1987 NISSAN PULSAR check oil

120 Emission Control
If the flap does not operate as described, renew
the air cleaner housing.

(2) Disconnect the vacuum hose from the servo
unit and connect it to a vacuum gauge.
(3) Start and run the engine at approximately
1 200 rpm. If the engine is cold there should be
vacuum. (4) As the engine temperature increases the
vacuum should decrease to zero. If the vacuum gauge does not read as described,
check that the vacuum supply hose is connected to the
thermal vacuum valve and the throttle body.

If no fault is found, renew the thermal vacuum
valve.

4. EXHAUST CONTROL SYSTEM
DESCRIPTION
The exhaust system is the greatest source of
pollutant emission from the internal combustion
engine.

On the Pulsar range of vehicles covered by this
manual, the exhaust control system consists of a
catalytic converter and the engine management sys-
tem. The engine management system constantly mon-
itors the exhaust gases via an oxygen sensor located in
the exhaust system. Fuel injection is then adjusted
accordingly to give the minimum amount of exhaust
emissions. Refer to the Fuel and Engine Management
section for further information.

CATALYTIC CONVERTER
The catalytic converter, which is located in the
exhaust system, converts hydrocarbons, oxides of
nitrogen and carbon monoxide present in the exhaust
gases into carbon dioxide, nitrogen, water and heat.

The catalytic converter does not require periodic
maintenance or replacement under normal circum-
stances. However, it can be damaged or poisoned by
excessively high exhaust gas temperatures, raw fuel
and the use of leaded fuel.

Installed view of the catalytic converter.
To prevent the use of leaded fuel, a small diam-
eter fuel filler neck with a spring loaded trap door is
used.

To prevent damage to the catalytic converter, the
following precautions sh ould be observed.

(1) Do not operate the vehicle on leaded fuel.
(2) Do not push or tow start the vehicle.
(3) Do not allow the engine to idle for prolonged
periods. (4) Do not operate the vehicle if the engine is
misfiring.
(5) Avoid running the vehicle out of fuel.
(6) Ensure that the engine oil is formulated to
contain low phosphorous levels.
To Inspect Catalytic Converter

(1) Inspect the converter for dents and damage.
If the converter is damaged, it should be renewed. (2) Inspect the converter heat shield for damage
and ensure that it is positioned correctly. Renew the
converter heat shield if necessary.
To Remove and Install
To remove and install the catalytic converter,
refer
to the Exhaust System heading in the Engine section.

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.

122 Clutch


Check the engine mountings for damage and deterio- ration.
NOTE: Clutch shudder is usually most
evident when reversing up an incline. As
loose or damaged engine mountings are a
cause for clutch shudder, thoroughly check
the engine mounting rubbers and mounting
hardware for damage or looseness before
removing the clutch for inspection.

CLUTCH GRAB
(1) Oil soaked driven plate facings: Renew the
clutch driven plate. Invest igate and rectify the source
of the oil leak.
(2) Cracked pressure plate face: Renew the pres-
sure plate assembly. (3) Loose or broken engine mountings: Check
and renew the engine mountings as necessary.
(4) Binding release mechanism: Check the oper-
ation of the release mechanism.
NOTE: Visually check the operation of the
cable actuated release mechanism. Check
the inner cable for fraying and jamming in
the outer cable.

INSUFFICIENT CLUTCH RELEASE
(1) Stretched, frayed or broken clutch cable:
Check and renew the clutch cable. (2) Worn or damaged release mechanism: Check
and renew components as necessary. (3) Insufficient pedal height: Check and adjust
the pedal height.
(4) Warped clutch driven plate: Renew the
clutch driven plate. (5) Excessive clutch release lever free play:
Check and adjust the release lever free play to
Specifications.
NOTE: Visually check that the clutch cable
operates the release lever before removing
the clutch for inspection.

RELEASE BEARING NOISE
(1) Dry or worn release bearing: Check and
renew the release bearing.
(2) Damaged pressure plate diaphragm spring;
Check and renew the pressure plate assembly.
NOTE: Lightly depress the clutch pedal with
the engine running to check for release
bearing noise. If the release bearing is faulty
and has to be renewed, always check the
other clutch components.


Check the diaphragm spring fingers for scoring and damage.
2. DESCRIPTION
The clutch consists of a single, dry, driven plate
assembly, splined to slide on the transaxle input shaft.
A diaphragm spring type pr essure plate assembly is
bolted to the engine flywheel.

The driven plate is sandwiched between the
pressure plate and the flywheel and transmits the
drive from the engine to the transaxle.

