Nissan ZD30DD and KA23DE engine factory workshop and repair manual download
Nissan ZD30DD and KA24DE engine factory workshop and repair manual
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Covers the Nissan ZD30DD and KA24DE engine
Engine Room Cover
Drive Belts
Air Cleaner
Throttle Body
Intake Manifold
Exhaust Manifold
Oil Pan and Strainer
Spark Plug
Fuel Injector
Rocker Cover
Camsahft
Timing Chains
Cylinder HEad
Engine Assembly
Cylinder Block
Specs
About the ZD30DD Engine
The Nissan ZD30 engine family is a 3 litre (2953 cc), inline four cylinder, diesel engine that replaced the Nissan QD engine. Available in both traditional turbo, variable geomtery turbo(aka VGT or VNT), and non turbo versions. The engine uses a Drive-by-wire engine management system with a draw-through MAF sensor. Produced from 1999-current, the newest models feature a common rail design.
Vehicles
The power differences stem from types of vehicles and routing of necessary pipings, as well types of manifold with different features. Engines that produce 170 hp (130 kW) have MAF sensors incorporated in them, while the 120 hp (89 kW) and 130 hp (97 kW) versions do not use a MAF sensor. Conversions can be done using the ECU from any of the higher horsepower units using the MAF sensor along with the MAF, which has to be wired into the loom of the 120 hp (89 kW) and 130 hp (97 kW) versions.
Version and production
ZD30DD is a DOHC, Fuel injected engine 105 hp (78 kW)
ZD30DDT version is a DOHC, Direct injected, 16 valve, turbocharged engine 148 hp (110 kW)
ZD30DDTi version is a DOHC, Direct injected, 16 valve, turbocharged, intercooled engine 121 hp (90 kW), 130 hp (97 kW), and 170 hp (130 kW).
The KA engines were a series of inline-4 four-stroke gasoline piston engines manufactured by Nissan, which were offered in 2.0 L and 2.4 L versions. The engines blocks were made of cast-iron, while the cylinder heads were made of aluminum.
Despite their large capacity, this motor was not equipped with balance shafts. When used in the passenger cars both versions of the KA24 used a crank girdle, as opposed to individual caps. In the Nissan Hardbody and Frontier applications a crank girdle was not used.
The 2.4 L (2389 cc) KA24DE was used in many Nissan cars and trucks. Most KA24DEs bound for the US were built in the Mexican city of Aguascalientes, with the exceptions of the 240SX, 1994-97 Altima (re-badged Bluebird SSS), and the U13 Bluebird released in Australia with FWD configuration which were manufactured in Fukuoka Prefecture, Japan. The Mexican block is the same as the KA24E but has a DOHC head on it and doesn't incorporate the design improvements of the block from Japan. The KA24DE is very similar to the KA24E. The KA24E is SOHC with three valves per cylinder actuated by rocker arms, and the KA24DE is DOHC with four valves per cylinder and shim-over-bucket valve actuation. Design improvements of the block from Japan include the use of a knock sensor, girdled main bearings, different oil pan (not interchangeable between Japanese and Mexican blocks), different oil pickup (front pickup on Japanese block and side on Mexican block), dipstick location (toward the rear of block on Mexican and mid block on Japanese) and piston oil squirters. In addition to the increased power and torque, the KA24DE has a higher redline than the KA24E.
Specifications
Bore × Stroke: 89.0 × 96.0 mm (3.50 in. x 3.78 in.)
Displacement: 2389cc (145cid)
Max power: 155 hp (116 kW) @ 5400 rpm (Frontier/Xterra Engines 143 HP @ 4300rpm)
Max torque: 160 ft·lb (217 Nm) @ 4400 rpm
Valve Configuration: DOHC, 16 valves
Compression ratio: 9.5:1(94-98), 9.0:1(91-93) (Frontier/Xterra Engines: 9.3:1)
Applications
2000-2004 Nissan Xterra
1998-2004 Nissan Frontier
1993-2001 Nissan Altima [1993-1999 Max Hp 150 - Max Torque 154 ft.lb. - Change Hp&Torque in 2000-01]
1991-1998 Nissan 240SX
1997-2000 Nissan R'nessa (4WD model, Japan)
1998-2001 Nissan Presage U30 (Japan)
1999-2001 Nissan Bassara U30 (Japan)
1993-1997 Nissan Bluebird U13
Isuzu COMO (Japanese: Isuzu COMO)
Nissan Largo
Nissan ZD30DD and KA24DE engine factory workshop and repair manual Download
- Safety first: wear safety glasses, gloves, long sleeves, and work on a flat surface. Disconnect the negative battery terminal before starting. Never rely on a jack alone — always use properly rated jack stands. Dispose used fluid per local regulations.
