1987 NISSAN PULSAR transmission

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.

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.

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.

General Information 13

A simple bush removing tool using a bolt, nut, suitable spacer and large and small washers.
Bushes in blind holes can also be removed using
hydraulic force. With the hole packed with grease,
insert a neat fitting drift and tap the drift into the hole.

The pressure of the grease on the rear of the bush
should force it from the hole.

ROTATING THE CRANKSHAFT
There are many occasions when it is necessary to
rotate the crankshaft to a certain position. These
include timing and valve adjustment and checking
valve timing.

To make the engine easier to rotate, remove the
spark plugs. This will re lieve compression pressure.

The simplest method is to use a socket or ring
spanner on the crankshaft pulley nut and turn the
engine in the normal direction of rotation.

On vehicles with manual transmission, the engine
can be turned by selecting top gear and rolling the
vehicle forward. A variation of this method is to raise
one of the driving wheels and, with top gear selected,
rotate the driving wheel in a forward direction to turn
the engine.

Alternatively, the engine can be brought to the
desired position by briefly actuating the starter motor.

32
ROADSIDE TROUBLE SHOOTING
CAUTION: To prevent severe electrical shock extreme care must be taken w\
hen
working on or near the electronic ignition system as dangerous high tension voltages
are produced in both the primary and secondary circuits. See the text fo\
r
precautionary notes.

This section deals with the common causes of
engine failure to start, as inevitably there will come a
time when every driver will experience this problem
and will therefore need to call upon his own resources
to rectify the trouble. Roadside breakdowns other
than engine failure can be identified by reference to
the Trouble Shooting section on the particular com-
ponent affected.

1. TROUBLE SHOOTING
Trouble shooting is only a process of elimination
and provided the procedure is carried out correctly
and systematically an accur ate diagnosis of the trouble
can be made in the minimum amount of time.

For an internal combustion engine to run there
are three basic requirements, these are ignition, fuel
and compression. There are other factors of course
but as a rule an engine's failure to start can be
attributed to a fault in one of these three systems.

Reports from field engineers of motoring organi-
sations prove that the bigg est percentage of engine
breakdowns are in the order of ignition or electrical
failure first, followed by fuel, with mechanical or
compression failure the least common.

Should the engine fail to start, first check that
there is adequate fuel in the tank and if so. carry out
the following checking procedures in the order de-
scribed.

TO JUMP START A VEHICLE
NOTE: Jump starting a vehicle can be
dangerous if the procedure described below
is not performed correctly. If any doubt
exists, it is recommended that the services of
a competent mechanic be obtained.

The vehicles covered by this manual are
equipped with complex electronic circuitry
which can be damaged by voltage surges.
These voltage surges can be generated when

jump starting, or being jump started by
another vehicle. If av ailable use jumper
leads equipped with a surge protection de-
vice and follow the lead manufacturers in-
structions carefully, particularly regarding
the connection and disconnection of the
leads.

(1) Ensure that the booster battery is 12 volts
and the negative terminal is earthed.
(2) Ensure that the vehicles are not touching and
that the ignition and all accessories on both vehicles
are switched Off. (3) Ensure that the transmissions on both vehi-
cles are in Park or Neutral and the handbrakes are
firmly applied. (4) Remove the vent caps from the battery and
check the electrolyte level. Replenish with distilled
water as necessary.

View showing the correct jumper lead connections for
jump starting a vehicle. The leads shown are equipped
with a surge protection device.

Engine 59
(5) If the engine is completely dismantled, thor-
oughly clean the cylinder block with solvent and
compressed air paying particular attention to the
oilways. Inspect the block for cracks and damage.

TO CHECK PISTON CLEARANCE
(1) Using an accurate cylinder measuring gauge,
measure and note the diameter of each bore as
previously described. (2) Measure each piston skirt using a microme-
ter as follows:
(a) On 1.6 liter models, measure each piston
skirt at a point 9 mm above the bottom skirt edge and
at right angles to the gudgeon pin axis. (b) On 1.8 liter models, measure each piston
skirt at a point 6 mm above the bottom skirt edge and
at right angles to the gudgeon pin axis.
(3) The difference between the bore and the
piston measurement is the piston clearance. If the
clearance exceeds the Specifications, renew the pistons
and rebore all the cylinders.
(4) Cylinders that have had new pistons installed
or that have been rebored should have the piston
clearance checked again.

and not engine or transmission oil, mineral spirits or
kerosene.

