1987 NISSAN PULSAR torque

Steering — Part 2 151
(8) Slide the rack out of the housing slightly so
that an adjustable spanner can be used to hold the
rack. (9) Using a Stillsons wrench, unscrew the ball
housings in turn using care not to allow the rack to
rotate. Keep all the tie rod parts in order. (10) Inspect the rack boots for cracks and deteri-
oration and renew as necessary. (11) Inspect the tie rod ends for wear and damage
and renew as necessary.

Dismantled view of the tie rod ball housing and the tie
rod end assemblies removed from the steering gear.

Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Using large Stillsons and a large adjustable
spanner, install the tie rod and ball housing
assemblies
to the rack. Tighten the ball housings to the specified
torque.

NOTE: To avoid damage to the rack or
pinion the adjustable spanner must be
firmly tightened over the rack teeth and the
rack must not be allowed to rotate when
installing the ball housings.

(2) Measure a point 9 mm in from the rear face
of the ball housing of the rack and at 90 deg to the
rack teeth. Centre punch this point.
(3) At this point drill a 4 mm hole, 10 mm deep
through the rack and into the ball housing thread.
(4) Place a locking pin above the hole and drive
it into position.
(5) Lubricate the rack, rack teeth and t i e rod
boot groove with suitable EPL 1 grease. (6) Install the rack boots and secure with the
clamps. Renew the clamps if necessary. (7) Install the tie rod end locknuts and then the
tie rod ends, ensuring that they are screwed on the
same number of turns as was necessary to remove
them.
(8) Tighten the locknuts to the specified torque.
(9) Install the mounting rubbers and brackets
to
the steering gear as noted on removal. (10) Install the steering gear assembly to
the
vehicle as previously described. (11) Check and if necessary adjust the front wheel toe in as described in the Front Suspension section
under the appropriate heading.

TO RENEW TIE ROD END
(1)
Raise the front of the vehicle and support it
on chassis stands. (2) Remove the relevant front wheel.
(3) Loosen the tie rod end locknut and remove
the tie rod end castellated nut. Disconnect the tie rod
from the steering arm by plac ing a suitable dolly or
hammer against one side of the steering arm eye and
striking the opposite side with a hammer. (4) Unscrew the tie rod end from the tie rod,
noting the number of turns necessary to remove it.
(5) Screw the new tie rod end onto the t i e rod
the same number of turn s noted during removal.
(6) Connect the t i e rod to the steering arm and
install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin.
(7) Install the front wheel and lower the vehicle
to the ground. (8) Check and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. Ensure that the rubber boots are not distorted
or twisted on the tie rod when the adjustment is
completed.
TO RENEW RUBBER BOOT

(1) Raise the front of the vehicle and support it
on chassis stands. (2) Remove the relevant t i e rod end as previ-
ously described. (3) Release the clamps securi ng the boot to the
tie rod and steering gear housing. (4) Unscrew and remove the locknut from the
tie rod. (5) Remove the rubber boot together with the
outer retaining clamp from the t i e rod. (6) Sparingly lubricate th e tie rod boot groove
with EPL 1 grease, install the new boot to the t i e
rod
and push it onto the steering gear rack housing. Install
and secure the inner and outer retaining clamps.
(7) Install the tie rod end locknut and screw
the
tie rod end onto the tie ro d the same number of turns
noted during removal. (8) Connect the tie rod to the steering arm and
install the castellated nut. Tighten the nut to the
specified torque and secure it with a new split pin. (9) Install the wheel and lower the vehicle to the
ground. (10) Check and if necessary, adjust the front
wheel toe in as described in the Front Suspension
section. Ensure that the rubber boots are not distorted
or twisted when the adjustment is completed.

152
PART 3. POWER STEERING
SPECIFICATIONS
Steering gear type ................Rack and pinion with
integral power cylinder
Steering column type .................... Energy absorbing
collapsible and lilt adjustable
Steering wheel free play ................................. 35 mm
Number of turns lock to lock:
TRW ...............................................................2.82
PR24SA ........................................................... 2.7
Linkage.....................................Direct from rack ends
to ti e rods and steering knuckles
Power steering pump

maximum pr essure.................................... 6 865 kPa
Lubricant ...................................................... Dexron II
TORQUE WRENCH SETTINGS
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
Power steering pump pulley nut ..................... 68 Nm
1. DESCRIPTION
The vehicles covered by this manual are equipped
with either a TRW power steering system or a
Japanese PR24SA power steering system.

Both types are similar in construction and appear-
ance.

