Nissan 200SX S15 Service & Repair Manual

AUTOMATIC TRANSMISSION SECTION AT CONTENTS PRECAUTIONS ...............................................................4 Supplemental Restraint System (SRS) ″AIR BAG″ ............................................................................4 Precautions ..................................................................4 Service Notice or Precautions .....................................5 Wiring Diagrams and Trouble Diagnosis .....................6 PREPARATION ...............................................................7 Special Service Tools ..................................................7 A/T FLUID ........................................................................9 Checking A/T Fluid ......................................................9 Changing A/T Fluid ......................................................9 OVERALL SYSTEM ...................................................... 11 A/T Electrical Parts Location ..................................... 11 Circuit Diagram ..........................................................12 Cross-sectional View .................................................13 Hydraulic Control Circuit ............................................14 Shift Mechanism ........................................................15 Control System ..........................................................24 Control Mechanism....................................................25 Control Valve .............................................................30 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ...............................................................32 CONSULT-II ...............................................................32 Diagnostic Procedure Without CONSULT-II ..............37 TROUBLE DIAGNOSIS - INTRODUCTION..................42 Introduction ................................................................42 Work Flow ..................................................................46 TROUBLE DIAGNOSIS - BASIC INSPECTION ...........48 A/T Fluid Check .........................................................48 Stall Test ....................................................................48 Line Pressure Test .....................................................51 Road Test ...................................................................52 TROUBLE DIAGNOSIS - GENERAL DESCRIPTION ...............................................................70 Symptom Chart ..........................................................70 TCM Terminals and Reference Value........................82 TROUBLE DIAGNOSIS FOR POWER SUPPLY..........86 Wiring Diagram - AT - MAIN......................................86 Diagnostic Procedure ................................................87 TROUBLE DIAGNOSIS FOR VHCL SPEED SEN.A/T (REVOLUTION SENSOR) ..............................89 Description .................................................................89 Wiring Diagram - AT - VSSA/T ..................................91 Diagnostic Procedure ................................................92 Component Inspection ...............................................93 TROUBLE DIAGNOSIS FOR VHCL SPEED SEN.MTR .......................................................................95 Description .................................................................95 Wiring Diagram - AT - VSSMTR................................96 Diagnostic Procedure ................................................97 TROUBLE DIAGNOSIS FOR THROTTLE POSI SEN ................................................................................98 Description .................................................................98 Wiring Diagram - AT - TPS ......................................100 Diagnostic Procedure ..............................................101 Component Inspection .............................................105 TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V A ...................................................................................106 Description ...............................................................106 Wiring Diagram - AT - SSV/A ..................................108 Diagnostic Procedure ..............................................109 Component Inspection ............................................. 110 TROUBLE DIAGNOSIS FOR SHIFT SOLENOID/V B ................................................................................... 111 Description ............................................................... 111 Wiring Diagram - AT - SSV/B .................................. 113 Diagnostic Procedure .............................................. 114 Component Inspection ............................................. 115 TROUBLE DIAGNOSIS FOR OVERRUN CLUTCH S/V................................................................................ 116 Description ............................................................... 116 Wiring Diagram - AT - OVRCSV.............................. 117 Diagnostic Procedure .............................................. 118 Component Inspection ............................................. 119 TROUBLE DIAGNOSIS FOR T/C CLUTCH SOL/V ...120 Description ...............................................................120 Wiring Diagram - AT - TCV......................................122 Diagnostic Procedure ..............................................123 GI MA EM LC EC FE CL MT PD AX SU BR ST RS BT HA SC EL IDX

