1987 NISSAN PULSAR wheel bolt torque

Brakes 183

To Dismantle
(1) Raise the rear of the vehicle and place it on
chassis stands. Remove the relevant rear wheel.
(2) Remove the brake hose retaining bolt from
the caliper body and plug the hose to prevent the loss
of fluid and the ingress of dirt. (3) Remove the handbrake cable bracket retain-
ing bolt and disconnect the handbrake cable from the
cam lever.
(4) Remove the guide bolts and slide the caliper
body off the pads. (5) Using a pair of long nose pliers with the nose
located in the recesses of the piston, rotate the piston
anticlockwise to remove it from the caliper body.
(6) Remove the dust cover retaining clip and dust
cover. Discard the dust cover. (7) Using a thin blunt probe, preferably made
from wood or plastic, remove and discard the piston
seal from the groove in the caliper bore. (8) Using internal snap ring pliers, remove the
snap ring from the caliper bore. (9) Withdraw the spring cover, spring, key plate,
pushrod and link from the caliper bore. Do not mix
these components from the left and right hand sides as
they differ. (10) Remove and discard the O ring from the
pushrod. (11) Remove the spring, nut and washer from the
cam lever. Remove the cam lever and cam from the
caliper body. (12) Remove the cam seal from the caliper using a
screwdriver.
(13) Clean all the caliper components in methy-
lated spirits and arrange the components in order on a
clean dry surface to aid assembly.
To Inspect

(1) Inspect the caliper bore and piston for pit-
ting, wear or damage. Renew the caliper assembly or
piston if damage is evident.

NOTE: Slight rust spots in the caliper bore
may be removed with fine emery paper. The
piston must not be polished as the plated
surface will be damaged.

(2) Inspect the guide bolts for wear or damage
and renew as necessary.
(3) Inspect the threads of the pushrod for wear or
damage and renew as necessary. (4) Inspect the nut inside the piston for wear,
damage and security. Renew the piston if any damage
is evident. (5) Inspect the cam for wear, damage or pitting,
renew as necessary. (6) Inspect the cam bearing in the caliper body
for wear, damage or pitting and renew the seal and
bearing as necessary. (7) Inspect the guide bolt rubbers for deteriora-
tion, wear or damage. Renew as required. To Assemble

(1)
Lubricate the cam bearing with multipurpose
grease and install the seal. (2) Install the cam and cam lever to the
caliper
body. Install the cam lever spring, washer and nut, and
tighten the nut to the specified torque. (3) Install a new O ring to the pushrod and
install
the link, pushrod, key plate, spring and spring cover to
the caliper body. The key plate must engage the caliper
body. Secure the assembly with the snap ring. (4) Dip a new piston seal in clean hydraulic brake
fluid. Insert the seal into the groove in the caliper bore
ensuring that the seal is correctly seated and not
twisted. (5) Install a new dust cover to the piston prior
to
installing the piston to the caliper bore.
(6) Coat the piston and caliper bore with clean
hydraulic brake fluid and using long nose pliers rotate
the piston clockwise into the caliper bore. (7) Locate the dust seal in the groove of the
caliper body and install the retaining clip.
(8) Lubricate the guide bolts using a suitable
grease. Install the caliper body and tighten the guide
bolts to the specified torque. (9) Replenish the master cylinder reservoir with
the recommended fluid and bleed the brakes as
described under the Hydraulic System heading. (10) Install the rear wheel and lower the vehicle to
the ground. (11) Road test the vehicle and check for correct
brake operation.
BRAKE DISC

To Check Runout
(1) Raise the rear of the vehicle and support it on
chassis stands. Remove the relevant rear wheel.
(2) Mount a dial gauge stand to a suspension
component and position the dial gauge plunger
against the wheel hub. Check that the end float is less

Using a dial gauge to measure the rear disc runout.

184 Brakes
than 0.05 mm. If the wheel hub end float exceeds
Specifications, the bearing must be renewed as de-
scribed in the Rear Suspension section.

(3) Position the dial gauge plunger against the
centre of the brake disc contact area. Rotate the hub
and measure the runout. Ma ximum allowable runout
is 0.07 mm. (4) If the runout exceeds the specified amount,
machine or renew the brake disc. (5) Install the rear wheel and lower the vehicle to
the ground. (6) Road test the vehicle and check for correct
brake operation.
To Remove and Install

(1) Raise the rear of the vehicle and support it
on chassis stands. Remove the relevant rear wheel.
(2) Remove the clip securing the brake hose to
the suspension unit and disengage the hose. (3) Remove the bolts retaining the caliper an-
chor plate. (4) Slide the caliper from the brake disc and
suspend the caliper clear of the work area using wire
or cord.
NOTE: Do not allow the caliper to hang on
the brake hose.

(5) Remove the grease cap from the rear hub.
(6) Remove the split pin, nut retainer, hub nut
and washer from the stub axle. (7) Remove the hub assembly from the stud
axle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Tighten the rear hub to the specified torque.
(2) Install the brake caliper and tighten all the
bolts to the specified torque. (3) Rotate the hub and check for roughness. If
the hub does not rotate smoothly, renew the hub
bearing as described in the Rear Suspension section. (4) Install the rear wheel and lower the vehicle to
the ground.
(5) Road test the vehicle and check for correct
brake operation.
To Inspect

(1) Inspect the machined faces of the disc for
scores, cracks, wear and signs of overheating. (2) Using a micrometer, measure the thickness
of the disc at several posit ions around the face of the
disc. Renew the disc if the minimum thickness is
below Specifications.

