1987 NISSAN PULSAR length

72 Cooling and Heating Systems

(16) After the vehicle has been driven several
kilometers check the coolant level in the reserve tank
and top up if necessary.

TO REMOVE
(1) Drain the cooling system as previously de-
scribed.
(2) Loosen the hose clamps and disconnect the
hoses from the radiator. (3) If applicable disconnect the automatic trans-
axle oil cooler hoses from the left hand side radiator
tank. Plug the hoses and fitt ings to prevent the entry
of dirt and the loss of fluid.
(4) Disconnect the hose from the reserve tank at
the top of the radiator. (5) On models with air conditioning, remove the
hoses and support bracket bolts and move the bracket
and hoses away from the top of the radiator. (6) Remove the radiator support bracket bolts
from the radiator support pa nel and lift the radiator
from the lower mountings and out of the vehicle.
NOTE: A radiator that has been in use for
some time should not be allowed to stand
empty for any length of time. The radiator
should be immersed in a tank of coolant or
otherwise kept full. If applicable, ensure that
no coolant is allowed to enter the automatic
transaxle oil cooler in the left hand side tank
of the radiator.

Failure to observe this precaution may
result in overheating when the engine is put
back into service. This is caused by internal
deposits in the radiator drying and flaking
and so obstructing the circulation of the
coolant in the system.

TO FLUSH AND CLEAN
(1) Remove the radiator as previously described.
(2) Apply a water hose to the radiator outlet and
reverse flush the radiator until the water flowing from
it is clean.

Cleaning the radiator core from the rear to the front
using a garden hose.
(3) Stand the radiator upright and apply a
stream of water or compressed air to the radiator core
from the rear to [he front. Maintain this procedure
until all dirt and foreign matter is removed from the
radiator core.
(4) With the aid of a light, make a visual check
of the core tubes through the radiator inlet or outlet
fittings. If it is apparent that the tubes are severely
impregnated with flakes of rust it will be necessary to
renew the radiator assembly.
TO REPAIR

The repair procedure described below is only
suitable for holes occurring in the radiator core tubes
that are not bigger than approximately 1 mm.

(1) Suitably mark the area of the leak using a
piece of chalk or similar. (2) Remove the radiator from the vehicle as
previously described, clean it thoroughly and dry the
damaged area with a hair dryer. (3) If necessary, carefully cut away or bend the
fins from the tubes to expose the affected area.
NOTE: Do not remove more than 25 mm
total finning from the radiator or cooling
performance will be affected.

(4) Clean the damaged area carefully using a
scraper and wipe clean using a cloth moistened with
petrol.
(5) Apply well mixed Nissan or Holden adhe-
sive part number 21411-J7025, or equivalent, spar-
ingly to the damaged area using a wooden spatula.
(6) Allow the repair to dry in ambient condi-
tions for a minimum of 3 hours before installing the
radiator to the vehicle and testing for leaks. Do not
use heat to promote drying.
TO INSTAL

Installation is a reversal of the removal procedure
with attention to the following points:
Reverse flushing the radiator using water pressure.

Cooling and Heating Systems
11. BLOWER FAN
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working below the glov e compartment, dis-
connect the wiring connector to the blower fan motor.
(3) Remove the bolts retaining the blower fan
motor and carefully lower the motor while disconnect-
ing the drain hose.

Installation is a reversal of the removal procedure
with attention to the following points:
( t ) Tighten all bolts securely.
(2) Check that the blow er fan operates correctly.

Dismantled view of the blower fan and associated
components.
12. AIR CONDITIONING
DESCRIPTION
The air conditioning system, when used in con-
junction with the heater, enables any reasonable tem-
perature to be achieved inside the vehicle. It can also
reduce the humidity of the incoming air, aiding
demisting even when cooling is not required.

The basic components of the air conditioning sys-
tem are an evaporator, co ndenser, compressor, re-
ceiver/dryer, expansion valve and pipes and hoses
carrying the refrigerant through the system. Various
subsidiary controls and sensors are also utilized to
protect the system against low or high pressure and
excessive temperature.

The refrigerant will boil at a very low tempera-
ture (-33 deg C) and therefore must be contained
under pressure. Escaping refrigerant can cause frost-
bite and eye damage and will produce a poisonous gas
when burnt. Also, if the system suffers a rapid loss of
refrigerant, oil from the compressor may be carried
out with the refrigerant. It is recommended that any
work requiring disconnection of the components be
referred to an au thorized dealer.

In the event of major repair s to the vehicle such as
engine removal, the compress or hoses are of sufficient


Schematic diagram of a typical air conditioning
system.
length to allow the compressor to be removed as the
engine is lowered from the engine compartment with-
out disturbing any refrigerant line connections.

