24L Four
24L Four
24L Four
1990 ENGINES
Nissan 2.4L 4-Cylinder
Axxess, Pickup, Stanza, 240SX
ENGINE IDENTIFICATION
Engine identification number is stamped on left side of
cylinder block between exhaust manifold runners.
ENGINE IDENTIFICATION CODES TABLE
Application
Engine Code
VIN Code
2.4L 4-Cylinder
Axxess & 240SX ................. KA24E .................. H
Pickup ......................... KA24E .................. S
Stanza ......................... KA24E .................. F
NOTE:
VALVE ARRANGEMENT
Right Side - All Intake.
Left Side - All Exhaust.
required.
ENGINE R & I
AXXESS, STANZA
NOTE:
bolts.
engine
vacuum
TORQUE
Installation
On Axxess 4WD models, adjust length between buffer rod
See Fig. 1. On all models, replace worn or separated rubber
mounts. Ensure proper placement of all electrical harnesses and
lines. To complete installation, reverse removal procedure. See
SPECIFICATIONS at end of article.
PICKUP
Removal
1) Release fuel pressure. See FUEL PRESSURE RELEASE in this
240SX
Removal & Installation
Information not available from manufacturer.
PICKUP, 240SX
Removal
1) Release fuel pressure. See FUEL PRESSURE RELEASE in this
article. Disconnect negative battery cable. Drain cooling system.
Remove power steering pump drive belt. Remove power steering pump,
brackets and idler pulley.
2) Label and disconnect necessary electrical wiring and
vacuum hoses. Disconnect accelerator cable bracket. Disconnect EGR
tube from exhaust manifold. Remove intake plenum-to-intake manifold
bolts.
3) Remove intake manifold-to-cylinder head bolts while
raising plenum upward. Remove rocker arm cover. Bring No. 1 piston to
TDC on compression stroke. Loosen camshaft sprocket bolt. Using Chain
Support (KV10105800), support timing chain. See Fig. 4. Remove
camshaft sprocket.
4) Remove cylinder head-to-engine front cover bolts. Loosen
cylinder head bolts in 2 or 3 steps in reverse order of tightening
sequence to prevent warping or cracking cylinder head. See Fig. 5.
Remove cylinder head.
refinish surface.
2) Maximum surface grinding limit of cylinder head plus block
is .008" (.20 mm). Replace head and/or block if machined or warped
beyond specification.
3) Using calipers, measure cylinder head height. See CYLINDER
HEAD SPECS TABLE at end of article. If cylinder head height is not
within specifications, replace cylinder head.
4) After resurfacing cylinder head, ensure camshaft rotates
freely by hand. Replace cylinder head if resistance is felt.
Installation
1) Ensure mating surfaces of cylinder head and block are
clean. Install cylinder head and new gasket.
2) Tighten head bolts to 22 ft. lbs. (30 N.m). See Fig. 5.
Tighten head bolts to 58 ft. lbs. (79 N.m). Loosen all bolts
completely. Tighten head bolts to 22 ft. lbs. (30 N.m). Tighten head
bolts to 54-61 ft. lbs. (73-83 N.m).
3) Ensure knockpin is positioned at 12 oclock in camshaft.
Set chain on camshaft by aligning Silver chain mating link to punch
mark on cam sprocket. Install camshaft sprocket to camshaft. Install
camshaft sprocket bolt and tighten to specification. Remove chain
stopper installed during removal.
4) Apply sealant to cylinder head and rubber plug. Install
rubber plug. Wipe off excess sealant. To complete installation,
reverse removal procedure. Run engine for several minutes, allow
engine to cool down and recheck head bolt torque.
Removal
1) Drain coolant and crankcase oil. Remove radiator and
cooling fan. Remove air cleaner. Label all wiring and vacuum lines for
reassembly reference.
2) Remove power steering, air conditioner and alternator
belts. On Pickup and 240SX, remove distributor cap and wiring from
distributor. Set No. 1 piston to TDC of compression stroke. Ensure
distributor rotor is pointing to No. 1 spark plug wire on distributor
cap.
