1987 NISSAN PULSAR wheel

Rear Suspension 167

NOTE: When a wheel bearing has been
removed from the hub it must be renewed.

(5) Press the new bearing into the hub, ensuring
that pressure is not exerted on the inner race of the
bearing and that the bearin g seal is not damaged. Do
not apply grease or oil to the mating surfaces of the
bearing and the hub.

NOTE: When installing the new bearing,
the press load must not exceed 3 tonnes.

(6) Inspect the snap ring for wear or cracks and
renew as necessary. Install the snap ring into the hub
ensuring that it is secur ely located in the groove.
(7) Apply multi-purpose grease to the bearing
sealing lip and install the hub as previously described.
4. SUSPENSION UNIT

Special Equipment Required:
To Dismantle — Spring compressor
TO REMOVE AND DISMANTLE
(1) On hatchback models, remove the rear par-
cel shelf and lower the rear seat backrests. Remove the
parcel shelf side panel re taining screws and remove
the relevant side panel.
(2) On sedan models, prise out the parcel shelf
retaining buttons using a suitable instrument and
withdraw the parcel shelf from the vehicle. If the rear
radio speakers are installed, remove the speaker grille
retaining screws and separate the speaker grilles from
the speakers prior to withdrawing the parcel shelf
from the vehicle. (3) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section. Remove the rear wheel from the vehicle.

View of the suspension unit with the spring compres-
sors installed.
(4) Remove the clip securing the brake hose to
the suspension unit and disengage the hose from the
suspension unit. (5) Support the weight of the knuckle assembly
and remove the bolts and nuts securing the suspension
unit to the knuckle assembly.
(6) Remove the nuts securing the suspension
unit to the body panel and maneuver the suspension
unit from the vehicle. (7) Thoroughly clean the suspension unit and
secure it in a soft jawed vice.
(8) Remove the dust cap from the upper mount-
ing and while holding the end of the piston rod with
an adjustable spanner, loosen the upper mounting
retaining nut. Do not re move the retaining nut.
(9) Using a suitable spring compressor, com-
press the coil spring and remove the upper mounting
retaining nut and washer. (10) Remove the upper mounting, insulator and
spring seat from th e suspension unit.
(11) Withdraw the upper insulator, coil spring,
lower insulator and dust cover from the suspension
unit. (12) Check the coil spring for cracks, deformation
and damage. Compare the free length with a new coil
spring and renew as necessary.
Location of the suspension unit retaining nuts. Hatch-
back model.

168 Rear Suspension
NOTE: If a coil spring is defective it is
advisable to renew both coil springs as a
matched set.

(13) Check the spring seat for cracks, deforma-
tion or wear and renew as necessary.
(14) Check the upper mounting and the insulator
for wear, damage, signs of melting rubber or deterio-
ration. (15) Check that the piston rod is not cracked,
bent or damaged.

Dismantled view of the suspension unit.
(16 ) Check the hydraulic operation of the suspen-
sion unit. With the suspension unit vertical, move the
piston rod up and down severa l times. A firm pressure
with no slack spots should be evident in both direc-
tions. Also check the suspen sion unit for fluid leakage.
If fluid leakage is present, renew the suspension unit,
preferably in pairs.

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

(1) Install the coil spring and lower insulator to
the suspension unit ensuring th at the flat end of the
spring is positioned at the top and the lower end of the
spring is located correctly in the suspension unit.

(2) Install the remaining co mponents to the sus-
pension unit, ensuring that the arrow on the spring
seat will be facing the stub axle when installed.
(3) Install a new upper mounting retaining nut,
tighten to the specified tor que and remove the spring
compressor. (4) Position the suspension unit inside the rear
wheel housing and maneuver the mounting studs
into position. With the aid of an assistant, install the
suspension unit retaining nuts and tighten to the
specified torque.

View of the suspension unit removed from the vehicle.
(5) Install the bolts securin g the suspension unit
to the knuckle assembly and tighten the nuts to the
specified torque.
(6) Install the brake hose to the suspension unit
and secure with the retaining clip. (7) Install the rear wheel and lower the vehicle to
the ground. (8) On hatchback models, install the parcel shelf
side panel and the parcel shelf. (9) On sedan models, install the parcel shelf and
insert the retaining buttons firmly. If removed, install
the radio speaker grilles.

Rear Suspension 169

5. CONTROL ARM
Special Equipment Required:
To Renew Control Arm Bush — Press and suitable
removal tool

TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section.

(2) Suitably mark the front and rear control
arms to ensure installation to the original locations.
NOTE: The front and rear control arms are
identical in appearance, however, on models
manufactured prior to March 1988 the
compound of the rubber bushes differ.

