Nissan PULSAR N13 Series / ASTRA LD Series. Manual — part 10

Engine

41

DROP IN OIL PRESSURE

(1) Oil level low in the sump: Check and replen-

ish the oil to the full mark on the dipstick.

(2) Thin or diluted oil: Change to the correct oil

grade and rectify the source of dilution.

(3) Oil pump relief valve stuck or spring broken;

Free up the relief valve or renew the broken relief
valve spring.

(4) Excessive bearing clearance: Renew the bear-

ing shells or recondition the crankshaft journals as
necessary.

(5) Excessive wear of the oil pump components:

Renew or recondition the oil pump.

NOTE: If the vehicle is not equipped with an
oil pressure gauge remove the oil sender unit
and connect a pressure gauge into the oil
gallery. Check the oil pressure with the
engine cold and hot. If the oil pump or relief
valve are faulty. low pressure will be indi-
cated with the engine both hot and cold.
However, if the bearings are at fault a fairly
high oil pressure will be indicated when the
engine is cold, but a marked drop in pressure
will occur when the engine is hot.

ENGINE WILL NOT ROTATE

(1) Starter motor drive jammed: Remove the

starter motor. Check and renew the damaged drive
and/or flywheel ring gear.

(2) Engine overheated and seized: Remove and

dismantle the engine. Check and renew any damaged
components. See the following note.

(3) Water in the cylinder due to a blown head

gasket or cracked cylinder block or head: Remove the
cylinder head. If the gasket is blown, check for
cylinder block and head distortion and reface if
necessary. Renew the cylinder head and/or cylinder
block if cracked.

(4) Broken crankshaft, connecting rod. piston

etc. due to overheating, fatigue etc: Remove and
dismantle the engine. Examine and renew any com-
ponents as necessary.

(5) Valve head broken off due to overheating,

fatigue etc: Remove the cylinder head and check the
head, piston and cylinder bore for damage. Repair or
renew as necessary.

NOTE: Invariably when an engine seizes
because of overheating due to lack of oil
and/or water, damage is done to the bear-
ings, pistons etc. Although there may be
instances where an engine will start and run
after it has cooled down and the oil and
water have been replenished, it will usually
be found that oil consumption increases, oil
pressure decreases and the engine will be
noisier, depending on the degree of damage.

When a cylinder head gasket blows allow-

ing water into the cylinders, or compression
loss between the cylinders, it is essential to
check the gasket faces on the cylinder block
and head for distortion. Sufficient water can
enter a cylinder because of a blown head
gasket, cracked cylinder or head to prevent
an engine from rotating.

This is normally preceded by difficult

starting, misfiring, excessive steam from the
exhaust and loss of water from the radiator.

Frequent jamming of the starter motor

drive with the flywheel ring gear can be due
to a bent starter armature shaft or damaged
teeth on the drive and/or ring gear. With the
starter motor removed, the flywheel ring
gear teeth can be examined through the
starter motor mounting aperture. Renewal
of the ring gear requires removal of the
transaxle, clutch and flywheel on manual
transaxle models and the removal of the
transaxle and drive plate on automatic
transaxle models. To check for a bent arma-
ture shaft, rotate the shaft by hand while
holding the end in close proximity to a fixed
object.

2. DESCRIPTION

The 1.6 and 1.8 liter engines are basically identi-

cal in design.

Both engines share the same stroke. The 1.8 liter

engine has a larger bore thus giving it increased
capacity.

The engine is a four cylinder, inline, overhead

camshaft design transversely mounted in the front of
the vehicle.

The camshaft runs in five integral support bear-

ings in the camshaft housing which in turn is mounted
directly on to the cylinder head and retained by the
cylinder head bolts.

Camshaft end float is controlled by a retaining

plate engaged in a groove machined in the rear
camshaft journal. The camshaft is driven by the
crankshaft timing gear via a reinforced rubber belt.

The aluminum cross flow cylinder head houses

the tappets, rocker arms and valve assemblies. An oil
pressure relief valve is installed to the cylinder head to
maintain oil pressure to the hydraulic tappets at a
predetermined setting.

