1987 NISSAN PULSAR battery

118 Emission Control


Installed view of the charcoal canister.
When the engine is at rest, fuel vapor through
evaporation gradually fills the air space in the fuel
tank. The sealed filler cap pr events the escape of this
vapor and pressure builds up within the system,
forcing the vapor to flow into the charcoal canister
which is located in the engine compartment beneath
the windscreen wiper motor.

The fuel check valve prevents liquid fuel entering
the charcoal canister when the fuel tank is full or the
vehicle is parked on a steep incline. When the engine
is running, the vapor is drawn via a hose from the
charcoal canister to the throttle body and burnt in the
combustion chambers.

TO RENEW CHARCOAL CANISTER
(1) Suitably mark and disconnect the hoses from
the canister. (2) Release the retaining spring and remove the
canister from the engine compartment. Installation is a reversal of the removal procedure.

TO RENEW FUEL CHECK VALVE
(1) Disconnect the negative battery terminal.
(2) Raise the rear of the vehicle and support it
on chassis stands. Remove the left hand rear wheel. (3) Drain the fuel from the fuel tank using a
hand pump or a suitable siphon. Do not siphon fuel
using the mouth.
(4) Remove the hoses from the check valve.
(5) Squeeze the retaining clip and remove the
check valve from the mounting bracket. Installation is a reversal of the removal procedure.

TO SERVICE THE SYSTEM
(1) Inspect the vacuum lines and connectors for
signs of leakage, cracks and deterioration and renew
as necessary. (2) Remove the fuel tank cap and check that a
slight resistance is felt, when vacuum is applied to the
one-way relief valve in the centre of the cap. Renew the fuel tank cap if no resistance is felt or
if the valve is blocked.

(3) Inspect the fuel tank cap seal for deteriora-
tion. Renew as necessary.

Installed view of the fuel check valve as seen with the
left hand rear wheel removed.
Check the fuel filler cap seal for damage.
23Q/LDZ GAUGE
Line drawing showing a hand vacuum pump.

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.

Automatic Transaxle 143
facing towards the radiator support panel at the front
of the vehicle.

The neutral safety switch allows electrical current
to pass to the starter circ uit only when the selector
lever is in the Park or Neutral position. The switch is
adjustable but non-repairable.

TO TEST
(1) Disconnect the neutral safety switch wiring
connector.
(2) Connect an ohmmeter between terminals 1
and 2 at the neutral safety switch wiring connector.
Continuity should exist when the selector lever is in
the P or N positions. (3) Perform the same check with terminals 3 and
4 with the selector lever in the R position. Continuity
should exist.
NOTE: If the readings are other than that
specified, the neutral safety switch will have
to be adjusted or renewed.


Neutral safety switch connector terminal identification.
TO ADJUST
(1) Select Neutral and firmly apply the hand-
brake. (2) Loosen the neutral safety switch retaining
bolts.
(3) Align the holes in the neutral safety switch
body and the neutral safety switch arm. (4) Install a 2.5 mm diameter split pin or drill bit
into the holes to align the arm with the neutral safety
switch body. (5) Secure the retaining bolts and test the switch
as previously described.

If the test indicates a fault, renew the neutral
safety switch.

TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the selector cable split pin and wave
washer from the transaxle selector lever.
(3) Disconnect the electric al connector and re-
move the neutral safety switch retaining bolts. (4) Maneuver the neutral safety switch clear of
the transaxle selector lever and withdraw the switch
from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Clean the area around the neutral safety
switch mounting.
(2) Apply a small amount of chassis grease to the
jaws of the neutral safety switch arm. (3) Check the adjustment of the selector cable as
previously described. (4) Adjust the neutral safety switch as previ-
ously described.

(5) Check the operation of the neutral safety
switch and ensure that the engine will not start in any
position other than P and N. Check that the reversing
lamps operate only when R is selected.

8. TRANSAXLE ASSEMBLY
Special Equipment Required:
To Remove and Install — Suitable trolley jack to
which the transaxle can be secured

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

(2) Disconnect the negative battery terminal. Remove the left hand side inner mudguard

(3)
panel.

(4) Remove the left hand drive shaft as de-
scribed in the Manual Tran saxle and Drive Shafts
section. (5) Disconnect the vehicle speed sensor wiring,
selector control cable and the neutral safety switch
wiring from the transaxle. Disconnect the kickdown
cable from the throttle linkage and the support
bracket. (6) Disconnect the oil cooler hoses from the
Using a 2.5 mm drill bit to adjust the neutral safety
switch.

