1987 NISSAN PULSAR brake

186 Brakes
(7) Using a pair of pliers, compress the hand-
brake cable spring and install the cable to the hand-
brake lever.
(8) Position the trailing shoe on the backing
plate with the upper end located on the wheel cylinder
piston and the lower end on the anchor plate. (9) Install the adjuster assembly to the
trailing
shoe ensuring that the adjuster fork is correctly
located on the upper end of the shoe. (10) Install the pin, spring and retainer to the
trailing shoe, turn the reta iner through 90 degrees and
secure the brake shoe to the backing plate. (11) Connect the upper and lower return springs
to the trailing shoe as noted on removal. (12) Position the leading shoe on the backing
plate with the upper end located on the wheel cylinder
piston and the lower end on the anchor plate. Ensure
that the adjuster assembly is correctly located on the
upper end of the shoe. (13) Install the pin, spring and retainer to the
leading shoe, turn the retainer through 90 degrees and
secure the shoe to the backing plate. (14) Connect the upper and lower return springs
to the leading shoe.
(15) By alternatively adjust ing the automatic ad-
juster manually and sliding the brake drum on and off
the brake shoe assembly, adjust the brakes until the
brake drum will just slide over the brake shoes. Ensure
that the adjuster lever contacts the adjuster star wheel.
Install the brake drum and operate the handbrake
several times to adjust the brake shoes. (16) Install the rear wheels and rotate each wheel
to ensure that the brake shoe linings are not dragging.
(17) Bleed the hydraulic system as described
under the Hydraulic System heading. (18) Adjust the handbrake as described under the
Brake Adjustments heading.
8. HANDBRAKE CABLE AND LEVER
ASSEMBLY

HANDBRAKE LEVER AND FRONT CABLE
ASSEMBLY

To Remove and Install
(1) Raise the vehicle and support it on chassis
stands. Release the handbrake.

(2) Working beneath the vehicle, remove the
exhaust pipe centre heat shield retaining bolts and
maneuver the shield from the vehicle. (3) Remove the rear handbrake cable front
clamp retaining nuts and disconnect the rear hand-
brake cable from the equalizer. (4) Working within the vehicle, remove the
carpet square from the rear of the console. Remove
the retaining screw from the front and rear of the rear
console section and maneuver the rear console from
the vehicle.

Dismantled view of the handbrake lever components.
(5) Disconnect the handbrake warning lamp
switch wiring. (6) Remove the handbrake lever assembly re-
taining bolts and remove the handbrake lever and
front cable assembly. (7) If necessary slide the boot and cover towards
the equalizer, straighten the tang on the lower edge of
the lever and remove the adjuster nut and washer.
(8) Withdraw the front cable from the lever and
remove the boot and cover. Inspect the cable for
chafing or broken strands. Renew the cable if damage
is evident. (9) Check the handbrake lever ratchet and pawl
for wear and renew as necessary. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Apply lubricant to all the working parts prior
to installation. (2) Ensure that the handbrake cable clamp is
correctly installed. (3) Adjust the handbrake cable as described
under the Brake Adjustments heading.
REAR HANDBRAKE CABLES
TO Remove and Install
(1) Raise the rear of the vehicle and support it
on chassis stands. Remove th e rear wheels and release
the handbrake.

(2) Working beneath the vehicle, remove the
exhaust pipe centre and rear heat shield retaining
bolts and maneuver the heat shields from the
vehicle.
(3) Remove the bolts and nuts retaining the
handbrake cable clamps to the underbody and discon-
nect the rear handbrake cable from the equalizer.
(4) On disc brake models, remove the handbrake
cable to bracket retaining clip on the rear of the
caliper and disconnect the handbrake cable from the
cam lever. Remove the cable from the vehicle.
(5) On drum brake models , proceed as follows:
(a) Remove and dismantle the rear brakes as

previously described.

Brakes 187
(b) Disengage the handbrake cable return spring
from the backing plate.

handbrake cable flange from the rear of the backing
plate and remove the cable from the vehicle.

(6) Inspect the rear handbrake cables for chafing
or broken strands. Renew the cables if damage is
evident.

