FOREWORD
.._--_._---~
---------------_
---'-
This manual contains maintenance and repair procedures for Nissan 200SX, model S13 series. In order to assure your safety and the efficient vehicle, this manual shou Id be read thoroughly. tant that the PRECAUTIONS
functioning
of the
It is especially impor-
in the GI section be completely
under"
stood before starting any repair task. All information
in this manual is based on the latest product
informa-
tion at the time of publication. The right is reserved to make changes in specifications and methods at any time without
notice.
IMPORTANT SAFETY NOTICE The proper performance of service is essential for both th-e safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, dures, tools
or parts which
NISSAN must first completely nor the vehicle's safety will
are not
anyone using service proce-
specifically
recommended
by
satisfy himself that neither his safety be jeopardized
by the service method
selected.
•.,••••• ;". NISSAN MOTOR CO.,LTD. Overseas Senice
Tokyo,Japan
Department
"--... ----
GENERAL .. - INFORMATION .... SECTION
------.--.---~---_._---
..
---_.
__
..
-_--_
GI. ~
.. __
1
CONTENTS PRECAUTIONS
----
--------
HOW TO USE THIS MANUAL HOW TO READ WIRING HOW TO FOLLOW IDENTIFICATION
FLOW CHART
_.._.._
IN TROUBLE
INFORMATION
TORQUE
GI- 2 _..__
DIAGRAMS
LIFTING POINTS AND TOW TRUCK TIGHTENING
__
-
.._ TOWING
OF STANDARD
BOLTS
DIAGNOSES __, .._
_
GI- 5
_ _
_
GI- 7
_.._
__
GI-10
__
rDI
GI-13 GI-17 GI-20
PRECAUTIONS Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section.
1. Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle. SGI285
2.
Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting and towing before working on the vehicle. These operations should be done on a level surface. 3. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder.
SGI231
4.
Before starting repairs which do not require battery power, always turn off the ignition switch, then disconnect the ground cable from the battery to prevent accidental short circuit.
SG 1232
5. To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe and muffler. Do not remove the radiator cap when the engine is hot
GI-2
PRECAUTIONS 6.
Before servicing the vehicle, protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons on your person do not scratch the paint.
7.
Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly. 8. Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. 9. Replace inner and outer races of tapered roller bearings and needle bearings as a set. 10. Arrange the disassembled parts in accordance with their assembled locations and sequence. 11. Do not touch the terminals of electrical components which use microcomputers (such as electronic control units). Static electricity may damage internal electronic components. 12. After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. 13. Use only the lubricants specified in MA section. 14. Use approved bonding agent, sealants or their equivalents when required. 15. Use tools and recommended special tools where specified for safe and efficient service repairs. 16. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. 17. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner.
Precautions for E.F.I. or E.C.C.S. Engine Control
unit
SGI291
1. Before connecting or disconnecting E.F.L or E.C.C.S. harness connector to or from any E.F.I or E.C.C.S. control unit, be sure to turn the ignition switch to the "OFF" position and disconnect the negative battery terminal. Otherwise, there may be damage to control unit. 2. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure to eliminate danger. 3. Be careful not to jar components such as control unit and air flow meter.
Precautions for Catalyst
Clean floor SGI290
If a large amount of unburned fuel flows into the converter, the converter temperature will be excessively high. To prevent this, follow the procedure below: 1. Use unleaded gasoline only. Leaded gasoline will seriously damage the catalytic converter. 2. When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. 3. Do not run engine when the fuel tank level is low, otherwise the engine may misfire causing damage to the converter. 4. Do not place the vehicle on inflammable material. Keep inflammable material off the exhaust pipe.
GI-3
I
HOW TO USE THIS MANUAL 8. The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. "Example" Tightening torque 59 • 78
N·m
(6.0 - 8.0 kg·m, 43 - 58 ft-Ib)
9. TROUBLE DIAGNOSES are included in sections dealing with complicated components. 10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference of data. 11. The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. • WARNING indicates the possibility of personal injury if instructions are not followed. • CAUTION indicates the possibility of component damage if instructions are not followed. • BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.
GI-6
HOW TO READ WIRING DIAGRAMS WIRING DIAGRAM Symbols used in WIRING DIAGRAM are shown below: Example CONNECTOR This shows that these connectors white 6 terminal connectors.
POWER SUPPLY -This shows the ignition switch position in which the system can be operated. -See POWER SUPPLY ROUTING in EL section for the detailed wiring diagram.
are
BRANCH M/T model
SWITCH Th is shows that continuity exists between terminals and when the switch is
CD
turned
•
n A/T
Q
model
~G----5
" "
ly~
ll _:ID m (Wh;"j
®
(ffiJ
-
@B ~
SWITCH
-b BODY
: M/T model
® : A/T
to ON position.
>-
L L~
e-S
~
®,
LOCATION NUMBER This number shows where the connector is located. See HARNESS LAYOUT in EL section. The number is identical with the one in HARNESS LAYOUT.
model
t
ABBREVIATIONS
®~ !)~ I:
GROUND
I
WIRE
COLOR ~
Black
SR
W
~
White
~
OR P
R G
~
Red Green
L Y
~ ~
Blue Yellow
LG
~
Light
= =
PU GY
~ ~ ~
Brown Orange Pink Purple Gray
S8
~
Sky Blue
Green
When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example:
Instrument harness
CODING
B
LlW ~
Blue with Wh,te Stripe
M: Main harness SG 1543
SWITCH POSITIONS Normally
Open ---0
Normally
closed
=
0---
Wiring diagram switches are shown with the vehicle in the following condition. • Ignition switch "OFF". • Doors, hood and trunk lid/back door closed. • Pedals are not depressed and parking brake is released.
SEL764E
GI-7 ..
'--..
HOW TO READ WIRING DIAGRAMS SUPER MULTIPLE JUNCTION •
•
(S.M.J.)