(3) Remove the nut and bolt securing the control
arms to the knuckle assembly.
(4) Suitably mark the rear inner pivot bolt cams
in relation to the crossmember to ensure correct
installation.
(5) Remove the rear control arm inner pivot
bolt, adjusting cam, nut and control arm from the
vehicle. (6) Remove the front control arm inner pivot
bolt, washer, nut and control arm from the vehicle.
(7) Inspect the control arm bushes for wear,
cracks and deterioration and renew as necessary. (8) Inspect the control arms for cracks, damage
and distortion and renew as necessary.
(9) Inspect the pivot bolts for damage and renew
as necessary. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the control arms to the original
loca-
tions, ensuring that the inner pivot bolts are installed
from the front of the crossmember.
(2) Align the marks on the rear inner pivot bolt

Dismantled view of the control arms and associated
components. Disc brake model.
cams and the crossmember that were made prior to
removal. Install the inner pivot bolt nuts but do not
tighten.

(3) Install the bolt that secures the control arms
to the knuckle assembly and tighten the nut finger
tight. (4) Lower the vehicle to the ground. With the
weight of the vehicle on th e rear wheels, ensure that
the marks on the inner pivot bolt cams and the
crossmember are aligned. (5) Tighten the inner and outer control arm
bolts and nuts to the specified torque. (6) Check and if necessary adjust the rear wheel
alignment. Refer to the Re ar Wheel Alignment head-
ing in this section.
TO RENEW CONTROL ARM BUSH

(1) Remove the control arm as previously de-
scribed. (2) Using a press and press plates or a bush
removal tool, remove the bush from the control arm.
NOTE: If a press or bush removal tool is not
available, a simple alternative can be made
using a long bolt, large and small washers, a
nut and a tubular spacer. This method is
illustrated in the General Information sec-
tion under the General Repair Procedures
heading.

(3) Install a new bush to the control arm
ensuring
that it is pressed squarely into the control arm. When
installed, the bush should be equidistant from either
end of the control arm bore. (4) Install the control arm as previously de-
scribed.
Ensure that the cam and the crossmember are suitably
marked prior to loosening the nut.

170 Rear Suspension

6. KNUCKLE ASSEMBLY
TO REMOVE AND INSTAL
(1) Remove the rear hub as previously de-
scribed.

(2) On drum brake models, disconnect the brake
pipe from the wheel cylinder and plug the cylinder
and brake pipe apertures to prevent the loss of brake
fluid and the entry of dirt. (3) Remove the backing plate retaining bolts and
remove the backing plate from the knuckle assembly. (4) Remove the nut and bolt securing the control
arms to the knuckle assembly. (5) Remove the bolts and nuts securing the
suspension unit to the knuckle assembly. (6) Remove the nut, washers and bush securing
the stabilizer bar to the knuckle assembly, rotate the
knuckle assembly and remove it from the stabilizer
bar. (7) Carefully clean the knuckle assembly. Do not
immerse the rubber bush in solvent as damage will
occur.
(8) Check the knuckle assembly for wear, cracks
and damage. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install the knuckle assembly onto the stabi-
liser bar, maneuver it into position with the suspen-
sion unit and install the retaining bolts and nuts.
Tighten the bolts and nuts to the specified torque.
(2) Install the control arms to the knuckle
assem-
bly and install the retaining bolt and nut. Do
not
tighten the retaining bolt and nut at this stage. (3) Install the bush, washers and retaining nut to
the stabilizer bar. Do not tighten the retaining nut at
this stage. (4) Install the backing plate to the knuckle as-
sembly and tighten the retaining bolts to the specified
torque.
(5) On drum brake models, connect the brake

pipe to the wheel cylinder and tighten the flare nut
securely.

(6) Install the rear hub as previously described.
(7) On drum brake models, bleed the brake
hydraulic system as described in the Brakes section.
(8) With the weight of the vehicle on the road
wheels, tighten the control arms retaining bolt and nut
and the stabilizer bar retaining nut to the specified
torque. (9) Check and if necessary adjust the rear wheel
alignment. Refer to the Re ar Wheel Alignment head-
ing in this section.
7. STABILISER BAR
TO REMOVE AND INSTAL
(1) Raise the rear of the vehicle and support it
on chassis stands as describe d in the Wheels and Tires
section. Remove the rear wheels.