(3) If the disc thickness is satisfactory but the
disc is scored, machine equal amounts from the
machined face on each side of the disc, to restore the
serviceability of the disc.


Inspect the machined faces of the disc for scores,
cracks, wear and signs of overheating.
NOTE: Disc machining is best entrusted to
a reliable brake specialist who can advise on
disc serviceability.

7. REAR DRUM BRAKES
TO REMOVE AND DISMANTLE
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove th e rear wheels and release
the handbrake.
(2) Remove the grease cap from the rear hub.
(3) Remove the split pin, nut retainer, hub nut
and washer from the stub axle. Remove the brake
drum and hub assembly.

(4) Mark each brake shoe and spring to ensure
correct assembly. (5) Rotate the star wheel until the adjuster
assembly is at its shortest length.
Installed view of the left hand side rear drum brake
components.

Electrical System 201
nosed pliers. This will safeguard the diodes
by transferring any excess heat to the jaws of
the pliers.

Using a suitable drift, install the bearing into
the drive end bracket, install the retainer plate and
screws. Tighten the screws securely. Using a suitable press and press plates, install
the bearing to the slip ring end of the rotor shaft.
Ensure that pressure is ex erted only on the inner race
and that the stop ring groove is nearest to the sl i p
rings. Ensure that the rotor sh aft rear bearing stop
ring is positioned so that the protruding part of the
ring is located in the deepest part of the groove. Install the stator, diode pack and
regulator
assembly to the slip ring e nd bracket. Install the
retaining nuts and washers and tighten securely. Install the nut and insulator to the terminal
and tighten securely. Using a piece of wire, hold the brushes in a
retracted position. Hold the drive end bracket in a soft jawed
vice and install the rotor shaft assembly to the drive
end bracket. Install the pulley, retaining nut and washer to
the rotor shaft and tighten the retaining nut to the
specified torque. Apply a heated 200 watt soldering iron to the
slip ring end bracket at the bearing mounting boss for
3-4 minutes to heat the bracket and allow the
installation of the rotor shaft rear bearing. Aligning the marks made on dismantling and
ensuring that the rotor sh aft rear bearing retaining
ring protrusion is located in the deepest part of its
groove, install the rotor/stator assembly to the slip ring
end bracket.
Remove the brush retr acting wire from the
alternator, ensure that the alternator component
marks are aligned, install the retaining through bolts
and tighten them securely. Check the alternator rotor for smooth oper-
ation and install the al ternator to the vehicle
as
previously described.
Check the alternator operation on the vehicle
as previously described.
8. STARTER MOTOR
Special Equipment Required:
To Renew Brushes — Soldering iron
To Renew Armature Bearings — Bearing puller
DESCRIPTION
Two types of starter motors are installed to the
range of vehicles covere d by this manual, either
Hitachi or Bosch.

The starter motor is the induced pole type with
four brushes and four pole shoes with field coils.

A solenoid switch is attached to the starter drive
end bracket. The solenoid plunger is connected to
the overrunning clutch and drive pinion assembly
through a lever and pivot arrangement.

When the solenoid windings are energized, the
plunger acting on the lever and pivot engages the drive
pinion with the flywheel ri ng gear and at the same
time closes the switch supplying power from the
positive lead of the battery to the starter motor field
coils and armature to operate the motor.

As the engine fires, the over-running clutch of the
drive pinion assembly prevents high speed rotation of.
and possible damage to, the starter armature if the
solenoid windings are not immediately de-energized
by releasing the ignition key.

The starter solenoid switch windings are energized
by the ignition switch.

TO TEST ON VEHICLE
Should the starter motor fail to operate when the
ignition switch is turned to the Start position, check
the following points:

Check the battery condition and state of
charge. Refer to the Battery heading for the correct
procedure.
Clean the battery terminals, taking particular
care to remove the scale from the positive ( + )
terminal post and terminal. Check the earth connection for tightness and
cleanliness.
Switch on the headlamps and turn the igni-
tion switch to Start. If the lamps dim but the starter
motor does not operate, it could indicate that a short
circuit has developed in the starting system. Check that the engine is not seized or that the
starter motor drive pinion and ring gear are not
locked as these conditions would -give the same
indications as above.

(5) If the lamps do not dim and the starter
motor does not operate, this would indicate an open
circuit such as a broken or disconnected wire or a
switch not operating.

If the vehicle is equipped with an automatic
transaxle, turn the ignition switch to Start and move
the selector lever through all the gear selection range.
If the starter motor operates in any position other
than N or P, the neutral safety switch is faulty.

(6) Check all the external wiring to ensure that
the fault is not external. If the external circuit proves
satisfactory, indicating that the problem is in the
starter motor, the unit will have to be removed and
tested.

TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Disconnect the wiring from the starter motor
solenoid. Remove the starter motor mounting bolts,