Table of Contents
Clymer Datsun & Nissan 200SX 1980-1987 Shop Manual
By Alan Ahlstrand
Third Edition, Published October 1987
Introduction
This detailed, comprehensive manual covers all 1980-1987 Nissan models. The expert text gives complete information on maintenance, repair and overhaul. Hundreds of photos and drawings guide you through every step. The book includes all you need to know to keep your 200SX running right. Where special tools are required or recommended, the tool numbers are provided. These tools can sometimes be rented from rental dealers, but they can always be purchased through your local Nissan dealer. A shop manual is a reference. You want to be able to find information fast. As in all Clymer books, this one is designed with this in mind. All chapters are thumb tabbed. Important items are indexed at the rear of the book. All the most frequently used specifications and capacities are summarized on the Quick Reference Data pages at the front of the book. Keep the book handy. Carry it in your glovebox. It will help you to better understand your car, lower repair costs and generally improve your satisfaction with your vehicle.
Shop Manual
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Contents
| QUICK REFERENCE DATA | IX |
|---|---|
| CHAPTER ONE GENERAL INFORMATION | 1 |
| Manual organization | 1 |
| Service hints | 2 |
| Expendable supplies | 4 |
| Shop tools | 4 |
| Emergency tool kit | 5 |
| Troubleshooting and tune-up equipment | 5 |
| CHAPTER TWO TROUBLESHOOTING | 9 |
| Starting system | 9 |
| Charging system | 9 |
| Ignition system | 13 |
| Engine performance | 14 |
| Engine oil pressure light | 18 |
| Fuel system (carburetted) | 18 |
| Fuel system (fuel injected) | 19 |
| Fuel pump test (mechanical and electrical) | 19 |
| Emission control systems | 20 |
| Engine noises | 24 |
| Electrical accessories | 25 |
| Cooling system | 26 |
| Clutch | 27 |
| Manual transmission/transaxle | 28 |
| Automatic transmssion | 28 |
| Brakes | 28 |
| Steering and suspension | 29 |
| Tyre wear analysis | 29 |
| Wheel balancing | 32 |
| CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP | 33 |
| Hoisting, jacking and lift points | 33 |
| Towing | 34 |
| Fuel stop checks | 34 |
| Scheduled maintenance | 38 |
| Tune-up | 47 |
| Fuel system service | 52 |
| CHAPTER FOUR 4-CYLINDER ENGINE | 57 |
| Engine identification | 57 |
| Engine removal/installation | 58 |
| Disassembly checklist | 60 |
| Decarbonizing or valve service | 63 |
| Valve and ring service | 63 |
| General overhaul | 63 |
| Intake and exhaust manifolds | 69 |
| Valve cover | 70 |
| Rocker arms and camshaft (Z-series engine) | 70 |
| Rocker arms and camshaft (CA-series engine) | 74 |
| Valves and valve seats | 76 |
| Front cover, timing chain and sprockets (Z-series engine) | 76 |
| Timing belt and sprockets (CA-series engine) | 78 |
| Oil pan and oil pump (Z-series engine) | 80 |
| Oil pan and oil pump (CA-series engine) | 82 |
| Cylinder head | 84 |
| Piston/connecting rod assembly | 86 |
| Crankshaft and main bearings | 90 |
| Flywheel or drive plate | 93 |
| Cylinder block | 94 |
| Core plug replacement | 94 |
| CHAPTER FIVE V6 ENGINE | 104 |
| Engine identification | 104 |
| Engine removal/installation | 105 |
| Disassembly checklist | 108 |
| Intake and exhaust manifolds | 113 |
| Valve covers | 114 |
| Rocker assemblies and valve lifters | 115 |
| Camshaft | 117 |
| Valves and valve seats | 119 |
| Timing belt | 119 |
| Oil pan and oil pump | 121 |
| Cylinder head | 123 |
| Piston/connecting rod assembly | 125 |
| Crankshaft and main bearings | 130 |
| Flywheel or drive plate | 133 |
| Cylinder block | 134 |
| Core plug replacement | 135 |
| CHAPTER SIX FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS | 140 |
| Air cleaner system | 140 |
| Fuel quality | 141 |
| Electronic fuel injection (EFI) systems | 143 |
| Fuel filter | 145 |
| Fuel pump | 145 |
| Exhaust system | 147 |
| Turbocharger | 149 |
| Emission control systems | 151 |
| CHAPTER SEVEN COOLING, HEATING AND AIR CONDITIONING SYSTEMS | 159 |
| Cooling system | 159 |
| Cooling system flushing | 161 |
| Cooling system checks | 164 |
| Thermostat | 165 |
| Radiator | 166 |
| Electric cooling fan (V6) | 168 |
| Cooling fan (engine-driven) | 169 |
| Water pump | 170 |
| Drive belts | 171 |
| Heater | 172 |
| Air conditioning | 176 |
| Routine maintenance | 179 |
| Refrigerant | 180 |
| CHAPTER EIGHT ELECTRICAL SYSTEM | 183 |
| Battery | 183 |
| Charging system | 189 |
| Starter | 191 |
| Ignition system | 197 |
| Distributor | 205 |
| Ignition coil | 206 |
| Lighting system | 206 |
| Steering column combination switch | 208 |
| Ignition switch | 212 |
| Relays | 212 |
| Oil pressure indicator switch | 213 |
| Water temperature gauge sender | 215 |
| Instruments | 217 |
| Horn | 217 |
| Windshield wipers and washers | 219 |
| Electrical circuit protection | 222 |
| Turn signals | 224 |
| CHAPTER NINE CLUTCH AND TRANSMISSION | 226 |
| Clutch | 226 |
| Manual transmission | 235 |
| Automatic transmission | 236 |
| CHAPTER TEN FRONT SUSPENSION AND STEERING | 244 |
| Front suspension | 244 |
| Wheel alignment | 249 |
| Wheel bearings | 251 |
| Steering system | 254 |
| Steering wheel and column | 265 |
| CHAPTER ELEVEN REAR SUSPENSION, DRIVE SHAFT, AXLE AND DIFFERENTIAL | 273 |
| Rear suspension | 273 |
| 4-link rear suspension | 273 |
| Independent rear suspension | 281 |
| Drive shaft | 286 |
| Differential | 290 |
| CHAPTER TWELVE BRAKES | 296 |
| Front disc brakes | 296 |
| Rear disc brakes | 303 |
| Master cylinder | 306 |
| Brake bleeding | 307 |
| Power brake vacuum booster | 308 |
| Proportioning valve | 310 |
| Stoplight switch | 311 |
| Brake pedal | 311 |
| Brake adjustment | 311 |
| INDEX | 315 |
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