1987 NISSAN PULSAR body

Engine 51

coolant temperature sensor and temperature sender
switch located in the thermostat housing.

(8) Remove the bolt securing the wiring clamp
to the rear of the manifold and maneuver the wiring
away from the cylinder head and the inlet manifold.
(9) Disconnect the throttle cable and on auto-
matic transaxle models, the kickdown cable from the
throttle body linkage. (10) Remove the bolls securing the throttle cable
bracket to the inlet manifold and place the bracket
and cable(s) to one side.
(11) Mark the fuel supply and return hoses to
ensure correct installation and disconnect the hoses
from the fuel rail or throttle body. Plug the hoses to
prevent the loss of fuel or the entry of dirt. (12) Mark the vacuum hoses connected to the
inlet manifold and throttle body to ensure correct
installation and disconnect the hoses. (13) Remove the nuts securing the engine pipe to
the exhaust manifold and separate the pipe from the
manifold. (14) Remove the oxygen sensor from the exhaust
manifold. Refer to the Fuel and Engine Management
section if necessary. (15) Remove the distributor and coil as described
in the Fuel and Engine Management section. (16) Disconnect the engine breather hoses from
the camshaft housing and cams haft housing top cover.
(17) Remove the bolts retaining the top cover to
the camshaft housing and remove the top cover. (18) Using an open end spanner, hold the cam-
shaft between the inlet and exhaust lobes of number
four cylinder and remove the camshaft timing gear
retaining bolt and the camshaft timing gear.
(19) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (20) Loosen the cylinder head bolts in the reverse
order of the tightening sequence, backing off each bolt
a quarter turn then half a turn at a time until the bolts
are loose.
NOTE: Do not loosen the head bolts while
the engine is warm as distortion of the
cylinder head could result.

(21) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (22) Remove the cylinder head and gasket from
the cylinder block. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Thoroughly clean the gasket surfaces of the
cylinder head, cylinder block and camshaft housing
and check all mating surfaces with a straight edge.
Ensure that all the oilways are clean and free of any
foreign material and lightly oil all operating parts with
engine oil.
(2) Install new gaskets throughout during
assem-
bly.

View of the cylinder head showing the bolt tightening
sequence.
(3) Ensure that the cylinde r head and gasket are
located correctly on the dowels on the cylinder block
face. The head gasket is marked TOP to aid in correct
installation. (4) With the cylinder head and gasket in posi-
tion on the cylinder block, apply an even smear of
Loctite 515 to the cylinder head and camshaft housing
mating surfaces. Take care that no sealant is forced
into the oil passages. (5) Install new cylinder head bolts and lubricate
the bolts and washers with engine oil,
(6) Apply an initial torque to the cylinder head
bolts of 25 Nm in the sequence shown in the
illustration. Further tighten the head bolts in the same
sequence in three separate 60 degree stages. Refer to
Specifications. (7) Install the bolts secur ing the camshaft drive
belt inner cover to the camshaft housing. Install the
camshaft timing gear and tighten the retaining bolt to
the specified torque. (8) Install and adjust the camshaft drive belt as
previously described. (9) Install the distributor, coil and oxygen sensor
as described in the Fuel and Engine Management
section.
(10) Using a new gasket, connect the engine pipe
to the exhaust manifold flange, coat the nuts with an
anti-seize compound and install and tighten the nuts
to
the specified torque. (11) Connect all hoses and electrical wiring dis-
connected during the removal of the cylinder head.
Ensure that all the hoses are returned to their original
locations. (12) Connect the throttle cable and where appli-
cable, the kickdown cable. Adjust the cables as
described in the Fuel and Engine Management section
and the Automatic Transaxle section. (13) Check the engine oil fo r correct level on the
dipstick and for dilution. Change the engine oil and
filter if necessary. (14) Fill the cooling system as described in the
Cooling and Heating Systems section. (15) Start the engine and check for oil or water

54 Engine
in the valve stem groove before releasing the spring
compressor. A sharp tap to the top of the valve stem
with a soft faced hammer will ensure that the collets
are correctly seated.

(7) Install the inlet and exhaust manifolds using
new gaskets and tighten the mounting nuts to the
specified torque as previously described. (8) Install a new sealing ring to the
thermostat
housing, install the housing to the cylinder head and
tighten the mounting bolts to the specified torque.
(9) Ensure that the lappet assemblies are filled
with clean engine oil and install the tappets in
their
respective bores in the cylinder head. (10) Install the thrust pads to the top of each
valve
assembly, ensuring that they are returned to their
original locations. (11) Coat the contact surfaces of the rocker arms
with molybdenum disulphide grease and install the
rocker arms to their origin al locations on the cylinder
head. (12) Install the cylinder head to the engine as
previously described.
8. ENGINE SUMP AND OIL PUMP PICKUP . PIPE

