1987 NISSAN PULSAR ad blue

40 Engine


Check the engine oil for level and dilution on the dipstick.
dosed. Before dismantling the engine to
inspect the big ends check the engine oil for
correct level and dilution on the dipstick.
Also, remove the oil pressure sender unit
and connect an oil pressure gauge into the
oil gallery to check the oil pressure readings.

MAIN BEARING NOISE (APPARENT)
(1) Loose flywheel: Tighten the flywheel securing
bolls to the specified torque. (2) Low oil pressure: Check the bearing to
journal clearance. Check the condition of the oil
pump and pressure relief valve. Recondition the oil
pump as necessary. (3) Excessive crankshaft end float: Renew the
main bearings. (4) Crankshaft journals out of round and exces-
sive bearing to journal clear ance: Regrind the journals
and renew the bearings (undersize).
(5) Insufficient oil supply: Replenish the oil in
the sump to the correct level.
NOTE: Main bearing noise is indicated by a
heavy but dull knock when the engine is
under load. A loose flywheel is indicated by
a thud or dull click when the ignition is
turned off. It is us ually accompanied by
vibration.

Crankshaft end float noise is indicated by
a sharp rap at idle speed. The crankshaft
can be readily checked for excessive end
float by levering the crankshaft backwards
and forwards.

If the oil pressure is not satisfactory,
remove the main bearing caps and assess
the bearing clearance using the Plastigage
method as described in this section. Ovality
and wear on the main bearing journals can
only be checked with a micrometer after the
crankshaft has been removed.

EXCESSIVE OIL CONSUMPTION
(1) Oil leaks: Check and renew the engine gas-
kets or seals as necessary.
(2) Damaged or worn valve stem oil seals:
Dismantle the cylinder head and renew the damaged
or worn oil seals. (3) Excessive valve stem to valve guide clear-
ance: Ream the valve guides and renew the valves as
necessary. (4) Worn or broken piston rings: Renew the
piston rings on all pistons. (5) Rings too tight or stuck in the grooves:
Renew the rings and clean the ring grooves.
(6) Excessive wear in the cylinders, pistons and
rings: Recondition the cylinders and renew the pistons
and rings. (7) Compression rings incorrectly installed. Oil
rings clogged or broken: Renew the piston rings.
NOTE: Before checking the engine for oil
leaks the engine should be completely de-
greased and cleaned. Run the engine at
operating temperature for a period and
visually check for oil leakage. By placing
white paper on the floor directly beneath the
engine any excessive leak can be readily
pinpointed.

Damaged or worn valve stem oil seals
which allow oil to be drawn down past the
valve stems into the combustion chambers
can be diagnosed by allowing the engine to
idle for a few minutes and then opening the
throttle. If oil is being drawn past the valve
stems a heavy discharge of blue smoke will
be seen at the tailpipe.

Piston, ring and cylinder bore troubles are
normally accompanied by a loss of compres-
sion. Cylinder compression can only be
accurately assessed by using a compression
gauge.

Run the engine over white paper to check for oil leaks.

Engine 53


Method of checking cylinder head for distortion.
(3) Carefully clean the deposits from the inlet
and exhaust ports, the auxiliary passages, the valve
guides and the manifolds, taking care not to damage
any mating surfaces. (4) Clean the cylinder head mounting faces,
wash the cylinder head in solvent and dry with
compressed air. Blow through all the oil holes with
compressed air to ensure that they are not blocked. (5) Check the cylinder head for distortion diag-
onally and lengthwise using a straight edge and feeler
gauges. Refer to Specifications for the distortion and
machining limits. (6) Check the cylinder head face and combus-
tion chambers for cracks, burn marks and corrosion. (7) Check the valve stem to guide clearance. If
the clearance is in excess of the Specifications, the
valve guide must be reamed and the appropriate
oversize valve installed. (8) Inspect the valve seats for pitting or burning
and if necessary, recut the seats with a valve seat
cutter to the recommended angle. When the seats are
correctly finished, the seat widths should conform to
the Specifications. (9) Lap the valves to the valve seats with a fine
lapping compound. Apply a smear of Prussian blue to
the valves or their respective seats to ensure that true
and concentric seating has been gained.