The power steering is a rack and pinion type
which is mounted on the lower section of the engine
compartment bulkhead by rubber mountings and
brackets.

Hydraulic pressure is supplied to the power
steering gear by a pump driven by a drive belt from
the engine.

The power steering pump has a separate fluid
reservoir located on the righ t side of the bulkhead.

No lubrication of the steering gear or steering
pump is required in service and in the event of the
loss of power assistance, the steering will continue to
operate but will require a greatly increased effort.
However, as the steering gear and pump are lubricated
by the power steering fluid, the cause of the loss of
power steering or fluid loss must be determined and
repaired promptly to prevent damage to the steering
pump and to a lesser extent, the steering gear.

The t i e rod ends and rubb er boots can be renewed
without removing the steering gear from the vehicle.
To renew the integral t i e rod and tie rod ball housings,
the steering gear must be removed.

As specialist knowledge and equipment are re-
quired to overhaul the power steering gear and the

hydraulic pump, it is recommended that these op-
erations be carried out by an authorized dealer.
However, procedures for the removal and installa-
tion of the steering gear and pump are fully de-
scribed in this section.

The steering column is of the energy absorbing
type and is designed to collapse in the event of a
severe front end collision. The energy absorbing com-
ponents are the column tu bes, steering shaft and tilt
bracket breakaway capsules. All these components
should be handled with extr eme care if service opera-
tions are to be carried out on the steering column
assembly.

2. IN CAR ADJUSTMENTS, CHECKS AND
MINOR REPAIRS

If the power steering system becomes partially or
fully inoperative it is most important that the follow-
ing preliminary inspection and testing procedure be
performed prior to undertaking any trouble shooting
or repair operations.

PUMP DRIVE BELT
Inspect the pump drive belt for breakage, glazing
or wear. If any of these characteristics are evident,
renew the belt using only a genuine replacement.

If the belt is loose but still serviceable, adjust it
using the procedure outlined in the Engine Tune-up
section.

NOTE: In most cases a loose drive belt can
be heard squealing when a load is placed on
the pump as the steering wheel is turned or
as the engine speed is increased.

Checking the power steering pump drive belt for
deterioration.

Steering — Part 3 155
(4) Support the rack carefully and lever back the
tabs of the ball housing lock washers. To prevent
damage to the steering gear, avoid any impact to the
steering rack.
(5) Holding the rack with an adjustable spanner,
unscrew the ball housings from the rack using a
Stillsons wrench. Remove and discard the lock wash-
ers. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the new lock washer to the
rack,
ensuring that the lockwasher tangs are located in the
rack end. (2) Install the ball housing as semblies to the rack.
Tighten the ball housings to the specified torque and
secure by bending the lock washer. (3) Before installing the rubber boots ensure that
the vent holes, located towards each end of the rack
near the ball housings, are clear. If necessary clear the
hole with a suitable probe. (4) Apply sealant to the la rge end of the rubber
boot and grease to the small end. and install the boots,
being careful not to damage or twist them. Secure the boots with the clamps and clip
s ensuring that the clips
are facing downwards.

(5) Install the t i e rod end locknuts and tie rod
ends to the t i e rod. Install the t i e rod ends the same
number of turns noted on removal. Tighten the lock-
nuts to the specified torque.

Install the power steerin g gear assembly to the
vehicle as described under the previous heading and
bleed the system as described under the heading In
Car Adjustments, Checks and Minor Repairs.

TO RENEW RUBBER BOOTS
The procedure to renew the rubber boots is fully
covered in the Manual Steering section under the
Steering Gear Assembly heading.

TO RENEW TIE ROD ENDS
The procedure to renew the t i e rod ends is fully
covered in the Manual Steering section under the
Steering Gear Assembly heading.

156
FRONT SUSPENSION
SPECIFICATIONS
Type.................. Independent MacPherson strut with
coil springs and control arms
Shock absorber .................. Hydraulic, non-repairable
Hub bearing end float (maximum) ............. 0.05 mm
Ball joint axial play (maximum) ....................0.7 mm
Ball joint turning torque (used)...............0.5-4.9 Nm
Wheel alignment:
Toe in ..................................................... 0-2 mm
Camber ........................................- 0 ° 1 0 ' ± 4 5 '
Caster ..............................................1 ° 1 0 ' ± 4 5 '
King pin inclination..................... 1 3 ° 5 5 ' ± 4 5 '
TORQUE WRENCH SETTINGS
Hub bearing nut..................................... 196-235 Nm
Suspension unit to steering knuckle nut ...... 118 Nm
Suspension unit to body nuts ......................... 29 Nm
Piston rod nut .................................................. 72 Nm
Brake caliper to steering knuckle bolts ........... 52 Nm
Ball joint to steering knuckle bolt ................... 86 Nm
Control arm bracket bolts ............................... 98 Nm
Control arm pivot bolt ................................ 118 Nm
Stabiliser bar link nuts..................................... 44 Nm
Stabiliser bar bracket bolts .............................. 21 Nm
1. FRONT SUSPENSION TROUBLE
SHOOTING

