1987 NISSAN PULSAR lock

Engine
edge of the bearing cap to cylinder block joint. Install
the bearing cap bolts and tighten to the specified
torque.

(17) Lubricate the l i p of the new oil seal with
lithium grease and carefully install the seal into
position over the crankshaft . Insert the seal as far as
possible using finger pressure and then fully install the
sea! using a tubular drift. Ensure that the seal is not
damaged during installation and that the seal is
mounted square to the block face.
(18) Install the remainder of the engine
compo-
nents by referring to the relevant headings in
this
section.
TO RENEW CRANKSHAFT OIL SEALS

Front
(1) Remove the camshaft drive belt as previ-
ously described.
(2) Disconnect the lower radiator hose and drain
the cooling system. (3) Select fifth gear on manual transaxle models
and firmly apply the handbrake. (4) On automatic transaxle models, remove the
torque converter inspection cover to allow access to
the ring gear. Have an assi stant hold the ring gear
using a suitable lever. (5) Remove the crankshaft timing gear retaining
bolt and discard. (6) 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. (7) Using a centre punch, tap a small hole in the
front face of the oil seal. (8) Insert a self tapping screw into the hole.
(9) Remove the seal from the oil pump by
gripping and pulling the end of the screw with a pair
of pliers. (10) Coat the l i p of a new seal with multi-purpose
grease. (11) Install the oil seal to the oil pump using a
tubular drift. Ensure that the lip of the oil seal faces
the inside of the housing.
(12) Install the remaining components in the re-
verse order of removal, usi ng a new crankshaft timing
gear retaining bolt and referring to the relevant
headings in this section as necessary.
Rear

(1) Remove the automatic transaxle or manual
transaxle as described in the appropriate section. (2) Remove the flywheel/drive plate as described
under the following heading. (3) Lever the oil seal from the rear of the
crankcase being careful not to damage the crankshaft.
(4) Coat the lip of a new seal with Lithium
grease.
(5) Install the oil seal over the crankshaft. Ensure
that the li p of the oil sea l faces towards the engine.
(6) Insert the seal as far as possible using finger
pressure, and then fully seat the seal using a tubular
drift. (7) Install the remaining components in the
re-
verse order of removal, referring to the relevant
headings in this section as necessary.
12. FLYWHEEL/DRIVE PLATE

Special Equipment Required:
To Renew Ring Gear — Suitable heat source
TO REMOVE
(1) Remove the transaxle from the vehicle as
described in the Manual or Automatic Transaxle
sections, whichever is applicable. (2) On manual transaxle models, mark the fly-
wheel and the clutch pressure plate cover to ensure
correct assembly.
View of the drive plate and retaining bolts.
Progressively loosen and remove the pressure
plate retaining bolts.

Using a dial gauge, check the runout of the clutch
face contacting surface of the flywheel. If the runout
exceeds 0.3 mm have the flywheel face surfaced by a
clutch specialist or authorized dealer.

(3) Suitably mark the flywheel or drive plate so
that the unit can be installed in the original position
on the crankshaft. Remove the retaining bolts. (4) Lift the flywheel or drive plate from the
engine.
TO CHECK AND INSPECT

Inspect the clutch face contacting surface of the
flywheel for cracks or excessive scoring.

(2) Inspect the ring gear teeth for damage, cracks
or wear. The ring gear on manual transaxle models
can be renewed separately from the flywheel, but on

64 Engine
automatic transaxle models the complete drive plate
must be renewed.

(3) Inspect the drive plate bolt holes for elonga-
tion which is caused by loose retaining bolts.
(4) Inspect the drive plate for cracks.
(5) Repair or renew the flywheel if necessary.
TO INSTAL

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

(1) The flywheel and drive plate retaining bolts
are special micro-encapsulated fasteners.

Install new micro-encapsulated bolts of the
correct
strength classification on assembly.

