1987 NISSAN PULSAR torque

114 Fuel and Engine Management
(6) Check the vehicle for the following:
(a) Low fuel pressure.
(b) Contaminated fuel.
(c) Vacuum leaks at the inlet manifold, engine
vacuum hoses and engine ventilation hoses. (d) Exhaust manifold leaks before the oxygen
sensor. (e) Correct MAP sensor operation.
(f) Blocked oxygen sensor metal vent cover eg.
plugged with mud etc. (g) Fuel injectors) partially blocked. Refer to a
fuel injection specialis t or a Nissan dealer.
If the above items have been checked and no
faults have been found, a faulty oxygen sensor is
indicated. Renew the oxygen sensor, run the engine
and ensure that no fault codes are set.

To Test — Code 45
(1) Run the engine until normal operating tem-
perature is attained. (2) With the ignition switched Off, connect a
jumper lead between terminals B and A on the
diagnostic link connector. (3) Start and run the engine at approximately
1 600-1 800 rpm for 2 minutes and note the ECM
warning lamp. If the ECM warning lamp is on more than off or
flashes at the rate of twice per second, proceed to the
following operation.

If the ECM warning lamp flashes evenly at the
rate of once per second an intermittent fault is
indicated. Proceed as follows:

(a) Check for faulty wiri ng connections. Check
that all wiring connectors are clean and secure. (b) Check that all earth wires are secure.
(4) Switch the engine Off and disconnect the
oxygen sensor wiring connector. (5) Using a jumper lead, connect the oxygen
sensor wiring connector to a suitable engine earth. (6) Start and run the engine at 1 600-1 800 rpm
and note the ECM warning lamp.
If the ECM warning lamp extinguishes for at least
30 seconds, proceed to operation (7).

If the ECM warning lamp flashes on more than off
or flashes at the rate of twice per second, switch the
engine Off and disconnect the control unit wiring
connectors. Using an ohmmeter, check that there is no
resistance between the co ntrol unit wiring connector
terminal D6 and earth. Repair or renew the wiring as
necessary.

If no fault can be found in the wiring harness,
renew the control unit.

NOTE: The wiring harness for terminal D6
earths through the righ t hand rear cylinder
head bolt.

(7) Check the vehicl e for the following:
(a) High fuel pressure.
(b) Leaking injector(s).
(c) Faulty ignition wiring.
(d) Charcoal canister purge system blocked or
restricted.
(e) Faulty coolant temper ature sensor circuit.
(f) Faulty MAT sensor circuit (1.8 liter engine).
(g) MAP sensor operation.
(h) Throttle position sensor operation.

If the above items have been checked and no
faults have been found, a faulty oxygen sensor is
indicated.

Renew the oxygen sensor, run the engine and
ensure that no fault codes are set.

To Remove and Install
(1) If the engine is cold, run the engine for
approximately two minutes to allow easy oxygen
sensor removal. (2) Disconnect the negative battery terminal and
the oxygen sensor connector.

View of the oxygen sensor removed from the exhaust
manifold.
(3) Remove the exhaust manifold heat shield
retaining bolts and remove the heat shield from the
engine.
(4) Remove the oxygen sensor with a short ring
spanner using care not to damage the sensor wire. Installation is a reversal of the removal procedure
with attention to the following points:

(1) When installing a sensor that has previously
been removed, coat the sen sor threads with anti-seize
compound. Nissan recommend a mixture of liquid
graphite and glass beads. (2) Install the sensor and tighten to the specified
torque. (3) Connect the electrical connector ensuring
that the wiring is secured away from the exhaust. (4) Install the heat shield and tighten the retain-
ing bolts securely. On 1.6 liter engines, ensure that the hot air inlet
tube is located correctly be tween the heat shield and
the air cleaner housing.

(5) Start the engine and check for leaks.
VEHICLE SPEED SENSOR
To Test - Code 24

(1) Check the fuel pump and meter fuses. If the
fuses are serviceable, proceed to operation (5). If a
fuse is blown, rectify the cause and renew the fuse.

