1987 NISSAN PULSAR boot

148 Steering — Part 2

3. STEERING COLUMN
Special Equipment Required:
To Remove Steering Wheel — Steering wheel
puller

TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working in the engine compartment, mark
the relationship between the steering shaft universal
coupling joint and the steering gear pinion shaft. (3) Remove the pinch bolts from the universal
joint. (4) Working inside the vehi cle, remove the steer-
ing wheel as previously described. (5) Remove the steering column shroud screws,
unclip the lower and upper covers and remove them
from the steering column. (6) Disconnect all the steering column wiring
connectors. (7) Remove the lower trim from underneath the
steering column.
(8) Fold back the insulator and remove the nuts
from the steering colu mn floor bracket.
(9) Remove the nuts from the lower steering
column bracket. (10) Remove the bolts from the tilt bracket
assembly. (11) Maneuver the steering column from the
vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Measure the dimension between the lower
bracket pin and the upper edge of the steering shaft as
shown in the illustration.

If the dimension is not as specified, the steering
shaft has collapsed and the steering column should be
renewed.

(2) Rotate the steering shaft in the column and
check the shaft bearing for roughness and damage.
Renew as necessary. (3) Inspect the steering shaft universal coupling
joints for wear and damage and renew as necessary. (4) Position the steering column assembly under

the dashboard ensuring that the floor bracket is
located correctly and that the steering shaft universal
joint is aligned with the steering gear pinion shaft
marks.

(5) Install all the steering bracket nuts and bolts
finger tight. (6) Install the universal coupling joint pinch bolts
and tighten securely.
(7) Tighten all the stee ring column nuts and
bolts securely. (8) Test the operation of all the steering column
controls when installation is complete.
TO DISMANTLE

(1) Remove the steering column assembly from
the vehicle as previously described. (2) Suitably mark the position of the universal
coupling joint and remove it from the steering shaft. (3) Mark the position of the rubber boot in
relation to the floor bracket and steering column.
Loosen the retaining bands and remove the boot and
floor bracket from th e steering column.
(4) Using snap ring pliers, remove the snap ring,
plain washer and wave washer from the upper end of
the steering shaft. (5) Loosen the combination switch retaining
screw, push the combination switch in, turn the switch
and remove it from the steering column. (6) Turn the ignition switch to the On position
and slide the steering shaft from the column assembly. (7) If necessary dismantle the tilt bracket com-
ponents after removing the through bolts. Note the
position of the components to aid assembly. (8) To remove and install the steering lock pro-
ceed as follows: (a) Remove the ignition switch retaining screw
and carefully withdraw the switch from the steering
lock bracket.

View of the steering column assembly removed from
the vehicle. Steering column length is shown as dimen- sion A. A - 534.7-537.3 mm. Dismantled view of the steering lock and ignition
switch assembly.

Steering — Part 2 149

Dismantled view of the steering column and tilt bracket assembly.
(b) Using a suitable drill, carefully remove the
heads of the steering lock br acket shear type retaining
bolt heads. Remove the steering lock bracket from the
column.
(c) Install the steering lock to the column
using
new shear bolts. Ensure that the steering lock is
operating correctly and tigh ten the shear bolts until
the heads snap off.
(d) Install the ignition switch and tighten
the
retaining screw securely.
TO CHECK AND INSPECT

(1) Thoroughly clean and dry the components
using a suitable solvent.
(2) Inspect the steering shaft for bends, damage
and wear. Pay particular attention to the steering shaft
universal coupling joint and the internal and external
splines. Renew as necessary. (3) Inspect the steering column upper bearing
for ease of operation and if necessary, renew the
column assembly.
TO ASSEMBLE

Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Install the steering shaft to the column.
Ensure that the steering shaft is correctly located in
the upper bearing and insta ll the wave washer and the
plain washer. Install the snap ring using a ring
spanner
which has minimum clearan ce over the steering shaft.
(2) Install the rubber boot and floor bracket
to
the steering column aligning the marks made during
removal. If no marks were made, align the cutouts of
the rubber boots with the protrusions on the steering
column and the floor bracket. (3) Before installing the tilt bracket assembly to
the column, measure the steering column length as
shown on the illustration.

If the length is not as specified, the steering
column and the steering shaft must be renewed as an
assembly.

