1987 NISSAN PULSAR water pump

Engine 55

9. OIL PUMP
TO REMOVE AND DISMANTLE
(1) Disconnect the negative battery terminal.
(2) Disconnect the lower radiator hose and drain
the cooling system. (3) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary. (4) Remove the right hand front wheel.
(5) Remove the fasteners securing the engine
splash guard to the right hand front inner mudguard
and remove the splash guard. (6) Remove the engine sump and oil pump
pickup pipe as previously described. Remove the oil
filter.
(7) Remove the camshaft timing belt as de-
scribed previously. (8) Disconnect the oil pressure sender electrical
connector. (9) Using a socket and bar, remove the bolt and
spacer retaining the crankshaft timing gear to the
crankshaft. Discard the bolt.
NOTE: It may be necessary to lock the
crankshaft when removing the crankshaft
timing gear retaining bolt. If necessary,
insert a piece of timber between the crank-
case and the crankshaft to prevent the
crankshaft turning.

(10) Remove the crankshaft timing gear from the
crankshaft. It may be necessary to lever the gear from
the crankshaft using two screwdrivers. Remove the
key and spacer from the crankshaft. (11) Remove the camshaft housing top cover.
(12) Using an open ended spanner, hold the
camshaft between the inlet and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.
(13) Remove the bolts securing the water pump
to the cylinder block and remove the water pump. If
necessary- refer to the Cooling and Heating Systems
section. (14) Remove the camshaft drive belt inner cover
retaining bolts and remove the inner cover. (15) Remove the bolts securing the oil pump to

Dismantled view of the oil pump assembly.
the cylinder block and remove the oil pump from the
engine. Discard the gasket.

(16) Remove the screws retaining the oil pump
cover plate and lift the cover plate from the rear of the
oil pump. (17) Lift the inner and outer rotors from the oil
pump housing. Note that the outer rotor may be
stamped with a mark which must face the cover plate
on assembly. (18) Unscrew the oil pressure relief valve plug
and remove the relief spring and plunger from the oil
pump housing. Discard the sealing washer from the
relief valve plug. (19) If necessary, remove the oil pressure gauge
sender unit.
(20) Remove the crankshaft oil seal from the
pump housing.
TO CHECK AND INSPECT

(1) Wash all the pump components thoroughly
in cleaning solvent and allow to dry.
(2) Inspect the inner and outer rotors and the
cover plate for scoring or wear. Renew the rotors
and/or the cover plate if these faults are evident. (3) Temporarily install the rotors into the oil
pump housing. Check the b acklash between the teeth
of the inner and outer rotors at the point where the
rotor teeth are most closely meshed. If the clearance at
this point exceeds the Specif ications, check the rotors
and housing for wear and renew as necessary. (4) Check the rotor end float by placing a
straight edge across the oil pump housing and measure
the clearance between the straight edge and the rotors
View of the oil pump and associated components.

56 Engine

Checking the oil pump rotor end float.
with a feeler gauge. Renew the oil pump if this
clearance exceeds the Specifications.

(5) Check the cover plate for wear and scoring
and renew as necessary. (6) Check the relief valve plunger and spring for
wear or damage. Renew any faulty components as
necessary.
TO ASSEMBLE AND INSTAL

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

(1) Liberally lubricate all components with clean
engine oil before assembly. (2) Install the relief valve plunger and spring into
the pump housing and install the relief valve
plug
using a new sealing washer. Tighten the plug securely. (3) Install the outer rotor into the pump housing with the F mark on the rotor facing towards the cover
plate, if applicable. Install the inner rotor ensuring that
it is correctly meshed with the teeth of the outer rotor.

(4)
Install the cover plate to the oil pump housing
and tighten the retaining screws to the specified
torque. (5) Install a new oil seal to the front of the oil
pump housing. Ensure that the lip of the oil seal faces
the inside of the oil pump housing. (6) If necessary, install the oil pressure gauge
sender unit.
(7) Turn the inner rotor in the oil pump housing.
Ensure that the oil pump rotates freely. (8) Ensure that the mating surfaces of the oil
pump and cylinder block are thoroughly clean. Coat
the oil pump gasket with an oil resistant sealer and
install the oil pump and gasket to the cylinder block. It
may be necessary to turn the oil pump slightly to align
the inner rotor and crankshaft. Tighten the retaining
bolts to the specified torque.
NOTE: Ensure that the oil seal installed to
the oil pump is not damaged when the oil
pump is positioned on the crankshaft.