- What you need (tools and why). Each tool listed with a short use‑explanation:
- Hydraulic floor jack: to raise the vehicle. Use the manufacturer’s jacking points, pump slowly, and never slide under the car supported only by the jack.
- Quality jack stands (pair): to support the vehicle after lifting. Place under solid frame or designated lift points and lower the car onto them gently; never use cinder blocks or unstable supports.
- Drain pan (wide, shallow): to catch ATF when you drop the transmission pan. Place under the pan, expect several liters/quarts.
- Socket set with ratchet and extensions (metric sizes): to remove pan bolts, valve body bolts, and solenoid retaining bolts. Use the correct size to avoid rounding bolts. Extensions help reach recessed bolts.
- Torque wrench (in-lb and ft-lb ranges): to tighten bolts to factory torque specs when reassembling (pan, valve body, solenoid). Proper torque prevents leaks and stripping.
- Combination wrenches (metric): for tight spots where a socket won’t fit.
- Screwdrivers (flat and Phillips): to peel up the pan gasket, pry connectors gently, or remove clamps.
- Pliers (needle-nose and slip-joint): to remove electrical clips and hold small parts.
- Plastic gasket scraper or thin putty knife: to remove old gasket material without gouging the pan flange or transmission case.
- Clean rags/shop towels and brake cleaner or transmission-safe parts cleaner: to clean the pan, magnet, valve body surfaces, and solenoids (if re-using).
- Small magnets / magnet on a stick: to retrieve metal debris and to inspect the pan magnet for metal particles.
- Multimeter (digital): to measure solenoid coil resistance and check connector voltage. Use the ohms setting for resistance; use DC volts to verify wiring under ignition ON when needed.
- OBD2 scanner with transmission code support or Nissan-compatible diagnostic tool: to read transmission trouble codes and perform active tests if supported. This helps confirm which solenoid is failing.
- Transmission funnel or fluid pump: to refill the transmission without spills. Pump may be required to reach the filler tube on many vehicles.
- Replacement pan gasket or RTV (high-temp RTV approved for transmissions), and new transmission filter: required whenever the pan is removed to avoid leaks and contamination.
- Replacement shift solenoid(s) OEM or high‑quality aftermarket: the actual electrical/mechanical parts that control gear shifting. You may replace only the failed solenoid or the entire solenoid pack/valve body assembly if the design dictates.
- Clean container or labeled bags and a marker: to keep bolts/parts organized.
- Work light or headlamp: to see under the car.
- (Optional, possibly required) Transmission jack or engine support: only if you must remove the transmission to access the solenoids (depends on the vehicle/transmission). A transmission is heavy and awkward; a jack designed for the job keeps it safe.
- (Optional but recommended) Service manual or factory repair documentation for your specific vehicle/transmission model: gives bolt torques, fluid type and capacity, solenoid resistance specs, and exact procedures.
- Why some extra tools might be required: some Nissan transmissions allow solenoid access from the pan/valve body; others require removing the transmission or a section of it. If the solenoids sit on the underside of the valve body and the valve body must be dropped, you will need a transmission jack or an assistant and possibly more specialty tools and torque-angle tools. The service manual tells you which.
- Preliminary diagnostic and parts decision:
- Use an OBD2/dedicated scan tool to read transmission (AT) codes. Codes pointing to solenoid A/B or pressure control solenoid indicate electrical or mechanical failure.
- Inspect the pan magnet and fluid. Lots of metal shavings or burnt fluid suggests internal damage; in that case replace more than a solenoid — consult a shop.
- Test solenoid electrical connectors with a multimeter: check coil resistance (compare to factory spec in manual) and check for voltage at the harness with ignition ON (not crank) to ensure wiring is good.
- Replace the solenoid if it is out of spec electrically, fails a bench 12 V activation test (if safe to do), is physically damaged, or contaminated beyond cleaning.
- Always replace the transmission filter and pan gasket whenever you remove the pan. These are inexpensive and prevent contaminants from causing repeat failures.
- Typical replacement parts and why:
- Shift solenoid (specific to transmission model): replaces the failed electrically actuated valve that controls fluid flow for gear changes.
- Transmission filter (paper or screen) and O‑ring/seal: catches debris and seals the filter assembly. A clogged or damaged filter reduces pressure and can cause shifting problems.
- Pan gasket or RTV: seals pan to transmission to prevent leaks.