(4) Install the tilt bracket, lever, through bolt,
washers and adjusting nu t to the t i l t bracket.
(5) Before installing the column assembly to the
vehicle adjust the column tilt lever as follows:
(a) Position the tilt lever in its locked position,
the end of the lever should contact the flanged portion
of the tilt bracket.
(b) Tighten the adjusting bolt to 11 Nm.
(c) Unlock the tilt lever fully and ensure that the
column moves smoothly up and down the tilt bracket. (d) Return the tilt lever to the locked position
and ensure that the column is locked securely. Adjust
the tilt bracket thro ugh bolt if necessary.
(6) Install the universal coupling joint to the
lower steering shaft and tighten the pinch bolt se-
curely.
(7) Install the steering column assembly to
the
vehicle as previously described.
4. STEERING GEAR ASSEMBLY
Special Equipment Required:
To Renew Tie Rod Ball Housings — Large Still-
sons.
TO REMOVE AND INSTAL
( 1 ) Working in the engine compartment and
with the wheels in the straight ahead position, suitably

150 Steering — Part 2

View of the steering gear and associated components removed from the vehicle.
mark the universal coupling joint in relation to the
steering gear pinion as an aid to installation.

(2) Remove the bolt retaining the universal
coupling joint to the steering gear pinion. (3) Raise the front of the vehicle, support it on
chassis stands at the jack ing points and remove the
front wheels. Refer to the Wheel and Tires section.
(4) Remove the split pins and castellated nuts
from the tie rod end studs and disconnect the tie rod
ends from the steering arms.
NOTE: Disconnect each tie rod end by
placing a suitable dolly or hammer against
one side of the steer ing arm eye and striking
the opposite side with a hammer.

(5) Remove the bolts from the steering gear
mounting brackets. (6) Separate the steering gear pinion from the
universal coupling joint and maneuver the steering
gear from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the steering gear mounting
bracket rubbers are in good condition. Renew if
necessary.
(2) Renew the split pins on the tie rod castel-
lated nuts.
(3) Check and if necessary adjust the front wheel
toe in. Refer to the Front Suspension section for the
correct procedure.
TO OVERHAUL

To overhaul the steering gear a range of special
tools is required. If the steering gear has a fault
which requires the removal of the rack or pinion it
is recommended that the necessary repairs be car-
ried out by an authorized dealer.

TO RENEW TIE ROD BALL HOUSINGS
(1) Remove the steering gear from the vehicle as
previously described.
(2) Note or mark the installed position of the
mounting rubbers as an aid to assembly and remove
the rubbers from the steering gear.
(3) Thoroughly clean the exterior of the steering
gear in a suitable cleaning solvent.
(4) Secure the steering gear in a soft jawed vice
and centralize the rack in the steering gear. (5) Loosen both the ti e rod end locknuts and
unscrew the tie rod ends from the tie rods, noting the
number of turns required to do so. Remove the
locknuts from the tie rods. (6) Remove the tie rod rubber boot retaining
clamps, detach the boot s from the steering gear
housing and slide them from the tie rods. Take care to
position a container to catch the oil contained in the
steering gear assembly. (7) Where the tie rod ball housing is retained by
staking, drill the staking away from the rack and t i e
rod using a 4.0 mm drill. Do not drill into the rack
more than is necessary to drill out the staking.
Where the tie rod ball housing is retained by a
lock pin, drill out the lock pin from the ball housing
and tie rod using a 4.0 mm drill. Do not exceed a
drilling depth of 10.0 mm.

Using a 4.0 mm drill to remove the staking from the tie
rod ball housing.

Steering — Part 2 151
(8) Slide the rack out of the housing slightly so
that an adjustable spanner can be used to hold the
rack. (9) Using a Stillsons wrench, unscrew the ball
housings in turn using care not to allow the rack to
rotate. Keep all the tie rod parts in order. (10) Inspect the rack boots for cracks and deteri-
oration and renew as necessary. (11) Inspect the tie rod ends for wear and damage
and renew as necessary.

Dismantled view of the tie rod ball housing and the tie
rod end assemblies removed from the steering gear.

Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Using large Stillsons and a large adjustable
spanner, install the tie rod and ball housing
assemblies
to the rack. Tighten the ball housings to the specified
torque.

NOTE: To avoid damage to the rack or
pinion the adjustable spanner must be
firmly tightened over the rack teeth and the
rack must not be allowed to rotate when
installing the ball housings.

