NISSAN PICK-UP 1999 Repair Manual

2. Install main bearing cap to cylinder block.
lTighten all bolts in correct order in two or three stages.
Refer to EM-2038 and EM-2046.
3. Measure inner diameter ªAº of each main bearing.
4. Measure outer diameter ªDmº of each crankshaft main jour-
nal.
5. Calculate main bearing clearance.
Main bearing clearance=AþDm
Standard:
0.020 - 0.047 mm (0.0008 - 0.0019 in)
Limit:
0.1 mm (0.004 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing.
a. When grinding crankshaft journal, confirm that ªLº
dimension in fillet roll is more than the specified limit.
ªLº: 0.1 mm (0.004 in)
b. Refer to SDS, EM-2055 & EM-2056 for grinding crank-
shaftandavailable service parts.
8. If crankshaft is reused, measure main bearing clearance and
select thickness of main bearing.
If crankshaft or cylinder block is replaced, select thickness of
main bearings as follows:
a. Grade number of each cylinder block main journal is punched
on the respective cylinder block. These numbers are
punched in either Arabic or Roman numerals.
EEM119
AEM026
SEM964
EEM120
CYLINDER BLOCKKA24DE
Inspection (Cont'd)
EM-2043

b. Grade number of each crankshaft main journal is punched on
crankshaft. These numbers are punched in either Arabic or
Roman numerals.
c. Select main bearing with suitable thickness according to the
following example or table.
For example:
Main journal grade number: 1
Crankshaft journal grade number: 2
Main bearing grade number=1+2
= 3 (Yellow)
Main bearing grade number and identification color:
Main journal grade number
012
Crankshaft
journal grade
number0 0 (Black) 1 (Brown) 2 (Green)
1 or I 1 (Brown) 2 (Green) 3 (Yellow)
2 or II 2 (Green) 3 (Yellow) 4 (Blue)
Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
lTighten bolts to the specified torque.
3. Measure inner diameter ªCº of each bearing.
4. Measure outer diameter ªDpº of each crankshaft pin journal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance=CþDp:
Standard
0.010 - 0.035 mm (0.0004 - 0.0014 in)
Limit
0.09 mm (0.0035 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing. Refer to step 5 of ªBEARING CLEARANCEº, EM-2042.
8. If crankshaft is replaced, select connecting rod bearing
according to the following table.
Connecting rod bearing grade number:
These numbers are punched in either Arabic or Roman numer-
als.
Crank pin grade numberConnecting rod bearing
grade number
00
1orI 1
2orII 2
SEM272C
AEM027
AEM028
SEM567B
CYLINDER BLOCKKA24DE
Inspection (Cont'd)
EM-2044

Method B (Using plastigage)
CAUTION:
lDo not turn crankshaft or connecting rod while plasti-
gage is being inserted.
lWhen bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. Then
if excessive bearing clearance exists, use a thicker main
bearing or undersized bearing so that the specified bear-
ing clearance is obtained.
CONNECTING ROD BUSHING CLEARANCE (Small
end)
1. Measure inner diameter ªCº of bushing.
2. Measure outer diameter ªDpº of piston pin.
3. Calculate connecting rod bushing clearance.
CþDp=
0.005 - 0.017 mm (0.0002 - 0.0007 in) (Standard)
0.023 mm (0.0009 in) (Limit)
If out of specification, replace connecting rod assembly
and/or piston set with pin.
REPLACEMENT OF CONNECTING ROD BUSHING
(Small end)
1. Drive in small end bushing until it is flush with end surface of
rod.
Be sure to align the oil holes.
2. Ream the bushing until clearance with piston pin is within
specification.
Clearance between connecting rod bushing and pis-
ton pin:
0.005 - 0.017 mm (0.0002 - 0.0007 in)
FLYWHEEL/DRIVE PLATE RUNOUT
Runout (Total indicator reading):
Flywheel (M/T model)
Less than 0.15 mm (0.006 in)
Drive plate (A/T model)
Less than 0.15 mm (0.006 in)
CAUTION:
lBe careful not to damage the ring gear teeth.
lCheck the drive plate for deformation and cracks.
lDo not allow any magnetic materials to contact the ring
gear teeth.
lDo not resurface the flywheel. Replace as necessary.
Assembly
PISTON
1. Heat piston to 60 to 70ÉC (140 to 158ÉF) and assemble
piston, piston pin and connecting rod.
lAlign the direction of piston and connecting rod.
lNumbers stamped on connecting rod and cap corre-
spond to each cylinder.
lAfter assembly, make sure connecting rod swings
smoothly.
EM142
AEM332
SEM062A
AEM100
SEM262C
CYLINDER BLOCKKA24DE
Inspection (Cont'd)
EM-2045

