Nissan PULSAR N13 Series / ASTRA LD Series. Instruction — 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 instruction 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.

Instruction 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.