(9) Install the camshaft drive belt inner cover.
(10) Install the water pump using a new O ring.
Coat the water pump and the engine block mating
surfaces with Dow Corning silicone grease or equiva-
lent. Do not fully tighten the water pump retaining
bolls at this stage. (11) Install the camshaft timing gear and tighten
the retaining bolt to the specified torque.
(12) Install the crankshaft timing gear spacer, key
and timing gear to the crankshaft. (13) Using a new crankshaft timing gear retaining
bolt, install the spacer and tighten the retaining bolt to
the specified torque. (14) Ensure that the oil pump pickup pipe and
screen are clean and free of foreign material. Install a
new O ring to the pipe and position the pickup pipe
and screen in position on the oil pump. Coat the
threads of the mounting bolts with Loctite 242 and
torque the bolts to the specified torque. (15) Fill a new oil filter with the correct grade of
engine oil and install the oil filter. (16) Install the sump as previously described.
(17) Install and adjust the camshaft drive belt as
described under the Camshaft Drive Belt heading. (18) Fill the engine with the correct grade and
quantity of oil. Refer to the Lubrication and Mainte-
nance section.
(19) Fill the cooling system as described in the
Cooling and Heating Systems section. (20) Start and run the engine and check for oil
and coolant leaks. (21) Install the engine splash guard to the
inner
right hand mudguard. (22) Install the right hand wheel and tighten the
wheel nuts as much as possible.
Checking the oil pump inner to outer rotor teeth
backlash.

60 Engine
NOTE: Should the ring end gap be greater
than the specified gap, another ring set
should be obtained and the ring end gaps
checked and compared with the Specifica-
tions.

(3) Treat each ring and cylinder bore individu-
ally and ensure that the rings are assembled to the
respective piston for the cylinder bore in which they
were installed to check the end gap.
(4) Assemble each oil control ring to its respec-
tive piston bottom groove as follows:
(a) Install the oil ring expander to the
piston
groove, ensuring that the ends of the expander are
bulled together and not overlapped. (b) Position one end of the lower side rail in the
groove and peel the ring over the piston and into the
groove. (c) Similarly install the upper side rail.
(5) Install the lower compression ring into
the
lower piston groove.

NOTE: The compression rings should be
installed with the manufacturers mark fac-
ing the top of the piston. To minimize the
possibility of ring breakage the rings can be
immersed in hot water prior to installation.

(6) Install the upper compression ring into
the
upper piston groove.
(7) Space the compression ring gaps 120 degrees
apart, and ensure that the o il ring gaps and the join in
the oil ring expander are not aligned. (8) With the rings correctly installed and
gapped, remove the bearing cap from the connecting
rod. (9) Liberally lubricate the piston assembly and
install the piston ring compressor to number one
piston.
NOTE: When installing the pistons to the

cylinder ensure that the front marking on
the piston is towards the front of the engine.

(10) Turn the crankshaft until number one crank-
pin is at the bottom of its stroke. (11) Install number one piston and connecting
rod
assembly into its bore. Push the assembly down the
bore until the connecting rod can be aligned with
number one crankpin.
NOTE: The bearing shells should be lubri-
cated with engine oil before installation.

(12) Install the connecting rod cap and tighten
the
retaining bolts to the specified torque.

NOTE: If new bearing shells were installed,
check the bearing clearance with Plastigage
as previously described.

(13) With the bearing clearance as specified, in-
stal the remaining pistons in the same manner.
(14) Ensure that the crankshaft turns without
binding.
(15) With all connecting rod bolts tightened to
the specified torque, install the associated
components
by referring to the relevant headings in this section.
11. CRANKSHAFT AND MAIN BEARINGS

Special Equipment Required:
To Inspect — Micrometer, Vee blocks, dial gauge
TO REMOVE
(1) With the engine assembly removed from the
vehicle and the transaxle separated from the engine,
refer to the appropriate headings or sections and
remove the following components: sump, oil pump
pickup pipe, oil pump, and flywheel or drive plate. (2) Remove the crankshaft rear oil seal from the



Using a ring compressor to install the piston.
Checking the crankshaft end float using feeler gauges.