(2) Measure a point 9 mm in from the rear face
of the ball housing of the rack and at 90 deg to the
rack teeth. Centre punch this point.
(3) At this point drill a 4 mm hole, 10 mm deep
through the rack and into the ball housing thread.
(4) Place a locking pin above the hole and drive
it into position.
(5) Lubricate the rack, rack teeth and t i e rod
boot groove with suitable EPL 1 grease. (6) Install the rack boots and secure with the
clamps. Renew the clamps if necessary. (7) Install the tie rod end locknuts and then the
tie rod ends, ensuring that they are screwed on the
same number of turns as was necessary to remove
them.
(8) Tighten the locknuts to the specified torque.
(9) Install the mounting rubbers and brackets
to
the steering gear as noted on removal. (10) Install the steering gear assembly to
the
vehicle as previously described. (11) Check and if necessary adjust the front wheel toe in as described in the Front Suspension section
under the appropriate heading.

TO RENEW TIE ROD END
(1)
Raise the front of the vehicle and support it
on chassis stands. (2) Remove the relevant front wheel.
(3) Loosen the tie rod end locknut and remove
the tie rod end castellated nut. Disconnect the tie rod
from the steering arm by plac ing a suitable dolly or
hammer against one side of the steering arm eye and
striking the opposite side with a hammer. (4) Unscrew the tie rod end from the tie rod,
noting the number of turns necessary to remove it.
(5) Screw the new tie rod end onto the t i e rod
the same number of turn s noted during removal.
(6) Connect the t i e rod to the steering arm and
install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin.
(7) Install the front wheel and lower the vehicle
to the ground. (8) Check and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. Ensure that the rubber boots are not distorted
or twisted on the tie rod when the adjustment is
completed.
TO RENEW RUBBER BOOT

(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the relevant t i e rod end as previ-
ously described. (3) Release the clamps securi ng the boot to the
tie rod and steering gear housing. (4) Unscrew and remove the locknut from the
tie rod. (5) Remove the rubber boot together with the
outer retaining clamp from the t i e rod. (6) Sparingly lubricate th e tie rod boot groove
with EPL 1 grease, install the new boot to the t i e
rod
and push it onto the steering gear rack housing. Install
and secure the inner and outer retaining clamps.
(7) Install the tie rod end locknut and screw
the
tie rod end onto the tie ro d the same number of turns
noted during removal. (8) Connect the tie rod to the steering arm and
install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin. (9) Install the wheel and lower the vehicle to the
ground. (10) Check and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. Ensure that the rubber boots are not distorted
or twisted when the adjustment is completed.

152
PART 3. POWER STEERING
SPECIFICATIONS
Steering gear type ................Rack and pinion with
integral power cylinder
Steering column type .................... Energy absorbing
collapsible and lilt adjustable
Steering wheel free play ................................. 35 mm
Number of turns lock to lock:
TRW ...............................................................2.82
PR24SA ........................................................... 2.7
Linkage.....................................Direct from rack ends
to ti e rods and steering knuckles
Power steering pump

maximum pr essure.................................... 6 865 kPa
Lubricant ...................................................... Dexron II
TORQUE WRENCH SETTINGS
Steering gear to bulkhead mounting bolts... 108 Nm
Tie rod to steering knuckle nut ...................... 98 Nm
Tie rod to tie rod end locknut....................... 98 Nm
Tie rod ball housing to rack............................ 88 Nm
Power steering pump pulley nut ..................... 68 Nm
1. DESCRIPTION
The vehicles covered by this manual are equipped
with either a TRW power steering system or a
Japanese PR24SA power steering system.

Both types are similar in construction and appear-
ance.

The power steering is a rack and pinion type
which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.

Hydraulic pressure is supplied to the power
steering gear by a pump driven by a drive belt from
the engine.

The power steering pump has a separate fluid
reservoir located on the righ t side of the bulkhead.

No lubrication of the steering gear or steering
pump is required in service and in the event of the
loss of power assistance, the steering will continue to
operate but will require a greatly increased effort.
However, as the steering gear and pump are lubricated
by the power steering fluid, the cause of the loss of
power steering or fluid loss must be determined and
repaired promptly to prevent damage to the steering
pump and to a lesser extent, the steering gear.

The t i e rod ends and rubb er boots can be renewed
without removing the steering gear from the vehicle.
To renew the integral t i e rod and tie rod ball housings,
the steering gear must be removed.

As specialist knowledge and equipment are re-
quired to overhaul the power steering gear and the

hydraulic pump, it is recommended that these op-
erations be carried out by an authorized dealer.
However, procedures for the removal and installa-
tion of the steering gear and pump are fully de-
scribed in this section.

