1987 NISSAN PULSAR steering

90 Fuel and Engine Management
To identify the code number, count the number of
times the ECM warning lamp flashes. Each fault code
comprises two groups of flashes separated by a 1.2
second pause. The first group represents tens and the
second group represents single units. For example 1
flash followed by a 1.2 second pause followed by 4
flashes would be code number 14. Similarly 4 flashes
followed by a 1.2 second pause followed by 2 flashes
would be code number 42.

The code will be displayed three times. If more
than one fault code is present, the self diagnosis
system will indicate each one in numerical order, with
a 3.2 second pause between each code, and then
repeat the sequence.

The fault codes can be identified as follows:
CODE NUMBER FAULT AREA
12 Satisfactory operation
13 Oxygen sensor open circuit
14 Coolant temperature sensor circuit (voltage low)
15 Coolant temperature sensor circuit (voltage high)
21 Throttle position sensor circuit (voltage high)
22Throttle position sensor circuit (voltage low)
23MAT sensor circuit (voltage' high) 1.8 liter engine
only
24 Vehicle speed sensor circuit
25 MAT sensor circuit

(voltage low) 1.8 liter engine
only
33 MAP sensor circuit

(voltage high)
34MAP sensor circuit (voltage low)
42 Electronic spark timing circuit
44
Oxygen sensor circuit

(lean exhaust)
45Oxygen sensor circuit (rich exhaust)
51 Mem-Cal
55 Control unit input circuits
Test Procedure
(1) Perform the following checks:

(a) Ensure that the battery voltage is above 11
volts. (b) Ensure that the throttle valve is fully closed.
(c) Place the transaxle in neutral.
(d) Ensure that the air conditioner, fan, tights
and all other accessories are switched off.
(2) Turn the ignition On and confirm that the
ECM warning lamp on the instrument cluster is
illuminated but not flashing.

If code 55 is displayed, refer to the Control Unit
heading, perform the circuit test procedure and rectify
the cause of the code before proceeding.

If the ECM warning lamp flashes codes other than
code 55, check the wiring harness between the diag-
nostic link connector terminal B and the control unit
wiring connector terminal A9 for shorts. Repair or
renew the wiring harness as necessary.

If no fault can be found, renew the control unit.
If the ECM warning lamp does not illuminate,
proceed as follows:

(a) Check the METER fuse located in the fuse
panel adjacent to the steering column and the fusible
links located in the fusible link connecting block at the
rear of the battery. Renew the fuse or fusible links as
necessary. (b) Check the wiring harness to the instrument
cluster. Repair or renew the harness. (c) Check the Check Engine lamp bulb. Renew if
necessary. (d) Check the EGI relay. Renew as necessary.
(3) Connect a jumper lead across terminals A
and B on the diagnostic link connector located under
the front passengers seat above the control unit.
(4) Note the codes indicated by the flashing
ECM warning lamp.
If code 12 is displayed, the system is operating
correctly.

If codes other than code 12 are displayed, refer to
the component or circuit test procedure under the
appropriate heading as indicated by the code number.

If more than one code is being displayed, test each
indicated fault working in the order of display of the
code numbers.

(5) After completing the self diagnosis test pro-
cedure, remove the jumper lead from the diagnostic
link connector. (6) After repairing or renewing the necessary

View showing the location of the diagnostic link
connector. Passengers seat removed for clarity.
Inset shows the diagnostic link connector terminal identification.

108 Fuel and Engine Management


Installed view of the control unit with the passengers seat removed.
(2) Secure the Mem-Cal unit retaining clips.
Ensure that the clips locate into the Mem-Cal unit. (3) When installing a new control unit, transfer
the identification and bar code label to the new
control unit. (4) Ensure that the control unit wiring connec-
tors are securely installed to the control unit. (5) Activate the self diagnosis codes. If code 51
is displayed or the Check Engine warning lamp is
constantly illuminated, the Mem-Cal unit is not fully
installed. If the Mem-Cal uni t is installed correctly, a
fault in the Mem-Cal unit is indicated. Renew the
Mem-Cal unit as previously described.
To Check Power Supply and Earth Circuit

(1) Disconnect the control unit wiring connec-
tors and check for voltage at terminals B1 and C16.