The exhaust valve springs are equipped with

rotators mounted below the valve springs which rotate
the exhaust valve assemblies. The rocker arms pivot
on hydraulic tappet assemblies and locate in notched
lash pads mounted on the valve stems. The camshaft
lobes bear directly onto the rocker arms and due to
the characteristics of the hydraulic tappet assemblies,
no provision is made for tappet clearance adjustment.

42

Engine

The cylinder block is a cast iron alloy, deep skirt

design and the crankshaft is supported in the cylinder
block by five precision insert replaceable main bear-
ings. Crankshaft end float is controlled by the flanged
centre main bearing. Connecting rods are I section
forgings equipped with precision insert replaceable big
end bearings. The gudgeon pins are an interference fit
in the connecting rod and a floating fit in the piston.

The cast aluminum pistons are equipped with

two compression rings and one oil control ring.

The twin rotor, involute gear oil pump is mounted

directly to the front face of the cylinder block. The
inner rotor is internally driven by the crankshaft. The
oil pump pressure relief valve is not adjustable, and
consists of a plunger and spring mounted in the oil
pump body.

The pump draws oil through a screen in the sump

and delivers it, via a full flow replaceable oil filter, to
the oil gallery from where it is distributed to the
hydraulic tappets, camshaft and crankshaft bearings
and to the overhead rocker and valve mechanism.

3. ENGINE AND TRANSAXLE ASSEMBLY

Special Equipment Required:

To Remove and Instill — Suitable lifting tackle,
extra long chassis stands, suitable trolley

TO REMOVE

NOTE: Due to the high residual pressure
within the fuel system, it will be necessary to
depressurize 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) Mark around the bonnet hinges with a soft

lead pencil Co facilitate correct installation. With the
aid of an assistant, remove the bonnet retaining bolts
and remove the bonnet from the vehicle.

(3) Drain the engine and transaxle lubricant.
(4) Open the coolant drain tap located on the

lower radiator pipe and drain the coolant.

(5) Loosen the hose clips and disconnect the

heater hoses from the heater pipes at the bulkhead.

NOTE: Do not use excessive force to remove
the heater hoses from the heater pipes or the
heater core will become dislodged from the
heater unit. If necessary, cut the heater
hoses from the pipes using a sharp knife.

(6) Loosen the hose clamps and disconnect the

radiator hoses from the engine assembly.

(7) Disconnect the positive lead from the bat-

tery.

(8) On 1.8 liter models, disconnect the air inlet

duct.

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

assembly. Refer to the Fuel and Engine Management
section if necessary.

(10) Disconnect the throttle cable from the throt-

tle body and from the camshaft housing top cover
bracket, if applicable.

(11) Disconnect the fuel supply and return hoses.

Mark the hoses as an aid to installation.

(12) Suitably mark and disconnect the charcoal

canister hoses.

(13) Disconnect the injector wires from the injec-

tors. On 1.6 liter models, slide the wiring out from the
throttle body.

(14) Disconnect the wiring from the throttle po-

sition sensor (TPS), idle air control (IAC) valve,
oxygen (O

2

) sensor wire, coolant temperature sensor,

coolant sender and on 1.8 liter models, the manifold
air temperature (MAT) sensor.

(15) Disconnect the wiring connector adjacent to

the top heater hose, the wiring from the alternator and
the two earth wires from underneath the cylinder head
bolts.

(16) Lay the wiring loom over on the passenger

side of the engine compartment, clear of the work
area.

(17) On manual transaxle models, loosen the

clutch cable adjusting nuts and remove the cable
through the slot in the lever. Remove the clutch cable
bracket from the transaxle after removing the retain-
ing bolts and place the cable to one side.

(18) Disconnect the wiring from the starter mo-

tor, speedometer sender and on manual transaxle
models, the reverse lamp switch wiring.

(19) If applicable, disconnect the power steering

lines from the pump and drain the fluid into a
container. Suitably plug the lines and the pump to
prevent the entry of dirt.

(20) On automatic transaxle models, disconnect

the selector cable and bracket from the transaxle
assembly.