68
COOLING AND HEATING SYSTEMS
SPECIFICATIONS
Coolant capacity ........................................ 6.0 liters
Thermostat:
Opening temperature........................... 91 deg
C

Fully open temperature .................... 103 deg
C

Cooling fan:
Fan cut in temperat ure ....................... 100 deg C
Fan cut out temperature ...................... 95 deg C
Radiator cap opening
pressure ................................................... 78 -98 kPa
TORQUE WRENCH SETTINGS
Water pump retaining bolts .............................25 Nm
Thermostat housing bolts .................................15 Nm
Sender unit .......................................................10 Nm
1. COOLING SYSTEM TROUBLE SHOOTING
COOLANT LEAKAGE - EXTERNAL
(1) Loose hose clips or faulty hoses: Tighten the
hose clips or renew the faulty water hoses.
(2) Leaking radiator core or tanks: Repair or
renew the radiator. (3) Leaking heater core or hoses: Repair or renew the heater core. Check the hose clips and hoses
and renew if necessary.

(4)
Leaks at the thermostat cover and/or water
pump O rings. Renew the O rings. (5) Worn or damaged water pump seal assembly:
Renew the water pump. (6) Worn or damaged water pump bearing as-
sembly: Renew the water pump.
(7) Loose or rusted welch plugs; Renew the
welch plugs. (8) Faulty cylinder head gasket or loose cylinder
head bolts: Renew the cylinder head gasket and
correctly tighten the cylinder head bolts. (9) External crack in the cy linder head or cylin-
der block: Repair or renew the faulty components.
NOTE: Check the system for external leak-
age by running the engine to operating
temperature over a dry floor and checking
for the leak source.

Check the vehicle interior below the
heater core for moisture. If a rusted welch
plug is found, it is a good practice to renew
all the welch plugs.

COOLANT LEAKAGE - INTERNAL
( 1 ) Cylinder head gasket leak due to warped
cylinder head or cylinder block gasket faces: Reface


Checking the radiator hose for deterioration.

Check the engine oil for level and dilution on the
dipstick.

Cooling and Heating Systems 69

the cylinder head or cylinder block and renew the
cylinder head gasket.

(2) Crack in the cylinder head or cylinder block:
Repair or renew as necessary.

NOTE; Check the engine for internal leak-
age by withdrawing the dipstick and inspect-
ing for emulsified oil. Run the engine and
check for excessive steam at the exhaust
pipe which would indi cate coolant leakage
into the combustion chamber.

COOLANT LOSS BY OVERFLOW
(1) Overfull system: Drain the excess coolant
from the system.
(2) Faulty radiator cap: Renew the faulty cap.
(3) Blocked radiator core tubes: Clean or renew
the radiator core.

(4) Faulty thermostat: Renew the thermostat.
(5) Coolant foaming due to poor quality anti-
freeze or corrosion inhibitor: Drain the system and
renew the coolant and additive.

Renew the radiator cap if the sealing rubber has
deteriorated.
ENGINE OVERHEATING
(1) Radiator cap defective: Renew the radiator
cap.
(2) Incorrect fuel mixture: Check the fuel system
as described in the Fuel and Engine Management
section. (3) Obstructed air passage through the radiator
core from the front to the rear: Blow the obstruction
from the rear to the front of the radiator core using
compressed air or water pressure. (4) Faulty thermostat: Renew the thermostat.
(5) Incorrect ignition timing: Check and adjust
the ignition timing as described in the Engine Tune-up
section. (6) Incorrect valve timing: Set the valve timing
as described in th e Engine section.
(7) Loss of coolant from the overflow: Check
and rectify as described under the heading Coolant
Loss By Overflow.
(8) Poor circulation: Check and rectify as de-
scribed under the heading Coolant Circulation Faulty.
(9) Low engine oil level: Stop the engine imme-
diately and replenish the oil in the sump. (10) Restricted muffler, catalytic converter or
damaged tailpipe, accompanied by loss of power:
Remove the restrictions or renew the faulty com-
ponents as necessary.
(11) Incorrectly adjusted or dragging brakes:
Check and rectify by adjustment or renewal of
components. (12) Faulty temperature gauge and/or sender unit:
Check and rectify as necessary.
NOTE: Engine overheating is indicated by
an excessive rise in engine temperature
shown by the temperature gauge.

Overheating is usually accompanied by
steam emitting from the coolant overflow
pipe and loss of engine power. A blown
cylinder head gasket may be indicated by
bubbles in the coolant.

