2) Inspect the converter heat shield for damage
and ensure that it is positioned correctly. Renew the
converter heat shield if necessary.
To Remove and Install
To remove and install the catalytic converter,
refer
to the Exhaust System heading in the Engine section.

121
CLUTCH
SPECIFICATIONS
Type................................................... Single dry plate
Operation................................................... Mechanical
Pressure plate type .................................... Diaphragm
Release bearing type .......................Prelubri cated ball
Driven plate:
Outside diameter .................................... 215 mm
Rivet depth limit ....................................0.3 mm
Runout limit .........................................0.5 mm
Maximum spline backlash ...................0.7 mm
Pressure plate:
Diaphragm spring height
(installed) ...................................... 30.5-32.5 mm
Spring finger vari ation limit.....................0.5 mm
Clutch pedal:
Height .............................................. 175-185 mm
Free play ....................................... 12.5-17.5 mm
Release lever free play............................ 2.5-3.5 mm
Flywheel machining limit ...............................0.3 mm
TORQUE WRENCH SETTINGS
Pressure plate bolts.......................................... 29 Nm
Pedal pivot pin nut ......................................... 22 Nm
Cable loc knut.................................................... 4 Nm
Lower clutch housing to engine bolts.............. 21 Nm
Centre and upper clutch housing
to engine bolts .................................................. 49 Nm
1. CLUTCH TROUBLE SHOOTING
CLUTCH SLIPPING
(!) Worn driven plate facing: Check and renew
the clutch driven plate.

(2) Insufficient clutch pedal free play: Check and
adjust the clutch pedal free play. Ensure that the
release lever free play is correct.
(3) Weak or broken pressure plate diaphragm
spring: Check and renew the pressure plate assembly. (4) Worn or scored flywh eel: Machine or renew
the flywheel. Worn or scored pressure plate face: Renew the
pressure plate assembly.


Renew the clutch driven plate if the friction material is
worn down to, or is within 0.3 mm of the rivets.
NOTE: In most cases clutch slippage is first
evident by a marked increase in engine revs,
for no apparent reason, when pulling up a
steep hill. The clutch condition can be
positively diagnosed as follows: With the
handbrake firmly applied, and the rear
wheels chocked, select top gear and release
the clutch with the engine running at ap-
proximately 2 000 rpm. Clutch slippage is
evident if the engine does not stall. Make the
test as quickly as possible to prevent any
further clutch damage.

CLUTCH SHUDDER
(1) Oil on the driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Scored pressure plate or flywheel face: Re-
new the pressure plate assembly or machine the
flywheel. (3) Loose or damaged driven plate hub: Check
and renew the clutch driven plate. (4) Loose driven plate facings: Renew the clutch
driven plate. (5) Cracked pressure plate face: Renew the pres-
sure plate assembly.

122 Clutch


Check the engine mountings for damage and deterio- ration.
NOTE: Clutch shudder is usually most
evident when reversing up an incline. As
loose or damaged engine mountings are a
cause for clutch shudder, thoroughly check
the engine mounting rubbers and mounting
hardware for damage or looseness before
removing the clutch for inspection.

CLUTCH GRAB
(1) Oil soaked driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Cracked pressure plate face: Renew the pres-
sure plate assembly. (3) Loose or broken engine mountings: Check
and renew the engine mountings as necessary.
(4) Binding release mechanism: Check the oper-
ation of the release mechanism.
NOTE: Visually check the operation of the
cable actuated release mechanism. Check
the inner cable for fraying and jamming in
the outer cable.

INSUFFICIENT CLUTCH RELEASE
(1) Stretched, frayed or broken clutch cable:
Check and renew the clutch cable. (2) Worn or damaged release mechanism: Check
and renew components as necessary. (3) Insufficient pedal height: Check and adjust
the pedal height.
(4) Warped clutch driven plate: Renew the
clutch driven plate. (5) Excessive clutch release lever free play:
Check and adjust the release lever free play to
Specifications.
NOTE: Visually check that the clutch cable
operates the release lever before removing
the clutch for inspection.

RELEASE BEARING NOISE
(1) Dry or worn release bearing: Check and
renew the release bearing.
(2) Damaged pressure plate diaphragm spring;
Check and renew the pressure plate assembly.
NOTE: Lightly depress the clutch pedal with
the engine running to check for release
bearing noise. If the release bearing is faulty
and has to be renewed, always check the
other clutch components.


