Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 42

Rear Suspension

169

5. CONTROL ARM

Special Equipment Required:

To Renew Control Arm Bush — Press and suitable
removal tool

TO REMOVE AND INSTAL

(1) Raise the rear of the vehicle and support it

on chassis stands as described in the Wheels and Tires
section.

(2) Suitably mark the front and rear control

arms to ensure installation to the original locations.

NOTE: The front and rear control arms are
identical in appearance, however, on models
manufactured prior to March 1988 the
compound of the rubber bushes differ.

(3) Remove the nut and bolt securing the control

arms to the knuckle assembly.

(4) Suitably mark the rear inner pivot bolt cams

in relation to the crossmember to ensure correct
installation.

(5) Remove the rear control arm inner pivot

bolt, adjusting cam, nut and control arm from the
vehicle.

(6) Remove the front control arm inner pivot

bolt, washer, nut and control arm from the vehicle.

(7) Inspect the control arm bushes for wear,

cracks and deterioration and renew as necessary.

(8) Inspect the control arms for cracks, damage

and distortion and renew as necessary.

(9) Inspect the pivot bolts for damage and renew

as necessary.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Install the control arms to the original

loca-
tions, ensuring that the inner pivot bolts are installed
from the front of the crossmember.

(2) Align the marks on the rear inner pivot bolt

Dismantled view of the control arms and associated

components. Disc brake model.

cams and the crossmember that were made prior to
removal. Install the inner pivot bolt nuts but do not
tighten.

(3) Install the bolt that secures the control arms

to the knuckle assembly and tighten the nut finger
tight.

(4) Lower the vehicle to the ground. With the

weight of the vehicle on the rear wheels, ensure that
the marks on the inner pivot bolt cams and the
crossmember are aligned.

(5) Tighten the inner and outer control arm

bolts and nuts to the specified torque.

(6) Check and if necessary adjust the rear wheel

alignment. Refer to the Rear Wheel Alignment head-
ing in this section.

TO RENEW CONTROL ARM BUSH

(1) Remove the control arm as previously de-

scribed.

(2) Using a press and press plates or a bush

removal tool, remove the bush from the control arm.

NOTE: If a press or bush removal tool is not
available, a simple alternative can be made
using a long bolt, large and small washers, a
nut and a tubular spacer. This method is
illustrated in the General Information sec-
tion under the General Repair Procedures
heading.

(3) Install a new bush to the control arm

ensuring
that it is pressed squarely into the control arm. When
installed, the bush should be equidistant from either
end of the control arm bore.

(4) Install the control arm as previously de-

scribed.

Ensure that the cam and the crossmember are suitably

marked prior to loosening the nut.

170

Rear Suspension

6. KNUCKLE ASSEMBLY

TO REMOVE AND INSTAL

(1) Remove the rear hub as previously de-

scribed.

(2) On drum brake models, disconnect the brake

pipe from the wheel cylinder and plug the cylinder
and brake pipe apertures to prevent the loss of brake
fluid and the entry of dirt.

(3) Remove the backing plate retaining bolts and

remove the backing plate from the knuckle assembly.

(4) Remove the nut and bolt securing the control

arms to the knuckle assembly.

(5) Remove the bolts and nuts securing the

suspension unit to the knuckle assembly.

(6) Remove the nut, washers and bush securing

the stabilizer bar to the knuckle assembly, rotate the
knuckle assembly and remove it from the stabilizer
bar.

(7) Carefully clean the knuckle assembly. Do not

immerse the rubber bush in solvent as damage will
occur.

(8) Check the knuckle assembly for wear, cracks

and damage.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Install the knuckle assembly onto the stabi-

liser bar, maneuver it into position with the suspen-
sion unit and install the retaining bolts and nuts.
Tighten the bolts and nuts to the specified torque.

(2) Install the control arms to the knuckle

assem-
bly and install the retaining bolt and nut. Do
not
tighten the retaining bolt and nut at this stage.

(3) Install the bush, washers and retaining nut to

the stabilizer bar. Do not tighten the retaining nut at
this stage.

(4) Install the backing plate to the knuckle as-

sembly and tighten the retaining bolts to the specified
torque.

(5) On drum brake models, connect the brake

pipe to the wheel cylinder and tighten the flare nut
securely.

(6) Install the rear hub as previously described.
(7) On drum brake models, bleed the brake

hydraulic system as described in the Brakes section.