(2) Thoroughly clean the crankshaft threads with
a thread tap. Clean the threads with solvent and dry
before installing the flywh eel or drive plate retaining
bolts.
(3) Tighten the flywheel or drive plate retaining
bolts to the specified torque and on manual transaxle
models, align the clutch plate as described in the
Clutch section.
TO RENEW FLYWHEEL RING GEAR
(1) With the flywheel removed from the vehicle,
drill a 6 mm diameter hole between two teeth of the
ring gear.

NOTE: Do not drill right through the ring
gear as this will damage the flange on the
flywheel.

(2) Secure the flywheel, with the drilled hole
uppermost in a soft jawed vice.
(3) Place a cold chisel above the hole in the ring
gear and hit it sharply to split the ring gear.
(4) Check the direction of the chamfered face of
the old ring gear. The new ring gear must be installed
to the flywheel with the chamfer in the same direction. (5) Remove the ring gear, clean the mounting
face on the flywheel and remove any burrs. (6) Polish a few spots of the ring gear with emery
cloth and heat the ring gear evenly until the polished
spots turn dark blue.
NOTE; Do not heat the ring gear past the
point required to achieve a dark blue color
or the tempering of the ring gear teeth will
be impaired.

(7) With the flywheel suitably supported, pick
the ring gear up using plie rs, and place it evenly onto
the flywheel. Use a hammer and a brass drift to ensure
that the ring gear seats ag ainst the flywheel flange.

NOTE: Allow the ring gear to cool slowly.
Do not quench it in water.

13. ENGINE MOUNTINGS
TO RENEW LEFT HAND SIDE MOUNTING
(1) Disconnect the positive and negative battery
terminals, loosen the battery clamp nuts and withdraw
the battery from the engine compartment.
(2) Remove the bolts retaining the battery car-
rier to the inner mudguard and remove the battery
carrier and associ ated components from the engine
compartment. (3) Support the transaxle using a jack. Interpose
a block of wood between the head of the jack and the
transaxle to prevent damage to the transaxle.

View of the flywheel and retaining bolts.

Dismantled view of the left hand side engine mounting
assembly installed to vehicles with an automatic tran-
saxle.

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.

68
COOLING AND HEATING SYSTEMS
SPECIFICATIONS
Coolant capacity ........................................ 6.0 liters
Thermostat:
Opening temperature........................... 91 deg
C

Fully open temperature .................... 103 deg
C

Cooling fan:
Fan cut in temperat ure ....................... 100 deg C
Fan cut out temperature ...................... 95 deg C
Radiator cap opening
pressure ................................................... 78 -98 kPa
TORQUE WRENCH SETTINGS
Water pump retaining bolts .............................25 Nm
Thermostat housing bolts .................................15 Nm
Sender unit .......................................................10 Nm
1. COOLING SYSTEM TROUBLE SHOOTING
COOLANT LEAKAGE - EXTERNAL
(1) Loose hose clips or faulty hoses: Tighten the
hose clips or renew the faulty water hoses.
(2) Leaking radiator core or tanks: Repair or
renew the radiator. (3) Leaking heater core or hoses: Repair or renew the heater core. Check the hose clips and hoses
and renew if necessary.

(4)
Leaks at the thermostat cover and/or water
pump O rings. Renew the O rings. (5) Worn or damaged water pump seal assembly:
Renew the water pump. (6) Worn or damaged water pump bearing as-
sembly: Renew the water pump.
(7) Loose or rusted welch plugs; Renew the
welch plugs. (8) Faulty cylinder head gasket or loose cylinder
head bolts: Renew the cylinder head gasket and
correctly tighten the cylinder head bolts. (9) External crack in the cy linder head or cylin-
der block: Repair or renew the faulty components.
NOTE: Check the system for external leak-
age by running the engine to operating
temperature over a dry floor and checking
for the leak source.

Check the vehicle interior below the
heater core for moisture. If a rusted welch
plug is found, it is a good practice to renew
all the welch plugs.

COOLANT LEAKAGE - INTERNAL
( 1 ) Cylinder head gasket leak due to warped
cylinder head or cylinder block gasket faces: Reface


Checking the radiator hose for deterioration.

