1987 NISSAN PULSAR brakes

146 Steering — Part 1

STEERING PULLS TO ONE SIDE
(1) Uneven tire wear or pressures: Check the
condition of the tires and inflate to the recommended
pressures.
(2) Incorrect front wheel alignment: Check and
align the front end.
(3) Dragging brakes: Check each wheel for drag-
ging brakes. Overhaul the brakes as necessary. (4) Damaged suspension or crossmember: In-
spect and renew the damaged components. (5) Faulty power steering gear assembly: Re-
move the power steering gear for overhaul.
FRONT WHEEL WOBBLE OR SHIMMY

(1) Uneven tire wear or incorrect tire pressures;
Check the condition of the tires and inflate to the
recommended pressures. (2) Tire or wheel imbalance: Check and balance
as necessary (3) Worn or badly adjusted hub bearings: Check
the condition and adjust the front hub bearings.
(4) Faulty or worn suspension, units: Check and
overhaul or renew as a pair.
NOTE: Check the steering linkage as previ-
ously described. Raise the front of the vehi-
cle and check the adjustment of the hub
bearings by moving the road wheel in and
out at the top and bottom. No movement in
the bearings should be felt. Check the sus-
pension units as outlined in the Front Sus-
pension section.

STEERING ERRATIC OR WANDERING
(1) Incorrect or uneven wheel alignment setting:
Check and adjust th e steering geometry.

(2) Smooth front tires: Check and renew the
tires as necessary.

Checking the steering gear mounting bolts for security.
(3) Steering gear assembly loose on the cross-
member: Inspect for damage and tighten the steering
gear mounting bolts.
(4) Wear in the tie rod ball housing: Renew the
worn t i e rod and ball housing. (5) Wear in the rack and pinion: Remove the
steering gear assembly for overhaul. (6) Loose or incorrectly adjusted hub bearings:
Check and adjust the front hub bearings.
FAILURE OF POWER ASSISTANCE

(1) Loose or broken pump drive belt: Renew or
adjust the pump drive belt.
(2) Low fluid level in the power steering reser-
voir: Check for leakage, repair or renew the faulty
components. Top up the fluid level. (3) Insufficient power steering pump pressure:
Check the delivery pressure, renew the pump if
defective. (4) Faulty power steering gear assembly: Re-
move the power steering gear assembly for overhaul.

158 Front Suspension


Installed view of the front suspension. When using a floor jack locate the head of the jack on the crossmember.
(2) Remove the cap, split pin, castellated re-
tainer and with the aid of an assistant applying the
brakes, loosen and remove the hub nut.
(3) Remove the split pin and the castellated nut
retaining the tie rod end to the steering knuckle. (4) Disconnect the tie rod end from the steering
knuckle using a suitable puller. Alternatively place a
suitable dolly or hammer against one side of the
steering knuckle eye and strike the opposite side with
a hammer.
(5) Remove the brake caliper anchor plate bolts,
withdraw the caliper from the disc and support it with
a piece of wire inside the inner mudguard. Ensure that
the brake hose is not twisted.
(6) Withdraw the brake disc from the hub.
(7) Loosely install the hub nut and tap on the nut
with a soft faced hammer to separate the drive shaft
from the hub. (8) Place a mark on the suspension unit to
steering knuckle cam head bolt to ensure correct wheel
alignment on assembly. (9) Remove the steering knuckle to suspension
unit nuts and bolts. (10) Remove the split pin and the castellated nut
retaining the lower ball joint stud to the steering
knuckle. (11) Disconnect the ball joint stud from the steering knuckle using a suitable puller or alternatively
place a suitable dolly or hammer against one side of
the steering knuckle eye and strike the opposite side
with a hammer.

