1987 NISSAN PULSAR height adjustment

124 Clutch


Illustration showing the clutch aligning tool. The tool
can be readily fabricated from a length of round section
wood or metal. Dimension A = diameter of the ma-
chined section of the crankshaft. Dimension B - inside
diameter of the driven plate hub.
to the release fork ensuring that the return spring is
correctly anchored.

(3) Install the release bearing to the clutch hous-
ing and install the clips re taining the release bearing
carrier to the release fork. (4) Install the driven plate to the flywheel in the
direction noted on removal. Install the aligning tool to
hold the driven plate in position.
NOTE: Some driven plates are marked
Flywheel side to indicate the correct in-
stalled direction.

(5) Install the pressure plate to the flywheel in the
position marked on removal. (6) Ensure that the driven plate is correctly
centered and install the pressure plate retaining
bolts.
Tighten the bolts progressively in a diagonal sequence
to the specified torque. (7) Install the transaxle to the vehicle as de-
scribed in the Manual Transaxle section. (8) Adjust the clutch pedal height and free play
as described under the Adjustments heading later in
this section.
4. CLUTCH PEDAL

TO REMOVE AND INSTAL
(1) Working in the engine compartment, loosen
the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.
(2) Working inside the vehicle, release the inner
clutch cable from the top of the clutch pedal.
(3) Remove the nut from the end of the clutch
pedal pivot pin. (4) Note the installed position of the clutch
pedal return spring and remove the pivot pin from the
clutch pedal.
(5) Remove the clutch pedal from the vehicle
and remove the bush from the clutch pedal. (6) Examine the clutch pedal and the bush for
bend, cracks, wear and damage. Examine the return

Installed view of the clutch pedal.
spring for cracks and fatigue. Renew parts as neces-
sary.

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

(1) Lubricate the hook on the top of the clutch
pedal and the pivot pin and bush with lithium base
molybdenum disulphide grease. (2) Install the return spring to the position noted
on removal. (3) If necessary, adjust the pedal height and free
play as described under the Adjustments heading later
in this section.
5. CLUTCH CABLE

TO REMOVE AND INSTAL
(1) Working in the engine compartment, loosen
the adjusting nut and disconnect the inner clutch
cable from the clutch release lever at the clutch
housing.
(2) Release the outer clutch cable retaining nut
and slide the outer cable out of the slot in the
mounting bracket.
View of the clutch cable assembly.

Clutch 125
(3) Remove the nuts retaining the outer cable
flange to the vehicle bulkhead.
(4) Working inside the ve hicle, disconnect the
inner cable from the top of the clutch pedal. (5) Pull the clutch cable through the bulkhead
into the engine compartment. (6) Release the clip retaining the centre of the
clutch cable and remove the cable from the vehicle. (7) Check the inner cable for fraying, wear and
damage. Check the outer cable for kinks, wear and
damage. If necessary, renew the cable assembly. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Lubricate the inner cable ends with lithium
base molybdenum disulphide grease prior to installa-
tion. (2) Tighten the nuts retaining the outer cable
flange to a torque of 11 Nm. (3) Check and if necessary , adjust the clutch
pedal height and free play as described under the
heading Clutch Adjustments.
6. CLUTCH ADJUSTMENTS
TO ADJUST PEDAL HEIGHT (1) Fold back the floor carpet and the sound
insulation from the drivers side floor panel.
(2) Measure the distance at right angles from the
floor panel to the centre of the pedal pad. (3) If the pedal height is not as specified, adjust
the pedal stop bolt until the correct pedal height is
obtained.

TO ADJUST PEDAL AND RELEASE LEVER
FREE PLAY
(1) Loosen the inner cable locknut at the release
lever clevis. (2) Push the release lever until resistance is felt
when the release bearing contacts the pressure plate
fingers and hold the release lever in this position.
(3) Tighten the inner cable adjusting nut until
the inner cable is taut.
(4) Loosen the adjusting nut 2.5-3.5 turns and
tighten the inner cable locknut. (5) Measure the release lever free play. If the free
play is not as specified, loosen the locknut and turn
the adjusting nut until the correct free play is
obtained.

View of the clutch release lever free play adjusting
nut.
(6) Lightly depress the clutch pedal until resis-
tance is felt when the release bearing contacts the
pressure plate fingers. Measure the distance from the
centre of the pedal pad in this position to the centre
of the pedal pad when the pedal is contacting the stop
bolt. If necessary, check and adjust the release lever
free play which should bring the pedal free play within
Specifications.

Measuring the clutch pedal height with the carpet
removed.

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.

Brakes 187
(b) Disengage the handbrake cable return spring
from the backing plate.

handbrake cable flange from the rear of the backing
plate and remove the cable from the vehicle.

(6) Inspect the rear handbrake cables for chafing
or broken strands. Renew the cables if damage is
evident.