FRONT END NOISE
(1) Loose upper suspension mounting or piston
rod: Tighten the mounting or piston rod nuts. (2) Loose or worn suspension unit lower ball
joint: Tighten or renew the lower ball joint.
(3) Noise in the suspension unit: Renew the
faulty suspension unit, preferably in pairs.
(4) Worn or loose steering gear: Overhaul the
steering gear assembly. (5) Worn front hub bearings: Renew the hub
bearings:
(6) Loose or defective stab ilizer bar, control arm
or mountings: Check, tighten or renew the mounting
rubbers.

Check the ball joints for wear and deterioration.
(7) Worn stabilizer bar link ball joints: Renew
the stabilizer bar links.
(8) Drive shafts worn or insufficiently lubri-
cated: Check the lubricant and the dust boots and
renew as necessary. (9) Drive shaft splines in the hub or the
differential worn or dama ged: Check and renew as
necessary.

NOTE: To check the front suspension com-
ponents for wear, raise the front of the
vehicle, support it on chassis stands and
allow both front wheel to hang free. With an
assistant pushing and pulling the front
wheels in and out at the top and then at the
bottom, check for excessive looseness at the
front hub bearings and lower control arm
inner pivot bushes. Noise or vibration in the
front end can also be caused by excessive
tire or wheel unbalance. Drive shaft joint
noise is usually more pronounced when
moving slowly with the steering on full lock.

POOR OR ERRATIC ROAD HOLDING
ABILITY

(1) Low or uneven tire pressures: Inflate the
tires to the recommended pressures.

(2) Defective suspension unit: Renew the faulty
unit, preferably in pairs.

158 Front Suspension


Installed view of the front suspension. When using a floor jack locate the head of the jack on the crossmember.
(2) Remove the cap, split pin, castellated re-
tainer and with the aid of an assistant applying the
brakes, loosen and remove the hub nut.
(3) Remove the split pin and the castellated nut
retaining the tie rod end to the steering knuckle. (4) Disconnect the tie rod end from the steering
knuckle using a suitable puller. Alternatively place a
suitable dolly or hammer against one side of the
steering knuckle eye and strike the opposite side with
a hammer.
(5) Remove the brake caliper anchor plate bolts,
withdraw the caliper from the disc and support it with
a piece of wire inside the inner mudguard. Ensure that
the brake hose is not twisted.
(6) Withdraw the brake disc from the hub.
(7) Loosely install the hub nut and tap on the nut
with a soft faced hammer to separate the drive shaft
from the hub. (8) Place a mark on the suspension unit to
steering knuckle cam head bolt to ensure correct wheel
alignment on assembly. (9) Remove the steering knuckle to suspension
unit nuts and bolts. (10) Remove the split pin and the castellated nut
retaining the lower ball joint stud to the steering
knuckle. (11) Disconnect the ball joint stud from the steering knuckle using a suitable puller or alternatively
place a suitable dolly or hammer against one side of
the steering knuckle eye and strike the opposite side
with a hammer.

(12)
Withdraw the steering knuckle from the
vehicle taking care not to drop the drive shaft or
damage its boot. (13) Clean and check the steering knuckle for
wear, cracks and damage. (14) If necessary, dismantle the hub and check
the bearing assembly using the dismantling procedure
described later in this section. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the steering knuckle and hub assembly
over the drive shaft and loosely install the ball joint
stud nut and the suspension unit to knuckle bolts and
nuts.
(2) Ensure that the suspension unit to steering
knuckle cam head bolt mark s are aligned and tighten
the retaining nuts to the specified torque.
NOTE: If the cam head bolt is not installed
in its original position, a wheel alignment
should be performed.

(3) Tighten the ball joint to steering knuckle stud
bolt to the specified torque.

