Nissan KA24DE/ZD30DD Engines Service & Repair Manual
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EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION
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ENGINE MECHANICAL
KA24DE
PRECAUTIONS ......................................................... 5
Precautions for Drain Coolant ................................. 5
Precautions for Disconnecting Fuel Piping ............. 5
Precautions for Removal and Disassembly ............ 5
Precautions for Inspection, Repair and Replace-
ment ........................................................................ 5
Precautions for Assembly and Installation .............. 5
Parts Requiring Angular Tightening ........................ 5
Precautions for Liquid Gasket ................................. 6
REMOVAL OF LIQUID GASKET SEALING ......... 6
LIQUID GASKET APPLICATION PROCEDURE ..... 6
PREPARATION .......................................................... 7
Special Service Tools .............................................. 7
Commercial Service Tools ....................................... 8
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................. 10
NVH Troubleshooting —Engine Noise .................. 10
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 11
ENGINE ROOM COVER ......................................... 12
Removal and Installation of Engine Room Right
Side ....................................................................... 12
REMOVAL .......................................................... 12
INSTALLTION .................................................... 12
Removal and Installation of Engine Room Rear
Cover ..................................................................... 12
REMOVAL .......................................................... 12
INSTALLATION .................................................. 13
DRIVE BELTS .......................................................... 14
Checking Drive Belts ............................................. 14
Tension Adjustment ............................................... 14
POWER STEERING PUMP BELT ..................... 14
AIR CONDITIONER COMPRESSOR BELT ...... 14
ALTERNATOR AND WATER PUMP BELT ........ 15
Removal and Installation ....................................... 15
REMOVAL .......................................................... 15
INSTALLATION .................................................. 15
AIR CLEANER AND AIR DUCT .............................. 16
Removal and Installation ....................................... 16
REMOVAL .......................................................... 16
INSTALLATION .................................................. 17
Changing Air Cleaner Element .............................. 18
REMOVAL .......................................................... 18
INSTALLATION .................................................. 18
THROTTLE BODY ................................................... 19
Removal and Installation ....................................... 19
REMOVAL .......................................................... 19
INSPECTION AFTER REMOVAL ...................... 20
INSTALLATION .................................................. 20
Disassembly and Assembly ................................... 20
DISASSEMBLY .................................................. 20
ASSEMBLY ........................................................ 20
INTAKE MANIFOLD ................................................ 21
Removal and Installation ....................................... 21
REMOVAL .......................................................... 21
INSPECTION AFTER REMOVAL ...................... 22
INSTALLATION .................................................. 22
EXHAUST MANIFOLD ............................................ 23
Removal and Installation ....................................... 23
REMOVAL .......................................................... 23
INSPECTION AFTER REMOVAL ...................... 24
INSTALLATION .................................................. 24
INSPECTION AFTER INSTALLATION ............... 24
OIL PAN AND OIL STRAINER ................................ 25
Removal and Installation ....................................... 25
REMOVAL .......................................................... 25
INSPECTION AFTER REMOVAL ...................... 25
INSTALLATION .................................................. 25
INSPECTION AFTER INSTALLATION ............... 26
SPARK PLUG (CONVENTIONAL) .......................... 27
Removal and Installation ....................................... 27
REMOVAL .......................................................... 27
INSPECTION AFTER REMOVAL ...................... 27
INSTALLATION .................................................. 27
FUEL INJECTOR AND FUEL TUBE ....................... 28
Removal and Installation ....................................... 28
REMOVAL .......................................................... 28
INSTALLATION .................................................. 29
INSPECTION AFTER INSTALLATION ............... 29
EM-2
ROCKER COVER .................................................... 30
Removal and Installation ....................................... 30
REMOVAL .......................................................... 30
INSTALLATION ................................................... 30
CAMSHAFT .............................................................. 32
Removal and Installation ....................................... 32
REMOVAL .......................................................... 32
INSTALLATION ................................................... 34
INSPECTION AFTER REMOVAL ....................... 35
