1987 NISSAN PULSAR brake

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.

Front Suspension 161


View of the suspension unit and knuckle assembly removed as a unit to show the cam head bolt.
(1) With the piston rod fully extended, install the
coil springs. Ensure that the spring compressor is
tightened sufficiently.

NOTE: The flat coiled end of the spring
should face the top and the lower end of the
spring should be located correctly.

(2) Install the dust cover, bump rubber, insulator,
spring seat, thrust washer and mounting assembly
ensuring that the arrow on the spring seat will face the
outside of the vehicle when the suspension unit
assembly is installed.
(3) Install the piston rod nut and tighten the nut
securely.
(4) Remove the coil spring compressor from the
suspension unit assembly and tighten the piston rod
nut to the specified torque. (5) Install the suspension unit assembly to the
vehicle, holding it in position by loosely installing the
upper mounting retaining nuts. (6) Install the suspension unit assembly lower
mounting to the steering knuckle, align the mating
marks on the cam head bolt and tighten the nuts and
bolts to the specified torque.
NOTE: If the cam head bolt is not installed

in its original position, a wheel alignment
must be performed.

(7) Tighten the upper retaining nuts to the
specified torque.
(8) Install the brake hoses to the suspension unit.
Lower the vehicle to the ground.
(9) Check the front wheel alignment and adjust
as necessary. Refer to the Suspension and Steering
Angles heading in this section.
5. CONTROL ARM
Special Equipment Required:
To Renew Ball Joint and Control Arm Bushes —
Press, suitable t ubes and mandrels
To Test Ball Joint — Small torque wrench or
preload gauge, spring scale

TO REMOVE AND INSTAL
(1) Loosen the front wheel nuts, raise the front
of the vehicle and support it on chassis stands.
Remove the front wheel.

(2) Remove the split pin from the ball joint
retaining nut and remove the nut.
(3) Disconnect the ball joint from the control
arm using a suitable puller, or alternatively place a
suitable dolly against one si de of the control arm eye
and strike the opposite side with a hammer until the
ball joint stud is free from the control arm eye. (4) Remove the nut retaining the stabilizer link
to the control arm.

(5) Remove the nut and through bolt from the
front control arm bush. (6) Remove the bolts from the rear control arm
bush bracket and withdraw the control arm from the
vehicle. (7) Inspect the control arm for cracks, damage
and distortion and renew if necessary. (8) Inspect the ball joint and bushes for damage,
deterioration and excessive wear. If necessary renew
BALLJOINT
View of the control arm and associated components.

Rear Suspension 165


Checking the rear control arm outer pivot bolt for security.
(5) Loose or worn control arm bushes or pivot
bolts: Check and tighten or renew the worn compo-
nents.

NOTE: Check the service ability of the sus-
pension units, control arm bushes and pivot
bolts as previously described.

If incorrect rear wheel alignment is sus-
pected, it is recommended that the vehicle be
taken to a wheel alignment specialist or a
Nissan dealer to be checked and if necessary
adjusted.

Visually inspect the stabilizer bar for
damage.

2. DESCRIPTION
The independent type rear suspension consists of
a suspension unit, a knuckle assembly which incorpo-
rates the stub axle, inboard control arms and a
stabilizer bar.

The suspension unit consists of a sealed, oil filled
shock absorber, enclosed at the upper end by a coil
spring on which an upper mounting assembly is
located and attached to the body.

The shock absorber piston rod is attached to the
centre of the suspension unit upper mounting assem-
bly.

The lower end of the suspension unit is attached
to the knuckle assembly to which the brake caliper
and/or the brake backing plate is mounted.

The control arms are attached to the knuckle
assembly at the outer end, and the crossmember at the
inner end.

The stabilizer bar is attached to the knuckle
assembly and mounted to the underbody. As well as
reducing body roll when cornering it also secures the
knuckle assembly, preventing fore and aft movement.

Adjustment of the toe out is provided by a
graduated cam mounted on the rear control arm inner
pivot bolt. Each graduation on the cam is equivalent
to 2 mm adjustment.

Camber is set in production and cannot be
adjusted. If the camber is not within Specifications,
inspect the suspension components and renew the
damaged or worn components as necessary.


Installed view of the rear suspension.

166 Rear Suspension

3. REAR HUB
Special Equipment Required
To Check Hub Bearing End Float — Dial gauge
To Renew Bearing — Press and suitable drift

TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the rear wheel and release
the handbrake.

(2) On models with rear drum brakes, proceed
to operation (6).
(3) Remove the clip securing the brake hose to
the suspension unit and disengage the hose.
(4) Remove the bolts securing the brake caliper
to the knuckle assembly. (5) Slide the caliper from the disc and support it
away from the working area, ensuring that no excess
strain is placed on the brake hose. (6) Rotate the hub and check that it rotates
smoothly. If it does not rotate smoothly, renew the
hub bearing. (7) Mount a dial gauge with the plunger posi-
tioned against the outer face of the hub. Move the hub
back and forth in line with the stub axle and note the
reading on the dial gauge. If the end float exceeds
Specifications, renew the hub bearing.
(8) Remove the hub grease cap from the rear
hub. (9) Remove the split pin from the stub axle and
remove the nut retainer, the hub retaining nut and
washer. Remove the hub assembly from the stub axle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the hub retaining nut to the specified
torque. (2) Check the hub bearing end float as previ-
ously described.
(3) On models with disc brakes, install the brake

caliper and tighten the retaining bolts to the torque
specified in the Brakes section. Install the brake hose to
the suspension unit and secure with the retaining clip.