If there is no voltage check the fusible link which
is located third from the front in the fusible link
connecting block. If the fu sible link is serviceable,
repair the open circuit in the wiring harness.

(2) Check for continuity to earth on terminals
A12, D1, D6 and also D3 and D10 on 1.8 liter
engines.

If there is no continuity check the earth connec-
tions at the right hand rear cylinder head bolts. If the
connections are clean and secure, repair the open
circuit in the wiring harness.

MEM-CAL UNIT
To Test - Code 51

If code 51 is displayed during the self diagnosis
test procedure, pr oceed as follows:

(1) Check that the Mem-Cal unit is fully inserted
in the control unit. (2) Erase the fault code memory and retest for
fault codes. (3) If code 51 is still displayed, renew the
Mem-Cal unit.
(4) Erase the fault code memory and retest for
fault codes. (5) If code 51 is still displayed, renew the control
unit.
To Remove and Install

The Mem-Cal unit is incorporated within the
control unit. Refer to the previous heading for the
removal and installation procedure.

FUEL PUMP AND EGI RELAYS
To Remove and Install
(1) Disconnect the negative battery terminals.
(2) Remove the fuse panel cover which is lo-
cated adjacent to the steering column under the
instrument cluster. (3) Remove the spare fuse holder from the fuse
panel and remove the releva nt relay from the connec-
tor. Installation is a reversal of the removal procedure.


View showing the location of the EGI and fuel pump
relays.
To Test Relays
NOTE: When testing the fuel pump relay
circuit ensure that th e EGI relay is service-
able and installed to the relay connector

(1) Remove the relevant relay as previously
described. (2) Using an ohmmeter, check for continuity
between terminals 1 and 2, and 3 and 5. Continuity should exist be tween terminals 1 and 2
but should not exist between terminals 3 and 5.

(3) Using suitable jumper leads, apply 12 volts
to terminal 1 and connect terminal 2 to a good earth
point. (4) Connect the ohmmeter between terminals 3
and 5. Continuity should exist. If continuity does not
exist, renew the relay.

Manual Transaxle and Drive Shafts 137


Dismantled view of the gear lever assembly.
(7) Remove the bushes, spacer and O rings from
the bottom of the gear lever.
(8) Remove the nuts retaining the floor bracket
to the vehicle floor panel and remove the bracket from
the vehicle. (9) If necessary, disconnect the control rod and
the support rod from the transaxle and remove the
rods from the vehicle. (10) Check all the components for deterioration,
wear and damage. Renew the unserviceable compo-
nents as necessary. Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Install all the components to the locations
noted during dismantling.
(2) Lubricate all the pivot points with multipur-
pose grease prior to assembly. (3) Tighten all the nuts securely.
(4) Road test the vehicle and check for correct
gear selection.
6. DRIVE SHAFTS

TO REMOVE AND INSTAL
(1) Remove the dust cap from the centre of the
front hub. Remove the split pin and nut retainer from
the outer end of the drive shaft. (2) With an assistant applying the brakes, loosen
the nut on the outer end of the drive shaft.
(3) Raise the front of the vehicle and support it
on chassis stands. If necessary, refer to the Wheels and
Tires section for the correct jacking points.

