1987 NISSAN PULSAR radio

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

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.

Electrical System 209
12. INSTRUMENT CLUSTER
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Remove the retaining screws from the instru-
ment cluster surround. Carefully withdraw the instrument cluster
surround from the instrument panel sufficiently to
enable the wiring to be disconnected. Remove the
surround from the vehicle.
.
FLEXIBLE PRINTED
CIRCUIT

Rear view of the instrument cluster removed from the
vehicle.

(4) Remove the instrument cluster assembly
retaining screws and gently ease the assembly from the
instrument panel sufficiently to enable the wiring to be
disconnected.

If necessary, remove the instruments as follows:
Carefully depress the retaining clips on the
front lens and remove the front lens. On models equipped with a tachometer, slide
the plastic rib from between the speedometer and the
tachometer. Remove the screws retaining the speedome-
ter and the tachometer or fuel/temperature gauges
from the rear of the instrument cluster.
CLUSTER ASSEMBLY

(d) Withdraw both instruments from the front of
the instrument cluster being careful as these instru-
ments are held by protruding pin terminals.

NOTE: Do not touch the faces of the instru-
ment dials as they mark easily.

(e) On models equipped with a tachometer,
remove the retaining nuts and remove the tempera-
ture and/or the fuel gauge from the cluster assembly.

Installation is a reversal of the removal procedure
ensuring that all electrical connectors are correctly
installed.

13. BLOWER FAN
The removal and installation procedure for the
blower fan is described in the Cooling and Heating
Systems section.

14. RADIO/CASSETTE
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Remove the release hole covers on each side
of the radio/cassette.

Dismantled view of the instrument cluster.
Illustration of the radio/cass ette removal tool showing
the required dimensions.
BULB HOLDERS
BULB HOLDERS
Removing the release hole covers from the radio/cas-
sette.

210 Electrical System


Using the radio/cassette removal tools during removal of the unit.
Construct the special tools as illustrated,
insert both tools into the release holes on the radio/
cassette and carefully withdraw the radio/cassette
from the mounting bracket.
Disconnect the wiring harness terminal plug
and remove the radio/cassette.
Installation is a reversal of the removal procedure
with attention to the following points:

Remove the special tools from the radio/
cassette, connect the wiring harness terminal and push
the radio/cassette into the mounting bracket. Install the release hole covers on each side
of
the radio/cassette.
15. LAMP UNITS

HEADLAMPS
To Remove and Install
Disconnect the negative battery terminal.
If removing the drivers side headlamp on 1.8
liter engines, remove the bo lt securing the air cleaner
intake duct and remove the air cleaner intake duct.

Dismantled view of the headlamp assembly.
Remove the radiator grille as described in
the Body section. Remove the bolt and nut from the front and
rear of the inner headlamp. Remove the side indicator lamp assembly
and remove the bolts from the side of the headlamp.
Maneuver the headlamp inner side out first
and remove the headlamp from the vehicle. Installation is a reversal of the removal procedure.

To Adjust Headlamp Aim
Ensure that the tires are inflated to the
correct pressure and that the vehicle is positioned on
level ground.
The vehicle should be unladen, with a full
fuel tank and the driver sitting in the vehicle. When using a headlamp aiming machine,
refer to the manufacturers instructions for equipment
being used.

Partially removed view of the headlamp assembly. Diagram showing the correct light patterns using an
aiming board. Dimension A = 5 meters.

222 Electrical System

Wiring diagram (WD4) for the horn, audio, front wiper/washer and rear wiper/washer circuits.
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. Fuse No. 18 Batt
2. Horn relay
3. Horn switch
4. Horn
5. Stop lamp switch
6. L H stop lamp
7. R H stop lamp
8. To No. 28 WD2
9. To No. 14 WD6
10. To No. 8 WD1
11. Radio cassette and clock
12. L H front speaker
13. L H rear speaker
14. R H front speaker
15. R H rear speaker
16. Fuse No. 19 Batt
17. Fuse No. 20 Batt
18. Fuse No. 6 ACC
19. Rear washer motor
20. Rear wiper/washer
motor
21. Rear wiper motor
22. Fuse No. 7 ACC
23. Front wiper motor
24. Front washer motor
25. Intermittent wiper relay
26. Front wiper/washer
switch
27. Variable intermittent
switch

Body 235
lever and remove the screws underneath. Withdraw
the rear console.

On manual transaxle models, unscrew the
gear lever knob and prise out the gear lever rubber
boot. On automatic transaxle models, prise out the
panel around the selector lever and maneuver the
panel over the lever. Remove the screws retaining the front of the
console to the floor panel and withdraw the console
from the vehicle. Installation is a reversal of the removal procedure.

9, DASHBOARD
TO REMOVE AND INSTAL
Disconnect the negative battery terminal.
Remove the centre console as previously
described in this section. Remove the steering wheel as described in
the Steering section. Remove the upper and lower steering col-
umn shrouds and remove the combination switch.
Refer to the Electrical System section if necessary. Remove the retaining screws and withdraw
the lower trim panel from underneath the steering
column. Remove the screws from underneath the
bonnet lock handle and slide the bonnet lock handle
downwards out of the dashboard. Remove the screws retaining the centre fas-
cia panel, two upper and two lower, withdraw the
fascia panel slightly and disconnect the wiring to the
cigarette lighter.

Dismantled view of the centre console assembly. Au-
tomatic transaxle model.
Remove the radio/cassette bracket retaining
screws. Disconnect the aerial and the wiring and
withdraw the radio/cassette from the centre bracket. Remove the heater control knobs and re-
move the heater fascia panel screws. Carefully remove
the heater fascia panel leaving the heater controls in
place.
Loosen the bolt retaining the large wiring
connector at the lower right hand side of the dash-
board. As the bolt is loosened it will force the
connector apart. Using a screwdriver, carefully prise out the
demister ducts from th e top of the dashboard.
Using a suitable socket, remove the bolts
from underneath the demister ducts. Remove the bolts from the outer lower edges
and the lower part of th e centre bracket assembly.
NOTE: Refer to the illustration for the
location of the dashboard retaining bolts.

(14) With the aid of an assistant lift the dash-
board straight up at the door pillar brackets. Tilt the


View of the dashboard removed from the vehicle. The arrows indicate the location of the retaining bolts.