Valve Clearance ..................................................... 38
INSPECTION ...................................................... 38
ADJUSTMENT ................................................... 38
SECONDARY TIMING CHAIN ................................. 41
Removal and Installation ....................................... 41
REMOVAL .......................................................... 41
INSPECTION AFTER REMOVAL ....................... 44
INSTALLATION ................................................... 45
PRIMARY TIMING CHAIN ....................................... 49
Removal and Installation ....................................... 49
REMOVAL .......................................................... 50
INSPECTION AFTER REMOVAL ....................... 51
INSTALLATION ................................................... 51
CYLINDER HEAD .................................................... 55
On-Vehicle Service ................................................ 55
CHECKING COMPRESSION PRESSURE ........ 55
Removal and Installation ....................................... 56
REMOVAL AND INSTALLATION ........................ 56
Disassembly and Assembly ................................... 57
DISASSEMBLY .................................................. 57
ASSEMBLY ........................................................ 58
INSPECTION AFTER DISASSEMBLY ............... 58
ENGINE ASSEMBLY ............................................... 63
Removal and Installation ....................................... 63
REMOVAL .......................................................... 64
INSTALLATION ................................................... 65
INSPECTION AFTER INSTALLATION ............... 66
CYLINDER BLOCK .................................................. 67
Disassembly and Assembly ................................... 67
DISASSEMBLY .................................................. 68
ASSEMBLY ........................................................ 70
How to Select Piston and Bearing ......................... 74
DESCRIPTION ................................................... 74
HOW TO SELECT PISTON ................................ 75
HOW TO SELECT CONNECTING ROD BEAR-
ING ..................................................................... 75
HOW TO SELECT MAIN BEARING ................... 76
Inspection After Disassembly ................................ 78
CRANKSHAFT SIDE CLEARANCE ................... 78
CONNECTING ROD SIDE CLEARANCE .......... 78
PISTON AND PISTON PIN CLEARANCE ......... 78
PISTON RING SIDE CLEARANCE .................... 79
PISTON RING END GAP ................................... 79
CONNECTING ROD BEND AND TORSION ...... 80
CONNECTING ROD BEARING (BIG END) ....... 80
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) .......................................... 80
CYLINDER BLOCK DISTORTION ..................... 81
INNER DIAMETER OF MAIN BEARING HOUS-
ING ...................................................................... 81
PISTON TO CYLINDER BORE CLEARANCE ...82
OUTER DIAMETER OF CRANKSHAFT JOUR-
NAL ..................................................................... 83
OUTER DIAMETER OF CRANKSHAFT PIN ..... 83
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ................................................................ 83
CRANKSHAFT RUNOUT ................................... 83
OIL CLEARANCE OF CONNECTING ROD
BEARING ............................................................ 84
OIL CLEARANCE OF MAIN BEARING .............. 84
CRUSH HEIGHT OF MAIN BEARING ............... 85
OIL JET ............................................................... 85
OIL JET RELIEF VALVE ..................................... 85
FLY WHEEL RUNOUT ....................................... 86
SERVICE DATA AND SPECIFICATIONS (SDS) ..... 87
Standard and Limit ................................................. 87
GENERAL SPECIFICATIONS ............................ 87
DRIVE BELTS ..................................................... 87
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................. 87
SPARK PLUG ..................................................... 88
SECONDARY TIMING CHAIN ........................... 88
CYLINDER HEAD ............................................... 88
VALVE ................................................................. 88
CAMSHAFT AND CAMSHAFT BEARING .......... 92
CYLINDER BLOCK ............................................. 92
PISTON, PISTON RING AND PISTON PIN ....... 93
CONNECTING ROD ........................................... 94
CRANKSHAFT .................................................... 94
MAIN BEARING .................................................. 95
CONNECTING ROD BEARING .......................... 95
FLYWHEEL ......................................................... 96
Tightening Torque .................................................. 96
ZD30DD
PRECAUTIONS ........................................................ 98
Precautions for Drain Coolant ................................ 98
Precautions for Disconnecting Fuel Piping ............ 98
Precautions for Removal and Disassembly ........... 98
Precautions for Inspection, Repair and Replace-
ment ....................................................................... 98
Precautions for Assembly and Installation ............. 98
Parts Requiring Angular Tightening ....................... 98
Precautions for Liquid Gasket ................................ 99
REMOVAL OF LIQUID GASKET SEALING ....... 99
LIQUID GASKET APPLICATION PROCEDURE...99
PREPARATION ...................................................... 100
Special Service Tools ........................................... 100