121
CLUTCH
SPECIFICATIONS
Type................................................... Single dry plate
Operation................................................... Mechanical
Pressure plate type .................................... Diaphragm
Release bearing type .......................Prelubri cated ball
Driven plate:
Outside diameter .................................... 215 mm
Rivet depth limit ....................................0.3 mm
Runout limit .........................................0.5 mm
Maximum spline backlash ...................0.7 mm
Pressure plate:
Diaphragm spring height
(installed) ...................................... 30.5-32.5 mm
Spring finger vari ation limit.....................0.5 mm
Clutch pedal:
Height .............................................. 175-185 mm
Free play ....................................... 12.5-17.5 mm
Release lever free play............................ 2.5-3.5 mm
Flywheel machining limit ...............................0.3 mm
TORQUE WRENCH SETTINGS
Pressure plate bolts.......................................... 29 Nm
Pedal pivot pin nut ......................................... 22 Nm
Cable loc knut.................................................... 4 Nm
Lower clutch housing to engine bolts.............. 21 Nm
Centre and upper clutch housing
to engine bolts .................................................. 49 Nm
1. CLUTCH TROUBLE SHOOTING
CLUTCH SLIPPING
(!) Worn driven plate facing: Check and renew
the clutch driven plate.

(2) Insufficient clutch pedal free play: Check and
adjust the clutch pedal free play. Ensure that the
release lever free play is correct.
(3) Weak or broken pressure plate diaphragm
spring: Check and renew the pressure plate assembly. (4) Worn or scored flywh eel: Machine or renew
the flywheel. Worn or scored pressure plate face: Renew the
pressure plate assembly.


Renew the clutch driven plate if the friction material is
worn down to, or is within 0.3 mm of the rivets.
NOTE: In most cases clutch slippage is first
evident by a marked increase in engine revs,
for no apparent reason, when pulling up a
steep hill. The clutch condition can be
positively diagnosed as follows: With the
handbrake firmly applied, and the rear
wheels chocked, select top gear and release
the clutch with the engine running at ap-
proximately 2 000 rpm. Clutch slippage is
evident if the engine does not stall. Make the
test as quickly as possible to prevent any
further clutch damage.

CLUTCH SHUDDER
(1) Oil on the driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Scored pressure plate or flywheel face: Re-
new the pressure plate assembly or machine the
flywheel. (3) Loose or damaged driven plate hub: Check
and renew the clutch driven plate. (4) Loose driven plate facings: Renew the clutch
driven plate. (5) Cracked pressure plate face: Renew the pres-
sure plate assembly.

124 Clutch


Illustration showing the clutch aligning tool. The tool
can be readily fabricated from a length of round section
wood or metal. Dimension A = diameter of the ma-
chined section of the crankshaft. Dimension B - inside
diameter of the driven plate hub.
to the release fork ensuring that the return spring is
correctly anchored.

(3) Install the release bearing to the clutch hous-
ing and install the clips re taining the release bearing
carrier to the release fork. (4) Install the driven plate to the flywheel in the
direction noted on removal. Install the aligning tool to
hold the driven plate in position.
NOTE: Some driven plates are marked
Flywheel side to indicate the correct in-
stalled direction.

(5) Install the pressure plate to the flywheel in the
position marked on removal. (6) Ensure that the driven plate is correctly
centered and install the pressure plate retaining
bolts.
Tighten the bolts progressively in a diagonal sequence
to the specified torque. (7) Install the transaxle to the vehicle as de-
scribed in the Manual Transaxle section. (8) Adjust the clutch pedal height and free play
as described under the Adjustments heading later in
this section.
4. CLUTCH PEDAL

TO REMOVE AND INSTAL
(1) Working in the engine compartment, loosen
the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.
(2) Working inside the vehicle, release the inner
clutch cable from the top of the clutch pedal.
(3) Remove the nut from the end of the clutch
pedal pivot pin. (4) Note the installed position of the clutch
pedal return spring and remove the pivot pin from the
clutch pedal.
(5) Remove the clutch pedal from the vehicle
and remove the bush from the clutch pedal. (6) Examine the clutch pedal and the bush for
bend, cracks, wear and damage. Examine the return

Installed view of the clutch pedal.
spring for cracks and fatigue. Renew parts as neces-
sary.