2. Set piston rings as shown.
CAUTION:
lWhen piston rings are not replaced, make sure that pis-
ton rings are mounted in their original positions.
lWhen piston rings are being replaced and no punchmark
is present, piston rings can be mounted with either side
up.
3. Align piston rings so that end gaps are positioned as shown.
CRANKSHAFT
1. Set main bearings in their proper positions on cylinder block
and main bearing caps.
lConfirm that correct main bearings are used. Refer to
EM-2042.
lApply new engine oil to bearing surfaces.
2. Install crankshaft and main bearing caps and tighten bolts to
the specified torque. Refer to EM-2038.
lApply new engine oil to the bolt threads and seat sur-
face.
lPrior to tightening bearing cap bolts, place bearing cap
in its proper position by shifting crankshaft in the axial
direction.
lTighten bearing cap bolts gradually in two or three
stages. Start with center bearing and move outward as
shown in figure.
lAfter securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM215EB
SEM264C
SEM160B
SEM448C
EEM121
CYLINDER BLOCKKA24DE
Assembly (Cont'd)
EM-2046

3. Measure crankshaft end play.
Crankshaft end play:
Standard
0.05 - 0.18 mm (0.0020 - 0.0071 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace No. 3 bearing with a new one.
4. Install connecting rod bearings in connecting rods and con-
necting rod caps.
lConfirm that correct bearings are used.
Refer to EM-2044.
lInstall bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
lApply new engine oil to bearing surfaces, bolt threads
and seating surfaces.
5. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
lArrange so that front mark on piston head faces toward
front of engine.
lMake sure connecting rod does not scratch cylinder
wall.
lMake sure connecting rod bolts do not scratch crank-
shaft journals.
lApply new engine oil to piston rings and sliding surface
of piston.
b. Install connecting rod bearing caps.
Tighten connecting rod bearing cap nuts using the following
procedure.
Connecting rod bearing nut:
(1) Tighten to 14 to 16 Nzm
(1.4 to 1.6 kg-m, 10 to 12 ft-lb).
(2) Tighten bolts 60
+5
þ0degrees clockwise
with an angle wrench.
If an angle wrench is not available, tighten
them to 38 to 44 Nzm (3.9 to 4.5 kg-m, 28 to 33
ft-lb).
6. Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.2 - 0.4 mm (0.008 - 0.016 in)
Limit
0.6 mm (0.024 in)
If beyond the limit, replace connecting rod and/or crankshaft.
EEM122
SEM159B
SEM269CB
EEM123
EEM124
CYLINDER BLOCKKA24DE
Assembly (Cont'd)
EM-2047

REPLACING PILOT BUSHING
1. Remove pilot bushing.
2. Install pilot bushing.
SEM916AD
AEM402
CYLINDER BLOCKKA24DE
Assembly (Cont'd)
EM-2048

