1987 NISSAN PULSAR brake light

FRONT SUSPENSION............................ 156
Specifications......................................................... 156
Front suspension tr ouble shooting ........................ 156
Description ............................................................ 157
Steering knuckle.................................................... 157
Suspension unit..................................................... 159
Control arm ........................................................... 161
Stabiliser bar ........................................................ 162
Suspension and steering angles .......................... 163
REAR SUSPENSION................................ 164
Specifications ........................................................ 164
Rear suspension tr ouble shooting ........................ 164
Description ............................................................ 165
Rear hub ............................................................... 166
Suspension unit .................................................... 167
Control arm ........................................................... 169
Knuckle assembly.................................................. 170
Stabiliser bar ........................................................ 170
Rear wheel alignment ........................................... 171
BRAKES...................................................... 172
Specifications......................................................... 172
Brakes trouble shooting ........................................ 172
Description ............................................................ 174
Master cyli nder...................................................... 175
Brake servo unit .................................................... 177
Front brakes ......................................................... 178
Rear disc brakes................................................... 181
Rear drum brakes ................................................. 184
Handbrake cable and le ver assembly ................... 186
Brake adjustments ................................................ 187
Brake pedal ........................................................... 187
Hydraulic system................................................... 188
ELECTRICAL SYSTEM............................ 190
Specifications......................................................... 190
Battery and charging system trouble shooting ....... 190
Battery and starting system trouble shooting ........ 191
Lighting system trouble shooting ........................... 192
Turn signal lamp trouble shooting ........................ 192
Test equipment and so me applications................. 193
Battery ................................................................... 194
Alternator ............................................................... 196
Starter motor ......................................................... 201
Ignition system ...................................................... 206
Steering wheel ....................................................... 206
Switches and controls........................................... 206
Instrument cluster.................................................. 209
Blower fan .............................................................. 209
Radio/cassette...................................................... 209
lamp units ............................................................ 210
Windscreen wiper ................................................. 213
Fuses, fusible links and relays ............................. 215
Trailer wiring ......................................................... 216
Wiring diagrams ................................................... 218
BODY........................................................... 225
Windscreen and re ar glass .................................. 225
Front doors ........................................................... 225
Rear doors............................................................ 228
Engine bonnet...................................................... 231
Tailgate and lock — hatchback ............................ 231
Luggage compartment lid and lock — sedan ........ 233
Radiator grille.............................................................. 234
Centre console...................................................... 234 Dashboard ............................................................ 235
Scat belts ............................................................. 236
Seats .................................................................... 236
Vehicle cleaning ........................................................... 237
CONVERSION TABLES.......................... 238

General Information 11
Lifting Equipment
When using lifting equipment to lift heavy com-
ponents such as the engine and/or transmission, use
metal slings or chain in preference to rope. If rope
must be used, ensure that it is not placed against sharp
edges on the component.

Automotive Lubricants and Solvents
Avoid prolonged skin contact with oils, greases
and solvents as some can cause skin irritations and
dermatitis.

Exercise caution when us ing cleaning solvents as
many are inflammable. Do not smoke. Keep naked
flames and sparks clear of the work area.

Compressed Air
Never point an air hose at another person or allow
compressed air to blow onto your skin. High pressure
air forced against the skin can enter the bloodstream
and prove fatal.

Suspension and Steering Components
Damaged suspension and steering components
should not be welded. Many of these components are
fabricated from toughened metals. If welded they may
lose their strength or become brittle. Damaged com-
ponents should be renewed.

Air Conditioning
Avoid disconnecting air conditioning hoses as
escaping refrigerant can cause frostbite. The refriger-
ant is highly flammable and when burnt, a poisonous
gas is produced.

VEHICLE SAFETY
To prevent damage to the vehicle during servicing
or repair work, note the following precautions.

Brake Fluid
If spilt on the vehicle paintwork, brake fluid
should be immediately washed away with clean water
and allowed to dry naturally, not wiped with a cloth.