(10) Install each valve in its respective port
and
check the valve stem height above the cylinder head.
Refer to the illustration. The extended height must
not exceed 18.4 mm. If the height exceeds the
Specifications, the valve or the cylinder head must be
renewed. Do not remove any material from the valve
stem tip.
(11) Check the valve spring tensions and compare
with the Specifications.
Check that the springs are not bent or distorted.

If a spring tester is not available, check the springs
by comparison with new springs. This can be done
using a surface plate and stra ight edge for checking the
free length and using a new spring and a used spring
loaded in a vice end on end, with a plate in between.
Measure from the plate to the vice jaw adjacent to
both the new and used springs. A used spring is
serviceable if it does not show collapse in excess of
five percent when subjected to this comparison test.

(12) Check the exhaust valve rotators for wear
and ensure that the rotators turn freely. (13) Clean the cylinder block face of all carbon
and rust deposits and ensure that all old gaskets are
removed. Do not allow the waste deposits to enter the
oil or water galleries. Clean all waste materials from the cylinder bores.

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

(1) Lubricate all component wear surfaces with
engine oil before assembly to ensure adequate lubri-
cation when starting. (2) If the oil pressure relief valve was removed
from the cylinder head, proceed as follows:
(a) Using a brass tube inserted in the welch plug
hole at the distributor end of the cylinder head, tap
the relief valve into position. (b) Install the welch plug and the recessed screw
in their respective positions, after coating the plug and
the screw with Loctite 242 or equivalent.
(3) Install the inlet valve spring seats and
the
exhaust valve rotators over the valve guides before
installing the valve stem seals onto the valve guides.
(4) Install the valve stem seals, ensuring that
the
rib of the moulding on the inside of the seal is
correctly positioned in the groove of the valve guide
and that the spring clip retainer is correctly posi-
tioned.
NOTE: The valve stem seals can be posi-
tioned correctly and without damage using
an upturned valve spring retainer.

(5) Install the valves to their original location in
the cylinder head. Use care when installing the valves
to prevent damage to the seals.
(6) Install the valve springs, retainers and
collets.
Ensure that the valve retain ing collets are fully seated
Dimension A is the correct position to measure the
valve stem installed height. Dimension A = 18.4 mm.

64 Engine
automatic transaxle models the complete drive plate
must be renewed.

(3) Inspect the drive plate bolt holes for elonga-
tion which is caused by loose retaining bolts.
(4) Inspect the drive plate for cracks.
(5) Repair or renew the flywheel if necessary.
TO INSTAL

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

(1) The flywheel and drive plate retaining bolts
are special micro-encapsulated fasteners.

Install new micro-encapsulated bolts of the
correct
strength classification on assembly.

(2) Thoroughly clean the crankshaft threads with
a thread tap. Clean the threads with solvent and dry
before installing the flywh eel or drive plate retaining
bolts.
(3) Tighten the flywheel or drive plate retaining
bolts to the specified torque and on manual transaxle
models, align the clutch plate as described in the
Clutch section.
TO RENEW FLYWHEEL RING GEAR
(1) With the flywheel removed from the vehicle,
drill a 6 mm diameter hole between two teeth of the
ring gear.

NOTE: Do not drill right through the ring
gear as this will damage the flange on the
flywheel.

(2) Secure the flywheel, with the drilled hole
uppermost in a soft jawed vice.
(3) Place a cold chisel above the hole in the ring
gear and hit it sharply to split the ring gear.
(4) Check the direction of the chamfered face of
the old ring gear. The new ring gear must be installed
to the flywheel with the chamfer in the same direction. (5) Remove the ring gear, clean the mounting
face on the flywheel and remove any burrs. (6) Polish a few spots of the ring gear with emery
cloth and heat the ring gear evenly until the polished
spots turn dark blue.
NOTE; Do not heat the ring gear past the
point required to achieve a dark blue color
or the tempering of the ring gear teeth will
be impaired.

(7) With the flywheel suitably supported, pick
the ring gear up using plie rs, and place it evenly onto
the flywheel. Use a hammer and a brass drift to ensure
that the ring gear seats ag ainst the flywheel flange.