Check the engine oil for level and dilution on the
dipstick.

Cooling and Heating Systems 69

the cylinder head or cylinder block and renew the
cylinder head gasket.

(2) Crack in the cylinder head or cylinder block:
Repair or renew as necessary.

NOTE; Check the engine for internal leak-
age by withdrawing the dipstick and inspect-
ing for emulsified oil. Run the engine and
check for excessive steam at the exhaust
pipe which would indi cate coolant leakage
into the combustion chamber.

COOLANT LOSS BY OVERFLOW
(1) Overfull system: Drain the excess coolant
from the system.
(2) Faulty radiator cap: Renew the faulty cap.
(3) Blocked radiator core tubes: Clean or renew
the radiator core.

(4) Faulty thermostat: Renew the thermostat.
(5) Coolant foaming due to poor quality anti-
freeze or corrosion inhibitor: Drain the system and
renew the coolant and additive.

Renew the radiator cap if the sealing rubber has
deteriorated.
ENGINE OVERHEATING
(1) Radiator cap defective: Renew the radiator
cap.
(2) Incorrect fuel mixture: Check the fuel system
as described in the Fuel and Engine Management
section. (3) Obstructed air passage through the radiator
core from the front to the rear: Blow the obstruction
from the rear to the front of the radiator core using
compressed air or water pressure. (4) Faulty thermostat: Renew the thermostat.
(5) Incorrect ignition timing: Check and adjust
the ignition timing as described in the Engine Tune-up
section. (6) Incorrect valve timing: Set the valve timing
as described in th e Engine section.
(7) Loss of coolant from the overflow: Check
and rectify as described under the heading Coolant
Loss By Overflow.
(8) Poor circulation: Check and rectify as de-
scribed under the heading Coolant Circulation Faulty.
(9) Low engine oil level: Stop the engine imme-
diately and replenish the oil in the sump. (10) Restricted muffler, catalytic converter or
damaged tailpipe, accompanied by loss of power:
Remove the restrictions or renew the faulty com-
ponents as necessary.
(11) Incorrectly adjusted or dragging brakes:
Check and rectify by adjustment or renewal of
components. (12) Faulty temperature gauge and/or sender unit:
Check and rectify as necessary.
NOTE: Engine overheating is indicated by
an excessive rise in engine temperature
shown by the temperature gauge.

Overheating is usually accompanied by
steam emitting from the coolant overflow
pipe and loss of engine power. A blown
cylinder head gasket may be indicated by
bubbles in the coolant.

COOLANT CIRCULATION FAULTY
(1) Partial blockage of the radiator core tubes:
reverse flush or renew the radiator core.
(2) Sludge deposits in the engine water jacket:
Clean and flush the engine water jacket and add
inhibitor to the coolant. (3) Faulty water pump: Renew the water pump.
(4) Faulty thermostat: Renew the thermostat.
(5) Collapsing lower radiator hose: Renew the
lower radiator hose and check the radiator core tubes. (6) Insufficient coolant in the system: Replenish
the coolant and check for leaks.
NOTE: If rust or sludge deposits are sus-
pected, check the color of the coolant in the
radiator. Rusty or muddy coolant indicates
rust or sludge in the system.

2. HEATER AND AIR CONDITIONER TROUBLE SHOOTING

NO HOT AIR INSIDE VEHICLE
Faulty thermostat: Renew the thermostat.
Faulty heater valve: Check and renew the

Blocked heater hoses: Remove the blockage.
Blocked heater core: Clean or renew the core.

NOTE: Ensure that the engine is reaching
normal operating temperature. If in doubt
check the operation of the thermostat as
described under the Thermostat heading in
this section.

(1)
(2)
valve.
(3)
(4)

70 Cooling and Heating Systems


Installed view of the heater hoses. 1.6 liter models with the air cleaner removed for clarity
.
When the engine is at normal operating
temperature and the heater valve is open,
both of the heater hoses should feel
warm/hot. If the valve is not allowing the
coolant to flow, one hose will be hot while
the other will be cold.