If the operation of the air conditioning system is
in doubt, it is recommended that the vehicle be taken
to an authorized dealer for testing and repair.

TO CHECK REFRIGERANT CHARGE
(1) Start the engine and operate the air condi-
tioner on maximum cooling for a few minutes.
(2) Observe the flow of refrigerant through the
sight glass located at the top of the receiver/dryer. On
some models it may be necessary to use a mirror to
see the sight glass. (3) If the system is operating correctly, the sight
glass will be clear during the operation of the com-
pressor. Occasional bubbles may be seen when the
compressor cycles on and off during operation, but a
NUT j-
Bubbles in the sight glass when the air conditioner is
operating indicates a low refrigerant charge.

Fuel and Engine Management 93
liter engines, or the throttle body hose fitting on 1.6
liter engines.

(5) Tighten all connectors securely. Check for
external leaks as previously described. (6) Start the engine and note the pressure while
the engine is idling.
(7) Switch the engine Off and check that the
residual pressure does not decrease.
If the fuel pressure is within Specifications and
does not decrease, the fuel system is in a serviceable
condition. Depressurize the fuel system and discon-
nect the pressure gauge.

If the fuel pressure is a bove Specifications proceed
to operation (9).

If the fuel pressure is below Specifications proceed
to the following operation.

If the fuel pressure decreases, an internal leak is
indicated. Proceed to the following heading and carry
out the test procedure.


Testing the fuel system pressure using a pressure
gauge. 1.8 liter engine.
NOTE: There may be a small initial de-
crease in pressure when the engine is
switched Off This is acceptable and does not
indicate a fault in the system.

(8) If the fuel pressure is below Specifications
proceed as follows:

(a) Check the fuel lines for blockages and kinks
or a blocked fuel filter or fuel pump pickup strainer. (b) If no fault can be found in the previous
checks, on 1.8 liter engines clamp the fuel return hose
at the fuel rail. On 1.6 liter engines, clamp the hose that is
connected to the front throttle body hose fitting.

(c) Connect a jumper lead between terminals G
and H on the diagnostic link connector and switch the
ignition On.

NOTE: Do not operate the fuel pump for
longer than is necessary to obtain a pressure
reading.

If the fuel pressure is less than 270 kPa on 1.8 liter
engines or 90 kPa on 1.6 liter engines, renew the fuel
pump.

If the fuel pressure is more than previously
specified, renew the pressure regulator assembly on
1.8 liter engines or the pressure regulator diaphragm
on 1.6 liter engines.

(9) If the fuel pressure in operation (6) is above
Specifications, proceed as follows:

(a) On 1.8 liter engines, disconnect the fuel
return hose from the pressure regulator outlet.

On 1.6 liter engines, disc onnect the fuel return
hose from the front throttle body hose fitting.

(b) Connect a suitable length of fuel hose to the
pressure regulator or the front throttle body hose
filling and place the opposite end of the hose into a
petroleum resistant container. (c) Connect a jumper lead between terminals G
and H on the diagnostic link connector and switch the
ignition On. If the fuel pressure is 230-270 kPa on 1.8 liter
engines or 62-90 kPa on 1.6 liter engines, locate and
remove the restriction in the fuel return hose or pipe.

If the fuel pressure is more than previously
specified, renew the pressure regulator assembly on
1.8 liter engines or the pressure regulator diaphragm
on 1.6 liter engines.

TO TEST FOR INTERNAL FUEL LEAKAGE
Check the residual fuel pressure as previously
described.

If the pressure has decreased it is an indication of
an internal leak. With the pressure gauge still at-
tached, proceed as follows:

(1) Switch the ignition On to pressurize the fuel
system.
(2) As the pressure begins to decrease clamp the
fuel supply hose shut. If the pressure remains steady
the fuel pump may be consid ered faulty and should be
renewed as described later in this section. (3) If the pressure continues to decrease switch
the ignition On after it has been Off at least 10
seconds. As the pressure begi ns to decrease clamp the
fuel return hose shut. If the pressure remain steady on 1.8 liter engines,
renew the pressure regulator. If the pressure continues
to decrease, leaking inject ors are indicated. Remove
the injectors as described later in this section to locate
the leaking injectors.

If the pressure remains stea dy on 1.6 liter engines,
renew the pressure regulator diaphragm as described
later in this section. If the pressure continues to
decrease remove the injector and renew the O ring
seals as described later in this section. If this fails to
rectify the fault remove the injector and clean or
renew the injector as necessary.

Fuel and Engine Management 99
stalled on each side of the air cleaner mounting
bracket when installing the mounting bolts.

