Nissan Z24

1985 Nissan Pickup 2.0L 4-CYL - VIN [F] & 2.4L 4-CYL - VIN [N] 1985 Engines - 2.0L & 2.4L 4-Cylinder

2.0L 4-CYL - VIN [F] & 2.4L 4-CYL - VIN [N] 1985 Engines - 2.0L & 2.4L 4-Cylinder

ENGINE IDENTIFICATION NOTE NOTE::

For For eng engiine repa repaiir pro proce cedu dure res s not not cove covere red d in in thi this s art artiicle, cle, see see ENG ENGIINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

ENGINE CODING ENGINE IDENTIFICATION CODES Application 2.0L 4-Cylinder 2.4L 4-Cylinder

Engine Code Z2 0 Z2 4

VIN Code F N

ADJUSTMENTS VALVE ADJUSTMENT

NOTE NOTE::

Valv Valves es shou should ld be adju adjust sted ed with with engi engine ne at norm normal al oper operat atin ing g tem tempe pera ratu ture re.. Col Cold d specifications are provided for initial settings after assembly.

1. DO NOT adjust valves with engine running. Remove Re move air cleaner, distributor high tension wire and valve cover. Turn crankshaft to set No. 1 cylinder at TDC on compression stroke. 2. Ensure high high point point on No. 1 cam lobe lobe points down. Adjust Adjust intake intake valve of No. 1 and No. 2 cylinder; cylinder; exhaust valve of No. 1 and No. 3. Turn engine until high point on No. 1 cam lobe points up. Adjust remaining valves. VALVE CLEARANCE SPECIFICATIONS Valve Intake Exhaust

Hot .012" (.30 mm) .012" (.30 mm)

(1)

Cold .008" (.21 mm) .009" (.23 mm)

(1) Use for initial settings only.

REMOVAL & INSTALLATION ENGINE

NOTE NOTE::

Remo Remove ve engi engine ne and and tra trans nsmi miss ssio ion n as as a unit unit.. Sep Separ arat ate e eng engin ine e fro from m tra trans nsmi miss ssio ion n after removal.

lunes, 10 de octubre de 2016 18:41:3 21 2

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© 2011 Mitchell Repair Information Company, LLC.


Removal

1. Disconnect Disconnect battery. battery. Drain Drain cooling cooling system and crankcas crankcase. e. Mark hood and hinges hinges for reassemb reassembly ly reference. reference. Remove hood. Detach hoses and tubes and remove air cleaner. Disconnect all engine-to-chassis cables, hoses and wires. 2. If equipped, equipped, remove air air conditioner conditioner compress compressor, or, power steeri steering ng belt and pump and set set aside.DO NOT drain oil from pump or discharge systems. Hold units out of way with wire to prevent interference with engine removal. 3. On manual transmis transmission, sion, disconnect disconnect shift shift lever rubber rubber boot. Remove nut from from shift lever. lever. Remove lever. lever. Remove clutch slave cylinder. On automatic transmission, disconnect joint between control lever and selector rod. Remove oil cooler lines. Remove radiator hoses, shroud and radiator. 4. Raise and support support vehicle. vehicle. Remove Remove undercover. undercover. Disconnect Disconnect speedomet speedometer er cable and switch switch wires wires on transmission case. Remove parking brake cable at brake lever. Remove front exhaust pipe from manifold. On automatic transmission, disconnect vacuum hose and oil pipes. 5. On 2WD, index index mark drive drive shaft shaft and remove. remove. Plug end end of transmiss transmission. ion. On 4WD, 4WD, index mark mark and remove front drive shaft assembly from transfer case. Attach lifting hoist to engine. Ra ise enough to take weight off engine mounts. 6. On 4WD, suspend suspend front differenti differential al carrier. carrier. Remove front front carrier mount mount bolt. Remove Remove front carrier carrier rear mount bolts and crossmember. Lower front carrier slowly. Remove front and rear engine mount bolts and mounts. Pull engine forward. Remove engine and transmission as an assembly. Installation

Replace any rubber engine mounts showing signs of deterioration or separation. Ensure proper placement of all electrical harnesses and engine mounts. Reverse removal procedure to complete installation. INTAKE & EXHAUST MANIFOLDS Removal

1. Disconnect Disconnect battery. battery. Drain cooling cooling system. system. Remove air cleaner cleaner assembly. assembly. Disconnect Disconnect heater heater housing-tohousing-towater inlet tube, at inlet. Remove bolt holding water and fuel tubes to head. 2. Remove heater heater housing-to-t housing-to-thermos hermostat tat housing housing tube. Disconnect Disconnect fuel line, line, wiring wiring and all related components. 3. Remove carbureto carburetor, r, mount bolts bolts and nuts and and intake manifold manifold assembly. assembly. Discard Discard gasket. gasket. SeeFig. 1 . Disconnect front exhaust pipe from exhaust manifold. Remov e manifold mount bolts and exhaust manifold assembly. Discard gaskets.

lunes, 10 de octubre de 2016 18:41:22

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Fig. 1: Removing Intake & Exhaust Manifolds

NOTE:

Replace gaskets whenever manifolds are removed.