Commercial Service Tools ................................... 102
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ........................................... 103
NVH Troubleshooting —Engine Noise ................. 103
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 104
ENGINE ROOM COVER ........................................ 105
Removal and Installation of Engine Room Right
EM-3
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Side ..................................................................... 105
REMOVAL ........................................................ 105
INSTALLATION ................................................ 105
Removal and Installation of Engine Room Rear
Cover ................................................................... 105
REMOVAL ........................................................ 105
INSTALLATION ................................................ 106
DRIVE BELTS ........................................................ 107
Checking Drive Belt ............................................. 107
Tension Adjustment ............................................. 107
Removal and Installation ..................................... 107
WATER PUMP, ALTERNATOR AND A/C COM-
PRESSOR BELT .............................................. 107
Drive Belt Auto Tensioner .................................... 109
REMOVAL ........................................................ 109
INSPECTION AFTER REMOVAL .................... 109
INSTALLATION ................................................ 109
Dummy Pulley ..................................................... 109
REMOVAL ........................................................ 109
INSPECTION AFTER REMOVAL .................... 109
INSTALLATION ................................................ 109
AIR CLEANER AND AIR DUCT ............................. 110
Removal and Installation ...................................... 110
REMOVAL ......................................................... 110
INSTALLATION ................................................. 111
Changing Air Cleaner Element ............................. 112
REMOVAL ......................................................... 112
INSTALLATION ................................................. 112
INTAKE MANIFOLD COLLECTOR AND INTAKE
MANIFOLD ............................................................. 113
Removal and Installation ...................................... 113
REMOVAL ......................................................... 113
INSPECTION AFTER REMOVAL ..................... 115
INSTALLATION ................................................. 115
EXHAUST MANIFOLD ........................................... 117
Removal and Installation ...................................... 117
REMOVAL ......................................................... 117
INSPECTION AFTER REMOVAL ..................... 118
INSTALLATION ................................................. 118
INSPECTION AFTER INSTALLATION ............. 118
OIL PAN AND OIL STRAINER ............................... 119
Removal and Installation ...................................... 119
REMOVAL ......................................................... 119
INSTALLATION ................................................ 120
INSPECTION AFTER INSTALLATION ............ 120
GLOW PLUG ......................................................... 121
Removal and Installation ..................................... 121
REMOVAL ........................................................ 121
INSTALLATION ................................................ 122
VACUUM PUMP .................................................... 123
Removal and Installation ..................................... 123
REMOVAL ........................................................ 123
INSTALLATION ................................................ 123
INSPECTION AFTER INSTALLATION ............ 123
INJECTION TUBE AND INJECTION NOZZLE ..... 125
Removal and Installation ..................................... 125
REMOVAL ........................................................ 125
INSPECTION AFTER REMOVAL .................... 127
INSTALLATION ................................................ 127
INSPECTION AFTER INSTALLATION ............. 128
ELECTRONICCONTROLFUELINJECTIONPUMP . 129
Removal and Installation ..................................... 129
REMOVAL ........................................................ 129
INSTALLATION ................................................ 132
INSPECTION AFTER INSTALLATION ............. 134
ROCKER COVER .................................................. 135
Removal and Installation ..................................... 135
REMOVAL ........................................................ 135
INSTALLATION ................................................ 136
CAMSHAFT ........................................................... 138
Removal and Installation ..................................... 138
REMOVAL ........................................................ 139
INSPECTION AFTER REMOVAL .................... 139
INSTALLATION ................................................ 141
Valve Clearance .................................................. 142
INSPECTION ................................................... 142
ADJUSTMENTS ............................................... 144
TIMING CHAIN ....................................................... 147
Removal and Installation ..................................... 147
REMOVAL ........................................................ 147
INSPECTION AFTER REMOVAL .................... 149
INSTALLATION ................................................ 149
TIMING GEAR ........................................................ 151