Assembled view of the left hand side drive shaft
assembly.
(4) Remove the split pin and castellated nut
retaining the tie rod to the steering knuckle. (5) Disconnect the tie rod end from the steering
knuckle using a suitable puller or alternatively place a
hammer or dolly on one side of the steering knuckle
and strike the opposite side with a hammer.
(6) Remove the split pin and castellated nut
retaining the suspension ball joint to the bottom of the
steering knuckle. (7) Disconnect the suspension ball joint from
the steering knuckle using a suitable puller or alterna-
tively place a hammer or dolly on one side of the
steering knuckle and strike the opposite side with a
hammer. (8) Remove the retaining bolts and remove the
brake caliper from the stee ring knuckle. Refer to the
Assembled view of the right hand side drive shaft
assembly.

138 Manual Transaxle and Drive Shafts
Brakes section if necessary. Suspend the caliper with
wire or cord attached to the coil spring.

(9) Hold the steering knuckle and hub assembly
and tap the drive shaft out of the hub using a soft

faced hammer.
(10) Drain the oil from the transaxle into a
container.
(11) Prise the drive shaft out of the transaxle and
remove the drive shaft from the vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the drive sh aft is firmly attached
to the differential side gear by attempting to pull the
shaft out of the gear. (2) Tighten all nuts securely and install new split
pins. (3) Fill the transaxle with the specified grade and
quantity of oil.
TO DISMANTLE AND ASSEMBLE

(1) Remove the drive shaft from the vehicle as
previously described.
(2) Remove and discard both the inner C.V.
joint boot retaining clips from the inner C.V. joint. (3) Roll back the large en d of the inner C.V.-
joint boot using a thin blade screwdriver, prise out the
C.V. joint retaining ring.
(4) Withdraw the C.V. joint housing from the
drive shaft and ball assembly. (5) Remove the inner snap ring retaining the ball
assembly to the drive shaft and withdraw the ball
assembly. (6) Remove the remaining inner C.V. joint re-
taining snap ring and the C.V. joint boot from the
drive shaft. (7) Noting their installed positions remove the
cage and ball assembly off the inner race and press the
balls out of the cage. (8) Remove and discard the clips retaining the
outer C.V. joint boot to the drive shaft and remove
the C.V. joint boot.
NOTE: The outer C.V. joint cannot be
dismantled.

(9) Wash all parts in a suitable solvent and blow
dry with compressed air.
(10) Inspect the ball contact faces of the inner ball
race and C.V. joint housing for pitting and wear.

(11) Inspect the ball cage and the balls for wear
and damage. (12) Rotate the drive shaft with the outer C.V.
joint at a sharp angle and inspect the internal
components of the outer C.V. joint for wear and
damage. Renew if necessary by tapping the C.V. joint
from the drive shaft.
NOTE: Do not reuse the retaining snap ring
if the C. V. joint is removed from the drive
shaft.

(13) Check the C.V. joint boots for damage and
deterioration. (14) Renew all worn or damaged components as
necessary. Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Thoroughly pack the outer C.V. joint with
molybdenum disulphide grease. (2) Install the outer C.V. joint boot and retain in
position using new retaining clips. Ensure that the
boot and the clips ar e correctly seated.
(3) Install the inner C.V. joint boot, small
end
first, onto the drive shaft and pull it well down the
shaft. (4) Install the outer snap ri ng for the inner C.V.
joint into its locating groove in the drive shaft. (5) Position the inner ball race inside the ball
cage with the chamfered end of the ball race towards
the small end of the cage. (6) Press the balls firmly into the ball cage,
ensure that the balls are fully seated. (7) Install the ball assem bly onto the drive
shaft
with the small end of the cage towards the outer C.V.
joint and install the inner snap ring retaining the
ball
assembly onto the drive shaft.
(8) Pack the C.V. joint with the prescribed
amount of molybdenum disul phide grease. Refer to
Specifications. (9) Install the C.V. joint retaining ring into the
C.V. joint housing. Ensure that the retaining ring is
correctly seated.

Dismantled view of the inner C.V. joint. Install the ball assembly onto the drive shaft, with the
small end of the cage towards the outer C.V. joint.