3) On all models, remove power steering pump, power steering
idler pulley and power steering brackets (if equipped). Remove
alternator and adjusting bracket. Remove compressor idler pulley and
crankshaft pulley. On Pickup and 240SX, remove oil pump together with
pump drive spindle.
4) On all models, remove rocker arm cover. Remove oil pan.
See OIL PAN R & I in this article. On Axxess and Stanza, remove engine
mount at front of engine near alternator.
5) On all models, remove front cover bolts. Note bolt
locations for reassembly reference. Remove front cover together with
distributor (Pickup and 240SX) and water pump. DO NOT damage head
gasket. Disassemble as necessary.
Inspection
Check oil seal surface of crankshaft for nicks or damage.
Repair as necessary.
Installation
1) Before installation, apply sealant at mating corners of
oil pan gasket, cylinder head gasket and front cover gaskets. Press
new oil seal in front cover with dust seal lip facing outside.
2) Apply lithium grease to oil seal sealing lip before cover
is installed. Use new gaskets and sealant. Front cover mount bolts are
different lengths. Ensure bolts are in proper locations during
installation. Install front cover. To complete installation, reverse
removal procedure.
NOTE:
Inspection
Inspect rocker arms, retaining bolts and shafts for wear or
damage. If excessive wear or damage is found, replace rocker arm
and/or shaft.
Reassembly & Installation
1) Ensure camshaft knockpin is positioned at 12 oclock (No.
1 piston at TDC compression). Assemble rocker arm shaft. Install
rocker arm shaft brackets and rocker arms on shaft. See Fig. 8.
2) Intake rocker arm shaft has a single punch mark. Exhaust
rocker arm shaft has 2 punch marks. Both shafts should be installed so
punch marks on front surface face up. Marks are used to identify oil
hole direction and must be installed correctly for lubrication
purposes. See Fig. 8.
3) DO NOT move rocker arms from original locations. Mount
rocker arm shaft assembly on alignment dowel pin in head. Gradually
tighten bolts to specification, in 2 or 3 steps from center outward.
See TORQUE SPECIFICATIONS at end of article.
4) Apply sealant to cylinder head and rubber plug. Install
rubber plug. Wipe off excess sealant. Install rocker arm cover.
Reconnect negative battery cable.
CAMSHAFT R & I
NOTE:
Removal
1) Disconnect negative battery cable. Drain cooling system.
Remove rocker arm cover. Set No. 1 cylinder at TDC of compression
stroke. Loosen camshaft sprocket bolt. DO NOT allow camshaft or
crankshaft to rotate. Using Chain Support (KV10105800) wedged in space
between timing chain rails, support timing chain. See Fig. 1.
2) Remove camshaft sprocket. Loosen rocker arm shaft bolts
evenly in 2 or 3 steps, moving from outside to inside in sequence.
Remove rocker arm assembly with bolts. Remove camshaft.
CAUTION: DO NOT allow crankshaft to rotate with timing chain removed
or damage to valves may result.
Inspection
Measure camshaft bearing journals and camshaft bearing inside
diameter to determine oil clearance. Check camshaft lobe height. Place
camshaft in "V" blocks and check camshaft runout. See CAMSHAFT
specifications table at end of article.
Installation
1) Install camshaft on cylinder head with camshaft knockpin
at 12 oclock position. Install rocker arm assembly by aligning rocker
arm shaft on dowel pin of cylinder head.
2) Tighten rocker arm bolts evenly, in 2 or 3 steps, in an
outward sequence from center. See TORQUE SPECIFICATIONS at end of
article.
3) Set chain on camshaft sprocket by aligning mating marks.
See Fig. 7. Install camshaft sprocket on camshaft. Install camshaft
sprocket bolt and tighten to specification. See TORQUE SPECIFICATIONS
at end of article. Remove chain stopper.
4) Apply sealant to cylinder head and rubber plug. Install
rubber plug. Wipe off excess sealant. Install rocker arm cover. Fill
cooling system and reconnect negative battery cable.
PICKUP, 240SX
Removal
1) Slowly open radiator cap to release system pressure. Drain
coolant from drain plugs on left rear of cylinder block and radiator.