147
PART 2. MANUAL STEERING
SPECIFICATIONS
Steering gear type ............................ Rack and pinion
Steering column type ...................... Energy absorbing
collapsible and tilt adjustable
Steering wheel free play

(maximum ) ...................................................... 35 mm
Linkage........................... Direct from rack ends to t i e
rods and steering knuckles
Turns lock to lock ................................................. 3.6
Steering column length .................. 534.7-537.3 mm
Steering gear lubricant.............. Castrol EPL 1 grease
TORQUE WRENCH SETTINGS
Steering wheel retaining nut ............................ 39 Nm
Steering gear to bulkhead
mounting bolts .............................................. 108 Nm
Tie rod to steering knuckle nut...................... 98 Nm
Tie rod to tie rod end locknut ....................... 98 Nm
Tie rod ball housing to rack............................ 88 Nm
Steering column to mounting
bracket bolt ...................................................... 14 Nm
Steering column universal
coupling joint pinch bolts ............................... 29 Nm
2. STEERING WHEEL
Special Equipment Required:
To Remove Steering Wheel - Steering wheel
puller

TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Using a small screwdriver, carefully prise the
centre ornament from the steering wheel.

View of the steering wheel removed from the vehicle.
Steering wheels may vary between models.

1. DESCRIPTION
The steering gear is a rack and p i n i o n type
which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.

The design of this assembly requires a range of
special tools to dismantle and assemble the steering
gear. If the steering gear is found to have a fault which
requires overhaul of the rack and pinion, it is recom-
mended that this be performed by an authorized work-
shop or steering specialist.

However, the procedures for the removal and
installation of the steering gear and the renewal of the
tie rods, the tie rod ends and the rubber boots are fully
covered in this section.

The rack and pinion assembly requires no lubri-
cation during service.

The steering column is of the energy absorbing
type designed to compress in the event of a severe
front end collision. The energy absorbing units are the
outer steering column, the tilt bracket and the steering
shaft. All these units shoul d be handled with extreme
care if service operations are performed on the
steering column assembly.

(3) Remove the steering wh eel retaining nut and
mark the steering shaft and steering wheel hub in
relation to each other as an aid to assembly.
(4) Remove the steering wheel from the steering
shaft.
NOTE: If the steering wheel will not sepa-
rate from the steering shaft, loosen the horn
pad retaining screws at the rear of the
steering wheel and withdraw the horn pad
after disconnecting the wire. A puller can
now be used to pull the steering wheel from
the steering shaft. Do not strike the end of
the steering shaft as sharp blows can cause
irreparable damage to the collapsible steer-
ing shaft.

(5) If necessary the steering wheel can be dis-
mantled as shown in the illustration.

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

(1) Apply a light coat of multipurpose grease to
the horn slip ring and the turn signal canceling pins.
(2) Ensure that the marks on the steering wheel
and steering shaf t are aligned.
(3) Tighten the steering wheel retaining nut to
the specified torque.

148 Steering — Part 2

3. STEERING COLUMN
Special Equipment Required:
To Remove Steering Wheel — Steering wheel
puller

TO REMOVE AND INSTAL
(1) Disconnect the negative battery terminal.
(2) Working in the engine compartment, mark
the relationship between the steering shaft universal
coupling joint and the steering gear pinion shaft. (3) Remove the pinch bolts from the universal
joint. (4) Working inside the vehi cle, remove the steer-
ing wheel as previously described. (5) Remove the steering column shroud screws,
unclip the lower and upper covers and remove them
from the steering column. (6) Disconnect all the steering column wiring
connectors. (7) Remove the lower trim from underneath the
steering column.
(8) Fold back the insulator and remove the nuts
from the steering colu mn floor bracket.
(9) Remove the nuts from the lower steering
column bracket. (10) Remove the bolts from the tilt bracket
assembly. (11) Maneuver the steering column from the
vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Measure the dimension between the lower
bracket pin and the upper edge of the steering shaft as
shown in the illustration.

If the dimension is not as specified, the steering
shaft has collapsed and the steering column should be
renewed.

(2) Rotate the steering shaft in the column and
check the shaft bearing for roughness and damage.
Renew as necessary. (3) Inspect the steering shaft universal coupling
joints for wear and damage and renew as necessary. (4) Position the steering column assembly under

the dashboard ensuring that the floor bracket is
located correctly and that the steering shaft universal
joint is aligned with the steering gear pinion shaft
marks.