Front Suspension 159
(4) Install the tie rod end to the steering knuckle
and tighten the castellated nut securely. Install a
new
split pin.
(5) Install the brake disc to the hub.
(6) Install the brake caliper to the steering
knuckle and tighten the retaining bolts to the specified
torque. (7) Install the hub nut and washer to the
drive
shaft and with the aid of an assistant applying the
brakes, tighten the hub nut to the specified torque. (8) Install the hub nut retainer and a new
split
pin to the drive shaft. (9) Check the hub end float as described later in
this section. (10) Install the fron t wheel and lower the vehicle
to the ground.
TO DISMANTLE

NOTE: The front wheel bearing assembly is
non-serviceable. If the wheel bearing is dis-
mantled for any reason it should be re-
newed.

(1) Remove the steering knuckle from the vehi-
cle as previously described. (2) Hold the steering knuckle assembly in a vice
with soft jaw guards. (3) Using a hammer and a suitable pipe or tube
that pushes on the inside of the hub, drive out the
wheel hub and outside inner race from the steering
knuckle assembly. (4) Using snap ring pliers, remove the snap ring
that retains the outer bearing race from the wheel side
of the steering knuckle. (5) Using a suitable press and press plates,
support the steering knuckle with the outside face
downwards. To aid in dismantling, position the inside
inner race in the bearing and press the assembly from
the steering knuckle. Discard the bearing assembly. (6) Using a bearing puller and a press, remove
the inner race from the hub assembly. If the inner race cannot be removed from the hub
in this manner, it may be necessary to grind the race

using an angle grinder and split the race using a cold
chisel.

(7) Thoroughly clean and dry the steering
knuckle and hub in a suitable solvent. (8) Inspect all the components for wear, damage
and cracks and renew if necessary.
TO ASSEMBLE

Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Apply grease to the oil seal lips of the new
bearing assembly.

NOTE: Ensure that (he inside of the outer
race of the bearing is precoated with wheel
bearing grease. If necessary, pack the outer
race of the wheel bearing with wheel bearing
grease after it is installed to the steering
knuckle.

(2) Using the press and press plates, support the
steering knuckle with the outside face uppermost.
Using a suitable diameter steel tube that contacts on
the outer race only, press the outer race full into the
steering knuckle.
(3) Install the snap ring to the groove in the
steering knuckle.
(4) Install the inner races to the steering
knuckle
and support the inner race on the press using a
suitable tube or mandrel. (5) Using the press and a suitable tube press the
hub assembly into the steerin g knuckle. When using
the press ensure that the pressing force does not
exceed 29 kN. (6) With the press exerting a force of 44.1 kN
rotate the steering knuckle from side to side several
turns to ensure that the wh eel bearings are operating
smoothly.
(7) Install the steering knuckle to the vehicle
as
previously described.
TO CHECK HUB END FLOAT

(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheel.
(2) Mount the dial gauge on the steering knuckle
so that the dial gauge plunger is against the wheel hub.
(3) Zero the dial gauge and attempt to move the
hub in and out. Total hub e nd float should not exceed
0.05 mm. (4) Renew the wheel bearing as previously de-
scribed if necessary.
4. SUSPENSION UNIT

Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) Raise the front of the vehicle and support it
on chassis stands. Remove the front wheels.
Dismantled view of the steering knuckle and hub
components.

Front Suspension 161


View of the suspension unit and knuckle assembly removed as a unit to show the cam head bolt.
(1) With the piston rod fully extended, install the
coil springs. Ensure that the spring compressor is
tightened sufficiently.

NOTE: The flat coiled end of the spring
should face the top and the lower end of the
spring should be located correctly.

(2) Install the dust cover, bump rubber, insulator,
spring seat, thrust washer and mounting assembly
ensuring that the arrow on the spring seat will face the
outside of the vehicle when the suspension unit
assembly is installed.
(3) Install the piston rod nut and tighten the nut
securely.
(4) Remove the coil spring compressor from the
suspension unit assembly and tighten the piston rod
nut to the specified torque. (5) Install the suspension unit assembly to the
vehicle, holding it in position by loosely installing the
upper mounting retaining nuts. (6) Install the suspension unit assembly lower
mounting to the steering knuckle, align the mating
marks on the cam head bolt and tighten the nuts and
bolts to the specified torque.
NOTE: If the cam head bolt is not installed

in its original position, a wheel alignment
must be performed.

(7) Tighten the upper retaining nuts to the
specified torque.
(8) Install the brake hoses to the suspension unit.
Lower the vehicle to the ground.
(9) Check the front wheel alignment and adjust
as necessary. Refer to the Suspension and Steering
Angles heading in this section.
5. CONTROL ARM
Special Equipment Required:
To Renew Ball Joint and Control Arm Bushes —
Press, suitable t ubes and mandrels
To Test Ball Joint — Small torque wrench or
preload gauge, spring scale

TO REMOVE AND INSTAL
(1) Loosen the front wheel nuts, raise the front
of the vehicle and support it on chassis stands.
Remove the front wheel.