Catalytic Converter
The following should be observed to prevent
damage to the catalytic converter:

Do not operate the vehicle on leaded fuel.
Do not push or tow start the vehicle.
Do not allow the engine to idle for prolonged
periods.

Do not switch the ignition off while the vehicle is
in motion and the transmission is in gear.

Do not 'prime' the engine by pouring fuel into the
inlet manifold.

Do not operate the vehicle if the engine is
misfiring.

Avoid running the vehicle out of fuel.
Ensure that the engine oil is formulated to contain
low phosphorus levels.

Electronic Components
The electronic components of the ignition and
fuel injection systems can be damaged by the use of
incorrect testing equipment.

It is essential in all tests where voltage or resis-
tance is to be measured that a digital display multi-
meter with a minimum 10 megohm input impedance
be used.

Some types of tachometers, timing lights and
ignition system analyzers are not compatible with
certain engine electronic systems. It is therefore
recommended that the manufacturer of the test equip-
ment be consulted before using the equipment.

Jump starting, or being jump started by another
vehicle can cause damage to the electronic compon-
ents of the vehicle. Refer to the Roadside Trouble
shooting section for the correct jump starting proce-
dure.

3. GENERAL REPAIR PROCEDURES
SEIZED FASTENERS
Seized bolts, nuts or screws should first have a
liberal amount of penetrating oil applied. The fastener
should be left for a period of time to allow the oil to
penetrate and soften the corrosion which is causing
the binding.

Often, a sharp hammer blow to the head of the
fastener can dislodge the corrosion and permit it to be
loosened.

An impact driver, which can be fitted with a
socket or screwdriver bit, can be used to loosen a
seized fastener.

Another method is to heat the component in
which the fastener is seized. However, extreme cau-
tion should be exercised when heating aluminum
alloy components as the melting point is much lower
than that of steel.

If the above methods fail to free a seized nut,
carefully hacksaw through one side of the nut until it
can be split. Care should be taken that the threads of
the bolt or stud are not damaged.

Should a bolt or stud break below the surface of
the component, it will be necessary to use a screw
extractor to remove the remaining part. Follow the
screw extractor manuf acturers instructions.


Tap and die set and assorted screw extractors.

14
LUBRICATION AND MAINTENANCE
SPECIFICATIONS
CAPACITY AND GRADE
Engine:
Lubricant........................................... 15W-50 SF
Sump capacity including filter ........... 3.3 liters
Cooling system capacity............................ 6.0 liters
Manual transaxle:
Lubricant....................................... 80W-90 GL-4
Capacity ............................................... 2.7 liters
Automatic transaxle:
Lubricant.............................................. Dexron II
Capacity ............................................... 6.0 liters
Power steering:
Lubricant.............................................. Dexron II
Capacity ............................................... 1.0 liters
Manual steering lubricant ........ Castrol EPLl grease
Brake fluid type ................................................ Dot 4
1. HOW TO GREASE AND OIL CHANGE
(1) Run the front of the vehicle onto car ramps
and stop the engine. Chock the front wheels. (2) Raise the rear of the vehicle and place
chassis stands under the rear jacking points.
NOTE: It is best if the vehicle is kept as level
as possible to avoi d false readings when
checking the lubricant levels.



(3) Clean around the engine sump drain plug.
(4) Place a drain tin under the engine sump,
remove the engine sump drain plug and allow the
engine sump to completely drain.
NOTE: It is best to drain the engine sump
with the oil at operating temperature. How-
ever, if the oil is hot take care to avoid
scalding.

