1987 NISSAN PULSAR fuel cap release

10 General Information

If tools are to be stored for any length of time, it is
good policy to wipe them with an oily cloth.

Bladed screwdrivers should be checked for dam-
age to the tip. If necessary, the tip can be returned to
its original profile by careful grinding. Do not grind
screwdriver tips to a sharp point.

Hammer heads should be secure on their handles
and should be regularly checked for cracking or other
damage.

Chisels and punches should be checked for dam-
age or 'mushrooming' of the head. Any faults should
be rectified by grinding.

Hydraulic jacks should be regularly checked for
fluid leaks. Chassis stands and car ramps should be
checked for damage and cracks. Any equipment that
is suspect should not be used.

STORES
For routine maintenance, stores of automotive
oils, greases and additives should be kept on hand.
The following is a suggested list.

Engine oil.
Brake fluid.
Manual transmission or automatic transmission
oil — automatic transmission oil is also used in
the power steering system.
Rear axle oil.
Cooling system corrosion inhibitor/antifreeze.
Chassis grease.
High melting point grease, for hub bearings etc.
Penetrating oil or spray.
Kerosene or similar cleaning solvent.
Methylated spirits.

Oils and greases are available in handy pack size for
do-it-yourself lube jobs.
2. SAFETY
PERSONAL SAFETY
Safety when working on a motor vehicle is basical-
ly a matter of commonsense. Some safety precautions
to prevent personal in juries are as follows.

Raising a Vehicle
Always jack a vehicle on firm, level ground and at
the specified jacking points . Ensure that the wheels
remaining on the ground are fully chocked.

After raising the vehicle, place chassis stands
underneath and allow the weight of the vehicle to rest
on them. Do not use bricks, blocks of wood or similar
material.

NOTE: Never work under a vehicle which is
only supported by a jack.

Electrical System
Always disconnect the negative battery terminal
when working on any electrical components. Avoid
wearing metal watches, rings and chains which may
short across live terminals.

As battery gases are explosive, keep naked flames
and sparks clear of the work area. When connecting
and disconnecting jumper leads, use extreme caution
to avoid sparking.

Electronic Ignition Systems
Electronic ignition systems produce dangerous
high tension voltages in bo th the primary and second-
ary circuits which can be fatal. Exercise extreme
caution when working on or near any ignition system
components. Do not disconnect high tension leads
while the engine is running.

Work Area
Do not run the engine in a confined space. Ensure
that the work area is adequately ventilated.

Spilt oil or water should be cleaned immediately
to avoid the possibility of slipping.

Fuel System
Always disconnect the negative battery terminal
when working on any fuel components. Do not smoke.
Keep naked flames and sparks clear of the work area.

Do not siphon fuel using the mouth. Use a hand
pump or suitable siphon.

Do not attempt to repair a fuel tank by welding it.
This is an extremely hazardous procedure and should
be entrusted to a specialist.

Cooling System
To avoid scalding, use caution when releasing the
radiator cap on an engine wh ich is at normal operating
temperature. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to release.
When the pressure is released, remove the cap from
the radiator.

Brakes
As asbestos is used in some brake lining material,
avoid inhaling brake dust. Do not use compressed air
to remove the dust. Gentle brushing with a small
brush or using a vacuum cleaner with a hose attach-
ment are the safest methods of cleaning the brakes.
The above precautions also apply to the clutch plate
lining material.

48 Engine

TO INSTAL
(1) Check that the camshaft and crankshaft
timing gears have not been moved and that the timing
marks are still aligned. It will be necessary to tempo-
rarily install the crankshaft pulley to check that the
timing marks are still aligned. (2) Install the drive belt to the crankshaft timing
gear around the water pump gear and onto the
camshaft timing gear.
NOTE: If the original drive belt is being
installed, ensure that the arrow marked on
the belt prior to removal is pointing in the
direction of rotation.

(3) Use the adjusting tool to turn the water
pump assembly sufficiently to engage the water pump
pulley with the drive belt. (4) Install the inner cover lower retaining bolt.
(5) Ensure that the drive be lt is correctly meshed
with the teeth of the camshaft, crankshaft and water
pump gears. Install the crankshaft pulley and tighten
the bolts to Specifications. (6) Adjust the drive belt as described under the
following heading.
(7) Install the drive belt outer cover and fasten
the retaining clips. (8) Install and adjust the alternator and if
equipped, the power steeri ng and air conditioning
drive belts as desc ribed in the Engine Tune-up section.
TO ADJUST

(1) Remove the alternator drive belt and if
equipped, the power steering and air conditioning
drive belts. (2) Release the clips securing the camshaft drive
belt outer cover to the inner cover and remove the
outer cover. (3) Turn the engine in the direction of rotation
until the timing marks on the camshaft and the inner
cover are aligned. (4) Loosen the water pump retaining bolts and
using the adjusting tool, rotate the water pump
housing to gain the required belt tension. The belt is
correctly tensioned when it can be grasped between
the thumb and forefinger midway between the cam-
shaft timing gear and the water pump gear and turned
ninety degrees from i t s operating position.
After the belt has been tensioned, tighten the
water pump retaining bolts to the specified torque.