The "S.M.J." indicated in wiring diagrams is shown in a simplified form. The terminal arrangement should therefore be referred to in the foldout at the end of the Service Manual. The foldout should be spread to read the entire wiring diagram.
Example
STARTING Wiring
STARTING
SYSTEM
SYSTEM
SUPER MULTIPLE JUNCTION (S.M.J.I
Diagram
Super Multiple
Junction
(S.M.JJ
r-
R
'I S.M.J. Refer to last page ( (Foldout page).
(--R
B1
2--- B
DO
(Main harness)
J L--( BR
------1
~
(I nstrument harness)
(Main harness)
(I nstrU ment harness)
SEL653F
GI-9
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
. INSPECTION
START
"f.i.1 CHECK POWER SUPPLY. 1) Turn ignition switch "ON". 2) Check voltage between terminal @ and ground. "Battery voltage should exist.
N.G.
-"
O.K.
2 5GI561
a c
~ CHECK GROUND CIRCUIT. 1) Turn ignition switch "OFF". 2) Disconnect crank angle sensor harness connector. 3) Check resistance betWeen terminal @ and ground. Resistance: Approximately
DlSCOII!II:CT
EO [1m!
N.G.
-"
Check the following items. 1) Harness continuity between crank angle sensor and battery. 2) E.C.C.S. relay-1 (See page EF & EC-106.) 3) "BR" fusible link 4) Power source for E.CU. (See page EF & EC-104.) 5) Ignition switch
Check the following items. 1) Harness continuity between crank angle sensor and ground 2) Ground circuit for E.C.U. (See page EF & EC-104.)
on
~ 5GI562
O.K.
NOTICE The flow chart indicates work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1) Use the flow chart after locating probable causes of a problem following the "Preliminary Check" Qr the "Symptom Chart". 2) After repairs, recheck that the problem has been completely eliminated. 3) Refer to Component Parts Location and Harness Layout for the Systems described in each section for identification/location of components and harness connectors. 4) Refer to the Circuit Diagram for Quick Pinpoint Check. If you must perform circuit continuity between harness connectors more detail, such as in case of sub-harness is used, refer to Wiring Diagram and Harness Layout in EL section for identification of harness connectors. 5) When checking circuit continuity, ignition switch should be
"OFF". 6) Before checking voltage at connectors, check battery voltage. 7) After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as it was.
GI-10
I
IDENTIFICATION INFORMATION Model Variation Model L.H. drive
Destination
Without catalytic converter
With catalytic converter
Differential carrier
Transmission
Engine
Body R.H. drive
-
-
RS13FTO
FS5W71C
-
-
RS13ATO
RE4R01A
RLS13FTO
-
-
FS5W71 C
R LS13ATO
-
-
RE4R01A
Europe
RLS13FTO
-
FS5W71C
-
Fast Back
R200
CA 18DET RLS13ATO
-
Except Europe
RE4R01A
-
-
RS13FTU
FS5W71C
-
RS13ATU
RE4R01A
-
RLS13FT
-
FS5W71 C
-
R LS13AT
-
RE4R01A
Prefix and suffix designations
R R
F~t
o
CA18DETengine
o
R.H. drive
L
L.H. drive
o
0
L
S13
A
T
U
Bock ~
o
Europe
(Without
o
Europe
(With catalytic
U
R.H. drive (Except
Europe)
L_H_drive (Except
Europe)
--0
means no indication.
GI-13
T
Turbocharger
A
Automatic
F
5-speed manual
catalytic
converter)
converter)
model transmission transmission
IDENTIFICATION INFORMATION Identification Number
Vehicle
identification
Vehicle
plate
identification
number
(Chassis number)
Tire placard (Driver side)
SG 1554
VEHICLE IDENTIFICATION
NUMBER (Chassis number)
Prefix and suffix designations (For Europe) JN1 JN1
Nissan
o
Stopgap
R
Fast Back
(no meaning)
0
R
S13
U
T T
o
000030
T
~
Vehicle serial number
o
Stopgap
u
For Europe
(no me.aning)
Model
(Except for Europe) R R
Fast Back
o
CA 18DET engine
o
means no indication.
T
o
$13
T
Vehicle serial number Model
GI-14
I
000001
IDENTIFICATION
INFORMATION
Identification Number (Cont' d) IDENTIFICATION
PLATE
Europe
Except
NISSAN MOTOR CO ..LTD.JAPAN
Lt
I
NISSAN MOTOR CO., LTD. JAPAN
Lt
& & ill it
1-
2TTPE
/1
TIP
~
W
I
a
COlOURIM flRBUOlST
Europe
-4>;JO\.
nPE TIPO
1
Type approval
2
Vehicle
identification
number
(Chassis number)
3
Gross vehicle weight
4
A
I.I-\
kg kg
& &,
&
a
7 ~ = ~:
I.:"-
£NCtN£
y ~
MOTOR
~
J.;"":I
7
'?
;.r,)J..
/"
weight
+ Gross trailing capacity (Weightl
o
~"'CIO"
C[
TRMS .. AXLE TRANS.,
Gross combination Gross vehicle weight
CHASSIS "0. "0 Dl CHASIS MODlL MOOllO
ilia
number
J1,J1.
