1987 NISSAN PULSAR oil

Engine 43
CAMSHAFT HOUSING TOP COVER
Front view of the 1.8 liter engine and automatic transaxle assembly removed from the vehicle.
release the driveshafts from the transaxle. Tie the
driveshafts to the underbody of the vehicle using wire
and ensuring that excessive st rain is not placed on the
joints.

NOTE: If the driveshafts will not release
from the transaxle, a lever can be used
between the driveshaft and the transaxle.
Care must be taken when using the lever not
to damage the transaxle oil seals.

(26) Remove the engine pipe from the engine.
Refer to the procedure at the end of this section if
necessary.
(27) Remove the engine crossmember retaining
bolts and nuts and remove the crossmember from
beneath the vehicle. (28) Attach the lifting tackle to the engine and
raise the engine slightly to take the weight off the
engine mountings. (29) Remove the front, rear, left and right engine
mounting bolts and nuts. Withdraw the mountings
from the engine compartment. (30) Slowly lower the engine and transaxle assem-
bly from the engine compartment. On air conditioned vehicles, remove the air
conditioning compressor an d hoses after the engine
has been lowered slightly. Secure the compressor to

one side, clear of the work area, with wire or similar.
NOTE: Do not disconnect the hoses from
the air conditioning compressor. Escaping
refrigerant can cause frostbite and eye dam-
age.

( 3 1 ) Lower the engine and transaxle assembly
onto a suitable trolley and maneuver the engine from
beneath the vehicle.

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

(1) Position the engine and transaxle assembly
beneath the front of the vehicle.
(2) Install the lifting tackle and raise the engine
assembly into position in the engine compartment.
NOTE: On air conditioned models, ensure
that the air conditioning compressor is in-
stalled to the engine as the engine is in-
stalled to the engine compartment.

(3) Install the engine and transaxle
assembly
mounting nuts, bolts and washers finger tight before
the full weight of the assembly is taken by the

44 Engine

Rear three quarter view of the 1.8 liter engine and automatic transaxle assembly.
mountings. Lower the assembly onto the mountings
and tighten the mounting nuts and bolts.

(4) Install a new exhaust flange gasket.
(5) Fill the engine and transaxle with the correct
quantity and grade of lubricant. (6) Fill the cooling system as described in the
Cooling and Heating Systems section. (7) On models with power steering, fill the power
steering reservoir with the recommended fluid.
(8) Start and run the engine until it reaches the
normal operating temperatur e and check for fuel, oil
and coolant leaks.
4. MANIFOLDS
INLET MANIFOLD - 1.6 Liter Models

To Remove and Install
NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to

depressurise the system before removing the
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.

(1) Disconnect the negative battery terminal.
(2) Remove the wingnuts retaining the air
cleaner to the throttle body, lift the air cleaner
upwards slightly and disconnect the vacuum hoses. (3) Drain the cooling system as described in the
Cooling and Heating Systems section. (4) Loosen the hose clamps and disconnect the
engine coolant hoses from the rear of the manifold.
(5) Disconnect the small branch of the engine
ventilation hose from the rear of the inlet manifold. (6) On automatic transaxle models, disconnect
the kickdown cable from the throttle lever by releasing
the wire spring clip and re moving the cable end socket
from the ball.
(7) Turn the throttle lever to the full throttle
position. Using the slack in the throttle cable, release
the throttle cable end thr ough the slot provided.

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.

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.

50 Engine
(4) Ensure that the tappet assemblies are full of
clean engine oil and insert the tappets in their
respective bores in the cylinde r head. Install the thrust
pads to the top of each valve assembly ensuring that
they are returned to their original location.
(5) 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. (6) Clean the mating surfaces of the camshaft
housing and cylinder head. Apply a bead of Loctite
515 to the cylinder head and camshaft housing mating
surfaces. Take care that no sea lant is forced into the
oil passages and install the camshaft housing to the
cylinder head.
(7) Install new cylinder head bolts and lubricate
the bolts and washers with oil.
(8) Apply an initial torque to the cylinder head
bolts of 25 Nm in the corr ect sequence as shown in
the illustration under the Cylinder Head heading.
Further tighten the head bolts in the correct sequence,
in three separate 60 degree stages. Refer to Specifica-
tions. (9) Install the bolts securing the camshaft
drive
belt inner cover to the camshaft housing. (10) Install the camshaft timing gear to the cam-
shaft ensuring that it is correctly located. Tighten the
camshaft timing gear retain ing boll to the specified
torque. (11) Install and adjust the camshaft drive belt as
described under the previous heading. (12) Install the distributor. Refer to the Fuel and
Engine Management section.
(13) Connect the lower radiat or hose and fill the
cooling system with the required coolant. Refer to the
Cooling and Heating Systems section if necessary. (14) Start and run the engine until normal oper-
ating temperature is attained and tighten the cylinder
head bolts another 30-50 degrees in the correct
sequence, ensuring that the tension does not exceed
135 Nm.
TO RENEW CAMSHAFT OIL SEAL,
CAMSHAFT INSTALLED

(1) Remove the camshaft drive belt from the
camshaft timing gear as described under the previous
heading.
(2) Remove the camshaft housing top cover
retaining bolts, remove the cover and discard the
gasket.
(3) Use an open end spanner to 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. (4) 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.
(5) Clean the seal recess and the camshaft sea!
running surface. (6) Lubricate the lip of a new oil seal with engine
oil and slide the seal over the camshaft. Ensure that
the lip of the seal faces to wards the inside of the
camshaft housing. Tap evenly around the edges of the
seal until it is fully seated in the camshaft housing.
(7) Install the camshaft timing gear to the cam-
shaft, ensuring that it is co rrectly located. Tighten the
camshaft timing gear retain ing bolt to the specified
torque. Do not allow the camshaft to rotate while
tightening the bolt. (8) Install and adjust the drive belt as described
under the previous heading. Ensure that the timing
marks are aligned. (9) Install the camshaft hou sing top cover using a
new gasket. Tighten the retaining bolts to the specified
torque.
7. CYLINDER HEAD

Special Equipment Required:
To Dismantle and Assemble — Valve spring com-
pressor

To Inspect — Dial gauge and straight edge
To Install — Drive belt adjusting tool

TO REMOVE AND INSTAL
NOTE: Due to the high residua! pressure
within the fuel system, it will be necessary to
depressurize the system before removing any
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.

Allow the engine to cool prior to the
removal of the cylinder head to prevent
possible distortion of the cylinder head.

(1) Disconnect the negative battery terminal and
remove the nuts securing the earth wires to the
cylinder head bolts.
(2) Remove the camshaft drive belt as previ-
ously described.
(3) Disconnect the lower radiator hose and drain
the cooling system. Refer to the Cooling and Heating
Systems section if necessary. (4) Remove the alternator adjusting bracket
mounting bolt and insulating washers from the inlet
manifold. Loosen the adjusting bolt at the alternator
and slide the bracket away from the cylinder head. (5) Disconnect the upper radiator hose, coolant
by-pass hose and the heater hose from the thermostat
housing and on 1.6 liter m odels, the coolant hoses
from the inlet manifold. (6) Disconnect the electrica l connectors from the
throttle body, fuel injectors, coil, distributor and on
1.8 liter models, the MAT sensor. (7) Disconnect the oxygen sensor wiring connec-
tor and remove the wiring connectors from the

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.