1987 NISSAN PULSAR check engine

Engine 47


Line drawing showing the dimensions for the fabrication of a camshaft drive belt adjusting tool.
(5) Release the clips securing the camshaft drive
belt outer cover to the inner cover and remove the
outer cover.
(6) Turn the engine in the direction of rotation
until the timing marks on the camshaft gear and the
inner cover are aligned and the timing marks on the
crankshaft pulley and the pointer on the inner timing
cover are also aligned.
(7) If the drive belt is to be reused, mark the
drive belt with an arrow to ensure that it is installed
in the original direction of rotation. (8) Remove the Allen head bolts securing the
crankshaft pulley to the crankshaft gear and remove
the pulley. (9) Loosen the water pump retaining bolts and
using the adjusting tool, rotate the water pump
housing to release the camsh aft drive belt tension.
NOTE: A drive belt tension adjusting tool
can be manufactured from a piece of 10 mm
thick steel to the dimensions given in the
illustration.

(10) Remove the inner cover lower retaining bolts
and maneuver the camshaft drive belt from the
camshaft and crankshaft gears. Do not rotate the
crankshaft or camshaft.

TO CHECK AND INSPECT
(1) Inspect the drive belt for any signs of wear,
damaged teeth or torn backing. Renew the belt if it is
contaminated by oil. Do not wash or clean a drive belt
in solvents. Any slight contamination may be wiped
off using a dry cloth.

NOTE: If the drive belt is contaminated
with oil, the crankshaft and camshaft oil


Dismantled view of the camshaft drive belt
components.
seals must be checked and any oil leak
rectified prior to installing a new drive belt.

(2) Check the water pump for rough or exces-
sively noisy operation. Ensure that the assembly slides
smoothly in the cylinder bloc k and that the seal is not
leaking. Refer to the Cooling and Heating Systems
section if it is necessary to renew the water pump
assembly. (3) Check the water pump, camshaft and crank-
shaft timing gears for any wear or damage.
Check the drive belt for the illustrated faults.

48 Engine

TO INSTAL
(1) Check that the camshaft and crankshaft
timing gears have not been moved and that the timing
marks are still aligned. It will be necessary to tempo-
rarily install the crankshaft pulley to check that the
timing marks are still aligned. (2) Install the drive belt to the crankshaft timing
gear around the water pump gear and onto the
camshaft timing gear.
NOTE: If the original drive belt is being
installed, ensure that the arrow marked on
the belt prior to removal is pointing in the
direction of rotation.

(3) Use the adjusting tool to turn the water
pump assembly sufficiently to engage the water pump
pulley with the drive belt. (4) Install the inner cover lower retaining bolt.
(5) Ensure that the drive be lt is correctly meshed
with the teeth of the camshaft, crankshaft and water
pump gears. Install the crankshaft pulley and tighten
the bolts to Specifications. (6) Adjust the drive belt as described under the
following heading.
(7) Install the drive belt outer cover and fasten
the retaining clips. (8) Install and adjust the alternator and if
equipped, the power steeri ng and air conditioning
drive belts as desc ribed in the Engine Tune-up section.
TO ADJUST

(1) Remove the alternator drive belt and if
equipped, the power steering and air conditioning
drive belts. (2) Release the clips securing the camshaft drive
belt outer cover to the inner cover and remove the
outer cover. (3) Turn the engine in the direction of rotation
until the timing marks on the camshaft and the inner
cover are aligned. (4) Loosen the water pump retaining bolts and
using the adjusting tool, rotate the water pump
housing to gain the required belt tension. The belt is
correctly tensioned when it can be grasped between
the thumb and forefinger midway between the cam-
shaft timing gear and the water pump gear and turned
ninety degrees from i t s operating position.
After the belt has been tensioned, tighten the
water pump retaining bolts to the specified torque.

NOTE: Over tensioning of the drive belt will
result in noisy operation and premature
wear of the belt.

(6) Install the outer drive belt cover.
(7) Install and adjust the alternator, and if
equipped, the power steering and air conditioning
drive belts as desc ribed in the Engine Tune-up section. 6. CAMSHAFT. ROCKER ARMS AND TAPPETS

Special Equipment Required:
To Check Camshaft — Dial gauge, Vee blocks and
micrometers
To Install — Drive belt adjusting tool
It is recommended that a new cylinder head
gasket is installed and the cylinder head bolts renewed
when the camshaft housing is removed.