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

(1) Ensure that the handbrake cable clamps are
correctly installed. (2) On drum brake models, install the
handbrake
cable to the backing plate by carefully tapping the
flange on the handbrake cable. Ensure that the cable is
not damaged. (3) Adjust the handbrake cable as described
under the Brake Adjustments heading.
9. BRAKE ADJUSTMENTS

FRONT AND REAR DISC BRAKES
The disc brakes are self adjusting and no manual
adjustment is required or provided.

REAR DRUM BRAKES
Depress the handbrake lever button, apply and
release the handbrake lever several times to adjust the
rear brake shoes.

HANDBRAKE
(1) Raise the rear of the vehicle and support it
on chassis stands. (2) Remove the carpet square from the rear of
the console. Remove the retaining screws from the
front and rear of the rear console section and manoeu-
vre the rear console from the vehicle. (3) Tighten the adjusting nut until the hand-
brake lever pull is between 7-11 notches. (4) Check that the rear wheels are not binding. If
the rear wheels do not rotate freely refer to the Brakes
Trouble Shooting for possible causes.
(5) With the ignition switched On, check that
the handbrake warning lamp is extinguished when the
lever is fully released. (6) Lower the vehicle to the ground and test the
handbrake on an incline.
10. BRAKE PEDAL

TO REMOVE AND INSTAL
(1) Working inside the vehicle remove the re-
taining clip from the clevis pin and remove the clevis
pin connecting the brake pedal to the pushrod.

Dismantled view of the brake pedal components.
(2) Remove the nut from the pivot bolt and
withdraw the brake pedal pivot bolt.
(3) Maneuver the brake pedal from the mount-
ing bracket. (4) Remove the spring from the brake pedal.
(5) Inspect the return spring for breakage or
fatigue. Renew as required.
(6) Inspect the pedal pivot bolt for damage or
wear. Renew as required. (7) Inspect the brake pedal for wear, cracks or
fatigue. Renew as required. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Sparingly lubricate the pedal pivot bolt and
clevis pin with a suitable grease. (2) Ensure that the brake pedal pivot bolt is
correctly located in the pedal bracket. (3) Ensure that the clevis pin is inserted fully
through the clevis and the retaining clip is correctly
installed. (4) Check and if necessary adjust the brake
pedal height and stop lamp switch as described below.
TO ADJUST PEDAL HEIGHT

The dimension for the pedal height is measured at
right angles from the floor, with the carpet pulled
back, to the centre of the pedal pad.

(1) Working inside the ve hicle, disconnect the
wiring from the stop lamp switch.
(2) Loosen the stop lamp switch locknut and
position the switch away from the brake pedal. (3) Loosen the locknut on the brake pedal push-
rod and adjust the pushrod to achieve a pedal height
of 155-165 mm on manual transaxle models or
164-174 mm on automatic transaxle models. Tighten
the locknut. (4) Adjust the stop lamp switch as described
under the following heading.

188 Brakes

Illustration showing the brake pedal adjustments. Di-
mension H = brake pedal height, Dimension C = stop
lamp switch clearance, Dimension F - brake pedal free
play.
TO ADJUST STOP LAMP SWITCH
(1) Loosen the stop lamp switch locknut and
disconnect the wiring from the switch.
(2) Adjust the stop lamp switch to achieve a
clearance of 0.3-1.0 mm between the pedal stop and
the threaded end of the switch. (3) Tighten the locknut and connect the wiring
to the switch. Ensure that the stop lamps are off when
the pedal is released.
(4) Ensure that the pedal free play is 1.0-3.00
mm after adjustments have been completed.
11. HYDRAULIC SYSTEM

TO BLEED
Bleeding the hydraulic system should only be
necessary when some portion of the hydraulic system
has been disconnected or fluid has been drained,
allowing air to enter the system.

The brake fluid in the hydraulic system should be
changed every 30 000 km or 18 months. The proce-
dure for changing the brake fluid and bleeding the
hydraulic system are simila r with attention to the
notes in the text.

There are four points in the system where bleeder
valves are installed, one on each front caliper and one
on each rear wheel cylinder or rear caliper.

14. Fill the fluid reservoir with clean hydraulic
brake fluid and maintain at least one third full
throughout the entire operation. 15. Attach a transparent hose to the bleeder
valve on the left rear cali per and immerse the other
Bleeding the right hand rear brake caliper.
end of the hose in a small amount of clean brake fluid
contained in a clean glass jar held higher than the
bleeder valve.