(5) Check that the sealing gasket on the sump
plug is in a serviceable condition. (6) When the engine sump has completely
drained, install and firmly tighten the sump drain plug.
Wipe around the plug after installation. (7) Place the drain tin under the oil filler,
remove the oil filter using a filter removal tool and
allow the residual engine oil to drain. Smear the
scaling ring of the new filter with engine oil and
lighten the filter by hand as per the instructions
supplied with the new filter.
NOTE: Before installing the new filter, en-
sure that the sealing gasket from the old
filter has not adhered to the filter sealing
surface on the engine.

(8) Remove the level checking plug from the

Location of the engine sump drain plug.
Removing the engine oil filter using a filter removal tool.

WHEELS AND TYRES
SPECIFICATIONS
TYRES PRESSURES
Front:
Normal load ............................................ 200 kPa
Heavy load or high speed ......................230 kPa
Rear:
Normal load............................................ 180 kPa
Heavy load or high speed ...................... 210 kPa
NOTE: The above pressures are measured
cold and are meant as a guide only. Always
refer to the tire placard positioned on the
inside of the glove compartment lid and the
tire manufacturers recommendations first.

TORQUE WRENCH SETTINGS
Wheel nut torque .............................................98 Nm
1. HOW TO CHANGE A ROAD WHEEL
(1) Ensure that the vehicle is on level firm
ground and clear of any passing traffic. (2) If necessary, switch on the hazard
flashers.
(3) Switch off the engine a nd place the transaxle
in the (P) Park position on automatic transaxle
models or in reverse gear on manual transaxle models.

(4) Apply the handbrake firmly and chock the
front and rear of the wheel diagonally opposite the
wheel being changed.
(5) Remove the spare wheel, tool kit and jack
located in the luggage compartment. (6) On vehicles equipped with full wheel covers,
remove the trim from the wheel. (7) Using the wheel spanner, loosen the wheel
nuts progressively in a diagonal sequence half a turn.
(8) Position the jack und er the jacking point
closest to the wheel being removed and raise the jack
until the head of the jack contacts the jacking point.
(9) Raise the vehicle slightly and check that the
jack is stable and vertical.

Underbody view showing the jacking and supporting
points. O indicates the jacking points and X indicates
the supporting points.
Chock the front and rear of the wheel diagonally
opposite the wheel being changed. View of the jack correctly installed to the rear jacking
point.

Fuel and Engine Management 91
components, erase the self diagnosis memory as
described under the following heading.

(7) Repeat the self diagnosis test procedure and
ensure that code 12 is displayed.

To Erase Memory
(1) With the ignition Off, remove the fusible link
that is positioned third from the front of the fusible
link connecting block located at the rear of the
battery. (2) Install the fusible link after 10 seconds.

View showing the location of the fusible links.
TO CHECK AND ADJUST IGNITION TIMING
(1) Connect a timing light to the engine as
previously described under the Service Precautions
and Procedures heading.
(2) Start the engine and allow it to reach normal
operating temperature. (3) Connect a jumper lead between terminals A
and B on the diagnostic link connector. (4) With the engine idling at the specified speed,
check the ignition timing with the timing light.
The timing mark on the crankshaft pulley should
be aligned with the pointer on the inner liming belt
cover.

(5) If necessary, loosen the distributor body
retaining nuts and turn the distributor until the timing
marks are aligned. (6) Tighten the distributor body retaining nuts
and check that the timing is correct. (7) Remove the jumper lead from the diagnostic
link connector and disconnect the timing light from
the engine.
TO ADJUST BASE IDLE SPEED

NOTE: The idle speed is controlled by the
idle air control (IAC) valve and is not

adjustable. The throttle stop screw controls
the base idle speed a nd is factory set. The
following base idle speed adjustment should
only be performed if the throttle body has
been renewed, or if comprehensive testing of
related components indicates that adjust-
ment is required.

(1) Before adjusting the base idle speed perform
the following tests;

(a) Check the spark plug gaps, the high tension
leads and the ignition timin g as described previously
in the Engine Tune-up section.
(b) Check the air inlet syst em for leaks between
the throttle body and inlet manifold and the inlet
manifold and cylinder head.
NOTE; Any vacuum leaks will make the
engine idle faster than it should.

