#### OVERHAUL AND STRUT CARTRIDGE REPLACEMENT

CAUTION
The coil springs are under considerable tension, and can exert enough force to cause serious injury. Disassemble the struts only using the proper tools, and use extreme caution.

Coil springs on all models must be removed with the aid of a coil spring compressor. If you don't have one, don't try to improvise by using something else: you could risk injury.

Always follow manufacturer's instructions when operating a spring compressor. You can now buy cartridge type shock absorbers for many Datsun/Nissan: installation procedures are not the same as those given here. In this case, follow the instructions that come with the shock absorbers.

To remove the coil spring, you must first remove the strut assembly from the vehicle. See above for procedures.

1. Secure the strut assembly in a vise.
2. Attach the spring compressor to the spring, leaving the top few coils free.

   Fig. 1: Spring and strut assembly — 200SX

   Fig. 2: Spring and strut disassembly

   Fig. 3: Spring and strut disassembly

   Fig. 4: Spring and strut disassembly

   Fig. 5: Spring and strut disassembly

   Fig. 6: Spring and strut disassembly

   Fig. 7: Spring and strut disassembly

   Fig. 8: Spring and strut disassembly

3. Remove the dust cap from the top of the strut to expose the center nut, if a dust cap is provided.
4. Compress the spring just far enough to permit the strut insulator to be turned by hand. Remove the self locking center nut.
5. Take out the strut insulator, strut bearing, oil seal, upper spring seat and bound bumper rubber from the top of the strut. Note their sequence of removal and be sure to assemble them in the same order.
6. Remove the spring with the spring compressor still attached.
7. Reassembly the strut assembly and observe the following:
   1. Make sure you assemble the unit with the shock absorber piston rod fully extended.
   2. When assembling, take care that the rubber spring seats, both top and bottom, and the spring are positioned in their grooves before releasing the spring.
8. To remove the shock absorber: Remove the dust cap, if so equipped, and push the piston rod down until it bottoms. With the piston in this position, loosen and remove the gland packing shock absorber retainer. This calls for Datsun/ Nissan Special Tool ST35490000 or equivalent tool J26083.

   NOTE: If the gland tube is dirty, clean it before removing it to prevent dirt from contaminating the fluid inside the strut tube.

9. Remove the O-ring from the top of the piston rod guide and lift out the piston rod together with the cylinder. Drain all of the fluid from the strut and shock components into a suitable container. Clean all parts.

   NOTE: The piston rod, piston rod guide and cylinder are a matched set: single parts of this shock assembly should not be exchanged with parts of other assemblies.

10. Assembly the shock absorber into the assembly with the following notes:
    1. After installing the cylinder and piston rod assembly (the shock absorber kit) in the outer casing, remove the piston rod guide, if so equipped, from the cylinder and pour the correct amount of new fluid into the cylinder and strut outer casing. To find this amount consult the instructions with your shock absorber kit. The amount of oil should be listed. Use only Nissan Genuine Strut Oil or its equivalent.

       NOTE: It is important that the correct amount of fluid be poured into the strut to assure correct shock absorber damping force.

    2. Install the O-ring, fluid and any other cylinder components. Fit the gland packing and tighten it after greasing the gland packing-to-piston rod mating surfaces.

       NOTE: When tightening the gland packing, extend the piston rod about 3–5 in. (76–127mm) from the end of the outer casing to expel most of the air from the strut.

    3. After the kit is installed, bleed the air from the system in the following manner: hold the strut with its bottom end facing down. Pull the piston rod out as far as it will go. Turn the strut upside down and push the piston in as far as it will go. Repeat this procedure several times until an equal pressure is felt on both the pull out and the push in strokes of the piston rods. The remaining assembly is the reverse of disassembly.