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

(1) Lubricate the hook on the top of the clutch
pedal and the pivot pin and bush with lithium base
molybdenum disulphide grease. (2) Install the return spring to the position noted
on removal. (3) If necessary, adjust the pedal height and free
play as described under the Adjustments heading later
in this section.
5. CLUTCH CABLE

TO REMOVE AND INSTAL
(1) Working in the engine compartment, loosen
the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.
(2) Release the outer clutch cable retaining nut
and slide the outer cable out of the slot in the
mounting bracket.
View of the clutch cable assembly.

Clutch 125
(3) Remove the nuts retaining the outer cable
flange to the vehicle bulkhead.
(4) Working inside the ve hicle, disconnect the
inner cable from the top of the clutch pedal. (5) Pull the clutch cable through the bulkhead
into the engine compartment. (6) Release the clip retaining the centre of the
clutch cable and remove the cable from the vehicle. (7) Check the inner cable for fraying, wear and
damage. Check the outer cable for kinks, wear and
damage. If necessary, renew the cable assembly. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Lubricate the inner cable ends with lithium
base molybdenum disulphide grease prior to installa-
tion. (2) Tighten the nuts retaining the outer cable
flange to a torque of 11 Nm. (3) Check and if necessary , adjust the clutch
pedal height and free play as described under the
heading Clutch Adjustments.
6. CLUTCH ADJUSTMENTS
TO ADJUST PEDAL HEIGHT (1) Fold back the floor carpet and the sound
insulation from the drivers side floor panel.
(2) Measure the distance at right angles from the
floor panel to the centre of the pedal pad. (3) If the pedal height is not as specified, adjust
the pedal stop bolt until the correct pedal height is
obtained.

TO ADJUST PEDAL AND RELEASE LEVER
FREE PLAY
(1) Loosen the inner cable locknut at the release
lever clevis. (2) Push the release lever until resistance is felt
when the release bearing contacts the pressure plate
fingers and hold the release lever in this position.
(3) Tighten the inner cable adjusting nut until
the inner cable is taut.
(4) Loosen the adjusting nut 2.5-3.5 turns and
tighten the inner cable locknut. (5) Measure the release lever free play. If the free
play is not as specified, loosen the locknut and turn
the adjusting nut until the correct free play is
obtained.

View of the clutch release lever free play adjusting
nut.
(6) Lightly depress the clutch pedal until resis-
tance is felt when the release bearing contacts the
pressure plate fingers. Measure the distance from the
centre of the pedal pad in this position to the centre
of the pedal pad when the pedal is contacting the stop
bolt. If necessary, check and adjust the release lever
free play which should bring the pedal free play within
Specifications.

Measuring the clutch pedal height with the carpet
removed.

126
MANUAL TRANSAXLE AND DRIVE SHAFTS

SPECIFICATIONS
TRANSAXLE
Type .....................................Five speed, synchromesh
on all forward gears
Model .......................................................... RS5F31A
Gear ratios: 1.6 liter -