(c) Check that all wiring connectors and vacuum
hoses are securely connected. (d) Ensure that the transaxle is in Park or
Neutral. (e) Ensure that the air cleaner element is service-
able.

(2) On 1.6 liter engines, remove the air cleaner
assembly, disconnect the vacuum hose from the
throttle body and seal the vacuum hose fitting.
(3) Ensure that the throttle valve moves freely
and returns to the fully closed position when slowly
released. (4) Connect an accurate tachometer to the en-
gine as previously descri bed under the Service Pre-
cautions and Procedures heading.
(5) Start the engine and allow the engine to
warm up and the idle rpm to stabilize. Check that all
electrical accessories and the air conditioning, if
equipped, are turned off. (6) With the engine idling in Park or Neutral,
slowly disconnect the brake servo unit vacuum supply
hose from the inlet manifold. Allow the engine to run
for one minute.
Location of the base idle adjusting screw. 1.8 liter
engine.

Fuel and Engine Management
(8) Remove the bolts retaining 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 fouling the lower bumper panel.
(9) Remove the bolts retaining the stabilizer bar
mounting brackets to the underbody and allow the
stabilizer bar to drop.
(10) Remove the bolts retaining the exhaust heat
shield to the underbody, located at the front of the
fuel tank. (11) Remove the handbrake cable mounting
bracket retaining nuts and remove the mounting
brackets from the mounting studs. (12) Remove the fuel tank retaining bolts and
maneuver the fuel tank from the vehicle. Installation is a reversal of the removal procedure
with attention to the following points:

(1) When installing the fuel tank, ensure that the
fuel pump wiring harness is directed through the
aperture in the floor. (2) Install the stabilizer bar mounting
bracket
bolts and tighten to the specified torque. Refer to the
Rear Suspension section.
(3) Using a new gasket, install the intermediate
exhaust pipe to the catalyti c converter ensuring that
the earth wire terminal is installed and tighten the
bolts securely. (4) Connect the fuel filler neck hose, the fuel
check valve hose and the breat her hose ensuring that
they are secured firmly. (5) Tighten the fuel tank drain plug to the
specified torque. (6) Connect the fuel hoses to the fuel pump,
using the marks made during removal to ensure
correct installation. (7) Install the fuel pump wiring harness and the
rubber grommet to the fuel pump cover plate. Install
the cover plate and tighten the retaining bolts se-
curely.
(8) Connect the fuel pump wiring connector
securely. (9) Check for fuel leaks as previously described.
6. AIR FLOW COMPONENTS
NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.

AIR CLEANER ASSEMBLY
To Renew Element
The procedure for renewing the air cleaner ele-
ment is covered in the Engine Tune-up section.

To Remove and Install — 1.8 Liter Engine
(1) Disconnect the negative battery terminal.
(2) Release the air intake hose retaining clamps,
disconnect the hose from the air cleaner upper
housing and the throttle body and remove the hose. (3) Remove the screw securing the air cleaner
intake duct to the front panel mounting bracket. (4) Remove the hexagon head screws retaining
the air cleaner mounting bracket to the right hand
inner mudguard and remove the air cleaner from the
engine compartment. (5) Release the upper housing retaining clips,
separate the upper housing from the lower housing
and remove the element. (6) Remove the air cleaner intake duct retaining
screw and disconnect the duct from the lower air
cleaner housing. (7) If necessary, remove the bolts securing the
mounting bracket to the ai r cleaner lower housing and
separate the mounting bracket from the housing. (8) Thoroughly clean the upper and lower hous-
ings in cleaning solvent and check for cracks, splits or
damage that would allow unfiltered air to enter the
engine. Renew any components as necessary.
Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the r ubber insulators are in-
Dismantled view of the ai r cleaner assembly. 1.8 liter
engine.

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.

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.