COOLANT CIRCULATION FAULTY
(1) Partial blockage of the radiator core tubes:
reverse flush or renew the radiator core.
(2) Sludge deposits in the engine water jacket:
Clean and flush the engine water jacket and add
inhibitor to the coolant. (3) Faulty water pump: Renew the water pump.
(4) Faulty thermostat: Renew the thermostat.
(5) Collapsing lower radiator hose: Renew the
lower radiator hose and check the radiator core tubes. (6) Insufficient coolant in the system: Replenish
the coolant and check for leaks.
NOTE: If rust or sludge deposits are sus-
pected, check the color of the coolant in the
radiator. Rusty or muddy coolant indicates
rust or sludge in the system.

2. HEATER AND AIR CONDITIONER TROUBLE SHOOTING

NO HOT AIR INSIDE VEHICLE
Faulty thermostat: Renew the thermostat.
Faulty heater valve: Check and renew the

Blocked heater hoses: Remove the blockage.
Blocked heater core: Clean or renew the core.

NOTE: Ensure that the engine is reaching
normal operating temperature. If in doubt
check the operation of the thermostat as
described under the Thermostat heading in
this section.

(1)
(2)
valve.
(3)
(4)

70 Cooling and Heating Systems


Installed view of the heater hoses. 1.6 liter models with the air cleaner removed for clarity
.
When the engine is at normal operating
temperature and the heater valve is open,
both of the heater hoses should feel
warm/hot. If the valve is not allowing the
coolant to flow, one hose will be hot while
the other will be cold.

NO COOLED AIR INSIDE VEHICLE
(1) Compressor drive belt slipping or broken:
Renew and/or adjust the drive belt as described in the
Engine Tune-up section.
(2) Insufficient refrigerant: Check the system for
leaks and charge as necessary. Refer to the Air
Conditioning heading in th is section for information
on checking the refrigerant level. (3) Compressor inoperative: Check for power to
the compressor clutch before removing the compres-
sor for repair by a specialist. (4) Heater system allowing warm air to mix with
cooled air: Check the operation of the heater system.
NOTE: The above trouble shooting proce-
dures are basic checks only. If the air
conditioning system is suspect, it is rec-
ommended that the vehicle be taken to an
authorized dealer for testing and repair.
It is normal for water to be seen drain-
ing under the vehicle from the evaporator
after the vehicle has been operated with
the air conditioning on.

3. DESCRIPTION
The cooling system is of the sealed, pressurized
type with fan and water pump assistance. The system
is pressurized in order to raise the boiling point of the
coolant and so increase the efficiency of the engine.

Provision for pressure a nd vacuum relief of the
system is incorporated in the radiator cap.

The radiator overflow hose is connected to a
reserve tank mounted adjacent to the battery. As the
coolant volume expands due to an increase in tem-
perature, the pressure valve in the radiator cap opens
and allows the excess coolant to flow into the reserve
tank. When the engine is stopped and the temperature
of the coolant falls, the vacuum valve in the radiator
cap opens and allows the excess coolant in the reserve
tank to siphon back into the radiator. Thus the
necessity for frequent topping up of the coolant is
eliminated.

The temperature of the cooling system is con-
trolled by a thermostat located in the thermostat
housing attached to the cylinder head.

The thermostat prevents circulation of coolant
through the radiator by directing coolant through the
by-pass circuit, until the engine has reached operating
temperature. This restricted circulation allows the
engine to reach operating temperature quickly, im-
proving drivability and fuel economy.

Removal of the thermostat to cure overheating is
not recommended because th e by-pass circuit will
remain open reducing the amount of water flowing
through the radiator.

An anti-corrosion inhibitor should always be
added to the coolant to protect the cooling and
heating systems from corrosion.

The water pump is mounted to the front of the
engine and is driven by the camshaft drive belt. It is
equipped with a double row ball bearing and a spring
loaded seal assembly. The water pump is a disposable
unit and cannot be repaired.

The fan is driven by an electric motor which is
actuated by the coolant temperature sensor and the
control unit.

On vehicles equipped with air conditioning, an
additional electric fan is m ounted to the radiator. This
fan is controlled by a sw itch connected to the air
conditioning compressor.

The radiator consists of an aluminum core with
plastic side tanks. Minor damage to the core can be
repaired using Nissan repair agent.

The left hand tank of the radiator houses the
transaxle oil cooler on automatic transaxle models.

To drain the cooling system a drain plug is
provided on the lower radiator pipe outlet.

4. RADIATOR
NOTE: To avoid scalding, use caution when
releasing the radiator cap on an engine
which is at the normal operating tempera-
ture. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to
release. When the pressure is released turn
the cap past the stop and remove it from the
radiator.