(2) If renewing the element, ensure that the
specified element is installed and is correctly seated in
the air cleaner housing. (3) Ensure that the air intake hose clamps are
tightened securely.
To Remove and Install — 1.6 Liter Engine

(1) Disconnect the negative battery terminal.
(2) Remove the nuts and washers retaining the
air cleaner to the throttle body assembly. (3) Release the top cover retaining clips and
remove the top cover and the air cleaner element.
Remove the air cleaner retainer from the throttle body
bolts. (4) Disconnect the engine vent hose from the air
cleaner support clamp. (5) Slightly raise the air cleaner and tilt it
towards the windscreen. Disc onnect the engine vent
hose and the temperature sensor vacuum hose from
the underside of the air cleaner. (6) Remove the air cleaner housing from the
engine.

Dismantled view of the air cleaner.
(7) Thoroughly clean the air cleaner housing and
top cover and check for cracks or damage that would
allow unfiltered air to enter the engine. Renew any
components as necessary.

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

(1) Inspect the air cleaner base gasket. Renew if
necessary. (2) Connect the engine vent hose and the tem-
perature sensor vacuum hose. (3) Install the air cleaner ensuring that the hot air
inlet tube is located correc tly between the exhaust heat
shield and the air cleaner housing. (4) When installing the top cover retaining nuts,
hand tighten only. THROTTLE BODY ASSEMBLY

To Remove and Install — 1.8 Liter Engine
(1)
Disconnect the negative battery terminal.
(2) Release the air intake hose clamp and dis-
connect the air intake hose from the throttle body. (3) Unclip the actuating rod from the throttle
lever using a small screwdriver under the ball socket if
necessary.
(4) Mark the throttle body vacuum hoses with
quick drying paint or similar and disconnect the hoses
from the throttle body. Disconnect the engine vent
hose from the throttle body. (5) Disconnect the wiring connectors from the
throttle position sensor and the IAC valve.
(6) Remove the retaining nuts and withdraw the
throttle body and gasket.
View of the throttle body and actuating rod. The rod
length must be set so that dimension A - 8—9 mm for
automatic transaxle models and 3—4 mm for manual
transaxle models.

View of the throttle body and associated components.

100 Fuel and Engine Management
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all throttle body passages are
clean. Blow out with compressed air if necessary. (2) Install the throttle body to the inlet
manifold
using a new gasket and tighten the retaining nuts to
the specified torque. (3) Connect the vacuum hoses to the throttle
body in the positions previously marked. (4) Clip the actuating rod to the throttle body
lever. Check the dimensions shown in the illustration
and adjust the rod length if necessary.
(5) Check the adjustment of the throttle cable as
described later in this section.
(6) Connect the air intake hose and tighten the
hose clamps securely.
To Remove and Install — 1.6 Liter Engine

(1) Depressurize the fuel system as previously
described. (2) Disconnect the negative battery terminal.
(3) Remove the air cleane r assembly and base
gasket as previously described. (4) Mark the fuel supply and return hoses,
release the clamps and disconnect the hoses from the
throttle body assembly. (5) Disconnect the injector, throttle position
sensor and the IAC valve wiring connectors. Remove
the injector wiring harness from the throttle body
assembly and place it to one side.
(6) Mark and disconnect the vacuum hoses from
the throttle body assembly. (7) On automatic transaxle models, disconnect
the kickdown actuating rod from the throttle linkage.
(8) Slide the outer throttle cable from the
mounting bracket, rotate the throttle linkage and disconnect the inner throttle cable from the throttle
linkage.

(9)
Remove the bolts retaining the throttle body
assembly to the inlet manifold and remove the
assembly and the gasket from the engine. (10) If necessary remove the retaining screws and
remove the fuel meter assembly, the IAC valve and
the throttle position sensor from the throttle body
assembly. Installation is a reversal of the removal procedure
with attention to the following points:

(1) If removed, install the fuel meter assembly,
the throttle position sensor and the IAC valve as
described under the relevant headings. (2) Install the throttle body assembly to the inlet
manifold using a new gasket and tighten the retaining
bolts to the specified torque. (3) Connect the vacuum ho ses to the throttle
body using the marks made on removal to ensure
correct installation. (4) On automatic transaxle models, connect the
kickdown actuating rod to the throttle linkage.
(5) Install the throttle cable and check the adjust-
ment as described later in this section.
INLET MANIFOLD

To Remove and Install
To remove and install the inlet manifold, refer to
the relevant heading in the Engine section.

IDLE AIR CONTROL (IAC) VALVE
To Test

(1) Connect an accurate tachometer to the en-
gine. (2) With the engine at normal operating temper-
ature and all accessories switched Off, note the idle
speed.
(3) With the ignition switched Off, disconnect
the IAC valve wiring connector. (4) Start the engine and check the idle speed.
If the idle speed is the same as that noted in

operation (2) proceed to operation (7).
If the idle speed is higher than noted in operation
(2) proceed as follows.