(2) Remove the nut. washer and bush retaining
the stabilizer bar to each knuckle assembly. (3) Remove the bolts retain ing the intermediate
exhaust pipe to the rear of the catalytic converter,
remove the bolt securing the exhaust mounting to the
underbody and slightly lower the intermediate exhaust
pipe. Support the intermediate pipe to prevent the
tailpipe contacting the lower bumper panel. (4) Remove the bolts retaining the stabilizer bar
mounting brackets to the underbody and withdraw
the stabilizer ba r from each knuckle assembly. Ma-
noeuvre the stabilizer bar from the vehicle.
(5) Remove the mounting rubbers from the
stabilizer bar and the rubber bush and spacer from
each knuckle assembly. (6) Inspect the stabilizer bar for cracks and
damage and renew as necessary. (7) Inspect the stabilizer bar mounting brackets
for wear and damage and renew as necessary. (8) Inspect the mounting rubbers, the rubber
bushes and spacers for wear and deterioration and
renew as necessary.

View of the knuckle assembly removed from the
vehicle. Disc brake model. View of the stabilizer bar mounting bracket and rubber
removed from the stabilizer bar.

Rear Suspension 171
Installation is a reversal of the removal procedure
with attention to the following points:

(1) When installing the stabilizer bar to the
knuckle assembly bushes, ensu re that the thicker bush
is installed to the front of the knuckle assembly. Install
the rear bush, washers and nut but do not tighten at
this stage. (2) Install the stabil izer bar mounting
brackets,
ensuring that the end with the large bevel is facing the
front of the vehicle. Tighte n the retaining bolts to the
specified torque. (3) Using a new gasket, install the intermediate
exhaust pipe to the catalytic converter, ensuring that
the earth wire terminal is installed, and tighten the
bolts securely. Install the exhaust mounting
retaining
bolt. (4) Install the rear wheels and lower the
vehicle
to the ground. With the wei ght of the vehicle on the
road wheels, tighten the stabilizer bar retaining nuts to
the specified torque.
8. REAR WHEEL ALIGNMENT
Specialized equipment is required to measure the
rear wheel alignment. It is therefore recommended
that the vehicle be referred to a specialist suspension
workshop or an authorized dealer for measurement
and adjustment. The suspension components should
be inspected and renewed as necessary prior to having
the wheel alignment checked. If any suspension com-
ponents are renewed, the re ar wheel toe out may be
temporarily adjusted as described below.

TO INSPECT
Examine the tread of the tires. Excessive or
uneven wear will indicate misalignment or damaged
or worn components. Refer to the Tire Wear Trouble
Shooting Chart in the Wheels and Tires section for
possible causes and renew the faulty components.

Badly worn tires should be renewed prior to
having the wheel alignment checked.

TO CHECK AND ADJUST TOE OUT
NOTE: The following procedures are only a
temporary measure. Th e vehicle should be
referred to a specialis t suspension work-
shop or authorized dealer for accurate
measurement and adjustment.

(1) Position the vehicle on a level floor and
bounce the vehicle several tim es to settle the suspen-
sion. (2) Move the vehicle forward approximately 5
meters, with the front wheels straight ahead, to settle
the tires and suspension to the normal running
position.
(3) Place a chalk line across both tire treads at a
point equivalent to the stub axle height and to the rear
of the suspension. Place a vertical mark at the chalk line in the
centre of each tire.

(4) Using a telescopic gauge or tape measure,
measure the distance between both vertical marks and
record the measurement. (5) Move the vehicle forward until the marks are
to the front of the suspen sion, with the horizontal
marks at the same height as in operation (3). (6) Measure the distance between both vertical
marks. (7) The difference between the two measure-
ments will be the amount of toe out of the rear wheels. (8) If the toe out is not as specified, adjust the
rear control arm cams as follows: (9) Measure the distance between the inner
wheel rim and the adjusting flange on the rear
crossmember. Measure the distance on the other side
of the vehicle in the corresponding positions. (10) If the measurements are equal, loosen the
cam nut and turn the cam bolt to move the rear
control arm half the distance required to bring the
rear wheel toe out to specifications. Repeat this
operation on the other side of the vehicle.
(11) If the measurements obtained in operation
(9) are not equal, proceed as follows:
(a) If the toe out is less than specifications,
decrease the length of the shorter arm.
(b) If the toe out is greater than specifications,
increase the length of the longer arm.
NOTE: The toe out will alter approximately
2 mm with each graduation of the adjusting
cam.

Diagram indicating rear wheel toe out. B should be less than A. Refer to Specifications.