Removal and Installation ..................................... 151
REMOVAL ........................................................ 152
INSPECTION AFTER REMOVAL .................... 155
INSTALLATION ................................................ 157
CYLINDER HEAD .................................................. 160
On-Vehicle Service .............................................. 160
CHECKING COMPRESSION PRESSURE ...... 160
Removal and Installation ..................................... 161
REMOVAL ........................................................ 161
INSPECTION AFTER REMOVAL .................... 162
INSTALLATION ................................................ 163
Disassembly and Assembly ................................. 166
DISASSEMBLY ................................................ 166
ASSEMBLY ...................................................... 167
INSPECTION AFTER DISASSEMBLY ............. 167
ENGINE ASSEMBLY ............................................. 172
Removal and Installation ..................................... 172
REMOVAL ........................................................ 172
INSTALLATION ................................................ 174
INSPECTION AFTER INSTALLATION ............. 175
CYLINDER BLOCK ............................................... 176
Disassembly and Assembly ................................. 176
DISASSEMBLY ................................................ 177
ASSEMBLY ...................................................... 181
How to Select Piston ........................................... 184
DESCRIPTION ................................................. 184
SELECTIVE PISTON COMBINATION ............. 184
INSPECTION AFTER DISASSEMBLY ............. 185
EM-4
SERVICE DATA AND SPECIFICATIONS (SDS) ...194
Standard and Limit ............................................... 194
GENERAL SPECIFICATIONS .......................... 194
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ................................................................ 194
DRIVE BELTS .................................................. 194
CYLINDER HEAD ............................................ 195
VALVE ............................................................... 195
CAMSHAFT AND CAMSHAFT BEARING ....... 199
CYLINDER BLOCK ........................................... 199
PISTON, PISTON RING AND PISTON PIN ..... 200
CONNECTING ROD ......................................... 201
CRANKSHAFT .................................................. 201
AVAILABLE MAIN BEARING ............................ 202
AVAILABLE CONNECTING ROD BEARING .... 202
MISCELLANEOUS COMPONENTS ................. 202
Tightening torque ................................................. 203
PRECAUTIONS
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[KA24DE]
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PRECAUTIONS PFP:00001
Precautions for Drain Coolant EBS007JS
● Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping EBS007JT
● Before starting work, make sure no fire or spark producing items are in the work area.
● Release fuel pressure before disassembly.
● After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and Disassembly EBS007JU
● When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.
● Exercise maximum care to avoid damage to mating or sliding surfaces.
● Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
● When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement EBS007JV
● Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
and replace if necessary.
Precautions for Assembly and Installation EBS007JW
● Use torque wrench to tighten bolts or nuts.
● When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.
● Replace with new gasket, packing, oil seal or O-ring.
● Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
● Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
● Release air within route after draining coolant.
● After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
Parts Requiring Angular Tightening EBS007JX
● Use an angle wrench for the final tightening of the following engine parts:
– Cylinder head bolts
– Connecting rod cap nuts
● Do not use a torque value for final tightening.
● The torque value for these parts are for a preliminary step.
● Ensure thread and seat surfaces are clean and coated with engine oil.
EM-6
[KA24DE]
PRECAUTIONS
Precautions for Liquid Gasket EBS007JY
REMOVAL OF LIQUID GASKET SEALING
● After removing the mounting bolts and nuts, disconnect and
remove the liquid gasket sealing using a seal cutter.
CAUTION:
Be careful not to damage the mating surfaces.
● In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
● If there is a groove for the liquid gasket application, apply the
gasket to the groove.
● As for the bolt holes, normally apply the gasket inside the holes.
Occasionally, it should be applied outside the holes. Make sure
to read the text of service manual.
● Within five minutes of gasket application, install the mating com-
ponent.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe them.
PBIC0275E
PBIC0003E
EMA0622D
PREPARATION
EM-7
[KA24DE]
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PREPARATION PFP:00002
Special Service Tools EBS007JZ
Tool number
Tool name
Description
KV10111100
Seal cutter
Removing steel oil pan and rear timing chain
case
KV10117100
Heated oxygen sensor wrench
Loosening or tightening heated oxygen
sensors with 22 mm (0.87 in) hexagon nut
KV10105800
Timing chain stopper
Removing and installing idler sproket
KV101151S0
Lifter stopper set
1 KV10115120
Lifter stopper
2 KV10115110
Camshaft pliers
Changing valve lifter shims
KV10112100
Angle wrench
Tightening bolts for bearing cap, cylinder
head, etc.