14. Unscrew the bleeder valve one
complete turn.
15. Have an assistant depress the brake
pedal slowly to the full extent of its travel. Close
the bleeder valve and allow the brake pedal to
r e t u r n w i t h o u t assistance. 16. Repeat operations (3) and (4) until
a con stant stream of fluid, without any air
bubbles, is being discharged into the gl ass jar,
hold the brake pedal down and tighten the
bleeder valve.
Bleeding the right hand front brake caliper.

Brakes 189
NOTE: If changing the brake fluid, continue to be made. Always use new brake fluid for
bleeding the system until clean new fluid t opping up the reservoir.
flows from the bleeder hose. (6) Carry out the operation on the right front,
Do not allow the fluid level in the reser- right rear, right rear and left front brake in that order.
voir to fall below the one third full level at (7) Replenish the reservoir with the specified
any time during the operation or air will brake fluid to the indicated level and install the
enter the system and a fresh start will have reservoir cap.

208 Electrical System

STOP LAMP SWITCH
To Remove and Install
Disconnect the switch wi ring at the connec-
tors.
Loosen the switch locknut and unscrew the
switch from the pedal bracket.
Installation is a reversal of the removal procedure
with attention to the following points:

The stop lamp switch is also the return stop for
the brake pedal. Adjust the pedal free play as de-
scribed in the Brakes section.


Installed view of the stop lamp switch and the flasher
unit.
HANDBRAKE WARNING LAMP SWITCH
To Remove and Install
Lift the small plastic cover directly under the
handbrake and remove the screws.
Remove the carpet at the rear of the centre
console and remove the screws.
Carefully remove the console from the hand-
brake assembly. Remove the retaining screw and withdraw
the switch from the handbrake lever. To Test


Remove the handbrake console as described
in the previous text.
Disconnect the switch wiring at the con-
nector. Connect an ohmmeter between the switch
terminal and a suitable earth. Pull the handbrake lever up.
If no reading is displayed on the ohmmeter,
the switch is faulty and should be renewed using the
procedure previously described. Installation is a reversal of the removal procedure.

COURTESY LAMP DOOR SWITCH
To Remove and Install
With the door fully open, remove the retain-
ing screw from within the rubber cover of the switch. Withdraw the switch from the centre door
pillar.
Disconnect the wiring from the switch and
remove the switch from the vehicle. Installation is a reversal of the removal procedure.


View of the courtesy lamp door switch removed from
the vehicle.
REVERSE LAMP SWITCH
On automatic transaxle models, a combined neu-
tral safety switch and reverse lamp switch is installed
on the side of the transaxle. The test and renewal
procedures are described in the Automatic Transaxle
section.

To Remove and Install
Disconnect the wiring connector terminals at
the reverse lamp switch. Remove the reverse lamp switch from the
transaxle housing. Installation is a reversal of the removal procedure.
Installed view of the handbrake warning lamp switch.

216 Electrical System

NOTE: While checking the operation of the
fusible link, loosely connect the battery-
terminal only, to safeguard against damage
to the wiring harness.

(5) If the circuit is still inoperative or the fusible
link burns out again, refer the problem to an auto-
motive electrician.

RELAY LOCATIONS
The various relays employed in the vehicle elec-
trical system are located behind the fusible links
adjacent to the washer bottle in the engine compart-
ment, on the engine compartment bulkhead, under
the windscreen wiper motor and in the fuse box at the
lower right hand side of the dashboard.

The engine compartment relays power the radia-
tor fan, horn, condenser fan, bulb check, automatic
transaxle neutral safety switch, air conditioner and
condenser motor.


Installed view of the fuse box relays.
The fuse box relays power the fuel pump, ignition,
some accessories and the el ectronic control module.

18. TRAILER WIRING
There are several brands of trailer wiring connec-
tors available with a variet y of pin configurations. The
most common is the seven pin type which provides
for two auxiliary circuits, usually used for reverse
lamps and electric trailer brakes.


Installed view of the engine compartment relays.
Installed view of the engine compartment relays.


Useful connections which can be used if the trailer to
be towed is fitted with different type plug to the towing
vehicle socket
Brylite seven pin trailer plug and socket.

Electrical System 217
When installing a trailer socket, it may be neces-
sary to replace the original vehicle flasher unit with a
heavy duty unit to maintain the flash rate in accor-
dance with local regulations. Local regulations may
also require the installation of a dashboard mounted
repeater lamp.