Installation

When installing manifolds, use new gaskets. Ensure mating surfaces of cy linder head and manifolds are clean, flat and free of nicks or other damage. Set mount studs in cylinder head, before installing intake manifold, to aid alignment. To complete installation, reverse removal procedure. CYLINDER HEAD Removal

1. Disconnect battery. Drain cooling system. Disconnect spark plug wires. Remove radiator and heater lunes, 10 de octubre de 2016 18:41:22

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hoses. Disconnect drive belts and alternator brackets. Move alternator aside. 2. Remove fan, pulley and water pump. If equipped with air conditioning and/or power steering, remove as outlined in engine removal procedure. Remove air cleaner. Disconnect throttle linkage. Disconnect cables, hoses and wires from cylinder head-to-chassis or engine. Disconnect hoses and vacuum lines from intake manifold-to-cylinder head or engine block. 3. Remove carburetor. Remove intake manifold assembly with EGR valve. Remove front exhaust pipe, exhaust manifold assembly and valve cover. 4. Turn crankshaft so No. 1 piston is at TDC on compression stroke. Scribe aligning marks on timing chain and camshaft sprocket, if necessary, for reassembly reference. Remove camshaft sprocket. Use Support Tool (KV10105800) for timing chain as shown. See Fig. 2 .

Fig. 2: Holding Timing Chain With Support Tool

NOTE:

Before removal, ensure timing chain and sprockets are marked for reassembly reference.

5. Remove bolts securing cylinder head-to-front cover. Remove the cylinder head mount bolts in reverse of tightening sequence. See Fig. 3 . Remove cylinder head. Inspection

1. Check cylinder head for cracks, flaws or damage. Replace as necessary. Inspect head and block mating surfaces for warpage. Warpage limit is .004" (.10 mm) or less.


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2. If beyond limit, refinish surface. Maximum surface grinding limit of head and/or block is .008" (.20 mm). Replace head and/or block if machined or warped beyond service limit. Installation

1. Ensure mating surfaces of cylinder head and block are clean. Install head and gasket without sealer. Set No. 1 piston at TDC on compression stroke. Insert head bolts. 2. Tighten No. 1 and No. 2 head bolts to 14 ft. lbs. (19 N.m). Install and align sprockets and timing chain. Install remaining components in reverse order of removal, using new seals, gaskets and sealant where required. 3. Tighten head bolts in 3 steps, in proper sequence, to final specified torque. See Fig. 3 . Run engine for several minutes, let it cool down and recheck head bolt torque.

Fig. 3: Cylinder Head Tightening Sequence

NOTE:

Remove the cylinder head mount bolts in reverse of the tightening sequence.

ENGINE FRONT COVER Removal


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1. With engine removed from vehicle and mounted on engine stand, remove oil pan, strainer, oil pump and drive spindle. Remove crankshaft pulley and front cover-to-cylinder head mount bolts. 2. Check bolt locations for reassembly reference and remove front cover-to-block mount bolts. Remove front cover and gaskets. Inspection

Check the height difference between cylinder block upper face and front cover upper face. Difference must not exceed .006" (.15 mm). Correct as necessary. Check oil seal surface of crankshaft for nicks or damage. Repair as necessary.

CAUTION: Front cover mount bolts are of different lengths. Ensure bolts are in proper locations during installation. 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 at outside. 2. Apply lithium grease to sealing lip of oil seal before cover is installed. Using new gaskets, install front cover and related components. TIMING CHAIN & SPROCKETS Removal

1. Set No. 1 piston at TDC on compression stroke. Remove fan, belts, crankshaft pulley and valve cover. Remove fuel pump and fuel pump drive cam. 2. Scribe reference marks, remove camshaft drive sprocket and carefully lower timing chain. Remove cylinder head-to-front cover mount bolts. Remove cylinder head-to-block mount bolts. Remove head. 3. Set timing chain on Support Tool (KV10105800). Remove oil pan, strainer, oil pump, drive spindle and engine front cover. Remove timing chain tensioner and guide. Remove timing chain, oil slinger, oil pump drive gear and crankshaft drive sprocket. Inspection

1. Check camshaft sprocket tooth surface for flaws and wear. Replace if any damage is found. Install sprocket on camshaft and check for runout. Camshaft sprocket runout limit, at total indicator reading, is .004" (.10 mm). 2. If runout exceeds specification, replace sprocket. Check timing chain for damage and excessive wear at roller links. Replace if faulty or stretched. Check c hain tensioner and guide for breakage or wear. Replace as necessary.

