1987 NISSAN PULSAR brake light

Brakes 173
Inspect the handbrake cable for chafing or fraying.
(4) Seized handbrake cables: Renew the hand-
brake cables.

NOTE: Raise the vehicle and spin the
wheels one at a time to check for binding. If
the wheels are not binding, have an assistant
apply and release the brakes. Check if the
brakes release immediately. A clogged mas-
ter cylinder port will cause binding on the
two wheels fed by that particular circuit
from the master cylinder. Open the bleeder
valve on one of the o ffending wheels to check
if pressure build up is the cause of the
binding. A seized handbrake cable will usu-
ally cause binding on a rear wheel. Discon-
nect the handbrake cable and check if the
wheel will then turn freely.

LOW SPONGY BRAKE PEDAL
(1) Incorrectly adjusted brake shoes: Check and
adjust the brake shoes.


(2) Insufficient fluid in the system: Check for
leaks, replenish the fluid to the specified level and
bleed the hydraulic system.
(3) Air in the brake hydraulic system: Bleed the
hydraulic system. (4) Master cylinder faulty: Repair or renew as
necessary.
NOTE: A spongy brake pedal in most cases
is caused by air in the hydraulic system. For
air to enter the system one or more of the
sealing rubbers or brake lines must be
sucking in air. Always rectify the cause of
the trouble before bleeding the hydraulic
system. Faulty components usually show up
as fluid leakage.

BRAKES LOCK ON APPLICATION
(1) Gummy linings or brake pads due to oil or
fluid contamination: Renew the linings or brake pads
and rectify the source of contamination. (2) Scored or eccentric brake drum or warped
disc: Check and machine or renew the drum or disc as
necessary.
(3) Incorrect or distorted linings or disc pads:
Check and renew as necessary. (4) Brake servo unit faulty: Repair or renew the
brake servo unit. (5) Broken or stretched brake shoe return
springs: Check and renew th e faulty brake springs.
(6) Faulty brake pressure proportioning valve:
Renew the brake pressure proportioning valve.
NOTE: If this condition arises, remove all
the wheels and check the condition of the
friction material for oil contamination and
excessive wear. Check the shoe return
springs for stretching by comparing their
free length with new sp rings. An eccentric-
brake drum or warped disc will be indicated
by pulsating of the brake pedal when the
brakes are lightly applied.

BRAKE PEDAL PULSATES
(1) Eccentric brake drums or warped disc: Check
and machine or renew the drum or disc as required.
(2) Loose or worn hub bearings: Renew the hub
bearings as necessary.
NOTE: Brake drums or discs that are run-
ning out must be machined. This job is best
entrusted to a brake specialist who will also
be able to determine if a new disc or drum
needs to be installed.

BRAKE FADE
(1) Incorrect shoe adjustment: Check and adjust
the shoe to drum clearance. (2) Eccentric brake drum: Check and machine or
renew the brake drum.

Check the brake hoses for deterioration, chafing and
leaks.

Brakes 175
A pressure proportioning valve is incorporated in
each circuit to prevent premature locking of the rear
wheels during severe braking.

The four wheel hydraulically operated brakes
utilize disc brakes on each front wheel and disc brakes
or leading and trailing drum brake shoes on each rear
wheel.

The front disc brakes comprise a disc attached to
the hub assembly and a caliper bolted to the steering
knuckle.

The rear disc brakes comprise a disc and hub
assembly attached to the rear stub axle and a caliper
and anchor plate bolted to the backing plate.

The front and rear calipers are of the sliding type.
As pad wear takes place, the caliper piston is allowed
to slide outwards through the seal to take up a new
position in the caliper bore. Elastic deformation of the
seal takes place when the brakes are applied, which
returns the piston slightly when the brakes are re-
leased. Thus a constant clearance is maintained
between the pads and the disc when the brakes are in
the off position.

The disc brakes do not require periodical adjust-
ment in service to compensate for pad wear as they
are self adjusting.

The leading and trailing shoe drum brakes on the
rear wheels use a double ended wheel cylinder to
operate both brake shoes at the top. The lower end of
each brake shoe abuts a fixed anchor point. The brake
shoes are automatically adju sted when the brakes are
operated.

The handbrake operates the rear brakes via a
cable arrangement.

3. MASTER CYLINDER
Special Equipment Required:
To Install New Seals — Suitable machined drift
TO REMOVE
(1) Depress the brake pedal several times to
deplete the vacuum from the system.