LI£
Iii,
Bift!3IiJ*~'fi::f± SG 1025
PlMT
Gross axle weight
(Front)
Gross axle weight
(Rear)
7
Type
8
Body color code
9
Trim color code
10
PLANTA MADE
5 6
IN JM'AN
SGI316
Model
11
Engine model
12
Engine displacement
13
Transmission
14
Axle model
model
ENGINE SERIAL NUMBER CA18DET
engine
SGI555
MANUAL TRANSMISSION FS5W71 C
NUMBER
AUTOMATIC TRANSMISSION
NUMBER
RE4R01A
SG 1557
GI-15
IDENTIFICATION
INFORMATION
Dimensions Unit: Europe 4,535 (178.5) 1,690 (66.5) 1,290 (50.8) 1,465 (57.7)
Overall length Overall width Overall height Front tread R ear tread Wheelbase
1,465 (57.7) 2,475 (97.4)
Except
mm (in)
Europe
4,520 (178.0) 1,690 (66.5) 1,290 (50.8) 1,465 (57.7) 1,460 (57.5) 2,475 (97.4)
Wheels and Tires Road wheel
Tire size
Steel Aluminum Offset Conventional Spare
., 1: Option *2:
Europe
GI-16
I
6"JJx 15 6-JJ x 1 5" 1 mm (in)
40 ( 1 .57)
195/60R 15 86H 195/60R1587V'2 T125!70D15"2
LIFTING POINTS AND TOW TRUCK TOWING Garage Jack and Safety Stand WARNING: • Never get under the vehicle while it is supported only by the jack. Always use safety stands to support the frame when you have to get under the vehicle . • Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front wheels are raised. CAUTION: Place a wooden or rubber block between safety stand and vehicle body when the supporting body is flat.
SGt717
GI-17
LIFTING POINTS AND TOW TRUCK TOWING 2-pole Lift WARNING: When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. When setting the lift arm, do not allow the arm to contact the brake tubes and fuel lines.
Note:
Lift-up points are the same as pantograph jack points.
5GI553
Tow Truck Towing CAUTION: • All applicable local laws regarding the towing operation must be obeyed. • It is necessary to use proper towing equipment to avoid possible damage to the vehicle during a towing operation. • When towing with the rear wheels on the ground, release the parking brake and move the gearshift lever to neutral ("N" position).
NISSAN recommends that vehicle be towed (rear) wheels off the ground as illustrated.
5GI383
GI-18
I
with the driving
LIFTING POINTS AND TOW TRUCK TOWING Tow Truck Towing (Cant' d) TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (With rear wheels on ground) Observe the following restricted towing speeds and distances" Speed: Below 50 km/h (30 MPH) Distance: Less than 65 km (40 miles) If the speed or distance must necessarily be greater, remove the propeller shaft beforehand to prevent damage to the transmission. Front (Europe)
-----
Towing hook
TOWING POINT Always pull the cable straight out from the vehicle. Never pull on the hook at a sideways angle.
~
~
SGI591
GI-19
_____
----
AU_TO_M_ATIC TRANSMISSION _______
I..----_.-.
n"--
S_EON ~
~ ••_·-
,,_~
CONTENTS PREPARATION _
AT-
PRECAUTIONS
AIT CONTROL DIAGRAM ONNEHICLE
SERVICE
REMOVAL AND
AT-
3
·. AT-
4
AT-
7
,
TROUBLE DIAGNOSES
2
- AT- 11
INSTALLATION
·· AT- 75
MAJOR OVERHAUL
AT- 76
DISASSEMBLY
AT- 80
REPAIR FOR COMPONENT PARTS
AT- 91
ASSEMBLy
AT-136
SERVICE DATA AND SPECIFICATIONS
(S.D.S,)
AT-156
When you read wiring diagrams: •
Read GI section, "HOW
•
See EL section, "POWER
TO READ
WIRING
SUPPLY
ROUTING"
DIAGRAMS"
.
for power distribution
When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW CHART
IN TROUBLE
DIAGNOSES".
circuit. FLOW
PRECAUTIONS Service Notice 8
8
8
Before proceeding with disassembly, thoroughIy clean the outside of the transmission. It is
8
It is very important to perform functional whenever they are indicated.
important
to prevent the internal parts from
8
The valve body contains precision parts and re-
becoming
contaminated
by
dirt
or
other
and serviced. Place removed parts in order on a parts rack so they can be put back in the valve
area. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that
body in the same positions and sequences. Care will also prevent springs and small parts from becoming scattered or lost. 8
mission. When disassembling parts, place them in order in a parts rack so that they can be put back All
parts should be carefully
8
Before assembly, apply a coat of recommended A.T.F.
cleaned with a
Gaskets, seals and a-rings should be replaced
to all parts. Petroleum jelly
may be
applied to a-rings and seals and used to hold
general purpose, non-flammable solvent before inspection or reassembly. 8
Properly installed valves, sleeves, plugs, etc. will slide along their bores in the valve body under their own weight.
into the unit in their proper positions. 8
care when parts are removed
foreign matter. Disassembly should be done in a clean work
could interfere with the operation of the trans8
quires extreme
tests
small bearings and washers in place during reassembly. Do not use grease. 8
any time the transmission is disassembled.
Extreme care should be taken to avoid damage to a-rings, seals and gaskets when assembling.
8
After overhaul, refill the transmission with new A.T.F.
"
"
AT-3
.
AfT CONTROL DIAGRAM
------------------------------------------------------Electrical Control Chart
Vehicle
-
--+
signal
Speed
sensor
singnal pressure Vehicle
Engine
Overdrive switch Kickdown
ElectricaJ Hydraulic
AfT
signal
Overdrive off indicator lamp
switch Control
Power supply
r---·--
~-~--
-----
signal
~
---
I
Idle switch
I
FulHhrottle switch
I
Throttle
switch
Shift solenoid
A
temperature sensor
Shift solenoid
B
Inhibitor Fluid
I
Overrun clutch solenoid
I
sensor
I
Engine rpm signal
Revolution sensor
I 1
-
Lock-up
solenoid
------~
_
AIT
controi
unit
SAT817B
Mechnical Operation Band servo Shift
Reverse
High
Forward
position
clutch
clutch
clutch
Overru n clutch
2nd
3rd
4th
apply
release
apply
Forward
Low
Low &
one-way
one-way
reverse
cI utch
clutch
brake
Lock-up
P
PARK
0
R
0
REVERSE
N
D ~4
1st
0
2nd
0
3rd
0
0
4th
0
13>
·,E
0
1st
• •
0 ~20
0
~30
0
0
@
2nd
0
0
1st
0
0
0
1
0
2nd
"3. ~ 4.