(12)
Withdraw the steering knuckle from the
vehicle taking care not to drop the drive shaft or
damage its boot. (13) Clean and check the steering knuckle for
wear, cracks and damage. (14) If necessary, dismantle the hub and check
the bearing assembly using the dismantling procedure
described later in this section. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the steering knuckle and hub assembly
over the drive shaft and loosely install the ball joint
stud nut and the suspension unit to knuckle bolts and
nuts.
(2) Ensure that the suspension unit to steering
knuckle cam head bolt mark s are aligned and tighten
the retaining nuts to the specified torque.
NOTE: If the cam head bolt is not installed
in its original position, a wheel alignment
should be performed.

(3) Tighten the ball joint to steering knuckle stud
bolt to the specified torque.

Front Suspension 159
(4) Install the tie rod end to the steering knuckle
and tighten the castellated nut securely. Install a
new
split pin.
(5) Install the brake disc to the hub.
(6) Install the brake caliper to the steering
knuckle and tighten the retaining bolts to the specified
torque. (7) Install the hub nut and washer to the
drive
shaft and with the aid of an assistant applying the
brakes, tighten the hub nut to the specified torque. (8) Install the hub nut retainer and a new
split
pin to the drive shaft. (9) Check the hub end float as described later in
this section. (10) Install the fron t wheel and lower the vehicle
to the ground.
TO DISMANTLE

NOTE: The front wheel bearing assembly is
non-serviceable. If the wheel bearing is dis-
mantled for any reason it should be re-
newed.

(1) Remove the steering knuckle from the vehi-
cle as previously described. (2) Hold the steering knuckle assembly in a vice
with soft jaw guards. (3) Using a hammer and a suitable pipe or tube
that pushes on the inside of the hub, drive out the
wheel hub and outside inner race from the steering
knuckle assembly. (4) Using snap ring pliers, remove the snap ring
that retains the outer bearing race from the wheel side
of the steering knuckle. (5) Using a suitable press and press plates,
support the steering knuckle with the outside face
downwards. To aid in dismantling, position the inside
inner race in the bearing and press the assembly from
the steering knuckle. Discard the bearing assembly. (6) Using a bearing puller and a press, remove
the inner race from the hub assembly. If the inner race cannot be removed from the hub
in this manner, it may be necessary to grind the race

using an angle grinder and split the race using a cold
chisel.

(7) Thoroughly clean and dry the steering
knuckle and hub in a suitable solvent. (8) Inspect all the components for wear, damage
and cracks and renew if necessary.
TO ASSEMBLE

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

(1) Apply grease to the oil seal lips of the new
bearing assembly.

NOTE: Ensure that (he inside of the outer
race of the bearing is precoated with wheel
bearing grease. If necessary, pack the outer
race of the wheel bearing with wheel bearing
grease after it is installed to the steering
knuckle.

(2) Using the press and press plates, support the
steering knuckle with the outside face uppermost.
Using a suitable diameter steel tube that contacts on
the outer race only, press the outer race full into the
steering knuckle.
(3) Install the snap ring to the groove in the
steering knuckle.
(4) Install the inner races to the steering
knuckle
and support the inner race on the press using a
suitable tube or mandrel. (5) Using the press and a suitable tube press the
hub assembly into the steerin g knuckle. When using
the press ensure that the pressing force does not
exceed 29 kN. (6) With the press exerting a force of 44.1 kN
rotate the steering knuckle from side to side several
turns to ensure that the wh eel bearings are operating
smoothly.
(7) Install the steering knuckle to the vehicle
as
previously described.
TO CHECK HUB END FLOAT

(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheel.
(2) Mount the dial gauge on the steering knuckle
so that the dial gauge plunger is against the wheel hub.
(3) Zero the dial gauge and attempt to move the
hub in and out. Total hub e nd float should not exceed
0.05 mm. (4) Renew the wheel bearing as previously de-
scribed if necessary.
4. SUSPENSION UNIT

Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheels.
Dismantled view of the steering knuckle and hub
components.

