1991 Nissan Stanza Service Manual FSM (OEM)

• Covers the 1991 Nissan Stanza U12 Series sedan with the KA24E engine, including E and GXE grades for Non-California, California, and Canadian specifications
• Model identification tables distinguish RS5F50A / RS5F50V 5-speed manual and RE4F02A / RE4F02V automatic transaxle applications
• Nissan Motor Co., Ltd. factory service publication, ©1990; this PDF contains 150 pages covering General Information through EF & EC-32
• Includes factory E.C.C.S. diagnostics, CONSULT functions, engine overhaul data, special service tool numbers, system diagrams, wiring information, and specification tables

Model Coverage and File Scope

The identification section goes beyond a generic “1991 Stanza” application. It breaks the U12 sedan down by E and GXE grade, destination market, engine, and transaxle code. All listed variants use the KA24E engine, while the transmission identification separates RS5F50A and RS5F50V manual units from RE4F02A and RE4F02V automatic units. VIN, engine serial number, and transaxle-number locations are also illustrated.

The scope of this particular file is important. It contains the General Information, Maintenance, Engine Mechanical, Engine Lubrication & Cooling Systems, and the first 32 pages of the Engine Fuel & Emission Control System section. The manual's quick-reference index lists later clutch, transaxle, suspension, brake, steering, body, heater/A/C, and electrical sections, but those chapters are not present in this 150-page PDF. Transmission variants are identified here, but dedicated MT and AT overhaul procedures are outside the supplied file.

KA24E Engine Repair Data

The engine material is detailed enough for internal repair work rather than routine maintenance alone. Factory procedures cover compression testing, timing-chain service, front and rear oil seals, cylinder-head removal and inspection, engine removal, cylinder-block disassembly, piston and connecting-rod inspection, crankshaft measurement, bearing selection, and final assembly checks.

Service Data and Specifications tables give measurable rebuild limits throughout the section. Main bearing clearance is 0.020-0.047 mm, with a 0.10 mm limit; connecting-rod bearing clearance is 0.010-0.035 mm. Compression pressure is specified at 1,206 kPa (175 psi) standard, 1,010 kPa (146 psi) minimum, with a 98 kPa (14 psi) maximum difference between cylinders.

Cylinder-head fasteners use a staged torque/angle procedure. For the final tightening operation, Nissan specifies an 80-85° turn with an angle wrench; where an angle wrench is unavailable, the manual gives 74-83 Nm (54-61 ft-lb) as the alternative value. This distinction matters when comparing the manual with simplified torque lists that show only a single number.

Fluid data is equally specific: engine oil refill with filter is 3.5 liters, cooling-system capacity is 7.4 liters, manual-transaxle gear-oil capacity is 4.7 liters, and automatic-transaxle fluid capacity is 7.4 liters.

E.C.C.S. Diagnostics and System Documentation

The electronic engine-control material documents the Nissan E.C.C.S. architecture rather than treating fuel injection as a black box. Component descriptions cover the E.C.C.S. control unit, crank-angle sensor, air-flow meter, engine-temperature sensor, throttle sensor and soft/hard idle switch, injectors, pressure regulator, exhaust-gas sensor, power transistor, A.A.C. valve, E.G.R. controls, swirl-control system, vehicle-speed sensor, and related inputs.

Factory CONSULT coverage includes diagnostic mode, work support, self-diagnostic results, data monitor, active test, and ECU part-number reading. The diagnostic flow-chart instructions also explain connector views, harness-side versus terminal-side identification, continuity checks, and cross-references between component locations, harness layouts, and circuit diagrams.

Representative drawings and charts include the Lubrication Circuit, Cooling Circuit, E.C.C.S. System Diagram, Vacuum Hose Drawing, Circuit Diagram, and E.C.C.S. Wiring Diagram. Later pages in the supplied file cover fuel-injection control, ignition timing, idle-speed control, fuel-pump control, E.G.R., fuel-pressure regulator control, swirl control, radiator-fan logic, fail-safe operation, and the factory idle-speed/ignition-timing/idle-mixture inspection flow.

Factory Tools and Repair-Specific Cautions

Special service tools are identified by number and intended operation, including the KV101092S0 valve spring compressor, KV109B0010 valve oil seal drift, KV10111100 seal cutter, ST25051001 oil pressure gauge, and EG11160000 ignition coil adapter harness used for engine-speed measurement. That tool information is especially useful when planning a cylinder-head, lubrication-system, or E.C.C.S. repair before disassembly begins.

Several Nissan cautions reveal where this repair work is easy to get wrong. The oil-pan section specifically warns against prying between the pan and cylinder block with a screwdriver because the sealing flange can be damaged. During cylinder-head removal, incorrect bolt-loosening order can cause head warpage or cracking. With the timing chain disconnected, the crankshaft and camshaft must not be rotated independently because valve-to-piston contact can result.

For engine removal, fuel-system work, cooling-system pressure checks, and electrical diagnosis, follow the factory precautions for vehicle support, fuel-pressure release, hot coolant, and battery or control-unit isolation.