Should the trailer socket and plug not be matched,
adaptors can be made or obtained to facilitate con-
nection.

TO INSTAL TRAILER SOCKET.
The minimum materials required are a trailer
socket, mounting bracket, seven core flex, insulated
wiring connectors and a rubber grommet.

(1) Disconnect the negative battery terminal.
(2)Locate the wiring harness for the lamps at
the rear of the vehicle.

For five pin sockets and plugs, use the following
standard trailer wiring code:

Terminal No.CircuitColor2 Left turn signal lampYellow
3Earth White
5 Ri
ght turn signal lampGreen
6Stop lamp Red
7 Tail lam
p Brown

Minimum material needed for wiring up a trailer.
Utilux trailer socket and plug shown.
(3) Identify the wires for the right turn signal
lamp, left turn signal lamp, tail lamp, stop lamp,
reverse lamp and earth. Use the vehicle wiring
diagram in this section to determine the wire color
for each lamp circuit.
(4)Connect the seven core flex to the various
lamp wires using insulated connectors.
For seven pin sockets and plugs, use the following
standard trailer wiring code:

Terminal No.CircuitColor1 Left turn signal lamp Yellow
2 Reversing lamp Black
3EarthWhite
4 Right turn signal Green
lamp
5Electric brakesBlue
6 Stop lampRed
7
Tail lampBrown
For six pin sockets and pl ugs, use the following
standard trailer wiring code:
Terminal No.CircuitColor1 Tail LampBrown
2 Left Turn Signal Lamp Yellow
3Right Turn Signal LampGreen
4 Stop LampRed
5AuxilaryBlue
6 Earth White

(5) Drill a suitably si
zed hole through the vehicle
floor and install a rubber grommet to the hole.

NOTE: Before drilling the hole, check
whether there is an existing hole which may-
be used. Ensure that a rubber grommet is
installed to prevent chafing of the wires.

Pass the seven core flex through the rubber
grommet. Cut the seven core flex to the required length
and slide the dust cover onto the flex. Remove approximately 15 mm of insulation
from each wire in the flex.
Connect the wires of the seven core flex to
the terminals of the socket, using the standard wiring
code and following the socket manufacturers connec-
tion procedure. Assemble the socket and install the dust cover
to the rear of the socket. Install the mounting bracket as close as
possible to the tow bar ball and high enough to
maintain vehicle ground clearance. Install the socket to the mounting bracket.
Connect a trailer plug to the socket and test
for correct lamp operation.
TO INSTAL TRAILER PLUG

The minimum materials required are a trailer
plug, seven core flex and insulated wiring connectors.

The installation procedure for the trailer plug is
similar to that for the socket with attention to the
following points:

Connect the trailer wiring to the plug accord-
ing to the standard wiring color code and the plug
manufacturers instructions. Use a suitable length of
seven core flex and insulated connectors should the
trailer wiring not be long enough.
If the trailer wiring does not conform to the
standard color code, identify each circuit as follows: (a) Locate the trailer earth wire.

PLUG

218 Electrical System
Connect a jumper lead from the negative
terminal of a 12 volt battery to the earth wire. Connect a jumper lead from the positive
terminal of a 12 volt battery and connect each of the
trailer lamp wires in turn to the positive battery terminal jumper lead, noting the color of the wire
and the lamp circuit operated.

(3) After installation, connect the trailer plug to
the socket on the vehicle and check for correct lamp
operation.


Vehicle and trailer wired to conform to Australian Standard AS2513. Sockets and plug shown are as viewed
from the terminal side of the component. Refer to the text for the correct terminal applications when using a
5 or 6 pin socket and plug.

COLOUR CODE
B - Black
G - Green
L - Blue
N - Brown
R - Red
W - Whlte
Y -Yellow

1 To vehicle wiring 7.Trailer reverse lamp

harness 8.Trailer L H turn signal
2. 7 pin socket — Bosch. lamp

Hella. Utilux 9.6 pin socket - Utilux
3 7 pin plug - Bosch, 10.5 pin socket - Bosch

Hella, Utilux Hella
4. Trailer R H turn signal 11.7 pin socket - Brylite

lamp 12.Trailer electric brakes
5. Trailer tail lamp
6. Trailer stop lamp