TO REMOVE
(1) Disconnect the negative battery terminal.
(2) Raise the front of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section for the correct procedure.
(3) Remove the sump plug and drain the engine
oil into a container. Install and tighten the plug
after the oil has been drained.
(4)
Remove the engine pipe as described at the
end of this section.
(5) Remove the nuts and bolts retaining the
engine crossmember to the vehicle underbody and
withdraw the crossmember from the vehicle. On
automatic transaxle models, it will be necessary to
release the selector cable from the crossmember
bracket.
(6) Remove the sump retaining bolts and wash-
ers and if necessary firmly bump the sump with the
palm of the hand and remove it from the engine. (7) Remove the bolts retaining the oil pump
pickup pipe to the oil pump and disconnect the
pickup pipe from the support bracket. Remove the
pickup pipe and discard the O ring seal. (8) Remove the scraper and gasket from the
engine. (9) Clean the gasket material from the sump,
engine block and the scraper.
NOTE: If the scraper assembly is damaged
it should be renewed.

TO INSTAL
(1) Wash the inside of the sump to remove
carbon and sludge deposits. Check for any metal
deposits which may indicate an imminent component
failure. (2) Inspect the sump for dents and cracks.
Ensure that the gasket sea ling face is not distorted or
damaged. (3) Clean the pickup pipe screen with solvent
and a brush. (4) Using a new O ring seal, install the pickup
pipe. Coat the pipe retain ing bolts with Loctite 242
and tighten to the specified torque. (5) Apply a bead of KP510-00150 sealer or
equivalent to the oil pump to cylinder block mating
joint area. (6) Ensure that the sump gasket is correctly
located on the scraper and install the sump to
the
engine. Apply Loctite 242 to the threads of the sump
bolts and tighten the bolts to the specified torque.
(7) Install the front exhaust pipe using a
new
gasket and coat the threads of the flange nuts with an
anti-seize compound before tightening the nuts to the
specified torque. (8) Install the engine crossmember and
tighten
the nuts and bolts securely. If applicable, connect the
automatic transaxle selector cable to the crossmember
bracket. (9) Ensure that the sump drain plug is secure
and lower the vehicle to the ground. (10) Fill the engine with the specified amount and
grade of engine oil. Refer to the Lubrication and
Maintenance section if necessary. (11) Start and run the engine and check for oil
leaks.
View of the sump, oil pump pickup, gasket and scraper
removed from the engine.

Engine 65
(4) Hold the nut and remove the mounting
through bolt. (5) Remove the bolts retaining the mounting to
the transaxle and maneuver the mounting from the
engine compartment. (6) If necessary remove the bolts retaining the
support bracket to the inner mudguard and withdraw
the support bracket. Installation is a reversal of the removal procedure
ensuring that the weight of the engine is bearing on
the engine mounting before tightening the through
bolt securely.

TO RENEW RIGHT HAND SIDE MOUNTING
(1) Disconnect the negative battery terminal.
(2) On 1.8 liter models, remove the air cleaner
assembly. Refer to the Fuel and Engine Management
section if necessary. (3) Support the engine under the sump using a
jack. Interpose a block of wood between the head of
the jack and the sump to prevent damage.
(4) Hold the nut and remove the mounting
through bolt and rubber. (5) Remove the bolts retain ing the mounting to
the inner mudguard and maneuver the mounting
from the engine compartment. (6) If necessary, remove the nuts and bolts
retaining the support brackets to the engine assembly
and withdraw the support brackets.

Installation is a reversal of the removal procedure
ensuring that the weight of the engine is bearing on
the engine mounting before tightening the through
bolt securely.

TO RENEW FRONT TORQUE DAMPER
(1) Raise the front of the vehicle, remove the
splash guard fasteners and remove the splash guard(s)
from the front of the vehicle.
(2) Remove the through bolts and nuts from the
torque damper.
NOTE: It may be necessary to unclip the
wiring harness from the lower radiator sup-
port panel to gain access to the front through
bolt.


Dismantled view of the front torque damper. The arrow of the engine bracket must face upwards.
(3) Withdraw the torque damper from the
engine.
(4) If necessary the support brackets can be
removed. Installation is a reversal of the removal procedure
ensuring that the arrow on the engine bracket faces
upwards.

TO RENEW REAR ENGINE MOUNTING AND
TORQUE DAMPER

Automatic and manual transaxle models both use
a similar rear engine moun ting with different support
brackets. Manual transaxle models use a rear torque
damper.

(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the stabilizer bar mounting bracket
bolts and allow the rear of the stabilizer bar to hang
down slightly. (3) Remove the nuts and bolts retaining the
engine crossmember to the vehicle underbody and
withdraw the crossmember from the vehicle.
Dismantled view of the right hand side engine mount-
ing assembly.