--
NEUTRAL
2
~ 1. ~ 2.
Remarks
Operates when overdrive
switch
0
is set in "OFF"
0 position.
• • • • • • •
Oil pressure is applied to both 2nd "apply" side and 3rd "release" side of band servo piston. "release" side is greater than that on the "apply" side, brake band does not contract. ~2 above, and brake band contracts. Oil pressure is appl ied to 4th "apply" side in condition
AIT will not shift to 4th when overdrive
o o
Operates when throttle
•
Operates during
\19
Operates but does not affect
Q
Operates when throttle
switch
is set in "OFF"
position.
Operates. opening
"progressive"
is less than 1/16.
Engine brake activates_
acceleration. power
opening
transmission.
is less than 1/16 but does not affect
engine brake.
AT-5
However,
Automatic shift 1 ,-, 2 •.• 3 c;)
rC
0
m ~
.'
>
L 1)
L 1)
1:'
1:'
cr ~
ENGINE TEMPERATURE SENSOR
Er®
uj..J .0 0",
@Q) ==
.'-+-
-'" ",9:;
02~ .02 Wo=>
®
®®
L
THROTTLE VALVE SWITCH
III
+'
'"
E
(Idlc
0
I'
Iiil:wl'tchJ
'" '" ~ lJ)
.c
()
(!J
ft
+' 0
r-
®
L.J....
W
~ DROPPING
..
I®
RESISTOR
[F"'I
""
LINE
thoQttl.
~-
,,.,,,,, "'-
'"'"
PRESSURE
SOLENOID
8'0'11' "tch)
~
..J r-'" •.... 0
®JJ
--
@Q)
·1'
@
aU)
"'2
Iw r-U)
OVERRUN
lJ)
CLUTCH
.sOLENOID
;;:;
I'
@ )-
n:: w ..... r-
'"
[J)
®~ ®~- ~
1
'COW
•....
TEMPERATURE
"''''' "'--
2 :::>
SENSOR
'"
®
..J a n:: r2
'"
a 0 r-
""
"-
'"= '" '" •.
LOCK-UP
""
'"
" '"
,
I 0 r-r-
'"
UJ
= '"
~ ~'"UJr'" Z OL
~
~o .....
'"'"
SOLENOID I'
® .sHIFT .sOLENOID. A
lJ)
'"
I'
@ SHIFT
'"""
SOLENOID
I'
® KICKDOWN
8
.sWITCH
= 8
""
B
®
I'
@
~2 20 (:J
z a
I'
;:::
III ® ® ®
«
'"'"
2
-n:: [J)W 0
"','"
I--DW OWl-WWW
..JD...>:: wu")o
>::1-Ow 0>::
..J a
~
®
o. D. OFF INOI CA TOR
'" or °o I-2
u.
01-00.
"
U. 0>
0
.3: ou")
~
00 SAT903B
AT-27
TROUBLE DIAGNOSES Wiring Diagram METER
COM8INATION
,,~
! GNI TI ON SWI TCH ON or START
O· D. OFF
O. D. CONTROL SW! TCH
2
ELECTRIC SPEEDOMETER
7
12
cl
2"
rn:J
@VEW
I '-'
~
®~
m
m
CD'" co
'"
L
I
(Ma i n
'II)
+-'
OJ
E
o
1:
'-'
'"
+-'
harness)
co
,..'""-
®
;
KICKDOWN SWITCH
~
I
®IIIII~IIII ®1:111I~1111 '"~ QJ
I
1111blllll@ IIII ~II:II® I co
,.." «
80DY
BODY
GROUND
GROUND
0 >--
7-
'f/R
(E. F. 1.
@)
harness) LG /R y /W y /G
w /L
1
a
LG /6 OR ~
DR /6
4B-LG /R y/ G 54~ Y/ W 56-W/ L S7~Y
53-
56 57 -...J _L..J.....I~t:J ~ "\"~a...mCI:I"\.,\'~"\,"\ tr....J.......J t:lt.::JQ.~(!)"" o I
L. L,~
INHIBITOR
SWITCH
~
~f--
89 - -S8
-Y/B
---Y/L
n_
"'~m ci --'
UNIT
=N
C8 - -GY B7 - -G/R A7 - -R/B A8 - -G/L H2 - -1/B 12 Y/l,-
G/R R/B
___ __
--G/L --
--L
-
SB GY
"\.a::
--,",
m
CONTROL
@D L....:.-_
last page page) ]
~ "i
=0 =:z:
BR G/W BR G/L
G/B
@)
=
@
(Eng i ne room harness)
~ ;{c
B
PU
"
L..--GY/R L/Y L/W
LG/R
I Y/w Y/G
W/L
o
i~I
a..
(SUb-
harness]
8
LG/B
OR./L
P Y/R
~
l5
I
--'
~ ~ ...J
OJ
" "
>-
>-
@ ~ @ ~ --'
OJ
>-
>-
@)® ~ BODY
GROUND a::
" " 0
(Eng i ne room harness no. 2)
IL~ ::Ja IZ
SPEED SENSOR
J:: u f::J --' u 0 z~ :Ja a::z
'0
--'v)
aV)
0 V) Z
Lu
V)
Lu
-«
m
0
0
a:: ::J
a:: ~fa::...., ::J-« lLa --'a:: l1.W Z WLu a.. f-L: Z--' V)
U)
a
f-z
~---'l1.W
:CD Hot [SO°C (176°F)] :
©
AfT control unit
PU
terminal
1.56V
-->-
0.45V O.K.
Perform self-diagnosis driving for a while.
after
1. Perform A/T control unit input/output signal inspection. 2. If N.G., recheck AIT control unit pin terminals for damage or connection of A/T control unit harness connector.
OK SA T750B
INSPECTION
,
J
END
,
ENGINE
REVOLUTION
SIGNAL
Perform self-diagnosis (Mode III) for engine control. Check ignition signal circuit condition. Resistor
CHECK
Check ignition signal circuit for engine control. - Refer to section EF & EC.