(8) With the weight of the vehicle on the road

wheels, tighten the control arms retaining bolt and nut
and the stabilizer bar retaining nut to the specified
torque.

(9) Check and if necessary adjust the rear wheel

alignment. Refer to the Rear Wheel Alignment head-
ing in this section.

7. STABILISER BAR

TO REMOVE AND INSTAL

(1) Raise the rear of the vehicle and support it

on chassis stands as described in the Wheels and Tires
section. Remove the rear wheels.

(2) Remove the nut. washer and bush retaining

the stabilizer bar to each knuckle assembly.

(3) 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 contacting the lower bumper panel.

(4) Remove the bolts retaining the stabilizer bar

mounting brackets to the underbody and withdraw
the stabilizer bar from each knuckle assembly. Ma-
noeuvre the stabilizer bar from the vehicle.

(5) Remove the mounting rubbers from the

stabilizer bar and the rubber bush and spacer from
each knuckle assembly.

(6) Inspect the stabilizer bar for cracks and

damage and renew as necessary.

(7) Inspect the stabilizer bar mounting brackets

for wear and damage and renew as necessary.

(8) Inspect the mounting rubbers, the rubber

bushes and spacers for wear and deterioration and
renew as necessary.

View of the knuckle assembly removed from the

vehicle. Disc brake model.

View of the stabilizer bar mounting bracket and rubber

removed from the stabilizer bar.

Rear Suspension

171

Installation is a reversal of the removal procedure

with attention to the following points:

(1) When installing the stabilizer bar to the

knuckle assembly bushes, ensure that the thicker bush
is installed to the front of the knuckle assembly. Install
the rear bush, washers and nut but do not tighten at
this stage.

(2) Install the stabilizer bar mounting

brackets,
ensuring that the end with the large bevel is facing the
front of the vehicle. Tighten the retaining bolts to the
specified torque.

(3) Using a new gasket, install the intermediate

exhaust pipe to the catalytic converter, ensuring that
the earth wire terminal is installed, and tighten the
bolts securely. Install the exhaust mounting
retaining
bolt.

(4) Install the rear wheels and lower the

vehicle
to the ground. With the weight of the vehicle on the
road wheels, tighten the stabilizer bar retaining nuts to
the specified torque.

8. REAR WHEEL ALIGNMENT

Specialized equipment is required to measure the

rear wheel alignment. It is therefore recommended
that the vehicle be referred to a specialist suspension
workshop or an authorized dealer for measurement
and adjustment. The suspension components should
be inspected and renewed as necessary prior to having
the wheel alignment checked. If any suspension com-
ponents are renewed, the rear wheel toe out may be
temporarily adjusted as described below.

TO INSPECT

Examine the tread of the tires. Excessive or

uneven wear will indicate misalignment or damaged
or worn components. Refer to the Tire Wear Trouble
Shooting Chart in the Wheels and Tires section for
possible causes and renew the faulty components.

Badly worn tires should be renewed prior to

having the wheel alignment checked.

TO CHECK AND ADJUST TOE OUT

NOTE: The following procedures are only a
temporary measure. The vehicle should be
referred to a specialist suspension work-
shop or authorized dealer for accurate
measurement and adjustment.

(1) Position the vehicle on a level floor and

bounce the vehicle several times to settle the suspen-
sion.

(2) Move the vehicle forward approximately 5

meters, with the front wheels straight ahead, to settle
the tires and suspension to the normal running
position.

(3) Place a chalk line across both tire treads at a

point equivalent to the stub axle height and to the rear
of the suspension.

Place a vertical mark at the chalk line in the

centre of each tire.

(4) Using a telescopic gauge or tape measure,

measure the distance between both vertical marks and
record the measurement.

(5) Move the vehicle forward until the marks are

to the front of the suspension, with the horizontal
marks at the same height as in operation (3).

(6) Measure the distance between both vertical

marks.

(7) The difference between the two measure-

ments will be the amount of toe out of the rear wheels.

(8) If the toe out is not as specified, adjust the

rear control arm cams as follows:

(9) Measure the distance between the inner

wheel rim and the adjusting flange on the rear
crossmember. Measure the distance on the other side
of the vehicle in the corresponding positions.

(10) If the measurements are equal, loosen the

cam nut and turn the cam bolt to move the rear
control arm half the distance required to bring the
rear wheel toe out to specifications. Repeat this
operation on the other side of the vehicle.