General Specifications
Cylinder arrangement In-line 4
Displacement cm
3(cu in) 2,389 (145.78)
Bore and stroke mm (in) 89 x 96 (3.50 x 3.78)
Valve arrangement DOHC
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
Number of main bearings 5
Compression ratio 9.2
COMPRESSION PRESSURE
Unit: kPa (bar, kg/cm2, psi)/300 rpm
Compression pressure
Standard 1,226 (12.26, 12.5, 178)
Minimum 1,030 (10.30, 10.5, 149)
Differential limit between
cylinders98 (0.98, 1.0, 14)
Inspection and Adjustment
CYLINDER HEADUnit: mm (in)
Standard Limit
Head surface distortionLess than
0.03 (0.0012)0.1 (0.004)
SEM519E
VALVEUnit: mm (in)
SEM188
Valve head diameter ªDº
Intake 36.5 - 36.7 (1.437 - 1.445)
Exhaust 31.2 - 31.4 (1.228 - 1.236)
Valve length ªLº
Intake101.02 - 102.65
(3.9772 - 4.0413)
Exhaust98.52 - 99.12
(3.8787 - 3.9024)
Valve stem diameter ªdº
Intake 6.965 - 6.980 (0.2742 - 0.2748)
Exhaust 6.945 - 6.960 (0.2734 - 0.2740)
Valve seat angle ªaº
Intake & Exhaust 45É15¢- 45É45¢
Valve margin ªTº
Intake 1.15 - 1.45 (0.0453 - 0.0571)
Exhaust 1.44 - 1.75 (0.0567 - 0.0689)
Valve margin ªTº limit More than 0.5 (0.020)
Valve stem end surface
grinding limitLess than 0.2 (0.008)
SERVICE DATA AND SPECIFICATIONS (SDS)KA24DE
EM-2049

Valve spring
Free height mm (in) 50.37 (1.9831)
Pressure
N (kg, lb) at height mm (in)
Standard418.0 (42.6, 93.9)
at 29.17 (1.1484)
Limit393.0 (40.1, 88.4)
at 29.17 (1.1484)
Out-of-square mm (in) Less than 2.2 (0.087)
Valve guideUnit: mm (in)
SEM301D
Standard Service
Valve guide
Outer
diameterIntake11.023 - 11.034
(0.4340 - 0.4344)11.223 - 11.234
(0.4418 - 0.4423)
Exhaust11.023 - 11.034
(0.4340 - 0.4344)11.223 - 11.234
(0.4418 - 0.4423)
Valve guide
Inner diam-
eter (Fin-
ished size)Intake 7.000 - 7.018 (0.2756 - 0.2763)
Exhaust 7.000 - 7.018 (0.2756 - 0.2763)
Cylinder head
valve guide
hole diameterIntake10.975 - 10.996
(0.4321 - 0.4329)11.175 - 11.196
(0.4400 - 0.4408)
Exhaust10.975 - 10.996
(0.4321 - 0.4329)11.175 - 11.196
(0.4400 - 0.4408)
Interference fit of valve
guide0.027 - 0.059 (0.0011 - 0.0023)
Standard Limit
Stem to guide
clearanceIntake0.020 - 0.053
(0.0008 - 0.0021)0.08 (0.0031)
Exhaust0.040 - 0.073
(0.0016 - 0.0029)0.1 (0.004)
Valve deflection limit 0.2 (0.008)
Projection length ªLº 13.3 - 13.9 (0.524 - 0.547)
Valve lifterUnit: mm (in)
Valve lifter outer diameter33.960 - 33.975
(1.3370 - 1.3376)
Lifter guide inner diameter34.000 - 34.021
(1.3386 - 1.3394)
Clearance between lifter and filter guide0.025 - 0.061
(0.0010 - 0.0024)
Valve clearance adjustmentUnit: mm (in)
Valve clearance (Hot)
Intake 0.31 - 0.39 (0.012 - 0.015)
Exhaust 0.33 - 0.41 (0.013 - 0.016)
Available shims
Thickness mm (in) Identification mark
1.96 (0.0772) 196
1.98 (0.0780) 198
2.00 (0.0787) 200
2.02 (0.0795) 202
2.04 (0.0803) 204
2.06 (0.0811) 206
2.08 (0.0819) 208
2.10 (0.0827) 210
2.12 (0.0835) 212
2.14 (0.0843) 214
2.16 (0.0850) 216
2.18 (0.0858) 218
2.20 (0.0866) 220
2.22 (0.0874) 222
2.24 (0.0882) 224
2.26 (0.0890) 226
2.28 (0.0898) 228
2.30 (0.0906) 230
2.32 (0.0913) 232
2.34 (0.0921) 234
2.36 (0.0929) 236
2.38 (0.0937) 238
2.40 (0.0945) 240
2.42 (0.0953) 242
2.44 (0.0961) 244
2.46 (0.0969) 246
2.48 (0.0976) 248
2.50 (0.0984) 250
2.52 (0.0992) 252
2.54 (0.1000) 254
2.56 (0.1008) 256
2.58 (0.1016) 258
2.60 (0.1024) 260
2.62 (0.1031) 262
2.64 (0.1039) 264
2.66 (0.1047) 266
2.68 (0.1055) 268
SEM308D
SERVICE DATA AND SPECIFICATIONS (SDS)KA24DE
Inspection and Adjustment (Cont'd)
EM-2050