First .......................................................... 3.333:1
Second...................................................... 1.955:1
Third......................................................... 1.286:1
Fourth....................................................... 0.975:1
Fifth.......................................................... 0.810:1
Reverse .................................................... 3.417:1
1.8 liter -
First .......................................................... 3.063:1
Second...................................................... 1.826:1
Third......................................................... 1.286:1
Fourth ....................................................... 0.975:1
Fifth.......................................................... 0.810:1
Reverse .................................................... 3.417:1
Gear end float:
Fifth...............................................0.18-0.41 mm
Second, third and fourth................0.20-0.40 mm
First ...............................................0.18-0.31 mm
Synchro ring to gear clearance:
Standard ............................................ 1.0-1.3 mm
Minimum ................................................. 0.7 mm
Turning torque (new bearings):
Differential assembly ........................ 3.9-7.8 Nm
Total differential and mainshaft __ 5.9-13.7 Nm
Differential and final drive:
Type ........................ Helical ring gear and pinion
Ratio......................................................... 4.167:1
Lubricant:
Grade ............................................. 80W-90 GL-4
Capacity ..................................................2.7 liters
DRIVE SHAFTS
C.V. joint lubrication:
Lubricant ........ Valvoline Special Moly EP grease
Amount ................................................. 40 grams
TORQUE WRENCH SETTINGS
Transaxle case retaining bolts ........
Cover plate to transaxle case .......................... 8.3 Nm
Input shaft bearing retainer bolts ..................... 21 Nm
Control bracket bolts ...................................... 8.3 Nm
Reverse check plug.......................................... 25 Nm
Ring gear to differential case........................... 88 Nm
Filler and drain plugs....................................... 34 Nm
Reverse lamps switch ...................................... 29 Nm
Upper and centre clutch housing to engine…...49 Nm
Lower clutch housing to engine ...................... 21 Nm

1. MANUAL TRANSAXLE AND DRIVE
SHAFT
TROUBLE SHOOTING

DIFFICULT GEAR CHANGE
(1) Faulty clutch or clutch release mechanism:
Check and adjust or overhaul the clutch or the clutch
release mechanism. (2) Loose control bracket retaining bolts: Dis-
mantle the transaxle and tighten the control bracket
retaining bolts. Apply Loctite or an equivalent to the
bolt threads to prevent a repeat of the problem.
(3) Faulty gear lever assembly: Check and
renew
or repair the gear lever assembly. (4) Bent or worn gear lever control rod: Repair
or renew the faulty components. (5) Worn transaxle selector mechanism: Over-
haul the transaxle assembly. Renew components as
necessary.
.21 NmCheck the synchronizing teeth on the gears and synchro
rings for chipping or wear.

128 Manual Transaxle and Drive Shafts
TRANSAXLE NOISE (FORWARD GEARS
ENGAGED, VEHICLE MOVING)

(1) Insufficient lubricant: Fill the transaxle with
the correct grade and quantity of oil. (2) Worn input shaft or mainshaft bearings:
Overhaul the transaxle and renew the faulty bearings. (3) Chipped or pitted gears: Check and overhaul
the transaxle and renew the faulty gears. (4) Damaged or worn sync hroniser assemblies:
Overhaul the transaxle and renew the synchroniser
assemblies.
FINAL DRIVE GEAR NOISE

(1) Insufficient lubricant: Fill the transaxle case
with the correct grade and quantity of oil. (2) Chipped or pitted final drive gear and/or ring
gear: Overhaul the transaxle and renew components as
necessary. (3) Worn differential carrier bearings: Overhaul
the differential assembly.
(4) Worn mainshaft or input shaft bearings:
Overhaul the transaxle.
NOTE: Check the oil level in the transaxle
case and the condition of the front hub
bearings and drive shaft joints prior to
overhauling the transaxle.

EXCESSIVE BACKLASH IN FINAL DRIVE
(1) Excessive end float in the differential carrier
bearings due to worn or incorrect bearing preload
adjustment: Check and adjust the bearing preload or
renew the bearings.

(2) Ring gear to differential case bolts loose:
Overhaul the transaxle and tighten the bolts to the
specified torque.

(3) Excessive wear in the final drive gear: Check
and overhaul the transaxle. (4) Excessive wear in the differential pinions,
side gears or pinion shaft: Overhaul the differential
assembly.
NOTE: Prior to overhauling the differential,
check the serviceability of the C.V joints on
the drive shafts.