(2) Raise the bonnet and install covers to
both
the front mudguards. Cover the areas of paintwork
beneath the master cylinder with absorbent cloth.
(3) Disconnect the wiring from the pressure
sensing switch. (4) Disconnect the brake pipes from the master
cylinder and plug the outlets and pipes to prevent the
loss of fluid and the ingress of dirt.
(5) Remove the nuts retaining the master cylin-
der to the brake servo unit and remove the master
cylinder from the vehicle.
TO DISMANTLE

(1) Remove the master cylinder as previously
described. (2) Remove the reservoir cap and diaphragm,
drain and discard the brake fluid from the reservoir. (3) Carefully remove the reservoir from the
master cylinder by pulling it from the reservoir
retainers by hand. Remove and discard the retainers
from the master cylinder. (4) Using internal snap ring pliers, remove the
snap ring from the primary reservoir port. (5) Remove the fast fill valve assembly and the
O ring from the port. Remove and discard the valve
washer from the fast fill valve.
(6) Remove the proportioning valve plugs and
the O rings. Discard the O rings. Withdraw the springs
and valve plungers from the master cylinder. Remove
and discard the seals from the valve plungers. (7) Remove the pressure sensing switch and
lever assembly from the master cylinder. {8) Remove the cylinder end plug from the
master cylinder. Remove and discard the O ring from
the plug.

(9) Carefully tap the front of the master cylinder
vertically on a block of wo od and remove the pressure
differential pistons from the master cylinder. Remove
and discard the O rings from the pistons. (10) Push the primary piston forward in the
cylinder with a blunt rod and while holding the
pressure, remove the stop pin from the master cylin-
der.
(11) The primary piston may now be withdrawn
from the cylinder bore. The secondary piston, retainer
and spring can also be withdrawn by carefully tapping
the master cylinder on a block of wood. (12) Prise the legs of the seal retainer upwards
and remove it from the primary piston. Remove the
seal and guide. Discard the seal and retainer.
NOTE: The secondary piston must no! be
dismantled by removing the screw. This
assembly has a factory p reset length and the
screw must not be altered in service.

(13) Remove the main seal and the guide from
the front of the secondary piston. Stretch the rear seal
from the groove and remove it from the piston. Take

Installed view of the master cylinder and servo unit. Air
duct removed for clarity. 1.8 liter model.

176 Brakes
care not to damage the piston surfaces where the inner
diameter of the piston seals locate.

(14) Remove the garter springs, back up rings,
seals and the retainer from the master cylinder, noting
the installed direction of the seals to aid assembly.

NOTE: It is important that care is taken not
to damage the bore surface or the seal
surfaces during removal of these parts. Note
the order and direction during removal,

(15) Remove the external O ring from the master
cylinder body.

TO CLEAN AND INSPECT
(1) Wash all components thoroughly in methyl-
ated spirits. Do not use petrol, kerosene or other
cleaning solvents. (2) Check the master cyli nder bore for wear,
scoring or pitting.
NOTE: Do not hone the master cylinder
bore. If the bore is pitted or worn, renew the
master cylinder as an assembly.

(3) Ensure that all the inlet and compensating
ports between the reservoir and the cylinder bore are
free of any obstructions.

(4) Discard all rubber parts and if applicable, the
piston assemblies.

NOTE: Where possible use a genuine major
repair kit which contains pre-assembled rub-
ber seals and pistons when overhauling a
master cylinder. The use of a major kit will
ensure a thorough overhaul and long service
from the unit.

TO ASSEMBLE
(1) Liberally coat the cylinder bore and all
internal parts with clean brake fluid.

NOTE: Install all parts supplied with the
repair kit.

(2) Install the seal retainer in the mouth of
the
master cylinder, small diameter first.
(3) Install the seal, in the direction rioted
on
removal, against the seal retainer, followed by the first
back up ring, large diameter first. (4) Install the garter spring against the back up
ring. Insert a machined drift into the bore and lightly
push the garter spring into its locating groove. (5) Install the remaining seal, in the
direction
noted on removal, against the garter spring already
PRIMARY PISTON SEAL
BACK UP RING

Dismantled view of the master cylinder.

Brakes 177
installed. Install the second back up ring, large
diam-
eter first.