145
STEERING
PART 1. STEERING TROUBLE SHOOTING
FAULTS, CAUSES AND REMEDIES
EXCESSIVE PLAY OR LOOSENESS IN
STEERING GEAR

(1) Tie rod end ball joint loose or worn: Tighten
or renew the worn tie rod end ball joint. (2) Steering gear assembly loose on cross-
member: Inspect for damage and tighten the steering
gear mounting bolts. (3) Steering gear worn: Overhaul the steering
gear.


(2) Low fluid level in the power steering reser-
voir: Check for leakage, repa ir and/or renew the faulty
components. Top up the fluid level.
(3) Suspension worn or out of alignment: Check
the front suspension for wear, renew the worn com-
ponents and realign. (4) Misalignment between the steering gear and
column mountings: Check and align the steering gear
and column mountings. (5) Binding in the steering shaft universal coup-
ling joints: Check the join ts and renew if necessary.
(6) Ingress of dirt into the steering gear due to a
defective boot: Clean, check and lubricate the internal
components of the steering gear and renew the
defective boot. (7) Insufficient power steering pump pressure:
Check the pump drive belt tension and reservoir fluid
level. If necessary renew the pump assembly.
NOTE: Ensure that both front tires have
ample depth of tread and are inflated to the
correct pressure. Check the front suspension
components for wear before having the steer-
ing geometry checked. See the Front Sus-
pension section for the component checking
procedures.


Check the tie rod ends for wear and the rubber boots for deterioration.
(4) Worn front hub bearings: Check the condi-
tion and renew the front hub bearings. (5) Worn or damaged front suspension control
arm bushes: Renew the control arm or bushes.
NOTE: Looseness in th e steering linkage is
best assessed with the weight of the vehicle
on the front wheels. Have an assistant turn
the steering wheel from left to right while the
inspection for wear is being made. If loose-
ness is found to be in the steering gear, it
will be necessary to overhaul the steering
gear assembly.

HEAVY STEERING
(1) Low or uneven tir e pressures: Check the
tires and inflate to the recommended pressures.


Checking the steering rack boot s for splits and deteri-
oration.

146 Steering — Part 1

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

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

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

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

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

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

147
PART 2. MANUAL STEERING
SPECIFICATIONS
Steering gear type ............................ Rack and pinion
Steering column type ...................... Energy absorbing
collapsible and tilt adjustable
Steering wheel free play

(maximum ) ...................................................... 35 mm
Linkage........................... Direct from rack ends to t i e
rods and steering knuckles
Turns lock to lock ................................................. 3.6
Steering column length .................. 534.7-537.3 mm
Steering gear lubricant.............. Castrol EPL 1 grease
TORQUE WRENCH SETTINGS
Steering wheel retaining nut ............................ 39 Nm
Steering gear to bulkhead
mounting bolts .............................................. 108 Nm
Tie rod to steering knuckle nut...................... 98 Nm
Tie rod to tie rod end locknut ....................... 98 Nm
Tie rod ball housing to rack............................ 88 Nm
Steering column to mounting
bracket bolt ...................................................... 14 Nm
Steering column universal
coupling joint pinch bolts ............................... 29 Nm
2. STEERING WHEEL
Special Equipment Required:
To Remove Steering Wheel - Steering wheel
puller

TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Using a small screwdriver, carefully prise the
centre ornament from the steering wheel.

View of the steering wheel removed from the vehicle.
Steering wheels may vary between models.

1. DESCRIPTION
The steering gear is a rack and p i n i o n type
which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.

The design of this assembly requires a range of
special tools to dismantle and assemble the steering
gear. If the steering gear is found to have a fault which
requires overhaul of the rack and pinion, it is recom-
mended that this be performed by an authorized work-
shop or steering specialist.

However, the procedures for the removal and
installation of the steering gear and the renewal of the
tie rods, the tie rod ends and the rubber boots are fully
covered in this section.

The rack and pinion assembly requires no lubri-
cation during service.