NOTE: Over tensioning of the drive belt will
result in noisy operation and premature
wear of the belt.

(6) Install the outer drive belt cover.
(7) Install and adjust the alternator, and if
equipped, the power steering and air conditioning
drive belts as desc ribed in the Engine Tune-up section. 6. CAMSHAFT. ROCKER ARMS AND TAPPETS

Special Equipment Required:
To Check Camshaft — Dial gauge, Vee blocks and
micrometers
To Install — Drive belt adjusting tool
It is recommended that a new cylinder head
gasket is installed and the cylinder head bolts renewed
when the camshaft housing is removed.

TO REMOVE
(1) Disconnect the negative battery terminal.
Remove the nuts securing the earth wires to the
cylinder head bolts and remove the earth wires.
(2) On 1.6 liter models, remove the air cleaner
wingnuts and withdraw the air cleaner.
(3) Disconnect the engine breather hoses from
the camshaft housing and the camshaft housing top
cover. (4) Remove the camshaft housing top cover
retaining bolts and remove the top cover. Discard the
gasket.
(5) Remove the camshaft dr ive belt as described
under the previous heading. (6) Using an open ended spanner, hold the
camshaft between the inle t and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.
(7) Remove the distributor, distributor cap and
high tension leads. If necessary refer to the Fuel and
Engine Management section. (8) Check the camshaft end float before remov-
ing the camshaft from the engine. Mount a dial gauge
to the cylinder block with the plunger bearing on the
distributor drive end of the camshaft. (9) Lever the camshaft towards the dial gauge
and zero the gauge. Move the camshaft in the opposite
direction away from the dial gauge and note the
reading obtained. Check this measurement against
Specifications.

Checking the camshaft end float.

70 Cooling and Heating Systems


Installed view of the heater hoses. 1.6 liter models with the air cleaner removed for clarity
.
When the engine is at normal operating
temperature and the heater valve is open,
both of the heater hoses should feel
warm/hot. If the valve is not allowing the
coolant to flow, one hose will be hot while
the other will be cold.

NO COOLED AIR INSIDE VEHICLE
(1) Compressor drive belt slipping or broken:
Renew and/or adjust the drive belt as described in the
Engine Tune-up section.
(2) Insufficient refrigerant: Check the system for
leaks and charge as necessary. Refer to the Air
Conditioning heading in th is section for information
on checking the refrigerant level. (3) Compressor inoperative: Check for power to
the compressor clutch before removing the compres-
sor for repair by a specialist. (4) Heater system allowing warm air to mix with
cooled air: Check the operation of the heater system.
NOTE: The above trouble shooting proce-
dures are basic checks only. If the air
conditioning system is suspect, it is rec-
ommended that the vehicle be taken to an
authorized dealer for testing and repair.
It is normal for water to be seen drain-
ing under the vehicle from the evaporator
after the vehicle has been operated with
the air conditioning on.

3. DESCRIPTION
The cooling system is of the sealed, pressurized
type with fan and water pump assistance. The system
is pressurized in order to raise the boiling point of the
coolant and so increase the efficiency of the engine.

Provision for pressure a nd vacuum relief of the
system is incorporated in the radiator cap.

The radiator overflow hose is connected to a
reserve tank mounted adjacent to the battery. As the
coolant volume expands due to an increase in tem-
perature, the pressure valve in the radiator cap opens
and allows the excess coolant to flow into the reserve
tank. When the engine is stopped and the temperature
of the coolant falls, the vacuum valve in the radiator
cap opens and allows the excess coolant in the reserve
tank to siphon back into the radiator. Thus the
necessity for frequent topping up of the coolant is
eliminated.

The temperature of the cooling system is con-
trolled by a thermostat located in the thermostat
housing attached to the cylinder head.

The thermostat prevents circulation of coolant
through the radiator by directing coolant through the
by-pass circuit, until the engine has reached operating
temperature. This restricted circulation allows the
engine to reach operating temperature quickly, im-
proving drivability and fuel economy.

Removal of the thermostat to cure overheating is
not recommended because th e by-pass circuit will
remain open reducing the amount of water flowing
through the radiator.

An anti-corrosion inhibitor should always be
added to the coolant to protect the cooling and
heating systems from corrosion.

The water pump is mounted to the front of the
engine and is driven by the camshaft drive belt. It is
equipped with a double row ball bearing and a spring
loaded seal assembly. The water pump is a disposable
unit and cannot be repaired.