66 Engine

View of the rear engine mounting. Automatic transaxle models.
(4) Remove the bolt retaining the exhaust
mounting to the engine mounting bracket. (5) Remove the engine mounting through bolt.
(6) Remove the bolts and nuts retaining the
engine mounting to the floor panel and remove the
mounting from the vehicle.
(7) On manual transaxle models, the torque
damper can be removed after removal of the through
bolts and nuts. (8) If necessary, remove the bolts retaining the
support bracket to the engine and withdraw the
support bracket.
Installation is a reversal of the removal procedure.

14. EXHAUST SYSTEM
TO REMOVE AND INSTAL

Engine Pipe
(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the nuts retaining the engine pipe to
the exhaust manifold flange.

NOTE: It is advisable to soak all exhaust
system nuts and bolts wi th penetrating oil to
prevent breakage when removing.

(3) Remove the bolts from the flexible joint and
withdraw the engine pipe from the vehicle. Discard
the gasket.

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

(1) Clean any carbon build up from the exhaust
flange and pipe joints. (2) Inspect the condition of the flexible joint
spring. Renew the engine pipe assembly if necessary. (3) Use a new exhaust manifold flange gasket
and coat the manifold studs with anti-seize com-
pound. (4) Ensure that all nuts and bolts are tightened
securely.
Rear System

(1) Raise the front and rear of the vehicle and
support it on chassis stands. (2) Loosen the clamp securing the tailpipe and
muffler assembly to the rear pipe. (3) Remove the mounting bolts and slide the
tailpipe and muffler assembly from the rear pipe.
NOTE; Should difficulty be experienced
when separating the exhaust pipes, they
may be cut with a hacksaw or pipe cutter if
a replacement system is to be installed.

If heat is used to loosen frozen joints take
extreme care near floor panels, fuel and
brake lines or electrical wiring.

(4) Remove the bolts from the intermediate pipe
and rear pipe mountings and lower the exhaust
system. Use care not to drop the catalytic converter.
(5) If necessary the cataly tic converter can be
removed from the intermediate pipe and the rear pipe
assembly by removing the retaining bolts.

Underbody view of the exhaust system. Underbody view of the tailpipe and muffler.

78 Cooling and Heating Systems
The air conditioner operates only when the engine
is running as the compressor is belt driven from the
engine.

Operating the air conditioner with the tempera-
ture control raised to a hot setting will produce
dehumidified hot air which is particularly useful for
demisting the vehicle glass.

Maximum cooling is achieved by operating the air
conditioner with the temperature control lowered
fully to the coldest setting . Operate the fan at high
speed when using the coldest temperature setting to
avoid forming ice on the evaporator.

TO REMOVE AND INSTAL HEATER UNIT
(1) Remove the dashboard as described in the
Body section. (2) Drain the cooling system as previously de-
scribed in this section. (3) Loosen the hose clamps and disconnect the
heater hoses from the heater pipes.
NOTE: If the heater hos es will not come off
the heater pipes, do not use excess force or
the heater core retaining strap will be dam-
aged. Cut the hoses from the heater pipes.

(4) Remove the steering column upper mount-
ing bolts. (5) Remove the steering column cross support
bolts and move the support towards the right hand
side of the vehicle. (6) Remove the centre support retaining bolts
and remove the centre support from the vehicle.
(7) Remove the demister duct and the right
hand side ventilator duct from the vehicle. (8) Disconnect the blower fan wiring connector
from the rear of the heater controls. (9) Remove the heater retaining bolts.
(10) On models with air conditioning, it will be
necessary to loosen the evaporator mounting bolts. (11) Working in the engine compartment, push
the heater pipe grommet through the bulkhead. (12) Maneuver the heater unit upwards slightly
and out from the bulkhead using care not to damage
the heater pipes. (13) To remove the heater core and tap assembly,
remove the screws from the retaining strap and slide
the heater core from the heater unit.
Installation is a reversal of the removal procedure
with attention to the following points:

(1 ) Before installing the heater unit to the

View of the heater unit with the dashboard, centr e support, demister duct and right hand ventilator
duct removed.

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.

Fuel and Engine Management 85


View of the 1.6 liter engine showing the engine management components. Air cleaner removed for clarity.
series of tests on various components in the system
and records the results, If a fault is discovered, the
ECM warning lamp on the instrument cluster will
illuminate while the engine is running. When the self
diagnosis mode is activated, the ECM warning lamp
will flash codes indicating the area in which the fault
has occurred.

This function is very useful in locating system
faults, particularly intermittent problems. However,
the self diagnosis mode does not provide comprehen-
sive testing of the EFI system, and therefore should
always be used in conjunction with the other test
procedures described later in this section in order to
accurately locate system faults.

The high energy electronic ignition system con-
sists of a distributor and an ignition coil.