NOTE:

Install camshaft sprocket with No. 2 hole on sprocket located at camshaft dowel. Align timing chain mark at No. 2 mark on sprocket. Adjust slack side chain guide tensioner to zero protrusion.


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Installation

1. Ensure that crankshaft and camshaft keys point upward. Install oil pump gear so that large chamfer faces rearward. 2. Set timing chain so that mating marks align with crankshaft and camshaft sprockets. Complete installation in reverse order of removal.

Fig. 4: Timing Chain & Sprocket Alignment lunes, 10 de octubre de 2016 18:41:22

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ROCKER ARM & SHAFT Removal

With valve cover and gasket removed, loosen rocker arm mount bolts. DO NOT remove bolts from No. 1 or No. 5 end bracket or rocker and shaft bracket will spring out. Remove rocker arm assembly. Disassemble each rocker arm and shaft carefully. Note component locations for reassembly reference. Inspection

Check rocker arms and shafts for wear or damage. Standard rocker arm-to-shaft clearance should be .0003.0019" (.007-.049 mm). If excessive wear or damage is found, replace rocker arm and/or shaft.

NOTE:

Rocker arm shaft brackets use alphabetical identification marks on each bracket and cylinder head location.

Installation

1. With valve assembly and camshaft installed in cylinder head, assemble rocker shaft assembly. Ensure camshaft dowel pin is at front side of head and positioned at 12 o'clock. Install rocker shaft bracket, valve rocker and spring onto shaft. See Fig. 5 .


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Fig. 5: Installing Rocker Arm & Shaft Assembly

NOTE:

Valve rockers are the same for intake and exhaust.

2. Intake rocker shaft has an identification slit on front surface. The exhaust rocker shaft does not. Both shafts should be assembled so that punch marks on front surface face up. Marks are used to identify oil hole direction. See Fig. 6 .


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Fig. 6: Assembling Rocker Arm Shafts Using Identification Marks

NOTE:

The intake rocker shaft has identification slit on the front surface while the exhaust shaft does not.

3. Valve rocker is the same for intake and exhaust. Rockers for No. 1 and No. 3 cylinder are marked with "1". Rockers for No. 2 and No. 4 are marked with "2". DO NOT mix rockers from original locations. 4. Mount rocker shaft assembly onto knock pin in head. Tighten to specification. Set cylinder head on blocks to make space for valves. Otherwise, when shaft assembly is tightened, some valves will open and interfere. After assembling cylinder head, turn camshaft until No. 1 piston is at TDC on compression stroke. CAMSHAFT Removal

With cylinder head removed, loosen rocker arm bolts evenly, from outside, in sequence. DO NOT remove bolts from each end bracket of rocker arm shaft assembly or assembly will spring apart. Remove rocker arm assembly. Carefully remove camshaft. Inspection

1. Check camshaft, journals and cam bracket bearing surfaces for wear or damage. Maximum journal-tolunes, 10 de octubre de 2016 18:41:22

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bushing clearance limit is .004" (.10 mm) or less. Check camshaft for bend. With camshaft in "V" blocks, set dial indicator on center journal. Using total gauge reading, bend limit is .008" (.20 mm). 2. Check the camshaft lobe height. Standard height is 1.5150-1.5170" (38.481-38.531 mm) for intake and exhaust lobes. Maximum wear limit of cam lobe is .0098" (.250 mm). Replace camshaft if beyond limits. 3. Check camshaft end play with dial indicator. Maximum end play is .008" (.20 mm). If beyond limit, replace camshaft, brackets and/or cylinder head assembly. Installation

1. Install camshaft on cylinder head with front camshaft dowel pin at 12 o'clock position. Install rocker arm assembly by aligning to dowel pin on cylinder head. 2. Place cylinder head on wooden blocks to allow for valve space. Tighten rocker arm bolts evenly, in 2 or 3 steps, in outward sequence from center bracket. CAMSHAFT BEARINGS

Measure inner diameter of camshaft bearing and outer diameter of camshaft journal with micrometer and telescopic hole gauge. Standard journal diameter is 1.2967-1.2974" (32.935-32.955 mm). Standard bearing clearance is .0018-.0035" (.045-.090 mm). Maximum bearing clearance is .004" (.10 mm). If excessively worn or damaged, replace camshaft and/or cylinder head assembly. VALVE ARRANGEMENT

Right Side - All Intake. Left Side - All Exhaust.