Component Inspection .............................................124 TROUBLE DIAGNOSIS FOR BATT/FLUID TEMP SEN ..............................................................................125 Description ...............................................................125 Wiring Diagram - AT - BA/FTS ................................127 Diagnostic Procedure ..............................................128 Component Inspection .............................................131 TROUBLE DIAGNOSIS FOR ENGINE SPEED SIG ..132 Description ...............................................................132 Wiring Diagram - AT - ENGSS ................................133 Diagnostic Procedure ..............................................134 TROUBLE DIAGNOSIS FOR LINE PRESSURE S/V................................................................................136 Description ...............................................................136 Wiring Diagram - AT - LPSV....................................138 Diagnostic Procedure ..............................................139 Component Inspection .............................................140 TROUBLE DIAGNOSIS FOR CONTROL UNIT (RAM), CONTROL UNIT (ROM) .................................142 Description ...............................................................142 Diagnostic Procedure ..............................................143 TROUBLE DIAGNOSIS FOR CONTROL UNIT (EEPROM)....................................................................144 Description ...............................................................144 Diagnostic Procedure ..............................................145 TROUBLE DIAGNOSES FOR SYMPTOMS ...............146 Wiring Diagram - AT - NONDTC .............................146 1. POWER Indicator Lamp Does Not Come On .....149 2. POWER or SNOW Indicator Lamp Does Not Come On .................................................................150 3. O/D OFF Indicator Lamp Does Not Come On....151 4. POWER Indicator Lamp Does Not Come On .....152 5. Engine Cannot Be Started In ″P″ and ″N″ Position ....................................................................153 6. In ″P″ Position, Vehicle Moves Forward Or Backward When Pushed .........................................154 7. In ″N″ Position, Vehicle Moves ...........................155 8. Large Shock. ″N″ -> ″R″ Position .......................157 9. Vehicle Does Not Creep Backward In ″R″ Position ....................................................................159 10. Vehicle Does Not Creep Forward In ″D″, ″2″ Or ″1″ Position .........................................................162 11. Vehicle Cannot Be Started From D 1 .................165 12. A/T Does Not Shift: D 1 -> D 2 Or Does Not Kickdown: D 4 -> D 2 ..................................................168 13. A/T Does Not Shift: D 2 -> D 3 .............................171 14. A/T Does Not Shift: D 3 -> D 4 .............................174 15. A/T Does Not Perform Lock-up .........................177 16. A/T Does Not Hold Lock-up Condition ..............179 17. Lock-up Is Not Released ...................................181 18. Engine Speed Does Not Return To Idle (Light Braking D 4 -> D 3 ).....................................................182 19. Vehicle Does Not Start From D 1 .......................184 20. A/T Does Not Shift: D 4 -> D 3 , When Overdrive Control Switch ″ON″ -> ″OFF″ ...............185 21. A/T Does Not Shift: D 3 -> 2 2 , When Selector Lever ″D″ -> ″2″ Position.........................................186 22. A/T Does Not Shift: 2 2 -> 1 1 , When Selector Lever ″2″ -> ″1″ Position .........................................187 23. Vehicle Does Not Decelerate By Engine Brake........................................................................188 24. TCM Self-diagnosis Does Not Activate (PNP, Overdrive Control, A/T Check and TP Switches Circuit Checks) ........................................................189 A/T SHIFT LOCK SYSTEM.........................................198 Description ...............................................................198 Wiring Diagram - SHIFT - ........................................199 Diagnostic Procedure ..............................................200 Component Check ...................................................202 KEY INTERLOCK CABLE ..........................................203 Removal ...................................................................203 Installation ................................................................203 SHIFT CONTROL SYSTEM ........................................204 Control Device .........................................................204 ON-VEHICLE SERVICE ..............................................205 Control Valve Assembly and Accumulators .............205 Revolution Sensor Replacement .............................205 Rear Oil Seal Replacement .....................................206 Parking Pawl Components Inspection.....................206 Park/Neutral Position Switch Adjustment ................206 Manual Control Linkage Adjustment........................207 REMOVAL AND INSTALLATION ...............................208 Removal ...................................................................208 Installation ................................................................209 OVERHAUL ................................................................. 211 Components............................................................. 211 Oil Channel ..............................................................213 Locations of Needle Bearings, Thrust Washers and Snap Rings .......................................................214 DISASSEMBLY............................................................215 REPAIR FOR COMPONENT PARTS .........................226 Oil Pump ..................................................................226 Control Valve Assembly ...........................................230 Control Valve Upper Body .......................................236 Control Valve Lower Body .......................................241 Reverse Clutch ........................................................243 High Clutch ..............................................................246 Forward and Overrun Clutches ...............................249 Low & Reverse Brake..............................................253 Forward Clutch Drum Assembly ..............................257 Rear Internal Gear and Forward Clutch Hub ..........259 Band Servo Piston Assembly ..................................262 Parking Pawl Components ......................................266 ASSEMBLY..................................................................268 CONTENTS (Cont’d) AT-2