Cushion rubbers are interposed between the hub
of the driven plate assembly and the plate friction
surfaces in order to cushion the drive.

The release mechanism is actuated by the clutch
pedal through a cable to the release lever and bearing.

Operation of the clutch pedal moves the release
lever which pushes the release bearing into contact
with the diaphragm spring fingers, forcing the dia-
phragm centre towards the flywheel. When the outer
edge of the diaphragm deflects, the clutch is caused to
disengage.

Clutch pedal free play is adjusted at the release
lever end of the clutch cable.

Clutch pedal height is adjusted at the pedal stop
on the pedal mounting bracket located under the
dashboard.

Clutch 123
3. CLUTCH UNIT AND RELEASE MECHANISM

Special Equipment Required:
To Install — Clutch aligning tool
TO REMOVE
(1) Remove the transaxle from the vehicle as
described in the Manual Transaxle section. (2) Mark the pressure plate cover in relation to
the flywheel to ensure installation to the original
location. (3) Progressively loosen and remove the pressure
plate assembly retaining bolts working in a diagonal
sequence across the assembly. (4) Remove the pressure plate and driven plate
assemblies from the flywheel. Note the installed
direction of the driven plate to aid assembly.
(5) Disengage the clips retaining the release
bearing carrier to the release fork and slide the release
bearing assembly out of the clutch housing. Note the
installed position of the re taining clips to aid assem-
bly. (6) Align the release fork retaining pins with the
slots in the clutch housing and remove the pins using
a pin punch.
(7) Remove the release lever and shaft and
withdraw the release fork and return spring from the
clutch housing.
TO CHECK AND INSPECT

(1) Check the driven plate facings. Renew the
driven plate if the facings are worn down to within
0.3 mm of the rivet heads or are gummy and oil
soaked.
(2) Check the driven plate hub cushion rubbers
for deterioration and damage. Renew the driven plate
if the hub is damaged. (3) Mount the driven plate on the transaxle
input shaft and measure the spline backlash at the
outer edge of the driven plate. Renew the driven plate
if the spline backlash is beyond Specifications. (4) Check the pressure pl ate assembly for wear
on the diaphragm spring fingers, cracked diaphragm
spring and a cracked or distorted cover. Check that
the pressure plate face is not badly scored.

(5) Check the flywheel face for heat cracks, burn
marks and scoring. Renew the flywheel if it is badly
scored.

NOTE: Slight glazing or burn marks on the
pressure plate or flywheel faces can be
corrected using emery paper. Minor scoring
on the flywheel face may be corrected by
machining the flywheel.

(6) Rotate the release bearing by hand and check
for noise or roughness. Renew the bearing and carrier
as an assembly if fa ults are found.
(7) Check the release lever and shaft for wear
and damage. Renew as necessary.
(8) Check the release shaft bushes and seal for
wear or damage. Renew as necessary.
(9) Check the release fork for wear and the
return spring for fatigue. Renew as necessary.
TO INSTAL

(1) Sparingly apply lithium base molybdenum
disulphide grease to the tr ansaxle input shaft splines,
release bearing carrier bore and rear contact surfaces,
release shaft bushes and release fork contact surfaces.
Slide the driven plate onto the transaxle input shaft
and remove the excess grease from the splines. (2) Install the release shaft to the clutch housing,
return spring and release fork. Install the retaining pins
Dismantled view of the flywheel, driven plate and
clutch pressure plate.
Dismantled view of the clutch release components.

Manual Transaxle and Drive Shafts 127
(6) Lubricating oil too thick: Drain the transaxle
and refill with the corre ct amount and grade of
lubricating oil. (7) Excessive end float in the mainshaft or input
shaft gears: Overhaul the transaxle.
NOTE: Check the clutch for correct opera-
tion. If reverse gear can be selected without
any gear clash this is a good indication that
the clutch is operating normally. Also check
that the correct type and grade of lubricating
oil is being used.

SLIPPING OUT OF GEAR
(1) Worn gear control rod assembly bushes:
Check and renew the worn components as necessary. (2) Faulty gear lever assembly: Check and renew
the faulty components. (3) Faulty synchroniser mechanism: Overhaul
the transaxle.

Check the engine mountings for damage and deterio-
ration.
(4) Worn or fatigued detent components: Renew
the faulty components as necessary.
(5) Excessive end float in the mainshaft or input
shaft: Overhaul the transaxle. Check and renew the
faulty components.
NOTE: In most cases, slipping out of gear is
caused by wear or damage to internal
components of (he tran saxle. However, prior
to removing and dismantling the transaxle
assembly, check the engine mounting rub-
bers and mounting hardware as vibrations
caused by loose or deteriorated engine
mountings can cause the transaxle to slip
out of gear.