NOTE:

To remove valves, camshaft MUST be removed. See CAMSHAFT Removal & Installation.

VALVE Removal

With cylinder head removed, remove camshaft. Remove valves using Valve Spring Compressor (ST12070000 or KV101092S0). Keep disassembled parts in order. Inspection

1. Check valve head diameter, stem diameter and seat angle. Inspect valves for worn, damaged or deformed valve head or stem. 2. If head is worn to .02" (.5 mm) in-margin thickness, replace valve. Valve stem end surface grinding limit is .02" (.5 mm). Installation


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Install valve spring seat and oil seal on valve guide. Place springs in position with c lose-coiled (painted) end toward cylinder head. Use compressor and install valve retainers and keepers. VALVE GUIDE Clearance Check

1. Measure clearance between valve stem and valve guide with micrometer and telescopic hole gauge. Check diameter of valve stem at top, center and bottom. Insert hole gauge in guide bore. Measure at center. 2. Standard intake valve stem-to-guide clearance is .0008-.0021" (.020-.053 mm) and exhaust valve stem-toguide clearance is .0016-.0029" (.040-.073 mm). Maximum stem-to-guide clearance is .004" (.10 mm). 3. Move valve left-to-right in guide. Maximum movement limit at valve tip is .008" (.20 mm), with tip 1.18" (30 mm) from head upper surface. Replace guide if worn beyond limits. Replacement

1. If clearance is beyond limits and valve stem is not worn, replace guide. To replace, heat head to 302-320° F (150-160°C). Using Guide Remover (ST11320000) or equivalent, drive guide out from combustion chamber side. 2. With head at room temperature, ream guide hole to .4797-.4802" (12.185-12.196 mm). Standard guide hole diameter is .4718-.4723" (11.985-11.996 mm). Standard guide outside diameter is .4733.4738" (12.023-12.034 mm). Interference fit of valve guide-to-head is .0011-.0019" (.027-.049 mm).

NOTE:

Valve guides of .008" (.20 mm) oversize are available for service.

3. To install guide, reheat head. Fit snap ring on new valve guide and press guide into head until snap ring comes in contact with head surface. See Fig. 7 .


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Fig. 7: Installing Intake & Exhaust Valve Guides

NOTE:

Ensure that the valve guide snap rings are installed to the proper depth.

4. Use Reamer (ST11032000) to finish guide bore to .3150-.3157" (8.000-8.018 mm). Reface valve seat surface, as needed, after valve or guide repair or replacement. VALVE SEAT INSERTS

1. Check valves and valve seat inserts for pitting at valve contact surface. Standard intake valve seat contact is .083" (2.10 mm) and exhaust seat contact is .067" (1.70 mm). Correct valve seat surface or replace if excessively worn.

NOTE:

Valve seat inserts of .020" (.50 mm) oversize are available for service.

2. To remove old inserts, set machine depth stop so that boring cannot continue beyond bottom face of insert recess in head. Machine cylinder head recess diameter, in concentric circles, to valve guide center for correct fit. 3. Heat cylinder head to 302-392°F (150-200°C). Install insert, ensuring that it seats on bottom face of recess. Cut valve seats to correct face angle, seat width and head diameter of valve being installed. VALVE SPRINGS Removal


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1. With head removed, remove rocker arm assembly and camshaft. Compress valve spring with Valve Spring Compressor (ST12070000 or KV101092S0). Remove keepers. Disconnect compressing tool. Remove spring retainer and valve springs. 2. Remove oil seal, using Valve Lip Seal Remover/Installer (KV10107900). Remove valve spring seat. Keep components in correct order for installation. Inspection

1. Check valve springs for squareness using steel square and surface plate. Standard out of square limit is .087" (2.20 mm) for outer spring and .075" (1.90 mm) for inner spring. 2. Measure free length, tension and assembled height of each spring. If measurement is not within specifications, replace spring. Installation

Install spring seat. Using installer tool, drive oil seal onto each valve guide. Install valve, springs, retainer and keepers. Ensure valve spring is installed with small pitch side (painted) facing down. Install camshaft and rocker arm assembly. To complete installation, reverse removal procedure. VALVE SPRING INSTALLED HEIGHT

With valves closed, inner spring should have height of 1.38" (35 mm) and outer spring should have height of 1.57" (40 mm). Replace spring if height is not to specification.