(11) If the measurements obtained in operation

(9) are not equal, proceed as follows:

(a) If the toe out is less than specifications,

decrease the length of the shorter arm.

(b) If the toe out is greater than specifications,

increase the length of the longer arm.

NOTE: The toe out will alter approximately
2 mm with each graduation of the adjusting
cam.

Diagram indicating rear wheel toe out. B should be less

than A. Refer to Specifications.

172

BRAKES

SPECIFICATIONS

Type:

Except Pulsar/Vector GL from

July 1989 and Astra models ... Four wheel disc

Pulsar/Vector GL from

July 1989 and Astra models —

Front. . . . . . . . . . . . . . . ...Disc

Rear. . . . . . . . . . . . . . . ..Drum

Operation:

Footbrake. . . ... Vacuum assisted diagonally

split dual hydraulic

Handbrake. . . . Mechanical on rear wheels

Fluid type . . . . . . . . . . . . . . ...Dot 4

Master cylinder:

Make . . . . . . . . . . . . . . Girlock

Bore diameter —

Large . . . . . . . . . . . . . 25.40 mm

Small . . . . . . . . . . . . . 20.64 mm

Front disc brakes:

Caliper bore diameter . . . . . . ... 48.1 mm

Disc diameter . . . . . . . . . . 240 mm

Disc thickness, minimum . . . . . . .16 mm

Disc runout, maximum . . . . . . . 0.07 mm

Disc pad thickness, minimum . . . . . 2 mm

Rear disc pads:

Caliper bore diameter . . . . . . . 30.16 mm

Disc diameter . . . . . . . . . . 234 mm

Disc thickness, minimum . . . . . . ...9 mm

Disc runout, maximum. . . . . . .. 0.07 mm

Disc pad thickness, minimum . . . . . 2 mm

Rear drum brakes:

Wheel cylinder bore diameter . . . 15.87 mm

Drum diameter, maximum. . . ... 204.50 mm

Drum out of round, maximum . . . .. 0.03 mm

Drum runout, maximum. . . . . . 0.05 mm

Brake lining wear limit . . . . . . ... 1.5 mm

TORQUE WRENCH SETTINGS

Brake pedal bracket to body . . . . . . ... 11 Nm

Brake pedal pivot bolt . . . . . . . . . . 11 Nm

Brake servo unit to body. . . . . . . . . II Nm

Brake servo unit to master cylinder . . . ... 11 Nm

Pressure differential piston plug . . . . . .. 12 Nm

Proportioning valve plug. . . . . . . . . 27 Nm

Caliper anchor plate bolts. . . . . . . ... 52 Nm

Caliper guide bolts . . . . . . . . . . .. 31 Nm

Brake hose to caliper. . . . . . . . . ... 34 Nm

Handbrake cable bracket bolt. . . . . . . 49 Nm

Handbrake lever to body . . . . . . . . 11 Nm

Cable clamp to body . . . . . . . . . ... 11 Nm

Cam lever nut. . . . . . . . . . . . .. 49 Nm

1. BRAKES TROUBLE SHOOTING

BRAKE PEDAL HARD

(1) Seized caliper piston or wheel cylinder: Over-

haul the caliper or wheel cylinder.

(2) Seized master cylinder piston: Overhaul the

master cylinder.

(3) Seized pedal pivot: Rectify or renew the

pedal pivot shaft and bushes.

(4) Restricted brake line: Remove the restriction

or renew the brake line.

(5) Vacuum servo system inoperative: Check

and repair the servo system.

NOTE: The vacuum servo system can be
checked as follows: With the engine
switched off, pump the brake pedal several
times to deplete any vacuum in the system.
With the engine still switched off, press
down firmly on the brake pedal and hold it
there noting the position and pressure re-
quired. Start the engine. If the servo unit is
operating correctly, the brake pedal will sink
slightly and the pressure required to hold it
may reduce. If the pedal does not sink
slightly when the engine is started, check the
vacuum supply to the servo unit. If vacuum
is reaching the brake servo unit, the unit can
be considered inoperative.

BRAKE DRAG

(1) Clogged master cylinder ports: Clean the

master cylinder and the fluid reservoir. Renew the
brake fluid.

(2) Seized caliper piston or wheel cylinder: Over-

haul the caliper or wheel cylinder.

(3) Seized handbrake linkage: Free up or renew

the linkage.