NO DRIVE IN ANY GEAR
(1) Sheared ring gear to differential case bolts:
Overhaul the differential assembly.

(2) Broken drive shaft: Check and renew com-
ponents as necessary.

(3) Inner C.V. joint shaft out of mesh with
differential side gear: Weak or broken inner C.V. joint
shaft snap ring. Renew as necessary.

NOISE OR VIBRATION IN DRIVE SHAFTS
( 1 ) Bent or twisted drive shafts: Check and
renew the drive shafts as necessary.


Check the drive shaft rubber boots for deterioration.
(2) Worn or damaged inner or outer C.V. joint:
Check and renew components as necessary. (3) Lack of lubricant due to damaged C.V. joint
boots: Check the C.V. joints for wear, repack the C. V.
joints and renew th e C.V. joint boot.
(4) Loose drive shaft hub nut: Tighten the hub
nut to Specifications. (5) Worn splines on the drive shaft or C.V. joint
inner race. Check and renew the faulty components or
drive shaft as an assembly.
NOTE: Noise or vibration in the front end
can also be caused by excessive tire or wheel
unbalance.

2. DESCRIPTION
The five speed transaxle installed in the Pulsar
range of vehicles covered by this manual has synchro-
mesh on all the forward gears.

The reverse gear is a spur idler gear which is
selected by sliding the idler gear into mesh with the
input shaft and the mainshaft.

The transaxle and differential assemblies are ac-
commodated in the same housing and the one oil level
check covers both assemblies.

Gear selection is by mean s of selector forks and a
striking rod which is operated by a floor mounted gear
lever assembly. A mechanism inside the transaxle
prevents the selection of re verse gear from fifth gear
until the gear lever is moved sideways in neutral. The
differential and final dr ive assembly runs on two
tapered roller bearings. Pr eload on these bearings is
adjusted by shims installed behind the bearing cups.
The assembly is driven by the mainshaft pinion
engaging the ring gear on the differential case.

The drive shafts are engaged with the differential
side gears at the inner end and the front wheel hubs at
the outer end.

The drive shafts and each C.V. joint can be

Manual Transaxle and Drive Shafts 129

renewed as individual units. The C.V. joints are
lubricated in manufacture and need no attention in
service unless one of the r ubber boots is damaged. In
this case the joint can be cl eaned and repacked with
the recommended grease and a new boot installed.

From July 1989, Pulsar Q and Vector SSS manual
transaxle models are equipped with a limited slip
differential incorporating a viscous coupling. The
coupling is not repairable and must be renewed as an
assembly if unserviceable. A test procedure for the
viscous coupling is included in the text in this section.

3. TRANSAXLE ASSEMBLY
Special Equipment Required:
To Dismantle and Assemble — Puller set, press
and press plates, dial gauge
To Measure Mainshaft Turning Torque —
Suitable slotted adaptor and torque gauge

TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands.

(2) Remove the battery as described in the
Electrical System section. (3) Remove the drive shafts as described later in
this section. (4) Disconnect and remove the starter motor as
described in the Elect rical System section.

Front view of the transaxle removed from the vehicle.
(5) Support the rear of the engine using a jack
with a piece of timber between the jack head and the
engine sump.
(6) Remove the bolts retaining the clutch hous-
ing to the engine. (7) Disconnect the vehicle speed sensor wiring,
the reverse lamp wiring, the gear lever control rod and
the gear lever support rod from the transaxle. (8) Remove the transaxle mounting through bolt
and remove the bolts retaining the mounting bracket
to the transaxle.
(9) With the left hand front wheel removed,
remove the left hand inner mudguard panel. (10) Maneuver the transaxle away from the
engine. Lower and withdraw the transaxle from under
the vehicle.
NOTE: Do not allow the transaxle to hang
on the clutch driven plate during removal.
Support the transaxle on a trolley jack if
necessary.

