Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 11

Engine

45

Installed view of the inlet manifold. 1.6 liter models. Air

cleaner removed.

(8) Remove the bolts retaining the throttle cable

bracket to the inlet manifold and place the bracket
with cable(s) attached to one side.

(9) Suitably mark the supply and return fuel

hoses and disconnect them from the throttle body.

(10) Suitably mark and disconnect the air pre-

heat, map sensor, charcoal canister and brake booster
vacuum hoses from the throttle body.

(11) Disconnect the electrical connector from the

throttle body.

(12) Remove the inlet manifold nuts and with-

draw the inlet manifold assembly. Discard the gasket.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Ensure that all the carbon and old gasket

material is cleaned from the manifold and cylinder
head faces.

(2) Check the face of the manifold for distortion

using a straight edge and a feeler gauge.

(3) Use a new gasket and ensure that the mani-

fold retaining nuts are tightened to the specified
torque in a spiral pattern from the centre outwards.

(4) Connect the vacuum hoses, the throttle cable

and where applicable, the kickdown cable. Adjust the
throttle cable as outlined in the Fuel and Engine
Management section and the kickdown cable as
described in the Automatic Transaxle section.

(5) Fill the cooling system as described in the

Cooling and Heating Systems section.

(6) Start the engine and check for air, fuel and

water leaks.

INLET MANIFOLD - 1.8 Liter Models

To Remove and Install

NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurise the system before removing any
fuel supply components. Refer to the Fuel

and Engine Management section for the
correct procedure.

(1) Disconnect the negative battery terminal.
(2) Loosen the hose clamp and disconnect the

air inlet duct from the throttle body.

(3) Suitably mark and disconnect the vacuum

hoses from the throttle body.

(4) On automatic transaxle models disconnect

the kickdown cable from the throttle lever by releasing
the wire spring clip and removing the cable and socket
from the ball.

(5) Turn the throttle lever to the full throttle

position. Using the slack in the throttle cable, release
the throttle cable end through the slot provided.

(6) Remove the bolts retaining the throttle cable

bracket to the inlet manifold and place the bracket
with cable(s) attached to one side.

(7) Disconnect the wiring connectors from the

idle air control (IAC) valve and the throttle position
sensor (TPS).

(8) Disconnect the wiring connectors from the

fuel injectors and manifold air temperature (MAT)
sensor.

NOTE: A small screwdriver or similar tool
can be used to release the wire spring clips
on the injector connectors.

(9) Suitably mark and disconnect the fuel supply

and return lines from the fuel rail.

(10) Remove the inlet manifold nuts and with-

draw the inlet manifold assembly. Discard the gasket.

Installation is a reversal of the removal procedure

with attention to the following points:

View of the inlet manifold removed from the engine.

46

Engine

(1) Ensure that all carbon and old gasket mate-

rial is cleaned from the manifold and cylinder head
faces.

(2) Check the face of the manifold for distortion

using a straight edge and a feeler gauge.

(3) Use a new gasket and ensure that the mani-

fold retaining nuts are tightened to the specified
torque in a spiral pattern from the centre outwards.

(4) Adjust the throttle cable as described in the

Fuel and Engine Management section and the kick-
down cable as described in the Automatic Transaxle
section.

(5) Start the engine and check for air, fuel and

water leaks.

EXHAUST MANIFOLD

To Remove and Install

(1) Bring the engine to operating temperature

and remove the oxygen sensor.

(2) Disconnect the negative battery terminal.
(3) On 1.6 liter models, remove the air cleaner

nuts, disconnect the vacuum hose and withdraw the
air cleaner from the vehicle.

(4) Remove the front exhaust pipe flange mount-

ing nuts and separate the exhaust pipe from the
manifold.

(5) Remove the heat shield retaining bolts and

withdraw the heat shield from the exhaust manifold.

(6) Remove the exhaust manifold to cylinder

head retaining nuts and remove the manifold from the
engine. Discard the manifold gasket.

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Ensure that all carbon is cleaned from the

manifold and cylinder head mating surfaces.

(2) Check the face of the manifold for distortion

using a straight edge and feeler gauges.

(3) Use new gaskets on assembly.
(4) Tighten the exhaust manifold retaining nuts

to the specified torque in the sequence shown in the
illustration.

(5) Install the oxygen sensor. Refer to the Fuel

and Engine Management section.

(6) Coat the threads of the front exhaust pipe to

manifold retaining nuts with an anti-seize solution
and tighten the nuts to the specified torque.

5. CAMSHAFT DRIVE BELT

Special Equipment Required:

To Adjust — Drive belt adjusting tool

TO REMOVE

(1) Disconnect the negative battery terminal.
(2) Raise the front of the vehicle, support it on

chassis stands and remove the right hand front wheel.
Refer to the Wheels and Tires section.

(3) Remove the fasteners securing the engine

splash guard to the right hand front inner mudguard
and remove the splash guard.

(4) Loosen the alternator adjusting bolt and if

equipped, the power steering and air conditioning
adjusting bolts. Remove the drive belt(s).

View of the exhaust manifold and components showing

the correct tightening sequence.

View of the 1.8 liter engine with the upper timing belt

cover removed showing the camshaft gear timing
marks. Inset shows the crankshaft pulley timing

marks.

Engine

47

Line drawing showing the dimensions for the

fabrication of a camshaft drive belt adjusting tool.