The steering column is of the energy absorbing
type and is designed to collapse in the event of a
severe front end collision. The energy absorbing com-
ponents are the column tu bes, steering shaft and tilt
bracket breakaway capsules. All these components
should be handled with extr eme care if service opera-
tions are to be carried out on the steering column
assembly.

2. IN CAR ADJUSTMENTS, CHECKS AND
MINOR REPAIRS

If the power steering system becomes partially or
fully inoperative it is most important that the follow-
ing preliminary inspection and testing procedure be
performed prior to undertaking any trouble shooting
or repair operations.

PUMP DRIVE BELT
Inspect the pump drive belt for breakage, glazing
or wear. If any of these characteristics are evident,
renew the belt using only a genuine replacement.

If the belt is loose but still serviceable, adjust it
using the procedure outlined in the Engine Tune-up
section.

NOTE: In most cases a loose drive belt can
be heard squealing when a load is placed on
the pump as the steering wheel is turned or
as the engine speed is increased.

Checking the power steering pump drive belt for
deterioration.

154 Steering —
(2) Remove the air inlet duct from the air
cleaner and throttle body. (3) Position a container or a piece of cloth
beneath the steering pump reservoir and disconnect
the fluid return and power steering pump supply hose
from the reservoir.
(4) Loosen the steering pump drive belt as
described in the Engi ne Tune-up section.
(5) Loosen the return hose clamp and the supply
union and disconnect the hoses from the power
steering pump. Plug the hoses to prevent the loss of
fluid.
(6) Loosen the retaining bolts and withdraw the
pump. (7) Thoroughly clean the exterior of the steering
pump and inspect it for cracks, damage and signs of
leakage.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the pump and retaining bolts.
(2) Install the drive belt and adjust it as de-
scribed in the Engine Tune-up section. (3) Install the hoses to the power steering pump
and tighten securely. (4) Top up the pump reservoir and purge the
power steering system of air as previously described.
TO OVERHAUL

As specialist knowledge and equipment arc re-
quired to overhaul the power steering pump, it is
recommended that this operation be performed by an
authorized dealer or steering specialist.

6. POWER STEERING GEAR ASSEMBLY
Special Equipment Required:
To Renew Tie Rod Ball Housings — Large Still-
sons
TO REMOVE AND INSTAL
The procedures for removing and installing the
power steering gear are similar to those carried out in
the Manual Steering section under the Steering Gear
Assembly heading except fo r the following differences.

(1) Place a container under the pressure and
return pipes that are conn ected to the steering gear
valve housing. Remove the pipes and allow the fluid
to drain into the container. (2) Suitably seal the pipes and the steering gear
to prevent the entry of di rt whilst the pipes are
removed.
(3) Upon removal of the power steering gear,
thoroughly clean the steering gear except the tie rod
ends in a suitable solvent. Be careful not to allow the
solvent to enter the apertu res where the pressure and
return pipes were removed. (4) Check the pipes and co nnections for cracks,
damage or obstructions and renew as necessary.

Installed view of the power steering gear with the
engine removed.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the pressure and return pipes to the
steering gear valve housing and tighten securely. (2) Fill the power steering reservoir to the cor-
rect level and bleed the system as described previously
under the heading In Car Adjustments. Checks and
Minor Repairs. (3) Check all power steering pipe connections
for leaks and repair as necessary. (4) Check, and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. After adjustment ensure that the rubber boots
are not distorted or twisted and the rubber boot
clamps and clips are facing downward.
TO OVERHAUL

As specialist knowledge and equipment are re-
quired to overhaul the power steering gear, it is rec-
ommended that this opera tion be performed by an
authorized dealer or steering specialist.

TO RENEW TIE ROD BALL HOUSINGS
TRW Steering Gear
The renewal of the tie rod ball housings is the
same as for the manual steering gear. Refer to Part 2.
Manual Steering section.

PR24SA Steering Gear
(1) Remove the power steering gear assembly
from the vehicle as previously described.
(2) Carefully mount the power steering gear in a
vice equipped with soft jaws. Loosen the tie rod end
locknuts without disturbing the location of the tie rod
ends and unscrew the tie rod ends, taking note of the
number of turns required to remove them. Unscrew
and remove the locknuts from the tie rod. (3) Remove the clamps from the rubber boots
and remove the boots.

