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Description
NISSAN S15 Series Service Manual PDF DOWNLOAD
FILE DETAILS:
NISSAN S15 Series Service Manual PDF DOWNLOAD
Language : English
Pages : 1392
Downloadable :Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
NISSAN S15 Series Service Manual PDF DOWNLOAD
fwd 1
START 0
QUICK REFERENCE INDEX 1
FOREWORD 2
GI – General Information 0
MA – Maintenance 0
EM – Engine Mechanical 0
LC – Engine Lubrication & Cooling Systems 0
EC – Engine Control System 0
FE – Accelerator Control, Fuel & Exhaust Systems 0
CL – Clutch 0
MT – Manual Transmission 0
AT – Automatic Transmission 0
PD – Propeller Shaft & Differential Carrier 0
AX – Front & Rear Axle 0
SU – Front & Rear Suspension 0
BR – Brake System 0
ST – Steering System 0
RS – Restraint System 0
BT – Body & Trim 0
HA – Heater & Air Conditioner 0
SC – Starting & Charging System 0
EL – Electrical System 0
IDX – Alphabetical Index 1
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
at 3
QUICK REFERENCE INDEX 0
Table of Contents 3
PRECAUTIONS 6
Supplemental Restraint System (SRS) “AIR BAG” 6
Precautions 6
Service Notice or Precautions 7
Wiring Diagrams and Trouble Diagnosis 8
PREPARATION 9
Special Service Tools 9
A/T FLUID 11
Checking A/T Fluid 11
Changing A/T Fluid 11
OVERALL SYSTEM 13
A/T Electrical Parts Location 13
Circuit Diagram 14
Cross-sectional View 15
Hydraulic Control Circuit 16
Shift Mechanism 17
Control System 26
Control Mechanism 27
Control Valve 32
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION 34
CONSULT-II 34
Diagnostic Procedure Without CONSULT-II 39
TROUBLE DIAGNOSIS – INTRODUCTION 44
Introduction 44
Work Flow 48
TROUBLE DIAGNOSIS – BASIC INSPECTION 50
A/T Fluid Check 50
Stall Test 50
Line Pressure Test 53
Road Test 54
TROUBLE DIAGNOSIS – GENERAL DESCRIPTION 72
Symptom Chart 72
TCM Terminals and Reference Value 84
TROUBLE DIAGNOSIS FOR POWER SUPPLY 88
Wiring Diagram – AT – MAIN 88
Diagnostic Procedure 89
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN A/T (REVOLUTION SENSOR) 91
Description 91
Wiring Diagram – AT – VSSA/T 93
Diagnostic Procedure 94
Component Inspection 95
TROUBLE DIAGNOSIS FOR VHCL SPEED SEN MTR 97
Description 97
Wiring Diagram – AT – VSSMTR 98
Diagnostic Procedure 99
TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN 100
Description 100
Wiring Diagram – AT – TPS 102
Diagnostic Procedure 103
Component Inspection 107
TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V A 108
Description 108
Wiring Diagram – AT – SSV/A 110
Diagnostic Procedure 111
Component Inspection 112
TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V B 113
Description 113
Wiring Diagram – AT – SSV/B 115
Diagnostic Procedure 116
Component Inspection 117
TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH S/V 118
Description 118
Wiring Diagram – AT – OVRCSV 119
Diagnostic Procedure 120
Component Inspection 121
TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V 122
Description 122
Wiring Diagram – AT – TCV 124
Diagnostic Procedure 125
Component Inspection 126
TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN 127
Description 127
Wiring Diagram – AT – BA/FTS 129
Diagnostic Procedure 130
Component Inspection 133
TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG 134
Description 134
Wiring Diagram – AT – ENGSS 135
Diagnostic Procedure 136
TROUBLE DIAGNOSIS FOR LINE PRESSURE S/V 138
Description 138
Wiring Diagram – AT – LPSV 140
Diagnostic Procedure 141
Component Inspection 142
TROUBLE DIAGNOSIS FOR CONTROL UNIT (RAM), CONTROL UNIT (ROM) 144
Description 144
Diagnostic Procedure 145
TROUBLE DIAGNOSIS FOR CONTROL UNIT (EEPROM) 146
Description 146
Diagnostic Procedure 147
TROUBLE DIAGNOSES FOR SYMPTOMS 148
Wiring Diagram – AT – NONDTC 148
1 POWER Indicator Lamp Does Not Come On 151
2 POWER or SNOW Indicator Lamp Does Not Come On 152
3 O/D OFF Indicator Lamp Does Not Come On 153
4 POWER Indicator Lamp Does Not Come On 154
5 Engine Cannot Be Started In “P” and “N” Position 155
6 In “P” Position, Vehicle Moves Forward Or Backward When Pushed 156
7 In “N” Position, Vehicle Moves 157
8 Large Shock “N” -> “R” Position 159
9 Vehicle Does Not Creep Backward In “R” Position 161
10 Vehicle Does Not Creep Forward In “D”, “2” Or “1” Position 164
11 Vehicle Cannot Be Started From D1 167
12 A/T Does Not Shift: D1 -> D2 Or Does Not Kickdown: D4 -> D2 170
13 A/T Does Not Shift: D2 -> D3 173
14 A/T Does Not Shift: D3 -> D4 176
15 A/T Does Not Perform Lock-up 179
16 A/T Does Not Hold Lock-up Condition 181
17 Lock-up Is Not Released 183
18 Engine Speed Does Not Return To Idle (Light Braking D4 -> D3) 184
19 Vehicle Does Not Start From D1 186
20 A/T Does Not Shift: D4 -> D3, When Overdrive Control Switch “ON” -> “OFF” 187
21 A/T Does Not Shift: D3 -> 22, When Selector Lever “D” -> “2” Position 188
22 A/T Does Not Shift: 22 -> 11, When Selector Lever “2” -> “1” Position 189
23 Vehicle Does Not Decelerate By Engine Brake 190
24 TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control, A/T Check and TP Switches Circuit Checks) 191
A/T SHIFT LOCK SYSTEM 200
Description 200
Wiring Diagram – SHIFT – 201
Diagnostic Procedure 202
Component Check 204
KEY INTERLOCK CABLE 205
Removal 205
Installation 205
SHIFT CONTROL SYSTEM 206
Control Device 206
ON-VEHICLE SERVICE 207
Control Valve Assembly and Accumulators 207
Revolution Sensor Replacement 207
Rear Oil Seal Replacement 208
Parking Pawl Components Inspection 208
Park/Neutral Position Switch Adjustment 208
Manual Control Linkage Adjustment 209
REMOVAL AND INSTALLATION 210
Removal 210
Installation 211
OVERHAUL 213
Components 213
Oil Channel 215
Locations of Needle Bearings, Thrust Washers and Snap Rings 216
DISASSEMBLY 217
REPAIR FOR COMPONENT PARTS 228
Oil Pump 228
Control Valve Assembly 232
Control Valve Upper Body 238
Control Valve Lower Body 243
Reverse Clutch 245
High Clutch 248
Forward and Overrun Clutches 251