TO REMOVE
(1) Disconnect the negative battery terminal.
Remove the nuts securing the earth wires to the
cylinder head bolts and remove the earth wires.
(2) On 1.6 liter models, remove the air cleaner
wingnuts and withdraw the air cleaner.
(3) Disconnect the engine breather hoses from
the camshaft housing and the camshaft housing top
cover. (4) Remove the camshaft housing top cover
retaining bolts and remove the top cover. Discard the
gasket.
(5) Remove the camshaft dr ive belt as described
under the previous heading. (6) Using an open ended spanner, hold the
camshaft between the inle t and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.
(7) Remove the distributor, distributor cap and
high tension leads. If necessary refer to the Fuel and
Engine Management section. (8) Check the camshaft end float before remov-
ing the camshaft from the engine. Mount a dial gauge
to the cylinder block with the plunger bearing on the
distributor drive end of the camshaft. (9) Lever the camshaft towards the dial gauge
and zero the gauge. Move the camshaft in the opposite
direction away from the dial gauge and note the
reading obtained. Check this measurement against
Specifications.

Checking the camshaft end float.

Engine 49


Dismantled view of the camshaft housing and components.
(10) If the measurement is not within Specifica-
tions, check the retaining plate and the retaining plate
groove in the camshaft for wear or scoring after
dismantling. Renew the defective parts as necessary
on assembly. (11) Disconnect the lower radiator hose and drain
the cooling system.
NOTE: If the coolant is to be reused, drain
the coolant into a clean container.

(12) Remove the bolts securing the camshaft
drive belt inner cover to the camshaft housing. (13) Remove the cylinder head bolts in the re-
verse order of the tighten ing sequence, backing off
each bolt a quarter of a turn then half a turn at a time
until the bolts are loose.
NOTE: Do not loosen the cylinder head
bolts while the engine is warm as distortion
of the cylinder head could result.

(14) Remove the cylinder head bolts and lift the
camshaft housing from the cylinder head. (15) The rocker arms, thrust pads and tappet
assemblies can now be removed from the cylinder
head. Number a rack from 1 to 8 and keep each
assembly in order so that they can be returned to their
original positions.
(16) From the distributor drive end of the cam-
shaft housing, remove the bolts securing the camshaft
retaining plate to the camshaft housing and remove
the retaining plate. (17) Withdraw the camshaft from the camshaft
housing taking care to supp ort the camshaft to avoid
scoring the inner surfaces of the camshaft bearings.
(18) With a pointed drift, tap a small hole in the
front face of the oil seal. Insert a self tapping screw in
the hole and using a pair of pliers, pull on the screw
to remove the oil seal from the housing. Discard the
oil seal.
TO CLEAN AND INSPECT

(1) Wash all parts in cleaning solvent and dry
with compressed air. Ensure that all oil ways in the
camshaft and rocker arms are free from obstruction.
(2) Check the camshaft lobes, the rocker arms. the thrust pads and the ta
ppet assemblies for pitting
and wear. The tappet assemblies are non-serviceable
and should be renewed as an assembly if wear is
apparent or internal damage is suspected.

(3) Support the camshaft at each end on Vee
blocks and using a dial gauge with its plunger bearing
on the centre journal, rotate the camshaft and check
for bend. (4) Using micrometers, measure the outside of
each camshaft journal and the inside of each camshaft
tunnel in the camshaft housing. Compare these mea-
surements to Specifications and renew defective parts
as necessary. (5) Check the retaining plate and the retaining
plate groove in the camshaft for wear and scoring.
Renew defective parts as necessary.

Dismantled view of the valve operating components.
TO INSTAL
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Lubricate the lip of a new oil seal with engine
oil and position the seal squarely in the camshaft
housing. Ensure that the li p of the seal faces towards
the inside of the camshaft housing. Tap around the
edge of the seal with a soft faced hammer until the seal
is fully seated in the recess in the camshaft housing. (2) Apply clean engine oil to the camshaft bear-
ings and camshaft journals. Insert the camshaft into
position taking care not to damage the bearings with
the edges of the cam lobes or journals. (3) Apply engine oil to the camshaft retaining
plate and position it in the groove in the camshaft.
Install the retaining bolts and tension the bolts to the
specified torque.

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

52 Engine
leaks and rectify as necessary. Check and if necessary
adjust the ignition timing as described in the Engine
Tune-up section.

(16) When the engine has reached normal oper-
ating temperature, tighten the cylinder head bolts
another 40-50 degrees in the correct sequence shown
in the illustration, ensuring that the tension does not
exceed 135 Nm.

TO DISMANTLE
(1) Remove the cylinder head as previously
described.
(2) Remove the thermostat housing and sealing
ring from the cylinder head.
(3) Remove the nuts securing the inlet and
exhaust manifolds to the cylinder head and remove
the manifolds. Discard the gaskets. (4) Lift the rocker arm and thrust pad from the
top of each valve assembly, keeping them in order for
assembly to their or iginal locations.
(5) Slide each hydraulic tappet from its bore in
the cylinder head, also keeping them in order for
assembly to their or iginal locations.
(6) Before removing the valves the deposits in

Installed view of the cylinder head oil pressure relief
valve.
the combustion chambers s hould be removed. Care
should be taken not to damage the cylinder head
gasket face.