Valve seatUnit: mm (in)
AEM456
SEM621F
Standard Service
Cylinder head seat recess diameter (D)In. 37.500 - 37.516 (1.4764 - 1.4770) 38.000 - 38.016 (1.4961 - 1.4967)
Ex. 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)
Valve seat interference fitIn. 0.064 - 0.096 (0.0025 - 0.0038)
Ex. 0.064 - 0.096 (0.0025 - 0.0038)
Valve seat outer diameter (d)In. 37.580 - 37.596 (1.4795 - 1.4802) 38.080 - 38.096 (1.4992 - 1.4998)
Ex. 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)
Depth (H)In. 6.1 - 6.3 (0.240 - 0.248)
Ex. 6.1 - 6.3 (0.240 - 0.248)
Height (h
1)In. 5.8 - 6.0 (0.228 - 0.236) 5.3 - 5.5 (0.209 - 0.217)
Ex. 5.9 - 6.0 (0.232 - 0.236) 5.32 - 5.42 (0.209 - 0.213)
Height (h
2)In. 0.24 - 0.64 (0.0094 - 0.0252)
Ex. 0.43 - 0.73 (0.0169 - 0.0287)
Depth (L)In. 42.02 - 42.52
Ex. 42.03 - 42.53
SERVICE DATA AND SPECIFICATIONS (SDS)KA24DE
Inspection and Adjustment (Cont'd)
EM-2051

CYLINDER BLOCK
SEM400E
Unit: mm (in)
Standard Limit
DistortionÐ 0.1 (0.004)
Cylinder boreInner diameterGrade 1 89.000 - 89.010 (3.5039 - 3.5043)
0.2 (0.008)* Grade 2 89.010 - 89.020 (3.5043 - 3.5047)
Grade 3 89.020 - 89.030 (3.5047 - 3.5051)
Out-of-round (X þ Y) Less than 0.015 (0.0006) Ð
Taper (A þ B) Less than 0.010 (0.0004) Ð
Difference in inner diameter between cylinders Less than 0.03 (0.0012) 0.2 (0.008)
Piston-to-cylinder clearance 0.020 - 0.040 (0.0008 - 0.0016) Ð
Cylinder block height
(From crankshaft center)246.95 - 247.05 (9.7224 - 9.7264) 0.2 (0.008)**
* Wear limit
** Total amount of cylinder head resurfacing and cylinder block resurfacing
SERVICE DATA AND SPECIFICATIONS (SDS)KA24DE
Inspection and Adjustment (Cont'd)
EM-2052