Low & Reverse Brake 255
Forward Clutch Drum Assembly 259
Rear Internal Gear and Forward Clutch Hub 261
Band Servo Piston Assembly 264
Parking Pawl Components 268
ASSEMBLY 270
Assembly (1) 270
Adjustment 278
Assembly (2) 281
A/T FLUID COOLER SYSTEM 288
A/T Fluid Cooler 288
SERVICE DATA AND SPECIFICATIONS (SDS) 290
General Specifications 290
Shift Schedule 290
Stall Revolution 290
Line Pressure 290
Return Springs 291
Accumulator O-ring 292
Clutches and Brakes 292
Oil Pump and Low One-way Clutch 294
Total End Play 294
Reverse Clutch Drum End Play 295
Removal and Installation 295
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
ax 297
QUICK REFERENCE INDEX 0
Table of Contents 297
FRONT AXLE 298
Precautions 298
PRECAUTIONS 298
Preparation 298
SPECIAL SERVICE TOOLS 298
COMMERCIAL SERVICE TOOLS 298
Noise, Vibration and Harshness (NVH) Troubleshooting 299
NVH TROUBLESHOOTING CHART 299
On-vehicle Service 299
FRONT AXLE PARTS 299
FRONT WHEEL BEARING 300
Wheel Hub and Knuckle 301
COMPONENTS 301
REMOVAL 301
INSTALLATION 302
ABS Sensor Rotor 303
REMOVAL 303
INSTALLATION 303
Baffle Plate 303
REMOVAL 303
INSTALLATION 303
Service Data and Specifications (SDS) 304
WHEEL BEARING (FRONT) 304
REAR AXLE 305
Precautions 305
PRECAUTIONS 305
Preparation 305
SPECIAL SERVICE TOOLS 305
COMMERCIAL SERVICE TOOLS 305
Noise, Vibration and Harshness (NVH) Troubleshooting 306
On-vehicle Service 306
REAR AXLE PARTS 306
REAR WHEEL BEARING 306
DRIVE SHAFT 307
Wheel Hub and Axle Housing 307
COMPONENTS 307
REMOVAL 307
INSTALLATION 308
DISASSEMBLY 309
INSPECTION 310
ASSEMBLY 310
Drive Shaft 311
COMPONENTS 311
REMOVAL 311
INSTALLATION 311
COMPONENTS 312
DISASSEMBLY 312
INSPECTION 313
ASSEMBLY 314
Service Data and Specifications (SDS) 316
DRIVE SHAFT 316
WHEEL BEARING (REAR) 316
br 317
QUICK REFERENCE INDEX 0
Table of Contents 317
PRECAUTIONS 319
Supplemental Restraint System (SRS) “AIR BAG” 319
Precautions for Brake System 319
Wiring Diagrams and Trouble Diagnoses 319
PREPARATION 320
Commercial Service Tools 320
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 321
NVH Troubleshooting Chart 321
ON-VEHICLE SERVICE 322
Checking Brake Fluid Level 322
Checking Brake Line 322
Changing Brake Fluid 322
Checking Brake Booster, Vacuum Hoses, Connections and Check Valve 322
Checking Disc Brake 323
ROTOR 323
CALIPER 323
PAD 323
Bleeding Brake System 324
BRAKE HYDRAULIC LINE 325
Hydraulic Circuit 325
Removal 325
Inspection 326
Installation 326
PROPORTIONING VALVE 327
Inspection 327
Removal and Installation (Built-in type) 327
BRAKE PEDAL AND BRACKET 328
Removal and Installation 328
Inspection 328
Adjustment 328
MASTER CYLINDER 330
Removal 330
Disassembly 331
Inspection 331
Assembly 331
Installation 332
BRAKE BOOSTER 333
On-vehicle Service 333
OPERATING CHECK 333
AIRTIGHT CHECK 333
Removal 333
Inspection 333
OUTPUT ROD LENGTH CHECK 333
Installation 334
VACUUM PIPING 335
Vacuum Hose 335
Removal and Installation 335
Inspection 335
HOSES AND CONNECTORS 335
CHECK VALVE 335
FRONT DISC BRAKE 336
Components 336
Pad Replacement 337
REMOVAL 337
INSTALLATION 338
Removal 339
Disassembly 339
Inspection 340
CALIPER 340
PISTON 340
PAD PIN AND CLIPS 340
ROTOR 340
Assembly 341
Installation 342
Brake Burnishing Procedure 342
REAR DISC BRAKE 343
Components 343
Removal 344
Disassembly 344
Inspection – Caliper 345
CYLINDER BODY 345
TORQUE MEMBER 345
PISTON 345
PIN AND PIN BOOT 346
Inspection – Rotor 346
RUBBING SURFACE 346
RUNOUT 346
THICKNESS 346
Assembly 346
Installation 348
PARKING BRAKE CONTROL 349
Components 349
Removal and Installation 349
Inspection 350
Adjustment 350
ABS 351
DESCRIPTION 351
Purpose 351
Operation 351
ABS Hydraulic Circuit 351
System Components 352
System Description 352
SENSOR 352
CONTROL UNIT 352
ABS ACTUATOR 353
Component Parts and Harness Connector Location 354
Schematic 355
Wiring Diagram – ABS – 356
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION 359
CONSULT-II 359
CONSULT-II APPLICATION TO ABS 359
ECU (ABS CONTROL UNIT) PART NUMBER MODE 359
CONSULT-II Inspection Procedure 360
SELF-DIAGNOSIS PROCEDURE 360
SELF-DIAGNOSTIC RESULTS MODE 361
DATA MONITOR PROCEDURE 362
ACTIVE TEST PROCEDURE 363
DATA MONITOR MODE 364
ACTIVE TEST MODE 364
REMOVAL AND INSTALLATION 403
Wheel Sensors 403
Sensor Rotor 403
REMOVAL 403
INSTALLATION 404
Control Unit 404
ABS Actuator 405
REMOVAL 405
INSTALLATION 405
SERVICE DATA AND SPECIFICATIONS (SDS) 406
General Specifications 406
Front Disc Brake 406
Rear Disc Brake 406
Brake Pedal 406
Parking Brake Control 407
TROUBLE DIAGNOSIS – INTRODUCTION 365
How to Perform Trouble Diagnoses for Quick and Accurate Repair 365
INTRODUCTION 365
TROUBLE DIAGNOSIS – BASIC INSPECTION 366
Preliminary Check 366
Ground Circuit Check 369
ABS CONTROL UNIT GROUND 369
ABS ACTUATOR GROUND 369
TROUBLE DIAGNOSES FOR SELF-DIAGNOSTIC ITEMS 370
Wheel Sensor or Rotor 370
DIAGNOSTIC PROCEDURE 1 370
ABS Actuator Solenoid Valve 372
DIAGNOSTIC PROCEDURE 2 372
Solenoid Valve Relay 375
DIAGNOSTIC PROCEDURE 3 375
Motor Relay or Motor 380
DIAGNOSTIC PROCEDURE 4 380
Low Voltage 386
DIAGNOSTIC PROCEDURE 5 386
Control Unit 388
DIAGNOSTIC PROCEDURE 6 388
TROUBLE DIAGNOSES FOR SYMPTOMS 389
1 ABS Works Frequently 389
2 Unexpected Pedal Action 389
3 Long Stopping Distance 391
4 ABS Does Not Work 391
5 Pedal Vibration and Noise 392
6 Warning Lamp Does Not Come On When Ignition Switch Is Turned On 393
7 Warning Lamp Stays On When Ignition Switch Is Turned On 397
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
bt 409
QUICK REFERENCE INDEX 0
Table of Contents 409
PRECAUTIONS 410
Service Notice 410
Supplemental Restraint System (SRS) “AIR BAG” 410
Maintenance 410
CLIP AND FASTENER 411
Description 411
BODY FRONT END 414
Removal and Installation 414
FRONT BUMPER ASSEMBLY 414
BODY REAR END AND OPENER 418
Removal and Installation 418
REAR BUMPER ASSEMBLY 418
DOOR 421
Adjustment 421
STRIKER ADJUSTMENT 421
Door Glass 422
DOOR GLASS AND REGULATOR 422
