1987 NISSAN PULSAR suspension

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

INTRODUCTION
This Service and Repair Manual
covers the Australian manufac-
tured Nissan Pulsar (hatchback) and Vector (sedan) N13 Series 1
(J87 - 91 and
the Holden Astra LD Series 1987 - 89.

Two engines were available: a 1.8 l i t e r engine with multi-point fuel injec-
tion, and a 1.6 liter throttle body injected engine. The engines are similar
having single overhead camshafts and computer controlled fuel injection and
ignition control. There was a choice of three speed automatic or five speed
manual transaxles.

A viscous coupling limited s l i p differential was introduced from July 1989
to the five speed manual transaxle models of the Pulsar Q and Vector SSS.

Disc brakes are fitted at the front of a l l models, while the rear brakes are
either discs or drums.

All models are equipped with independent coil spring suspension. Steering
can be by either manual or power assisted rack and pinion.

This manual includes information on trouble shooting, lubrication and
maintenance, specifications and the rem oval, installation and overhaul of com-
ponents which are considered to be with in the scope of the average, well
equipped home mechanic.

Certain repair jobs covered in this manual require the use of special
equipment not normally found in a home tool kit. When such equipment is
required, the equipment and i t s functi on is brought to the users attention
underneath the heading for that component. Some jobs, such as automatic
transmission overhaul, should he left to an authorized dealer or a specialist
who has the extensive knowledge and equi pment required. In these cases, the
removal and installation procedures are fully covered, enabling the unit to be
removed for repair or a reconditioned unit to be installed.

Reference in the manual to the left an d right hand sides of the vehicle are
from the point of view of someone sta nding at the back of the vehicle and
looking forward.

Inexperienced operators should not a ttempt a service or repair operation
before completely reading the appropriat e section (or other sections which may
be referred to) in the manual.

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.

22 Wheels and Tires


View of the jack correctly installed to the front jacking point
.
(10) Continue to raise the jack until the tire
clears the ground sufficiently to allow the spare wheel
to be installed.
(11) Remove the wheel nuts and lift the wheel
off the hub.
NOTE: Under no circumstances get under
the vehicle while the jack is the only means
of support.

(12) Install the spare wh eel and install the wheel
nuts with the chamfered e nds contacting the wheels.
Tighten the wheel nuts as much as possible by hand.

(13) Lower the jack and securely tighten the
wheel nuts progressively in a diagonal sequence using
the wheel spanner. (14) Where removed, install the wheel cover.
(15) Return the spare wheel, jack and tool kit to
their relevant storage positions.

ABNORMAL WEAR ON CENTRE OF TREAD
(1) Over inflation of tires: Check and reduce to
the recommended pressure.


ABNORMAL WEAR ON INSIDE OF TREAD
(1) Excessive negative camber angle: Check the
wheel alignment. (2) Sagging coil springs: Check and renew the
coil springs as a pair. (3) Loose or worn hub bearing assembly: Check
and renew the hub bearing assembly. (4) Bent, loose or worn suspension components:
Check and renew any faulty components.
ABNORMAL WEAR ON OUTSIDE OF TREAD

(1) Excessive positive camber: Check the front
wheel alignment.
(2) Excessive speed when cornering: Revise driv-
ing habits. (3) Bent, loose or worn suspension components:
Check and renew any faulty components.


2. TYRE WEAR TROUBLE SHOOTING
ABNORMAL WEAR ON BOTH SIDES OF
TREAD

(1) Under inflation of tires: Check and inflate to
the recommended pressure.
(2) Overloading: Reduce the maximum loading. FLAT SPOTS ON TREAD OR IRREGULAR
WEAR

(1)
Static or dynamic unbalance of the wheel
and tire assembly: Check the balance of the wheel and
tire assembly. (2) Lateral run out of the wheel: Check and (rue
up or renew the wheel.
Tighten the wheel nuts in a diagonal sequence using
the wheel spanner.

Wheels and Tires 23
(3) Excessive play in the front suspension ball
joints: Check and renew the ball joints.
(4) Excessive play in the hub bearing assembly:
Check and renew the hub bearing assembly.
WORN SPOTS ON CENTRE OF TREAD

(1) Static unbalance of the wheel and tire asem-
bly: Check the balance of the wheel and tire assembly
(2) Radial run out (eccentricity) of the wheel:
Check and renew the wheel.
FEATHERED EDGES ON TREAD PATTERN

(1) Excessive speed when cornering: Revise driv-
ing habits. (2) Excessive toe-in or toe-out: Check and adjust
the wheel alignment.

(3) Bent, loose or worn suspension components:
Check and renew any faulty components.

NOTE: To preserve tire life it is good policy
to periodically have the front wheel balanced
and the steering geometry checked on a
reliable wheel alignment machine.

Under no circumstances mix radial ply
and conventional ply tire s. Install only tires
of the same construction to all four wheels.

3. CARE AND MAINTENANCE
STEEL WHEELS
Steel wheels should be regularly cleaned of all
foreign matter, such as dirt and mud. If foreign matter
is allowed to build up it will affect the balance of the
wheel and may cause vibrations and uneven tire wear.
If the paint has been chipped or scratched it should be
touched up as soon as possible to prevent rust.

Any minor damage to the wheel rim can usually
be repaired using a suitable hammer after the wheel
has been removed from the vehicle. However, any
major rim damage or buckling of the wheel will
necessitate the renewal of the wheel. It is good policy
to occasionally remove the wheels from the vehicle
and inspect them for damage, cracks or corrosion.

ALLOY WHEELS
Alloy wheels should be regularly cleaned of all
foreign matter such as dirt and mud. If foreign matter

Wheels should be cleaned regularly of dirt and mud.
is allowed to build up it will affect the balance of the
wheel and may cause vibrations and uneven tire wear.