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

(1) Lubricate the input shaft splines sparingly
with lithium base molybdenum disulphide grease. (2) Support the transaxle during installation. Do
not allow the transaxle to hang on the clutch driven
plate. (3) Tighten all bolts to the specified torque.
(4) Fill the transaxle with the specified quantity
and grade of oil. (5) Road test the vehicle and check for correct
transaxle operation. Also ch eck for transaxle oil leaks
and rectify as necessary.
TO DISMANTLE

(1) Remove the clutch release components from Rear view of the transaxle removed from the vehicle.

Manual Transaxle and Drive Shafts 133

Dismantled view of the 1st/2nd gear synchro assembly.
(6) Select a snap ring to obtain the minimum
clearance in the input shaft groove and install the snap
ring to the rear of the input shaft.

NOTE: The maximum allowable clearance
is O.I mm. Snap rings are available from
2.00 mm to 2.30 mm in increments of
.05 mm.

(7) Ensure that the fifth gear end float is within
the specifications. (8) Install the bearing retain er to the front of the
input shaft in the direction noted on removal.
(9) Install the front bearing and spacer to
the input shaft. (10) Select a snap ring to obtain the minimum
clearance in the input shaft groove and install the snap
ring to the front of the input shaft.
NOTE: The maximum allowable clearance
is 0.1 mm. Snap rings are available from
1.27 mm to 1.45 mm in increments of
.06 mm.

(11) Assemble the components of the first/
second and third/fourth sy nchro assemblies aligning

the marks made on dismantling. Ensure that the ends
of the shift plate springs are not aligned.

(12) Install the needle roller bearing and first gear
to the mainshaft.
(13) Install the firs t/second synchro assembly to
the mainshaft. Ensure that the slots in the synchro ring are aligned with the shift plates.
(14) Install the steel ball to the mainshaft
using
grease to retain the ball. (15) Install second gear to the mainshaft and
install
the bush aligning the groove in the bush with the steel
ball. (16) Install third gear to the mainshaft.
(17) Install the third/fourth synchro assembly to
the mainshaft ensuring that the slots in the synchro
ring are aligned with the shift plates.
(18) Install the other steel ball to the mainshaft
using grease to retain the ball. (19) Install the fourth gear bush to the mainshaft
aligning the groove in the bush with the ball. (20) Install the fourth gear to the mainshaft.
(21) Install the fifth gear to the mainshaft.
(22) Install the thrust washer to the mainshaft.
(23) Select C rings to obtain the minimum clear-
ance in the mainshaft grooves and install the C rings to
the mainshaft groove. Install the C ring holder to the
mainshaft.
NOTE: The maximum allowable clearance
is 0.1 mm. C rings are available in thick-
nesses of 3.63 mm to 4.54 mm in incre-
ments of 0.07 mm.

(24) Install the rear and front bearing cones to the
mainshaft using a press and press plates. (25) Ensure that the mainshaft first, second, third
and fourth gear end floats are within the Specifica-
tions.
(26) Temporarily install the differential assembly
to the clutch housing. (27) Install the transaxle case to the clutch
hous-
ing. (28) Tighten the transaxle case retaining bolts to
the specified torque. (29) Install a suitable slotted adaptor into
the
differential pinion shaft a nd, using a torque gauge,
measure the differential tu rning torque. The turning
torque should be in a range from slightly below
3.9 Nm to 7.9 Nm. If the turning torque is not as specified, proceed to
the Differential and Final Drive heading and perform
operations (22) to (29).

If the turning torque is as specified, proceed as
follows:

(30) Remove the transaxle case and install
the
mainshaft to the clutch housing ensuring that the resin
oil channel is located centrally in the end of the
mainshaft. (31) Install the transaxle case to the clutch hous-
ing.
Dismantled view of the 3rd/4th gear synchro
assembly.