Door Glass Fitting Adjustment 424
IN-OUT ADJUSTMENT (AT THE GLASS WAIST) 425
FORE-AFT TILT ADJUSTMENT 425
IN-OUT TILT ADJUSTMENT (AT GLASS UPPER STOP) 425
UP-STOP ADJUSTMENT 426
FORE-AFT ADJUSTMENT 426
Door Limit Switch Reset (Driver side only) 427
RESET CONDITIONS 427
RESET PROCEDURES 427
Door Lock 428
BELL CRANK ADJUSTMENT 428
OUTSIDE HANDLE ROD ADJUSTMENT 428
REMOVAL 429
INSTRUMENT PANEL ASSEMBLY 430
Removal and Installation 430
SIDE AND FLOOR TRIM 434
Removal and Installation 434
DOOR TRIM 437
Removal and Installation 437
ROOF TRIM 439
Removal and Installation 439
TRUNK ROOM TRIM 441
Removal and Installation 441
EXTERIOR 442
Removal and Installation 442
FRONT SEAT 446
Removal and Installation 446
REAR SEAT 447
Removal and Installation 447
SUNROOF 448
Adjustment 448
Removal 448
Trouble Diagnoses 452
DIAGNOSTIC TABLE 452
WIND DEFLECTOR 452
ADJUSTMENT 453
DRAIN HOSES 454
WEATHERSTRIP 455
LINK AND WIRE ASSEMBLY 455
WINDSHIELD AND WINDOWS 456
Removal and Installation 456
REMOVAL 456
INSTALLATION 456
WINDSHIELD AND WINDOWS 457
DOOR MIRROR 460
Removal and Installation 460
BODY (ALIGNMENT) 461
Alignment 461
ENGINE COMPARTMENT 462
UNDERBODY 464
cl 467
QUICK REFERENCE INDEX 0
Table of Contents 467
PRECAUTIONS 468
Precautions 468
PREPARATION 469
Special Service Tools 469
Commercial Service Tools 469
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 470
NVH Troubleshooting Chart 470
CLUTCH 470
CLUTCH SYSTEM – HYDRAULIC TYPE 471
Components 471
Inspection and Adjustment 472
ADJUSTING CLUTCH PEDAL 472
AIR BLEEDING PROCEDURE 472
CLUTCH MASTER CYLINDER 473
Components 473
Removal 473
Installation 474
Disassembly 474
Inspection 474
Assembly 475
OPERATING CYLINDER 476
Components 476
Removal 476
Disassembly 476
Inspection 476
Assembly 477
Installation 477
PIPING 478
Removal 478
Installation 478
CLUTCH RELEASE MECHANISM 479
Components 479
Removal and Installation 479
Inspection 480
Lubrication 480
CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 481
Components 481
Inspection and Adjustment 481
CLUTCH DISC 481
CLUTCH COVER AND FLYWHEEL 481
FLYWHEEL INSPECTION 482
Installation 482
SERVICE DATA AND SPECIFICATIONS (SDS) 483
Clutch Control System 483
Clutch Master Cylinder 483
Clutch Operating Cylinder 483
Clutch Disc 483
Clutch Cover 483
Clutch Pedal 483
ec 485
QUICK REFERENCE INDEX 0
Table of Contents 485
TROUBLE DIAGNOSIS – INDEX 488
Alphabetical & P No Index for DTC 488
PRECAUTIONS 490
Supplemental Restraint System (SRS) “AIR BAG” 490
Precautions for On Board Diagnostic (OBD) System of Engine 490
Engine Fuel & Emission Control System 491
Wiring Diagrams and Trouble Diagnosis 493
PREPARATION 494
Special Service Tools 494
Commercial Service Tools 494
ENGINE AND EMISSION CONTROL OVERALL SYSTEM 495
Engine Control Component Parts Location 495
Circuit Diagram 498
System Diagram 499
Vacuum Hose Drawing 500
System Chart 501
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION 502
Multiport Fuel Injection (MFI) System 502
Electronic Ignition (EI) System 504
Air Conditioning Cut Control 505
Fuel Cut Control (at no load & high engine speed) 506
Evaporative Emission System 506
Positive Crankcase Ventilation 509
BASIC SERVICE PROCEDURE 511
Fuel Pressure Release 511
Fuel Pressure Check 511
Fuel Pressure Regulator Check 512
Injector 512
Fast Idle Cam (FIC) 513
How to Check Idle Speed and Ignition Timing 514
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION 517
Introduction 517
Diagnostic Trouble Code (DTC) 517
Malfunction Indicator Lamp (MIL) 519
CONSULT-II 523
TROUBLE DIAGNOSIS – INTRODUCTION 530
Introduction 530
Work Flow 532
TROUBLE DIAGNOSIS – BASIC INSPECTION 534
Basic Inspection 534
TROUBLE DIAGNOSIS – GENERAL DESCRIPTION 551
Fail-safe Chart 551
Symptom Matrix Chart 552
CONSULT-II Reference Value in Data Monitor Mode 556
Major Sensor Reference Graph in Data Monitor Mode 558
ECM Terminals and Reference Value 560
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT 566
Description 566
Diagnostic Procedure 566
TROUBLE DIAGNOSIS FOR POWER SUPPLY 567
Main Power Supply and Ground Circuit 567
DTC 0101 CAMSHAFT POSITION SENSOR (CMPS) 574
Component Description 574
ECM Terminals and Reference Value 574
On Board Diagnosis Logic 575
DTC Confirmation Procedure 575
Wiring Diagram 577
Diagnostic Procedure 578
Component Inspection 581
DTC 0102 MASS AIR FLOW SENSOR (MAFS) 582
Component Description 582
CONSULT-II Reference Value in Data Monitor Mode 582
ECM Terminals and Reference Value 582
On Board Diagnosis Logic 582
Fail-safe Mode 583
DTC Confirmation Procedure 583
Wiring Diagram 585
Diagnostic Procedure 586
Component Inspection 588
DTC 0103 ENGINE COOLANT TEMPERATURE SENSOR (ECTS) (CIRCUIT) 589
Component Description 589
CONSULT-II Reference Value in Data Monitor Mode 589
On Board Diagnosis Logic 589
Fail-safe Mode 590
DTC Confirmation Procedure 590
Wiring Diagram 591
Diagnostic Procedure 592
Component Inspection 593
DTC 0201 IGNITION SIGNAL 594
Component Description 594
CONSULT-II Reference Value in Data Monitor Mode 594
ECM Terminals and Reference Value 594
On Board Diagnosis Logic 595
DTC Confirmation Procedure 595
Wiring Diagram 596
Diagnostic Procedure 598
Component Inspection 603
DTC 0208 OVERHEAT (COOLING SYSTEM) 604
System Description 604
CONSULT-II Reference Value in Data Monitor Mode 604
ECM Terminals and Reference Value 604
On Board Diagnosis Logic 605
Overall Function Check 606
Wiring Diagram 607
Diagnostic Procedure 608
Main 12 Causes of Overheating 619
Component Inspection 619
DTC 0304 KNOCK SENSOR (KS) 621
Component Description 621
ECM Terminals and Reference Value 621
On Board Diagnosis Logic 621
DTC Confirmation Procedure 621
Wiring Diagram 622
Diagnostic Procedure 623
Component Inspection 624
DTC 0403 THROTTLE POSITION SENSOR 625
Component Description 625
CONSULT-II Reference Value in Data Monitor Mode 625
ECM Terminals and Reference Value 626
On Board Diagnosis Logic 626
Fail-safe Mode 626