Remove upper radiator shroud. Loosen alternator bracket and remove fan
belt.
2) Remove power steering belt (if equipped). Remove fan.
Remove pump mount bolts. Remove water pump with fan pulley, fan
coupling and gasket. Remove fan bolts and fan coupling nuts.
Inspection
Inspect water pump body and impeller vanes for corrosion.
Check pump bearing for excessive play or rough operation. Inspect fan
coupling for oil leakage or bent bimetallic spring.
Installation
1) Using new gasket, install water pump by reversing removal
procedure. Adjust belt tension and fill cooling system. Check hoses
for proper attachments and damage.
2) Start engine and check for leaks. Check thermostat for
proper operation. Pressure leak test cooling
system using pressure
tester and a maximum of 14 psi (1.0 kg/cm ) pressure. Replace
components as necessary.
NOTE:
PICKUP
Removal
1) Raise vehicle and support with safety stands. Remove
undercover. Drain engine oil. On 2WD models, remove front suspension
crossmember. On 4WD models, remove front differential carrier member
bolts. Remove front differential carrier bolts and support
differential carrier.
2) On 4WD models, remove transmission to rear engine mount
bracket nuts. Remove engine mount bolts or nuts. Lift up engine. If
necessary, disconnect exhaust pipes. On all models, remove oil pan.
Installation
Remove old gasket from mating surfaces. Apply a continuous
bead of liquid gasket to mating surfaces. To complete installation,
reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS at end of article.
240SX
Removal
Raise vehicle and support with safety stands. Drain engine
oil. Remove front stabilizer bar bolts and nuts from side member.
Loosen engine mounts and raise engine. Remove oil pan bolts and remove
oil pan through front side.
Installation
Remove old gasket from mating surfaces. Apply a continuous
bead of liquid gasket to mating surfaces. To complete installation,
reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS at end of article.
VALVES SERVICE
1) After disassembly, inspect valve head diameter, stem
diameter and seat angle. Inspect valves for worn, damaged or deformed
valve head or stem. Inspect valve keeper grooves for excessive wear.
2) If valve head is worn to .020" (.50 mm) margin thickness,
replace valve. Valve stem end surface grinding limit is .008" (.20
mm).
3) Install valve spring seat and oil seal over top of valve
guide. Place springs in position with close-coiled (painted Red) end
toward cylinder head. Lubricate valve, valve retainers and keepers.
Use valve spring compressor to install valve spring.
Application
In. (mm)
PISTON & ROD ASSEMBLY R & I
Removal
1) Remove cylinder head and front cover. See CYLINDER HEAD R
& I and FRONT COVER & OIL SEAL R & I in this article. Remove oil pan
and oil strainer. See OIL PAN R & I in this article.
2) Ensure rod cap and connecting rod is stamped with a
matching identification number. Remove connecting rod nuts. Remove
connecting rod cap with bearing half. Remove piston and rod assembly.
See OVERHAUL PROCEDURES article.
Inspection
1) Measure cylinders for out-of-round and taper. See CYLINDER
BLOCK SPECS TABLE at end of article. If specification is exceeded,
cylinders must be bored. If boring cylinders to oversize, proceed to
FITTING PISTONS in this article.
2) Install connecting rod with bearings, on crank journal and
tighten to specification in 2 stages. See TORQUE SPECIFICATIONS at end
of article. Measure rod side thrust clearance. Standard thrust
clearance at connecting rod big end is .008-.016" (.20-.40 mm).
Maximum limit is .024" (.60 mm). Replace rod and/or crankshaft if
specification is exceeded.
Installation
1) Apply oil to rings, piston and cylinder wall. Ensure ring
gaps are approximately 180 degrees apart and not located on thrust
side of piston or in line with piston pin.
2) Ensure grade mark stamped on top of piston is toward front
of engine. Install cylinder head, front cover and related components.
Install oil pan with new gasket. Tighten bolts evenly in a crisscross
pattern. DO NOT overtighten. To complete installation, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS
at end of article.
