1999 NISSAN PICK-UP Repair Manual

12. Remove power steering pump from the engine.
13. Remove transmission. Refer to MT or AT section (ªRemovalº,
ªREMOVAL AND INSTALLATIONº).
14. Remove LH and RH engine mounts.
15. Remove engine.
Installation
lInstall in reverse order of removal.
AEM395
ENGINE REMOVALKA24DE
Removal (Cont'd)
EM-2037

SEM014G
CYLINDER BLOCKKA24DE
EM-2038

CAUTION:
lWhen installing sliding parts (bearings, pistons, etc.),
lubricate contacting surfaces with new engine oil.
lPlace removed parts such as bearings and bearing caps
in their proper order and direction.
lWhen installing connecting rod nuts and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
lDo not allow any magnetic materials to contact the ring
gear teeth of flywheel or drive plate.
Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove oil pan.
4. Remove timing chain. Refer to ªRemovalº in ªTIMING
CHAINº (EM-2015).
5. Remove water pump.
6. Remove cylinder head.
7. Remove pistons with connecting rods.
8. Remove bearing caps and crankshaft.
lBefore removing bearing caps, measure crankshaft end
play. Refer to EM-2047.
lBolts should be loosened in two or three steps.
Inspection
PISTON AND PISTON PIN CLEARANCE
1. Measure inner diameter of piston pin hole ªdpº.
Standard diameter ªdpº:
20.993 - 20.999 mm (0.8265 - 0.8267 in)
2. Measure outer diameter of piston pin ªDpº.
Standard diameter ªDpº:
20.989 - 21.001 mm (0.8263 - 0.8268 in)
3. Calculate piston pin clearance.
dp þ Dp = þ0.002 to 0.01 mm (þ0.0001 to 0.0004 in)
If it exceeds the above value, replace piston assembly with
pin.
SEM744-C
EEM118
AEM023
AEM024
CYLINDER BLOCKKA24DE
EM-2039

PISTON RING SIDE CLEARANCE
Side clearance:
Top ring 0.04 - 0.08 mm (0.0016 - 0.0031 in)
2nd ring 0.03 - 0.07 mm (0.0012 - 0.0028 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston ring.
If clearance exceeds maximum limit with new ring, replace pis-
ton.
PISTON RING END GAP
End gap:
Top ring
0.28 - 0.52 mm (0.0110 - 0.0205 in)
2nd ring
0.45 - 0.69 mm (0.0177 - 0.0272 in)
(R or T is punched on the ring.)
0.55 - 0.70 mm (0.0217 - 0.0276 in)
(N is punched on the ring.)
Oil ring
0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
Refer to SDS, EM-2054.
If out of specification, replace piston ring. If gap exceeds maxi-
mum limit with a new ring, rebore cylinder and use oversized
piston and piston rings. Refer to SDS, EM-2054.
lWhen replacing the piston, check cylinder block surface for
scratches or seizure. If scratches or seizure are found, hone
or replace the cylinder block.
CONNECTING ROD BEND AND TORSION
Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length
If it exceeds the limit, replace connecting rod assembly.
SEM249CA
SEM250C
SEM038F
SEM003F
CYLINDER BLOCKKA24DE
Inspection (Cont'd)
EM-2040

CYLINDER BLOCK DISTORTION AND WEAR
1. Clean upper face of cylinder block.
Use a reliable straightedge and feeler gauge to check the
flatness of cylinder block surface. Check along six positions
shown in figure.
Limit:
0.1 mm (0.004 in)
2. If out of specification, resurface it.
The limit for cylinder block resurfacing is determined by cyl-
inder head resurfacing.
Amount of cylinder head resurfacing is ªAº
Amount of cylinder block resurfacing is ªBº
The maximum limit is as follows:
A+B=0.2mm(0.008 in)
Nominal cylinder block height
from crankshaft center:
246.95 - 247.05 mm (9.7224 - 9.7264 in)
3. If necessary, replace cylinder block.
PISTON-TO-BORE CLEARANCE
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Standard inner diameter:
Refer to SDS, EM-2052.
Wear limit: 0.2 mm (0.008 in)
Out-of-round (X þ Y) standard: 0.015 mm (0.0006 in)
Taper (A þ B) standard: 0.010 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
2. Check for scratches and seizure. If seizure is found, hone it.
lIf cylinder block and piston are replaced, match piston
grade with grade number on cylinder block upper sur-
face.
3. Measure piston skirt diameter.
Piston diameter ªAº:
Refer to SDS, EM-2054.
Measuring point ªaº (Distance from the top):
Approximately 48 mm (1.89 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance ªBº:
0.020 - 0.040 mm (0.0008 - 0.0016 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to SDS,
EM-2054.
SEM255CB
SEM040
SEM257C
SEM258C
CYLINDER BLOCKKA24DE
Inspection (Cont'd)
EM-2041

6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter ªAº.
Rebored size calculation:
D=A+BþC
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps and tighten bolts to the specified
torque. This will prevent distortion of cylinder bores.
8. Cut cylinder bores.
lWhen any cylinder needs boring, all other cylinders
must also be bored.
lDo not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so at a time.
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
lMeasurement should be done after cylinder bore cools
down.
CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
2. With a micrometer, measure journals for taper and out-of-
round.
Out-of-round (X þ Y):
Main journal Less than 0.01 mm (0.0004 in)
Crank pin Less than 0.005 mm (0.0002 in)
Taper (A þ B):
Main journal Less than 0.01 mm (0.0004 in)
Crank pin Less than 0.005 mm (0.0002 in)
3. Measure crankshaft runout.
Runout (Total indicator reading):
Less than 0.10 mm (0.0039 in)
BEARING CLEARANCE
lUse Method A or Method B. Method A is preferred because
it is more accurate.
Method A (Using bore gauge and micrometer)
Main bearing
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.
SEM316A
SEM254C
SEM448C
CYLINDER BLOCKKA24DE
Inspection (Cont'd)
EM-2042

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