The fan is driven by an electric motor which is
actuated by the coolant temperature sensor and the
control unit.

On vehicles equipped with air conditioning, an
additional electric fan is m ounted to the radiator. This
fan is controlled by a sw itch connected to the air
conditioning compressor.

The radiator consists of an aluminum core with
plastic side tanks. Minor damage to the core can be
repaired using Nissan repair agent.

The left hand tank of the radiator houses the
transaxle oil cooler on automatic transaxle models.

To drain the cooling system a drain plug is
provided on the lower radiator pipe outlet.

4. RADIATOR
NOTE: To avoid scalding, use caution when
releasing the radiator cap on an engine
which is at the normal operating tempera-
ture. Turn the cap anti-clockwise to the first
stop and allow any pressure in the system to
release. When the pressure is released turn
the cap past the stop and remove it from the
radiator.

92 Fuel and Engine Management

Installed view of the throttle body assembly showing
the location of the base idle adjusting screw. 1.6 liter
engine.
(7) Disconnect the IAC valve wiring connector
and slowly connect the vacuum supply hose to the
inlet manifold. Allow five seconds to elapse and note
the engine speed.
(8) If the engine speed is not to Specifications,
remove the plug from the throttle body housing on 1.6
liter engines, or the cap from the base idle adjusting
screw on 1.8 liter engines, and adjust the idle screw
until the engine speed is 625 rpm. (9) Stop the engine and connect the IAC valve
wiring connector. (10) On 1.8 liter engines, install a new cap to
the
base idle adjusting screw.
On 1.6 liter engines, seal the throttle stop screw
with silicone sealant and install the air cleaner assem-
bly.

(11) Erase the memory codes as previously de-
scribed.
(12) Start the engine and increase the speed to
3 000 rpm for 10 seconds to allow the idle air control
valve to reset.
5. FUEL SUPPLY COMPONENTS

Special Equipment Required:
To Check Fuel Pressure — 0-500 kPa pressure
gauge

NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.

TO DEPRESSURISE FUEL SYSTEM
(1) Lift the front edge of the rear seat cushion on
each side, slide the cushion forward and remove it
from the vehicle. (2) Disconnect the fuel pump wiring harness
connector.
When depressurizing the fuel system, remove the rear
seat cushion and disconnect the fuel pump wiring
connector.
(3) Start and run the engine until it stalls.
Operate the starter motor for 10 seconds to ensure
that the pressure has dissipated.
(4) Connect the fuel pump wiring connector and
install the rear seat cushion.
NOTE: Failure to depressurize the fuel sys-
tem when instructed may result in a fuel
spray and possible fire.

TO TEST FOR EXTERNAL LEAKS
(1) Connect a jumper lead between terminals G
and H on the diagnostic link connector.
(2) Switch the ignition On.
(3) Check for leaks at all hose connections and
joints between the fuel pump and the engine. (4) Switch the ignition Off and remove the
jumper lead from the diagnostic link connector.
(5) If renewal of a component is necessary,
depressurize the fuel system as previously described. (6) Use only hoses and clamps as specified by
the manufacturer.
TO CHECK FUEL PRESSURE

(1) Depressurize the fuel system as previously
described. (2) On 1.6 liter engines, remove the air cleaner
as described in this section under the Air Cleaner
Assembly heading. (3) On 1.8 liter engines, release the hose clamp
securing the fuel supply hos e to the fuel rail and
disconnect the hose. On 1.6 liter engines, release the hose clamp
securing the fuel supply hose to the rear throttle body
hose fitting and disconnect the hose.

(4) Using a suitable gauge, tee piece, short piece
of fuel hose and clamps, install the pressure
gauge
between the fuel supply ho se and the fuel rail on 1.8

104 Fuel and Engine Management

(3) Gently pull the outer throttle cable until the
inner cable remains taut without moving the throttle
linkage. (4) Install the snap ring into the groove
posi-
tioned second from the insulator.
(5) Depress the throttle pedal and check that the
throttle valve opens fully and returns to the idle
position when the pedal is released. (6) On 1.6 liter engines, install the air
cleaner
assembly.
7. ELECTRONIC COMPONENTS
NOTE: Before proceeding with any of the
operations in this section, refer to the Ser-
vice Precautions and Procedures heading.

TO CHECK IGNITION SYSTEM
(1) Perform the test procedure described in the
Roadside Trouble Shooting section. Repair or renew
components as necessary. (2) Perform the self diagnosis test procedure as
previously described and rectify any faults. If there is
no spark, proceed as follows. (3) Disconnect the 4 pin wiring connector from
the distributor and check for spark at a spark plug
high tension lead using the test spark plug. If there is a spark, renew the pickup coil in the
distributor.

If there is no spark, proceed as follows.
(4) Connect the coil high tension lead to the test
spark plug and check for spark.