FITTING PISTONS
1) Inspect cylinder block for cracks or flaws. Using dial
bore gauge, measure cylinder bore for out-of-round or taper. See
CYLINDER BLOCK SPECS TABLE at end of article. If out-of-round or taper
exceeds specification, cylinder will need to be bored. When any one
cylinder is bored, all cylinders must be bored.
CRANKCASE CAPACITY
Application
Axxess, Stanza (1) & 240SX .....................
Pickup
2WD ..........................................
4WD ..........................................
Qts. (L)
3.8 (3.5)
4.1 (3.9)
3.5 (3.3)
OIL PRESSURE
PICKUP, 240SX
Removal & Disassembly
1) Set No. 1 piston at TDC of compression stroke. Check
distributor rotor position for reassembly reference. Remove mount
bolts. Remove oil pump and drive spindle assembly.
2) Remove cover, gasket and gears from oil pump body. See
Fig. 13. Wash parts with solvent. Inspect for wear or damage.
Inspection
Using a feeler gauge, check clearances.See Fig. 14. With
rotor in pump body and gasket installed, place straightedge over
rotor. Check clearance between rotor and straightedge. Clearance
should not exceed .0031" (.08 mm).
NOTE:
Fig. 13: Exploded View of Oil Pump Assembly (Pickup & 240SX)
Courtesy of Nissan Motor Co., U.S.A.
TORQUE SPECIFICATIONS
Application
ENGINE SPECIFICATIONS
GENERAL ENGINE SPECIFICATIONS
Application
Specification
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS
Application
In. (mm)
Crankshaft
End Play ........................... .002-.007 (.05-.18)
Runout ...................................... .004 (.10)
Main Bearings
Journal Diameter
Axxess, Stanza & 240SX
Grade 0 ............... 2.3609-2.3612 (59.967-59.975)
Grade 1 ............... 2.3606-2.3609 (59.959-59.967)
Grade 2 ............... 2.3603-2.3606 (59.951-59.959)
Pickup
Grade 0 ............... 2.5057-2.5060 (63.645-63.652)
Grade 1 ............... 2.5060-2.5064 (63.652-63.663)
Grade 2 ............... 2.5064-2.5068 (63.663-63.672)
Journal Out-of-Round & Taper .............. .0004 (.010)
Oil Clearance .................. .0008-.0019 (.020-.047)
Connecting Rod Bearings
Journal Diameter
Axxess, Stanza & 240SX
Grade 0 ............... 1.9672-1.9675 (49.968-49.974)
Grade 1 ............... 1.9670-1.9672 (49.962-49.968)
Grade 2 ............... 1.9668-1.9670 (49.956-49.962)
Pickup .................. 2.3603-2.3612 (59.951-59.975)
Journal Out-of-Round & Taper .............. .0002 (.005)
Oil Clearance .................. .0004-.0014 (.010-.035)
CONNECTING RODS SPECIFICATIONS
Application
Bore Diameter
Pin Bore
Axxess, Stanza
& 240SX .................
Pickup ....................
In. (mm)
.8268-.8272 (21.000-21.012)
.8247-.8259 (20.948-20.978)
PISTONS, PINS & RINGS SPECIFICATIONS
Application
In. (mm)
Pistons
Clearance ...................... .0008-.0016 (.020-.040)
Diameter
Grade 1 ................. 3.5027-3.5031 (88.970-88.980)
Grade 2 ................. 3.5031-3.5035 (88.980-88.990)
Grade 3 ................. 3.5035-3.5039 (88.990-89.000)
Pins
Diameter
Axxess, Stanza
& 240SX ................. .8263-.8268 (20.989-21.000)
Pickup .................... .8265-.8266 (20.994-20.996)
Piston Fit
Axxess, Stanza & 240SX (1) ........... 0-.0002 (0-.005)
Pickup ........................ .0003-.0005 (.008-.012)
Rod Fit
Axxess, Stanza & 240SX ........ .0002-.0007 (.005-.017)
Pickup (1) .................... .0006-.0013 (.015-.033)
Rings
No. 1
End Gap ....................... .0110-.0169 (.280-.430)
Side Clearance ................ .0016-.0031 (.040-.080)
No. 2
End Gap
Ring Marked
"R" or "T" (Axxess, Stanza
& 240SX) ................ .0177-.0236 (.450-.600)
"N" (Axxess, Stanza
& 240SX) ................ .0217-.0276 (.550-.700)
Pickup ..................... .0177-.0272 (.450-.690)
Side Clearance ................ .0012-.0028 (.030-.070)
No. 3 (Oil)
End Gap ....................... .0079-.0236 (.200-.600)
Side Clearance
Rinken Rings ................ .0026-.0053 (.065-.135)
(1) - Interference fit or negative clearance.