166 Rear Suspension

3. REAR HUB
Special Equipment Required
To Check Hub Bearing End Float — Dial gauge
To Renew Bearing — Press and suitable drift

TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the rear wheel and release
the handbrake.

(2) On models with rear drum brakes, proceed
to operation (6).
(3) Remove the clip securing the brake hose to
the suspension unit and disengage the hose.
(4) Remove the bolts securing the brake caliper
to the knuckle assembly. (5) Slide the caliper from the disc and support it
away from the working area, ensuring that no excess
strain is placed on the brake hose. (6) Rotate the hub and check that it rotates
smoothly. If it does not rotate smoothly, renew the
hub bearing. (7) Mount a dial gauge with the plunger posi-
tioned against the outer face of the hub. Move the hub
back and forth in line with the stub axle and note the
reading on the dial gauge. If the end float exceeds
Specifications, renew the hub bearing.
(8) Remove the hub grease cap from the rear
hub. (9) Remove the split pin from the stub axle and
remove the nut retainer, the hub retaining nut and
washer. Remove the hub assembly from the stub axle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the hub retaining nut to the specified
torque. (2) Check the hub bearing end float as previ-
ously described.
(3) On models with disc brakes, install the brake

caliper and tighten the retaining bolts to the torque
specified in the Brakes section. Install the brake hose to
the suspension unit and secure with the retaining clip.

TO RENEW BEARING
(1) Remove the rear hub as previously de-
scribed. (2) Remove the snap ring from the rear of the
hub assembly. (3) Support the rear of the hub around the
bearing housing, ensuring that the bearing will not be
obstructed when being pressed out. (4) Using a suitable drift, press the bearing out
of the hub.

Dismantled view of the rear hub assembly. Drum brake
model.

Tightening the hub retaining nut with a torque wrench. Dismantled view of the rear hub assembly. Disc brake
model.

170 Rear Suspension

6. KNUCKLE ASSEMBLY
TO REMOVE AND INSTAL
(1) Remove the rear hub as previously de-
scribed.

(2) On drum brake models, disconnect the brake
pipe from the wheel cylinder and plug the cylinder
and brake pipe apertures to prevent the loss of brake
fluid and the entry of dirt. (3) Remove the backing plate retaining bolts and
remove the backing plate from the knuckle assembly. (4) Remove the nut and bolt securing the control
arms to the knuckle assembly. (5) Remove the bolts and nuts securing the
suspension unit to the knuckle assembly. (6) Remove the nut, washers and bush securing
the stabilizer bar to the knuckle assembly, rotate the
knuckle assembly and remove it from the stabilizer
bar. (7) Carefully clean the knuckle assembly. Do not
immerse the rubber bush in solvent as damage will
occur.
(8) Check the knuckle assembly for wear, cracks
and damage. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the knuckle assembly onto the stabi-
liser bar, maneuver it into position with the suspen-
sion unit and install the retaining bolts and nuts.
Tighten the bolts and nuts to the specified torque.
(2) Install the control arms to the knuckle
assem-
bly and install the retaining bolt and nut. Do
not
tighten the retaining bolt and nut at this stage. (3) Install the bush, washers and retaining nut to
the stabilizer bar. Do not tighten the retaining nut at
this stage. (4) Install the backing plate to the knuckle as-
sembly and tighten the retaining bolts to the specified
torque.
(5) On drum brake models, connect the brake

pipe to the wheel cylinder and tighten the flare nut
securely.

(6) Install the rear hub as previously described.
(7) On drum brake models, bleed the brake
hydraulic system as described in the Brakes section.
(8) With the weight of the vehicle on the road
wheels, tighten the control arms retaining bolt and nut
and the stabilizer bar retaining nut to the specified
torque. (9) Check and if necessary adjust the rear wheel
alignment. Refer to the Re ar Wheel Alignment head-
ing in this section.
7. STABILISER BAR
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section. Remove the rear wheels.