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

(1) Ensure that the handbrake cable clamps are
correctly installed. (2) On drum brake models, install the
handbrake
cable to the backing plate by carefully tapping the
flange on the handbrake cable. Ensure that the cable is
not damaged. (3) Adjust the handbrake cable as described
under the Brake Adjustments heading.
9. BRAKE ADJUSTMENTS

FRONT AND REAR DISC BRAKES
The disc brakes are self adjusting and no manual
adjustment is required or provided.

REAR DRUM BRAKES
Depress the handbrake lever button, apply and
release the handbrake lever several times to adjust the
rear brake shoes.

HANDBRAKE
(1) Raise the rear of the vehicle and support it
on chassis stands. (2) Remove the carpet square from the rear of
the console. Remove the retaining screws from the
front and rear of the rear console section and manoeu-
vre the rear console from the vehicle. (3) Tighten the adjusting nut until the hand-
brake lever pull is between 7-11 notches. (4) Check that the rear wheels are not binding. If
the rear wheels do not rotate freely refer to the Brakes
Trouble Shooting for possible causes.
(5) With the ignition switched On, check that
the handbrake warning lamp is extinguished when the
lever is fully released. (6) Lower the vehicle to the ground and test the
handbrake on an incline.
10. BRAKE PEDAL

TO REMOVE AND INSTAL
(1) Working inside the vehicle remove the re-
taining clip from the clevis pin and remove the clevis
pin connecting the brake pedal to the pushrod.

Dismantled view of the brake pedal components.
(2) Remove the nut from the pivot bolt and
withdraw the brake pedal pivot bolt.
(3) Maneuver the brake pedal from the mount-
ing bracket. (4) Remove the spring from the brake pedal.
(5) Inspect the return spring for breakage or
fatigue. Renew as required.
(6) Inspect the pedal pivot bolt for damage or
wear. Renew as required. (7) Inspect the brake pedal for wear, cracks or
fatigue. Renew as required. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Sparingly lubricate the pedal pivot bolt and
clevis pin with a suitable grease. (2) Ensure that the brake pedal pivot bolt is
correctly located in the pedal bracket. (3) Ensure that the clevis pin is inserted fully
through the clevis and the retaining clip is correctly
installed. (4) Check and if necessary adjust the brake
pedal height and stop lamp switch as described below.
TO ADJUST PEDAL HEIGHT

The dimension for the pedal height is measured at
right angles from the floor, with the carpet pulled
back, to the centre of the pedal pad.

(1) Working inside the ve hicle, disconnect the
wiring from the stop lamp switch.
(2) Loosen the stop lamp switch locknut and
position the switch away from the brake pedal. (3) Loosen the locknut on the brake pedal push-
rod and adjust the pushrod to achieve a pedal height
of 155-165 mm on manual transaxle models or
164-174 mm on automatic transaxle models. Tighten
the locknut. (4) Adjust the stop lamp switch as described
under the following heading.

188 Brakes

Illustration showing the brake pedal adjustments. Di-
mension H = brake pedal height, Dimension C = stop
lamp switch clearance, Dimension F - brake pedal free
play.
TO ADJUST STOP LAMP SWITCH
(1) Loosen the stop lamp switch locknut and
disconnect the wiring from the switch.
(2) Adjust the stop lamp switch to achieve a
clearance of 0.3-1.0 mm between the pedal stop and
the threaded end of the switch. (3) Tighten the locknut and connect the wiring
to the switch. Ensure that the stop lamps are off when
the pedal is released.
(4) Ensure that the pedal free play is 1.0-3.00
mm after adjustments have been completed.
11. HYDRAULIC SYSTEM

TO BLEED
Bleeding the hydraulic system should only be
necessary when some portion of the hydraulic system
has been disconnected or fluid has been drained,
allowing air to enter the system.

The brake fluid in the hydraulic system should be
changed every 30 000 km or 18 months. The proce-
dure for changing the brake fluid and bleeding the
hydraulic system are simila r with attention to the
notes in the text.

There are four points in the system where bleeder
valves are installed, one on each front caliper and one
on each rear wheel cylinder or rear caliper.

14. Fill the fluid reservoir with clean hydraulic
brake fluid and maintain at least one third full
throughout the entire operation. 15. Attach a transparent hose to the bleeder
valve on the left rear cali per and immerse the other
Bleeding the right hand rear brake caliper.
end of the hose in a small amount of clean brake fluid
contained in a clean glass jar held higher than the
bleeder valve.

14. Unscrew the bleeder valve one
complete turn.
15. Have an assistant depress the brake
pedal slowly to the full extent of its travel. Close
the bleeder valve and allow the brake pedal to
r e t u r n w i t h o u t assistance. 16. Repeat operations (3) and (4) until
a con stant stream of fluid, without any air
bubbles, is being discharged into the gl ass jar,
hold the brake pedal down and tighten the
bleeder valve.
Bleeding the right hand front brake caliper.