NO COOLED AIR INSIDE VEHICLE
(1) Compressor drive belt slipping or broken:
Renew and/or adjust the drive belt as described in the
Engine Tune-up section.
(2) Insufficient refrigerant: Check the system for
leaks and charge as necessary. Refer to the Air
Conditioning heading in th is section for information
on checking the refrigerant level. (3) Compressor inoperative: Check for power to
the compressor clutch before removing the compres-
sor for repair by a specialist. (4) Heater system allowing warm air to mix with
cooled air: Check the operation of the heater system.
NOTE: The above trouble shooting proce-
dures are basic checks only. If the air
conditioning system is suspect, it is rec-
ommended that the vehicle be taken to an
authorized dealer for testing and repair.
It is normal for water to be seen drain-
ing under the vehicle from the evaporator
after the vehicle has been operated with
the air conditioning on.

3. DESCRIPTION
The cooling system is of the sealed, pressurized
type with fan and water pump assistance. The system
is pressurized in order to raise the boiling point of the
coolant and so increase the efficiency of the engine.

Provision for pressure a nd vacuum relief of the
system is incorporated in the radiator cap.

The radiator overflow hose is connected to a
reserve tank mounted adjacent to the battery. As the
coolant volume expands due to an increase in tem-
perature, the pressure valve in the radiator cap opens
and allows the excess coolant to flow into the reserve
tank. When the engine is stopped and the temperature
of the coolant falls, the vacuum valve in the radiator
cap opens and allows the excess coolant in the reserve
tank to siphon back into the radiator. Thus the
necessity for frequent topping up of the coolant is
eliminated.

The temperature of the cooling system is con-
trolled by a thermostat located in the thermostat
housing attached to the cylinder head.

The thermostat prevents circulation of coolant
through the radiator by directing coolant through the
by-pass circuit, until the engine has reached operating
temperature. This restricted circulation allows the
engine to reach operating temperature quickly, im-
proving drivability and fuel economy.

Removal of the thermostat to cure overheating is
not recommended because th e by-pass circuit will
remain open reducing the amount of water flowing
through the radiator.

An anti-corrosion inhibitor should always be
added to the coolant to protect the cooling and
heating systems from corrosion.

The water pump is mounted to the front of the
engine and is driven by the camshaft drive belt. It is
equipped with a double row ball bearing and a spring
loaded seal assembly. The water pump is a disposable
unit and cannot be repaired.

The fan is driven by an electric motor which is
actuated by the coolant temperature sensor and the
control unit.

On vehicles equipped with air conditioning, an
additional electric fan is m ounted to the radiator. This
fan is controlled by a sw itch connected to the air
conditioning compressor.

The radiator consists of an aluminum core with
plastic side tanks. Minor damage to the core can be
repaired using Nissan repair agent.

The left hand tank of the radiator houses the
transaxle oil cooler on automatic transaxle models.

To drain the cooling system a drain plug is
provided on the lower radiator pipe outlet.

4. RADIATOR
NOTE: To avoid scalding, use caution when
releasing the radiator cap on an engine
which is at the normal operating tempera-
ture. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to
release. When the pressure is released turn
the cap past the stop and remove it from the
radiator.

Cooling and Heating Systems
7. THERMOSTAT HOUSING
Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) On 1.6 liter models, remove the air cleaner
assembly from the engine. Refer to the Fuel and
Engine Management section if necessary. (3) Drain the cooling system as previously de-
scribed. (4) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (5) Remove the bolts retaining the camshaft
drive belt rear cover to the cylinder block and remove
the rear cover.
\ COOLANT TEMPERATURE SENSOR TEMPERATURE SENDER SWITCH
View of the thermostat housing and
components.
(6) Disconnect the top radi ator hose, the heater
hose and the inlet manifold heater hose from the
thermostat housing.
(7) Disconnect the wire from the temperature
sender switch and the coolant temperature sensor. (8) Remove the bolts retaining the thermostat
housing to the cylinder head and remove the thermo-
stat housing and the O ring from the cylinder head. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that all mounting faces are clean.
(2) Renew the O ring on installation.
NOTE; Ensure that the O ring is not
twisted. Do not use sealant.