O.K. CHECK
25
AfT control
---
N.G.
CIRCUIT
unit
INPUT
SIGNAL.
N.G.
Check the following •
Harness continuity between AIT control unit and ignition coil.
2. Check voltage between AIT control unit terminal @ and ground.
• •
Resistor Ignition coil - Refer to section EF & EC.
SA T624B
,-----
Voltage: AfT control unit
items.
1.
9.5 - 12V O.K.
terminal
Perform self-diagnosis driving for a while.
again after
O.K.
SAT751B
INSPECTION
END
N.G.
,. Perform A/T control unit input/output signal inspection. 2. If N,G., recheck AIT control unit pin terminals for damage or connection of A/T control unit harness connector.
AT-43 ,., .• ,.
" " '" '" --" ----' a ~
-~
'"" ~ ~ ~ ~ ~ 0:; 00
:::
'"
oq-
a
M If)
M
M l!)
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oqill
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- '" en
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c
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C
C
0
C
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U
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'-
'-
U
([
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w
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[1 SAT647A
AT-79
DISASSEMBL Y
-------------------------------------------~
......;
Disassembly 1. Remove torque converter while pulling straight out.
KV31102100 (Rotate) Wire (Hold)
by holding
it firmly and turning
2. Check torque converter one-way clutch. a. Insert Tool into spline of one-way clutch inner race. b. Hook bearing support unitized with one-way clutch outer race with suitable wire. c. Check that one-way clutch inner race rotates only clockwise with Tool while holding bearing support with wire.
SAT019B
(-~"
I.
l--',
3.
Remove inhibitor switch from transmission
4. a. b.
Remove oil pan. Drain ATF from rear extension. Raise oil pan by placing wooden blocks under converter housing and rear extension. Separate the oil pan and transmission case . Always place oil pan straight down so that foreign particles inside will not move.
c. •
case.
I.: 'j' "
SA Tl B6B
5.
Place transmission
into Tool with the control valve facing up.
",
SAT1878
AT-SO
I
j
DISASSEMBL V
Disassembly (Cont'd) 6.
Check oil pan and oil strainer for accumulation of foreign particles. • If materials of clutch facing are found, clutch plates may be worn. • If metal filings are found, clutch plates, brake bands, etc. may be worn. • If aluminum filings are found, bushings or aluminum cast parts may be worn. In above cases, replace torque converter and check unit for cause of particle accumulation.
7. •
Remove lock-up solenoid and fluid connectors. Be careful not to damage connector.
temperature
8. a.
Remove oil strainer. Remove oil strainer from control valve assembly. Then remove O-ring from oil strainer.
b.
Check oil strainer screen for damage.
sensor
SAT008B
Screen
.-
SAT025B
9. Remove control valve assembly. a. Straighten terminal clips to free terminal cords then remove terminal clips .
.=-~_-_ .._,~W," ------.-- .. ---
l
_
..--.
---
AT-81
DISASSEMBL Y
Disassembly (Cont'd) 11. Remove converter housing. a. Remove converter housing from transmission
case.
b. Remove O-rings from converter housing. c. Remove traces of sealant. • Be careful not to scratch converter housing.
12. Remove O-ring from input shaft.
,.
13. Remove oil pump assembly. a. Attach Tool to oil pump assembly and extract it evenly from transmission case.
ST25850000 SA TOn 6
b. Remove O-ring from oil pump assembly. c. Remove traces of sealant from oil pump housing . • Be careful not to scratch pump housing.
AT-83
DISASSEMBLY Disassembly (Cont'd) 16. Remove front side clutch and gear components. a. Remove clutch pack (reverse clutch, high clutch and front sun gear) from transmission case.
-
b. c.
Remove front bearing race from clutch pack. Remove rear bearing race from clutch pack.
d.
Remove front planetary carrier from transmission
e. f.
Remove front needle bearing from front planetary carrier. Remove rear bearing from front planetary carrier.
g.
Remove rear sun gear from transmission
.@ \
,\
~
".
, ''' .•.•
i ,
...-/"
Front
Rear SATl13B
SAT96BA
AT-8S
case.
case.
DISASSEMBL Y
Disassembly (Cont'd) d.
Remove output shaft and parking gear as a unit from transmission case. e. Remove parking gear from output shaft.
f.
Remove needle bearing from transmission
case.
19. Remove rear side clutch and gear components. a. Remove front internal gear.
~
,.
(
Hole for pawl
b. Remove bearing race from front internal gear.
c.
Remove needle bearing from rear internal gear.
",
AT-87
DISASSEMBL
Y
Disassembly (Cont'd) d.
Remove rear internal gear, forward clutch hub and overrun clutch hub as a set from transmission case.
e.
Remove needle bearing from overrun clutch hub.
f.
Remove overrun clutch forward clutch hub.
g.
Remove thrust washer from overrun clutch hub.
h.
Remove forward clutch assembly from transmission case.
hub from
rear internal gear and
"
/,' ., .
., i:
AT-SS
I
DISASSEMBL Y
Disassembly (Cont'd)
~I
b.
Remove retaining pin from transmission
case.
c-
While pushing detent spring down, remove manual plate and parking rod from transmission case.
d.
Remove manual shaft from transmission
e.
Remove spacer and detent spring from transmission
f.
Remove oil seal from transmission
case.
case.
case.
··Of
SA T044B
AT-90
I
REPAIR FOR COMPONENT PARTS Oil Pump (Cont'd) 5.
oj
•
_.---/
•
.. .
Install seal rings carefully after packing ring grooves with petroleum jelly. Press rings down into jelly to a close fit. Seal rings come in two different diameters. Check fit carefully in each groove. Small dia. seal ring: No mark Large dia. seal ring: Yellow mark in area shown by arrow Do not spread gap of seal ring excessively while installing. It may deform ring .