- Transmission fluid (correct spec and quantity): old or contaminated fluid causes poor shifting; refill with the manufacturer-specified fluid (consult manual or filler cap).
- Valve body gasket(s) or O‑rings if you remove the valve body: ensure leak-free reassembly.
- In some models the solenoids come as a pack or attached to the valve body; you may need the entire solenoid pack or valve body assembly if individual solenoids aren’t sold separately or if the valve body is damaged.
- General replacement steps (high level, for a beginner to follow safely):
- Read codes and confirm the solenoid is the likely cause using a scan tool and multimeter. Note codes and which solenoid(s) are affected.
- Gather parts: correct solenoid(s) for your transmission, new filter, pan gasket or RTV, correct ATF.
- Lift vehicle safely with jack and support on jack stands. Ensure secure support before crawling under.
- Place drain pan under transmission. Loosen and remove pan bolts starting at the corners to let fluid trickle out; be ready to catch fluid. Lower pan carefully — it may stick to the gasket.
- Inspect fluid and pan magnet for metal debris. Clean pan and magnet thoroughly with parts cleaner and rags.
- Remove the transmission filter (if accessible from pan drop). Expect more fluid to drain. Replace filter with new one and replace any O‑rings/gaskets.
- If solenoids are accessible from the valve body after removing the pan/filter, locate the solenoid pack (usually attached with bolts and electrical connectors). Disconnect electrical connectors (mark them if multiple).
- Remove retaining bolts, gently remove solenoid(s) or solenoid pack. Save bolts in labeled bag.
- Test the removed solenoid(s) with a multimeter for coil resistance. If you have a bench power source and know what you’re doing, you may briefly apply 12 V to confirm clicking (do this cautiously — solenoids actuate quickly and only brief pulses). If you’re not comfortable, replace suspect solenoids based on codes and resistance.
- Install new solenoid(s) or solenoid pack. Replace any valve body gaskets/O‑rings if removed. Torque bolts to factory spec.
- Reinstall transmission filter and new pan gasket (or apply RTV as specified). Clean flange surfaces well before sealing.
- Reinstall pan and torque bolts in the correct sequence to factory specs. Tighten gradually and evenly to avoid warping.
- Lower the vehicle, refill with specified ATF to the correct level (use filler tube or dipstick method per service manual). Use a pump or funnel for neat fill.
- Start engine and let reach operating temperature, cycle gear selector through each gear with brake on to circulate fluid, check for leaks, and re-check fluid level per manual (some require checking hot with engine running and selector in park).
- Clear codes and test-drive to confirm shifting is restored. Re-scan to ensure no codes return.
- How to use the multimeter for solenoid checks (brief, safe instructions):
- Set multimeter to ohms. With solenoid unplugged, measure resistance across the two solenoid pins. Compare to factory spec (service manual). Typical transmission solenoids are often in the tens of ohms, but specs vary — replace if open/infinite or radically out of spec.
- To check harness voltage (ignition ON or as specified), set multimeter to DC volts, back-probe harness connector carefully, and have an assistant cycle ignition or gearbox as directed. Expect battery voltage on the switched feed when commanded (use manual for exact checks).
- Common pitfalls and warnings:
- Wrong ATF, wrong solenoid part, or incomplete gasket replacement causes leaks and shifting faults. Use manufacturer-specified fluid and correct parts.
- Bolts with different lengths: keep bolts labeled by hole location. Mixing lengths can damage the valve body.
- Over-torquing pan bolts strips threads; under-torquing leaks. Use a torque wrench and manual specs.
- If you find excessive metal in the pan, or multiple solenoids failing, consider professional inspection — internal wear may require transmission overhaul.
- If solenoids are integral to a valve body assembly and sold only as a pack, replacing only one may be impossible.
- Final notes (practical and concise):
- Get the factory service manual or a reliable repair guide for your specific vehicle/transmission model before starting — it contains torque specs, fluid type and capacity, solenoid resistance values, connector pinouts, and exact step sequences.
- If you prefer not to remove the valve body or the job requires removing the transmission, consider a professional shop — transmission removal increases complexity and risk.
- Replace filter and gasket every time you open the pan. Replace any solenoid that fails electrical tests or is mechanically sticky.
- Keep parts receipts and record fluid type/quantity for future maintenance.
- Quick checklist of replacement parts to have on hand before starting:
- Correct shift solenoid(s) or solenoid pack for your transmission
- Transmission filter and any O‑rings
- Pan gasket or high-temp RTV
- Correct type and quantity of transmission fluid
- New pan bolts if original are damaged or torque‑to‑yield
No extra commentary. rteeqp73
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