NOTE: Allow the ring gear to cool slowly.
Do not quench it in water.

13. ENGINE MOUNTINGS
TO RENEW LEFT HAND SIDE MOUNTING
(1) Disconnect the positive and negative battery
terminals, loosen the battery clamp nuts and withdraw
the battery from the engine compartment.
(2) Remove the bolts retaining the battery car-
rier to the inner mudguard and remove the battery
carrier and associ ated components from the engine
compartment. (3) Support the transaxle using a jack. Interpose
a block of wood between the head of the jack and the
transaxle to prevent damage to the transaxle.

View of the flywheel and retaining bolts.

Dismantled view of the left hand side engine mounting
assembly installed to vehicles with an automatic tran-
saxle.

Cooling and Heating Systems 73
(1) Renew all hoses that show signs of cracking
or perishing.
(2) Before finally tightening the hose clips, en-
sure that the hoses are push ed fully onto the radiator
and are not kinked. (3) On automatic transaxle models, ensure that
the oil cooler hoses are correctly installed to the
radiator and show no signs of leakage. Check and top
up the automatic transaxle fluid as necessary.
5. COOLING FAN
The radiator cooling fan is controlled by the
electronic control unit, and on vehicles with air
conditioning, the condenser fan relay. On vehicles
with air conditioning there are two cooling fans, one
is larger than the other. The large fan is for the
radiator and the smaller fan provides extra cooling
when the air conditioning is activated. Each fan is
controlled by a separate system.

TO TEST COOLING FAN AND SYSTEM
(1) With the cooling system cold and the air
conditioning, if applicable, switched off, switch the
ignition On and confirm that the cooling fan is
stationary.

NOTE: Leave the ignition On for all tests
unless otherwise stated.

(2) In the above test, if the cooling fan rotates,
proceed as follows:

(a) Disconnect the cooling fan relay from the
rear of the engine compartment relay box.
(b) If the fan stops, backprobe terminal C1 at
the electronic control unit using an LED test lamp
connected to the positive battery terminal. If no
circuit exists, renew the cooling fan relay.

View showing the location of the diagnostic link
connector. Passengers seat removed for clarity.
If a circuit exists, check the wiring harness
between the electronic control unit and the relay for
short circuits to earth and repair if necessary. If no
short circuit is present renew the electronic control
unit.


Schematic layout of the cooling fan, coolant temper-
ature sensor and related electrical components.

Installed view of the engine compartment relays. KEY

1. To Battery
2. Fusible link
COLOUR CODE
3. Fusible link
B-Black
4. Fusible linkL- Blue
5. I
gnition relayY- Yellow
6. Fuse 20 am
pW-White
7. Coolin
g fan relayO-Orange
8. Coolin
g fan
9. Coolant tem
perature
sensor
10. To air conditionin
g
fan rela
y
11. To throttle
position
sensor
12. Control unit

Fuel and Engine Management 95
(3) Disconnect the vacuum hose from the pres-
sure regulator.
(4) Release the fuel hose clamps, disconnect the
hoses from the pressure regulator and remove the
pressure regulator. Installation is a reversal of the removal procedure
ensuring that the fuel hose clamps are tightened
securely.

To Remove and Install — 1.6 Liter Engine
(1) Depressurize the fuel system as previously
described. (2) Disconnect the negative battery terminal.
(3) Remove the air cleaner assembly. If neces-
sary, refer to the Air Cleane r Assembly heading in this
section. (4) Remove the screws securing the pressure
regulator cover to the throttle body assembly. When removing the final screw hold the cover
firmly as it is under spring tension.

(5) Remove the cover, spring seat, spring and
diaphragm from the thrott le body assembly. Discard
the diaphragm.


View of the pressure regulator components removed
from the throttle body assembly. 1.6 liter engine.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Install a new diaphragm ensuring that
the
diaphragm is correctly seat ed in the groove in the
throttle body assembly. (2) Apply Loctite 262 to the threads of the
retaining screws.
(3) Place the spring seat and the spring in the
cover and install the cover to the throttle body
assembly, ensuring that the cover is positioned on the
locating dowels. (4) While holding the cover in position install
the
retaining screws and tighten securely.
NOTE: When installing the pressure regu-
lator cover ensure that the diaphragm is not
disturbed, to prevent the possibility of a fuel
leak.