(5) Install all the steering bracket nuts and bolts
finger tight. (6) Install the universal coupling joint pinch bolts
and tighten securely.
(7) Tighten all the stee ring column nuts and
bolts securely. (8) Test the operation of all the steering column
controls when installation is complete.
TO DISMANTLE

(1) Remove the steering column assembly from
the vehicle as previously described. (2) Suitably mark the position of the universal
coupling joint and remove it from the steering shaft. (3) Mark the position of the rubber boot in
relation to the floor bracket and steering column.
Loosen the retaining bands and remove the boot and
floor bracket from th e steering column.
(4) Using snap ring pliers, remove the snap ring,
plain washer and wave washer from the upper end of
the steering shaft. (5) Loosen the combination switch retaining
screw, push the combination switch in, turn the switch
and remove it from the steering column. (6) Turn the ignition switch to the On position
and slide the steering shaft from the column assembly. (7) If necessary dismantle the tilt bracket com-
ponents after removing the through bolts. Note the
position of the components to aid assembly. (8) To remove and install the steering lock pro-
ceed as follows: (a) Remove the ignition switch retaining screw
and carefully withdraw the switch from the steering
lock bracket.

View of the steering column assembly removed from
the vehicle. Steering column length is shown as dimen- sion A. A - 534.7-537.3 mm. Dismantled view of the steering lock and ignition
switch assembly.

Steering — Part 3 153

TO CHECK FLUID LEVEL
Check the fluid level in the power steering reser-
voir when the fluid is cold.

If it is necessary to top up the fluid, fill to between
the arrow marks on the dipstick using the recom-
mended fluid.

NOTE: Do not overfill the reservoir.
Checking the power steering fluid level using the
dipstick incorporated in the cap.
TO CHECK FOR FLUID LEAKS
Using a suitable solvent, clean around all power
steering assemblies and hose fittings where fluid
leakage might occur and start the engine. Turn the
steering wheel from one steering lock to the other
several times and stop the engine. Check for leakage.
Where leakage is found at ho se fittings, tighten and
recheck.

If the leak remains, renew the hoses or fittings as
required.

Where leakage is found in the steering gear
assembly or pump assembly, specialist attention is
necessary.

TO CHECK STEERING WHEEL FREE PLAY
With the engine running and the steering wheel in
the straight ahead positi on, measure the free move-
ment of the steering wheel before the front wheels
move. This is specified as steering wheel free play and
if it exceeds Specifications, check for free play in the
steering linkages and the universal coupling joints. If
these components are satisfactory, it will be necessary
to remove the steering gear from the vehicle for
renewal or overhaul.

PUMP BELT TENSION
The procedure for adjusting the power steering
pump bell tension is describe d in the Engine Tune-up
section

TO PURGE THE POWER STEERING SYSTEM
OF AIR

(1) Check that the pump reservoir is filled to the
correct mark on the dipstick. (2) Raise the front of the vehicle and support it
on chassis stands. (3) Turn the steering wheel quickly from lock to
lock several times, recheck the fluid level within the
pump reservoir and top up if required. (4) Start the engine, allow it to idle and slowly
turn the steering wheel from lock to lock several times.
Do not hold the steering at full lock for more than 15
seconds. (5) Check the fluid level in the pump reservoir,
top up if necessary. (6) If the fluid is aerated within the pump
reservoir or if pump noise persists, repeat operations
(3) to (6).
3. STEERING WHEEL

The procedure for removing and installing the
steering wheel is fully covered in the Manual Steering
section under the above heading.

4. STEERING COLUMN
The procedure for removing, dismantling and
assembling the steering column is fully covered in the
Manual Steering section under the above heading.

5. POWER STEERING PUMP
TO REMOVE AND INSTAL
( 1 ) Disconnect the negative battery terminal.

View of the power steering pump removed from the
vehicle.