KV10116200
Valve spring compressor
KV10111200
Adapter
Disassembling and assembling valve
components
KV10116100
Valve oil seal puller
Removing valve oil seal
ZZA0013D
ZZA1007D
ZZA1006D
ZZA0103D
ZZA0120D
ZZA0993D
ZZA0015D
EM-8
[KA24DE]
PREPARATION
Commercial Service Tools EBS007K0
KV10116300
Valve oil seal drift
Installing valve oil seal
a: 25 mm (0.98 in) dia.
b: 14.4 mm (0.567 in) dia.
c: 11.8 mm (0.465 in) dia.
d: 10 mm (0.39 in) dia.
e: 11 mm (0.43 in)
f: 9 mm (0.35 in)
ST0501S000
Engine stand assembly
Engine overhaul
KV10105001
Engine attachment
ST16610001
Pilot bushing puller
Removing crankshaft pilot bushing
(M/T model only)
KV10114700
Main bearing cap remover
EM03470000
Piston ring compressor
Installing piston assembly into cylinder bore
WS39930000
Tube presser
Pressing the tube of liquid gasket
Tool number
Tool name
Description
NT602
ZZA0022D
ZZA1061D
ZZA0046D
ZZA0023D
S-NT044
S-NT052
PREPARATION
EM-9
[KA24DE]
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Tool number
Tool name Description
Quick connector release Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of PARTS
CATALOG: Part No. 16441 6N210)
Spark plug wrench Removing and installing spark plug
Valve seat cutter set Finishing valve seat dimensions
Piston ring expander Removing and installing piston ring
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 109.5 mm (0.413 in) dia.
b: 6.6 mm (0.260 in) dia.
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
d1 : 7.0 mm (0.276 in) dia.
d2 : 11.175 mm (0.440 in) dia.
Rear oil seal drift Installing rear oil seal
PBIC0198E
S-NT047
S-NT048
S-NT030
S-NT015
S-NT016
ZZA0025D
EM-10
[KA24DE]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting —Engine Noise EBS007K1
PBIC0192E
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Fast Download Speeds
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Full Search Facility
Print one or all pages of your manual
$46.99
$61.99
Nissan KA24DE/ZD30DD Engines Service & Repair Manual
Models covered:
- Nissan KA24DE
- Nissan ZD30DD
Vehicles with KA24DE engine:
- Nissan 240SX (1989-1998)
- Nissan Altima (1993-2001)
- Nissan Frontier (1998-2004)
- Nissan Xterra (2000-2004)
- Nissan Serena (1993-2001)
- Nissan Bluebird U14 (1996-1998)
- Nissan Avenir W11 (1998-2000)
- Nissan R'nessa N30 (1997-2001)
Vehicles with ZD30DD engine:
- Nissan Caravan (1999-2012)
- Nissan Elgrand (1999-2002)
- Nissan Navara (1999-2004)
- Nissan Pathfinder (1995-2004)
- Nissan Patrol (1999-2013)
- Nissan Terrano II (1999-2006)
This service and repair manual for Nissan KA24DE and ZD30DD engines provides detailed technical instructions for maintenance, troubleshooting, and mechanical repairs. Designed to meet factory specifications, it includes step-by-step procedures, factory-recommended service intervals, and diagnostic techniques to ensure efficient engine performance.
The manual covers essential systems, including the fuel injection system, cooling system, lubrication, ignition, and timing. It also features factory-authorized wiring diagrams, torque settings, and exploded parts views, making it ideal for both routine maintenance and more complex repairs on KA24DE and ZD30DD engines.
Available in digital format, this manual can be accessed on computers and mobile devices, offering convenience for both workshop and field use. Whether you’re a professional mechanic or a hands-on owner, this comprehensive guide is a valuable resource for keeping your Nissan KA24DE or ZD30DD engine running reliably in demanding conditions.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