Cooling and Heating Systems
7. THERMOSTAT HOUSING
Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) On 1.6 liter models, remove the air cleaner
assembly from the engine. Refer to the Fuel and
Engine Management section if necessary. (3) Drain the cooling system as previously de-
scribed. (4) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (5) Remove the bolts retaining the camshaft
drive belt rear cover to the cylinder block and remove
the rear cover.
\ COOLANT TEMPERATURE SENSOR TEMPERATURE SENDER SWITCH
View of the thermostat housing and
components.
(6) Disconnect the top radi ator hose, the heater
hose and the inlet manifold heater hose from the
thermostat housing.
(7) Disconnect the wire from the temperature
sender switch and the coolant temperature sensor. (8) Remove the bolts retaining the thermostat
housing to the cylinder head and remove the thermo-
stat housing and the O ring from the cylinder head. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all mounting faces are clean.
(2) Renew the O ring on installation.
NOTE; Ensure that the O ring is not
twisted. Do not use sealant.

(3) Tighten the thermostat housing retaining
bolts to the specified torque. (4) Adjust the camshaft drive belt tension as
described in the Engine section under the heading
Camshaft Drive Belt. (5) Fill the cooling system as previously de-
scribed and check for coolant leaks. 8. WATER PUMP

Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
NOTE: The water pump is non-repairable
and if faulty must be renewed as a complete
assembly.

(1)
Drain the cooling system as previously de-
scribed.
(2) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (3) Remove the water pump retaining bolts and
remove the water pump and the O ring from the
engine. Installation is a reversal of the removal procedure
with attention to the following points:


View of the water pump and components removed
from the vehicle.
(1) Ensure that all mounting faces are clean.
(2) Use a new O ring and smear it with a liberal
amount of silicone grease.
(3) Install the water pump to the engine but
do
not tighten the retaining bolts until the camshaft drive
belt has been installed and tensioned correctly as
described in the Engine section under the heading
Camshaft Drive Belt.
(4) Fill the cooling system as previously de-
scribed in this section and check for coolant leaks.
9. WELCH PLUGS

To facilitate the casting of the cylinder block and
cylinder head passages and water jackets, a number of
openings had to be ma de at manufacture.

82
FUEL AND ENGINE MANAGEMENT
CAUTION: To prevent severe electrical shock, extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

SPECIFICATIONS
FUEL INJECTION
Type:
1.6 liter engine .................................. Single point
1.8 liter engine................................... Multi point
FUEL PUMP
Type ................................................................ Electric
Pressure at idle:
1.6 liter engine ..................................... 62-90 kPa
1.8 liter engine ................................ 190-230 kPa
FUEL FILTER
Type ................................................ Inline, disposable
AIR FILTER
Type ................................... Disposable paper element
DISTRIBUTOR
Make ........................................................ Delco Remy
Advance contro l .......................................... Electronic
Rotation of rotor .................................. Anti-clockwise
Firing order....................................................1 -3-4-2
ADJUSTMENTS
Base idle speed ..................................... 550-650 rpm
Ignition timing.......................................... 10° BTDC
TORQUE WRENCH SETTINGS
Throttle body nuts.......................................... 10 Nm
*Throttle body bolts ........................................ 12 Nm
*Fuel hose fittings............................................ 35 Nm
Fuel rail bolts ....................................................8 Nm
Fuel tank drain plug ........................................ 24 Nm
Coolant temperature sensor ............................ 12 Nm
Oxygen sensor .................................................. 40 Nm
MAT sensor..................................................... 14 Nm
*1.6 liter engine
l . 8 liter engine

1. FUEL AND ENGINE MANAGEMENT
TROUBLE SHOOTING

NOTE: The following Trouble Shooting pro-
cedures are basic checks only. If these pro-
cedures fail to locate the fault, refer to the
System Diagnosis and Adjustments heading
for more thorough testing.

Prior to performing any of the following
operations, refer to the Service Precautions
and Procedures heading.

ENGINE WILL NOT START OR HARD TO
START
(1) Water in the fuel: Dr ain the fuel from the
system and renew the fuel filter.
(2) Fault in the power supply: Check the battery,
fusible links and fuses. Check for clean, secure con-
nections, particularly the earth connections. Check the
EG1 and fuel pump relays.
NOTE: If the fuel pump relay fails, power
will be supplied to the fuel pump via the oil
pressure switch. When starting the engine,


Check that the MAP sensor hose is not blocked or split
and ensure that all electrical connections are clean and
secure.