The alloy wheels are coated with a clear protective
finish. Do not use abrasive cleaner, polishing com-
pounds, steel wool etc. when cleaning the wheels. Only
mild soap and warm wate r are recommended. Alloy
wheels are particularly su sceptible to corrosion dam-
age particularly if exposed to salt water.

Alloy wheels being relatively soft in comparison to
steel are easily scuffed, however, this will not affect the
serviceability of the wheel. Where heavy damage has
been sustained to the wheel it should be renewed.
Buckling or cracking of an alloy wheel cannot be
repaired.

TYRES
The depth of the tire tread grooves should never
be allowed to be less than 1.5 mm before the tires are
renewed. The tires should also be renewed when any
damage, whether it be internal or external, is evident.
Minor punctures or leaks s hould be properly repaired.
Refer the tire to a tire spec ialist if there is any doubt
about the serviceability of the tire.

The tread, tread grooves and sidewalls should be
regularly inspected for foreign matter i.e. nails, stones
etc. Where foreign matter is detected it should be
removed from the tire and if necessary, the puncture
repaired.

The tire valves should always have the caps
installed, be regularly cleaned of dirt or dust and be
inspected for leakage and damage every time the tire
pressures are checked.

Regularly inspect the tread of the tires for signs of
uneven wear. If uneven wear is apparent, refer to the
heading Tire Wear Trouble Shooting in this section
for possible causes and cures. If the uneven tire wear
is noticed early enough, the cause correctly identified
and the necessary cure carried out, the life of the tire
should be extended.

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.

Manual Transaxle and Drive Shafts 137


Dismantled view of the gear lever assembly.
(7) Remove the bushes, spacer and O rings from
the bottom of the gear lever.
(8) Remove the nuts retaining the floor bracket
to the vehicle floor panel and remove the bracket from
the vehicle. (9) If necessary, disconnect the control rod and
the support rod from the transaxle and remove the
rods from the vehicle. (10) Check all the components for deterioration,
wear and damage. Renew the unserviceable compo-
nents as necessary. Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

(1) Install all the components to the locations
noted during dismantling.
(2) Lubricate all the pivot points with multipur-
pose grease prior to assembly. (3) Tighten all the nuts securely.
(4) Road test the vehicle and check for correct
gear selection.
6. DRIVE SHAFTS

TO REMOVE AND INSTAL
(1) Remove the dust cap from the centre of the
front hub. Remove the split pin and nut retainer from
the outer end of the drive shaft. (2) With an assistant applying the brakes, loosen
the nut on the outer end of the drive shaft.
(3) Raise the front of the vehicle and support it
on chassis stands. If necessary, refer to the Wheels and
Tires section for the correct jacking points.

Assembled view of the left hand side drive shaft
assembly.
(4) Remove the split pin and castellated nut
retaining the tie rod to the steering knuckle. (5) Disconnect the tie rod end from the steering
knuckle using a suitable puller or alternatively place a
hammer or dolly on one side of the steering knuckle
and strike the opposite side with a hammer.
(6) Remove the split pin and castellated nut
retaining the suspension ball joint to the bottom of the
steering knuckle. (7) Disconnect the suspension ball joint from
the steering knuckle using a suitable puller or alterna-
tively place a hammer or dolly on one side of the
steering knuckle and strike the opposite side with a
hammer. (8) Remove the retaining bolts and remove the
brake caliper from the stee ring knuckle. Refer to the
Assembled view of the right hand side drive shaft
assembly.

145
STEERING
PART 1. STEERING TROUBLE SHOOTING
FAULTS, CAUSES AND REMEDIES
EXCESSIVE PLAY OR LOOSENESS IN
STEERING GEAR

(1) Tie rod end ball joint loose or worn: Tighten
or renew the worn tie rod end ball joint. (2) Steering gear assembly loose on cross-
member: Inspect for damage and tighten the steering
gear mounting bolts. (3) Steering gear worn: Overhaul the steering
gear.


(2) Low fluid level in the power steering reser-
voir: Check for leakage, repa ir and/or renew the faulty
components. Top up the fluid level.
(3) Suspension worn or out of alignment: Check
the front suspension for wear, renew the worn com-
ponents and realign. (4) Misalignment between the steering gear and
column mountings: Check and align the steering gear
and column mountings. (5) Binding in the steering shaft universal coup-
ling joints: Check the join ts and renew if necessary.
(6) Ingress of dirt into the steering gear due to a
defective boot: Clean, check and lubricate the internal
components of the steering gear and renew the
defective boot. (7) Insufficient power steering pump pressure:
Check the pump drive belt tension and reservoir fluid
level. If necessary renew the pump assembly.
NOTE: Ensure that both front tires have
ample depth of tread and are inflated to the
correct pressure. Check the front suspension
components for wear before having the steer-
ing geometry checked. See the Front Sus-
pension section for the component checking
procedures.


Check the tie rod ends for wear and the rubber boots for deterioration.
(4) Worn front hub bearings: Check the condi-
tion and renew the front hub bearings. (5) Worn or damaged front suspension control
arm bushes: Renew the control arm or bushes.
NOTE: Looseness in th e steering linkage is
best assessed with the weight of the vehicle
on the front wheels. Have an assistant turn
the steering wheel from left to right while the
inspection for wear is being made. If loose-
ness is found to be in the steering gear, it
will be necessary to overhaul the steering
gear assembly.

HEAVY STEERING
(1) Low or uneven tir e pressures: Check the
tires and inflate to the recommended pressures.


Checking the steering rack boot s for splits and deteri-
oration.