DTC Confirmation Procedure 626
Wiring Diagram 628
Diagnostic Procedure 629
Component Inspection 630
DTC 0504 A/T CONTROL 632
System Description 632
ECM Terminals and Reference Value 632
On Board Diagnosis Logic 632
DTC Confirmation Procedure 632
Overall Function Check 633
Wiring Diagram 634
Diagnostic Procedure 635
HEATED OXYGEN SENSOR 1 (FRONT) 636
Component Description 636
CONSULT-II Reference Value in Data Monitor Mode 636
ECM Terminals and Reference Value 636
Wiring Diagram 637
Diagnostic Procedure 638
Component Inspection 640
HEATED OXYGEN SENSOR 1 HEATER (FRONT) 642
Description 642
ECM Terminals and Reference Value 642
Wiring Diagram 643
Diagnostic Procedure 644
Component Inspection 645
VEHICLE SPEED SENSOR (VSS) 646
Component Description 646
ECM Terminals and Reference Value 646
Wiring Diagram 647
Diagnostic Procedure 648
IDLE AIR CONTROL VALVE (IACV) – AUXILIARY AIR CONTROL (AAC) VALVE 650
Description 650
CONSULT-II Reference Value in Data Monitor Mode 650
ECM Terminals and Reference Value 651
Wiring Diagram 652
Diagnostic Procedure 653
Component Inspection 656
INTAKE VALVE TIMING CONTROL SOLENOID VALVE 657
Component Description 657
Operation 657
CONSULT-II Reference Value in Data Monitor Mode 658
ECM Terminals and Reference Value 658
Wiring Diagram 659
Diagnostic Procedure 660
Component Inspection 662
WASTEGATE VALVE CONTROL SOLENOID VALVE 663
Description 663
CONSULT-II Reference Value in Data Monitor Mode 663
ECM Terminals and Reference Value 664
Wiring Diagram 665
Diagnostic Procedure 666
Component Inspection 669
PARK/NEUTRAL POSITION (PNP) SWITCH 670
Component Description 670
CONSULT-II Reference Value in Data Monitor Mode 670
ECM Terminals and Reference Value 670
Wiring Diagram 671
Diagnostic Procedure 672
INJECTOR 678
Component Description 678
CONSULT-II Reference Value in Data Monitor Mode 678
ECM Terminals and Reference Value 678
Wiring Diagram 679
Diagnostic Procedure 680
Component Inspection 682
START SIGNAL 683
CONSULT-II Reference Value in Data Monitor Mode 683
ECM Terminals and Reference Value 683
Wiring Diagram 684
Diagnostic Procedure 685
FUEL PUMP 687
System Description 687
Component Description 687
CONSULT-II Reference Value in Data Monitor Mode 687
ECM Terminals and Reference Value 688
Wiring Diagram 689
Diagnostic Procedure 690
Component Inspection 692
IACV-FICD SOLENOID VALVE 693
Component Description 693
ECM Terminals and Reference Value 693
Wiring Diagram 694
Diagnostic Procedure 695
Component Inspection 696
POWER STEERING OIL PRESSURE SWITCH 697
Component Description 697
CONSULT-II Reference Value in Data Monitor Mode 697
ECM Terminals and Reference Value 697
Wiring Diagram 698
Diagnostic Procedure 699
Component Inspection 701
ELECTRICAL LOAD SIGNAL 702
CONSULT-II Reference Value in Data Monitor Mode 702
ECM Terminals and Reference Value 702
Wiring Diagram 703
Diagnostic Procedure 704
MI & DATA LINK CONNECTORS 708
Wiring Diagram 708
SERVICE DATA AND SPECIFICATIONS (SDS) 709
Fuel Pressure Regulator 709
Idle Speed and Ignition Timing 709
Mass Air Flow Sensor 709
Engine Coolant Temperature Sensor 709
Fuel Pump 709
IACV-AAC Valve 709
Injector 709
Throttle Position Sensor 709
Heated Oxygen Sensor 1 (Front) Heater 709
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
el 711
QUICK REFERENCE INDEX 0
Table of Contents 711
PRECAUTIONS 713
Supplemental Restraint System (SRS) “AIR BAG” 713
Wiring Diagrams and Trouble Diagnosis 713
HARNESS CONNECTOR 714
Description 714
STANDARDIZED RELAY 715
Description 715
POWER SUPPLY ROUTING 717
Schematic 717
Wiring Diagram – POWER – 718
Inspection 724
GROUND 725
Ground Distribution 725
COMBINATION SWITCH 736
Check 736
Replacement 737
HEADLAMP 738
Component Parts and Harness Connector Location 738
System Description 738
Wiring Diagram – H/LAMP – 739
Trouble Diagnoses 741
Bulb Replacement 742
Aiming Adjustment 744
PARKING, LICENSE AND TAIL LAMPS 745
Wiring Diagram – TAIL/L – 745
STOP LAMP 747
Wiring Diagram – STOP/L – 747
BACK-UP LAMP 748
Wiring Diagram – BACK/L – 748
TURN SIGNAL AND HAZARD WARNING LAMPS 749
Wiring Diagram – TURN – 749
Trouble Diagnoses 751
Blub Replacement 751
Electrical Components Inspection 752
ILLUMINATION 753
Schematic 753
Wiring Diagram – ILL – 754
INTERIOR ROOM LAMP 757
System Description 757
Wiring Diagram – ROOM/L – 759
Trouble Diagnoses for Interior Lamp Timer 760
SPOT AND TRUNK ROOM LAMPS 767
Wiring Diagram – INT/L – 767
METERS AND GAUGES 768
Component Parts and Harness Connector Location 768
System Description 768
Combination Meter 770
Schematic 772
Wiring Diagram – METER – 773
Meter/Gauge Operation and Odo/Trip Meter Segment Check in Diagnosis Mode 774
Trouble Diagnoses 775
Electrical Components Inspection 781
WARNING LAMPS 783
Schematic 783
Wiring Diagram – WARN – 784
Electrical Components Inspection 787
A/T INDICATOR 788
Wiring Diagram – AT/IND – 788
WARNING BUZZER 789
Component Parts and Harness Connector Location 789
System Description 789
Wiring Diagram – BUZZER – 791
Trouble Diagnoses 792
FRONT WIPER AND WASHER 797
System Description 797
Wiring Diagram – WIPER – 799
Removal and Installation 800
Washer Nozzle Adjustment 801
Washer Tube Layout 802
HORN 803
Wiring Diagram – HORN – 803
CIGARETTE LIGHTER 804
Wiring Diagram – CIGAR – 804
CLOCK 805
Wiring Diagram – CLOCK – 805
REAR WINDOW DEFOGGER 806
Component Parts and Harness Connector Location 806
System Description 806
Wiring Diagram – DEF – 807
Trouble Diagnoses 808
Electrical Components Inspection 810
Filament Check 811
Filament Repair 812
AUDIO 813
Wiring Diagram – AUDIO – 813
AUDIO ANTENNA 814
Location of Antenna 814
Window Antenna Repair 814
POWER SUNROOF 816
System Description 816
Wiring Diagram – SROOF – 817
Trouble Diagnoses 819
DOOR MIRROR 820
Wiring Diagram – MIRROR – 820
POWER WINDOW 821
System Description 821
Schematic 823
Wiring Diagram – WINDOW – 824
Trouble Diagnoses 827
POWER DOOR LOCK 830
Component Parts and Harness Connector Location 830