OVERHAUL PISTON & ROD ASSEMBLY Removal

1. With cylinder head, front cover and oil pan removed, remove connecting rod nuts. Remove rod cap with bearing half. Check top of cylinder bore for ridge. If scraper will not remove carbon build-up, remove using ridge reamer. 2. Push piston and rod assembly, with bearing half, out through top of block. Keep rod caps with their respective piston and rod assemblies. Caps are not interchangeable. Inspection

1. Check connecting rod for bend or torsion using rod aligner tool. Standard bend and torsion limit is .0012" (.030 mm) and maximum limit is .002" (.05 mm) or less, in 3.94" (100 mm) of length. 2. Install rod, with bearings, on crank pin and tighten to 33-40 ft. lbs. (45-54 N.m). Measure rod side thrust clearance. Standard clearance, at rod big end, is .008-.012" (.20-.30 mm). Maximum limit is .024" (.60 mm). Replace rod if not to specifications. Installation


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1. To install piston and connecting rod assembly, apply oil to rings, piston and cylinder wall. Ensure ring gaps are approximately 180° apart and not on thrust side of piston or in line with piston pin. 2. Bearing halves must be properly seated in rod and cap. Install ring compressor. Compress rings. Install piston in cylinder. Ensure grade mark stamped in top of piston is toward front of engine and oil hole on rod faces right side of block. See Fig. 8 .

Fig. 8: Installing Piston & Rod Assembly

NOTE:

Ensure the grade mark on piston top faces the front and connecting rod oil hole faces right side of block.

3. With piston installed and rod and bearings seated against crankshaft journal, install rod caps to their respective piston and rod assembly. Install cylinder head, front cover and related components. Install new gasket and oil pan. Tighten bolts evenly, in a criss-cross pattern. DO NOT overtighten. FITTING PISTONS & RINGS

1. Inspect cylinder block for cracks or flaws. Using bore gauge, measure cylinder bore for out-of-round or lunes, 10 de octubre de 2016 18:41:22

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excessive taper. If bore out-of-round or taper exce eds .0006" (.015 mm), refinish cylinder bore. When any one cylinder is bored, all cylinders must be bored.

NOTE:

Before cylinder block machining operations, ensure main bearing caps are installed and tightened to specification. Bore cylinders in the order of No. 2-4-1-3 to prevent distortion.

2. Determine piston oversize according to amount of wear in cylinder. Standard cylinder bore diameter is 3.3465-3.3484" (85.000-85.050 mm) for 2.0L and 3.5039-3.5059" (89.000-89.050 mm) for 2.4L. Bore wear limit is .008" (.20 mm). Standard diameter d ifference between cylinders is .002" (.05 mm) or less and limit is .008" (.02 mm). 3. Measure piston diameter at thrust face. Standard piston diameter is 3.3451-3.3470" (84.965-85.015 mm) for 2.0L and 3.5026-3.5045" (88.965-89.015 mm) for 2.4L. Add piston-to-cylinder clearance. Finish hone of cylinder may then be determined. 4. After honing cylinder to final fit, measure piston-to-cylinder clearance using pull scale and feeler gauge. With piston and cylinder at room temperature (70°F, 2 0°C), a force of .4-3.3 lbs. (.2-1.5 kg) should be obtained when extracting a .0016" (.04 mm) feeler gauge. 5. If pistons are reused, de-carbon piston and ring grooves with scraper and piston groove cleaner tool. Clean oil slots in bottom land of oil ring groove. Check for scratches, wear or damage. Measure side clearance of rings in grooves as each ring is installed.

NOTE:

If only piston rings are replaced, measure gap at bottom of bore. Oversize pistons and rings are available in .02 mm, .5 mm and 1 mm.

6. Standard side clearance for top ring is .0016-.0029" (.040-.073 mm). For 2nd ring, clearance is .0012.0025" (.030-.063 mm). Maximum side clearance for top and 2nd ring is .004" (.10 mm). If side clearance exceeds limits, replace piston and rings. 7. Check ring end gap. Install ring squarely in cylinder, using piston. Standard end gap is .010-.016" (.25-.40 mm) for top ring, .006-.010" (.15-.30 mm) for second ring and .012-.035" (.30-.90 mm) for oil ring. When installing piston rings, ensure stamped mark on ring faces up. See Fig. 9 .


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Fig. 9: Installation Order Of Piston Rings

NOTE:

Install the rings with the top mark facing up and the ring gaps spaced properly.