(6) Install the second garter spring. Insert
a
machined drift into the bore and lightly push the
garter spring into its locating groove.
(7) Smear the secondary piston with clean brake
fluid. Ease the seal over the piston body into the
groove adjacent to the spring, ensuring that the seal lip
faces the spring and that the nylon spacer is against
the back of the seal. (8) Install the guide onto the secondary
piston,
large internal diameter first, followed by the main seal
with the lip facing away from the spring. (9) Lubricate the secondary piston assembly
with clean brake fluid and install the secondary spring
and retainer to the piston. Install the complete assem-
bly into the master cylinder bore. (10) Smear the primary piston with clean brake
fluid. Install the guide, large internal diameter first,
followed by the main seal with the lip facing towards
the small end of the piston.
(11) Install the retainer to the spigot on the front
end of the primary piston ensuring that the legs of the
retainer engage with the groove on the piston. (12) Lubricate the primary piston assembly with
clean brake fluid and install the assembly into the
master cylinder bore. With a blunt rod, push the
assembly down the bore sufficiently to preload the
pistons. While holding the preload, install the stop pin
and valve assemblies into
the master cylinder body and tighten securely. (13) Install a new O ring to the groove on the boss
of the mounting flange of the master cylinder.
(14) Install new O rings to th e pressure differential
pistons, smear them with cl ean brake fluid and install
them into the master cylinder body. (15) Install a new O ring to the pressure differen-
tial end plug, install the plug to the master
cylinder
body and tighten to the specified torque. (16) Using a blunt probe entered through the
sensing switch location hole, separate the pressure
differential pistons and install the switch actuating
lever between them. (17) Screw the sensing switch into its locating
hole until the detents on the switch body just contact
the locating hole facing (w ith the radial grooves).
Screw the switch assembly in a further half to one full
turn ensuring that the dete nts locate in the grooves.
(18) Install new valve seal s to the proportioning
valve plungers, with the serrations of the seals facing
away from the hexagons of the plungers.
(19) Install the new O rings to the
proportioning
valve plugs. (20) Install the valve springs over the stems of the
proportioning valves, insert the install the valve
plugs.
Tighten the plugs to the specified torque.
(21) Install a new O ring to the base of the fast fill
valve assembly. Install a new valve washer to the base
of the valve.
(22) Install the fast fill valve assembly in
the
primary reservoir port (nearest to the mounting flange
of the master cylinder) and install the snap ring
to
retain the assembly. Ensure that the snap ring is
correctly seated in the groove. (23) Smear the new reservoir retainers with clean
brake fluid and install them into the reservoir ports.
Carefully press the brake fluid reservoir into position,
ensuring that the outlet extensions are fully inserted in
the reservoir retainers. (24) Install the reservoir cap insert to the dia-
phragm and press the cap assembly onto the reservoir.
TO INSTAL

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

(1) Pour a small amount of clean brake fluid into
the reservoir and pump the master cylinder pistons
with a blunt rod until fluid begins to emerge from the
outlets. (2) Install the master cylinder to the brake servo
unit and loosely install the master cylinder retaining
nuts. (3) Connect the brake pipes to the master cylin-
der outlets, but do not tighten at this stage. (4) Securely tighten the nuts retaining the master
cylinder to the brake servo unit.
(5) Securely tighten the brake pipes and connect
the wiring to the pressure sensing switch.

(6) Fill the master cylinder reservoir with clean
brake fluid and bleed the brakes as described under
the Hydraulic System heading. (7) Check and if necessary adjust the brake
pedal height and free play as described under the
Brake Pedal heading.
4. BRAKE SERVO UNIT

TO CHECK OPERATION
(1) With the engine switched off, apply the
footbrake several times to exhaust all vacuum from
the system.
(2) Apply the footbrake and hold the brake pedal
fully depressed.
(3) Start the engine. If the servo unit is function-
ing satisfactorily a distinct downward movement of
the
brake pedal should be noticed. Should the pedal fail to move downward when the
engine has been started, the vacuum system can be
considered inoperative.

NOTE: If the pedal continues to fall away
there is a fault in the hydraulic system.

(4) Ensure that the brake pedal is fully released,
start the engine and run it at medium speed. Stop the
engine.

180 Brakes
the caliper body. Plug the brake hose to prevent the
loss of fluid and the ingress of dirt. Remove and
discard the sealing washers.

(3) Remove the guide bolts and slide the caliper
body from the anchor plate and pad assembly. (4) Remove the piston dust cover retaining clip.
Remove and discard the dust cover.
BRAKEPAD BRAKE PAD
Dismantled view of the front brake caliper.
(5) Place a piece of wood in front of the piston
and using low air pressure applied to the brake hose
aperture, gently force the piston from the caliper bore.
(6) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (7) Clean all the caliper components in methyl-
ated spirits and arrange the components in order, on
a clean, dry surface to aid in assembly.
To Inspect

(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.