(3) Tighten the thermostat housing retaining
bolts to the specified torque. (4) Adjust the camshaft drive belt tension as
described in the Engine section under the heading
Camshaft Drive Belt. (5) Fill the cooling system as previously de-
scribed and check for coolant leaks. 8. WATER PUMP

Special Equipment Required:
To Adjust Camshaft Drive Belt — Adjusting tool
TO REMOVE AND INSTAL
NOTE: The water pump is non-repairable
and if faulty must be renewed as a complete
assembly.

(1)
Drain the cooling system as previously de-
scribed.
(2) Remove the camshaft drive belt as described
in the Engine section under the heading Camshaft
Drive Belt. (3) Remove the water pump retaining bolts and
remove the water pump and the O ring from the
engine. Installation is a reversal of the removal procedure
with attention to the following points:


View of the water pump and components removed
from the vehicle.
(1) Ensure that all mounting faces are clean.
(2) Use a new O ring and smear it with a liberal
amount of silicone grease.
(3) Install the water pump to the engine but
do
not tighten the retaining bolts until the camshaft drive
belt has been installed and tensioned correctly as
described in the Engine section under the heading
Camshaft Drive Belt.
(4) Fill the cooling system as previously de-
scribed in this section and check for coolant leaks.
9. WELCH PLUGS

To facilitate the casting of the cylinder block and
cylinder head passages and water jackets, a number of
openings had to be ma de at manufacture.

Cooling and Heating Systems 77
These openings are plugged with welch plugs. The
plugs may have to be renewed when cleaning the
engine water jackets or when defective due to corro-
sion.

TO RENEW
NOTE: If a welch plug is found to be
corroded it is good policy to renew all the
welch plugs.

(1) Drain the radiator and cylinder block.
(2) Remove the necessary engine components or
accessories to gain ampl e working space around the
welch plug. (3) Using a punch and hammer, tap the welch
plug on its outer circumference into its opening. (4) Grasp the edge of the welch plug with a pair
of multi-grip pliers and using the shoulder of the pliers
as a fulcrum, lever the plug out of its opening. (5) Thoroughly clean and dry the welch plug
opening.
(6) Lightly smear the edge of a new welch plug
and the opening with Loctite 675. (7) Place the welch plug onto the opening and
using a tube or socket fitting the rim of the plug, drive
the plug squarely into its opening.
NOTE; The welch plug must be driven into
the opening straight and squarely or leaks
may occur.

(8) Install the components which were removed
to gain access to the plug. (9) Fill the cooling system as previously de-
scribed. With the reserve tank pressure cap installed,
run the engine until it reaches normal operating
temperature and check for coolant leaks.
10. HEATER UNIT, WATER VALVE AND
CONTROLS
DESCRIPTION
The heater controls use four adjustments to direct
air through the vehicle.

The air intake control selects fresh air from
outside the vehicle or recirculates air from inside the
vehicle. The recirculate position is used in dusty
conditions or to rapidly heat or cool the vehicle
interior. The fresh air positi on is the best to deodorize
the vehicle interior or demist the windscreen.

The air control lever is used to direct air to the
face outlets, the floor outle ts and the windscreen
outlets. This control also has two bi-level positions
where air may be directed to the face and floor outlets
or the windscreen and floor outlets.

The temperature control opens or shuts the heater
water valve to control the flow of engine coolant
through the heater core, which raises or lowers the
temperature of the air passing through the core.
Maximum heating is only available when the engine is
at the normal operating temperature.

The fan speed control switches the fan on and off
and is used to select the desired fan speed.

Air conditioned models use identical controls
with the addition of an air conditioner on/off button.
The centre of the button is illuminated when the air
conditioner is switched on.

Tap the welch plug on its ou ter circumference into the
cylinder block.
Using a correct fitting tube or socket, drive the welch
plug into its opening. View of the heater controls.