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PISTON PINS

1. Piston pin is press fit into connecting rod and has sliding fit in piston. To remove, set piston and rod assembly in Hydraulic Press (ST13030001) and p ress pin out of rod. DO NOT damage piston during removal. 2. Check pin and pin hole for signs of gauling or excessive wear. Using micrometer and telescopic hole gauge, measure diameter of piston pin, piston pin hole and rod small end. Determine pin-to-piston and pin-to-rod clearance. 3. Standard piston pin diameter is .8265-.8267" (20.993-20.998 mm). Standard piston pin hole inside diameter is .8268-.8271" (21.001-21.008 mm). Standard rod small end diameter is .8254-.8259" (20.95620.978 mm). 4. Check pin-to-piston and pin-to-rod clearance in specifications table. To assemble piston and rod, warm piston to room temperature. Insert pin into piston with finger pressure only. Hold piston and rod in proper alignment and press in pin. Assemble with oil ho le of rod big end toward right side of block. CRANKSHAFT Removal

1. With engine removed from vehicle, remove cylinder head and oil pan. Remove flywheel and rear plate. Remove oil strainer, oil pump and drive spindle. Remove front cover, chain tensioner, guide and timing chain. 2. Remove oil slinger, oil pump drive gear and crankshaft sprocket. Remove piston and rod assemblies. Remove main bearing caps, from outside, in sequence. Use Puller (KV101041SO) to remove center and rear main bearing caps. See Fig. 10 .

NOTE:

Keep main bearing caps in order for reassembly reference.


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Fig. 10: Removing Center & Rear Main Bearing Caps

NOTE:

Remove the center and rear main bearing cap slowly.

3. Remove the rear oil seal and crankshaft. Remove the baffle plate and steel net from the crankcase. See Fig. 11 .


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Fig. 11: Removing Rear Oil Seal

NOTE:

DO NOT damage rear oil seal riding surface of crankshaft during removal or installation.


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Inspection

1. Check crankshaft journals and crankpins for scoring, wear, cracks, taper and out-of-round. Standard taper and out-of-round limit is .0004" (.010 mm) or less. Maximum taper and out-of-round is .0012" (.030 mm). Check crankshaft for bend by placing on "V" blocks. 2. Use dial indicator at center journal of crankshaft. Standard bend limit is .0010" (.025 mm) or less. If bend exceeds .002" (.05 mm), which is half of indicator reading, replace crankshaft. 3. Check crankshaft pilot bushing for wear or damage. If necessary, pull bushing from crankshaft using Pilot Bushing Puller (ST16610001). Clean bushing hole. Insert bushing to .16" (4 mm). DO NOT damage bushing edge or insert excessively. 4. Check flywheel friction surface for cracks, damage or wear. Measure friction surface runout using a dial indicator. Runout limit is .006" (.15 mm). Resurface or replace flywheel if not within limits. Check tooth surfaces of ring gear for flaws or wear. Replace ring gear if necessary. Installation

1. Install baffle plate and steel net into crankcase. Install upper main bearing halves into block. Ensure bearings are on correct journal. Journal No. 3 requires a thrust bearing. Bearing for No. 1 is the same as for No. 5. Bearing for No. 2 is the same as for No. 4.

NOTE:

Upper and lower bearings are not interchangeable. Upper bearings have an oil groove.

2. Apply oil to upper main bearing surfaces. Install crankshaft. Install main bearing caps with arrow pointing toward front. Shift crankshaft forward. Tighten main bearing caps, in 2 or 3 steps, starting at center bearing and working outward. Ensure crankshaft rotates smoothly.

NOTE:

Apply sealer to rear main bearing cap at point where cap contacts cylinder block.

3. Check crankshaft end play. See THRUST BEARING ALIGNMENT . Apply sealant to side seals and install in rear main bearing cap. Apply oil to outside and sealing lip of oil seal. Install seal, with dust seal lip to outside, using Oil Seal Drift (KV10105500). 4. Wipe oil or foreign matter from fitting surfaces and install rear end plate or drive plate and flywheel. Install piston and rod assemblies. Install remaining components in reverse of removal proce dure. THRUST BEARING ALIGNMENT

Thrust bearing is installed on No. 3 main bearing journal. Check crankshaft end play by inserting a feeler gauge between flange of thrust bearing and crankshaft. Standard end play is .002-.007" (.05-.18 mm) and service limit is .012" (.30 mm). MAIN BEARING CLEARANCE

1. Check bearings for scoring or wear. Replace if damaged. Clean oil from crankshaft. Check clearance using Plastigage method. Standard main bearing clearance is .0008-.0024" (.020-.062 mm). If clearance lunes, 10 de octubre de 2016 18:41:22

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exceeds .0047" (.120 mm), replace bearings. 2. Bearings are available in undersizes. For 2.4L, only bearing undersize of .25 mm is available. For 2.0L, bearings are available in undersizes of .25 mm, .50 mm and .75 mm.

NOTE:

Plastigage should run parallel with crankshaft. DO NOT block oil hole or turn crankshaft with Plastigage inserted.