INJECTORS
To Test Injector Circuit and Injectors
(1) Disconnect the injector wiring connectors.
(2) Connect a test lamp between the injector
wiring connector terminals, ensuring that the test
lamp probes do not contact each other. (3) With the ignition switched On the test lamp
should not light. On 1.8 liter engines, check each of
the other connectors.
If the test lamp lights check the wiring harness for
a short to earth between the injector wiring connec-
tor(s) and the control unit wiring connector termi-
nal - D15 and D16 on 1.8 liter engines, or D16 on
1.6 liter engines.

(4) With the aid of an assistant, operate the
starter motor. The test lamp should flash. On 1.8 liter
engines, check each of the other connectors.

If the test lamp does not flash when connected to
the injector wiring connecto r(s), proceed to operation
(6).

If the test lamp lights as described, proceed as
follows.

If the test lamp lights but fails to flash, a faulty
control unit is indicated. Pr ior to renewing the control
unit, check the condition of the injectors as follows.

(5) Connect an ohmmeter between the terminals
of the injectors).

The resistance should be more than 1.2 ohms on
1.6 liter engines or more than 12 ohms on 1.8 liter
engines.

If the injector resistance is as specified, the
injector circuit can be considered serviceable.

If the injector resistance is not as specified, renew
the faulty injector(s).

(6) With the ignition switched On, probe the
injector wiring connector terminals with a test lamp to
earth.

If the test lamp lights when the probe contacts the
pink wire terminal on 1.6 liter engines, or the white
wire terminal on 1.8 liter engines, check the wiring
harness for a short to volt age between the injector
wiring connector(s) and the control unit wiring con-
nector terminal(s) D16 on 1.6 liter engines, or D15
and D16 on 1.8 liter engines.

If the test lamp does not light when the probe
contacts the blue wire termin al on 1.6 liter engines, or
the black and red wire term inal on 1.8 liter engines,
check the EGI relay and circ uit as described under the
EG! and Fuel Pump Relays heading in this section.

If the test lamp lights when the probe contacts the
blue wire terminal on 1.6 lite r engines, or the blue and
red wire terminal on 1.8 liter engines, proceed as
follows.

(7) Switch the ignition Off and connect the
injector wiring connectors). (8) Switch the ignition On and, using a test lamp
to earth, backprobe the cont rol unit wiring connector

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

Electrical System 219


Wiring diagram (WDI) for the starting, charging and engine management systems.
COLOUR CODE
The first letter of the code
represents the main wire color,
the other letters represent the
trace colors.

B - BLACK
L - BLUE
G - GREEN
R - RED
Y - YELLOW
W - WHITE
N - BROWN
O - ORANGE
K - PINK
S - GREY V - VIOLET
P - PURPLE X - LIGHT GREEN
Z - LIGHT BLUE
M - DARK GREEN
T - DARK BLUE
A - LIGHT BROWN
E - SLATE
D - TAN

KEY 1. Battery
2. Fusible links
3. To BATT WD4
4. Alternator
5. Starter motor
6. To No 27 WD2
7. Ignition switch
8. To No.10 WD4
9. To ECU BIO
10. Inhibitor relav
11. Neutral safety
switch
12. Fuse No.8 Ignition
13. Ignition coil
14. Distributor
15. To ECU A1
16. Fuel pump relay
17. Fuel pump
18. ALDL connector - Terminal G
19. Oil pressure switch
20. To No. 19 WD2
21. To No. 4 WD2
22. Reverse lamp switch
23. Fuse No. 9 Ignition
24. L H reverse lamp
25. R H reverse lamp
26. EGI relay
27. ECU C16 and B1
28. ECU A6
29. To ECU D16
30. To ECU D15
31. Injectors
32. Ignition relay
33. To No. 1 WD2
34. To tachometer
35. Condensor
36. Bypass circuit (manual transaxle)