1987 NISSAN PULSAR Workshop Manual

Steering — Part 3 153

TO CHECK FLUID LEVEL
Check the fluid level in the power steering reser-
voir when the fluid is cold.

If it is necessary to top up the fluid, fill to between
the arrow marks on the dipstick using the recom-
mended fluid.

NOTE: Do not overfill the reservoir.
Checking the power steering fluid level using the
dipstick incorporated in the cap.
TO CHECK FOR FLUID LEAKS
Using a suitable solvent, clean around all power
steering assemblies and hose fittings where fluid
leakage might occur and start the engine. Turn the
steering wheel from one steering lock to the other
several times and stop the engine. Check for leakage.
Where leakage is found at ho se fittings, tighten and
recheck.

If the leak remains, renew the hoses or fittings as
required.

Where leakage is found in the steering gear
assembly or pump assembly, specialist attention is
necessary.

TO CHECK STEERING WHEEL FREE PLAY
With the engine running and the steering wheel in
the straight ahead positi on, measure the free move-
ment of the steering wheel before the front wheels
move. This is specified as steering wheel free play and
if it exceeds Specifications, check for free play in the
steering linkages and the universal coupling joints. If
these components are satisfactory, it will be necessary
to remove the steering gear from the vehicle for
renewal or overhaul.

PUMP BELT TENSION
The procedure for adjusting the power steering
pump bell tension is describe d in the Engine Tune-up
section

TO PURGE THE POWER STEERING SYSTEM
OF AIR

(1) Check that the pump reservoir is filled to the
correct mark on the dipstick. (2) Raise the front of the vehicle and support it
on chassis stands. (3) Turn the steering wheel quickly from lock to
lock several times, recheck the fluid level within the
pump reservoir and top up if required. (4) Start the engine, allow it to idle and slowly
turn the steering wheel from lock to lock several times.
Do not hold the steering at full lock for more than 15
seconds. (5) Check the fluid level in the pump reservoir,
top up if necessary. (6) If the fluid is aerated within the pump
reservoir or if pump noise persists, repeat operations
(3) to (6).
3. STEERING WHEEL

The procedure for removing and installing the
steering wheel is fully covered in the Manual Steering
section under the above heading.

4. STEERING COLUMN
The procedure for removing, dismantling and
assembling the steering column is fully covered in the
Manual Steering section under the above heading.

5. POWER STEERING PUMP
TO REMOVE AND INSTAL
( 1 ) Disconnect the negative battery terminal.

View of the power steering pump removed from the
vehicle.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

POOR OR ERRATIC ROAD HOLDING
ABILITY

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

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

Front Suspension 157


Check the stabilizer bar links for wear and damage.
(3) Incorrect front end alignment: Check and
adjust the alignment as necessary. (4) Defective stabilizer bar mounting rubbers or
worn link ball joints: Renew component as necessary. (5) Weak or broken front coil spring: Renew
both springs as a matching pair. (6) Broken or weak rear coil spring: Renew both
springs as matching pair. (7) Drive shaft bent or distorted: Check and
renew as necessary. (8) Tie rod end worn or damaged: Check and
renew as necessary.
(9) Control arm ball joint worn or damaged:
Check and renew as necessary.
(10) Control arm mounting bolts loose: Tighten
the control arm bolts. (11) Wheel hub bearing worn: Check and renew
as necessary. NOTE: As a quick guide to suspension unit
condition, bounce the front of the vehicle up
and down (one side at a time), the vehicle
should come to rest in a single movement. If
it bounces two or three times before stop-
ping, the suspension unit should be renewed.
If the from of the vehicle is tower on one
side than the other, remove the coil spring
and check its free length against a new
spring. If the spring is found to be unservice-
able it is good practice to install two new
springs as a matching pair. This also applies
to the springs on the rear of the vehicle.

2. DESCRIPTION
The front suspension is an independent type
comprising two Macpherson strut suspension units
mounted vertically on each side of the vehicle. The
lower end of the suspension unit is bolted to the
steering knuckle, which in turn houses the front hub
bearings. The steering knuckle pivots on the control
arm by means of a ball joint.

The control arm pivots at its inner ends on rubber
bushes.

A stabilizer bar is attached to both ends of the
control arms using ball joint links. The stabilizer bar
is attached to the front underbody by brackets and
mounting rubbers.

Each front suspension unit assembly comprises a
tubular shock absorber type suspension unit, sur-
rounded at the upper end by a coil spring. On top of
the coil spring is the upper mounting which attaches
to the underside of the inner mudguard panel. The
piston rod of the suspensi on unit is attached to the
centre of the upper mounting by a rubber mounted
bearing.

When a suspension unit is found to be defective it
is recommended that both suspension units be re-
newed as a pair.

Camber is adjusted by means of a cam on the
upper steering knuckle to suspension unit mounting
bolt.

The kingpin inclination and caster are set in
production and cannot be adjusted. Any variation in
these angles will be caused by worn or damaged
components.

3. STEERING KNUCKLE
Special Equipment Required:
To Renew Wheel Bearing — Press and press plates
and suitable tubes and mandrels
To Check Hub End Float — Dial gauge
TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheel.


Checking the control arm bolts for security.

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.

160 Front Suspension

(2) Disconnect the flexible brake hoses from the
suspension unit bracket.
(3) Using quick drying paint, place mating
marks on the camber adjustin g cam head bolt and the
suspension unit lower mounti ng as an aid to installa-
tion. (4) Remove the bolts and nuts retaining the
suspension unit lower mounting to the steering
knuckle. (5) Open the bonnet and remove the nuts
retaining the suspension unit upper mounting to the
inner mudguard panel and remove the suspension
unit assembly from the vehicle. Use care when
removing not to damage the drive shaft boot.

(6) Remove the dust cover and loosen the piston
rod nut but do not remove it at this stage. (7) Install a spring compressor to the
suspension
unit assembly. Compress the coil spring and remove
the piston rod nut. (8) Remove the washer, upper mounting assem-
bly, the thrust washer, spring seat, insulator, coil
spring, bump rubber and dust cover from the suspen-
sion unit. (9) Check the operation of the suspension unit.
With the suspension unit in a vertical position, move
the piston rod up and down a number of times. A

Dismantled view of the front suspension unit.
uniform resistance should be felt with no abnormal
slack spots or noise evident. If the suspension unit is
defective, it should be renewed.

NOTE: It is recommended that the suspen-
sion unit on the opposite side be renewed at
the same time.

(10) Check the upper mounting assembly for
damage and fatigue. Check the thrust washer for wear.
Check all rubber components, the spring seat and
insulator for wear, damage and deterioration. Renew
worn or damaged components. (11) Check the coil spring for fatigue by compar-
ison with a new spring. Al so check the spring for
cracks and damage. If the coil spring is defective, it is
recommended that the springs on both sides be
renewed.
TO ASSEMBLE AND INSTAL

Assembly and installation is a reversal of the
removal and dismantling procedure with attention to
the following points:
View of the front suspension unit with the spring
compressor installed.