,
~
,,
!
I i
I· i
I.
AT-95
. ,..
:,,'~ ) \ ; , ; ~r ·;"~'t1~,"
1"._ .,.' ",
..
111:
REPAIR FOR COMPONENT PARTS
II, I' 1"
1
1 I,i
Control Valve Assembly (Cont'd) DISASSEMBL Y 1. Remove solenoids. a. Remove lock-up solenoid and side plate from lower body. b. Remove a-ring from solenoid.
SAT1948
c. d.
Remove line pressure solenoid from upper body. Remove a-ring from solenoid.
e. f.
Remove 3-unit solenoid assembly from upper body. Remove a-rings from solenoids.
2. a.
Disassemble upper and lower bodies. Place upper body facedown, and remove bolts, reamer bolts and support plates. b. Remove lower body, separator plate and separate gasket as a unit from upper body . • Be careful not to drop pilot filter, orifice check valve, spring and steel balls.
c.
Place lower body facedown, and remove separate gasket and separator plate. d. Remove pilot filter, orifice check valve and orifice check spring.
SA T670A
l
AT-97
REPAIR FOR COMPONENT PARTS Control Valve Assembly (Cont'd) e.
Check to see that steel balls are properly positioned upper body and then remove them from upper body.
in
SAT671A
INSPECTION Lower and upper bodies • Check to see that there are pins and retainer plates in lower body_
SAT672A
• •
Check to see that there are pins and retainer plates in upper body_ Be careful not to lose these parts.
SAT673A
• •
Check to make sure that oil circuits are clean and free from damage, Check tube brackets and tube connectors for damage.
Separator plates • Check to make sure that separator plate is free of damage and not deformed and oil holes are clean.
AT-98
I
REPAIR FOR COMPONENT PARTS
...;
Control Valve Assembly (Cont'd) ASSEMBLY 1. Install upper and lower bodies. a. Place oil circuit of upper body face up. Install steel balls in their proper positions.
Reamer
b.
Install reamer bolts from bottom of upper body and install separate gaskets.
c.
Place oil circuit of lower body face up. Install orifice check spring. orifice check valve and pilot filter.
bolt (short) SAT681A
SAT682A
d.
Install lower separate gaskets and separator plates on lower body. e. Install and temporarily tighten support plates, fluid temperature sensor and tube brackets
Unit:
mm (in)
SAT197B
AT -1 00
I
REPAIR FOR COMPONENT PARTS
-
Control Valve Assembly (Cant' d) f. •
Temporarily assemble lower and upper bodies, using reamer bolt as a guide . Be careful not to dislocate or drop steel balls, orifice check spring, orifice check valve and pilot filter.
SAT198B
g. Install and temporarily their proper locations.
tighten
bolts and tube brackets
in
Bolt length and location: Bolt symbol Item Bolt length
®--
mm (in)
a
b
c
d
70 (2.76)
50 (1.97)
33 (1.30)
27 (1.06)
2. Install solenoids. a. Attach O-ring and install lock-up solenoid and side plates onto lower body.
Side plate
b. Attach O-rings and install 3-unit solenoids upper body.
, '\ C",
1
,\
assembly onto
c. Attach O-ring and install line pressure solenoid onto upper body. 3. Tighten all bolts.
SAT667A
AT-101
REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd) DISASSEMBLY 1. Remove valves at parallel pins. • Do not use a magnetic hand.
a.
Use a wire paper clip to push out parallel pins.
b.
Remove parallel pins while pressing their corresponding plugs and sleeves. Remove plug slowly to prevent internal parts from jumping out.
•
c. • •
Place mating surface of valve facedown, and remove internal parts. If a valve is hard to remove, place valve body facedown and lightly tap it with a soft hammer. Be careful not to drop or damage valves and sleeves.
SAT824A
2. Remove valves at retainer plates. a. Pry out retainer plate with wire paper clip.
AT-103
m
, I: ~ ,I"
Ii I
!
'
REPAIR FOR COMPONENT PARTS Control Valve Upper Body (Cont'd) b. Remove retainer plates while holding spring_
c. • •
Place mating surface of valve facedown, and remove internal parts. If a valve is hard to remove, lightly tap valve body with a soft hammer. Be careful not to drop or damage valves, sleeves, etc.
/
SAT827A
•
•
4-2 sequence valve and relay valve are located far back in upper body_ If they are hard to remove, carefully push them out using stiff wire_ Be careful not to scratch sliding surface of valve with wire .
i.
.i j I
iJ';: !
AT-104
I
I
REPAIR FOR COMPONENT
PARTS
Control Valve Lower Body "'"
c: o
d
u;
,
0.
01
.c:
~
W tV
m
DOOR LOCK TI MER (Front R. H. dash side)
®C0'~ ~ BODY GROUND
CD:
L H.
dr i ve
mode I
®:
R. H.
dr I ve
mode I
Unleck
0 C')
;::t::'"
C
0 0
;c
I
INSTRUMENT •
PANEL
When removing instrument panel assembly, remove defroster grille, combination control, cluster lid C and S.M.J. first.
meter, A/C
or heater
Pawl [;]
* ~
/
~
PaWI
~
~
"
Locating
pin (For air duct)
Combination
meter
Locating
I
~
* :
Instrument
panel assembly mounting
bolts
BF-16
pin
D
INSTRUMENT
PANEL
'-...--/ super Multiple Junction (S.M.J.) _ Instrument harness Fuse block
Pawl (2 places each for upper and lower surface)
(;!I
Pawl (4 places each for upper and lower surface)
Ii
o
II)
I.', "
-""-L
// Locati ng pin
IJ
Metal clip
SBF178E
BF-17
INTERIOR AND EXTERIOR Interior (Cont'd)
Ii
1!1 Metal clip
Pawl
Pawl
SBF434E
BF~ 19
INTERIOR AND EXTERIOR Interiar (Cant' d) ROOF TRIM
Roof trim rear end
a
SBF387E
BF-20
INTERIOR
r
AND EXTERIOR
Exterior
4
SBF388E
BF-21
..