(2) Remove the nut. washer and bush retaining
the stabilizer bar to each knuckle assembly. (3) Remove the bolts retain ing the intermediate
exhaust pipe to the rear of the catalytic converter,
remove the bolt securing the exhaust mounting to the
underbody and slightly lower the intermediate exhaust
pipe. Support the intermediate pipe to prevent the
tailpipe contacting the lower bumper panel. (4) Remove the bolts retaining the stabilizer bar
mounting brackets to the underbody and withdraw
the stabilizer ba r from each knuckle assembly. Ma-
noeuvre the stabilizer bar from the vehicle.
(5) Remove the mounting rubbers from the
stabilizer bar and the rubber bush and spacer from
each knuckle assembly. (6) Inspect the stabilizer bar for cracks and
damage and renew as necessary. (7) Inspect the stabilizer bar mounting brackets
for wear and damage and renew as necessary. (8) Inspect the mounting rubbers, the rubber
bushes and spacers for wear and deterioration and
renew as necessary.

View of the knuckle assembly removed from the
vehicle. Disc brake model. View of the stabilizer bar mounting bracket and rubber
removed from the stabilizer bar.

172
BRAKES
SPECIFICATIONS
Type:
Except Pulsar/Vector GL from
July 1989 and Astra models ... Four wheel disc
Pulsar/Vector GL from
July 1989 and Astra models —
Front...............................................................Disc
Rear..............................................................Drum
Operation:
Footbrake ............... Vacuum assisted diagonally
split dual hydraulic
Handbrake................ Mechanical on rear wheels

Fluid type ...........................................................Dot 4
Master cylinder:
Make ........................................................ Girlock
Bore diameter —
Large .................................................... 25.40 mm
Small .................................................... 20.64 mm
Front disc brakes:
Caliper bore diameter ........................... 48.1 mm
Disc diameter ........................................ 240 mm
Disc thickness, minimum ......................... 16 mm
Disc runout, maximum ......................... 0.07 mm
Disc pad thickness, minimum ....................2 mm
Rear disc pads:
Caliper bore diameter ......................... 30.16 mm
Disc diameter ........................................ 234 mm
Disc thickness, minimum ...........................9 mm
Disc runout, maximum .......................... 0.07 mm
Disc pad thickness, minimum ....................2 mm
Rear drum brakes:
Wheel cylinder bore diameter ............ 15.87 mm
Drum diameter, maximum ............... 204.50 mm
Drum out of round, maximum.............. 0.03 mm
Drum runout, maximum ........................ 0.05 mm
Brake lining wear limit ........................... 1.5 mm
TORQUE WRENCH SETTINGS
Brake pedal bracket to body........................... 11 Nm
Brake pedal pivot bolt ..................................... 11 Nm
Brake servo unit to body................................. I I N m
Brake servo unit to master cylinder ............... 11 Nm
Pressure differential piston plug ...................... 12 Nm
Proportioning valve plug................................. 27 Nm
Caliper anchor plate bolts ............................... 52 Nm
Caliper guide bolts .......................................... 31 Nm
Brake hose to caliper....................................... 34 Nm
Handbrake cable bracket bolt ......................... 49 Nm
Handbrake lever to body ................................ 11 Nm
Cable clamp to body....................................... 11 Nm
Cam lever nut.................................................. 49 Nm
1. BRAKES TROUBLE SHOOTING
BRAKE PEDAL HARD
(1) Seized caliper piston or wheel cylinder: Over-
haul the caliper or wheel cylinder.
(2) Seized master cylinder piston: Overhaul the
master cylinder. (3) Seized pedal pivot: Rectify or renew the
pedal pivot shaft and bushes. (4) Restricted brake line: Remove the restriction
or renew the brake line.
(5) Vacuum servo system inoperative: Check
and repair the servo system.
NOTE: The vacuum servo system can be
checked as follows: With the engine
switched off, pump the brake pedal several
times to deplete any vacuum in the system.
With the engine still switched off, press
down firmly on the brake pedal and hold it
there noting the position and pressure re-
quired. Start the engine. If the servo unit is
operating correctly, the brake pedal will sink
slightly and the pressure required to hold it
may reduce. If the pedal does not sink
slightly when the engine is started, check the
vacuum supply to the servo unit. If vacuum
is reaching the brake servo unit, the unit can
be considered inoperative.