(2) Remove the split pin from the ball joint
retaining nut and remove the nut.
(3) Disconnect the ball joint from the control
arm using a suitable puller, or alternatively place a
suitable dolly against one si de of the control arm eye
and strike the opposite side with a hammer until the
ball joint stud is free from the control arm eye. (4) Remove the nut retaining the stabilizer link
to the control arm.

(5) Remove the nut and through bolt from the
front control arm bush. (6) Remove the bolts from the rear control arm
bush bracket and withdraw the control arm from the
vehicle. (7) Inspect the control arm for cracks, damage
and distortion and renew if necessary. (8) Inspect the ball joint and bushes for damage,
deterioration and excessive wear. If necessary renew
BALLJOINT
View of the control arm and associated components.

162 Front Suspension
the ball joint or bushes as described later in this
section.

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

(1) When installing the control arm bush
bracket, ensure that the protrusion on the bracket is
towards the inside of the vehicle.
(2) Do not fully tighten the control arm bush
bolts and through bolt nut until the curb weight of the
vehicle is on the suspension.
NOTE: Curb weight is with the vehicle
unladen except for a full tank of fuel and
normal amounts of oil and water and with
the spare lyre, jack and hand tools in their
normal positions.

(3) Tighten the ball joint nut to the specified
torque and retain with a new split pin.

TO CHECK AND RENEW BALL JOINT
(1) Remove the control arm from the vehicle as
previously described.

(2) Install the ball joint nut and turn the ball
joint at least ten revolutions to ensure that the ball
joint is correctly seated. (3) Using a spring scale with the hook placed
over the split pin hole, check the ball joint swinging
torque. A new ball joint should measure 15.7-80.4 N
and a used ball joint should measure 7.8-80.4 N.
Renew the ball joint if necessary. (4) Using a small torque wrench or preload
gauge, measure the force requi red to rotate the ball
joint. A new ball joint should measure between
1.0-4.9 Nm and a used ball joint should measure
between 0.5-4.9 Nm. Renew the ball joint if neces-
sary.

(5) To renew the ball joint, remove the snap ring
from the stud end of the ball joint using snap ring
pliers. (6) Support the control arm in a press, ball joint
stud uppermost, with a suitable tube that is large
enough for the ball joint to pass through. (7) Press the ball joint out from the control arm.
(8) Press a new ball joint into the control arm
using a suitable tube that pushes on the outer circum-
ference of the joint only.
(9) Install the snap ring and install the
control
arm to the vehicle as previously described.

TO RENEW CONTROL ARM BUSHES
(1) Remove the control arm from the vehicle as
previously described. Mark the position of the rear
control arm bush. (2) To remove the rear control arm bush use a
bearing puller and a press. When installing the bush
use a suitable tube that pushes on the inner edge of the
bush only. NOTE: Ensure that the bush is installed
with the flat portion in its original location.

(3)
To remove the front control arm bush use a
suitable tube that pushes on the outer circumference
of the bush and a split tu be supporting the control
arm. (4) After the bush has been pressed out approx-
imately half way, cut the protruding part of the bush
using a hacksaw. Cutting the bush in this way will
allow removal.
(5) Support the control arm and push the new
bush in from the outside using a suitable tube that
pushes on the outer circumference only. (6) Install the control ar m to the vehicle as
previously described.
6. STABILISER BAR
TO REMOVE AND INSTAL
(1) Raise the front of the vehicle and support it
on chassis stands.

(2) Remove the bolts at the flexible joint retain-
ing the front engine pipe to the exhaust pipe located
below the stabilizer bar. (3) Remove the bolt from the exhaust pipe
mounting below the stabilizer bar. Disconnect the
exhaust pipe at the flexible joint and allow the front of
the pipe to hang down. (4) Remove the stabilizer bar bracket retaining
bolts and remove the stabilizer bar brackets from the
vehicle. (5) Remove the stabilizer bar lower link nuts
from each control arm. When removing the lower nuts
it may be necessary to hold the upper nuts with a
spanner.
(6) Maneuver the stabilizer bar from the
vehicle.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the stabilizer bar mounting rub-
bers are in a serviceable condition and secure in the
mounting brackets.

Dismantled view of one end of the stabilizer bar.