1991–1999 Nissan Serena C23 Service Manual (P/N SM2E-1C23E0E)

• Covers Nissan Serena C23 coach and van configurations with GA16DE, SR20DE, and LD20-II engines, including European left- and right-hand-drive models.
• Engine mechanical repair covers removal, cylinder-head and cylinder-block work, compression testing, intake/exhaust valve-clearance inspection, gasoline-engine timing chains, and the diesel timing belt.
• Fuel-system coverage runs from E.C.C.S./E.F.I. diagnosis with and without CONSULT to diesel injection-pump overhaul, nozzle testing, and Quick-Glow troubleshooting.
• RS5W71C five-speed manual transmission disassembly and assembly, shift-cable adjustment, hydraulic clutch service, and R200V/H190A differential setup, including H190A limited-slip repair.
• Chassis procedures distinguish independent and rigid rear axles, with wheel-bearing and drive-shaft service, front-strut disassembly, wheel alignment, and manual- and power-steering work.
• Brake sections cover front discs, rear drums, hydraulic bleeding, load-sensing-valve adjustment, and ABS fault diagnosis.
• Electrical wiring and connector diagrams support circuit testing. Heater and A/C coverage includes performance diagnosis, evacuation and charging, compressor-oil adjustment, and clutch service.

C23 Configurations and Publication Details

This Nissan Europe service manual is the September 1992 edition. The Volume 1 cover carries Publication No. SM2E-1C23E0E. Supplied as a 1,254-page scanned PDF set in 21 files, it contains 719 pages from the Volume 1 sections and 535 from Volume 2, including the separate 16-page wiring-diagram file. The page count includes duplicate scans.

Printed pages EM-88 and EM-141–142 are missing, interrupting GA16DE valve-clearance adjustment and LD20-II cylinder-block procedures.

Model-code and VIN tables distinguish four- and five-door bodies, window and panel vans, trim levels, and European destinations. Coverage follows the two-wheel-drive, manual-transmission configurations in this edition; an automatic-transmission overhaul section is not included.

Engine Management, Diesel Injection, and Cooling

The gasoline diagnostic chapters pair E.C.C.S. Component Parts Location views with Vacuum Hose Drawing pages and circuit-specific fault charts. CONSULT material covers self-diagnostic results, Data Monitor, Active Test, and ECU input/output reference values. Troubleshooting extends to starting and idle complaints, fuel-pressure checks, ignition faults, and individual sensors and actuators.

Diesel work goes beyond routine fuel-filter service. The pump material includes governor and cold-start-device work, bench testing, and adjustment. Nozzle coverage addresses opening-pressure and spray-pattern checks. Quick-Glow wiring distinguishes versions with and without E.G.R., so the diesel electrical system is not treated as a single configuration.

Lubrication and cooling chapters cover oil-pump inspection, oil-pressure testing, water pumps, thermostats, and engine-compartment fan electrical diagnosis. The Cooling System Diagram supports engine-specific coolant draining, refilling, and air-release procedures, including rear-heater arrangements.

Drivetrain and Chassis Repair Detail

Differential procedures cover pinion-height selection, bearing preload, backlash, and tooth-contact inspection. The limited-slip material adds friction-disc and plate inspection and adjustment. Clutch documentation identifies the SR20DE-specific damper rather than applying one hydraulic layout to every engine.

Brake diagnosis includes the actuator, wheel sensors, and control circuitry. The tool listings identify the KV991V0010 brake-fluid pressure gauge and the KDAS0003 ABS checker, alongside the related checks. Suspension sections separate rear spring, link, and axle-shaft work by axle design.

Incorrect differential tooth contact can shorten hypoid-gear life. The diesel timing-belt precautions identify a valve-to-piston collision risk when the crankshaft and camshaft are moved independently with the belt removed.

Electrical, Body, and A/C Coverage

Power Supply Routing, harness layouts, and Super Multiple Junction (S.M.J.) Terminal Arrangement views support electrical repair across the starting, charging, lighting, and accessory circuits. Engine-specific E.C.C.S. wiring is supplied in the separate diagram file.

Body coverage includes door adjustment, power windows and locks, sunroof work, glass, and body-alignment measurements. A/C specifications distinguish single and twin systems and ZEXEL DCW-17 and DKS-16H compressors; the compressor service pages detail DKS-16H clutch removal and adjustment.

Factory Specifications and Torque Data

Component tightening torques, fluid capacities, recommended lubricants, wear limits, clearances, and electrical test values accompany the relevant repair sections. Engine internal measurements, transmission shim selections, brake inspection limits, and front/rear alignment data are organized under Service Data and Specifications (S.D.S.). Cooling-system capacities are separated by engine and rear-heater configuration.

Important shop notice: Always verify your lifting points and wear appropriate safety gear before applying torque values or performing heavy maintenance. Brake-hydraulic and refrigerant work require the precautions and equipment specified in the relevant sections.