BRAKE DRAG
(1) Clogged master cylinder ports: Clean the
master cylinder and the fluid reservoir. Renew the
brake fluid. (2) Seized caliper piston or wheel cylinder: Over-
haul the caliper or wheel cylinder.
(3) Seized handbrake linkage: Free up or renew
the linkage.

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.

174 Brakes
(3) Linings saturated with hydraulic fluid: Re-
new the linings in sets. (4) Incorrect linings installed: Check and install
the recommended linings in sets.
NOTE: In most cases brake fade is caused
by overuse of the footbrake, which in turn
causes a build up of heat at the friction
material and drums or disc. Once this
excessive build up of heat is allowed to
dissipate the brakes should again function
normally.

BRAKES OVERHEAT
(1) Incorrect shoe adjustment: Check and adjust
the shoe to drum clearance.
(2) Broken shoe return springs: Renew any
faulty springs.
(3) Faulty handbrake cables or incorrect adjust-
ment: Check and renew or adjust the cables. (4) Frozen wheel cylinder or caliper pistons:
Overhaul the cylinders or calipers. (5) Obstructed or damaged hydraulic hose or
line: Remove the obstruction or renew the hydraulic
hose or line.
(6) Obstructed master cylinder compensating
port: Clean the compensating port. (7) Blocked vent in the master cylinder reservoir
cap; Check and remove the obstruction in the vent. (8) Overuse of footbrake: Revise driving habits.
NOTE: To check for brake binding raise the
vehicle and spin each wheel in turn by hand.
If it is found that one wheel cylinder or
caliper piston is sti cking it is advisable to
overhaul all the wheel cylinders and calipers.

BRAKE FAILURE
(1) Faulty master cylinder: Remove and over-
haul the master cylinder. (2) Loss of fluid due to a leaking wheel cylinder:
Overhaul or renew the wheel cylinders and bleed the
hydraulic system.
(3) Loss of fluid due to a leaking caliper: Over-
haul or renew the caliper assemblies and bleed the
hydraulic system. (4) Loss of fluid due to a fractured pipe or faulty
union: Renew the faulty components as necessary and
bleed the hydraulic system. (5) Air in the hydraulic system: Locate the
source of the air leak, rectify the problem and bleed
the hydraulic system. (6) Water in the hydraulic fluid: Drain, flush,
refill and bleed the hydraulic system.
NOTE: To locate the source of a fluid leak,
fill the master cylinder reservoir with fluid
and check for obvious signs of external
leakage while an assistant pumps the brake
pedal.


Check the brake pipe unions for leaks.
BRAKE NOISE
(1) Brakes squeal on application: Glazed friction
material or missing or da maged disc pad anti-squeal
shims. (2) Grinding noise on application: Friction ma-
terial worn out. Check the friction material and
discs/drums. Renew the brake pads/shoes and ma-
chine or renew the brake discs/drums as necessary.

Inspect the brake discs for scoring and wear.
2. DESCRIPTION
The brakes are operated by hydraulic pressure in
two independent circuits by means of a tandem dual
circuit master cylinder coupled to a brake servo unit
mounted on the bulkhead between the brake pedal
and master cylinder.

The brake circuits are sp lit diagonally. The left
hand front and right hand rear brakes are connected
to the primary circuit, and the right hand front and
left hand rear brakes are connected to the secondary
circuit. Should a malfunction occur in one circuit, the
remaining circuit is capable of stopping the vehicle.