Check the diaphragm spring fingers for scoring and damage.
2. DESCRIPTION
The clutch consists of a single, dry, driven plate
assembly, splined to slide on the transaxle input shaft.
A diaphragm spring type pr essure plate assembly is
bolted to the engine flywheel.

The driven plate is sandwiched between the
pressure plate and the flywheel and transmits the
drive from the engine to the transaxle.

Cushion rubbers are interposed between the hub
of the driven plate assembly and the plate friction
surfaces in order to cushion the drive.

The release mechanism is actuated by the clutch
pedal through a cable to the release lever and bearing.

Operation of the clutch pedal moves the release
lever which pushes the release bearing into contact
with the diaphragm spring fingers, forcing the dia-
phragm centre towards the flywheel. When the outer
edge of the diaphragm deflects, the clutch is caused to
disengage.

Clutch pedal free play is adjusted at the release
lever end of the clutch cable.

Clutch pedal height is adjusted at the pedal stop
on the pedal mounting bracket located under the
dashboard.

124 Clutch


Illustration showing the clutch aligning tool. The tool
can be readily fabricated from a length of round section
wood or metal. Dimension A = diameter of the ma-
chined section of the crankshaft. Dimension B - inside
diameter of the driven plate hub.
to the release fork ensuring that the return spring is
correctly anchored.

(3) Install the release bearing to the clutch hous-
ing and install the clips re taining the release bearing
carrier to the release fork. (4) Install the driven plate to the flywheel in the
direction noted on removal. Install the aligning tool to
hold the driven plate in position.
NOTE: Some driven plates are marked
Flywheel side to indicate the correct in-
stalled direction.

(5) Install the pressure plate to the flywheel in the
position marked on removal. (6) Ensure that the driven plate is correctly
centered and install the pressure plate retaining
bolts.
Tighten the bolts progressively in a diagonal sequence
to the specified torque. (7) Install the transaxle to the vehicle as de-
scribed in the Manual Transaxle section. (8) Adjust the clutch pedal height and free play
as described under the Adjustments heading later in
this section.
4. CLUTCH PEDAL

TO REMOVE AND INSTAL
(1) Working in the engine compartment, loosen
the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.
(2) Working inside the vehicle, release the inner
clutch cable from the top of the clutch pedal.
(3) Remove the nut from the end of the clutch
pedal pivot pin. (4) Note the installed position of the clutch
pedal return spring and remove the pivot pin from the
clutch pedal.
(5) Remove the clutch pedal from the vehicle
and remove the bush from the clutch pedal. (6) Examine the clutch pedal and the bush for
bend, cracks, wear and damage. Examine the return

Installed view of the clutch pedal.
spring for cracks and fatigue. Renew parts as neces-
sary.

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

(1) Lubricate the hook on the top of the clutch
pedal and the pivot pin and bush with lithium base
molybdenum disulphide grease. (2) Install the return spring to the position noted
on removal. (3) If necessary, adjust the pedal height and free
play as described under the Adjustments heading later
in this section.
5. CLUTCH CABLE

TO REMOVE AND INSTAL
(1) Working in the engine compartment, loosen
the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.
(2) Release the outer clutch cable retaining nut
and slide the outer cable out of the slot in the
mounting bracket.
View of the clutch cable assembly.

Clutch 125
(3) Remove the nuts retaining the outer cable
flange to the vehicle bulkhead.
(4) Working inside the ve hicle, disconnect the
inner cable from the top of the clutch pedal. (5) Pull the clutch cable through the bulkhead
into the engine compartment. (6) Release the clip retaining the centre of the
clutch cable and remove the cable from the vehicle. (7) Check the inner cable for fraying, wear and
damage. Check the outer cable for kinks, wear and
damage. If necessary, renew the cable assembly. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Lubricate the inner cable ends with lithium
base molybdenum disulphide grease prior to installa-
tion. (2) Tighten the nuts retaining the outer cable
flange to a torque of 11 Nm. (3) Check and if necessary , adjust the clutch
pedal height and free play as described under the
heading Clutch Adjustments.
6. CLUTCH ADJUSTMENTS
TO ADJUST PEDAL HEIGHT (1) Fold back the floor carpet and the sound
insulation from the drivers side floor panel.
(2) Measure the distance at right angles from the
floor panel to the centre of the pedal pad. (3) If the pedal height is not as specified, adjust
the pedal stop bolt until the correct pedal height is
obtained.