System Description 830
Wiring Diagram – D/LOCK – 831
Trouble Diagnoses 833
UNIFIED METER CONTROL UNIT (TIME CONTROL SYSTEM) 841
Description 841
Schematic 842
Time Control System Inspection Table 843
NATS (NISSAN ANTI-THEFT SYSTEM) 844
Component Parts and Harness Connetor Location 844
System Description 845
System Composition 845
Wiring Diagram – NATS – 846
CONSULT-II 847
Trouble Diagnoses 849
How to Replace NATS IMMU 863
ELECTRICAL UNITS LOCATION 864
Engine Compartment 864
Passenger Compartment 866
HARNESS LAYOUT 868
How to Read Harness Layout 868
Outline 869
Main Harness 870
Engine Room Harness 872
Engine Control Harness 876
Engine Sub Harness 878
Engine Harness 879
Body Harness 880
Tail Harness 882
Room Lamp Harness 883
Door Harness 884
BULB SPECIFICATIONS 885
Headlamp 885
Exterior Lamp 885
Interior Lamp 885
WIRING DIAGRAM CODES (CELL CODES) 886
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
em 887
QUICK REFERENCE INDEX 0
Table of Contents 887
PRECAUTIONS 889
Parts Requiring Angular Tightening 889
Liquid Gasket Application Procedure 889
Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves 889
DEALER DISPOSAL INSTRUCTIONS 890
PREPARATION 892
Special Service Tools 892
Commercial Service Tools 894
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 896
NVH Troubleshooting – Engine Noise 897
OUTER COMPONENT PARTS 898
Removal and Installation 898
MEASUREMENT OF COMPRESSION PRESSURE 901
DRIVE BELTS 902
Checking 902
AIR CLEANER 903
Changing 903
VISCOUS PAPER TYPE 903
SPARK PLUG 904
Changing 904
PLATINUM-TIPPED TYPE 904
OIL PAN 906
Components 906
Removal 906
Installation 909
TIMING CHAIN 911
Components 911
Removal 912
Inspection 914
Installation 915
OIL SEAL 920
Replacement 920
VALVE OIL SEAL 920
FRONT OIL SEAL 920
REAR OIL SEAL 921
INTAKE MANIFOLD 922
Removal 922
Installation 923
CYLINDER HEAD 924
Components 924
Removal 925
Disassembly 927
Inspection 929
CYLINDER HEAD DISTORTION 929
CAMSHAFT VISUAL CHECK 929
CAMSHAFT RUNOUT 929
CAMSHAFT CAM HEIGHT 929
CAMSHAFT JOURNAL CLEARANCE 930
CAMSHAFT END PLAY 930
CAMSHAFT SPROCKET RUNOUT 931
VALVE GUIDE CLEARANCE 931
VALVE GUIDE REPLACEMENT 931
VALVE SEATS 932
REPLACING VALVE SEAT FOR SERVICE PARTS 933
VALVE DIMENSIONS 934
VALVE SPRING 934
HYDRAULIC LASH ADJUSTER 934
ROCKER ARM, SHIM AND ROCKER ARM GUIDE 935
Assembly 935
Installation 938
TURBOCHARGER 944
Removal 944
Disassembly 945
Inspection 946
OIL AND WATER TUBES 946
ROTOR SHAFT 946
TURBINE WHEEL 947
COMPRESSOR WHEEL 947
WASTEGATE VALVE 947
WASTEGATE VALVE ACTUATOR 948
Assembly 948
Installation 948
OIL TUBES 949
WATER TUBES 949
CHARGE AIR COOLER 950
Removal and Installation 950
Inspection 950
ENGINE ASSEMBLY 951
Removal and Installation 951
REMOVAL 952
INSTALLATION 953
CYLINDER BLOCK 954
Components 954
Removal and Installation 955
Disassembly 955
PISTON AND CRANKSHAFT 955
Inspection 956
PISTON AND PISTON PIN CLEARANCE 956
PISTON RING SIDE CLEARANCE 956
PISTON RING END GAP 957
CONNECTING ROD BEND AND TORSION 957
CYLINDER BLOCK DISTORTION AND WEAR 957
PISTON-TO-BORE CLEARANCE 958
CRANKSHAFT 959
BEARING CLEARANCE 959
CONNECTING ROD BUSHING CLEARANCE (SMALL END) 962
REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) 962
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) 962
FLYWHEEL/DRIVE PLATE RUNOUT 963
OIL JET (FOR PISTON) 963
Assembly 964
PISTON 964
CRANKSHAFT 965
SERVICE DATA AND SPECIFICATIONS (SDS) 968
General Specifications 968
Compression Pressure 968
Drive Belt Deflection and Tension 969
Spark Plug 969
Cylinder Head 969
Valve 970
VALVE 970
VALVE SPRING 970
HYDRAULIC LASH ADJUSTER (HLA) 970
VALVE GUIDE 971
VALVE SHIM CLEARANCE ADJUSTMENT 971
AVAILABLE SHIM 972
VALVE SEAT 973
VALVE SEAT RESURFACE LIMIT 974
Camshaft and Camshaft Bearing 974
Cylinder Block 975
Piston, Piston Ring and Piston pin 976
PISTON 976
PISTON RING 976
PISTON PIN 976
Connecting Rod 977
Crankshaft 978
Main Bearing 979
STANDARD 979
UNDERSIZE 979
Connecting Rod Bearing 979
STANDARD SIZE 979
UNDERSIZE 979
Bearing Clearance 980
Miscellaneous Components 980
fe 981
QUICK REFERENCE INDEX 0
Table of Contents 981
PREPARATION 982
Special Service Tool 982
ACCELERATOR CONTROL SYSTEM 983
Removal and Installation 983
Adjusting Accelerator Wire 983
FUEL SYSTEM 984
Checking Fuel Lines 984
Changing Fuel Filter 984
Removal and Installation 985
Fuel Tank 986
REMOVAL 986
INSTALLATION 988
Fuel Pump and Fuel Level Sensor Unit 988
REMOVAL 989
INSTALLATION 990
EXHAUST SYSTEM 991
Checking Exhaust System 991
Removal and Installation 991
foldout 993
QUICK REFERENCE INDEX 0
SUPER MULTIPLE JUNCTION (SMJ) 993
FUSE BLOCK – JUNCTION BOX (J/B) 994
FUSE AND FUSIBLE LINK BOX 995
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 996
gi 997
QUICK REFERENCE INDEX 0
Table of Contents 997
PRECAUTIONS 999
Precautions 999
PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” 999
PRECAUTIONS FOR NATS (NISSAN ANTI-THEFT SYSTEM) 999
GENERAL PRECAUTIONS 1000
PRECAUTIONS FOR MULTIPORT FUEL INJECTION SYSTEM OR ENGINE CONTROL SYSTEM 1002
PRECAUTIONS FOR THREE WAY CATALYST 1002
PRECAUTIONS FOR TURBOCHARGER 1002
PRECAUTIONS FOR HOSES 1003
PRECAUTIONS FOR ENGINE OILS 1003
PRECAUTIONS FOR FUEL 1004
PRECAUTIONS FOR AIR CONDITIONING 1004
HOW TO USE THIS MANUAL 1005
HOW TO READ WIRING DIAGRAMS 1007
Sample/Wiring Diagram – EXAMPL – 1007
OPTIONAL SPLICE 1008
Description 1009
CONNECTOR SYMBOLS 1011
SWITCH POSITIONS 1012
DETECTABLE LINES AND NON-DETECTABLE LINES 1012
MULTIPLE SWITCH 1013
REFERENCE AREA 1014
HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 1016
Work Flow 1016
Incident Simulation Tests 1017
INTRODUCTION 1017
VEHICLE VIBRATION 1017
HEAT SENSITIVE 1018
FREEZING 1018
WATER INTRUSION 1019
ELECTRICAL LOAD 1019
COLD OR HOT START UP 1019
Circuit Inspection 1019
INTRODUCTION 1019
TESTING FOR “OPENS” IN THE CIRCUIT 1020
TESTING FOR “SHORTS” IN THE CIRCUIT 1021
GROUND INSPECTION 1022
VOLTAGE DROP TESTS 1022
CONTROL UNIT CIRCUIT TEST 1024