(2) Honing should be carried out by moving the
hone up and down fast enough to obtain a cross hatch
pattern. When hone marks intersect at 60 degrees, the
pattern is most satisfactory for correct seating of rings.
(3) After honing it is necessary that the block be
cleaned again to remove all traces of abrasives.
NOTE: When deglazing, the cylinder should
be honed only sufficiently to eliminate the
glazed condition. Excessive honing will in-
crease the bore size and alter the piston
clearance.

(4) When honing is complete, ensure that the
cylinder bore, crankcase area and oilways are thor-
oughly cleaned. (5) After the cylinder block has been cleaned and
dried, wipe the bores with a lint free cloth and smear
them with engine oil to prevent rusting.
NOTE: All abrasives must be removed from
the engine components after honing. A so-
lution of soap and water should be used with
a brush and the components thoroughly
dried. A bore can be considered clean when
it can be wiped clean with a white cloth and
the cloth remains clean. Oil the bores after
cleaning to prevent rusting.

TO FIT NEW PISTON RINGS AND INSTAL
PISTONS

Once the correct piston and the bore relationship
has been determined and the pistons cleaned or
renewed as necessary, proceed as follows:

(1) Place a ring into number one cylinder bore
and using an inverted piston push the ring down 50
mm into the cylinder bore. (2) Withdraw the piston and measure the gap in
the ring with feeler gauges. Adjust the end gap of the
ring by filing as necessary. See the Specifications for
the ring end gap.
Measuring the piston diameter using a micrometer. On
1.6 liter models, dimension A = 9 mm. On 1.8 liter
models, dimension A - 6 mm.
TO INSPECT AND DEGLAZE CYLINDER
BORES

Cylinder bores that are fit for further service with
the original pistons, but require re-ringing, should be
deglazed with a hone. Before honing the cylinder
bores with crankshaft insta lled, place plenty of clean
rag over the crankshaft to keep the abrasive materials
from entering the crankcase area.

(1) Deglaze the cylinder walls using a cylinder
surfacing hone equipped with suitable stones. Inspect
the cylinder walls after each 20 strokes. Use honing oil
Checking the piston ring end gap.

Fuel and Engine Management 97
circuitry do not immerse it in cleaning
solvent as this may result in irreparable
damage.

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

(1) Lubricate the new O ring seals with auto-
matic transmission fluid prior to installing them to the
injector. If removed, ensure that the lower filter screen
is installed. (2) Firmly push the injector into the throttle
body assembly until it is fully seated, ensuring that the
injector connection terminals face towards the rear of
the vehicle.
(3) Apply Loctite 262 to the injector retaining
plate screw and tighten securely.
(4) Start the engine and check for fuel leaks as
previously described.
(5) Install the air cleaner and tighten the retain-
ing nuts securely.
FUEL METER ASSEMBLY - 1.6 LITRE
ENGINE

To Remove and Install
(1) Remove the injector as previously described.
(2) Mark the fuel supp ly and return hoses,
release the clamps and disconnect the hoses from the
fuel meter assembly.
(3) Remove the air cleaner assembly base gasket
from the fuel meter assembly. (4) Remove the bolts and screws securing the
fuel meter assembly to the throttle body and remove the fuel meter assembly. Remove and discard the
gasket.

(5) If necessary, remove the fuel pressure regu-
lator as previously described.

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

(1) If removed, install the fuel pressure
regulator
as previously described.
(2) Place a new gasket on the throttle body,
aligning the holes in the gasket with those in the
throttle body, ensuring that the idle air passage is not
blocked. (3) Coat the fuel meter assembly retaining
screws with Loctite 26 2 and tighten securely.
(4) Install the fuel meter assembly retaining bolts
and tighten to the specified torque.
(5) Connect the fuel supply and return hoses and
tighten the clamps securely. (6) Install the injector as previously described.
(7) Start the engine and check for fuel leaks.
Rectify as necessary. (8) Install the air cleaner assembly.
FUEL TANK

To Remove and Install
(1) Depressurize the fuel system as previously
described.
(2) Disconnect the negative battery terminal.
(3) Remove the fuel pump cover plate retaining
screws, disconnect the wi ring harness rubber grommet
from the cover plate and remove the cover plate from
the wiring harness. (4) Raise the rear of the vehicle and support it
on chassis stands. Refer to the Wheels and Tires
section if necessary. (5) Remove the fuel tank drain plug and drain
the fuel into a petroleum resistant container. (6) Mark the fuel hoses and disconnect the hoses
from the fuel pump.
(7) Disconnect the hoses from the fuel filler neck
pipe, the fuel check valve and the fuel tank breather
pipe.
View of the fuel meter assembly removed from the
throttle body. HANDBRAKE CABLE MOUNTING
Installed view of the fuel tank.