NOTE: Slight rust spots in the caliper bore
may he removed with fine emery paper. The
piston must not be polished as the plated
surface wilt be damaged.

(2) Inspect the guide bolts for wear or damage.
Renew as necessary.

To Assemble
(1) Dip a new piston seal in clean hydraulic
brake fluid. Insert the seal into the groove in the
caliper bore ensuring that the seal is correctly seated
and not twisted.
(2) Install a new dust cover to the piston prior to
installing the piston to the caliper bore. (3) Coat the piston and caliper bore with clean
hydraulic brake fluid and insert the piston squarely
into the caliper bore.
(4) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(5) Lubricate the guide bolts using a suitable
grease. Install the caliper body to the anchor plate and
install and tighten the guide bolts to the
specified
torque. (6) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydr aulic System heading.
(7) Install the front wheels and lower the vehicle
to the ground. (8) Road test the vehicle and check for correct
brake operation.
BRAKE DISC

To Check Runout
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant front wheel. (2) Install the wheel nuts with the flat side of
the
wheel nut towards the disc. Lightly tighten the nuts to
secure the disc against the hub.

Rotate the hub and check for disc runout.
(3) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less
than 0.05 mm. Excessive e nd float will necessitate
renewal of the hub bearing. (4) Position the dial gauge plunger against the
centre of the brake disc. Ro tate the hub and measure
the runout. Maximum allowable runout is 0.07 mm. (5) If the runout exceeds Specifications, machine
or renew the brake disc. (6) Install the fron t wheel and lower the vehicle
to the ground.
To Remove and Install

(1) Raise the front of the vehicle and support it
on chassis stands. Remove the relevant wheel. (2) Remove the bolts retaining the caliper an-

Brakes 183

To Dismantle
(1) Raise the rear of the vehicle and place it on
chassis stands. Remove the relevant rear wheel.
(2) Remove the brake hose retaining bolt from
the caliper body and plug the hose to prevent the loss
of fluid and the ingress of dirt. (3) Remove the handbrake cable bracket retain-
ing bolt and disconnect the handbrake cable from the
cam lever.
(4) Remove the guide bolts and slide the caliper
body off the pads. (5) Using a pair of long nose pliers with the nose
located in the recesses of the piston, rotate the piston
anticlockwise to remove it from the caliper body.
(6) Remove the dust cover retaining clip and dust
cover. Discard the dust cover. (7) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (8) Using internal snap ring pliers, remove the
snap ring from the caliper bore. (9) Withdraw the spring cover, spring, key plate,
pushrod and link from the caliper bore. Do not mix
these components from the left and right hand sides as
they differ. (10) Remove and discard the O ring from the
pushrod. (11) Remove the spring, nut and washer from the
cam lever. Remove the cam lever and cam from the
caliper body. (12) Remove the cam seal from the caliper using a
screwdriver.
(13) Clean all the caliper components in methy-
lated spirits and arrange the components in order on a
clean dry surface to aid assembly.
To Inspect

(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.

NOTE: Slight rust spots in the caliper bore
may be removed with fine emery paper. The
piston must not be polished as the plated
surface will be damaged.

(2) Inspect the guide bolts for wear or damage
and renew as necessary.
(3) Inspect the threads of the pushrod for wear or
damage and renew as necessary. (4) Inspect the nut inside the piston for wear,
damage and security. Renew the piston if any damage
is evident. (5) Inspect the cam for wear, damage or pitting,
renew as necessary. (6) Inspect the cam bearing in the caliper body
for wear, damage or pitting and renew the seal and
bearing as necessary. (7) Inspect the guide bolt rubbers for deteriora-
tion, wear or damage. Renew as required. To Assemble

(1)
Lubricate the cam bearing with multipurpose
grease and install the seal. (2) Install the cam and cam lever to the
caliper
body. Install the cam lever spring, washer and nut, and
tighten the nut to the specified torque. (3) Install a new O ring to the pushrod and
install
the link, pushrod, key plate, spring and spring cover to
the caliper body. The key plate must engage the caliper
body. Secure the assembly with the snap ring. (4) Dip a new piston seal in clean hydraulic brake
fluid. Insert the seal into the groove in the caliper bore
ensuring that the seal is correctly seated and not
twisted. (5) Install a new dust cover to the piston prior
to
installing the piston to the caliper bore.
(6) Coat the piston and caliper bore with clean
hydraulic brake fluid and using long nose pliers rotate
the piston clockwise into the caliper bore. (7) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(8) Lubricate the guide bolts using a suitable
grease. Install the caliper body and tighten the guide
bolts to the specified torque. (9) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydraulic System heading. (10) Install the rear wheel and lower the vehicle to
the ground. (11) Road test the vehicle and check for correct
brake operation.
BRAKE DISC

To Check Runout
(1) Raise the rear of the vehicle and support it on
chassis stands. Remove the relevant rear wheel.
(2) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less

Using a dial gauge to measure the rear disc runout.