HOW TO FOLLOW TROUBLE DIAGNOSES 1026
How to Follow Test Groups in Trouble Diagnoses 1027
Harness Wire Color and Connector Number Indication 1028
TYPE 1: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN ILLUSTRATION 1028
TYPE 2: HARNESS WIRE COLOR AND CONNECTOR NUMBER ARE SHOWN IN TEXT 1028
Key to Symbols Signifying Measurements or Procedures 1029
CONSULT-II CHECKING SYSTEM 1031
Function and System Application 1031
Nickel Metal Hydride Battery Replacement 1031
Checking Equipment 1032
CONSULT-II Data Link Connector (DLC) Circuit 1032
INSPECTION PROCEDURE 1032
IDENTIFICATION INFORMATION 1033
Model Variation 1033
AUSTRALIA 1033
PREFIX AND SUFFIX DESIGNATIONS 1033
Identification Number 1034
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT 1034
IDENTIFICATION PLATE 1035
ENGINE SERIAL NUMBER 1035
MANUAL TRANSMISSION NUMBER 1035
AUTOMATIC TRANSMISSION NUMBER 1035
Dimensions 1036
Wheels and Tires 1036
LIFTING POINTS AND TOW TRUCK TOWING 1037
Preparation 1037
SPECIAL SERVICE TOOLS 1037
Boad-on Lift 1037
Garage Jack and Safety Stand 1038
2-pole Lift 1039
Tow Truck Towing 1039
TOWING AN AUTOMATIC TRANSMISSION MODEL WITH FOUR WHEELS ON GROUND OR TOWING WITH FRONT WHEELS RAISED (WITHREAR WHEELS ON GROUND) 1040
TOWING POINT 1040
TIGHTENING TORQUE OF STANDARD BOLTS 1041
SAE J1930 TERMINOLOGY LIST 1042
SAE J1930 Terminology List 1042
ha 1047
QUICK REFERENCE INDEX 0
Table of Contents 1047
PRECAUTIONS 1048
Supplemental Restraint System (SRS) “AIR BAG” 1048
Precautions for Working with HFC-134a (R-134a) 1048
General Refrigerant Precautions 1049
Precautions for Leak Detection Dye 1049
Precaution for Identification Label on Vehicle 1049
Precautions for Refrigerant Connection 1050
Precautions for Servicing Compressor 1053
Precautions for Service Equipment 1053
Wiring Diagrams and Trouble Diagnoses 1055
PREPARATION 1056
Special Service Tools 1056
HFC-134a (R-134a) Service Tools and Equipment 1057
DESCRIPTION 1060
Refrigeration System 1060
Component Layout 1061
Control Operation 1062
Discharge Air Flow 1063
System Description 1064
TROUBLE DIAGNOSES 1065
Component Location 1065
Circuit Diagram – Air Conditioner 1067
Wiring Diagram – A/C, Heater – 1068
Wiring Diagram – A/C, M – 1069
How to Perform Trouble Diagnoses for Quick and Accurate Repair 1073
Operational Check 1074
A/C System 1076
Intake Door 1078
Blower Motor 1082
Insufficient Cooling 1089
Insufficient Heating 1097
Air Mix Door 1098
Mode Door 1105
Bi-Level Door 1108
Magnet Clutch 1111
Noise 1122
SERVICE PROCEDURE 1123
HFC-134a (R-134a) Service Procedure 1123
Maintenance of Lubricant Quantity in Compressor 1125
Compressor 1127
Compressor Clutch – DKV-11G (ZEXEL make) 1128
Thermal Protector 1131
Heater Unit (Heater Core) 1132
Blower Unit 1134
Cooling Unit (A/C Evaporator) 1135
Refrigerant Lines 1136
Fluorescent Dye Leak Detector 1140
Belt 1141
Idle Air Control Valve (IACV) – Auxiliary Air Control (AAC) Valve 1141
A/C Control System 1141
Ventilation Air Filter 1142
SERVICE DATA AND SPECIFICATIONS (SDS) 1144
Manual 1144
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
idx 1145
QUICK REFERENCE INDEX 0
GI – General Information 0
MA – Maintenance 0
EM – Engine Mechanical 0
LC – Engine Lubrication & Cooling Systems 0
EC – Engine Control System 0
FE – Accelerator Control, Fuel & Exhaust Systems 0
CL – Clutch 0
MT – Manual Transmission 0
AT – Automatic Transmission 0
PD – Propeller Shaft & Differential Carrier 0
AX – Front & Rear Axle 0
SU – Front & Rear Suspension 0
BR – Brake System 0
ST – Steering System 0
RS – Restraint System 0
BT – Body & Trim 0
HA – Heater & Air Conditioner 0
SC – Starting & Charging System 0
EL – Electrical System 0
lc 1153
QUICK REFERENCE INDEX 0
Table of Contents 1153
ENGINE LUBRICATION SYSTEM 1154
Precautions 1154
LIQUID GASKET APPLICATION PROCEDURE 1154
Preparation 1154
SPECIAL SERVICE TOOLS 1154
Lubrication Circuit 1155
Oil Pressure Check 1155
Oil Pump 1156
REMOVAL 1156
DISASSEMBLY AND ASSEMBLY 1156
INSPECTION 1157
REGULATOR VALVE INSPECTION 1157
INSTALLATION 1158
Changing Engine Oil 1158
Changing Oil Filter 1159
Service Data and Specifications (SDS) 1160
OIL PRESSURE CHECK 1160
REGULATOR VALVE INSPECTION 1160
OIL PUMP INSPECTION 1160
ENGINE OIL CAPACITY 1160
ENGINE COOLING SYSTEM 1161
Precautions 1161
LIQUID GASKET APPLICATION PROCEDURE 1161
Preparation 1161
SPECIAL SERVICE TOOL 1161
Cooling Circuit 1162
System Check 1162
CHECKING COOLING SYSTEM HOSES 1162
CHECKING COOLING SYSTEM FOR LEAKS 1163
CHECKING RADIATOR 1163
CHECKING RADIATOR CAP 1163
Water Pump 1164
REMOVAL 1164
INSPECTION 1164
INSTALLATION 1164
Thermostat 1165
REMOVAL AND INSTALLATION 1165
INSPECTION 1165
Water Outlet 1166
INSPECTION 1166
INSTALLATION 1166
Radiator 1166
COMPONENTS 1166
Cooling Fan (Crankshaft driven) 1167
DISASSEMBLY AND ASSEMBLY 1167
INSPECTION 1167
Cooling Fan Control System 1167
Changing Engine Coolant 1167
-DRAINING ENGINE COOLANT- 1167
-REFILLING ENGINE COOLANT- 1168
-FLUSHING COOLING SYSTEM- 1169
Radiator (Aluminum type) 1170
PREPARATION 1170
DISASSEMBLY 1170
ASSEMBLY 1171
INSPECTION 1172
Overheating Cause Analysis 1173
Service Data and Specifications (SDS) 1174
THERMOSTAT 1174
RADIATOR 1174
ENGINE COOLANT CAPACITY 1174
ma 1175
QUICK REFERENCE INDEX 0
Table of Contents 1175
PRE-DELIVERY INSPECTION ITEMS 1176
GENERAL MAINTENANCE 1177
PERIODIC MAINTENANCE 1178
Engine and Emission Control Maintenance 1179
Chassis and Body Maintenance 1180
Maintenance Under Severe Driving Conditions 1181
RECOMMENDED FLUIDS AND LUBRICANTS 1182
Fluids and Lubricants 1182
SAE Viscosity Number 1183
Engine Coolant Mixture Ratio 1183
mt 1185
QUICK REFERENCE INDEX 0
Table of Contents 1185
PREPARATION 1187
Special Service Tools 1187
Commercial Service Tools 1189
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1190
NVH Troubleshooting Chart 1190
MANUAL TRANSMISSION 1190
M/T OIL 1191
Checking M/T Oil 1191
Changing M/T Oil 1191
ON-VEHICLE SERVICE 1192