172
BRAKES
SPECIFICATIONS
Type:
Except Pulsar/Vector GL from
July 1989 and Astra models ... Four wheel disc
Pulsar/Vector GL from
July 1989 and Astra models —
Front...............................................................Disc
Rear..............................................................Drum
Operation:
Footbrake ............... Vacuum assisted diagonally
split dual hydraulic
Handbrake................ Mechanical on rear wheels

Fluid type ...........................................................Dot 4
Master cylinder:
Make ........................................................ Girlock
Bore diameter —
Large .................................................... 25.40 mm
Small .................................................... 20.64 mm
Front disc brakes:
Caliper bore diameter ........................... 48.1 mm
Disc diameter ........................................ 240 mm
Disc thickness, minimum ......................... 16 mm
Disc runout, maximum ......................... 0.07 mm
Disc pad thickness, minimum ....................2 mm
Rear disc pads:
Caliper bore diameter ......................... 30.16 mm
Disc diameter ........................................ 234 mm
Disc thickness, minimum ...........................9 mm
Disc runout, maximum .......................... 0.07 mm
Disc pad thickness, minimum ....................2 mm
Rear drum brakes:
Wheel cylinder bore diameter ............ 15.87 mm
Drum diameter, maximum ............... 204.50 mm
Drum out of round, maximum.............. 0.03 mm
Drum runout, maximum ........................ 0.05 mm
Brake lining wear limit ........................... 1.5 mm
TORQUE WRENCH SETTINGS
Brake pedal bracket to body........................... 11 Nm
Brake pedal pivot bolt ..................................... 11 Nm
Brake servo unit to body................................. I I N m
Brake servo unit to master cylinder ............... 11 Nm
Pressure differential piston plug ...................... 12 Nm
Proportioning valve plug................................. 27 Nm
Caliper anchor plate bolts ............................... 52 Nm
Caliper guide bolts .......................................... 31 Nm
Brake hose to caliper....................................... 34 Nm
Handbrake cable bracket bolt ......................... 49 Nm
Handbrake lever to body ................................ 11 Nm
Cable clamp to body....................................... 11 Nm
Cam lever nut.................................................. 49 Nm
1. BRAKES TROUBLE SHOOTING
BRAKE PEDAL HARD
(1) Seized caliper piston or wheel cylinder: Over-
haul the caliper or wheel cylinder.
(2) Seized master cylinder piston: Overhaul the
master cylinder. (3) Seized pedal pivot: Rectify or renew the
pedal pivot shaft and bushes. (4) Restricted brake line: Remove the restriction
or renew the brake line.
(5) Vacuum servo system inoperative: Check
and repair the servo system.
NOTE: The vacuum servo system can be
checked as follows: With the engine
switched off, pump the brake pedal several
times to deplete any vacuum in the system.
With the engine still switched off, press
down firmly on the brake pedal and hold it
there noting the position and pressure re-
quired. Start the engine. If the servo unit is
operating correctly, the brake pedal will sink
slightly and the pressure required to hold it
may reduce. If the pedal does not sink
slightly when the engine is started, check the
vacuum supply to the servo unit. If vacuum
is reaching the brake servo unit, the unit can
be considered inoperative.

BRAKE DRAG
(1) Clogged master cylinder ports: Clean the
master cylinder and the fluid reservoir. Renew the
brake fluid. (2) Seized caliper piston or wheel cylinder: Over-
haul the caliper or wheel cylinder.
(3) Seized handbrake linkage: Free up or renew
the linkage.

Brakes 173
Inspect the handbrake cable for chafing or fraying.
(4) Seized handbrake cables: Renew the hand-
brake cables.

NOTE: Raise the vehicle and spin the
wheels one at a time to check for binding. If
the wheels are not binding, have an assistant
apply and release the brakes. Check if the
brakes release immediately. A clogged mas-
ter cylinder port will cause binding on the
two wheels fed by that particular circuit
from the master cylinder. Open the bleeder
valve on one of the o ffending wheels to check
if pressure build up is the cause of the
binding. A seized handbrake cable will usu-
ally cause binding on a rear wheel. Discon-
nect the handbrake cable and check if the
wheel will then turn freely.

LOW SPONGY BRAKE PEDAL
(1) Incorrectly adjusted brake shoes: Check and
adjust the brake shoes.


(2) Insufficient fluid in the system: Check for
leaks, replenish the fluid to the specified level and
bleed the hydraulic system.
(3) Air in the brake hydraulic system: Bleed the
hydraulic system. (4) Master cylinder faulty: Repair or renew as
necessary.
NOTE: A spongy brake pedal in most cases
is caused by air in the hydraulic system. For
air to enter the system one or more of the
sealing rubbers or brake lines must be
sucking in air. Always rectify the cause of
the trouble before bleeding the hydraulic
system. Faulty components usually show up
as fluid leakage.