TO RENEW BEARING
(1) Remove the rear hub as previously de-
scribed. (2) Remove the snap ring from the rear of the
hub assembly. (3) Support the rear of the hub around the
bearing housing, ensuring that the bearing will not be
obstructed when being pressed out. (4) Using a suitable drift, press the bearing out
of the hub.

Dismantled view of the rear hub assembly. Drum brake
model.

Tightening the hub retaining nut with a torque wrench. Dismantled view of the rear hub assembly. Disc brake
model.

Rear Suspension 167

NOTE: When a wheel bearing has been
removed from the hub it must be renewed.

(5) Press the new bearing into the hub, ensuring
that pressure is not exerted on the inner race of the
bearing and that the bearin g seal is not damaged. Do
not apply grease or oil to the mating surfaces of the
bearing and the hub.

NOTE: When installing the new bearing,
the press load must not exceed 3 tonnes.

(6) Inspect the snap ring for wear or cracks and
renew as necessary. Install the snap ring into the hub
ensuring that it is secur ely located in the groove.
(7) Apply multi-purpose grease to the bearing
sealing lip and install the hub as previously described.
4. SUSPENSION UNIT

Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) On hatchback models, remove the rear par-
cel shelf and lower the rear seat backrests. Remove the
parcel shelf side panel re taining screws and remove
the relevant side panel.
(2) On sedan models, prise out the parcel shelf
retaining buttons using a suitable instrument and
withdraw the parcel shelf from the vehicle. If the rear
radio speakers are installed, remove the speaker grille
retaining screws and separate the speaker grilles from
the speakers prior to withdrawing the parcel shelf
from the vehicle. (3) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section. Remove the rear wheel from the vehicle.

View of the suspension unit with the spring compres-
sors installed.
(4) Remove the clip securing the brake hose to
the suspension unit and disengage the hose from the
suspension unit. (5) Support the weight of the knuckle assembly
and remove the bolts and nuts securing the suspension
unit to the knuckle assembly.
(6) Remove the nuts securing the suspension
unit to the body panel and maneuver the suspension
unit from the vehicle. (7) Thoroughly clean the suspension unit and
secure it in a soft jawed vice.
(8) Remove the dust cap from the upper mount-
ing and while holding the end of the piston rod with
an adjustable spanner, loosen the upper mounting
retaining nut. Do not re move the retaining nut.
(9) Using a suitable spring compressor, com-
press the coil spring and remove the upper mounting
retaining nut and washer. (10) Remove the upper mounting, insulator and
spring seat from th e suspension unit.
(11) Withdraw the upper insulator, coil spring,
lower insulator and dust cover from the suspension
unit. (12) Check the coil spring for cracks, deformation
and damage. Compare the free length with a new coil
spring and renew as necessary.
Location of the suspension unit retaining nuts. Hatch-
back model.

168 Rear Suspension
NOTE: If a coil spring is defective it is
advisable to renew both coil springs as a
matched set.

(13) Check the spring seat for cracks, deforma-
tion or wear and renew as necessary.
(14) Check the upper mounting and the insulator
for wear, damage, signs of melting rubber or deterio-
ration. (15) Check that the piston rod is not cracked,
bent or damaged.

Dismantled view of the suspension unit.
(16 ) Check the hydraulic operation of the suspen-
sion unit. With the suspension unit vertical, move the
piston rod up and down severa l times. A firm pressure
with no slack spots should be evident in both direc-
tions. Also check the suspen sion unit for fluid leakage.
If fluid leakage is present, renew the suspension unit,
preferably in pairs.

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

(1) Install the coil spring and lower insulator to
the suspension unit ensuring th at the flat end of the
spring is positioned at the top and the lower end of the
spring is located correctly in the suspension unit.

(2) Install the remaining co mponents to the sus-
pension unit, ensuring that the arrow on the spring
seat will be facing the stub axle when installed.
(3) Install a new upper mounting retaining nut,
tighten to the specified tor que and remove the spring
compressor. (4) Position the suspension unit inside the rear
wheel housing and maneuver the mounting studs
into position. With the aid of an assistant, install the
suspension unit retaining nuts and tighten to the
specified torque.

View of the suspension unit removed from the vehicle.
(5) Install the bolts securin g the suspension unit
to the knuckle assembly and tighten the nuts to the
specified torque.
(6) Install the brake hose to the suspension unit
and secure with the retaining clip. (7) Install the rear wheel and lower the vehicle to
the ground. (8) On hatchback models, install the parcel shelf
side panel and the parcel shelf. (9) On sedan models, install the parcel shelf and
insert the retaining buttons firmly. If removed, install
the radio speaker grilles.