Replacing Rear Oil Seal 1192
REMOVAL 1192
INSTALLATION 1192
Position Switch Check 1192
DESCRIPTION 1193
Cross-sectional View 1193
Triple Cone Synchronizer 1194
SHIFT CONTROL 1195
Components 1195
REMOVAL AND INSTALLATION 1196
Removal 1196
Installation 1197
Air Breather Hose 1198
OVERHAUL 1199
Transmission Components 1199
REPAIR FOR COMPONENT PARTS 1200
Rear Extension 1200
COMPONENTS 1200
REMOVAL 1200
INSTALLATION 1200
DISASSEMBLY 1201
ASSEMBLY 1201
Transmission Case 1202
COMPONENTS 1202
REMOVAL 1203
INSTALLATION 1204
Counter Gear Bearing 1207
DISASSEMBLY AND ASSEMBLY 1207
6th Coupling Sleeve and Synchronizer Hub 1208
DISASSEMBLY AND ASSEMBLY 1208
INSPECTION 1208
Mainshaft Bearing Retainer 1208
DISASSEMBLY AND ASSEMBLY 1208
6th Counter Gear and Baulk Ring 1209
INSPECTION 1209
Clutch Housing 1209
COMPONENTS 1209
REMOVAL 1209
INSTALLATION 1211
Front Cover 1212
REMOVAL AND INSTALLATION 1212
DISASSEMBLY 1212
ASSEMBLY 1213
Reverse Idler Gear 1213
INSPECTION 1213
Main Drive Gear 1213
REMOVAL AND INSTALLATION 1213
DISASSEMBLY 1213
INSPECTION 1214
ASSEMBLY 1214
Mainshaft 1215
REMOVAL AND INSTALLATION 1215
INSPECTION BEFORE DISASSEMBLY 1215
DISASSEMBLY 1216
INSPECTION 1216
ASSEMBLY 1218
Counter Gear 1220
REMOVAL AND INSTALLATION 1220
INSPECTION BEFORE DISASSEMBLY 1220
DISASSEMBLY 1221
INSPECTION 1222
ASSEMBLY 1223
Shift Fork and Fork Rod 1224
REMOVAL AND INSTALLATION 1224
DISASSEMBLY AND ASSEMBLY 1225
INSPECTION 1225
SERVICE DATA AND SPECIFICATIONS (SDS) 1226
General Specifications 1226
Gear End Play and Oil Clearance 1226
Clearance Between Baulk Ring and Gear 1227
Available Snap Ring 1227
MAIN DRIVE GEAR SNAP RING 1227
COUNTER FRONT BEARING SNAP RING 1227
4TH COUNTER GEAR FRONT SNAP RING 1227
COUNTER DRIVE GEAR SNAP RING 1227
5TH & REVERSE SYNCHRONIZER HUB SNAP RING 1228
6TH MAIN GEAR REAR SNAP RING 1228
6TH SYNCHRONIZER HUB SNAP RING 1228
pd 1229
QUICK REFERENCE INDEX 0
Table of Contents 1229
PROPELLER SHAFT 1230
Preparation 1230
SPECIAL SERVICE TOOLS 1230
Noise, Vibration and Harshness (NVH) Troubleshooting 1231
NVH TROUBLESHOOTING CHART 1231
Components 1232
On-vehicle Service 1232
CHECKING PROPELLER SHAFT 1232
PROPELLER SHAFT VIBRATION 1233
APPEARANCE CHECKING 1233
Removal and Installation 1233
Inspection 1235
Disassembly 1235
CENTER BEARING 1235
Assembly 1236
CENTER BEARING 1236
Service Data and Specifications (SDS) 1237
GENERAL SPECIFICATIONS 1237
SERVICE DATA 1237
R200 1238
REAR FINAL DRIVE 1238
Preparation 1238
SPECIAL SERVICE TOOLS 1238
Noise, Vibration and Harshness (NVH) Troubleshooting 1240
On-vehicle Service 1240
CHECKING DIFFERENTIAL GEAR OIL 1240
CHANGING DIFFERENTIAL GEAR OIL 1240
FRONT OIL SEAL REPLACEMENT 1240
SIDE OIL SEAL REPLACEMENT 1241
Components 1243
Removal and Installation 1244
REMOVAL 1244
INSTALLATION 1244
Disassembly 1244
PRE-INSPECTION 1244
DIFFERENTIAL CARRIER 1245
DIFFERENTIAL CASE 1247
Inspection 1247
RING GEAR AND DRIVE PINION 1247
DIFFERENTIAL CASE ASSEMBLY 1247
BEARING 1248
Adjustment 1248
DRIVE PINION HEIGHT 1249
SIDE BEARING PRELOAD 1251
TOOTH CONTACT 1254
Assembly 1255
DIFFERENTIAL CASE 1255
DIFFERENTIAL CARRIER 1256
Service Data and Specifications (SDS) 1260
R200H AND R200V 1260
rs 1263
QUICK REFERENCE INDEX 0
Table of Contents 1263
SEAT BELTS 1264
Precautions 1264
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” 1264
PRECAUTION FOR SEAT BELT SERVICE 1264
Maintenance 1265
Front Seat Belt 1266
REMOVAL AND INSTALLATION 1266
Rear Seat Belt 1267
REMOVAL AND INSTALLATION 1267
Tether Anchor Plate 1268
REMOVAL AND INSTALLATION 1268
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) 1269
Precautions 1269
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) “AIR BAG” 1269
PRECAUTIONS FOR SRS “AIR BAG” 1269
WIRING DIAGRAMS AND TROUBLE DIAGNOSIS 1269
Preparation 1270
SPECIAL SERVICE TOOLS 1270
COMMERCIAL SERVICE TOOL 1270
SRS Configuration 1271
SRS Component Parts Location 1271
Maintenance Items 1272
Diagnosis Sensor Unit 1272
REMOVAL AND INSTALLATION 1272
Driver Air Bag Module and Spiral Cable 1274
REMOVAL AND INSTALLATION 1274
REMOVAL 1274
INSTALLATION 1275
Front Passenger Air Bag Module 1276
REMOVAL 1276
INSTALLATION 1277
Disposal of Air Bag Module 1278
CHECKING DEPLOYMENT TOOL 1278
DEPLOYMENT PROCEDURES FOR AIR BAG MODULE (OUTSIDE OF VEHICLE) 1279
DEPLOYMENT OF AIR BAG MODULE WHILE MOUNTED IN VEHICLE 1281
DISPOSING OF AIR BAG MODULE 1282
Trouble Diagnoses Introduction 1283
DIAGNOSIS FUNCTION 1283
DIAGNOSIS MODE FOR CONSULT-II 1283
HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II 1284
HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II 1284
HOW TO ERASE SELF-DIAGNOSIS RESULTS 1284
How to Perform Trouble Diagnoses for Quick and Accurate Repair 1286
INFORMATION FROM CUSTOMER 1286
PRELIMINARY CHECK 1286
WORK FLOW 1287
Wiring Diagram – SRS – 1288
SRS Operation Check 1290
DIAGNOSTIC PROCEDURE 1 1290
Trouble Diagnoses with CONSULT-II 1291
DIAGNOSTIC PROCEDURE 2 1291
DIAGNOSTIC PROCEDURE 3 1293
DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) 1295
DIAGNOSTIC PROCEDURE 5 1295
Trouble Diagnoses without CONSULT-II 1298
DIAGNOSTIC PROCEDURE 6 1298
DIAGNOSTIC PROCEDURE 7 1300
DIAGNOSTIC PROCEDURE 8 (CONTINUED FROM DIAGNOSTIC PROCEDURE 6) 1302
Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn Off 1303
DIAGNOSTIC PROCEDURE 9 1303
Trouble Diagnoses: “AIR BAG” Warning Lamp Does Not Turn On 1305
DIAGNOSTIC PROCEDURE 10 1305
Trouble Diagnoses: SRS Does Not Enter Diagnosis Mode Using Door Switch 1306
DIAGNOSTIC PROCEDURE 11 1306
Collision Diagnosis 1308
SRS INSPECTION 1308
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
sc 1311
QUICK REFERENCE INDEX 0
Table of Contents 1311
PRECAUTIONS 1312
Supplemental Restraint System (SRS) “AIR BAG” 1312
Wiring Diagrams and Trouble Diagnosis 1312
BATTERY 1313
How to Handle Battery 1313
METHODS OF PREVENTING OVER-DISCHARGE 1313
CHECKING ELECTROLYTE LEVEL 1313
SPECIFIC GRAVITY CHECK 1314