The steering column is of the energy absorbing
type designed to compress in the event of a severe
front end collision. The energy absorbing units are the
outer steering column, the tilt bracket and the steering
shaft. All these units shoul d be handled with extreme
care if service operations are performed on the
steering column assembly.

(3) Remove the steering wh eel retaining nut and
mark the steering shaft and steering wheel hub in
relation to each other as an aid to assembly.
(4) Remove the steering wheel from the steering
shaft.
NOTE: If the steering wheel will not sepa-
rate from the steering shaft, loosen the horn
pad retaining screws at the rear of the
steering wheel and withdraw the horn pad
after disconnecting the wire. A puller can
now be used to pull the steering wheel from
the steering shaft. Do not strike the end of
the steering shaft as sharp blows can cause
irreparable damage to the collapsible steer-
ing shaft.

(5) If necessary the steering wheel can be dis-
mantled as shown in the illustration.

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

(1) Apply a light coat of multipurpose grease to
the horn slip ring and the turn signal canceling pins.
(2) Ensure that the marks on the steering wheel
and steering shaf t are aligned.
(3) Tighten the steering wheel retaining nut to
the specified torque.

148 Steering — Part 2

3. STEERING COLUMN
Special Equipment Required:
To Remove Steering Wheel — Steering wheel
puller

TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working in the engine compartment, mark
the relationship between the steering shaft universal
coupling joint and the steering gear pinion shaft. (3) Remove the pinch bolts from the universal
joint. (4) Working inside the vehi cle, remove the steer-
ing wheel as previously described. (5) Remove the steering column shroud screws,
unclip the lower and upper covers and remove them
from the steering column. (6) Disconnect all the steering column wiring
connectors. (7) Remove the lower trim from underneath the
steering column.
(8) Fold back the insulator and remove the nuts
from the steering colu mn floor bracket.
(9) Remove the nuts from the lower steering
column bracket. (10) Remove the bolts from the tilt bracket
assembly. (11) Maneuver the steering column from the
vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Measure the dimension between the lower
bracket pin and the upper edge of the steering shaft as
shown in the illustration.

If the dimension is not as specified, the steering
shaft has collapsed and the steering column should be
renewed.

(2) Rotate the steering shaft in the column and
check the shaft bearing for roughness and damage.
Renew as necessary. (3) Inspect the steering shaft universal coupling
joints for wear and damage and renew as necessary. (4) Position the steering column assembly under

the dashboard ensuring that the floor bracket is
located correctly and that the steering shaft universal
joint is aligned with the steering gear pinion shaft
marks.

(5) Install all the steering bracket nuts and bolts
finger tight. (6) Install the universal coupling joint pinch bolts
and tighten securely.
(7) Tighten all the stee ring column nuts and
bolts securely. (8) Test the operation of all the steering column
controls when installation is complete.
TO DISMANTLE

(1) Remove the steering column assembly from
the vehicle as previously described. (2) Suitably mark the position of the universal
coupling joint and remove it from the steering shaft. (3) Mark the position of the rubber boot in
relation to the floor bracket and steering column.
Loosen the retaining bands and remove the boot and
floor bracket from th e steering column.
(4) Using snap ring pliers, remove the snap ring,
plain washer and wave washer from the upper end of
the steering shaft. (5) Loosen the combination switch retaining
screw, push the combination switch in, turn the switch
and remove it from the steering column. (6) Turn the ignition switch to the On position
and slide the steering shaft from the column assembly. (7) If necessary dismantle the tilt bracket com-
ponents after removing the through bolts. Note the
position of the components to aid assembly. (8) To remove and install the steering lock pro-
ceed as follows: (a) Remove the ignition switch retaining screw
and carefully withdraw the switch from the steering
lock bracket.

View of the steering column assembly removed from
the vehicle. Steering column length is shown as dimen- sion A. A - 534.7-537.3 mm. Dismantled view of the steering lock and ignition
switch assembly.