Assembly (1) ............................................................268 Adjustment ...............................................................276 Assembly (2) ............................................................279 A/T FLUID COOLER SYSTEM ...................................286 A/T Fluid Cooler.......................................................286 SERVICE DATA AND SPECIFICATIONS (SDS) .......288 General Specifications .............................................288 Shift Schedule..........................................................288 Stall Revolution ........................................................288 Line Pressure...........................................................288 Return Springs .........................................................289 Accumulator O-ring ..................................................290 Clutches and Brakes ...............................................290 Oil Pump and Low One-way Clutch ........................292 Total End Play..........................................................292 Reverse Clutch Drum End Play ..............................293 Removal and Installation .........................................293 GI MA EM LC EC FE CL MT PD AX SU BR ST RS BT HA SC EL IDX CONTENTS (Cont’d) AT-3

Supplemental Restraint System (SRS) “AIR BAG” NMAT0253 The Supplemental Restraint System such as “AIR BAG” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composi- tion which is available to NISSAN MODEL S15 is as follows: The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. Information necessary to service the system safely is included in the RS section of this Service Manual. WARNING: I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance should be per- formed by an authorized NISSAN dealer. I Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section. I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified with yellow harness connector. SEF289H Precautions NMAT0003 I Before connecting or disconnecting the TCM harness connector, turn ignition switch “OFF” and disconnect negative battery terminal. Failure to do so may damage the TCM. Because battery voltage is applied to TCM even if ignition switch is turned “OFF”. AAT470A I When connecting or disconnecting pin connectors into or from TCM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on TCM pin terminal, when connecting pin connectors. MEF040DA I Before replacing TCM, perform TCM input/output signal inspection and make sure whether TCM functions properly or not. (Refer to AT-82.) PRECAUTIONS Supplemental Restraint System (SRS) “AIR BAG” AT-4

I Before proceeding with disassembly, thoroughly clean the out- side of the transmission. It is important to prevent the internal parts from becoming contaminated by dirt or other foreign mat- ter. I 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. I Place disassembled parts in order for easier and proper assembly. I All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. I Gaskets, seals and O-rings should be replaced any time the transmission is disassembled. I It is very important to perform functional tests whenever they are indicated. I 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. I 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. I 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. I 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. Always follow the procedures when changing A/T fluid. Refer to “Changing A/T Fluid”, AT-9. Service Notice or Precautions NMAT0004 FAIL-SAFE NMAT0004S01 The TCM has an electronic Fail-Safe (limp home mode). This allows the vehicle to be driven even if a major electrical input/output device circuit is damaged. Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2” or “D”. The customer may complain of sluggish or poor acceleration. When the ignition key is turned “ON” following Fail-Safe operation, POWER indicator lamp blinks for about 8 seconds. [For “SELF-DIAGNOSTIC PROCEDURE (Without CONSULT-II)”, refer toAT-37.] The blinking of the POWER indicator lamp for about 8 seconds will appear only once and be cleared. The customer may resume normal driving conditions. Always follow the “WORK FLOW” (Refer to AT-46). GI MA EM LC EC FE CL MT PD AX SU BR ST RS BT HA SC EL IDX PRECAUTIONS Precautions (Cont’d) AT-5

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Nissan 200SX S15 Service & Repair Manual

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