Disconnect the transaxle oil cooler lines from the

transaxle. Plug the lines and fittings to prevent the
entry of dirt etc.

(21) Loosen the front wheel nuts, raise the front

of the vehicle and support it on extra long chassis
stands. Ensure that the vehicle is high enough to allow
removal of the engine from underneath.

(22) Remove the front wheels and the engine

splash guards from the vehicle.

(23) On manual transaxle models, remove the

stay rod and control rod bolts and nuts and disconnect
the rods from the transaxle.

(24) Remove the lower control arm to steering

knuckle ball joint nuts and separate the ball joints
from the steering knuckle by holding a dolly or a
hammer against one side of the steering knuckle and
hitting the other side with a hammer. The taper on the
ball joint will release from the steering knuckle.

(25) Pull the steering knuckles outward swiftly to

Engine

43

CAMSHAFT HOUSING TOP COVER

Front view of the 1.8 liter engine and automatic transaxle assembly removed from the vehicle.

release the driveshafts from the transaxle. Tie the
driveshafts to the underbody of the vehicle using wire
and ensuring that excessive strain is not placed on the
joints.

NOTE: If the driveshafts will not release
from the transaxle, a lever can be used
between the driveshaft and the transaxle.
Care must be taken when using the lever not
to damage the transaxle oil seals.

(26) Remove the engine pipe from the engine.

Refer to the procedure at the end of this section if
necessary.

(27) Remove the engine crossmember retaining

bolts and nuts and remove the crossmember from
beneath the vehicle.

(28) Attach the lifting tackle to the engine and

raise the engine slightly to take the weight off the
engine mountings.

(29) Remove the front, rear, left and right engine

mounting bolts and nuts. Withdraw the mountings
from the engine compartment.

(30) Slowly lower the engine and transaxle assem-

bly from the engine compartment.

On air conditioned vehicles, remove the air

conditioning compressor and hoses after the engine
has been lowered slightly. Secure the compressor to

one side, clear of the work area, with wire or similar.

NOTE: Do not disconnect the hoses from
the air conditioning compressor. Escaping
refrigerant can cause frostbite and eye dam-
age.

(31) Lower the engine and transaxle assembly

onto a suitable trolley and maneuver the engine from
beneath the vehicle.

TO INSTAL

Installation is a reversal of the removal procedure

with attention to the following points:

(1) Position the engine and transaxle assembly

beneath the front of the vehicle.

(2) Install the lifting tackle and raise the engine

assembly into position in the engine compartment.

NOTE: On air conditioned models, ensure
that the air conditioning compressor is in-
stalled to the engine as the engine is in-
stalled to the engine compartment.

(3) Install the engine and transaxle

assembly
mounting nuts, bolts and washers finger tight before
the full weight of the assembly is taken by the

44

Engine

Rear three quarter view of the 1.8 liter engine and automatic transaxle assembly.

mountings. Lower the assembly onto the mountings
and tighten the mounting nuts and bolts.

(4) Install a new exhaust flange gasket.
(5) Fill the engine and transaxle with the correct

quantity and grade of lubricant.

(6) Fill the cooling system as described in the

Cooling and Heating Systems section.

(7) On models with power steering, fill the power

steering reservoir with the recommended fluid.

(8) Start and run the engine until it reaches the

normal operating temperature and check for fuel, oil
and coolant leaks.

4. MANIFOLDS

INLET MANIFOLD - 1.6 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 the
fuel supply components. Refer to the Fuel
and Engine Management section for the
correct procedure.

(1) Disconnect the negative battery terminal.
(2) Remove the wingnuts retaining the air

cleaner to the throttle body, lift the air cleaner
upwards slightly and disconnect the vacuum hoses.

(3) Drain the cooling system as described in the

Cooling and Heating Systems section.

(4) Loosen the hose clamps and disconnect the

engine coolant hoses from the rear of the manifold.

(5) Disconnect the small branch of the engine

ventilation hose from the rear of the inlet manifold.

(6) On automatic transaxle models, disconnect

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

(7) 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.