190
ELECTRICAL SYSTEM
CAUTION: To prevent severe electrical shock extreme care must be taken when
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

SPECIFICATIONS
BATTERY
Type ..................................................12 volt lead acid
Polarity to earth .................................... Negative ( - )
Specific gravity:
Fully charged ................................... A bove 1.250
Fully discharged ................................Below 1.130
ALTERNATOR
Make .................................................Bosch or Hitachi
Maximum output .......................................... 70 amps
Polarity to earth .................................... Negative ( - )
Stator windings ......................................... Star wound
Regulator type ................................................ Integral
Brush length minimum:
Bosch ........................................................ 5.0 mm
Hitachi ............................. 6.0 mm or limit mark
STARTER MOTOR
Make .................................................Hitach i or Bosch
Type ............................ 4 pole 4 brush reduction gear
Operation control.................................. Solenoid and
overrunning clutch
Undercut of commutator (maximum):
Hitachi ...................................................... 0.8 mm
Brush length (minimum):
Bosch ........................................................ 8.0 mm
Hitachi ........................................................11 mm
Brush spring tension;
Hitachi ............................................... 15.7-19.6 N
Hitachi:
Drive pinion stopper clearance ........ 0.3-1.5 mm
Selective fit adjuster plates ........ 0.5 and 0.8 mm
IGNITION SYSTEM
The ignition system is an integral part of the
engine management system. The Specifications, testing
and overhaul procedures are fully covered in the Fuel
and Engine Management section.

TORQUE WRENCH SETTINGS
Alternator pulley retaining nut:
Bosch ......................................................... 50 Nm
Hitachi ....................................................... 59 Nm
1. BATTERY AND CHARGING SYSTEM
TROUBLE SHOOTING

BATTERY UNDERCHARGED
3. Loose or broken drive belt: Adjust or renew
the drive belt. 4. Faulty alternator regulator; Renew the regu-
lator unit.
5. Faulty battery: Install a new battery of
the
recommended type and capacity. 6. Faulty alternator: Overhaul or renew the
alternator. 7. Fault in the charging circuit wiring: Check
and repair or renew the wiring harness. 8. Faulty connections in the charging circuit:
Check and repair the connections. 9. Fusible link blown; Rectify the fault and
renew as necessary.
NOTE: Check the state of charge (specific
gravity) of the battery- as described under
the
Battery heading in this section. If the battery
is undercharged, check the possible causes in
the order given.

BATTERY OVERCHARGED
• Faulty alternator regulator unit:
Renew the
regulator unit.
• Faulty alternator: Overhaul or
renew the
alternator. • Faulty charging circuit wiring or
connec-
tions: Check and renew or repair the faulty
compo-
nents.
NOTE: An overcharged battery is indicated
by continual loss of water through boiling.

Electrical System 191
This is usually accompanied by discoloura-
tion of the electrolyte.

CHARGE INDICATOR LAMP REMAINS ON
• Loose or broken alternator drive belt: Adjust
or renew the drive belt.
• Faulty regulator unit: Check and renew the
regulator unit. • Faulty alternator: Check and overhaul the
alternator. • Short to earth in the warning lamp circuit:
Check and repair the circuit.

Checking the alternator drive belt for deterioration.
CHARGE INDICATOR LAMP DOES NOT
OPERATE

• Lamp bulb blown: Check and renew the
faulty bulb. • Open circuit in the wi ring or bulb socket:
Check and rectify the open circuit. • Faulty alternator diode: Overhaul the alter-
nator.
NOISE IN DRIVE BELT OR ALTERNATOR

(1) Drive belt frayed or out of alignment with
the pulleys: Renew the drive bell or align the pulleys.

• Loose alternator moun ting bolts or worn
bearings: Tighten the mounting bolts or renew the
bearings. • Loose alternator pulley: Tighten the pulley
retaining nut.
• Faulty alternator: Overhaul or renew the
alternator. • Faulty diodes in the alternator: Overhaul the
alternator, install a new heat sink.
NOTE: To check if the noise is in the
alternator or drive belt, loosen the alternator
and remove the drive belt. If the noise is
gone when the engine is run for a short time
check the serviceability of the belt and
alternator components.

2. BATTERY AND STARTING SYSTEM TROUBLE SHOOTING

STARTER LACKS POWER TO CRANK ENGINE
(1) Battery undercharged: Check the charging
system and rectify as necessary.


Cleaning the battery terminals using a battery post
cleaner.
• Battery faulty, will not hold charge: Check
and renew the battery. • Battery leads or terminals loose or corroded:
Clean and tighten the leads or terminals.
• Faulty starter motor: Check and overhaul the
starter motor. • Faulty starter solenoid switch or contacts:
Check and renew the solenoid as necessary.
STARTER WILL NOT ATTEMPT TO CRANK
ENGINE

(1 ) Open circuit in the starting system : Check
for dirty or loose leads or terminals, dirty commuta-
tor, faulty solenoid or faulty switch. On automatic
Spin the alternator pulley over by hand to check the
bearings for noise.