I
INTERIOR AND EXTERIOR Exterior (Cont' d)
CD
Windshield upper and side molding
Method 1
®,
@ Cowl top grille and hood rear sealing rubber
Cut off top portion of molding and clean glass and panel su rfaces.
~ ~ ..... -r -d.Jt-• ~ ~
----
·"'-.':', f~ ~
__c_.'
" ..... ...:;:. ~ ~
,
•
,.
Apply sealant to top portion molding_
"
of
q{J
--:I=--~
~9 -=-
~
~ Cut off lower portion of new molding.
:::::':::;i;Wl
: SBF211
•••
®
E
Hood front sealing rubber
Finish well to give it a good appearance.
Hood front
Method 2 1. Cut off sealant at glass end.
sealing rubber
Seal ing rubber bracket
2. Clean the side on which panel was mounted. 3. Set
molding
fastener and apply
primer to body molding. Apply
primer.\ Glass
sealant &
panel, and apply primer to
S?
'-l/~
Dam rubber
Double-faced
adhesive tape
SBF212E
4. Install molding
by aligning the molding mark
®
Center pillar finisher
located on center with vehicle center. Be sure to install tightly so that there is no gap around the corner.
z 7
sealing
SBF519B
waSher
0
CV
Windshield lower molding It is mounted with screws.
-
0_1 ~
Grommet
c§9 CF 113
Sealing washl
Grommet?SBF213E
J
BF-22
INTERIOR AND EXTERIOR Exterior (Cant' d) (j) ,
®
Body side weatherstrip and weatherstrip retainer
Body side weatherstrip
~
: ButYl tape
Butyl tape Double-faced adhesive tape
Weatherstrip retainer
Windshield pillar garnish Body side welt
Body side weatherstrip
Body side weatherstrip
Seal
Weatherstrip retainer
SBF214E
BF-23 ....•
••••••
'
.....:',
~
.
SEAT Rear Seat Striker installation
m
Seat back adjustment
[;]
hi"'1 -~ ~
B
13.16' ~
SBF184E
~
: N.m (kg-m, ft-Ib)
BF-26
(1.3·1.6, 9 ·12)
--
r
"
,
SUN ROOF
Handle adjustment
Female hinge
-----~
~M~•~
~
~
Hinge bracket
Handle base adjustment
Air deflector adjustment Drain hose . • After installation of dram hoses, make sure water drains smoothly.
)
I
r SBF186E
BF-27
....•
- ...
'-,
,
."'
WINDSHIELD AND WINDOWS Windshield REMOVAL
INSTALLATION
After removing moldings, remove glass.
•
Use genuine
Nissan Sealant
kit or equivalent.
Follow instructions
furnished
with
it.
Cutting SMlllnt
• • •
After installation, the vehicle should remain stationary for about 24 hours. Do not use sealant which is more than 12 months past its production date. Do not leave cartridge unattended with its cap open.
•
Keep primers and sealant in a cool, dry place. Nissan recommends stored in a refrigerator . Be sure to install moldings.
•
that they are
WARNING:
Clean bonding surf.u;e thoroughly.
Keep heat or open flames primers are flammable.
G lass side
away
as
CAUTION: Be careful removing.
not to scratch
glass when
I
Body side
Install spacars to panel with double-feced tape.
I G lass side
Install dllm rubber & spacers with double·faced
adhesive tape.
vehicle ce nte r
pacer
Body panel
~
cn ~
~ *0~
m
¢:
Install molding fastenor. When installing it, heat body panel and fastenor to approx. 30 to 400 C (86 to 0 104 F). _ . . Upper & Side molding fastener
A
rubber joint portion
Spacer mounting portion (Spacer should be installed at slit portion of dam rubber.)
SBF198E
Apply primer A.
f ~
/Fa;aner ~
~ SBF197E
Panel Double-faced ad has ive tape
Lower side of glass SBF719C
CAUTION: Allow primers minutes before step.
A
B
to dry for 10 to 15 proceeding to the next
WINDSHIELD AND WINDOWS Windshield (Cant'd)
@ Apply primer E.
@
1
Apply sealant evenly.
Dam rubber More than 12 (0.47)
Unit:
SBF038B
CAUTION: Allow primers to dry for 10 to 15 minutes before proceeding to the next step.
More than 7 (0.28)
SBF199E
CAUTION: Windshield glass should be installed within 15 minutes of applying sealant: sealant starts to harden 15 minutes after it is applied. Set glass in position and press glass Iightly and evenly.
Check for water leakage.
CAUTION: For sealant drying time, "Drying Time for Sealant".
refer
to
Apply sealant to upper & side molding fixing portion.
Install moldings. (F or details, refer to "Exterior".)
BF-29
CAUTION: Molding must be installed securely so that it is in position and leaves no gap.
WINDSHIELD AND WINDOWS Back Door Window • •
• •
Construction
and removal/reinstallation
method
of back door window are basically the same as those of
windshield. Major differences are that sealant & dam rubber are instailed to back door panel instead of glass surface. Spacer position is also changed. Moreover, there are locating pins in lower portion of glass. For details, refer to following figure. For sealant drying period, refer to "Drying Time for Sealant". For details of moldings, refer to "Exterior".
Locating pin (Left and right)
xx; .; 0;
m
Spacer Locating pin Molding clip
Lowar molding and spacer
m
Molding fastener When installing it, heat body panel & fastener to approx. 30 to 40° C (86 to 104° FJ.