Steering — Part 3 155
(4) Support the rack carefully and lever back the
tabs of the ball housing lock washers. To prevent
damage to the steering gear, avoid any impact to the
steering rack.
(5) Holding the rack with an adjustable spanner,
unscrew the ball housings from the rack using a
Stillsons wrench. Remove and discard the lock wash-
ers. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the new lock washer to the
rack,
ensuring that the lockwasher tangs are located in the
rack end. (2) Install the ball housing as semblies to the rack.
Tighten the ball housings to the specified torque and
secure by bending the lock washer. (3) Before installing the rubber boots ensure that
the vent holes, located towards each end of the rack
near the ball housings, are clear. If necessary clear the
hole with a suitable probe. (4) Apply sealant to the la rge end of the rubber
boot and grease to the small end. and install the boots,
being careful not to damage or twist them. Secure the boots with the clamps and clip
s ensuring that the clips
are facing downwards.

(5) Install the t i e rod end locknuts and tie rod
ends to the t i e rod. Install the t i e rod ends the same
number of turns noted on removal. Tighten the lock-
nuts to the specified torque.

Install the power steerin g gear assembly to the
vehicle as described under the previous heading and
bleed the system as described under the heading In
Car Adjustments, Checks and Minor Repairs.

TO RENEW RUBBER BOOTS
The procedure to renew the rubber boots is fully
covered in the Manual Steering section under the
Steering Gear Assembly heading.

TO RENEW TIE ROD ENDS
The procedure to renew the t i e rod ends is fully
covered in the Manual Steering section under the
Steering Gear Assembly heading.

156
FRONT SUSPENSION
SPECIFICATIONS
Type.................. Independent MacPherson strut with
coil springs and control arms
Shock absorber .................. Hydraulic, non-repairable
Hub bearing end float (maximum) ............. 0.05 mm
Ball joint axial play (maximum) ....................0.7 mm
Ball joint turning torque (used)...............0.5-4.9 Nm
Wheel alignment:
Toe in ..................................................... 0-2 mm
Camber ........................................- 0 ° 1 0 ' ± 4 5 '
Caster ..............................................1 ° 1 0 ' ± 4 5 '
King pin inclination..................... 1 3 ° 5 5 ' ± 4 5 '
TORQUE WRENCH SETTINGS
Hub bearing nut..................................... 196-235 Nm
Suspension unit to steering knuckle nut ...... 118 Nm
Suspension unit to body nuts ......................... 29 Nm
Piston rod nut .................................................. 72 Nm
Brake caliper to steering knuckle bolts ........... 52 Nm
Ball joint to steering knuckle bolt ................... 86 Nm
Control arm bracket bolts ............................... 98 Nm
Control arm pivot bolt ................................ 118 Nm
Stabiliser bar link nuts..................................... 44 Nm
Stabiliser bar bracket bolts .............................. 21 Nm
1. FRONT SUSPENSION TROUBLE
SHOOTING

FRONT END NOISE
(1) Loose upper suspension mounting or piston
rod: Tighten the mounting or piston rod nuts. (2) Loose or worn suspension unit lower ball
joint: Tighten or renew the lower ball joint.
(3) Noise in the suspension unit: Renew the
faulty suspension unit, preferably in pairs.
(4) Worn or loose steering gear: Overhaul the
steering gear assembly. (5) Worn front hub bearings: Renew the hub
bearings:
(6) Loose or defective stab ilizer bar, control arm
or mountings: Check, tighten or renew the mounting
rubbers.

Check the ball joints for wear and deterioration.
(7) Worn stabilizer bar link ball joints: Renew
the stabilizer bar links.
(8) Drive shafts worn or insufficiently lubri-
cated: Check the lubricant and the dust boots and
renew as necessary. (9) Drive shaft splines in the hub or the
differential worn or dama ged: Check and renew as
necessary.

NOTE: To check the front suspension com-
ponents for wear, raise the front of the
vehicle, support it on chassis stands and
allow both front wheel to hang free. With an
assistant pushing and pulling the front
wheels in and out at the top and then at the
bottom, check for excessive looseness at the
front hub bearings and lower control arm
inner pivot bushes. Noise or vibration in the
front end can also be caused by excessive
tire or wheel unbalance. Drive shaft joint
noise is usually more pronounced when
moving slowly with the steering on full lock.

POOR OR ERRATIC ROAD HOLDING
ABILITY

(1) Low or uneven tire pressures: Inflate the
tires to the recommended pressures.

(2) Defective suspension unit: Renew the faulty
unit, preferably in pairs.