Battery Test and Charging Chart 1316
CHART I 1316
CHART II 1317
A: SLOW CHARGE 1318
B: STANDARD CHARGE 1319
C: QUICK CHARGE 1321
STARTING SYSTEM 1322
System Description 1322
M/T MODELS 1322
A/T MODELS 1322
Wiring Diagram – START – 1323
Trouble Diagnoses 1324
Construction 1325
Removal and Installation 1325
REMOVAL 1325
INSTALLATION 1325
Inspection 1326
MAGNETIC SWITCH CHECK 1326
PINION/CLUTCH CHECK 1326
BRUSH CHECK 1326
YOKE CHECK 1327
ARMATURE CHECK 1327
Assembly 1328
PINION PROTRUSION LENGTH ADJUSTMENT 1328
CHARGING SYSTEM 1329
System Description 1329
Wiring Diagram – CHARGE – 1330
Trouble Diagnoses 1331
WITH IC REGULATOR 1331
MALFUNCTION INDICATOR 1331
Construction 1332
Removal and Installation 1332
REMOVAL 1332
INSTALLATION 1332
Disassembly 1333
REAR COVER 1333
REAR BEARING 1333
Inspection 1333
ROTOR CHECK 1333
BRUSH CHECK 1333
STATOR CHECK 1334
Assembly 1334
RING FITTING IN REAR BEARING 1334
REAR COVER INSTALLATION 1334
SERVICE DATA AND SPECIFICATIONS (SDS) 1335
Battery 1335
Starter 1335
Alternator 1335
SUPER MULTIPLE JUNCTION (SMJ) 0
FUSE BLOCK – JUNCTION BOX (J/B) 1
FUSE AND FUSIBLE LINK BOX 2
ELECTRICAL UNITS AND JOINT CONNECTOR (J/C) 3
st 1337
QUICK REFERENCE INDEX 0
Table of Contents 1337
PRECAUTIONS 1338
Supplemental Restraint System (SRS) “AIR BAG” 1338
Precautions for Steering System 1338
PREPARATION 1339
Special Service Tools 1339
Commercial Service Tool 1340
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING 1341
NVH Troubleshooting Chart 1341
ON-VEHICLE SERVICE 1342
Checking Steering Wheel Play 1342
Checking Neutral Position on Steering Wheel 1342
PRE-CHECKING 1342
CHECKING 1342
Front Wheel Turning Angle 1342
Checking Gear Housing Movement 1342
Adjusting Rack Retainer 1343
Checking and Adjusting Drive Belts 1343
Checking Steering Gear and Linkage 1343
STEERING GEAR 1343
STEERING LINKAGE 1343
Checking Fluid Level 1343
Checking Fluid Leakage 1343
Bleeding Hydraulic System 1344
Checking Steering Wheel Turning Force 1344
Checking Hydraulic System 1345
STEERING WHEEL AND STEERING COLUMN 1347
Components 1347
Removal and Installation 1347
STEERING WHEEL 1347
STEERING COLUMN 1348
Disassembly and Assembly 1349
Inspection 1350
TILT MECHANISM 1350
POWER STEERING GEAR AND LINKAGE 1351
Components 1351
Removal and Installation 1352
Disassembly 1353
Inspection 1354
BOOT 1354
RACK 1354
GEAR SUB-ASSEMBLY 1354
GEAR HOUSING CYLINDER 1354
TIE-ROD OUTER AND INNER SOCKETS 1355
Assembly 1355
Adjustment 1359
POWER STEERING OIL PUMP 1361
Components 1361
Pre-disassembly Inspection 1361
Disassembly 1362
Inspection 1363
Assembly 1363
SERVICE DATA AND SPECIFICATIONS (SDS) 1365
General Specifications 1365
Steering Wheel 1365
Steering Column 1365
Steering Gear and Linkage 1366
Power Steering 1367
su 1369
QUICK REFERENCE INDEX 0
Table of Contents 1369
FRONT SUSPENSION 1370
Precautions 1370
PRECAUTIONS 1370
Preparation 1370
SPECIAL SERVICE TOOLS 1370
COMMERCIAL SERVICE TOOLS 1370
Noise, Vibration and Harshness (NVH) Troubleshooting 1372
NVH TROUBLESHOOTING CHART 1372
Components 1373
On-vehicle Service 1374
FRONT SUSPENSION PARTS 1374
FRONT WHEEL ALIGNMENT 1374
Coil Spring and Shock Absorber 1377
COMPONENTS 1377
REMOVAL AND INSTALLATION 1378
DISASSEMBLY 1378
INSPECTION 1378
ASSEMBLY 1379
Tension Rod and Stabilizer Bar 1379
REMOVAL AND INSTALLATION 1379
Transverse Link and Lower Ball Joint 1380
REMOVAL AND INSTALLATION 1380
INSPECTION 1380
Service Data and Specifications (SDS) 1381
GENERAL SPECIFICATIONS (FRONT) 1381
FRONT WHEEL ALIGNMENT (UNLADEN*1) 1381
LOWER BALL JOINT 1381
WHEEL RUNOUT 1381
REAR SUSPENSION 1382
Precautions 1382
PRECAUTIONS 1382
Preparation 1382
COMMERCIAL SERVICE TOOLS 1382
Noise, Vibration and Harshness (NVH) Troubleshooting 1382
Components 1383
On-vehicle Service 1384
REAR SUSPENSION PARTS 1384
REAR WHEEL ALIGNMENT 1384
Removal and Installation 1386
REMOVAL AND INSTALLATION 1387
Coil Spring and Shock Absorber 1388
REMOVAL AND INSTALLATION 1388
DISASSEMBLY 1388
INSPECTION 1388
ASSEMBLY 1388
Multi-link and Lower Ball Joint 1389
REMOVAL AND INSTALLATION 1389
INSPECTION 1389
Stabilizer Bar 1390
REMOVAL 1390
INSPECTION 1390
INSTALLATION 1390
Service Data and Specifications (SDS) 1391
GENERAL SPECIFICATIONS (REAR) 1391
REAR WHEEL ALIGNMENT (UNLADEN*) 1391
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DESCRIPTION:
NISSAN S15 Series Service Manual PDF DOWNLOAD
FOREWORD
- This manual contains maintenance and repair procedures for NISSAN model S15 series. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly.
- It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task.
- All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice.
GENERAL PRECAUTIONS:
- Before proceeding with disassembly, thoroughly clean the outside of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter
- Disassembly should be done in a clean work area. I Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the transmission.
- Place disassembled parts in order for easier and proper assembly. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly.
- Gaskets, seals and O-rings should be replaced any time the transmission is disassembled. It is very important to perform functional tests whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced.
- Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent springs and small parts from becoming scattered or lost.
- Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight. I Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings and seals, or hold bearings and washers in place during assembly. Do not use grease.
- Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. I After overhaul, refill the transmission with new ATF.
- When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque converter and ATF cooling system.
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
- Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted
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