GEARS CLASH ON CHANGING DOWN
(1) Faulty clutch or clutch release mechanism:
Check, adjust or overhaul the clutch or the clutch
release mechanism.


Check the friction surface of the synchro rings and cones
for wear or damage.
(2) Faulty synchro rings or cones: Overhaul the
transaxle assembly.
(3) Lubricating oil too thick: Drain the transaxle
and refill with the correct grade and quantity of
lubricating oil. (4) Broken, weak or incorrect positioning of the
springs in the synchro asse mblies: Overhaul the tran-
saxle assembly.
(5) Excessive end float in the mainshaft or input
shaft gears: Overhaul the transaxle assembly.
NOTE: Check the clutch as previously de-
scribed prior to removing and dismantling
the transaxle. Also check that the correct
grade of transaxle oil is being used.

TRANSAXLE NOISE (IN NEUTRAL)
(1) Insufficient lubricant: Fill the transaxle with
the correct quantity and grade of lubricant. (2) Worn input shaft bearings: Overhaul the
transaxle and renew the bearings. (3) Chipped or pitted constant mesh gears:
Overhaul the transaxle and renew the damaged com-
ponents as necessary. (4) Worn mainshaft bearings: Overhaul the tran-
saxle as necessary.
NOTE: First check the oil level in the
transaxle. To isolate the noise in neutral,
run the engine, depress the clutch and
engage any gear. If the noise ceases with the
clutch depressed it indicates that the noise is
in the transaxle.

Check the input shaft for damaged gears.

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.

130 Manual Transaxle and Drive Shafts


Internal view of the transaxle showing the installed positions of the shift forks and control bracket.
the clutch housing. Refer to the Clutch section for the
correct procedure.

(2) Thoroughly clean the outsi de of the transaxle
assembly using solvent and compressed air. (3) Remove the bolts retaining the transaxle case
to the clutch housing and using a soft faced hammer,
tap the transaxle case to separate the mating surfaces.
(4) Carefully lift the transaxle case from the
clutch housing. Tilt the cas e to provide clearance for
the fifth gear shift fork. (5) Withdraw the spacer from the reverse idler
shaft and withdraw the fork shaft and spring from the
transaxle. (6) Remove the fifth and third/fourth shift forks
taking care not to lose the shift cap. (7) Remove the retaining bolts and remove the
control bracket and the first/second shift fork taking
care not to lose the shift cap. (8) Lift the mainshaft out of the clutch housing.
NOTE: When lifting, do not tilt the main-
shaft as the resin oil channel behind the
front mainshaft bearing could be damaged.

(9) Lift the differential assembly out of the
clutch housing.

NOTE: For information on the overhaul of

Dismantled view of the striking rod components.
the differential assembly refer to the Differ-
ential and Final Drive Assembly heading.

(10) Remove the retaining bolts from the input
shaft front bearing retainer. (11) Position the transaxle assembly on its side
and tap the input shaft out of the clutch housing using
a soft faced hammer. Remove the input shaft, bearing
retainer and reverse idler gear from the clutch hous-
ing.
(12) Remove the shift check ball, plug and spring
from the passage adjacent to the upper control
bracket retaining bolt on the clutch housing.
(13) Position the striking lever so that the retain-
ing pin will not contact the clutch housing and remove
the pin using a suitable punch.
(14) Remove the striking rod, striking lever and
striking interlock from the clutch housing.
(15) Remove the reverse check plug, spring and
balls from the clutch housing noting the installed
position of the small check ball.
(16) Remove the screws retaining the reverse and
fifth gear check assembly and remove the assembly
from the clutch housing.
(17) Remove and discard the input shaft and
striking rod oil seals from the clutch housing noting
the installed direction of the seals.
(18) Renew the rear input shaft bearing as fol-
lows:
(a) Remove the plastic oil channel from the
transaxle case.

(b) Using a suitable punch through the hole
adjacent to the r ear input shaft bearing, tap the small
welch plug out of the transaxle case.
(c) Using a suitable punch through the small
welch plug opening, tap the rear input shaft bearing
out of the transaxle case. (d) Using a suitable mandrel, tap the new rear
input shaft bearing into the transaxle case.
NOTE: It may be necessary to use a hydrau-
lic press if the bearing is a tight fit in the
housing.

(e) Apply sealer to a new welch plug and tap the
plug squarely into the transaxle case until the edge of
the plug is level with the case.
Dismantled view of the shift fork components.