(5) With the ignition switched Off, connect the
IAC valve wiring connector.

(6) Start the engine and check the idle speed.
If the idle speed is not the same as that noted in

operation (2) proceed to operation (7).
If the idle speed is the same as noted in operation
(2) the IAC valve is operating correctly. However, if
the engine is not idling correctly carry out the
following checks.

(a) Check the air inlet system for vacuum leaks.
NOTE: Any vacuum leak will cause a fast
idle.

View of the throttle body assembly showing the loca-
tion of the base idle adjusting screw. 1.8 literengine.

Fuel and Engine Management 101


Location of the idle air control (IAC) valve. Inset shows the terminal identification.
(b) Check for a binding throttle cable, throttle
shaft or throttle position sensor. (c) Check the coolant temperature sensor resis-
tance as described later in this section. (d) Ensure that the battery terminals and the
engine earth terminals are clean and secure.
(e) Check the operation of the Park/Neutral
switch and the transaxle as described in the Automatic
Transaxle section under the Neutral Safety Switch
heading. (f) Check the spark plug gaps as described in the
Engine Tune-up section.
(g) Check the base idle speed adjustment.
(h) Check the fuel pressure and check the system
for leaks as described previously.

(I) Check the alternator voltage output as de-
scribed in the Electrical System section to ensure that
it is between 9-17 volts.

(j) Remove the IAC valve and check the bore in
the throttle body for dirt or damage.

(7) Stop the engine, switch the ignition On and
connect a jumper lead between terminals A and B on
the diagnostic link connector. (8) Disconnect the wiring connector from the
IAC valve.
(9) Check for voltage at each of the terminals on
the IAC valve wiring connector using a test lamp. If the test lamp flashes at each terminal, correct
operation of the wiring and control unit is indicated.
check for faulty IAC valve terminals. If no fault is
found renew the IAC valve.

If the test lamp is a steady light at one or more
terminals, proceed to operation (10).

If the test lamp does not flash at one or more of
the terminals proceed as follows:

(a) Check the circuit with no voltage for shorts
and for continuity between the IAC valve and the
control unit. Repair or renew the wiring harness as
necessary.
(b) Measure the resistance across the IAC valve
terminals A and B, and across terminals C and D. The resistance should be more than 30 ohms.

If the resistance is not as specified, renew the IAC
valve.

If the resistance is as specified, check for faulty
wiring connector terminals on the IAC valve and the
control unit. If no fault is found, renew the control
unit

(10) Switch the ignition Oft' and disconnect the
control unit wiring connectors. (11) Switch the ignition On and check the IAC
connector with the test lamp again. If the light is stilt
steady on one or more terminals there is a short
circuit to voltage in the wiring harness. Repair or
renew as necessary. (12) If the light is not on, check for faulty IAC
valve terminals. If no fault is found renew the IAC
valve.
To Remove and Install

(1) Disconnect the negative battery terminal.
(2) On 1.6 liter engines, remove the air cleaner
assembly as previously described. (3) Disconnect the wiring connector from the
IAC valve. (4) Remove the IAC valve retaining screws and
withdraw the IAC valve and O ring.

View of the IAC valve removed from the throttle body
assembly. 1.6 liter engine.
(5) Clean the IAC sealing surfaces to ensure
proper operation.

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

(1) When installing a new IAC valve ensure that
the part number is correct as the valve is not
interchangeable between the 1.8 and 1.6 liter engines.
(2) Measure the length of the pintle extension as
shown in the illustration. If necessary push the pintle
in by exerting firm thum b pressure with a slight
rocking motion.
NOTE: Installing (he IAC valve with the
pintle protruding too far can damage the
valve.

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.

Manual Transaxle and Drive Shafts 139

SNAP RING
Assembled view of the inner C.V. joint.
(10) Slide the large end of the inner C.V. joint
boot over the inner C.V. joint housing and locate the
boot in the groove in the housing.
(11) Pull the C.V. joint until the boot is the
normal length. Deformation of the boot could occur if
this operation is neglected. (12) With no vacuum or pressure present in the
C.V. joint boot, install the two C.V. joint boot
retaining clips.

Install the C.V. joint retain ing ring into the C.V. joint
housing. Ensure that the retaining ring is correctly
seated.
NOTE: Ensure that the retaining dips are
securely installed preven ting the entry of
damaging dust or water and that the lock
tabs on the retaining clips are correctly bent
over.

(13) Install the remaining snap ring onto the inner
C.V. joint housing shaft and install the drive shaft to
the vehicle as previously described.