BRAKES LOCK ON APPLICATION
(1) Gummy linings or brake pads due to oil or
fluid contamination: Renew the linings or brake pads
and rectify the source of contamination. (2) Scored or eccentric brake drum or warped
disc: Check and machine or renew the drum or disc as
necessary.
(3) Incorrect or distorted linings or disc pads:
Check and renew as necessary. (4) Brake servo unit faulty: Repair or renew the
brake servo unit. (5) Broken or stretched brake shoe return
springs: Check and renew th e faulty brake springs.
(6) Faulty brake pressure proportioning valve:
Renew the brake pressure proportioning valve.
NOTE: If this condition arises, remove all
the wheels and check the condition of the
friction material for oil contamination and
excessive wear. Check the shoe return
springs for stretching by comparing their
free length with new sp rings. An eccentric-
brake drum or warped disc will be indicated
by pulsating of the brake pedal when the
brakes are lightly applied.

BRAKE PEDAL PULSATES
(1) Eccentric brake drums or warped disc: Check
and machine or renew the drum or disc as required.
(2) Loose or worn hub bearings: Renew the hub
bearings as necessary.
NOTE: Brake drums or discs that are run-
ning out must be machined. This job is best
entrusted to a brake specialist who will also
be able to determine if a new disc or drum
needs to be installed.

BRAKE FADE
(1) Incorrect shoe adjustment: Check and adjust
the shoe to drum clearance. (2) Eccentric brake drum: Check and machine or
renew the brake drum.

Check the brake hoses for deterioration, chafing and
leaks.

174 Brakes
(3) Linings saturated with hydraulic fluid: Re-
new the linings in sets. (4) Incorrect linings installed: Check and install
the recommended linings in sets.
NOTE: In most cases brake fade is caused
by overuse of the footbrake, which in turn
causes a build up of heat at the friction
material and drums or disc. Once this
excessive build up of heat is allowed to
dissipate the brakes should again function
normally.

BRAKES OVERHEAT
(1) Incorrect shoe adjustment: Check and adjust
the shoe to drum clearance.
(2) Broken shoe return springs: Renew any
faulty springs.
(3) Faulty handbrake cables or incorrect adjust-
ment: Check and renew or adjust the cables. (4) Frozen wheel cylinder or caliper pistons:
Overhaul the cylinders or calipers. (5) Obstructed or damaged hydraulic hose or
line: Remove the obstruction or renew the hydraulic
hose or line.
(6) Obstructed master cylinder compensating
port: Clean the compensating port. (7) Blocked vent in the master cylinder reservoir
cap; Check and remove the obstruction in the vent. (8) Overuse of footbrake: Revise driving habits.
NOTE: To check for brake binding raise the
vehicle and spin each wheel in turn by hand.
If it is found that one wheel cylinder or
caliper piston is sti cking it is advisable to
overhaul all the wheel cylinders and calipers.

BRAKE FAILURE
(1) Faulty master cylinder: Remove and over-
haul the master cylinder. (2) Loss of fluid due to a leaking wheel cylinder:
Overhaul or renew the wheel cylinders and bleed the
hydraulic system.
(3) Loss of fluid due to a leaking caliper: Over-
haul or renew the caliper assemblies and bleed the
hydraulic system. (4) Loss of fluid due to a fractured pipe or faulty
union: Renew the faulty components as necessary and
bleed the hydraulic system. (5) Air in the hydraulic system: Locate the
source of the air leak, rectify the problem and bleed
the hydraulic system. (6) Water in the hydraulic fluid: Drain, flush,
refill and bleed the hydraulic system.
NOTE: To locate the source of a fluid leak,
fill the master cylinder reservoir with fluid
and check for obvious signs of external
leakage while an assistant pumps the brake
pedal.


Check the brake pipe unions for leaks.
BRAKE NOISE
(1) Brakes squeal on application: Glazed friction
material or missing or da maged disc pad anti-squeal
shims. (2) Grinding noise on application: Friction ma-
terial worn out. Check the friction material and
discs/drums. Renew the brake pads/shoes and ma-
chine or renew the brake discs/drums as necessary.

Inspect the brake discs for scoring and wear.
2. DESCRIPTION
The brakes are operated by hydraulic pressure in
two independent circuits by means of a tandem dual
circuit master cylinder coupled to a brake servo unit
mounted on the bulkhead between the brake pedal
and master cylinder.

The brake circuits are sp lit diagonally. The left
hand front and right hand rear brakes are connected
to the primary circuit, and the right hand front and
left hand rear brakes are connected to the secondary
circuit. Should a malfunction occur in one circuit, the
remaining circuit is capable of stopping the vehicle.