CYLINDER BLOCK SPECIFICATIONS
Application
In. (mm)
Cylinder Bore
Standard Diameter
Grade 1 ................. 3.5039-3.5043 (89.000-89.010)
Grade 2 ................. 3.5043-3.5047 (89.010-89.020)
Grade 3 ................. 3.5047-3.5051 (89.020-89.030)
Maximum Taper ............................. .0004 (.010)
VALVES & VALVE SPRINGS SPECIFICATIONS
Application
Specification
Intake Valves
Face Angle .........................................
Head Diameter ............ 1.339-1.346" (34.00-34.20
Minimum Margin ............................ .02" (.5
Minimum Refinish Length ............... 4.72" (119.9
Stem Diameter ............ .2742-.2748" (6.965-6.980
Valve Tip Maximum Refinish .............. .008" (.20
Exhaust Valves
Face Angle .........................................
Head Diameter ............ 1.575-1.583" (40.00-40.20
Minimum Margin ............................ .02" (.5
Minimum Refinish Length ............ 4.7508" (120.67
Stem Diameter ............ .3129-.3134" (7.948-7.960
Valve Tip Maximum Refinish .............. .008" (.20
Valve Springs
Intake
Free Length
Inner Spring ...................... 2.100" (53.34
Outer Spring .................... 2.2614" (57.440
Out-of-Square
Inner Spring ........................ .091" (2.30
Outer Spring ........................ .098" (2.50
Pressure
Inner Spring
Outer Spring
Exhaust
Free Length
Inner Spring
Outer Spring
Out-of-Square
Inner Spring
Outer Spring
45
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
........................
........................
Pressure
Inner Spring
Outer Spring
45
mm)
mm)
mm)
mm)
mm)
CYLINDER HEAD SPECIFICATIONS
CYLINDER HEAD SPECIFICATIONS TABLE
Application
Specification
Valve Seats
Intake Valve
Seat Angle ........................................
Seat Width
Exhaust ................... .067-.083" (1.70-2.10
Intake .................... .063-.067" (1.60-1.70
Seat Bore
Diameter ........... 1.4350-1.4356" (36.00-36.016
Exhaust Valve
Seat Angle ........................................
Seat Width .................... .067-.083" (1.7-2.1
Seat Bore Diameter ...
1.4350-1.4356" (36.00-36.016
Valve Guides
Intake Valve
Valve Guide Cylinder
Head Bore I.D.
....
.4321-.4329" (10.975-10.996
Oversize Guide
Hole Diameter ....... .4400-.4408" (11.175-11.196
Valve Guide I.D. ........ .2756-.2763" (7.000-7.018
Valve Guide Installed Height . .587-.594" (14.9-15.1
Valve Stem-to-Guide
Oil Clearance ........... .0008-.0021" (.020-.053
Exhaust Valve
Valve Guide Cylinder
Head Bore I.D.
....
.4715-.4723" (11.975-11.996
Oversize Guide
Hole Diameter ....... .4793-.4802" (12.175-12.196
Valve Guide I.D. ........ .3150-.3157" (8.000-8.018
Valve Guide Installed
Height .................... .587-.594" (14.9-15.1
Valve Stem-to-Guide
Oil Clearance ........... .0016-.0028" (.040-.070
45
mm)
mm)
mm)
45
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
mm)
CAMSHAFT SPECIFICATIONS
Application
In. (mm)