(5) Release the clips securing the camshaft drive

belt outer cover to the inner cover and remove the
outer cover.

(6) Turn the engine in the direction of rotation

until the timing marks on the camshaft gear and the
inner cover are aligned and the timing marks on the
crankshaft pulley and the pointer on the inner timing
cover are also aligned.

(7) If the drive belt is to be reused, mark the

drive belt with an arrow to ensure that it is installed
in the original direction of rotation.

(8) Remove the Allen head bolts securing the

crankshaft pulley to the crankshaft gear and remove
the pulley.

(9) Loosen the water pump retaining bolts and

using the adjusting tool, rotate the water pump
housing to release the camshaft drive belt tension.

NOTE: A drive belt tension adjusting tool
can be manufactured from a piece of 10 mm
thick steel to the dimensions given in the
illustration.

(10) Remove the inner cover lower retaining bolts

and maneuver the camshaft drive belt from the
camshaft and crankshaft gears. Do not rotate the
crankshaft or camshaft.

TO CHECK AND INSPECT

(1) Inspect the drive belt for any signs of wear,

damaged teeth or torn backing. Renew the belt if it is
contaminated by oil. Do not wash or clean a drive belt
in solvents. Any slight contamination may be wiped
off using a dry cloth.

NOTE: If the drive belt is contaminated
with oil, the crankshaft and camshaft oil

Dismantled view of the camshaft drive belt

components.

seals must be checked and any oil leak
rectified prior to installing a new drive belt.

(2) Check the water pump for rough or exces-

sively noisy operation. Ensure that the assembly slides
smoothly in the cylinder block and that the seal is not
leaking. Refer to the Cooling and Heating Systems
section if it is necessary to renew the water pump
assembly.

(3) Check the water pump, camshaft and crank-

shaft timing gears for any wear or damage.

Check the drive belt for the illustrated faults.

48

Engine

TO INSTAL

(1) Check that the camshaft and crankshaft

timing gears have not been moved and that the timing
marks are still aligned. It will be necessary to tempo-
rarily install the crankshaft pulley to check that the
timing marks are still aligned.

(2) Install the drive belt to the crankshaft timing

gear around the water pump gear and onto the
camshaft timing gear.

NOTE: If the original drive belt is being
installed, ensure that the arrow marked on
the belt prior to removal is pointing in the
direction of rotation.

(3) Use the adjusting tool to turn the water

pump assembly sufficiently to engage the water pump
pulley with the drive belt.

(4) Install the inner cover lower retaining bolt.
(5) Ensure that the drive belt is correctly meshed

with the teeth of the camshaft, crankshaft and water
pump gears. Install the crankshaft pulley and tighten
the bolts to Specifications.

(6) Adjust the drive belt as described under the

following heading.

(7) Install the drive belt outer cover and fasten

the retaining clips.

(8) Install and adjust the alternator and if

equipped, the power steering and air conditioning
drive belts as described in the Engine Tune-up section.

TO ADJUST

(1) Remove the alternator drive belt and if

equipped, the power steering and air conditioning
drive belts.

(2) Release the clips securing the camshaft drive

belt outer cover to the inner cover and remove the
outer cover.

(3) Turn the engine in the direction of rotation

until the timing marks on the camshaft and the inner
cover are aligned.

(4) Loosen the water pump retaining bolts and

using the adjusting tool, rotate the water pump
housing to gain the required belt tension. The belt is
correctly tensioned when it can be grasped between
the thumb and forefinger midway between the cam-
shaft timing gear and the water pump gear and turned
ninety degrees from its operating position.

After the belt has been tensioned, tighten the

water pump retaining bolts to the specified torque.

NOTE: Over tensioning of the drive belt will
result in noisy operation and premature
wear of the belt.

(6) Install the outer drive belt cover.
(7) Install and adjust the alternator, and if

equipped, the power steering and air conditioning
drive belts as described in the Engine Tune-up section.

6. CAMSHAFT. ROCKER ARMS AND TAPPETS

Special Equipment Required:

To Check Camshaft — Dial gauge, Vee blocks and

micrometers

To Install — Drive belt adjusting tool

It is recommended that a new cylinder head

gasket is installed and the cylinder head bolts renewed
when the camshaft housing is removed.

TO REMOVE

(1) Disconnect the negative battery terminal.

Remove the nuts securing the earth wires to the
cylinder head bolts and remove the earth wires.

(2) On 1.6 liter models, remove the air cleaner

wingnuts and withdraw the air cleaner.

(3) Disconnect the engine breather hoses from

the camshaft housing and the camshaft housing top
cover.

(4) Remove the camshaft housing top cover

retaining bolts and remove the top cover. Discard the
gasket.

(5) Remove the camshaft drive belt as described

under the previous heading.

(6) Using an open ended spanner, hold the

camshaft between the inlet and exhaust lobes of
number four cylinder and remove the camshaft timing
gear retaining bolt and the camshaft timing gear.

(7) Remove the distributor, distributor cap and

high tension leads. If necessary refer to the Fuel and
Engine Management section.

(8) Check the camshaft end float before remov-

ing the camshaft from the engine. Mount a dial gauge
to the cylinder block with the plunger bearing on the
distributor drive end of the camshaft.

(9) Lever the camshaft towards the dial gauge

and zero the gauge. Move the camshaft in the opposite
direction away from the dial gauge and note the
reading obtained. Check this measurement against
Specifications.

Checking the camshaft end float.