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

Patrol - Chassis Code Y61
Caravan - Chassis Code E25 and VWE25
Urvan - Chassis Code E25
Homy - Chassis Code E25
Elgrand - Chassis Code E50, E51
Terrano - Chassis Code R50
Terrano - Chassis Code R20 (Europe only)

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).

Power and torque

Nissan Caravan - Urvan ZD30DD 105 hp (78 kW) @3800, 21.3 kg·m (209 N·m; 154 lb·ft) (MT)/ 23 kg·m (230 N·m; 170 lb·ft) (AT) @ 2000 rpm (non-turbo)
Nissan Caravan - Urvan ZD30DDTi Turbo Intercooled 121 hp (90 kW) @ 3200 rpm, 27 kg·m (260 N·m; 200 lb·ft) @ 1600-3200 rpm
Nissan Navara - ZD30DDT Turbo Non-Intercooler 148 hp (110 kW)
Nissan Patrol - ZD30DDTi Turbo Intercooler 158 hp (118 kW) @ 3600 rpm, ZD30DDTi Turbo Intercooler 170 hp (130 kW) @ 3600 rpm, 37.0 kg·m (363 N·m; 268 lb·ft) @ 1800 rpm
Nissan Terrano - ZD30DDTi Turbo Intercooled 170 hp (130 kW) @ 3600 rpm, 36.0 kg·m (353 N·m; 260 lb·ft) @ 1800 rpm
Nissan Elgrand - ZD30DDTi Turbo Intercooled 170 hp (130 kW) @ 3600 rpm, 36.0 kg·m (353 N·m; 260 lb·ft) @ 1800 rpm

About the Nissan 2.4L KA24DE engine

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

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