1988–1999 Nissan 200SX S13 Series Service & Repair Manual (CA18DET)

This Nissan factory service manual covers the 1988–1999 Nissan 200SX S13 Series Fast Back equipped with the turbocharged CA18DET engine. It documents left- and right-hand-drive configurations and models with and without a catalytic converter.

• Engine mechanical: Timing-belt replacement, compression testing, cylinder-block disassembly and assembly, bearing inspection, and turbocharger fault diagnosis.

• Fuel and ignition: E.F.I. and E.C.C.S. troubleshooting, sensor and injector checks, idle-control testing, vacuum routing, and fuel-pressure inspection.

• Transmission and final drive: FS5W71C manual and RE4R01A automatic transmission service, hydraulic clutch repair, R200 differential adjustment, and propeller-shaft inspection.

• Brakes and chassis: Disc-brake repair, A.B.S. self-diagnosis, wheel-bearing replacement, suspension alignment, and power-steering service.

• Body and climate control: Body alignment dimensions, window and door-lock circuits, heater controls, A/C performance testing, and compressor service.

• Workshop reference: Exploded assembly views, component locations, connector pinouts, wiring diagrams, torque tables, and component-specific inspection limits.

The diagnostic charts and precision inspection procedures suit experienced mechanics familiar with electrical testing, measuring tools, and engine or transmission service.

Engine Inspection, Timing, and Turbocharger Service

The engine section provides cylinder-head and hydraulic valve-lifter specifications, cylinder-block distortion checks, piston-ring end-gap data, and bearing-selection tables. Timing-belt procedures cover alignment, tensioning, and inspection of the belt, tensioner, and idler pulley.

Engine-section gaps: Printed pages EM-15–24 and EM-27–28 are missing from this PDF. These gaps interrupt the valve-seal, cylinder-head, and turbocharger material, so the file does not provide an uninterrupted procedure for those jobs.

Turbocharger inspection addresses low power, excessive power, oil consumption, shaft play, and bypass-valve operation. The manual specifies replacement of the turbocharger as an assembly and warns that interrupted oil delivery can damage its rotating components.

The Lubrication Circuit and Cooling Circuit diagrams trace flow through the engine, turbocharger, and oil cooler. Related procedures cover oil-pump inspection, oil-pressure testing, water-pump replacement, and radiator service.

Working on internal engine components or pressurized systems requires a proper shop environment and correct tooling.

E.C.C.S. Diagnostics and Electrical Fault Tracing

E.C.C.S. self-diagnosis covers stored faults, switch signals, and real-time checks. Mixture-feedback modes I and II apply only to catalyst-equipped models. The KV109D0020 Checker Box is documented alongside E.C.U. input/output voltage and resistance checks.

The Power Source & Ground Circuit for E.C.U. diagram, diagnostic flowcharts, harness layouts, and Super Multiple Junction (S.M.J.) terminal views help distinguish sensor faults from wiring, supply, or ground problems before components are replaced.

Connector-handling precautions address static electricity, which can damage the control unit’s internal electronics.

Transmission Overhaul and Differential Adjustment

Manual-transmission procedures cover shafts, bearings, synchronizers, and gear assembly, with separate European and non-European specifications. Automatic-transmission coverage extends to the valve body, clutch packs, band servo, stall testing, and line-pressure testing.

The Hydraulic Control Circuits and Electrical Control Chart relate solenoid operation to transmission function. Final-drive procedures cover R200 pinion-height selection, bearing preload, gear-tooth contact, and the differential oil-cooler system. Propeller-shaft inspection includes runout and center-bearing checks.

Brake, Steering, Body, and A/C Work

Brake procedures distinguish CL18VB/CL25VA front calipers, CL9H/AD9 rear brakes, and DS17HD parking brakes, with A.B.S. sensor and actuator tests. Front and rear suspension sections provide alignment and joint-inspection procedures.

PR24SC and PR26SC steering-gear coverage includes leak diagnosis, seal replacement, hydraulic testing, and adjustment. Body sections address glass replacement, door adjustment, and underbody measurement points.

Heater and A/C coverage includes control-cable adjustment, electrical diagnosis, performance charts, and separate service information for NVR 140S and DKV-14C compressors.

A Sample of Engine Clearances and Refill Data

These clearance and capacity figures are a small selection of the technical specifications in the manual.

For CA18DET lower-engine inspection, standard crankshaft end play is 0.05–0.18 mm, and standard main-bearing oil clearance is 0.021–0.048 mm. The inspection material distinguishes standard clearances from service limits.

The maintenance tables list an approximate cooling-system capacity of 7.0 liters, including the reservoir, and an approximate engine-oil refill of 3.5 liters with an oil-filter change.

PDF Search, Page Order, and Printing

Navigation and diagram detail: PDF text search and embedded bookmarks are unavailable. Some pages are out of sequence, several sections run in reverse order, and some diagrams require rotation. Small wiring labels require zooming.

The download contains one printable English PDF with 892 pages, including the cover, quick-reference index, foreword, seven appended wiring-diagram pages, 19 blank pages, and one page containing only its heading and footer. These are all included in the stated total.