(7) Using a valve spring compressor, compress
each spring in turn. Remove the split retaining collets
and slowly release the compressor.
(8) Remove the valve spring retainers and valve
springs. (9) Remove the valve stem seals from the top of
the valve guides and detach the exhaust valve rotators
and the inlet valve spring seats, from the cylinder
head. (10) Remove any burrs from the valve stem
grooves to prevent damage to the valve guides when
the valves are removed from the cylinder head. (11) Remove the valves, keeping them in order
for assembly to their original locations.
NOTE: To keep the valve assemblies in
order have a rack numbered from 1 to 8 and
instill the components in this rack, starting
from the front of the cylinder head.

(12) If the oil pressure relief valve in the cylinder
head is to be renewed, proceed as follows:

(a) Using a drift, remove the welch plug from
the distributor end of the cylinder head. (b) Remove the recessed screw from the thermo-
stat housing end of the cylinder head. (c) Using a long brass drift inserted in the oilway
through the tappet bores from the thermostat housing
end. remove the oil pressure relief valve from the
cylinder head. Discard the relief valve.
TO CLEAN AND INSPECT

(1) Clean the valves thoroughly and discard any
burnt, warped or cracked valves. (2) Have the valves refaced to the recommended
angle on a valve refacing machine. The valve stem tips
are specially hardened and should not be refaced.
Dismantled view of the valve and spring components.

Engine 53


Method of checking cylinder head for distortion.
(3) Carefully clean the deposits from the inlet
and exhaust ports, the auxiliary passages, the valve
guides and the manifolds, taking care not to damage
any mating surfaces. (4) Clean the cylinder head mounting faces,
wash the cylinder head in solvent and dry with
compressed air. Blow through all the oil holes with
compressed air to ensure that they are not blocked. (5) Check the cylinder head for distortion diag-
onally and lengthwise using a straight edge and feeler
gauges. Refer to Specifications for the distortion and
machining limits. (6) Check the cylinder head face and combus-
tion chambers for cracks, burn marks and corrosion. (7) Check the valve stem to guide clearance. If
the clearance is in excess of the Specifications, the
valve guide must be reamed and the appropriate
oversize valve installed. (8) Inspect the valve seats for pitting or burning
and if necessary, recut the seats with a valve seat
cutter to the recommended angle. When the seats are
correctly finished, the seat widths should conform to
the Specifications. (9) Lap the valves to the valve seats with a fine
lapping compound. Apply a smear of Prussian blue to
the valves or their respective seats to ensure that true
and concentric seating has been gained.

(10) Install each valve in its respective port
and
check the valve stem height above the cylinder head.
Refer to the illustration. The extended height must
not exceed 18.4 mm. If the height exceeds the
Specifications, the valve or the cylinder head must be
renewed. Do not remove any material from the valve
stem tip.
(11) Check the valve spring tensions and compare
with the Specifications.
Check that the springs are not bent or distorted.

If a spring tester is not available, check the springs
by comparison with new springs. This can be done
using a surface plate and stra ight edge for checking the
free length and using a new spring and a used spring
loaded in a vice end on end, with a plate in between.
Measure from the plate to the vice jaw adjacent to
both the new and used springs. A used spring is
serviceable if it does not show collapse in excess of
five percent when subjected to this comparison test.

(12) Check the exhaust valve rotators for wear
and ensure that the rotators turn freely. (13) Clean the cylinder block face of all carbon
and rust deposits and ensure that all old gaskets are
removed. Do not allow the waste deposits to enter the
oil or water galleries. Clean all waste materials from the cylinder bores.

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

(1) Lubricate all component wear surfaces with
engine oil before assembly to ensure adequate lubri-
cation when starting. (2) If the oil pressure relief valve was removed
from the cylinder head, proceed as follows:
(a) Using a brass tube inserted in the welch plug
hole at the distributor end of the cylinder head, tap
the relief valve into position. (b) Install the welch plug and the recessed screw
in their respective positions, after coating the plug and
the screw with Loctite 242 or equivalent.
(3) Install the inlet valve spring seats and
the
exhaust valve rotators over the valve guides before
installing the valve stem seals onto the valve guides.
(4) Install the valve stem seals, ensuring that
the
rib of the moulding on the inside of the seal is
correctly positioned in the groove of the valve guide
and that the spring clip retainer is correctly posi-
tioned.
NOTE: The valve stem seals can be posi-
tioned correctly and without damage using
an upturned valve spring retainer.

(5) Install the valves to their original location in
the cylinder head. Use care when installing the valves
to prevent damage to the seals.
(6) Install the valve springs, retainers and
collets.
Ensure that the valve retain ing collets are fully seated
Dimension A is the correct position to measure the
valve stem installed height. Dimension A = 18.4 mm.

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 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.