What are the most common Nissan 240SX problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 1991 Nissan 240SX has 14 documented issues. The most frequently reported are: Frame Rail and Strut Tower Rust Corrosion, KA24DE Timing Chain Guide Delamination and Rattle ('Rattle of Death'), Rear Subframe and Strut Tower Rust. Of these, 5 are rated critical and should be addressed promptly.
Is the Nissan 240SX reliable?
The 1991 Nissan 240SX has 14 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 5 issues are rated critical: Frame Rail and Strut Tower Rust Corrosion and KA24DE Timing Chain Guide Delamination and Rattle ('Rattle of Death') and Rear Subframe and Strut Tower Rust and Structural Rust: Rear Subframe Mounts, Front Frame Rails, and Floor Pans and KA24DE Timing Chain Guide Wear and Rattle. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Nissan 240SX problems?
Repair costs for known Nissan 240SX issues range from $30 to $3,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Frame Rail and Strut Tower Rust Corrosion, typically costs $400-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 1989-1998 Nissan 240SX Frame Rail and Strut Tower Rust Corrosion?
S13 and S14 chassis are highly prone to rust at the frame rails, particularly where the front strut towers meet the frame rails, and at the rear subframe mounting points. Salt-belt cars frequently show structural corrosion that compromises suspension geometry and crash safety. Ru… Repairs typically run $400-$3,500. Severity: high.
What is the 1991-1998 Nissan 240SX KA24DE Timing Chain Guide Delamination and Rattle ('Rattle of Death')?
The KA24DE's upper plastic timing chain guides delaminate and break with age, causing a loud rattle particularly at cold start. Broken guide fragments can be sucked into the oil pickup causing oil pressure loss, or wedge into cam gears. If the chain jumps timing, this interferenc… Repairs typically run $600-$1,800. Severity: high.
What is the 1990-1998 Nissan 240SX Rear Subframe and Strut Tower Rust?
The 240SX's rear subframe and strut towers corrode severely in rust-belt states. The rear subframe mounting points can rot to the point where the subframe separates from the unibody — an extremely dangerous condition. Rear strut towers also develop cracks and perforation from rus… Repairs typically run $200-$2,000. Severity: high.
What is the 1990-1998 Nissan 240SX Structural Rust: Rear Subframe Mounts, Front Frame Rails, and Floor Pans?
The S13/S14 unibody rusts in structurally critical, often-hidden areas: the rear subframe mounting points, the front frame rails near the tension-rod (front lower control arm) pickups, and the floor pans. Water and road salt collect in these boxed sections and behind the fuel/bra… Repairs typically run $300-$3,500. Severity: high.
What is the 1991-1998 Nissan 240SX KA24DE Timing Chain Guide Wear and Rattle?
The KA24DE engine in the 240SX uses a single timing chain with plastic-backed guides that wear and crack over time. As the guides deteriorate, the chain develops excessive slack, causing a distinctive rattle on cold start and eventually leading to jumped timing if left unaddresse… Repairs typically run $400-$1,200. Severity: high.
What is the 1990-1998 Nissan 240SX Body and Chassis Rust (Fenders, Quarter Panels, Hatch)?
The Nissan 240SX is highly susceptible to body rust, particularly in the rear quarter panels, rear fender wells, door bottoms, rear hatch/trunk area, and rocker panels. The S13 (1989-1994) is more rust-prone than the S14 (1995-1998) due to thinner body panels and less corrosion p… Repairs typically run $300-$3,000. Severity: medium.
What is the 1991-1998 Nissan 240SX Distributor / Cam Angle Sensor Failure and Internal Oil Leak (KA24DE)?
The KA24DE uses a camshaft-driven distributor that houses the optical Cam Angle Sensor (CAS) and the integral ignition module. Two age-related problems are common. First, the cap-to-distributor O-ring dries out, cracks, and lets oil weep out from under the cap; separately, a clog… Repairs typically run $30-$450. Severity: medium.
What is the 1991-1998 Nissan 240SX Distributor and Optical CAS Failure (Codes 11, 21)?
The KA24DE's distributor houses the optical crank angle sensor (CAS). The internal optical disc and bearings wear with age, causing intermittent or no-start conditions, often throwing ECU codes 11 (crank angle sensor) and 21 (ignition signal). The distributor O-ring also leaks oi… Repairs typically run $250-$700. Severity: medium.
What is the 1990-1998 Nissan 240SX Cooling System Age Failure: Cracked Plastic Overflow Tank and Radiator End Tanks?
The factory cooling system relies on aging plastic components. The plastic coolant overflow/reservoir tank grows brittle and cracks (a well-known S13 weak point), and the OEM radiator's plastic end tanks and crimp seams eventually seep or split. Both lead to gradual coolant loss… Repairs typically run $30-$400. Severity: medium.
What is the 1991-1998 Nissan 240SX Rear Main Seal and Valve Cover Oil Leaks?
The KA24DE engine in the 240SX is known for developing oil leaks from multiple locations as gaskets age. The rear main seal is the most problematic, leaking oil onto the clutch (manual trans) or flex plate (automatic). Valve cover gaskets also harden and leak, dripping oil onto t… Repairs typically run $200-$1,500. Severity: medium.
What is the 1990-1998 Nissan 240SX Mass Air Flow Sensor Failure / Limp-Mode Driveability?
The KA24DE (and KA24E) uses a hot-wire MAF that ages, corrodes at the connector, or loses its ground, causing erratic or dead airflow signal. When the ECU rejects the MAF signal it defaults to a fixed 'limp' fuel map: with the MAF unplugged the engine idles smoothly (but rich) an… Repairs typically run $50-$350. Severity: medium.
What is the 1991-1998 Nissan 240SX KA24DE Timing Chain Rattle / Upper Chain Guide Delamination?
The DOHC KA24DE's twin-cam timing chain system uses plastic-faced chain guides and an oil-pressure-fed hydraulic tensioner. With age and heat cycling the upper (and to a lesser extent lower) guides become brittle, delaminate, and shed plastic, and the tensioner can stick from oil… Repairs typically run $150-$1,200. Severity: medium.
What is the 1991-1998 Nissan 240SX KA24DE Valve Cover Gasket and Spark Tube Seal Oil Leaks?
The KA24DE valve cover gasket and spark plug tube seals become brittle from heat cycling and age, causing oil leaks. Oil can pool in spark plug tubes and seep onto plug wires/coil packs, causing misfires and ignition damage. The front timing cover also commonly weeps oil on high-… Repairs typically run $80-$350. Severity: low.
What is the 1990-1994 Nissan 240SX Pop-Up Headlight Motor and Link-Rod Failure (S13)?
The S13 240SX (1989-1994) uses electric pop-up headlights driven by a motor through a plastic link-rod assembly. Two age failures dominate: the small carbon motor brushes wear down and lose contact so the motor stalls or moves weakly, and the plastic link rod (Nissan PN 26034-40F… Repairs typically run $30-$300. Severity: low.