~--/r~
/
I~
Back door upper molding Back door glass
\ Double-faced adhesivetape Back door glass
Spacer
L Sealant Unit:
mm (in)
Back door side moldin9
P-=:
~ More than 12 (0.47)
~
Back door glass More than 7 (028)
o
Welt
More than 7 (028)
Back door panel Unit;
Welt-j!
mm (in)
Unit:
BF-30
I
mm (in)
SBF201 E
WINDSHIELD
l
AND WINDOWS
Side Window
Wire
Side window
Side window is a molded type. During removal or installation, observe the following instructions. 1. Cut sealant in the same manner as that outlined under "Windshield.". 2. Be careful not to scratch molding when cutting sealant. If molding is scratched, repair. 3. Remove clips and locating pins which have been exposed from vehicle body.
Side window Body panel
Wire
SBF375E
Sealant portion
[§)
Sealant portion
B
Doub/e-faced adhesivetape
More than 7 (0.28)
More than 12 (0.47)
/\ Body panel
rBody
panel
More than 7 (0.28) Unit:
mm (in)
Unit: mm (in)
Unit:
mm (in) SBF203E
BF-31
-
f
FRONT AND REAR AIR SPOILER • •
When installing, make sure that there are not gaps or waves at ends of air spoiler . Before installing spoiler, clean and remove oil from surface where spoiler will be mounted.
FRONT
AIR
SPOILER
Double-faced adhesive tape
Double-faced ad hes ive tape SBF190E
REAR
AIR
SPOILER
-f-$ €Y~ Sealing washer
I
Grommet
" to
:JJ
m c.c ..• m Z C)
2
-;-' ' f 1 l
W/R
J 7
UN1T
~ ~
C
L/Y- 1S R/Y- 1, G/Y- 35 L/R - 29 LG/R -27 GY/R-26
Y
Ell
r-
E!R/
L/R LG/R GY/R
BODY GROUND
@)
R/ G- 25 G/L-I W/L-2J QR/Lj J
G/r
G3
W/R
~ .:~e:.:'l __
BR/Y L/Y R/Y
OJ E2 FI
R/Y G/Y
CONTROL
(Ma In
~
W/L OR/L
J5 16
L/R LG/R GY/R
-
]
®
@J)
iIll----------~
L/Y
FUSE AND FUS1BlE (J n RElA Y BOX)
0
S. M. J.
:
FUSl BlE L1 NK
r-
A J
'"
~
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TI
lOA
G
L
I
s:
o
-=
: : :
OJ
t
,,, ,, ,, ,, ,, ,, ,, ,, ,, ,, , , ,,, ,,, ,, ,,
7
a
CJ 3 TI
.
I
ANT1-LOCK WARN1NG LAMP
cl-
UP
B0NC
.:0 :r o
METER
-j
((I
@
@9l ~
z
H
m
COHB1NATJON a
(I)
m
SWl TCH
~
R, H.
:r a -j a
B
5
STOP LAMP
model mode I
BODY GROUND
-
•... ";.,:;;'
~
- .-
en -< en -I m
s:
,
ANTI-LOCK BRAKING SYSTEM Removal and Installation CAUTION: Be careful not to damage sensor edge and sensor rotor teeth.
FRONT WHEEL SENSOR ~,
_/"-'-\1 _-.• I __ ..J " /_--""'\...-'L /;
"
~
18·26
~
(1.8 - 2.7, 13·20)
: N·m (kg-m, ft-Ib) 5BR519A
REAR SENSOR
Rear speed se.[1S0r
~18.26 ~ - 2.7, 13 - 20) (1,8
__ ~
Drive pinion
nut
~186-294 ~ (19·30,137-217)
_
'
Sensor rotor
~ Companion
: N'm (kg-m, ft-Ib)
flange 5B R520A
~
•
Remove rear sensor rotor propeller shaft removal. Refer to PO section.
with
companion
flange
after
BR-35 --
/'/1
circuits.
[See page EF & EC-84 (air flow meter),
~ 'f='" E'h'"9'; senSOr ~ (',,~ '--~
SEF307G
Perform self- I
valve
Replace the canister
Check cylinder head and gasket. [See EM section.]
and/or
the hoses.
No change
Canister
purge
APPLY
SEF314G Shut evaporated fuel to intake valve and try to drive.
.p~ ~
DISCONNECT Improved •• Check idle mixture ratio.
SUUU R~
Improved Replace the sensor. 11
Apply vacuum/pressure pressure regulatOr after disconnecting vacuum
to
hose, and try to drive.
EF & EC-56
fj)
i")~
III
[See page EF & EC-25.J Pressu re regulator
SEF291G
-- ... ""---.--.-"--
No change ••
EXhaustgalI~ sensor
[10:·: ~ SE F307 G Disconnect exhaust gas sensor connector and try to drive.
TROUBLE
DIAGNOSES
Diagnostic Table (Cont'd) YMPTOM
211 Engine stall -
& CONDITION POSSIBLE
I
0 8 9 0 0
CAUSES
0
SPEC I FICATIONS
Mixture
ratio
Ignition
sparks
CONTROL
Crank angle sensor
SYSTEM
while cruising
0
0
(weak, missing)
0
0 0
Air flow meter EXhaust gas sensor
SERVICE
o
PROCEDURE CHECK II, @)~
'I
~
I
1);' :
Disconnect exhaust gas sensor connector, and try to drive.
o
Move V (""
Improved
F373G
PERFORM
J".
()
II>
Self-diagnosis Mode III Self.diagnosis
•
N.G.
. - ON speed to the specified value by turning throttle sensor body. (Connect circuit tester with terminals @ and )~ on idle switch side and find out OFF -->- ON point.) 6) Tighten throttle sensor installing screws after setting.
EF & EC-100 ,
'-·~ I:·'''~ -''·'''.''./'o""",,,~ ''''~
..
~
."".'''''".''-.-,
..
TROUBLE DIAGNOSES .; NOTE
)' I
! \
I ;
EF & EC-101
TROUBLE DIAGNOSES Diagnostic Procedure 10 FU E L PUMP
(Not self-diagnostic item) FUEL PUMP
E. c. c. S. CONTROL
UNIT
~
®
m