If there is a spark, check the distributor cap and
rotor for cracks and moisture. Repair or renew as
necessary.

If there is no spark, proceed as follows.
(5) Disconnect the 2 pin wiring connector from
the distributor. (6) With the ignition switched On. measure the
voltage at terminals A and B on the distributor 2 pin
wiring connector. If the voltage at terminal B only is under 10 volts,
check the wiring harness for continuity between
terminal B on the distributor 2 pin wiring connector
and terminal 2 on the black ignition coil wiring
connector. Repair or renew the wiring harness as
necessary. If no fault is found, renew the ignition coll.

If the voltages at both terminals is under 10 volts,
check the wiring harness between terminal A on the
distributor 2 pin wiring connector and terminal 1 on
the black ignition coil wiring connector for continuity.
Also check the fuel pump fuse and the wiring harness
between the ignition switch and the ignition coil.
Repair or renew the wiring harness as necessary.

If the voltage at both terminals is 10 volts or
more, proceed as follows.

(7) Connect the 2 pin wiring connector to the
distributor. (8) With the ignition switched On, measure the
voltage at the tachometer signal wire.

Illustration identifying the 2 and 4 pin distributor wiring
connector terminals.
If the voltage is under 1 volt, check the tacho-
meter signal wire for continuity from the ignition coil.
Repair or renew the wiring harness as necessary.

If the voltage is 1-10 volts, renew the distributor
control module. If there is still no spark, renew the
ignition coil also.

If the voltage is over 10 volts, proceed as follows.
(9) With the ignition switch in the Start position,
check for voltage at the tachometer signal wire using
a test lamp.

If the test lamp flashes, replace the ignition coil
with a known serviceable un it. If there is still no
spark, install the original coil and renew the control
module.

If the test lamp remains illuminated, proceed as
follows.

(10) Remove the distributor cap and disconnect
the pickup coil wiring co nnector from the control
module. (11) Connect a voltmeter between the tachometer
signal wire and earth. (12) Connect the lead of a test lamp to a power
supply of 1.5-8 volts. (13) With the ignition switched On, momentarily
connect the probe of the test lamp to terminal P on
the control module and note the voltage. The voltage
should decrease to 7-9 volts. If there is no voltage decrease, check the control
module earth. If the earth is satisfactory, renew the
control module.

If the voltage decreases , proceed as follows.
(14) Check for spark at the coil high tension lead
as the test lamp is disconnected from terminal P on
the control module.

If there is no spark, proceed to operation (15).
If there is a spark, check that the steel rotor on the
distributor shaft is magnetized. If it is not renew the
distributor shaft assembly.

If the steel rotor is magnetized, check that the
resistance between the pickup coil leads is 500-1 500
ohms and not earthed. Renew the pickup coil as
necessary.

(15) Renew the ignition coil and check for spark.
If there is no spark check the coil high tension

lead. If no fault can be found, renew the control
module.

118 Emission Control


Installed view of the charcoal canister.
When the engine is at rest, fuel vapor through
evaporation gradually fills the air space in the fuel
tank. The sealed filler cap pr events the escape of this
vapor and pressure builds up within the system,
forcing the vapor to flow into the charcoal canister
which is located in the engine compartment beneath
the windscreen wiper motor.

The fuel check valve prevents liquid fuel entering
the charcoal canister when the fuel tank is full or the
vehicle is parked on a steep incline. When the engine
is running, the vapor is drawn via a hose from the
charcoal canister to the throttle body and burnt in the
combustion chambers.

TO RENEW CHARCOAL CANISTER
(1) Suitably mark and disconnect the hoses from
the canister. (2) Release the retaining spring and remove the
canister from the engine compartment. Installation is a reversal of the removal procedure.

TO RENEW FUEL CHECK VALVE
(1) Disconnect the negative battery terminal.
(2) Raise the rear of the vehicle and support it
on chassis stands. Remove the left hand rear wheel. (3) Drain the fuel from the fuel tank using a
hand pump or a suitable siphon. Do not siphon fuel
using the mouth.
(4) Remove the hoses from the check valve.
(5) Squeeze the retaining clip and remove the
check valve from the mounting bracket. Installation is a reversal of the removal procedure.

TO SERVICE THE SYSTEM
(1) Inspect the vacuum lines and connectors for
signs of leakage, cracks and deterioration and renew
as necessary. (2) Remove the fuel tank cap and check that a
slight resistance is felt, when vacuum is applied to the
one-way relief valve in the centre of the cap. Renew the fuel tank cap if no resistance is felt or
if the valve is blocked.

(3) Inspect the fuel tank cap seal for deteriora-
tion. Renew as necessary.

Installed view of the fuel check valve as seen with the
left hand rear wheel removed.
Check the fuel filler cap seal for damage.
23Q/LDZ GAUGE
Line drawing showing a hand vacuum pump.