The distributor has two functions. The first is to
produce and distribute secondary high tension voltage
to the spark plugs.

The second function is to provide the control unit
with information on engine speed and crankshaft
position.

The ignition timing is constantly adjusted by the
control unit to suit varying engine and vehicle oper-
ating conditions.

In the fuel injection system, a metered amount of
fuel is sprayed into the air stream. The air/fuel

mixture then enters the combustion chamber via the
inlet valves.

On 1.6 liter engines, the fuel is injected by a single
injector, located above the throttle valve within the
throttle body assembly. The injector fires twice per
engine revolution under most operating conditions.

On 1.8 liter engines, four injectors are used. The
fuel is distributed to the injectors via the fuel rail. All
injectors fire simultaneous ly once per engine revolu-
tion under most operating conditions.

Under conditions of high load the control unit
may signal the injector(s) to fire more often. However,
if the engine speed exceeds 6 700 rpm the control unit
will cease firing the injectors until the engine speed is
below 6 200 rpm.

Fuel is supplied under pressu re by an electric fuel
pump mounted in the fuel tank and the pressure is
regulated by a pressure regulator.

On 1.6 liter engines, the regulator consists of a
spring tensioned diaphragm which is mounted to the
side of the throttle body assembly. The fuel pressure is
regulated by the tension of the spring against the
diaphragm, opening and closing the fuel return port.

On 1.8 liter engines, the pressure regulator is
mounted adjacent to the fuel rail and consists of a
diaphragm with fuel pressu re acting on one side and
spring tension and manifold vacuum acting on the

86 Fuel and Engine Management
other. The fuel pressure is maintained at a constant
pressure relevant to the manifold vacuum. A dispos-
able paper element fuel filter is mounted on the engine
bulkhead.

The amount of fuel injected is relevant to the time
the injector remains open. The basic time the injector
remains open is governed by the control unit which
uses information from the various sensors to give
optimum engine efficiency for given conditions.

The idle air control (IAC) valve controls the fast
idle speed during engine warm up and maintains the
basic idle speed at a set value by compensating for
loads such as air conditioning or the selection of Drive
on automatic transaxle models.

The throttle body assembly is mounted to the
inlet manifold and controls the amount of air entering
the engine by the action of the throttle valve.

Efficient operation of the EFI system depends on
accurate signals being receiv ed by the control unit and
controlled air flow beyond the throttle valve. There-
fore it is essential that all air, fuel and electrical
connections be clean and tight.

3. SERVICE PRECAUTIONS AND
PROCEDURES

Electronic ignition systems can produce danger-
ously high voltages in both the primary and secondary
circuits. For this reason, extreme care must be taken
when working on or near the ignition system.

Do not start the engine if the battery terminals are
not clean and tight.

Do not use the fast charge or boost settings on a
battery charger to start the engine.

Do not disconnect the battery terminals while the
engine is running.

Disconnect the battery terminals before charging
the battery.

Disconnect the negative ba ttery terminal before
working on the engine management system.

Do not subject the control unit to temperatures
above 80 deg C.

Ensure that all wiring connectors are clean and
tight.

Disconnect the battery terminals and the control
unit wiring connectors before attempting any welding
operations.

Do not direct a steam cleaning or pressure
washing nozzle at engine management components
when cleaning the engine.

Ensure that the ignition is Off prior to disconnect-
ing the battery terminals, fusible links or the control
unit wiring connectors.

TO CONNECT ELECTRICAL TEST
EQUIPMENT

NOTE: Some types of tachometers, timing
lights and ignition system analysers are not
compatible with this engine management
system and may result in incorrect readings.
It is therefore recommended that the man-
ufacturer of the lest equipment be consulted
before proceeding to use the equipment.

If a test procedure requires the use of a
test lamp or voltmeter, ensure that only the
specified instrument is used to prevent mis-
leading diagnosis.

MULTIMETER
It is essential that in all tests where voltage or
resistance is to be measur ed, a digital display multi-
meter with a minimum 10 megohms impedance be
used.


The correct method of backprobing the wiring connec-
tors. The meter test probe should be modified with a piece of thin wire as shown.
All meter readings are to be performed with the
component wiring connectors installed unless other-
wise instructed. This can be done by inserting the
meter test probes from the wiring harness side of the
connector or backprobing. If the test probes are not
thin, they should be modified by attaching a thin piece
of wire to the end, giving a fine point that will not
damage the connector. Ensure that the wire is making
good contact with the probe.

If sealing plugs or boots are removed from wiring
connectors to facilitate bac kprobing, ensure that they
are correctly installed at the conclusion of the test
procedure.

To identify wiring connector terminals refer to the
wiring circuit diagrams.

Test Lamp
To avoid damage to the electronic components
when testing, the use of an LED (light emitting diode)
test lamp is recommended.