Nissan PULSAR N13 Series / ASTRA LD Series. Manual - part 2

General Information

 

 

Assorted test equipment — dwell tachometer, digital 

multimeter, timing light and test lamp.

 

Inspection lamp.

 

Test lamp.

 

Tachometer.

 

Timing light.

 

Digital multimeter.

 

Piston ring compressor.

 

Valve spring compressor.

 

Micrometer — inside, outside, multi range.

 

Vernier calipers.

 

Assorted pullers.

 

When purchasing tools, it is sound advice to select 

the highest quality that can be afforded, as the 
working life of cheaper tools is often very short.

 

 

 

Assorted measuring devices — inside and outside 

micrometers, vernier calipers, wire gauges and feeler 

gauges. 

Ensure that the tools are suitable for the system of 

bolt and nut sizing on the vehicle. The range of 
vehicles covered by this manual use metric sizes.

 

TOOL CARE

 

To ensure the longest possible life for hand tools, 

it is important that time be spent maintaining them.

 

At the conclusion of each job. all tools used should 

be washed thoroughly in kerosene or similar cleaning 
solvent. Ensure that all dirt and grease is removed, 
particularly from tools with moving parts such as 
pliers and adjustable spanners. The tools should then 
be wiped dry with a clean cloth.

 

Measuring devices should be given particular 

attention as their accuracy can be affected if not 
properly maintained. Feeler gauges should be kept 
clean at all times and the blades should be wiped with 
an oily cloth after use to prevent rusting.

 

Tension wrench, piston ring compressor and valve 

spring compressor. 

Slide hammer, ball joint puller, assorted pullers and 

press plates. 

Views showing the correct tip profiles for a bladed 

screwdriver.   Bladed   screwdrivers   should   not   be 

ground to a sharp point. 

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 injuries 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 both 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 which 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 using 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 manufacturers instructions.

 

 

Tap and die set and assorted screw extractors

.

12

 

General Information

 

 

Damaged threads can be repaired using a die nut 

on studs and bolts, and a tap on nuts and threaded 
holes in castings. If the threads of a threaded hole are 
damaged beyond repair, it will be necessary to drill 
and tap the hole to a larger size. Alternatively, a 
Helicoil insert can be used to Testore the hole to the 
original thread size.

 

STUDS

 

The simplest method for removing studs is to lock 

two nuts together on the threaded section. The stud 
should then be able to be removed by applying an 
unscrewing action to the lower nut.

 

Alternatively, there are various makes of stud 

extracting tools available.

 

 

Using two nuts locked together to remove a stud. 

OIL SEALS

 

Oil seals can usually be removed by levering out 

with a flat screwdriver or other suitable lever. Care 
should be taken not to damage the surface of the 
component which the seal lip runs on.

 

Seals can also be removed by inserting a number 

of self tapping screws into the seal body. The seal can 
then be withdrawn using pliers gripping the self 
tapping screws.

 

Always apply a smear of grease or oil to the seal lip 

prior to installation to provide initial lubrication.

 

Unless otherwise stated, oil seals should always be 

installed with the lip facing inwards or towards the 
substance to be sealed. During installation, the seal lip 
should be protected from damage from sharp com- 
ponents such as shaft splines by wrapping tape around 
the sharp edges.

 

Install the new seal using a wooden block, or a 

socket or length of tube of the appropriate diameter. 
Ensure that the seal is installed squarely or distortion 
and subsequent leakage may occur. If an installation 
depth is not specified, the seal should be installed 
flush with the component surface.

 

GASKETS

 

When separating mating components (i.e. 

cylinder 
head and cylinder block), do not insert screwdrivers or

 

similar levers between the components in an attempt 
to lever them apart. This can cause severe damage to 
the sealing surfaces, particularly if the components are 
made of alloy compounds.

 

The components can be separated by tapping 

along the joint with a soft faced hammer or piece of 
wood. Before installing a new gasket, the mating 
surfaces should be cleaned of all traces of old gasket 
material and sealant.

 

Check that the new gasket is correct by comparing 

the bolt holes and passages on the component face 
with the openings in the gasket.

 

Cork and paper gaskets which have been stored 

for some time may suffer from shrinkage. This can be 
rectified by soaking the gasket in water.

 

BEARINGS AND BUSHES

 

If the correct equipment is not available when 

removing and installing bearings and bushes, it is 
often possible to improvise.

 

Bearings can often be removed from shafts by 

tapping alternately on opposite sides with a hammer 
and drift.

 

 

A simple bush installing tool using a bolt, nut and two 

washers. 

If a press is unavailable, bushes can be installed by 

placing the bush and component between the jaws of a 
vice and screwing the jaws together until the bush is 
fully inserted. A vice can also be used to remove 
bushes by using suitably sized spacers against either 
vice jaw, one bearing on the bush and the other on the 
component. This method can also be used with a G 
clamp.

 

A simple removing and installing tool can be 

made using a long bolt, large and small washers, a nut 
and a tubular spacer. Refer to the illustrations for the 
method and applications.

 

Rubber bushes and bushes in blind holes can be 

removed using an expanding type masonry bolt 
(Rawlbolt Loxin). Install a neat fitting masonry bolt to 
the bush. Install and tighten the bolt until it grips the 
bush. The bolt and bush can then be removed using a 
slide hammer or levers.