220 Electrical System


Wiring diagram (WD2) for the instruments, hazard and turning signal systems.
COLOUR CODE
The first letter of the code
represents the main wire color,
the other letters represent the
trace colors.

B - BLACK
L - BLUE
G - GREEN
R - RED
Y - YELLOW
W- WHITE
N - BROWN
O - OHANGE
K - PINK
S - GREY V -VIOLET
P - PURPLE X - LIGHT GREEN Z - LIGHT BLUE M - DARK GREEN T - DARK BLUE A - LIGHT BROWN E - SLATE D - TAN
KEY 1. Fuse 11 Ignition
2. Speedometer
3. Vehicle speed sensor
4. To No. 21 WD1
5. To ECU A10
6. To No. 13 WD1
7. Tachometer
8. Voltage regulator
9. Resistor
10. Temperature gauge
11. Fuel gauge
12. Temperature sender
13. Fuel sender
14. To ECM lamp
15. Oil lamp
16. Park brake lamp
17. Low fuel lamp
18. To ECU A5
19. To No. 20 WD1
20. Park brake switch
21. Low fuel switch
22. Brake switch
23. Brake fail lamp
24. Bulb check relay
25. Charge lamp
26. Door ajar lamp
27. To No. 6 VWD1
28. To No. 8 WD4
29. To No. 18 WD6
30. To No. 17 WD6 31. Hazard switch

32. Flasher unit
33. Turn signal switch
34. L H front combination
lamp
35. L H side indicator lamp
36. L H rear combination lamp
37. L H instrument warning
lamp
38. R H instrument warning lamp
39. R H rear combination lamp
40. R H side indicator lamp
41. R H front combination lamp
42. Divider circuit

234 Body

LOCK ASSEMBLY
To Remove and Install

( 1 ) Remove the retaining bolts and withdraw the
lock assembly from the luggage compartment lid.

Installation is a reversal of the removal procedure
ensuring that the actuating arm on the lock is under
the lock cylinder pivot.

LOCK CYLINDER

Installed view of the lock and lock cylinder.
LOCK CYLINDER
To Remove and Install
Remove the bolt retaining the lock cylinder
pivot to the luggage compartment lid inner panel. Using a suitable screwdriver, remove the
lock cylinder retaining clip from under the lock. Withdraw the lock cylinder and pivot from
the vehicle. Installation is a reversal of the removal procedure.

(2) When the clips have been released, pull the
grille forward and remove it from the vehicle ensuring
that care is taken not to damage the grille.

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

Remove the grille retaining clips from the
radiator support panel and install them to the
grille.
Renew any damaged clips. Install the grille to the vehicle being careful to
align the grille clips before pushing the grille inwards.
Post July 1989 Pulsar Models

Fabricate a tool to engage the radiator grille
clips from the inside; an old spanner of suitable
dimensions can be ground down if necessary.
Using the above tool, turn the lower radiator
clips slightly to allow removal of the grille.

7. RADIATOR GRILLE
TO REMOVE AND INSTAL
Astra Models and Pre July 1989 Pulsar Models
(1) Using a flat bladed screwdriver, turn the
grille clips slightly to allow removal of the grille.


Installed view of the radiator grille on pre July 1989
models showing the retaining clip locations. Installed view of the radiator grille on post July 1989

models showing the retaining clip locations and the
special tool required to release the lower clips.
Using a flat bladed screwdriver, turn the
upper grille clips slightly to allow removal of the grille. When all the clips have been released, pull
the grille forward and remove it from the vehicle
ensuring that care is taken not to damage the grille.
Installation is a reversal of the removal procedure
with attention to the following points:

Remove the grille clips from the radiator
support panel and install them to the grille. Renew any
damaged clips.
Install the grille to the vehicle being careful to
align the grille clips before pushing the grille inwards.
8. CENTRE CONSOLE

TO REMOVE AND INSTAL
Remove the carpet square from the rear part
of the console and remove the screws underneath. Prise out the trim piece below the handbrake