CONNECTING ROD BEARING CLEARANCE

1. Check connecting rod bearing clearance using Plastigage method. Tighten connecting rod caps to 33-40 ft. lbs. (45-54 N.m). Standard rod bearing clearance is .0005-.0021" (.012-.054 mm). If clearance exceeds .0047" (.120 mm), replace bearings. 2. Bearings are available in undersizes. For 2.4L, only bearing undersize of .25 mm is available. For 2.0L, bearings are available in undersizes of .25 mm, .50 mm and .75 mm.

ENGINE LUBRICATION Oil drawn from pan passes through screen to oil pump and is delivered to oil filter and main oil gallery. Main oil gallery supplies oil to crankshaft main bearings and drilled passages in crankshaft. Oil sprayed from jet holes on connecting rods lubricates cylinders and piston pins. Oil from main gallery lubricates chain tensioner and timing chain. Cen ter hole in crankshaft center bearing feeds c amshaft bearings on cylinder head. Valve rocker mechanism is lubricated through oil g allery in camshaft and through a small channel at base circle portion of each cam. Rocker arms and valves are lubricated through small holes in oil pipe. CRANKCASE CAPACITY

For 4WD Pickup, the crankcase capacity is 4.5 qts. (4.3L) with oil filter. For 2WD Pickup, the crankcase capacity is 4.4 qts. (4.2L) with oil filter. OIL FILTER

Full-flow, disposable cartridge. OIL PRESSURE

50-60 psi (3.5-4.2 kg/cm2 ) at 3000 rpm.


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Fig. 12: Cutaway View Of Engine Oiling System OIL PUMP Removal

1. Pump assembly is installed at bottom right of front cover and held in place by four bolts. Pump is driven by helical gear on crankshaft and in turn drives distributor shaft. 2. Set No. 1 piston at TDC on compression stroke. Check distributor rotor position for reassembly reference. Remove mount bolts. Remove oil pump and drive spindle assembly. Inspection lunes, 10 de octubre de 2016 18:41:22

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1. Remove cover and gasket from oil pump body. Remove gears. Wash parts with solvent. Inspect for wear or damage. 2. With rotor in pump body and gasket installed, place straightedge over rotor. Check clearance between rotor and straightedge. Clearance should be .0024" (.060 mm) or less. 3. With gasket removed, clearance between pump body and straightedge should be .0012" (.030 mm) or less. Ensure clearances are within specifications.

NOTE:

Oil pump rotors and body are not serviced separately. If excessively worn or damaged, replace pump rotor set or complete pump assembly.

Installation

1. Install outer pump rotor with larger chamfered portion facing pump body side. Ensure distributor rotor is in same position as before removal. Fill pump housing with oil. Align punch mark on drive spindle with hole in pump. See Fig. 13 .

Fig. 13: Aligning Oil Pump Timing Marks

NOTE:

Ensure that distributor rotor is in same position as it was before oil pump removal.

2. Using new gasket, install oil pump and drive spindle assembly. Ensure drive spindle tip securely fits distributor fitting hole. Tighten all bolts. lunes, 10 de octubre de 2016 18:41:22

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OIL PUMP SPECIFICATIONS (1)

Application Rotor Side Clearance

(Rotor to Bottom Cover) (2) Rotor Tip Clearance Outer Rotor-to-Body Clearance

In. (mm)

.008 (.20) .008 (.20) .012 (.50)

(1) Wear limit specifications given. (2) Clearance is checked with gasket in place.

WATER PUMP Removal

To remove pump, open radiator cap and drain cooling system. Remove upper radiator shroud. Loosen alternator bracket and remove fan belt. If equipped, remove power steering belt. Remove fan. Remove pump mount bolts. Remove water pump with fan pulley, fan coupling and gasket. Inspection

Inspect water pump body and vane for corrosion or rust. Check pump bearing for excessive play or rough operation. Inspect fan coupling for oil leakage or bent bi-metal. Check thermostat for proper operation. Replace pump or component as necessary.

NOTE:

The water pump and fan coupling cannot be disassembled. Replace as a unit.

Installation

Using new gasket, install water pump by reversing removal procedure. Adjust belt tension and fill cooling system. After running engine for several minutes, check for leaks.

NOTE:

For information on cooling system capacities and other cooling system components, see appropriate article in ENGINE COOLING SYSTEMS section.

TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application Alternator Bracket Bolt Camshaft Sprocket Bolt Clutch Cover Bolt Connecting Rod Nut Crankshaft Pulley Cylinder Head Mount Bolt lunes, 10 de octubre de 2016 18:41:23

Ft. Lbs. (N.m) 33-40 (44-54) 87-116 (118-157) 12-15 (16-21) 33-40 (44-54) 87-116 (118-157) 58-65 (78-88) Page 25



Flywheel Mount Bolt Main Bear Cap Bolt Manifold Exhaust Mount Bolt Intake Mount Bolt Oil Pump Mount Bolt Rocker Arm Adjuster Nut Rocker Shaft Bracket Bolt Transmission-to-Engine Mount Bolt

101-116 (137-157) 33-40 (44-54) 12-15 (16-21) 12-15 (16-21) 8-11 (11-15) 12-16 (16-22) 11-18 (15-25) 32-43 (43-58) INCH Lbs. (N.m)

Cam Chain Guide Bolt Tensioner Bolt Cylinder Head To Front Cover Bolt Front Cover Mount Bolt 6 mm 8 mm Oil Pan Mount Bolt Valve Cover Bolt

35-86 (4-10) 35-86 (4-10) 35-86 (4-10) 35-86 (4-10) 86-144 (10-16) 35-86 (4-10) 35-86 (4-10)

ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS Application Federal Displacement Cu. In. Liters Fuel System HP @ RPM Torque Ft. @ RPM Compr. Ratio Bore Stroke

119.1 2.0 2-Bbl. 95 @ 5200 112 @ 2800 9.4:1 3.35 (85) 3.39 (86)

50 States (1) Displacement Cu. In. Liters Fuel System HP @ RPM Torque Ft. @ RPM

145.8 2.4 2-Bbl. 103 @ 4800 134 @ 2800


In. (mm)

Page 26



Compr. Ratio Bore Stroke

8.3:1 3.50 (89) 3.78 (96)

(1) Only gasoline engine available in Calif. Pickups; may be also used in some Federal Pickups.

VALVE SPECIFICATIONS VALVE SPECIFICATIONS Application Intake Head Diameter Face Angle Seat Angle Seat Width

In. (mm)

1.65 (42) 45° 45.5° (1)

.083 (2.10) .3136-.3142 (7.965-7.980) .0008-.0021 (.020-.053) n/a

Stem Diameter Stem Clearance Valve Lift Exhaust Head Diameter Face Angle Seat Angle Seat Width Stem Diameter Stem Clearance Valve Lift

1.496 (38) 45° 45.5° .067 (1.70) .3128-.3134 (7.945-7.960) .0016-.0029 (.040-.073) n/a

(1) 2.0L valve seat width shown, 2.4L width is .079" (2 mm)

PISTONS, PINS & RINGS SPECIFICATIONS PISTONS, PINS & RINGS SPECIFICATIONS Application Piston Clearance Pins Piston Fit Rod Fit

In. (mm) .0010-.0018 (.025-.045)

.0003-.0005 (.008-.012) (1)

.0006-.0014 (.015-.035)

Rings Ring No. 1 End Gap Side Clearance Ring No. 2


.010-.016 (.25-.40) .0016-.0029 (.040-.073)

Page 27



End Gap Side Clearance Oil Ring End Gap Side Clearance

.006-.012 (.15-.30) .0012-.0025 (.030-.063) .012-.035 (.30-.90) n/a

(1) Interference fit.

CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS CRANKSHAFT MAIN & CONNECTING ROD BEARINGS SPECIFICATIONS Application In. (mm) Main Bearings Journal Diameter 2.1631-2.1636 (54.942-54.955) Clearance .0008-.0024 (.020-.062) Thrust Bearing No. 3 Crankshaft End Play .002-.007 (.05-.18) Connecting Rod Bearings Journal Diameter 1.9670-1.9675 (49.961-49.974) Clearance .0005-.0021 (.012-.054) Side Play .008-.012 (.20-.30) VALVE SPRING SPECIFICATIONS VALVE SPRING SPECIFICATIONS Application Inner Free Length Pressure - Lbs. @ In. (Kg @ mm) Valve Closed Valve Open Outer Free Length Pressure - Lbs. @ In. (Kg @ mm) Valve Closed Valve Open

Specifications

1.736 (44.10) 24.3 @ 1.38 (11 @ 35) 57 @ 98 (26 @ 25) 1.959 (49.77) 50.7 @ 1.57 (23 @ 40) 115.3 @ 1.18 (52.3 @ 30)

CAMSHAFT SPECIFICATIONS CAMSHAFT SPECIFICATIONS Application Journal Diameter Clearance lunes, 10 de octubre de 2016 18:41:23

In. (mm) 1.2967-1.2974 (32.935-32.955) .0018-.0035 (.045-.090) Page 28



Lobe Lift


.218 (5.55)

Page 29


Nissan Z24

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