TO ADJUST PEDAL AND RELEASE LEVER
FREE PLAY
(1) Loosen the inner cable locknut at the release
lever clevis. (2) Push the release lever until resistance is felt
when the release bearing contacts the pressure plate
fingers and hold the release lever in this position.
(3) Tighten the inner cable adjusting nut until
the inner cable is taut.
(4) Loosen the adjusting nut 2.5-3.5 turns and
tighten the inner cable locknut. (5) Measure the release lever free play. If the free
play is not as specified, loosen the locknut and turn
the adjusting nut until the correct free play is
obtained.

View of the clutch release lever free play adjusting
nut.
(6) Lightly depress the clutch pedal until resis-
tance is felt when the release bearing contacts the
pressure plate fingers. Measure the distance from the
centre of the pedal pad in this position to the centre
of the pedal pad when the pedal is contacting the stop
bolt. If necessary, check and adjust the release lever
free play which should bring the pedal free play within
Specifications.

Measuring the clutch pedal height with the carpet
removed.

126
MANUAL TRANSAXLE AND DRIVE SHAFTS

SPECIFICATIONS
TRANSAXLE
Type .....................................Five speed, synchromesh
on all forward gears
Model .......................................................... RS5F31A
Gear ratios: 1.6 liter -

First .......................................................... 3.333:1
Second...................................................... 1.955:1
Third......................................................... 1.286:1
Fourth....................................................... 0.975:1
Fifth.......................................................... 0.810:1
Reverse .................................................... 3.417:1
1.8 liter -
First .......................................................... 3.063:1
Second...................................................... 1.826:1
Third......................................................... 1.286:1
Fourth ....................................................... 0.975:1
Fifth.......................................................... 0.810:1
Reverse .................................................... 3.417:1
Gear end float:
Fifth...............................................0.18-0.41 mm
Second, third and fourth................0.20-0.40 mm
First ...............................................0.18-0.31 mm
Synchro ring to gear clearance:
Standard ............................................ 1.0-1.3 mm
Minimum ................................................. 0.7 mm
Turning torque (new bearings):
Differential assembly ........................ 3.9-7.8 Nm
Total differential and mainshaft __ 5.9-13.7 Nm
Differential and final drive:
Type ........................ Helical ring gear and pinion
Ratio......................................................... 4.167:1
Lubricant:
Grade ............................................. 80W-90 GL-4
Capacity ..................................................2.7 liters
DRIVE SHAFTS
C.V. joint lubrication:
Lubricant ........ Valvoline Special Moly EP grease
Amount ................................................. 40 grams
TORQUE WRENCH SETTINGS
Transaxle case retaining bolts ........
Cover plate to transaxle case .......................... 8.3 Nm
Input shaft bearing retainer bolts ..................... 21 Nm
Control bracket bolts ...................................... 8.3 Nm
Reverse check plug.......................................... 25 Nm
Ring gear to differential case........................... 88 Nm
Filler and drain plugs....................................... 34 Nm
Reverse lamps switch ...................................... 29 Nm
Upper and centre clutch housing to engine…...49 Nm
Lower clutch housing to engine ...................... 21 Nm

1. MANUAL TRANSAXLE AND DRIVE
SHAFT
TROUBLE SHOOTING

DIFFICULT GEAR CHANGE
(1) Faulty clutch or clutch release mechanism:
Check and adjust or overhaul the clutch or the clutch
release mechanism. (2) Loose control bracket retaining bolts: Dis-
mantle the transaxle and tighten the control bracket
retaining bolts. Apply Loctite or an equivalent to the
bolt threads to prevent a repeat of the problem.
(3) Faulty gear lever assembly: Check and
renew
or repair the gear lever assembly. (4) Bent or worn gear lever control rod: Repair
or renew the faulty components. (5) Worn transaxle selector mechanism: Over-
haul the transaxle assembly. Renew components as
necessary.
.21 NmCheck the synchronizing teeth on the gears and synchro
rings for chipping or wear.